USER AND INSTALLATION MANUAL
Note: The H6 models are certified for use in Canada only.
XP100U-H2/ XP100U-H4
XP83U-H6*/ XP90U-H6*/ XP100U-H6*
*CANADA CERTIFICATION ONLY
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IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS
This manual contains important instructions for the Inverter1 that shall be followed during installation,
operation, and maintenance of the inverter.
Warning - These service instructions are for use by qualified personnel only. To reduce the risk of electric
shock, do not perform work other than that specified in the operating instructions unless you are qualified to
do so.
Caution - To reduce the risk of fire, connect only to a circuit provided with 150 (H4 models), 400 (H2 models)
and, 125 (H6 models) amperes maximum branch-circuit over current protection in accordance with the
National Electrical Code, ANSI/NFPA 70.
NOTE: THE H6 models are certified for use in Canada only.
Warnings
A warning describes a hazard to equipment or personnel. It calls attention to a procedure or practice, which,
if not correctly performed, could result in damage to or destruction of part or all of the Inverter equipment
and/or other equipment connected to the Inverter equipment or personal injury.
DANGER!
“DANGER” indicates a hazardous situation which, if not avoided, will result in death or serious injury.
WARNING!
"WARNING" indicates a hazardous situation which, if not avoided, could result in death or serious injury.
1
Hereinafter referred to as all five Models (XP100U-H2, XP100U-H4, XP100U-H6, XP83U-H6, and XP90U-H6), unless specific model names are
indicated.
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CAUTION!
"CAUTION" indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
BURN HAZARD!
Do not touch. The Inverter contains components that become hot during normal operation.
Other Symbols
INFORMATION!
This symbol accompanies notes that you should know and use to ensure optimal operation of the system.
Wiring Requirements
All wiring methods and materials shall be in accordance with the National Electrical Code ANSI/NFPA 70, as
well as all state and local code requirements. Cable sizes in the chart below are the minimum. Because the
field connections are bus bars for accepting crimp lugs, larger cables can be used if needed.
Grid Connection
XP100U-H4/ XP83U-H6/ HP90U-H6/ XP100U-H6
Number of GRID cables
Cable Size
Torque
A, B, C, N
4
1AWG
All 194℉ (90℃) copper wire, 40 lbs-ft
tightening torque
PE 1 4AWG
194℉ (90℃) copper wire, 40 lbs-ft
tightening torque
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XP100U-H2
Number of GRID cables
Cable Size
Torque
A, B, C, N
4
300kcmil
All 194℉ (90℃) copper wire, 40 lbs-ft
tightening torque
PE 1 4AWG
194℉ (90℃) copper wire, 40 lbs-ft
tightening torque
PV Connection
XP100U-H2/ XP100U-H4/ XP83U-H6/ XP90U-H6/ XP100U-H6
Number of PV strings
Cable Size
Torque
Hot,
Return
1
600kcmil
All 194℉ (90℃) copper wire, 40 lbs-ft
tightening torque
2
300kcmil
All 194℉ (90℃) copper wire, 40 lbs-ft
tightening torque
4
1/0AWG
All 194℉ (90℃) copper wire, 40 lbs-ft
tightening torque
PE 1 2AWG
194℉ (90℃) copper wire, 40 lbs-ft
tightening torque
CONTENTS
IMPORTANT SAFETY INSTRUCTIONS ........................................................................................... 2
1. About This Manual ............................................................................................................... 6
2. Safety ................................................................................................................................... 7
3. The blueplanet Inverter Overview ...................................................................................... 13
4. Unpacking .......................................................................................................................... 17
5. Installation & Transportation .............................................................................................. 18
6. Connecting the Conduit ..................................................................................................... 23
7. Electrical Connection ......................................................................................................... 26
8. Connecting User Interfaces ............................................................................................... 34
9. Commissioning .................................................................................................................. 45
10. Opening the Inverter .......................................................................................................... 47
11. Operating ........................................................................................................................... 49
12. Parameters ........................................................................................................................ 53
13. Faults & Warnings .............................................................................................................. 56
14. Maintenance ...................................................................................................................... 60
15. Error Codes ........................................................................................................................ 65
16. Specifications ..................................................................................................................... 69
17. Configuration ...................................................................................................................... 74
18. Certifications ...................................................................................................................... 75
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1. ABOUT THIS MANUAL
This manual provides information about the Inverter. This manual contains instructions to install, operate,
maintain and troubleshoot the KACO Inverter. The user must keep this manual available at all times.
This manual contains 5 sections and 3 appendixes.
Safety is important. The Inverter operates with high voltages. Improper use or control of the inverter can
cause an accident and damage to the inverter or the user. The user must understand directions thoroughly in
each section in order to properly install, operate, and maintain the Inverter.
1. The introduction describes the features of Inverter and details the components in the Inverter.
2. The installation & operation section details how to install and operate the Inverter and how to use the
Graphic User Interface (GUI).
3. The fault & warning section contains a list of error codes of the Inverter and their descriptions.
4. The maintenance section contains directions on how to clean and replace fans, and periodically check the
parts of the Inverter.
5. The parameters section contains parameter settings for the Inverter.
A. The specification section details the Inverter specifications.
B. The user Interface section will provide information about the digital interface, analog interface, Ethernet
and RS485 serial connection of the Inverter.
C. The configuration section shows the configuration of the Inverter.
Contact Information
KACO new energy Inc.
USA
Tel: +1 (415) 931-2046
Fax: +1 (415) 931-1688
E-mail: kacoinfo@kaco-newenergy.com
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2. SAFETY
Appropriate Usage
Any other application of the Inverter or installation of components and modifications which are not explicitly
allowed endanger the safety and void the warranty as well as the operation permit.
A: PV Modules
B: String Combiner Box
C: Inverter
D: AC overcurrent protection
E: Grid
Basic Solar Power System with the Inverter
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Safety Instructions
DANGER!
High voltages are present in the live components of the low voltage grid.
Death may result from burns and electric shock.
Do not touch the live components of the Inverter or low-voltage grid.
Pay close attention to all safety precaution measures regarding the low voltage grid.
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DANGER!
During operation, high voltages are present in the Inverter.
Death may result from burns and electric shock.
Before commencing work on the Inverter disconnect completely and ensure that the device will not be
accidentally energized.
Ensure that no voltage is present.
Ground and short-circuit.
Cover any nearby live parts.
DANGER!
Normally grounded conductors may be ungrounded and energized when a ground-fault is indicated.
Risk of electric shock.
Test before touching.
Contact customer support for information at KACO new energy, Inc. +1 (415) 931-2046.
WARNING!
Failure to follow the manual, the operating instructions and the safety precautions may lead to severe injury
from electrocution.
All work on the Inverter may only be done as described in this manual and must be performed by qualified
personnel.
Pay attention to all safety instructions.
Follow all operating instructions.
If problems occur when performing the work described here, contact the customer support department at
KACO new energy Inc. +1 (415) 931-2046.
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WARNING!
Operating the Inverter if it’s damaged may cause severe injury from electrocution.
The Inverter may only be used when it is functioning correctly.
Regularly check the XP Inverter for visible damage and operate only if there is no visible damage.
Ensure that all safety features are accessible at any time and that their correct operation is tested regularly.
ATTENTION!
The printed circuit board (PCB) components in the Inverter can be damaged by electrostatic discharge!
When working on the Inverter and when handling the PCB components observe all ESD safety
regulations. Discharge electrostatic charge by touching the grounded Inverter enclosure. Only
then is it safe to touch any electronic components.
Technical rules
The installation must be in compliance with the local regulations and technical rules, in particular with regard
to electrical connections. (National Electric Code NEC)
The installer is responsible for knowing and understanding local standards and regulations as well as utility
interconnection requirements.
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Regulations concerning the prevention of accidents
During the operation of the inverter, certain parts of the device carry high voltages, which may lead to severe
personal injury or even death. The following precautions should be followed to minimize the risk of lethal
hazards or personal injuries.
The installation of the device must be in compliance with the relevant safety regulations or other applicable
national or local provisions. Proper ground, conductor dimensioning and an appropriate short-circuit
protection must be provided to ensure operational safety.
All instrument covers must remain closed during operation.
Prior to performing some visual checks and maintenance work the inverter must be disconnected from all
power sources and protected against inadvertent activation. If measurements have to be conducted while
the inverter is connected to power, NEVER touch live terminals. Remove all jewelry from your wrists and
fingers. Ensure that the test equipment is in a proper and safe operating condition.
When working on the inverter while energized, make sure to stand on an insulated surface and ensure that
there is no connection to ground.
Follow the instructions exactly as given in these operating and installation instructions and especially
observe all information concerning possible hazards, warnings and precautions.
This manual may not cover all possible scenarios. Should a specific problem occur that is not sufficiently
explained, please contact your dealer or KACO new energy.
Modifications/Changes
CAUTION!
Hazard of damage due to unauthorized modifications/manipulation! By no means manipulate the inverter or
modify or change the inverter or any other parts of the installation
Performing any modifications or changes on the inverter is generally prohibited. Performing any changes or
modifications to the installation of the inverter is only permitted if in compliance with national standards and
performed by qualified personnel.
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Inverter shutdown
WARNING!
Hazardous live voltages can be present in the inverter even if the electrical connections are switched off or
disconnected. Please wait for 1 minute before accessing the inverter
The inverter must be switched off for adjusting, maintenance and repair work. Please proceed as follows:
1. Turn the inverter off by pushing the off button in the GUI.
2. Turn the AC and DC switches to the OFF position
a. (The off position is green and the on position is color coded red).
3. Disconnect the inverter from the PV array.
4. Disconnect the inverter from the grid.
5. Check that the inverter is disconnected from all voltage sources.
6. If possible Install lockout devices on the utility connection circuit breaker, AC and DC disconnect
switches.
7. Wait 1 minute for all capacitors inside inverter to discharge.
8. When reactivating the XP inverter expect a five minute commission window.
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3. THE BLUEPLANET INVERTER OVERVIEW
Full digital control using digital signal processing (DSP)
The KACO XP uses two DSPs to control the inverter and an ARM processor for user and external interface.
These full digital control schemes offer enhanced reliability, accuracy, efficiency, flexibility and convenience.
High reliability
The KACO Inverter features built in reliability with redundant power supplies, highly efficient cooling of critical
components and intelligent cooling fans. The fans are monitored and controlled according to load and
environmental temperature conditions. All components used in the KACO XP are designed for industrial use.
The IGBT stack was designed based on the IEEE WG PEBB TF2 standards. These standards mandate the
use of laminated DC bus-bars that provide for very low stray inductance and gate drive interfacing with
differential signaling. This feature enhances reliability and ease of maintenance. Full digital control
technology of the XP also enhances reliability by reducing component count compared to traditional analog
electronics.
Powerful human interface and networking
The Inverter’ features a powerful and friendly Graphic User Interface (GUI). The “all-in-one” design for the
GUI provides for more convenient operation and monitoring. The GUI is a big, easy to use display with color
TFT LCD (480 x 272 dots) and provides detailed operating information in different languages. RS232,
RS485, and Ethernet interfaces for networking are standard in the Inverter.
System flexibility
The Inverter provides 4 analog inputs, an S0 input, 1 programmable dry contact output A type (Normally
open) and B type (Normally closed), and 1 digital input. The analog inputs are preconfigured for the user and
allow easy connection of temperature sensors and a reference cell. The S0 input is preconfigured for smart
metering.
.
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Shape & Components
External shape
Front
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Left, Right and Back
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Location of the Safety Notices
The figure to the right shows the location of the
safety notice on the Inverter.
A. Front door handle.
Caution, risk of electric shock, hot surface
B. PEBB cover
Caution, risk of electric shock
C. Switch panel cover
Caution, risk of electric shock
D. Fuse panel cover
Caution, risk of electric shock
E. Control system panel
Caution, risk of electric shock
Refer to the operating instructions
F. Filter capacitor cover
Caution, risk of electric shock
The Inverter identification
You can identify the Inverter using the type plate. The inverter type identification plate can be found inside on
the doors of the cabinet.
Firmware
The Inverter’ firmware is shown on the display of the GUI. The Inverter’ operator manual describes how to
obtain the firmware version.
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4. UNPACKING
This section describes unpacking and inspection of the inverter.
Unpacking and inspection
All KACO inverters are thoroughly inspected before packing. Although they are shipped in sturdy packaging,
damage can still occur during shipping and delivery. It is important to carefully inspect the shipping container
and contents prior to installation. When you detect any external damage before or after unpacking, report the
damage immediately to your KACO dealer and the shipping company that delivered the unit. If it is
necessary to return the Inverter, please use the original packing material.
If you need assistance with damaged inverter, contact your dealer or KACO new energy Inc.
Contents
A: Inverter
B: User and Installation Manual
C: Test Report
D: Keys for GUI cover and front door
Storage
ATTENTION!
The inverter should be properly stored to ensure optimal performance.
The inverter should be closed when stored to protect from dust and moisture.
If the storage period is longer, the inverter should be kept in a dry place.
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5. INSTALLATION & TRANSPORTATION
Selecting an appropriate place of installation
If possible the inverter should be installed in an area that is as dry as possible. This is to ensure maximum
product longevity. Additionally, if the ambient temperature at the installation site is above or below the
specifications designated by the manufacturer, the inverter should then be mounted indoors where the
ambient temperature can be controlled within the specifications. Again, this is in order to ensure maximum
product longevity.
The following rules should be observed while choosing the site for the installation of your inverter:
1. Ensure good access for assembly or service work.
2. Please ensure free air circulation at the sides of the housing.
3. The place of installation must ensure proper heat dissipation. If necessary, provide forced ventilation of
the room to ensure that heat is dissipated adequately.
4. Ensure that the supporting area has an adequate load-bearing capacity.
Weights and Dimensions
The installation site must be easily accessible for installation or service work and should preferably not
expose the inverter to direct sunlight or enclose the inverter in an unventilated space.
XP100U-H2: Weight: 1400Kg
XP100U-H4: Weight: 1400Kg
XP83/90/100U-H6: Weight: 1100kg
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Minimum Workspace Requirements
The minimum clearance space shown below should be maintained for ventilation and access.
* If you use a left side conduit plate, the minimum clearance is 4 inches on the left side for installation but
actual clearance will be dictated by the requirements of conduit fitting installation and maintenance
accessibility.
Installation Site Requirements
The foundation must guarantee a solid and safe surface to bear the weight of the inverter.
*
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Preparation of the mounting surface
Prepare the mounting surface structure appropriately based on the chosen site
Secure the Inverter to the chosen site with the pre-installed L-brackets.
Position of the mounting holes (bottom view)
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Foundation L-bracket surface mount
Mounting L-bracket to the inverter
L-bracket for mounting
Transport Instructions
Please note the weight of the inverter and follow the instructions below.
The mode of transportation must support the weight the inverter.
During transport be certain to center the weight of the inverter as the center is closer to the left side.
Do NOT tilt the inverter while transporting.
The pictures below are examples for transportation.
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Fork lift from front or rear
Crane fork from front or rear
Eye nuts with crane rack
Slope angle = 0° in any direction
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6. CONNECTING THE CONDUIT
In this section, see how to insert the cables in the inverter and where to punch the holes for the
conduit fittings.
NOTICE!
When installing, please be cautious that water is not able to enter into the inside of the cabinet.
Only recognized NEC compliant watertight conduit and fittings must be used for outdoor
applications. Moisture can affect the performance of the inverter through improper conduit or
hubs.
How to install the cables
There are two ways of connecting cables shown in the following figures.
The field wiring area is designed for DC cable, AC cable and data cables.
The conduit entry points can be used for any cables. Example: Left side for DC conduit and bottom for AC
conduit.
Using the left side panel for cables
1. Remove the bolts which secure the plate to the inverter.
2. Remove the plate.
3. Mark all the holes for the conduit. You need conduit for the AC, DC and data cables.
4. Punch holes for the conduit.
5. Attach the plate to the Inverter.
6. Attach the bolts and tighten.
7. Attach the conduit with the appropriate conduit fittings.
a. Ensure that proper conduit duct sealant is used to prevent rodent and insect infestation.
b. The bottom plate must be secured in place during operation. If conduit is used, the
proper conduit fittings must be used.
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Left panel dimensions for conduit
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