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Operating Instructions n English translation of German original Powador-gridsave Battery system

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Operating Instructions

n English translation of German original

Powador-gridsaveBattery system

Operating instructions Powador-gridsave_EN Page 3

Operating Instructions

Contents

1 General Information 4

11 About this document 4

12 Name plate 5

13 Additional information 5

14 Intended use 5

2 Safety 6

21 Protection features 6

3 Description 7

31 Mode of Operation 7

32 Summary of the components 9

4 Technical Data 11

41 Electrical data 11

42 Mechanical data 12

5 Transportation and Delivery 14

51 Delivery 14

52 Storage 15

53 Transportation 15

6 Assembling the device 16

61 Installation 16

62 Installing components 17

7 Installing the device 19

71 Opening the connection area 19

72 Making the electrical connection 20

73 Connecting the interfaces25

74 Sealing the connection area 25

75 Starting up 26

76 Standard configuration 26

8 Configuration and Operation 28

81 Controls 28

9 MaintenanceTroubleshooting 32

91 Visual inspection32

92 Cleaning the device 32

93 Maintenance 33

94 Faults 33

10 Service 34

11 ShutdownDisassembly 35

111 Switching off the device 35

112 Uninstalling the device 36

113 Disassembling the device 36

12 Disposal 36

13 Appendix 37

General Information

Page 4 Operating instructions Powador-gridsave_EN

1 General Information

11 About this document

WARNINGImproper handling of the Powador-gridsave battery system can be hazardous rsaquo You must read and understand the operating instructions so that you can install and use the

device safely

111 Other applicable documents

During installation observe all assembly and installation instructions for components and other parts of the system These instructions also apply to the equipment related components and other parts of the system

112 Retention of documents

These instructions and other documents must be stored near the system and be available at all times

113 Safety warnings symbols guide information

DANGERHigh risk Failure to observe this warning will lead directly to serious bodily injury or death

WARNINGPotential riskFailure to observe this warning may lead to serious bodily injury or death

CAUTIONLow-risk hazardFailure to observe this warning will lead to minor or moderate bodily injury

CAUTIONRisk of damage to propertyFailure to observe this warning will lead to property damage

NOTEUseful information and notes

Authorised electrician The tasks indicated with this symbol may only be carried out by an authorised electrician

114 Symbols used

General hazard Risk of fire or explosion

High voltage Risk of burns

General Information

Operating instructions Powador-gridsave_EN Page 5

115 Instructions symbols guide

Instructions Prerequisite for the step

1 Carry out step

2 (Additional steps if applicable)

raquo Results of the step

12 Name plate The name plate is located on the inside of the cabinet door

13 Additional information

NOTEThe battery system uses lithium-based batteriesPlease check whether your insurance includes conditions for installation and operation of lithium batteries The retro-fitting of fire or smoke alarms may be necessary

NOTEThe EU Declaration of Conformity can be found in the appendixFor information on grid coupling grid protection and safety parameters along with more detailed instructions go to our web site httpkaco-newenergycomde

14 Intended useThe device is built according to the latest technological standards and safety regulations Nevertheless improper use may cause lethal hazards for the operator or third parties or may result in damage to the device and other property Operate the device only with a permanent connection to the public power grid Any other or additional use of the device is deemed improper This includes bull Mobile usebull Use in potentially explosive atmospheresbull Use in rooms where the humidity is higher than 95bull Operation outside of the specifications intended by the manufacturer

Safety

Page 6 Operating instructions Powador-gridsave_EN

2 SafetyDANGER

Lethal voltages are still present in the terminals and cables even after switching off and discon-nection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched Only authorised electricians are permitted to open install or maintain the device rsaquo Keep the device closed when in operation rsaquo Do not touch the cables or terminals when switching the unit on and off rsaquo Do not make any modifications to the device

The electrician is responsible for observing all existing standards and regulations bull Keep unauthorised persons away from the device and PV systembull Pay particular attention to the standard IEC 60364-7-7122002 ldquoRequirements for special installations or locations ndash

solar photovoltaic (PV) power supply systemsrdquobull Ensure operational safety by providing proper grounding conductor dimensioning and appropriate protection

against short circuitingbull Observe all safety instructions on the device and in these operating instructionsbull Switch off all voltage sources and secure them against being inadvertently switched back on before performing

visual inspections and maintenancebull When taking measurements while the battery system is live

ndash Do not touch the electrical connections ndash Remove all jewellery from your wrists and fingers ndash Ensure that the testing equipment is in safe operating condition

bull Stand on an insulated surface when working on the devicebull Do not place any objects on the housingbull Modifications to the surroundings of the device must comply with the applicable national and local standardsbull When working on the PV generator in addition to disconnecting this from the grid it is also necessary to switch off

the DC voltage using the DC isolator switch on the device

21 Protection featuresFor your safety the following monitoring and protection functions are integrated into the battery systembull Overvoltage conductorsvaristors to protect the power semiconductors from high-energy transients on the grid

and generator sidebull Temperature monitoring for the heat sink and batteriesbull Measurement of current in each battery modulebull Multilevel redundant overload exhaustive discharge and overcurrent protectionbull Comprehensive and regular self-testing of all componentsbull EMC filters to protect the inverter from high-frequency grid interferencebull Grid monitoring disconnection in accordance with VDE-AR-N 4105bull Overcurrent protection for the batterybull Fail-safe phase bridging

Description

Operating instructions Powador-gridsave_EN Page 7

3 Description

31 Mode of OperationThe battery system optimises internal consumption thus reducing the amount of electrical energy needed from the public grid Energy from a photovoltaic system that is not required in the home at that time is stored in a battery and supplied to the consumer as necessary Consumers are supplied with their own energy by the device in a manner which is flexible and optimised to their personal habits

311 System overview

BPM

Gridsave

Measurement

Meassurement

AC

Power Meterproduction

Grid

Distribution Box

Communication

BidirectionalPower Meter

AC circuit breaker

DC circuit breaker

Door

PV-Generator

BBC

350 - 800 VDC

3 x 400 VAC

Inverter

U [V]I [A]

P [W]

U [V]I [A]

P [W]

Powador Protect

Load

3 x 400 VAC

BMS

BatteryBattery

Battery

Power flow

Power flow

Power flow

RCD

Power supply

3 x 400 VAC

AC Main switch

3

40A

3

63A

40A

4

4

Energie- management-

System(EMS)

Figure 1 Schematic overview

Description

Page 8 Operating instructions Powador-gridsave_EN

312 Configuration

Powador-protect

CONNECTION BOX

PV INVERTER

BATTERY CONVERTER

PV-Circuit Breaker

ON

OFF

AC-Circuit Breaker

Residual-Current-Circuit Breaker

BATTERY

1

3

4

5

2

Figure 2 Configuration of the battery system

1 Connection box 4 Battery charging unit battery backup converter (BBC) 1

2 Energy management system (EMS) with LCD touchscreen

5 Battery unit with controller

3 Inverter

Description

Operating instructions Powador-gridsave_EN Page 9

32 Summary of the components

321 Connection box

ON

OFF

Powador Protect

off off off

B 32AAC-Circuit Breaker

IN=40AΔI=300mA

RCCB

off

Test

Typ A

CONNECTION BOX

1 2 3 4

Figure 3 Connection box

Key Function

1 DC isolator switch Disconnects the PV generator from the inverter battery unit

2 Measurement and control unit Powador-protect

Three-phase monitoring of the grid switches off the power supply in the event of impermissible voltage or frequency

3 Circuit breaker Disconnects the inverter from the AC grid

4 Residual current circuit breaker

Protects individuals and the installation by isolating the inverter

NOTEThe DC isolator switch circuit breaker and residual current circuit breaker will switch off the battery system Power will then be supplied from the public grid

322 Energy management system

Figure 4 Energy management system (EMS) with LCD touchscreen

NOTEThe energy management system (EMS) displays all relevant parameters in order to ensure optimum operation

Description

Page 10 Operating instructions Powador-gridsave_EN

323 Inverter

PV INVERTER

Figure 5 Inverter

NOTEThe inverter converts the DC voltage from the PV generator and the battery into AC voltage

324 Battery charging unit battery backup converter (BBC)

BATTERY CONVERTER

Figure 6 Battery charging unit battery backup converter (BBC)

NOTEThe battery charging unit battery backup converter (BBC) is the interface to the battery The high voltage from the PV generator is converted into non-hazardous safety extra low voltage (SELV) for the battery The battery charging unit battery backup converter (BBC) can transfer energy both into the battery and out of it

325 Battery management system (BMS)

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

326 Battery

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

Technical Data

Operating instructions Powador-gridsave_EN Page 11

4 Technical Data

41 Electrical data

Connection box

Home power grid

Input voltage 230V 400V 50Hz 60Hz 3-phase (3 N PE)

Grid configuration TN-C TN-S TT

Grid monitoring Powador-protect (as per VDE-AR-N 4105)

Grid isolation Double insulated 3 or 4 pin

Rated operating current [A] 75

Rated switching current AC-1 [A] 100

Rated switching current AC-3 [A] 50 (22 kW at 400 V)

Connection cross-section [mmsup2] max 25

PV input

Input voltage [V] 300 to 800

Input current [A] 30 String

Strings 2

Isolation Yes rotary switch

Inverter type 6400 8000

Input levels

Max recommended PV generator power [W] 7700 9600

Rated power peak power [VA] 6400 7000 8000 9000

DC MPP range from [V] to [V] 360 590

Open circuit voltage [V] 800

Input current [A] 190 240

cos phi 08 inductive hellip 08 capacitive

Polarity safeguard Short-circuit diode

Feed-in phases 1

Capable of stand-alone operation Yes

Efficiency [] 966

Output levels

Output voltage 230V 50Hz 60Hz 1-phase

Rated current [A] 278 35

Connection cross-section [mmsup2] max 6

Monitoring Isolation Circuit breaker residual current circuit breaker (RCD)

Table 1 Electrical data

Technical Data

Page 12 Operating instructions Powador-gridsave_EN

Battery charging unit battery backup converter (BBC)

BBC power [W] 3300

HV voltage [V] 350 to 600

Battery voltage [V] 38 to 58

Efficiency [] 970

Table 1 Electrical data

42 Mechanical data

Battery system

Display 43 LCD touchscreen

Interfaces RS485 Sym-Bus Ethernet USB digital inputsoutputs

Cable insertion Cable fitting 2x M40 2x M32 4x M25 12x M16

Ambient temperature [degC] 0 +40

Humidity [] lt95 (non-condensing)

Cooling Forced cooling temperature-controlled

Noise emission [dB] lt45

Note regarding cooling Do no cover air inletsoutlets keep clear 20 cm to the right and left

Temperature monitoring Individual monitoring of components with shutdown in the event of excess temperature

Maximum installation elevation [m above mean sea level] 2000

Protection class IP21

Housing form 19 sheet-steel control cabinet

H x W x D [mm] 1600 x 620 x 600

Weight [kg] 2435

Inverter

Ambient temperature range [degC] -20 +60

Temperature monitoring Yes

Cooling Active cooling

Connections Quick INOUT plug connector and busbar clips rear side

H x W x D [mm] 22225 x 4826 x 460

Weight [kg] 25

Table 2 Mechanical data

Technical Data

Operating instructions Powador-gridsave_EN Page 13

Battery charging unit battery backup converter (BBC)

Ambient temperature range [degC] -20 +70

Temperature monitoring Yes

Cooling Active cooling

Housing 19 plug-in module aluminium

Connections Quick INOUT plug connector and busbar clips rear side

H x W x D [mm] 13325 x 4826 x 460

Weight [kg] 15

Temperature-dependent impedance matching with shutdown if the temperature is too high

Table 2 Mechanical data

Transportation and Delivery

Page 14 Operating instructions Powador-gridsave_EN

5 Transportation and Delivery

51 DeliveryThe battery system leaves KACO new energy in fully functional electrical and mechanical condition Special packaging ensures that the units are transported safely The shipping company is responsible for any trans-port damage that occurs

511 Scope of delivery

Pallet A B

Figure Figure 7 Scope of delivery pallet A Figure 8 Scope of delivery pallet B

Contents bull Battery system Powador-gridsave (incl connection box battery management system (BMS) industrial PC Plexiglas cover and accessories)

bull Inverter bull Battery charging unit battery backup converter

(BBC)bull Battery system plug-in modules 1-5 ST (scope of

delivery can be found on the delivery document)bull Documentation

Weight (kg) 187 max 155 177 (without with Euro pool pallet)

H x W x D [mm] 1780x800x820 1200x1200x800

Packaging Cardboard box with polystyrene inserts and closures

512 Check the equipment included

bull Battery system and plug-in modules should be inspected thoroughly for transport damagebull Do not install damaged components in the control cabinetbull In the event of damage to the battery plug-in modules contact the KACO new energy Hotline immediately

Transportation and Delivery

Operating instructions Powador-gridsave_EN Page 15

Authorised electrician

DANGERRisk of fatal injury if incompatible components are usedThe battery and power electronics can be damaged if different delivery batches are combined and will carry potentially fatal voltages if connected rsaquo Assemble the system using the components provided by KACO new energy only rsaquo Check the serial numbers on the delivery document against the serial numbers of the individual

units on pallets A and B

52 StorageIncorrect storage can lead to system malfunctions Therefore please observe the following conditionsbull If storing for longer than six months store the device in an interior room in its original packaging bull If the original packaging has been removed store the device in a cool dry interior roombull Storage temperature -20 degC to +70 degCbull Relative humidity 0 to 95 (non-condensing)bull If the device is stored for a relatively long time at high humidity the device must be left for more than one day to

dry out sufficiently before connection to the power grid

53 Transportation

WARNINGImpact hazard risk of breakage to the components in the battery systemThe centre of gravity is located in the upper part of the device rsaquo Transport the device upright together with the pallet rsaquo Do not expose the device or components to any shocks rsaquo After unloading at least two people are required to transport the cabinet

WARNINGDanger due to impact and incorrect storage of the batteriesIn the event of damage batteries can release hazardous electrolyte gases which will cause irreversible burns if they come into contact with the skin rsaquo Transport the batteries in the vendors original packaging only rsaquo Remove the batteries from the original packaging shortly before installation rsaquo Do not store batteries in cars or outdoors rsaquo Check the condition of the battery before use

NOTEThe precise specifications of the UN on the transport of lithium batteries can be found under the designation Model Regulations on the transport of dangerous goods Ref STSGAC101 Recommendations on the transport of dangerous goods Part III sub-section 383 ldquoManual of Tests and Criteriardquo Ref STSGAC1011

Assembling the device

Page 16 Operating instructions Powador-gridsave_EN

Authorised electrician

6 Assembling the device

61 Installation

DANGERRisk of fatal injury from fire or explosionsFire caused by flammable or explosive materials in the vicinity of the battery system can lead to serious injuries rsaquo Do not mount the inverter in potentially explosive atmospheres or in the vicinity of highly flamma-

ble materials

CAUTIONBattery system is very heavy ndash risk of injury rsaquo Be aware of the weight of the battery system during transport rsaquo Select suitable mounting location and mounting base rsaquo Only install the battery system with the help of a second person

CAUTIONEquipment damage caused by aggressive gases in combination with humidityThe housing may be seriously damaged by aggressive gases (ammonia sulphur and other chemi-cals) in combination with ambient humidity caused by weather conditions - Installation in rooms containing aggressive gases is not permitted

NOTEAccess in the event of maintenance or serviceAny additional costs arising from unfavourable structural or mounting conditions in the event of a KACO service call-out shall be billed to the customer

611 Installation location

bull Dry well ventilated the waste heat must be conducted away from the battery systembull Unobstructed air circulationbull Easily accessible from the front top and sides without requiring additional resourcesbull Indoors protected against direct sunlight and direct water contact

612 Foundation

bull With sufficient load-bearing capacitybull Made from heat-resistant material (up to 90 degC)bull Must be flame resistant

NOTEPower reduction due to heat accumulationIf the recommended minimum clearances are not observed the device may go into power regula-tion mode due to insufficient ventilation and the resulting heat build-up rsaquo The construction and installation of the device may be performed only by a qualified electrician in

accordance with the valid standards and regulations rsaquo Maintain minimum clearances rsaquo Ensure sufficient heat dissipation

Assembling the device

Operating instructions Powador-gridsave_EN Page 17

Authorised electrician

0deg

1000 mm

200 mm 200 mm

500 mm

min carrying capacity 300 kgmsup2

200 mm200 mm

50 mm

Figure 9 Minimum clearances at the installation and assembly location

CAUTIONRisk of injury if the battery system tips overRisk of tipping due to high centre of gravity particularly with the door open rsaquo Anchor the device securely to the floor immediately after installation rsaquo Open the housing door using the enclosed cabinet key only once the device has been securely

anchored

510 mm200 mm

200 mm

400

mm

12 mmmin 110 mm

DesignationHex head wood screw 8x80 DIN571-vz Fischer dowel S12 Flat washer M8 galvanised DIN9021-vz

Units444

Figure 10 Dimensions for anchoring to the floor Table 3 Mounting parts

62 Installing components

CAUTIONAvoid improper handlingImproper handling can cause damage to components rsaquo Damaged components must not be installed rsaquo Always put the plug-in modules down horizontally to avoid damage to the components

Assembling the device

Page 18 Operating instructions Powador-gridsave_EN

Authorised electrician

WARNINGDanger caused by short circuit or sparkingSerious injury from touching or connecting live components rsaquo Damaged components must not be installed

Preparation1 Check the conditions for the installation location2 Open the housing doors using the enclosed cabinet key3 The cables should be professionally laid and prepared for connection4 Follow the installation sequence (1-4 step(s))

621 Step 1 Fit the battery (batteries)

NOTEPlease read the notes on installation and connection in the enclosed manual Features for the battery unit

622 Step 2 Connect battery (batteries) to the battery management system (BMS)

NOTEPlease read the notes on installation and connection in the enclosed manual Features for the battery unit

623 Step 3 Fit the battery charging unit battery backup converter (BBC)

Battery (batteries) connected to the battery management system (BMS)1 Carefully insert battery charging unit battery backup converter (BBC) into the compartment provided for it 2 Push in completely to establish direct contact with the rear busbars3 Secure battery charging unit battery backup converter (BBC) using the screws supplied

624 Step 4 Fit the inverter

Battery charging unit battery backup converter (BBC) is fitted1 Carefully insert inverter into the compartment provided for it 2 Push in completely to establish direct contact with the rear busbars 3 Secure inverter using the screws supplied

CAUTIONDamage to the control unit from introducing foreign objectsForeign objects can impair the function of the control unit and cause damage rsaquo Do not remove the front panel rsaquo Foreign objects should be removed immediately

Installing the device

Operating instructions Powador-gridsave_EN Page 19

Authorised electrician

7 Installing the device

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched The device may only be opened or serviced by an authorised electricianThe device must be completely assembled before being connected electrically rsaquo Observe all safety regulations and current technical connection specifications of the responsible

power supply company rsaquo De-energise the device using the DC isolator switch circuit breaker and residual current circuit

breaker rsaquo Secure both sides against being inadvertently switched back on rsaquo Ensure that the AC and DC sides are completely isolated and voltage free rsaquo Never open the plug-in modules rsaquo Hazardous voltages are present at the busbars rsaquo Disconnect from the grid and plant supply rsaquo First connect the battery system in the connection area

71 Opening the connection area

3

1

2

Figure 11 Open cover plateKey

1 Cover plate 3 Fastening screw

2 Lock

Opening the connection area You have completed assembly

1 Remove the fastening screw for the upper cover plate2 Slide the cover plate forwards out of the lock3 Lift the cover plate upward to remove raquo Make the electrical connection

Installing the device

Page 20 Operating instructions Powador-gridsave_EN

Authorised electrician

72 Making the electrical connectionMake the connection to the PV generator as well as the grid connection using the connection terminals Note the following cable cross-sections

Connection Possible cable cross-section Length of insulation to be stripped offAC home power grid 05 - 16 mmsup2 with end sleeve

05 - 25 mmsup2 without end sleeve18 mm sleeve18-20 mm

PV connection 05 - 16 mmsup2 with end sleeve05 - 25 mmsup2 without end sleeve

18 mm sleeve17-19 mm

Inverter output 05 - 4 mmsup2 with end sleeve05 - 6 mmsup2 without end sleeve

12 mm sleeve11-13 mm

Potential-free contacts 034 - 15 mmsup2 with end sleeve034 - 25 mmsup2 without end sleeve

12 mm sleeve 9-10 mm

Table 4 Cable cross-sections for connection terminals

NOTEThe threaded connections should be matched to the cable cross-section

NOTEOnly conductors and no insulation should be inserted into the connection terminals Individual wires or cables with end sleeves with the appropriate cross-section can be inserted directly into the connection terminal without a toolFine-strand cables without end sleeve or thin conductors will need a screwdriver (plain slot 35 mm) for connection To do this insert the blade of the screwdriver into the recess provided The cable can be inserted into the spring terminal by pressing downwards The spring terminal closes on removal of the screw-driver

Installing the device

Operating instructions Powador-gridsave_EN Page 21

Authorised electrician

X2X1F1 F2 X7 X4 St1

St2

St3

2 3 541 6

Figure 12 View from above of the connection area

Key

1 AC grid input (M40 cable fitting) 4 Network interface (M32 cable fitting)

2 AC grid output (M40 cable fitting) 5 Inverter input (M16 cable fitting)

3 Inverter output (M32 cable fitting) 6 Other connections (M16 cable fitting)

F1 F2 X7 X4 St1

St2

St3

L1 L2 L3 N PE L1 L2 L3 N N PE PE

X1 X2

PV+

PV-

L1 L2 L3 N PE32A 32A PEN

Cust

omer

co

nnec

tion

Figure 13 View from above of the connection area

Key

X1 AC grid input (main junction box meter) X7 PV generator input

X2 AC grid output (building electrical system) F1 F2 Phase bridging fuse

X4 Inverter output St 1-3 Potential-free contacts control outputs

Installing the device

Page 22 Operating instructions Powador-gridsave_EN

Authorised electrician

721 Connecting to the power grid

Because the device is installed between the main junction boxmeter and the buildings electrical system the maxi-mum grid current to the service line must not exceed the rated operating current of the battery system The cable cross-section must be selected in accordance with applicable standards to suit the connected load instal-lation type etc Moreover the terminal area and size of the cable fitting must be noted

NOTEThe fuse rating for the cable should be max 63A (automatic circuit breaker or safety fuse) even if the cross-section of the installed cable would permit a higher fuse rating Always follow the applicable regulations regarding the cable cross-section and installation typeThe device supports standard grid configurations such as TN-C TN-S and TT TN-SIf a TN-S grid is present directly at the power input and output of the device L1-L3 N and PE must each be connected The home power grid should have 4-pin isolationTN-C4-pin grid isolation is factory preset and disconnects L1 L2 L3 and N In a TN-C grid the N conduc-tor must not be disconnected If a TN-S grid is present directly at the power input and output of the device a cable bridge (included in delivery) must be installed between the N terminal on X1 and the N terminal on X2 N and PE must additionally be connected together To do this simply insert the enclosed terminal link into the N and PE terminals TTIn the case of a TT grid L1-L3 N and PE must each be connected The home power grid should have 4-pin isolation

NOTEPlease check with the operator of the mains grid whether there are special regulations for grid connection Grid isolation is factory preset to 4-pin is fail-safe and provided with grid and system protection as per VDE-AR-N 4105

Making the grid connection Use cables with 5 wires (L1 brown L2 black L3 grey N blue PE greenyellow) and the correct

cross-section1 Loosen cable fitting for AC connection2 Remove the outer cladding of the AC cables3 Insert the AC cables through the cable fitting into the connection area4 Strip the insulation from the AC cables5 Remove connection terminals6 Connect the cables in line with the terminal labels (Figure 13 on page 21)7 Close the connection terminals8 Check that all connected cables are securely fitted9 Tighten the cable fitting10 To meet the requirements of protection rating IP21 close the unused cable fittings with blind caps raquo The battery system is connected to the power grid

NOTEAn AC-side disconnection unit must be provided during the final installation stage This disconnec-tion unit must be installed so that it can be accessed at any time without obstruction If a residual current circuit breaker is necessary due to the installation specification a type A residual current circuit breaker must be used

Installing the device

Operating instructions Powador-gridsave_EN Page 23

Authorised electrician

7211 Output from the inverterRecommended cable cross-sections for the inverter output and fuse rating of cables for fixed wiring accord-ing to VDE 0100 part 430The fuse rating for the cable is dependent on the cable cross-section max 40A automatic circuit breaker

NOTEWhen the line resistance is high (ie long grid-side cables) the voltage at the grid terminals of the inverter will increase during feed-in to the grid The inverter monitors this voltage If the voltage exceeds the country-specific grid overvoltage limit value the inverter switches off rsaquo Ensure that the conductor cross-sections are sufficiently large or that the cable lengths are suffi-

ciently short

NOTEIn order to avoid asymmetries in the grid systems with multiple battery systems should be designed so that the inverters in the devices feed into the grid in differing phases rsaquo Follow the connection conditions for the particular type of grid and the schematic illustration

below

Country and grid-type

Grid monitoring Required monitoring

max asymmetry between phases L1L2L3

DE-NSP Three-phase or single phase phase unbalanced load 46 kVA

Table 5 Grid-type-specific connection conditions

L1

L2

L3

N

Connection X1 Connection X1 Connection X1 Connection X1

L1 L2 L3 N PE L1 L2 L3 N PE L1 L2 L3 N PE L1 L2 L3 N PE

Powador-gridsave inverter1 L1 - L1 L2 - L2 L3 - L32 L1 - L2 L2 - L3 L3 - L1 3 L1 - L3 L2 - L1 L3 - L2 4 L1 - L1 L2 - L2 L3 - L3

Figure 14 Grid-side connection for systems with multiple battery systems with three-phase grid monitoring

Installing the device

Page 24 Operating instructions Powador-gridsave_EN

Authorised electrician

722 Connecting the PV generator

Connect the PV generator on the left in the connection area (Figure 13 on page 21) Use the provided M16 cable fittings A maximum of two strings can be connected For this reason a DC string fuse can be dispensed with

DANGERRisk of fatal injury due to contact voltagesRemoving the cables from the terminals without first disconnecting the PV generator from the device can cause serious damage to health or damage to the system rsaquo During installation Electrically disconnect the DC positive and DC negative from the protective

earth (PE) rsaquo Completely de-energise the system (AC home power grid AC circuit breaker residual current circuit

breaker DC isolator switch) rsaquo Disconnect the battery system from the PV generator using the integrated DC isolator switch rsaquo Remove DC plug connectors

NOTEIn accordance with IEC 61730 Class A connected PV modules must be dimensioned for the DC system voltage provided and at least for the value of the AC grid voltage

7221 Before connecting

Ensure that there is no ground fault1 Determine the DC voltage between the

ndash protective earth (PE) and the positive cable of the PV generator and between the ndash protective earth (PE) and the negative cable of the PV generator

If stable voltages can be measured there is a ground fault in the DC generator or its wiring The ratio between the measured voltages gives an indication as to the location of this fault

2 Rectify any faults before taking further measurements3 Determine the electrical resistance between the

ndash protective earth (PE) and the positive cable of the PV generator and between the ndash protective earth (PE) and the negative cable of the PV generator

In addition ensure that the PV generator has a total insulation resistance of more than 20 MOhm since the inverter will not feed in if the insulation resistance is too low

4 Rectify any faults before connecting the DC generator

7222 Connecting the PV generator

DANGERRisk of fatal injury due to electric shockSevere injury or death will result if the live connections are touched When there is solar radiation DC voltage will be present at the open ends of the DC cables rsaquo Do not touch the exposed ends of the cables rsaquo Avoid short circuits

Installing the device

Operating instructions Powador-gridsave_EN Page 25

Authorised electrician

Connecting the PV generator Use cables with the correct cross-section

1 Remove cable fittings for DC connection2 Remove the outer cladding of the DC cables3 Insert the DC cables through the cable fittings into the connection area4 Strip the insulation from the DC cables5 Remove connection terminals6 Connect the cables in line with the terminal labels (See Figure 13 on page 21)7 Close the connection terminals8 Check that all connected cables are securely fitted9 Tighten the cable fittings10 To meet the requirements of protection rating IP21 close the unused cable fittings with blind caps raquo The PV generator is connected to the inverter

73 Connecting the interfaces

731 Ethernet interface

Pre-assembled Ethernet cables can be connected using the RJ45 socket in the connection space

Connecting the Ethernet cable1 Remove closure cap from RJ45 socket2 Connect the Ethernet cable3 The energy management system can now obtain an IP address by DHCP and is also available via this in the

network

NOTEThe network settings can be amended later in the Settings menu using the EMS

NOTEUse a suitable category 5 network cable The maximum length of a network segment is 100 m Ensure that the cable is correctly assigned The Ethernet connection of the battery system supports auto-sensing You can use both crossed and 11 configured Ethernet connection cables

74 Sealing the connection area

1 Finally check the cabling2 Ensure that all cables are firmly mounted3 Check that the cable fitting is secure and tighten if necessary4 Remove cable offcuts and particles of dirt or dust5 Fit the cover and slide back until it engages into position6 Check that the position is correct7 Screw the fastening screw onto the front of the cover

Installing the device

Page 26 Operating instructions Powador-gridsave_EN

Authorised electrician

75 Starting up

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched Only appropriately qualified and authorised electricians may open install or maintain the battery system rsaquo Keep the front doors and covers closed during operation

NOTEInitial start-up should be carried out using the available public AC grid

76 Standard configuration

Factory settingsCountry configuration Germany

Grid guidelines Low voltage directive

Language German

Time UTC +1 Central European Time

User Standard

Network parameters DHCP (network settings will be obtained automatically from the router)

NOTEPlease state the desired power limitation (60 or 70 of the PV system capacity) when you order For other variations please notify your KACO contact so that the parameters can be set at the factory prior to delivery

Installing the device

Operating instructions Powador-gridsave_EN Page 27

Authorised electrician

761 Step 1 AC home power grid

Check all cables and connections before starting up1 Switch on the AC home power grid using the AC main switch raquo Powador-protect measurement and control unit starts up and monitors the AC grid raquo Two green LEDs indicate that the grid parameters are met raquo After a further 60 seconds (shortly after the backlighting in the Powador-protect goes out) the Powador-pro-

tect will switch on the home grid2 Configure Powador-protect according to the enclosed Powador-protect instructions

(The instructions are also available on the website at wwwkaconewenergyde) raquo The AC power is supplied in the normal way by the public grid

762 Step 2 AC supply from the battery system

Check all cables and connections before starting up1 Remove external isolation means from the device2 Switch on the circuit breaker raquo The LCD touchscreen on the front panel comes on and the energy management system (EMS) starts up

3 Switch on the residual current circuit breaker raquo The battery system starts up

763 Step 3 Switch on the PV system

1 Switch on any optional external PV isolator switches2 Set the internal DC isolator switch to ON raquo The inverter and the battery charging unit battery backup converter (BBC) are connected to the PV system raquo The device monitors the PV voltage for approx 60 seconds then optimisation of internal consumption takes

place

764 Step 4 Switch on batteries

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

765 Step 5 Activate energy management

NOTEKACO new energy cannot provide any support for problems regarding the IT infrastructure (eg router configuration IP address assignment ports etc) as the structure settings and configuration of the network environment can be complex and very different from place to place In the event of any problems please contact an IT service provider

Remote access activated 1 Please call the KACO Hotline to make an appointment for activation of energy management

Configuration and Operation

Page 28 Operating instructions Powador-gridsave_EN

Authorised electrician

8 Configuration and Operation

81 ControlsThe battery system is fitted with a touchscreen which allows it to be controlled very precisely In normal operation the display is switched off Touching the screen activates the display and after a configurable period of time without being touched the dis-play will deactivate If the screen-save function is switched off the touchscreen will be on continuously

NOTEDepending on the tolerances of the measuring elements the measured and displayed values are not always the actual values However the measuring elements ensure maximum solar yield Due to these tolerances the daily yields shown on the touchscreen may deviate from the values on the grid operatorrsquos feed-in meter by up to 15

3

1

45

2

Figure 15 Overview (home screen)

Key

1 Home button 4 Current time

2 System components 5 Menu name

3 More information

811 Information about the system

Open start screen View changesjumps to the home screen

Show component detail Parameters of the selected component

Settings Define settings for the active user

raquo Displays settings

Configuration and Operation

Operating instructions Powador-gridsave_EN Page 29

Controls Left arrow jump back to previous menu item Up and down arrows navigate through the menu or change a value

Left arrow displayed value is reduced by one increment Right arrow displayed value is increased by one increment or change to the submenu

Display fields Grey box Text or figures (not selectable) Blue box Calls up submenu for the display in question

Activate and deactivate Activate function by ticking the box

Table 6 Information about the system

812 System components

PV generator Display of the current generator data

power voltage current temperature in the inverter

Battery Display of the current battery status

power (charging or discharging) voltage current charge status available capacity temperature of battery

Grid Display of the following either fed-in or drawn from the grid

power voltage current for phase L1-L3 total output frequency

Consumer (load) Display of the consumer data

power voltage current for phase L1-L3 total output

Energy flow raquo Displays the current energy flow in the system

Table 7 Information about system components

Configuration and Operation

Page 30 Operating instructions Powador-gridsave_EN

813 Menu structure

Icons used

Display menu Submenu

Option menu

Menu Submenu Display setting

Action in this menumeaning

PV generator Details

Power Displays the current DC-side power

Voltage Displays the current DC-side voltage

Current Displays the current DC-side amperage

Temp inverter

Displays the current temperature in the inverter housing

Battery Details

Power Displays the current AC-side power

Voltage Displays the current AC-side voltage

Current Displays the current AC-side amperage

Charge status Displays the current charge status

Capacity Displays the current battery capacity

Temperature Displays the current measured temperature of the battery

Grid Details

Power Displays the current AC-side power being drawn or fed-in

Voltage Displays the AC-side voltage being applied

Current Displays the current AC-side amperage being drawn or fed-in

Total output Displays the current AC-side total output being drawn or fed-in

Frequency Displays the frequency currently being applied to the grid junction

Consumer (load) Details

Power Displays the current AC-side power being drawn

Voltage Displays the current AC-side voltage being applied

Current Displays the current AC-side amperage being drawn

Total output Displays the current AC-side total output being drawn

Configuration and Operation

Operating instructions Powador-gridsave_EN Page 31

Menu Submenu Display setting

Action in this menumeaning

Settings

Country amp directive display

Display of the country settings voltage directives and grid type

Select menu language

DateTime Specify time zone date format and date and time

Screen Activate screen-save function and set the delay period

Network settings

Display of the network settings Configure network settings Once the DHCP server becomes available the IP

address subnet mask gateway and DNS server are automatically applied and the aforemen-tioned menu items are hidden

Off DHCP deactivated make settings manually

Version Displays the installed software version and built-in HW components (inverter BBC battery)

Vendor The touchscreen shows information about the device vendor

NOTEAs changes to the software are possible after the manual has been printed the illustrations and descriptions of the functions in these operating instructions may deviate from the software Please therefore note the current Application Notes on our website

MaintenanceTroubleshooting

Page 32 Operating instructions Powador-gridsave_EN

9 MaintenanceTroubleshooting

91 Visual inspectionInspect the device and the cables for visible external damage and note the operating status display In case of damage notify your installer Repairs may only be carried out by authorised electricians

NOTEThe battery system should be checked for proper operation by a qualified electrician at regular intervals

92 Cleaning the device

DANGERLethal voltages in the battery systemSerious injuries or death can result if moisture enters the system rsaquo Only use completely dry objects to clean the battery system rsaquo Only clean the outside of the battery system

Cleaning the battery system Do not use compressed air Use a vacuum cleaner or a soft brush to remove dust from the fan cover and from the top of the inverter on a

regular basis Remove dust from the ventilation inlets if necessary

MaintenanceTroubleshooting

Operating instructions Powador-gridsave_EN Page 33

Authorised electrician

93 Maintenance

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched The device is only permitted to be opened or serviced by an authorised electrician rsaquo Observe all safety regulations and the current technical connection specifications from the relevant

power supply company rsaquo Disconnect the AC and DC sides rsaquo Secure the AC and DC sides from being inadvertently switched back on rsaquo Only then should the device be opened rsaquo After shutdown wait at least 30 minutes before working on the device

CAUTIONDestruction of the DC connectionThe connection terminals can be destroyed by arcing if disconnected while still live rsaquo It is absolutely essential that the shutdown sequence be carried out in the correct order (See sec-

tion 111 on page 35)

94 Faults

941 Procedure

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched

When a fault occurs notify an appropriately authorised and qualified electrician or KACO new energy GmbH Service

Service

Page 34 Operating instructions Powador-gridsave_EN

10 ServiceIf 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 efficientlybull Serial nobull SW version of the components (the software version can be found in the Settings menu using the EMS)bull Module type and string circuitbull Date of installation Start-up reportbull Consignment identification Delivery address Contact person (with telephone number)bull Information about the accessibility of the installation site

Any additional costs arising from unfavourable structural or mounting conditions shall be billed to the customer

You can find our warranty conditions on our websitehttpkaco-newenergycomservicewarrantyFrom there you can easily navigate to our international websites by clicking on the appropriate flag

Please use our website to register your unit immediatelyYou can also select the appropriate flag on this page to access the website for your own countryIn this manner you can assist us in providing you with the quickest service possible Note The maximum length of the warranty is based on the currently applicable national warranty conditions

We have prepared a template for complaints This can be found at httpskaco-newenergycomservicecustomer-service

Hotlines

Technical troubleshooting Technical consultation

Inverters and battery systems ()

+49 (0) 71323818-660 +49 (0) 71323818-660

Data logging and accessories +49 (0) 71323818-690 +49 (0) 71323818-690

Construction site emergency () +49 (0) 71323818-630

Customer help desk Monday to Friday from 730 am to 530 pm (CET)

() Also on Saturdays from 800 am to 200 pm (CET)

ShutdownDisassembly

Operating instructions Powador-gridsave_EN Page 35

11 ShutdownDisassembly

111 Switching off the device

DANGERLethal voltages are still present in the terminals and cables even after switching off and discon-nection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched rsaquo Complete de-energisation only occurs if the bulk power supply is switched off upstream of the bat-

tery system

DANGERDestruction of the DC plug connectorDC plug connectors can be destroyed by arcing if disconnected while still live rsaquo It is absolutely essential that the following shutdown sequence is observed

1111 Step 1 Shutting down the PV system

1 Switch off any optional external PV isolator switches2 Set the internal DC isolator switch to OFF raquo The inverter and battery charging unit battery backup converter (BBC) are disconnected

1112 Step 2 Disconnect the batteries

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

1113 Step 3 Disconnect the AC supply

1 Connect external isolation means to the device2 Switch off the circuit breaker 3 Switch off the residual current circuit breaker raquo The battery system is switched off

1114 Step 4 AC home power grid

1 Shutdown the AC home power grid using the AC main switch raquo The battery system can be uninstalled

Disposal

Page 36 Operating instructions Powador-gridsave_EN

112 Uninstalling the device

NOTETo uninstall follow the same sequence as for installation but in reverse order

Switch off the device1 Unlock and open the housing door2 Remove the upper cover3 Release the DC and AC cables from the connection terminals4 Pull out the cables raquo The battery system is uninstalled Continue with the disassembly

113 Disassembling the device

NOTETo disassemble follow the same sequence as for assembly but in reverse order

Switch off the device1 Uninstall the components2 Remove the fastening from the device3 Securely pack up the battery system if it is to be used later

or have the battery system disposed of in accordance with section 12 on page 36

12 DisposalFor the most part both the battery system and the corresponding transport packaging are made from recyclable raw materialsBatteries and components Do not dispose of faulty batteries or the components together with household waste Ensure that the old device and accessories are disposed of in a proper mannerPackaging Ensure that the transport packaging is disposed of properlyBatteriesUsed or faulty batteries must be transported in special packaging If you need such packaging please contact the KACO Hotline

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

Appendix

Operating instructions Powador-gridsave_EN Page 37

13 Appendix

EU Declaration of Conformity

Vendorrsquos name and address

KACO new energy GmbH Carl-Zeiss-Straszlige 1 74172 Neckarsulm Germany

Product description Battery system

Type designation Powador-gridsave 135 kWh 6400 Powador-gridsave 135 kWh 8000

Powador-gridsave 270 kWh 6400 Powador-gridsave 270 kWh 8000

Powador-gridsave 405 kWh 6400 Powador-gridsave 405 kWh 8000

Powador-gridsave 540 kWh 6400 Powador-gridsave 540 kWh 8000

Powador-gridsave 577 kWh 6400 Powador-gridsave 577 kWh 8000

Powador-gridsave 675 kWh 6400 Powador-gridsave 675 kWh 8000

This is to confirm that the units listed above comply with the protection requirements set forth in the Directive of the Council of the European Union of 15th December 2004 on the harmonisation of the laws of the member states relating to Electromagnetic Compatibility (2004108EC) and the Low Voltage Directive (200695EC)The units are compliant with the following standards

200695EC ldquoDirective relating to electrical equipment designed for use within specific voltage limitsrdquo

Safety of the unitIEC 62109-12010IEC 62109-22011

2004108EC ldquoDirective relating to electromagneticcompatibilityrdquo

Interference immunityEN 61000-6-22005 Emitted interferenceEN 61000-6-32007

Secondary effects on the gridEN 61000-3-112000EN 61000-3-122005

The types mentioned above are therefore labelled with the CE markUnauthorised modifications to the supplied units andor any use of the units that is contrary to their intended use render this Declaration of Conformity null and void

Neckarsulm 0711 2013KACO new energy GmbH

pp Volker DietrichEnergy systems engineering management

Disposal

Page 38 Operating instructions Powador-gridsave_EN

Carl-Zeiss-Straszlige 1 middot 74172 Neckarsulm middot Germany middot Phone +49 7132 3818-0 middot Fax +49 7132 3818-703 middot infokaco-newenergyde middot wwwkaco-newenergyde

The

text

and

figu

res

refle

ct th

e cu

rren

t tec

hnic

al s

tate

at t

he ti

me

of p

rintin

g S

ubje

ct to

tech

nica

l cha

nges

Err

ors

and

omis

sion

s ex

cept

ed

3006

856-

01-1

4030

5

  • 1General Information
    • 11About this document
    • 12Name plate
    • 13Additional information
    • 14Intended use
      • 2Safety
        • 21Protection features
          • 3Description
            • 31Mode of Operation
            • 32Summary of the components
              • 4Technical Data
                • 41Electrical data
                • 42Mechanical data
                  • 5Transportation and Delivery
                    • 51Delivery
                    • 52Storage
                    • 53Transportation
                      • 6Assembling the device
                        • 61Installation
                        • 62Installing components
                          • 7Installing the device
                            • 71Opening the connection area
                            • 72Making the electrical connection
                            • 73Connecting the interfaces
                            • 74Sealing the connection area
                            • 75Starting up
                            • 76Standard configuration
                              • 8Configuration and Operation
                                • 81Controls
                                  • 9MaintenanceTroubleshooting
                                    • 91Visual inspection
                                    • 92Cleaning the device
                                    • 93Maintenance
                                    • 94Faults
                                      • 10Service
                                      • 11ShutdownDisassembly
                                        • 111Switching off the device
                                        • 112Uninstalling the device
                                        • 113Disassembling the device
                                          • 12Disposal
                                          • 13Appendix

Operating instructions Powador-gridsave_EN Page 3

Operating Instructions

Contents

1 General Information 4

11 About this document 4

12 Name plate 5

13 Additional information 5

14 Intended use 5

2 Safety 6

21 Protection features 6

3 Description 7

31 Mode of Operation 7

32 Summary of the components 9

4 Technical Data 11

41 Electrical data 11

42 Mechanical data 12

5 Transportation and Delivery 14

51 Delivery 14

52 Storage 15

53 Transportation 15

6 Assembling the device 16

61 Installation 16

62 Installing components 17

7 Installing the device 19

71 Opening the connection area 19

72 Making the electrical connection 20

73 Connecting the interfaces25

74 Sealing the connection area 25

75 Starting up 26

76 Standard configuration 26

8 Configuration and Operation 28

81 Controls 28

9 MaintenanceTroubleshooting 32

91 Visual inspection32

92 Cleaning the device 32

93 Maintenance 33

94 Faults 33

10 Service 34

11 ShutdownDisassembly 35

111 Switching off the device 35

112 Uninstalling the device 36

113 Disassembling the device 36

12 Disposal 36

13 Appendix 37

General Information

Page 4 Operating instructions Powador-gridsave_EN

1 General Information

11 About this document

WARNINGImproper handling of the Powador-gridsave battery system can be hazardous rsaquo You must read and understand the operating instructions so that you can install and use the

device safely

111 Other applicable documents

During installation observe all assembly and installation instructions for components and other parts of the system These instructions also apply to the equipment related components and other parts of the system

112 Retention of documents

These instructions and other documents must be stored near the system and be available at all times

113 Safety warnings symbols guide information

DANGERHigh risk Failure to observe this warning will lead directly to serious bodily injury or death

WARNINGPotential riskFailure to observe this warning may lead to serious bodily injury or death

CAUTIONLow-risk hazardFailure to observe this warning will lead to minor or moderate bodily injury

CAUTIONRisk of damage to propertyFailure to observe this warning will lead to property damage

NOTEUseful information and notes

Authorised electrician The tasks indicated with this symbol may only be carried out by an authorised electrician

114 Symbols used

General hazard Risk of fire or explosion

High voltage Risk of burns

General Information

Operating instructions Powador-gridsave_EN Page 5

115 Instructions symbols guide

Instructions Prerequisite for the step

1 Carry out step

2 (Additional steps if applicable)

raquo Results of the step

12 Name plate The name plate is located on the inside of the cabinet door

13 Additional information

NOTEThe battery system uses lithium-based batteriesPlease check whether your insurance includes conditions for installation and operation of lithium batteries The retro-fitting of fire or smoke alarms may be necessary

NOTEThe EU Declaration of Conformity can be found in the appendixFor information on grid coupling grid protection and safety parameters along with more detailed instructions go to our web site httpkaco-newenergycomde

14 Intended useThe device is built according to the latest technological standards and safety regulations Nevertheless improper use may cause lethal hazards for the operator or third parties or may result in damage to the device and other property Operate the device only with a permanent connection to the public power grid Any other or additional use of the device is deemed improper This includes bull Mobile usebull Use in potentially explosive atmospheresbull Use in rooms where the humidity is higher than 95bull Operation outside of the specifications intended by the manufacturer

Safety

Page 6 Operating instructions Powador-gridsave_EN

2 SafetyDANGER

Lethal voltages are still present in the terminals and cables even after switching off and discon-nection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched Only authorised electricians are permitted to open install or maintain the device rsaquo Keep the device closed when in operation rsaquo Do not touch the cables or terminals when switching the unit on and off rsaquo Do not make any modifications to the device

The electrician is responsible for observing all existing standards and regulations bull Keep unauthorised persons away from the device and PV systembull Pay particular attention to the standard IEC 60364-7-7122002 ldquoRequirements for special installations or locations ndash

solar photovoltaic (PV) power supply systemsrdquobull Ensure operational safety by providing proper grounding conductor dimensioning and appropriate protection

against short circuitingbull Observe all safety instructions on the device and in these operating instructionsbull Switch off all voltage sources and secure them against being inadvertently switched back on before performing

visual inspections and maintenancebull When taking measurements while the battery system is live

ndash Do not touch the electrical connections ndash Remove all jewellery from your wrists and fingers ndash Ensure that the testing equipment is in safe operating condition

bull Stand on an insulated surface when working on the devicebull Do not place any objects on the housingbull Modifications to the surroundings of the device must comply with the applicable national and local standardsbull When working on the PV generator in addition to disconnecting this from the grid it is also necessary to switch off

the DC voltage using the DC isolator switch on the device

21 Protection featuresFor your safety the following monitoring and protection functions are integrated into the battery systembull Overvoltage conductorsvaristors to protect the power semiconductors from high-energy transients on the grid

and generator sidebull Temperature monitoring for the heat sink and batteriesbull Measurement of current in each battery modulebull Multilevel redundant overload exhaustive discharge and overcurrent protectionbull Comprehensive and regular self-testing of all componentsbull EMC filters to protect the inverter from high-frequency grid interferencebull Grid monitoring disconnection in accordance with VDE-AR-N 4105bull Overcurrent protection for the batterybull Fail-safe phase bridging

Description

Operating instructions Powador-gridsave_EN Page 7

3 Description

31 Mode of OperationThe battery system optimises internal consumption thus reducing the amount of electrical energy needed from the public grid Energy from a photovoltaic system that is not required in the home at that time is stored in a battery and supplied to the consumer as necessary Consumers are supplied with their own energy by the device in a manner which is flexible and optimised to their personal habits

311 System overview

BPM

Gridsave

Measurement

Meassurement

AC

Power Meterproduction

Grid

Distribution Box

Communication

BidirectionalPower Meter

AC circuit breaker

DC circuit breaker

Door

PV-Generator

BBC

350 - 800 VDC

3 x 400 VAC

Inverter

U [V]I [A]

P [W]

U [V]I [A]

P [W]

Powador Protect

Load

3 x 400 VAC

BMS

BatteryBattery

Battery

Power flow

Power flow

Power flow

RCD

Power supply

3 x 400 VAC

AC Main switch

3

40A

3

63A

40A

4

4

Energie- management-

System(EMS)

Figure 1 Schematic overview

Description

Page 8 Operating instructions Powador-gridsave_EN

312 Configuration

Powador-protect

CONNECTION BOX

PV INVERTER

BATTERY CONVERTER

PV-Circuit Breaker

ON

OFF

AC-Circuit Breaker

Residual-Current-Circuit Breaker

BATTERY

1

3

4

5

2

Figure 2 Configuration of the battery system

1 Connection box 4 Battery charging unit battery backup converter (BBC) 1

2 Energy management system (EMS) with LCD touchscreen

5 Battery unit with controller

3 Inverter

Description

Operating instructions Powador-gridsave_EN Page 9

32 Summary of the components

321 Connection box

ON

OFF

Powador Protect

off off off

B 32AAC-Circuit Breaker

IN=40AΔI=300mA

RCCB

off

Test

Typ A

CONNECTION BOX

1 2 3 4

Figure 3 Connection box

Key Function

1 DC isolator switch Disconnects the PV generator from the inverter battery unit

2 Measurement and control unit Powador-protect

Three-phase monitoring of the grid switches off the power supply in the event of impermissible voltage or frequency

3 Circuit breaker Disconnects the inverter from the AC grid

4 Residual current circuit breaker

Protects individuals and the installation by isolating the inverter

NOTEThe DC isolator switch circuit breaker and residual current circuit breaker will switch off the battery system Power will then be supplied from the public grid

322 Energy management system

Figure 4 Energy management system (EMS) with LCD touchscreen

NOTEThe energy management system (EMS) displays all relevant parameters in order to ensure optimum operation

Description

Page 10 Operating instructions Powador-gridsave_EN

323 Inverter

PV INVERTER

Figure 5 Inverter

NOTEThe inverter converts the DC voltage from the PV generator and the battery into AC voltage

324 Battery charging unit battery backup converter (BBC)

BATTERY CONVERTER

Figure 6 Battery charging unit battery backup converter (BBC)

NOTEThe battery charging unit battery backup converter (BBC) is the interface to the battery The high voltage from the PV generator is converted into non-hazardous safety extra low voltage (SELV) for the battery The battery charging unit battery backup converter (BBC) can transfer energy both into the battery and out of it

325 Battery management system (BMS)

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

326 Battery

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

Technical Data

Operating instructions Powador-gridsave_EN Page 11

4 Technical Data

41 Electrical data

Connection box

Home power grid

Input voltage 230V 400V 50Hz 60Hz 3-phase (3 N PE)

Grid configuration TN-C TN-S TT

Grid monitoring Powador-protect (as per VDE-AR-N 4105)

Grid isolation Double insulated 3 or 4 pin

Rated operating current [A] 75

Rated switching current AC-1 [A] 100

Rated switching current AC-3 [A] 50 (22 kW at 400 V)

Connection cross-section [mmsup2] max 25

PV input

Input voltage [V] 300 to 800

Input current [A] 30 String

Strings 2

Isolation Yes rotary switch

Inverter type 6400 8000

Input levels

Max recommended PV generator power [W] 7700 9600

Rated power peak power [VA] 6400 7000 8000 9000

DC MPP range from [V] to [V] 360 590

Open circuit voltage [V] 800

Input current [A] 190 240

cos phi 08 inductive hellip 08 capacitive

Polarity safeguard Short-circuit diode

Feed-in phases 1

Capable of stand-alone operation Yes

Efficiency [] 966

Output levels

Output voltage 230V 50Hz 60Hz 1-phase

Rated current [A] 278 35

Connection cross-section [mmsup2] max 6

Monitoring Isolation Circuit breaker residual current circuit breaker (RCD)

Table 1 Electrical data

Technical Data

Page 12 Operating instructions Powador-gridsave_EN

Battery charging unit battery backup converter (BBC)

BBC power [W] 3300

HV voltage [V] 350 to 600

Battery voltage [V] 38 to 58

Efficiency [] 970

Table 1 Electrical data

42 Mechanical data

Battery system

Display 43 LCD touchscreen

Interfaces RS485 Sym-Bus Ethernet USB digital inputsoutputs

Cable insertion Cable fitting 2x M40 2x M32 4x M25 12x M16

Ambient temperature [degC] 0 +40

Humidity [] lt95 (non-condensing)

Cooling Forced cooling temperature-controlled

Noise emission [dB] lt45

Note regarding cooling Do no cover air inletsoutlets keep clear 20 cm to the right and left

Temperature monitoring Individual monitoring of components with shutdown in the event of excess temperature

Maximum installation elevation [m above mean sea level] 2000

Protection class IP21

Housing form 19 sheet-steel control cabinet

H x W x D [mm] 1600 x 620 x 600

Weight [kg] 2435

Inverter

Ambient temperature range [degC] -20 +60

Temperature monitoring Yes

Cooling Active cooling

Connections Quick INOUT plug connector and busbar clips rear side

H x W x D [mm] 22225 x 4826 x 460

Weight [kg] 25

Table 2 Mechanical data

Technical Data

Operating instructions Powador-gridsave_EN Page 13

Battery charging unit battery backup converter (BBC)

Ambient temperature range [degC] -20 +70

Temperature monitoring Yes

Cooling Active cooling

Housing 19 plug-in module aluminium

Connections Quick INOUT plug connector and busbar clips rear side

H x W x D [mm] 13325 x 4826 x 460

Weight [kg] 15

Temperature-dependent impedance matching with shutdown if the temperature is too high

Table 2 Mechanical data

Transportation and Delivery

Page 14 Operating instructions Powador-gridsave_EN

5 Transportation and Delivery

51 DeliveryThe battery system leaves KACO new energy in fully functional electrical and mechanical condition Special packaging ensures that the units are transported safely The shipping company is responsible for any trans-port damage that occurs

511 Scope of delivery

Pallet A B

Figure Figure 7 Scope of delivery pallet A Figure 8 Scope of delivery pallet B

Contents bull Battery system Powador-gridsave (incl connection box battery management system (BMS) industrial PC Plexiglas cover and accessories)

bull Inverter bull Battery charging unit battery backup converter

(BBC)bull Battery system plug-in modules 1-5 ST (scope of

delivery can be found on the delivery document)bull Documentation

Weight (kg) 187 max 155 177 (without with Euro pool pallet)

H x W x D [mm] 1780x800x820 1200x1200x800

Packaging Cardboard box with polystyrene inserts and closures

512 Check the equipment included

bull Battery system and plug-in modules should be inspected thoroughly for transport damagebull Do not install damaged components in the control cabinetbull In the event of damage to the battery plug-in modules contact the KACO new energy Hotline immediately

Transportation and Delivery

Operating instructions Powador-gridsave_EN Page 15

Authorised electrician

DANGERRisk of fatal injury if incompatible components are usedThe battery and power electronics can be damaged if different delivery batches are combined and will carry potentially fatal voltages if connected rsaquo Assemble the system using the components provided by KACO new energy only rsaquo Check the serial numbers on the delivery document against the serial numbers of the individual

units on pallets A and B

52 StorageIncorrect storage can lead to system malfunctions Therefore please observe the following conditionsbull If storing for longer than six months store the device in an interior room in its original packaging bull If the original packaging has been removed store the device in a cool dry interior roombull Storage temperature -20 degC to +70 degCbull Relative humidity 0 to 95 (non-condensing)bull If the device is stored for a relatively long time at high humidity the device must be left for more than one day to

dry out sufficiently before connection to the power grid

53 Transportation

WARNINGImpact hazard risk of breakage to the components in the battery systemThe centre of gravity is located in the upper part of the device rsaquo Transport the device upright together with the pallet rsaquo Do not expose the device or components to any shocks rsaquo After unloading at least two people are required to transport the cabinet

WARNINGDanger due to impact and incorrect storage of the batteriesIn the event of damage batteries can release hazardous electrolyte gases which will cause irreversible burns if they come into contact with the skin rsaquo Transport the batteries in the vendors original packaging only rsaquo Remove the batteries from the original packaging shortly before installation rsaquo Do not store batteries in cars or outdoors rsaquo Check the condition of the battery before use

NOTEThe precise specifications of the UN on the transport of lithium batteries can be found under the designation Model Regulations on the transport of dangerous goods Ref STSGAC101 Recommendations on the transport of dangerous goods Part III sub-section 383 ldquoManual of Tests and Criteriardquo Ref STSGAC1011

Assembling the device

Page 16 Operating instructions Powador-gridsave_EN

Authorised electrician

6 Assembling the device

61 Installation

DANGERRisk of fatal injury from fire or explosionsFire caused by flammable or explosive materials in the vicinity of the battery system can lead to serious injuries rsaquo Do not mount the inverter in potentially explosive atmospheres or in the vicinity of highly flamma-

ble materials

CAUTIONBattery system is very heavy ndash risk of injury rsaquo Be aware of the weight of the battery system during transport rsaquo Select suitable mounting location and mounting base rsaquo Only install the battery system with the help of a second person

CAUTIONEquipment damage caused by aggressive gases in combination with humidityThe housing may be seriously damaged by aggressive gases (ammonia sulphur and other chemi-cals) in combination with ambient humidity caused by weather conditions - Installation in rooms containing aggressive gases is not permitted

NOTEAccess in the event of maintenance or serviceAny additional costs arising from unfavourable structural or mounting conditions in the event of a KACO service call-out shall be billed to the customer

611 Installation location

bull Dry well ventilated the waste heat must be conducted away from the battery systembull Unobstructed air circulationbull Easily accessible from the front top and sides without requiring additional resourcesbull Indoors protected against direct sunlight and direct water contact

612 Foundation

bull With sufficient load-bearing capacitybull Made from heat-resistant material (up to 90 degC)bull Must be flame resistant

NOTEPower reduction due to heat accumulationIf the recommended minimum clearances are not observed the device may go into power regula-tion mode due to insufficient ventilation and the resulting heat build-up rsaquo The construction and installation of the device may be performed only by a qualified electrician in

accordance with the valid standards and regulations rsaquo Maintain minimum clearances rsaquo Ensure sufficient heat dissipation

Assembling the device

Operating instructions Powador-gridsave_EN Page 17

Authorised electrician

0deg

1000 mm

200 mm 200 mm

500 mm

min carrying capacity 300 kgmsup2

200 mm200 mm

50 mm

Figure 9 Minimum clearances at the installation and assembly location

CAUTIONRisk of injury if the battery system tips overRisk of tipping due to high centre of gravity particularly with the door open rsaquo Anchor the device securely to the floor immediately after installation rsaquo Open the housing door using the enclosed cabinet key only once the device has been securely

anchored

510 mm200 mm

200 mm

400

mm

12 mmmin 110 mm

DesignationHex head wood screw 8x80 DIN571-vz Fischer dowel S12 Flat washer M8 galvanised DIN9021-vz

Units444

Figure 10 Dimensions for anchoring to the floor Table 3 Mounting parts

62 Installing components

CAUTIONAvoid improper handlingImproper handling can cause damage to components rsaquo Damaged components must not be installed rsaquo Always put the plug-in modules down horizontally to avoid damage to the components

Assembling the device

Page 18 Operating instructions Powador-gridsave_EN

Authorised electrician

WARNINGDanger caused by short circuit or sparkingSerious injury from touching or connecting live components rsaquo Damaged components must not be installed

Preparation1 Check the conditions for the installation location2 Open the housing doors using the enclosed cabinet key3 The cables should be professionally laid and prepared for connection4 Follow the installation sequence (1-4 step(s))

621 Step 1 Fit the battery (batteries)

NOTEPlease read the notes on installation and connection in the enclosed manual Features for the battery unit

622 Step 2 Connect battery (batteries) to the battery management system (BMS)

NOTEPlease read the notes on installation and connection in the enclosed manual Features for the battery unit

623 Step 3 Fit the battery charging unit battery backup converter (BBC)

Battery (batteries) connected to the battery management system (BMS)1 Carefully insert battery charging unit battery backup converter (BBC) into the compartment provided for it 2 Push in completely to establish direct contact with the rear busbars3 Secure battery charging unit battery backup converter (BBC) using the screws supplied

624 Step 4 Fit the inverter

Battery charging unit battery backup converter (BBC) is fitted1 Carefully insert inverter into the compartment provided for it 2 Push in completely to establish direct contact with the rear busbars 3 Secure inverter using the screws supplied

CAUTIONDamage to the control unit from introducing foreign objectsForeign objects can impair the function of the control unit and cause damage rsaquo Do not remove the front panel rsaquo Foreign objects should be removed immediately

Installing the device

Operating instructions Powador-gridsave_EN Page 19

Authorised electrician

7 Installing the device

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched The device may only be opened or serviced by an authorised electricianThe device must be completely assembled before being connected electrically rsaquo Observe all safety regulations and current technical connection specifications of the responsible

power supply company rsaquo De-energise the device using the DC isolator switch circuit breaker and residual current circuit

breaker rsaquo Secure both sides against being inadvertently switched back on rsaquo Ensure that the AC and DC sides are completely isolated and voltage free rsaquo Never open the plug-in modules rsaquo Hazardous voltages are present at the busbars rsaquo Disconnect from the grid and plant supply rsaquo First connect the battery system in the connection area

71 Opening the connection area

3

1

2

Figure 11 Open cover plateKey

1 Cover plate 3 Fastening screw

2 Lock

Opening the connection area You have completed assembly

1 Remove the fastening screw for the upper cover plate2 Slide the cover plate forwards out of the lock3 Lift the cover plate upward to remove raquo Make the electrical connection

Installing the device

Page 20 Operating instructions Powador-gridsave_EN

Authorised electrician

72 Making the electrical connectionMake the connection to the PV generator as well as the grid connection using the connection terminals Note the following cable cross-sections

Connection Possible cable cross-section Length of insulation to be stripped offAC home power grid 05 - 16 mmsup2 with end sleeve

05 - 25 mmsup2 without end sleeve18 mm sleeve18-20 mm

PV connection 05 - 16 mmsup2 with end sleeve05 - 25 mmsup2 without end sleeve

18 mm sleeve17-19 mm

Inverter output 05 - 4 mmsup2 with end sleeve05 - 6 mmsup2 without end sleeve

12 mm sleeve11-13 mm

Potential-free contacts 034 - 15 mmsup2 with end sleeve034 - 25 mmsup2 without end sleeve

12 mm sleeve 9-10 mm

Table 4 Cable cross-sections for connection terminals

NOTEThe threaded connections should be matched to the cable cross-section

NOTEOnly conductors and no insulation should be inserted into the connection terminals Individual wires or cables with end sleeves with the appropriate cross-section can be inserted directly into the connection terminal without a toolFine-strand cables without end sleeve or thin conductors will need a screwdriver (plain slot 35 mm) for connection To do this insert the blade of the screwdriver into the recess provided The cable can be inserted into the spring terminal by pressing downwards The spring terminal closes on removal of the screw-driver

Installing the device

Operating instructions Powador-gridsave_EN Page 21

Authorised electrician

X2X1F1 F2 X7 X4 St1

St2

St3

2 3 541 6

Figure 12 View from above of the connection area

Key

1 AC grid input (M40 cable fitting) 4 Network interface (M32 cable fitting)

2 AC grid output (M40 cable fitting) 5 Inverter input (M16 cable fitting)

3 Inverter output (M32 cable fitting) 6 Other connections (M16 cable fitting)

F1 F2 X7 X4 St1

St2

St3

L1 L2 L3 N PE L1 L2 L3 N N PE PE

X1 X2

PV+

PV-

L1 L2 L3 N PE32A 32A PEN

Cust

omer

co

nnec

tion

Figure 13 View from above of the connection area

Key

X1 AC grid input (main junction box meter) X7 PV generator input

X2 AC grid output (building electrical system) F1 F2 Phase bridging fuse

X4 Inverter output St 1-3 Potential-free contacts control outputs

Installing the device

Page 22 Operating instructions Powador-gridsave_EN

Authorised electrician

721 Connecting to the power grid

Because the device is installed between the main junction boxmeter and the buildings electrical system the maxi-mum grid current to the service line must not exceed the rated operating current of the battery system The cable cross-section must be selected in accordance with applicable standards to suit the connected load instal-lation type etc Moreover the terminal area and size of the cable fitting must be noted

NOTEThe fuse rating for the cable should be max 63A (automatic circuit breaker or safety fuse) even if the cross-section of the installed cable would permit a higher fuse rating Always follow the applicable regulations regarding the cable cross-section and installation typeThe device supports standard grid configurations such as TN-C TN-S and TT TN-SIf a TN-S grid is present directly at the power input and output of the device L1-L3 N and PE must each be connected The home power grid should have 4-pin isolationTN-C4-pin grid isolation is factory preset and disconnects L1 L2 L3 and N In a TN-C grid the N conduc-tor must not be disconnected If a TN-S grid is present directly at the power input and output of the device a cable bridge (included in delivery) must be installed between the N terminal on X1 and the N terminal on X2 N and PE must additionally be connected together To do this simply insert the enclosed terminal link into the N and PE terminals TTIn the case of a TT grid L1-L3 N and PE must each be connected The home power grid should have 4-pin isolation

NOTEPlease check with the operator of the mains grid whether there are special regulations for grid connection Grid isolation is factory preset to 4-pin is fail-safe and provided with grid and system protection as per VDE-AR-N 4105

Making the grid connection Use cables with 5 wires (L1 brown L2 black L3 grey N blue PE greenyellow) and the correct

cross-section1 Loosen cable fitting for AC connection2 Remove the outer cladding of the AC cables3 Insert the AC cables through the cable fitting into the connection area4 Strip the insulation from the AC cables5 Remove connection terminals6 Connect the cables in line with the terminal labels (Figure 13 on page 21)7 Close the connection terminals8 Check that all connected cables are securely fitted9 Tighten the cable fitting10 To meet the requirements of protection rating IP21 close the unused cable fittings with blind caps raquo The battery system is connected to the power grid

NOTEAn AC-side disconnection unit must be provided during the final installation stage This disconnec-tion unit must be installed so that it can be accessed at any time without obstruction If a residual current circuit breaker is necessary due to the installation specification a type A residual current circuit breaker must be used

Installing the device

Operating instructions Powador-gridsave_EN Page 23

Authorised electrician

7211 Output from the inverterRecommended cable cross-sections for the inverter output and fuse rating of cables for fixed wiring accord-ing to VDE 0100 part 430The fuse rating for the cable is dependent on the cable cross-section max 40A automatic circuit breaker

NOTEWhen the line resistance is high (ie long grid-side cables) the voltage at the grid terminals of the inverter will increase during feed-in to the grid The inverter monitors this voltage If the voltage exceeds the country-specific grid overvoltage limit value the inverter switches off rsaquo Ensure that the conductor cross-sections are sufficiently large or that the cable lengths are suffi-

ciently short

NOTEIn order to avoid asymmetries in the grid systems with multiple battery systems should be designed so that the inverters in the devices feed into the grid in differing phases rsaquo Follow the connection conditions for the particular type of grid and the schematic illustration

below

Country and grid-type

Grid monitoring Required monitoring

max asymmetry between phases L1L2L3

DE-NSP Three-phase or single phase phase unbalanced load 46 kVA

Table 5 Grid-type-specific connection conditions

L1

L2

L3

N

Connection X1 Connection X1 Connection X1 Connection X1

L1 L2 L3 N PE L1 L2 L3 N PE L1 L2 L3 N PE L1 L2 L3 N PE

Powador-gridsave inverter1 L1 - L1 L2 - L2 L3 - L32 L1 - L2 L2 - L3 L3 - L1 3 L1 - L3 L2 - L1 L3 - L2 4 L1 - L1 L2 - L2 L3 - L3

Figure 14 Grid-side connection for systems with multiple battery systems with three-phase grid monitoring

Installing the device

Page 24 Operating instructions Powador-gridsave_EN

Authorised electrician

722 Connecting the PV generator

Connect the PV generator on the left in the connection area (Figure 13 on page 21) Use the provided M16 cable fittings A maximum of two strings can be connected For this reason a DC string fuse can be dispensed with

DANGERRisk of fatal injury due to contact voltagesRemoving the cables from the terminals without first disconnecting the PV generator from the device can cause serious damage to health or damage to the system rsaquo During installation Electrically disconnect the DC positive and DC negative from the protective

earth (PE) rsaquo Completely de-energise the system (AC home power grid AC circuit breaker residual current circuit

breaker DC isolator switch) rsaquo Disconnect the battery system from the PV generator using the integrated DC isolator switch rsaquo Remove DC plug connectors

NOTEIn accordance with IEC 61730 Class A connected PV modules must be dimensioned for the DC system voltage provided and at least for the value of the AC grid voltage

7221 Before connecting

Ensure that there is no ground fault1 Determine the DC voltage between the

ndash protective earth (PE) and the positive cable of the PV generator and between the ndash protective earth (PE) and the negative cable of the PV generator

If stable voltages can be measured there is a ground fault in the DC generator or its wiring The ratio between the measured voltages gives an indication as to the location of this fault

2 Rectify any faults before taking further measurements3 Determine the electrical resistance between the

ndash protective earth (PE) and the positive cable of the PV generator and between the ndash protective earth (PE) and the negative cable of the PV generator

In addition ensure that the PV generator has a total insulation resistance of more than 20 MOhm since the inverter will not feed in if the insulation resistance is too low

4 Rectify any faults before connecting the DC generator

7222 Connecting the PV generator

DANGERRisk of fatal injury due to electric shockSevere injury or death will result if the live connections are touched When there is solar radiation DC voltage will be present at the open ends of the DC cables rsaquo Do not touch the exposed ends of the cables rsaquo Avoid short circuits

Installing the device

Operating instructions Powador-gridsave_EN Page 25

Authorised electrician

Connecting the PV generator Use cables with the correct cross-section

1 Remove cable fittings for DC connection2 Remove the outer cladding of the DC cables3 Insert the DC cables through the cable fittings into the connection area4 Strip the insulation from the DC cables5 Remove connection terminals6 Connect the cables in line with the terminal labels (See Figure 13 on page 21)7 Close the connection terminals8 Check that all connected cables are securely fitted9 Tighten the cable fittings10 To meet the requirements of protection rating IP21 close the unused cable fittings with blind caps raquo The PV generator is connected to the inverter

73 Connecting the interfaces

731 Ethernet interface

Pre-assembled Ethernet cables can be connected using the RJ45 socket in the connection space

Connecting the Ethernet cable1 Remove closure cap from RJ45 socket2 Connect the Ethernet cable3 The energy management system can now obtain an IP address by DHCP and is also available via this in the

network

NOTEThe network settings can be amended later in the Settings menu using the EMS

NOTEUse a suitable category 5 network cable The maximum length of a network segment is 100 m Ensure that the cable is correctly assigned The Ethernet connection of the battery system supports auto-sensing You can use both crossed and 11 configured Ethernet connection cables

74 Sealing the connection area

1 Finally check the cabling2 Ensure that all cables are firmly mounted3 Check that the cable fitting is secure and tighten if necessary4 Remove cable offcuts and particles of dirt or dust5 Fit the cover and slide back until it engages into position6 Check that the position is correct7 Screw the fastening screw onto the front of the cover

Installing the device

Page 26 Operating instructions Powador-gridsave_EN

Authorised electrician

75 Starting up

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched Only appropriately qualified and authorised electricians may open install or maintain the battery system rsaquo Keep the front doors and covers closed during operation

NOTEInitial start-up should be carried out using the available public AC grid

76 Standard configuration

Factory settingsCountry configuration Germany

Grid guidelines Low voltage directive

Language German

Time UTC +1 Central European Time

User Standard

Network parameters DHCP (network settings will be obtained automatically from the router)

NOTEPlease state the desired power limitation (60 or 70 of the PV system capacity) when you order For other variations please notify your KACO contact so that the parameters can be set at the factory prior to delivery

Installing the device

Operating instructions Powador-gridsave_EN Page 27

Authorised electrician

761 Step 1 AC home power grid

Check all cables and connections before starting up1 Switch on the AC home power grid using the AC main switch raquo Powador-protect measurement and control unit starts up and monitors the AC grid raquo Two green LEDs indicate that the grid parameters are met raquo After a further 60 seconds (shortly after the backlighting in the Powador-protect goes out) the Powador-pro-

tect will switch on the home grid2 Configure Powador-protect according to the enclosed Powador-protect instructions

(The instructions are also available on the website at wwwkaconewenergyde) raquo The AC power is supplied in the normal way by the public grid

762 Step 2 AC supply from the battery system

Check all cables and connections before starting up1 Remove external isolation means from the device2 Switch on the circuit breaker raquo The LCD touchscreen on the front panel comes on and the energy management system (EMS) starts up

3 Switch on the residual current circuit breaker raquo The battery system starts up

763 Step 3 Switch on the PV system

1 Switch on any optional external PV isolator switches2 Set the internal DC isolator switch to ON raquo The inverter and the battery charging unit battery backup converter (BBC) are connected to the PV system raquo The device monitors the PV voltage for approx 60 seconds then optimisation of internal consumption takes

place

764 Step 4 Switch on batteries

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

765 Step 5 Activate energy management

NOTEKACO new energy cannot provide any support for problems regarding the IT infrastructure (eg router configuration IP address assignment ports etc) as the structure settings and configuration of the network environment can be complex and very different from place to place In the event of any problems please contact an IT service provider

Remote access activated 1 Please call the KACO Hotline to make an appointment for activation of energy management

Configuration and Operation

Page 28 Operating instructions Powador-gridsave_EN

Authorised electrician

8 Configuration and Operation

81 ControlsThe battery system is fitted with a touchscreen which allows it to be controlled very precisely In normal operation the display is switched off Touching the screen activates the display and after a configurable period of time without being touched the dis-play will deactivate If the screen-save function is switched off the touchscreen will be on continuously

NOTEDepending on the tolerances of the measuring elements the measured and displayed values are not always the actual values However the measuring elements ensure maximum solar yield Due to these tolerances the daily yields shown on the touchscreen may deviate from the values on the grid operatorrsquos feed-in meter by up to 15

3

1

45

2

Figure 15 Overview (home screen)

Key

1 Home button 4 Current time

2 System components 5 Menu name

3 More information

811 Information about the system

Open start screen View changesjumps to the home screen

Show component detail Parameters of the selected component

Settings Define settings for the active user

raquo Displays settings

Configuration and Operation

Operating instructions Powador-gridsave_EN Page 29

Controls Left arrow jump back to previous menu item Up and down arrows navigate through the menu or change a value

Left arrow displayed value is reduced by one increment Right arrow displayed value is increased by one increment or change to the submenu

Display fields Grey box Text or figures (not selectable) Blue box Calls up submenu for the display in question

Activate and deactivate Activate function by ticking the box

Table 6 Information about the system

812 System components

PV generator Display of the current generator data

power voltage current temperature in the inverter

Battery Display of the current battery status

power (charging or discharging) voltage current charge status available capacity temperature of battery

Grid Display of the following either fed-in or drawn from the grid

power voltage current for phase L1-L3 total output frequency

Consumer (load) Display of the consumer data

power voltage current for phase L1-L3 total output

Energy flow raquo Displays the current energy flow in the system

Table 7 Information about system components

Configuration and Operation

Page 30 Operating instructions Powador-gridsave_EN

813 Menu structure

Icons used

Display menu Submenu

Option menu

Menu Submenu Display setting

Action in this menumeaning

PV generator Details

Power Displays the current DC-side power

Voltage Displays the current DC-side voltage

Current Displays the current DC-side amperage

Temp inverter

Displays the current temperature in the inverter housing

Battery Details

Power Displays the current AC-side power

Voltage Displays the current AC-side voltage

Current Displays the current AC-side amperage

Charge status Displays the current charge status

Capacity Displays the current battery capacity

Temperature Displays the current measured temperature of the battery

Grid Details

Power Displays the current AC-side power being drawn or fed-in

Voltage Displays the AC-side voltage being applied

Current Displays the current AC-side amperage being drawn or fed-in

Total output Displays the current AC-side total output being drawn or fed-in

Frequency Displays the frequency currently being applied to the grid junction

Consumer (load) Details

Power Displays the current AC-side power being drawn

Voltage Displays the current AC-side voltage being applied

Current Displays the current AC-side amperage being drawn

Total output Displays the current AC-side total output being drawn

Configuration and Operation

Operating instructions Powador-gridsave_EN Page 31

Menu Submenu Display setting

Action in this menumeaning

Settings

Country amp directive display

Display of the country settings voltage directives and grid type

Select menu language

DateTime Specify time zone date format and date and time

Screen Activate screen-save function and set the delay period

Network settings

Display of the network settings Configure network settings Once the DHCP server becomes available the IP

address subnet mask gateway and DNS server are automatically applied and the aforemen-tioned menu items are hidden

Off DHCP deactivated make settings manually

Version Displays the installed software version and built-in HW components (inverter BBC battery)

Vendor The touchscreen shows information about the device vendor

NOTEAs changes to the software are possible after the manual has been printed the illustrations and descriptions of the functions in these operating instructions may deviate from the software Please therefore note the current Application Notes on our website

MaintenanceTroubleshooting

Page 32 Operating instructions Powador-gridsave_EN

9 MaintenanceTroubleshooting

91 Visual inspectionInspect the device and the cables for visible external damage and note the operating status display In case of damage notify your installer Repairs may only be carried out by authorised electricians

NOTEThe battery system should be checked for proper operation by a qualified electrician at regular intervals

92 Cleaning the device

DANGERLethal voltages in the battery systemSerious injuries or death can result if moisture enters the system rsaquo Only use completely dry objects to clean the battery system rsaquo Only clean the outside of the battery system

Cleaning the battery system Do not use compressed air Use a vacuum cleaner or a soft brush to remove dust from the fan cover and from the top of the inverter on a

regular basis Remove dust from the ventilation inlets if necessary

MaintenanceTroubleshooting

Operating instructions Powador-gridsave_EN Page 33

Authorised electrician

93 Maintenance

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched The device is only permitted to be opened or serviced by an authorised electrician rsaquo Observe all safety regulations and the current technical connection specifications from the relevant

power supply company rsaquo Disconnect the AC and DC sides rsaquo Secure the AC and DC sides from being inadvertently switched back on rsaquo Only then should the device be opened rsaquo After shutdown wait at least 30 minutes before working on the device

CAUTIONDestruction of the DC connectionThe connection terminals can be destroyed by arcing if disconnected while still live rsaquo It is absolutely essential that the shutdown sequence be carried out in the correct order (See sec-

tion 111 on page 35)

94 Faults

941 Procedure

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched

When a fault occurs notify an appropriately authorised and qualified electrician or KACO new energy GmbH Service

Service

Page 34 Operating instructions Powador-gridsave_EN

10 ServiceIf 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 efficientlybull Serial nobull SW version of the components (the software version can be found in the Settings menu using the EMS)bull Module type and string circuitbull Date of installation Start-up reportbull Consignment identification Delivery address Contact person (with telephone number)bull Information about the accessibility of the installation site

Any additional costs arising from unfavourable structural or mounting conditions shall be billed to the customer

You can find our warranty conditions on our websitehttpkaco-newenergycomservicewarrantyFrom there you can easily navigate to our international websites by clicking on the appropriate flag

Please use our website to register your unit immediatelyYou can also select the appropriate flag on this page to access the website for your own countryIn this manner you can assist us in providing you with the quickest service possible Note The maximum length of the warranty is based on the currently applicable national warranty conditions

We have prepared a template for complaints This can be found at httpskaco-newenergycomservicecustomer-service

Hotlines

Technical troubleshooting Technical consultation

Inverters and battery systems ()

+49 (0) 71323818-660 +49 (0) 71323818-660

Data logging and accessories +49 (0) 71323818-690 +49 (0) 71323818-690

Construction site emergency () +49 (0) 71323818-630

Customer help desk Monday to Friday from 730 am to 530 pm (CET)

() Also on Saturdays from 800 am to 200 pm (CET)

ShutdownDisassembly

Operating instructions Powador-gridsave_EN Page 35

11 ShutdownDisassembly

111 Switching off the device

DANGERLethal voltages are still present in the terminals and cables even after switching off and discon-nection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched rsaquo Complete de-energisation only occurs if the bulk power supply is switched off upstream of the bat-

tery system

DANGERDestruction of the DC plug connectorDC plug connectors can be destroyed by arcing if disconnected while still live rsaquo It is absolutely essential that the following shutdown sequence is observed

1111 Step 1 Shutting down the PV system

1 Switch off any optional external PV isolator switches2 Set the internal DC isolator switch to OFF raquo The inverter and battery charging unit battery backup converter (BBC) are disconnected

1112 Step 2 Disconnect the batteries

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

1113 Step 3 Disconnect the AC supply

1 Connect external isolation means to the device2 Switch off the circuit breaker 3 Switch off the residual current circuit breaker raquo The battery system is switched off

1114 Step 4 AC home power grid

1 Shutdown the AC home power grid using the AC main switch raquo The battery system can be uninstalled

Disposal

Page 36 Operating instructions Powador-gridsave_EN

112 Uninstalling the device

NOTETo uninstall follow the same sequence as for installation but in reverse order

Switch off the device1 Unlock and open the housing door2 Remove the upper cover3 Release the DC and AC cables from the connection terminals4 Pull out the cables raquo The battery system is uninstalled Continue with the disassembly

113 Disassembling the device

NOTETo disassemble follow the same sequence as for assembly but in reverse order

Switch off the device1 Uninstall the components2 Remove the fastening from the device3 Securely pack up the battery system if it is to be used later

or have the battery system disposed of in accordance with section 12 on page 36

12 DisposalFor the most part both the battery system and the corresponding transport packaging are made from recyclable raw materialsBatteries and components Do not dispose of faulty batteries or the components together with household waste Ensure that the old device and accessories are disposed of in a proper mannerPackaging Ensure that the transport packaging is disposed of properlyBatteriesUsed or faulty batteries must be transported in special packaging If you need such packaging please contact the KACO Hotline

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

Appendix

Operating instructions Powador-gridsave_EN Page 37

13 Appendix

EU Declaration of Conformity

Vendorrsquos name and address

KACO new energy GmbH Carl-Zeiss-Straszlige 1 74172 Neckarsulm Germany

Product description Battery system

Type designation Powador-gridsave 135 kWh 6400 Powador-gridsave 135 kWh 8000

Powador-gridsave 270 kWh 6400 Powador-gridsave 270 kWh 8000

Powador-gridsave 405 kWh 6400 Powador-gridsave 405 kWh 8000

Powador-gridsave 540 kWh 6400 Powador-gridsave 540 kWh 8000

Powador-gridsave 577 kWh 6400 Powador-gridsave 577 kWh 8000

Powador-gridsave 675 kWh 6400 Powador-gridsave 675 kWh 8000

This is to confirm that the units listed above comply with the protection requirements set forth in the Directive of the Council of the European Union of 15th December 2004 on the harmonisation of the laws of the member states relating to Electromagnetic Compatibility (2004108EC) and the Low Voltage Directive (200695EC)The units are compliant with the following standards

200695EC ldquoDirective relating to electrical equipment designed for use within specific voltage limitsrdquo

Safety of the unitIEC 62109-12010IEC 62109-22011

2004108EC ldquoDirective relating to electromagneticcompatibilityrdquo

Interference immunityEN 61000-6-22005 Emitted interferenceEN 61000-6-32007

Secondary effects on the gridEN 61000-3-112000EN 61000-3-122005

The types mentioned above are therefore labelled with the CE markUnauthorised modifications to the supplied units andor any use of the units that is contrary to their intended use render this Declaration of Conformity null and void

Neckarsulm 0711 2013KACO new energy GmbH

pp Volker DietrichEnergy systems engineering management

Disposal

Page 38 Operating instructions Powador-gridsave_EN

Carl-Zeiss-Straszlige 1 middot 74172 Neckarsulm middot Germany middot Phone +49 7132 3818-0 middot Fax +49 7132 3818-703 middot infokaco-newenergyde middot wwwkaco-newenergyde

The

text

and

figu

res

refle

ct th

e cu

rren

t tec

hnic

al s

tate

at t

he ti

me

of p

rintin

g S

ubje

ct to

tech

nica

l cha

nges

Err

ors

and

omis

sion

s ex

cept

ed

3006

856-

01-1

4030

5

  • 1General Information
    • 11About this document
    • 12Name plate
    • 13Additional information
    • 14Intended use
      • 2Safety
        • 21Protection features
          • 3Description
            • 31Mode of Operation
            • 32Summary of the components
              • 4Technical Data
                • 41Electrical data
                • 42Mechanical data
                  • 5Transportation and Delivery
                    • 51Delivery
                    • 52Storage
                    • 53Transportation
                      • 6Assembling the device
                        • 61Installation
                        • 62Installing components
                          • 7Installing the device
                            • 71Opening the connection area
                            • 72Making the electrical connection
                            • 73Connecting the interfaces
                            • 74Sealing the connection area
                            • 75Starting up
                            • 76Standard configuration
                              • 8Configuration and Operation
                                • 81Controls
                                  • 9MaintenanceTroubleshooting
                                    • 91Visual inspection
                                    • 92Cleaning the device
                                    • 93Maintenance
                                    • 94Faults
                                      • 10Service
                                      • 11ShutdownDisassembly
                                        • 111Switching off the device
                                        • 112Uninstalling the device
                                        • 113Disassembling the device
                                          • 12Disposal
                                          • 13Appendix

General Information

Page 4 Operating instructions Powador-gridsave_EN

1 General Information

11 About this document

WARNINGImproper handling of the Powador-gridsave battery system can be hazardous rsaquo You must read and understand the operating instructions so that you can install and use the

device safely

111 Other applicable documents

During installation observe all assembly and installation instructions for components and other parts of the system These instructions also apply to the equipment related components and other parts of the system

112 Retention of documents

These instructions and other documents must be stored near the system and be available at all times

113 Safety warnings symbols guide information

DANGERHigh risk Failure to observe this warning will lead directly to serious bodily injury or death

WARNINGPotential riskFailure to observe this warning may lead to serious bodily injury or death

CAUTIONLow-risk hazardFailure to observe this warning will lead to minor or moderate bodily injury

CAUTIONRisk of damage to propertyFailure to observe this warning will lead to property damage

NOTEUseful information and notes

Authorised electrician The tasks indicated with this symbol may only be carried out by an authorised electrician

114 Symbols used

General hazard Risk of fire or explosion

High voltage Risk of burns

General Information

Operating instructions Powador-gridsave_EN Page 5

115 Instructions symbols guide

Instructions Prerequisite for the step

1 Carry out step

2 (Additional steps if applicable)

raquo Results of the step

12 Name plate The name plate is located on the inside of the cabinet door

13 Additional information

NOTEThe battery system uses lithium-based batteriesPlease check whether your insurance includes conditions for installation and operation of lithium batteries The retro-fitting of fire or smoke alarms may be necessary

NOTEThe EU Declaration of Conformity can be found in the appendixFor information on grid coupling grid protection and safety parameters along with more detailed instructions go to our web site httpkaco-newenergycomde

14 Intended useThe device is built according to the latest technological standards and safety regulations Nevertheless improper use may cause lethal hazards for the operator or third parties or may result in damage to the device and other property Operate the device only with a permanent connection to the public power grid Any other or additional use of the device is deemed improper This includes bull Mobile usebull Use in potentially explosive atmospheresbull Use in rooms where the humidity is higher than 95bull Operation outside of the specifications intended by the manufacturer

Safety

Page 6 Operating instructions Powador-gridsave_EN

2 SafetyDANGER

Lethal voltages are still present in the terminals and cables even after switching off and discon-nection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched Only authorised electricians are permitted to open install or maintain the device rsaquo Keep the device closed when in operation rsaquo Do not touch the cables or terminals when switching the unit on and off rsaquo Do not make any modifications to the device

The electrician is responsible for observing all existing standards and regulations bull Keep unauthorised persons away from the device and PV systembull Pay particular attention to the standard IEC 60364-7-7122002 ldquoRequirements for special installations or locations ndash

solar photovoltaic (PV) power supply systemsrdquobull Ensure operational safety by providing proper grounding conductor dimensioning and appropriate protection

against short circuitingbull Observe all safety instructions on the device and in these operating instructionsbull Switch off all voltage sources and secure them against being inadvertently switched back on before performing

visual inspections and maintenancebull When taking measurements while the battery system is live

ndash Do not touch the electrical connections ndash Remove all jewellery from your wrists and fingers ndash Ensure that the testing equipment is in safe operating condition

bull Stand on an insulated surface when working on the devicebull Do not place any objects on the housingbull Modifications to the surroundings of the device must comply with the applicable national and local standardsbull When working on the PV generator in addition to disconnecting this from the grid it is also necessary to switch off

the DC voltage using the DC isolator switch on the device

21 Protection featuresFor your safety the following monitoring and protection functions are integrated into the battery systembull Overvoltage conductorsvaristors to protect the power semiconductors from high-energy transients on the grid

and generator sidebull Temperature monitoring for the heat sink and batteriesbull Measurement of current in each battery modulebull Multilevel redundant overload exhaustive discharge and overcurrent protectionbull Comprehensive and regular self-testing of all componentsbull EMC filters to protect the inverter from high-frequency grid interferencebull Grid monitoring disconnection in accordance with VDE-AR-N 4105bull Overcurrent protection for the batterybull Fail-safe phase bridging

Description

Operating instructions Powador-gridsave_EN Page 7

3 Description

31 Mode of OperationThe battery system optimises internal consumption thus reducing the amount of electrical energy needed from the public grid Energy from a photovoltaic system that is not required in the home at that time is stored in a battery and supplied to the consumer as necessary Consumers are supplied with their own energy by the device in a manner which is flexible and optimised to their personal habits

311 System overview

BPM

Gridsave

Measurement

Meassurement

AC

Power Meterproduction

Grid

Distribution Box

Communication

BidirectionalPower Meter

AC circuit breaker

DC circuit breaker

Door

PV-Generator

BBC

350 - 800 VDC

3 x 400 VAC

Inverter

U [V]I [A]

P [W]

U [V]I [A]

P [W]

Powador Protect

Load

3 x 400 VAC

BMS

BatteryBattery

Battery

Power flow

Power flow

Power flow

RCD

Power supply

3 x 400 VAC

AC Main switch

3

40A

3

63A

40A

4

4

Energie- management-

System(EMS)

Figure 1 Schematic overview

Description

Page 8 Operating instructions Powador-gridsave_EN

312 Configuration

Powador-protect

CONNECTION BOX

PV INVERTER

BATTERY CONVERTER

PV-Circuit Breaker

ON

OFF

AC-Circuit Breaker

Residual-Current-Circuit Breaker

BATTERY

1

3

4

5

2

Figure 2 Configuration of the battery system

1 Connection box 4 Battery charging unit battery backup converter (BBC) 1

2 Energy management system (EMS) with LCD touchscreen

5 Battery unit with controller

3 Inverter

Description

Operating instructions Powador-gridsave_EN Page 9

32 Summary of the components

321 Connection box

ON

OFF

Powador Protect

off off off

B 32AAC-Circuit Breaker

IN=40AΔI=300mA

RCCB

off

Test

Typ A

CONNECTION BOX

1 2 3 4

Figure 3 Connection box

Key Function

1 DC isolator switch Disconnects the PV generator from the inverter battery unit

2 Measurement and control unit Powador-protect

Three-phase monitoring of the grid switches off the power supply in the event of impermissible voltage or frequency

3 Circuit breaker Disconnects the inverter from the AC grid

4 Residual current circuit breaker

Protects individuals and the installation by isolating the inverter

NOTEThe DC isolator switch circuit breaker and residual current circuit breaker will switch off the battery system Power will then be supplied from the public grid

322 Energy management system

Figure 4 Energy management system (EMS) with LCD touchscreen

NOTEThe energy management system (EMS) displays all relevant parameters in order to ensure optimum operation

Description

Page 10 Operating instructions Powador-gridsave_EN

323 Inverter

PV INVERTER

Figure 5 Inverter

NOTEThe inverter converts the DC voltage from the PV generator and the battery into AC voltage

324 Battery charging unit battery backup converter (BBC)

BATTERY CONVERTER

Figure 6 Battery charging unit battery backup converter (BBC)

NOTEThe battery charging unit battery backup converter (BBC) is the interface to the battery The high voltage from the PV generator is converted into non-hazardous safety extra low voltage (SELV) for the battery The battery charging unit battery backup converter (BBC) can transfer energy both into the battery and out of it

325 Battery management system (BMS)

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

326 Battery

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

Technical Data

Operating instructions Powador-gridsave_EN Page 11

4 Technical Data

41 Electrical data

Connection box

Home power grid

Input voltage 230V 400V 50Hz 60Hz 3-phase (3 N PE)

Grid configuration TN-C TN-S TT

Grid monitoring Powador-protect (as per VDE-AR-N 4105)

Grid isolation Double insulated 3 or 4 pin

Rated operating current [A] 75

Rated switching current AC-1 [A] 100

Rated switching current AC-3 [A] 50 (22 kW at 400 V)

Connection cross-section [mmsup2] max 25

PV input

Input voltage [V] 300 to 800

Input current [A] 30 String

Strings 2

Isolation Yes rotary switch

Inverter type 6400 8000

Input levels

Max recommended PV generator power [W] 7700 9600

Rated power peak power [VA] 6400 7000 8000 9000

DC MPP range from [V] to [V] 360 590

Open circuit voltage [V] 800

Input current [A] 190 240

cos phi 08 inductive hellip 08 capacitive

Polarity safeguard Short-circuit diode

Feed-in phases 1

Capable of stand-alone operation Yes

Efficiency [] 966

Output levels

Output voltage 230V 50Hz 60Hz 1-phase

Rated current [A] 278 35

Connection cross-section [mmsup2] max 6

Monitoring Isolation Circuit breaker residual current circuit breaker (RCD)

Table 1 Electrical data

Technical Data

Page 12 Operating instructions Powador-gridsave_EN

Battery charging unit battery backup converter (BBC)

BBC power [W] 3300

HV voltage [V] 350 to 600

Battery voltage [V] 38 to 58

Efficiency [] 970

Table 1 Electrical data

42 Mechanical data

Battery system

Display 43 LCD touchscreen

Interfaces RS485 Sym-Bus Ethernet USB digital inputsoutputs

Cable insertion Cable fitting 2x M40 2x M32 4x M25 12x M16

Ambient temperature [degC] 0 +40

Humidity [] lt95 (non-condensing)

Cooling Forced cooling temperature-controlled

Noise emission [dB] lt45

Note regarding cooling Do no cover air inletsoutlets keep clear 20 cm to the right and left

Temperature monitoring Individual monitoring of components with shutdown in the event of excess temperature

Maximum installation elevation [m above mean sea level] 2000

Protection class IP21

Housing form 19 sheet-steel control cabinet

H x W x D [mm] 1600 x 620 x 600

Weight [kg] 2435

Inverter

Ambient temperature range [degC] -20 +60

Temperature monitoring Yes

Cooling Active cooling

Connections Quick INOUT plug connector and busbar clips rear side

H x W x D [mm] 22225 x 4826 x 460

Weight [kg] 25

Table 2 Mechanical data

Technical Data

Operating instructions Powador-gridsave_EN Page 13

Battery charging unit battery backup converter (BBC)

Ambient temperature range [degC] -20 +70

Temperature monitoring Yes

Cooling Active cooling

Housing 19 plug-in module aluminium

Connections Quick INOUT plug connector and busbar clips rear side

H x W x D [mm] 13325 x 4826 x 460

Weight [kg] 15

Temperature-dependent impedance matching with shutdown if the temperature is too high

Table 2 Mechanical data

Transportation and Delivery

Page 14 Operating instructions Powador-gridsave_EN

5 Transportation and Delivery

51 DeliveryThe battery system leaves KACO new energy in fully functional electrical and mechanical condition Special packaging ensures that the units are transported safely The shipping company is responsible for any trans-port damage that occurs

511 Scope of delivery

Pallet A B

Figure Figure 7 Scope of delivery pallet A Figure 8 Scope of delivery pallet B

Contents bull Battery system Powador-gridsave (incl connection box battery management system (BMS) industrial PC Plexiglas cover and accessories)

bull Inverter bull Battery charging unit battery backup converter

(BBC)bull Battery system plug-in modules 1-5 ST (scope of

delivery can be found on the delivery document)bull Documentation

Weight (kg) 187 max 155 177 (without with Euro pool pallet)

H x W x D [mm] 1780x800x820 1200x1200x800

Packaging Cardboard box with polystyrene inserts and closures

512 Check the equipment included

bull Battery system and plug-in modules should be inspected thoroughly for transport damagebull Do not install damaged components in the control cabinetbull In the event of damage to the battery plug-in modules contact the KACO new energy Hotline immediately

Transportation and Delivery

Operating instructions Powador-gridsave_EN Page 15

Authorised electrician

DANGERRisk of fatal injury if incompatible components are usedThe battery and power electronics can be damaged if different delivery batches are combined and will carry potentially fatal voltages if connected rsaquo Assemble the system using the components provided by KACO new energy only rsaquo Check the serial numbers on the delivery document against the serial numbers of the individual

units on pallets A and B

52 StorageIncorrect storage can lead to system malfunctions Therefore please observe the following conditionsbull If storing for longer than six months store the device in an interior room in its original packaging bull If the original packaging has been removed store the device in a cool dry interior roombull Storage temperature -20 degC to +70 degCbull Relative humidity 0 to 95 (non-condensing)bull If the device is stored for a relatively long time at high humidity the device must be left for more than one day to

dry out sufficiently before connection to the power grid

53 Transportation

WARNINGImpact hazard risk of breakage to the components in the battery systemThe centre of gravity is located in the upper part of the device rsaquo Transport the device upright together with the pallet rsaquo Do not expose the device or components to any shocks rsaquo After unloading at least two people are required to transport the cabinet

WARNINGDanger due to impact and incorrect storage of the batteriesIn the event of damage batteries can release hazardous electrolyte gases which will cause irreversible burns if they come into contact with the skin rsaquo Transport the batteries in the vendors original packaging only rsaquo Remove the batteries from the original packaging shortly before installation rsaquo Do not store batteries in cars or outdoors rsaquo Check the condition of the battery before use

NOTEThe precise specifications of the UN on the transport of lithium batteries can be found under the designation Model Regulations on the transport of dangerous goods Ref STSGAC101 Recommendations on the transport of dangerous goods Part III sub-section 383 ldquoManual of Tests and Criteriardquo Ref STSGAC1011

Assembling the device

Page 16 Operating instructions Powador-gridsave_EN

Authorised electrician

6 Assembling the device

61 Installation

DANGERRisk of fatal injury from fire or explosionsFire caused by flammable or explosive materials in the vicinity of the battery system can lead to serious injuries rsaquo Do not mount the inverter in potentially explosive atmospheres or in the vicinity of highly flamma-

ble materials

CAUTIONBattery system is very heavy ndash risk of injury rsaquo Be aware of the weight of the battery system during transport rsaquo Select suitable mounting location and mounting base rsaquo Only install the battery system with the help of a second person

CAUTIONEquipment damage caused by aggressive gases in combination with humidityThe housing may be seriously damaged by aggressive gases (ammonia sulphur and other chemi-cals) in combination with ambient humidity caused by weather conditions - Installation in rooms containing aggressive gases is not permitted

NOTEAccess in the event of maintenance or serviceAny additional costs arising from unfavourable structural or mounting conditions in the event of a KACO service call-out shall be billed to the customer

611 Installation location

bull Dry well ventilated the waste heat must be conducted away from the battery systembull Unobstructed air circulationbull Easily accessible from the front top and sides without requiring additional resourcesbull Indoors protected against direct sunlight and direct water contact

612 Foundation

bull With sufficient load-bearing capacitybull Made from heat-resistant material (up to 90 degC)bull Must be flame resistant

NOTEPower reduction due to heat accumulationIf the recommended minimum clearances are not observed the device may go into power regula-tion mode due to insufficient ventilation and the resulting heat build-up rsaquo The construction and installation of the device may be performed only by a qualified electrician in

accordance with the valid standards and regulations rsaquo Maintain minimum clearances rsaquo Ensure sufficient heat dissipation

Assembling the device

Operating instructions Powador-gridsave_EN Page 17

Authorised electrician

0deg

1000 mm

200 mm 200 mm

500 mm

min carrying capacity 300 kgmsup2

200 mm200 mm

50 mm

Figure 9 Minimum clearances at the installation and assembly location

CAUTIONRisk of injury if the battery system tips overRisk of tipping due to high centre of gravity particularly with the door open rsaquo Anchor the device securely to the floor immediately after installation rsaquo Open the housing door using the enclosed cabinet key only once the device has been securely

anchored

510 mm200 mm

200 mm

400

mm

12 mmmin 110 mm

DesignationHex head wood screw 8x80 DIN571-vz Fischer dowel S12 Flat washer M8 galvanised DIN9021-vz

Units444

Figure 10 Dimensions for anchoring to the floor Table 3 Mounting parts

62 Installing components

CAUTIONAvoid improper handlingImproper handling can cause damage to components rsaquo Damaged components must not be installed rsaquo Always put the plug-in modules down horizontally to avoid damage to the components

Assembling the device

Page 18 Operating instructions Powador-gridsave_EN

Authorised electrician

WARNINGDanger caused by short circuit or sparkingSerious injury from touching or connecting live components rsaquo Damaged components must not be installed

Preparation1 Check the conditions for the installation location2 Open the housing doors using the enclosed cabinet key3 The cables should be professionally laid and prepared for connection4 Follow the installation sequence (1-4 step(s))

621 Step 1 Fit the battery (batteries)

NOTEPlease read the notes on installation and connection in the enclosed manual Features for the battery unit

622 Step 2 Connect battery (batteries) to the battery management system (BMS)

NOTEPlease read the notes on installation and connection in the enclosed manual Features for the battery unit

623 Step 3 Fit the battery charging unit battery backup converter (BBC)

Battery (batteries) connected to the battery management system (BMS)1 Carefully insert battery charging unit battery backup converter (BBC) into the compartment provided for it 2 Push in completely to establish direct contact with the rear busbars3 Secure battery charging unit battery backup converter (BBC) using the screws supplied

624 Step 4 Fit the inverter

Battery charging unit battery backup converter (BBC) is fitted1 Carefully insert inverter into the compartment provided for it 2 Push in completely to establish direct contact with the rear busbars 3 Secure inverter using the screws supplied

CAUTIONDamage to the control unit from introducing foreign objectsForeign objects can impair the function of the control unit and cause damage rsaquo Do not remove the front panel rsaquo Foreign objects should be removed immediately

Installing the device

Operating instructions Powador-gridsave_EN Page 19

Authorised electrician

7 Installing the device

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched The device may only be opened or serviced by an authorised electricianThe device must be completely assembled before being connected electrically rsaquo Observe all safety regulations and current technical connection specifications of the responsible

power supply company rsaquo De-energise the device using the DC isolator switch circuit breaker and residual current circuit

breaker rsaquo Secure both sides against being inadvertently switched back on rsaquo Ensure that the AC and DC sides are completely isolated and voltage free rsaquo Never open the plug-in modules rsaquo Hazardous voltages are present at the busbars rsaquo Disconnect from the grid and plant supply rsaquo First connect the battery system in the connection area

71 Opening the connection area

3

1

2

Figure 11 Open cover plateKey

1 Cover plate 3 Fastening screw

2 Lock

Opening the connection area You have completed assembly

1 Remove the fastening screw for the upper cover plate2 Slide the cover plate forwards out of the lock3 Lift the cover plate upward to remove raquo Make the electrical connection

Installing the device

Page 20 Operating instructions Powador-gridsave_EN

Authorised electrician

72 Making the electrical connectionMake the connection to the PV generator as well as the grid connection using the connection terminals Note the following cable cross-sections

Connection Possible cable cross-section Length of insulation to be stripped offAC home power grid 05 - 16 mmsup2 with end sleeve

05 - 25 mmsup2 without end sleeve18 mm sleeve18-20 mm

PV connection 05 - 16 mmsup2 with end sleeve05 - 25 mmsup2 without end sleeve

18 mm sleeve17-19 mm

Inverter output 05 - 4 mmsup2 with end sleeve05 - 6 mmsup2 without end sleeve

12 mm sleeve11-13 mm

Potential-free contacts 034 - 15 mmsup2 with end sleeve034 - 25 mmsup2 without end sleeve

12 mm sleeve 9-10 mm

Table 4 Cable cross-sections for connection terminals

NOTEThe threaded connections should be matched to the cable cross-section

NOTEOnly conductors and no insulation should be inserted into the connection terminals Individual wires or cables with end sleeves with the appropriate cross-section can be inserted directly into the connection terminal without a toolFine-strand cables without end sleeve or thin conductors will need a screwdriver (plain slot 35 mm) for connection To do this insert the blade of the screwdriver into the recess provided The cable can be inserted into the spring terminal by pressing downwards The spring terminal closes on removal of the screw-driver

Installing the device

Operating instructions Powador-gridsave_EN Page 21

Authorised electrician

X2X1F1 F2 X7 X4 St1

St2

St3

2 3 541 6

Figure 12 View from above of the connection area

Key

1 AC grid input (M40 cable fitting) 4 Network interface (M32 cable fitting)

2 AC grid output (M40 cable fitting) 5 Inverter input (M16 cable fitting)

3 Inverter output (M32 cable fitting) 6 Other connections (M16 cable fitting)

F1 F2 X7 X4 St1

St2

St3

L1 L2 L3 N PE L1 L2 L3 N N PE PE

X1 X2

PV+

PV-

L1 L2 L3 N PE32A 32A PEN

Cust

omer

co

nnec

tion

Figure 13 View from above of the connection area

Key

X1 AC grid input (main junction box meter) X7 PV generator input

X2 AC grid output (building electrical system) F1 F2 Phase bridging fuse

X4 Inverter output St 1-3 Potential-free contacts control outputs

Installing the device

Page 22 Operating instructions Powador-gridsave_EN

Authorised electrician

721 Connecting to the power grid

Because the device is installed between the main junction boxmeter and the buildings electrical system the maxi-mum grid current to the service line must not exceed the rated operating current of the battery system The cable cross-section must be selected in accordance with applicable standards to suit the connected load instal-lation type etc Moreover the terminal area and size of the cable fitting must be noted

NOTEThe fuse rating for the cable should be max 63A (automatic circuit breaker or safety fuse) even if the cross-section of the installed cable would permit a higher fuse rating Always follow the applicable regulations regarding the cable cross-section and installation typeThe device supports standard grid configurations such as TN-C TN-S and TT TN-SIf a TN-S grid is present directly at the power input and output of the device L1-L3 N and PE must each be connected The home power grid should have 4-pin isolationTN-C4-pin grid isolation is factory preset and disconnects L1 L2 L3 and N In a TN-C grid the N conduc-tor must not be disconnected If a TN-S grid is present directly at the power input and output of the device a cable bridge (included in delivery) must be installed between the N terminal on X1 and the N terminal on X2 N and PE must additionally be connected together To do this simply insert the enclosed terminal link into the N and PE terminals TTIn the case of a TT grid L1-L3 N and PE must each be connected The home power grid should have 4-pin isolation

NOTEPlease check with the operator of the mains grid whether there are special regulations for grid connection Grid isolation is factory preset to 4-pin is fail-safe and provided with grid and system protection as per VDE-AR-N 4105

Making the grid connection Use cables with 5 wires (L1 brown L2 black L3 grey N blue PE greenyellow) and the correct

cross-section1 Loosen cable fitting for AC connection2 Remove the outer cladding of the AC cables3 Insert the AC cables through the cable fitting into the connection area4 Strip the insulation from the AC cables5 Remove connection terminals6 Connect the cables in line with the terminal labels (Figure 13 on page 21)7 Close the connection terminals8 Check that all connected cables are securely fitted9 Tighten the cable fitting10 To meet the requirements of protection rating IP21 close the unused cable fittings with blind caps raquo The battery system is connected to the power grid

NOTEAn AC-side disconnection unit must be provided during the final installation stage This disconnec-tion unit must be installed so that it can be accessed at any time without obstruction If a residual current circuit breaker is necessary due to the installation specification a type A residual current circuit breaker must be used

Installing the device

Operating instructions Powador-gridsave_EN Page 23

Authorised electrician

7211 Output from the inverterRecommended cable cross-sections for the inverter output and fuse rating of cables for fixed wiring accord-ing to VDE 0100 part 430The fuse rating for the cable is dependent on the cable cross-section max 40A automatic circuit breaker

NOTEWhen the line resistance is high (ie long grid-side cables) the voltage at the grid terminals of the inverter will increase during feed-in to the grid The inverter monitors this voltage If the voltage exceeds the country-specific grid overvoltage limit value the inverter switches off rsaquo Ensure that the conductor cross-sections are sufficiently large or that the cable lengths are suffi-

ciently short

NOTEIn order to avoid asymmetries in the grid systems with multiple battery systems should be designed so that the inverters in the devices feed into the grid in differing phases rsaquo Follow the connection conditions for the particular type of grid and the schematic illustration

below

Country and grid-type

Grid monitoring Required monitoring

max asymmetry between phases L1L2L3

DE-NSP Three-phase or single phase phase unbalanced load 46 kVA

Table 5 Grid-type-specific connection conditions

L1

L2

L3

N

Connection X1 Connection X1 Connection X1 Connection X1

L1 L2 L3 N PE L1 L2 L3 N PE L1 L2 L3 N PE L1 L2 L3 N PE

Powador-gridsave inverter1 L1 - L1 L2 - L2 L3 - L32 L1 - L2 L2 - L3 L3 - L1 3 L1 - L3 L2 - L1 L3 - L2 4 L1 - L1 L2 - L2 L3 - L3

Figure 14 Grid-side connection for systems with multiple battery systems with three-phase grid monitoring

Installing the device

Page 24 Operating instructions Powador-gridsave_EN

Authorised electrician

722 Connecting the PV generator

Connect the PV generator on the left in the connection area (Figure 13 on page 21) Use the provided M16 cable fittings A maximum of two strings can be connected For this reason a DC string fuse can be dispensed with

DANGERRisk of fatal injury due to contact voltagesRemoving the cables from the terminals without first disconnecting the PV generator from the device can cause serious damage to health or damage to the system rsaquo During installation Electrically disconnect the DC positive and DC negative from the protective

earth (PE) rsaquo Completely de-energise the system (AC home power grid AC circuit breaker residual current circuit

breaker DC isolator switch) rsaquo Disconnect the battery system from the PV generator using the integrated DC isolator switch rsaquo Remove DC plug connectors

NOTEIn accordance with IEC 61730 Class A connected PV modules must be dimensioned for the DC system voltage provided and at least for the value of the AC grid voltage

7221 Before connecting

Ensure that there is no ground fault1 Determine the DC voltage between the

ndash protective earth (PE) and the positive cable of the PV generator and between the ndash protective earth (PE) and the negative cable of the PV generator

If stable voltages can be measured there is a ground fault in the DC generator or its wiring The ratio between the measured voltages gives an indication as to the location of this fault

2 Rectify any faults before taking further measurements3 Determine the electrical resistance between the

ndash protective earth (PE) and the positive cable of the PV generator and between the ndash protective earth (PE) and the negative cable of the PV generator

In addition ensure that the PV generator has a total insulation resistance of more than 20 MOhm since the inverter will not feed in if the insulation resistance is too low

4 Rectify any faults before connecting the DC generator

7222 Connecting the PV generator

DANGERRisk of fatal injury due to electric shockSevere injury or death will result if the live connections are touched When there is solar radiation DC voltage will be present at the open ends of the DC cables rsaquo Do not touch the exposed ends of the cables rsaquo Avoid short circuits

Installing the device

Operating instructions Powador-gridsave_EN Page 25

Authorised electrician

Connecting the PV generator Use cables with the correct cross-section

1 Remove cable fittings for DC connection2 Remove the outer cladding of the DC cables3 Insert the DC cables through the cable fittings into the connection area4 Strip the insulation from the DC cables5 Remove connection terminals6 Connect the cables in line with the terminal labels (See Figure 13 on page 21)7 Close the connection terminals8 Check that all connected cables are securely fitted9 Tighten the cable fittings10 To meet the requirements of protection rating IP21 close the unused cable fittings with blind caps raquo The PV generator is connected to the inverter

73 Connecting the interfaces

731 Ethernet interface

Pre-assembled Ethernet cables can be connected using the RJ45 socket in the connection space

Connecting the Ethernet cable1 Remove closure cap from RJ45 socket2 Connect the Ethernet cable3 The energy management system can now obtain an IP address by DHCP and is also available via this in the

network

NOTEThe network settings can be amended later in the Settings menu using the EMS

NOTEUse a suitable category 5 network cable The maximum length of a network segment is 100 m Ensure that the cable is correctly assigned The Ethernet connection of the battery system supports auto-sensing You can use both crossed and 11 configured Ethernet connection cables

74 Sealing the connection area

1 Finally check the cabling2 Ensure that all cables are firmly mounted3 Check that the cable fitting is secure and tighten if necessary4 Remove cable offcuts and particles of dirt or dust5 Fit the cover and slide back until it engages into position6 Check that the position is correct7 Screw the fastening screw onto the front of the cover

Installing the device

Page 26 Operating instructions Powador-gridsave_EN

Authorised electrician

75 Starting up

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched Only appropriately qualified and authorised electricians may open install or maintain the battery system rsaquo Keep the front doors and covers closed during operation

NOTEInitial start-up should be carried out using the available public AC grid

76 Standard configuration

Factory settingsCountry configuration Germany

Grid guidelines Low voltage directive

Language German

Time UTC +1 Central European Time

User Standard

Network parameters DHCP (network settings will be obtained automatically from the router)

NOTEPlease state the desired power limitation (60 or 70 of the PV system capacity) when you order For other variations please notify your KACO contact so that the parameters can be set at the factory prior to delivery

Installing the device

Operating instructions Powador-gridsave_EN Page 27

Authorised electrician

761 Step 1 AC home power grid

Check all cables and connections before starting up1 Switch on the AC home power grid using the AC main switch raquo Powador-protect measurement and control unit starts up and monitors the AC grid raquo Two green LEDs indicate that the grid parameters are met raquo After a further 60 seconds (shortly after the backlighting in the Powador-protect goes out) the Powador-pro-

tect will switch on the home grid2 Configure Powador-protect according to the enclosed Powador-protect instructions

(The instructions are also available on the website at wwwkaconewenergyde) raquo The AC power is supplied in the normal way by the public grid

762 Step 2 AC supply from the battery system

Check all cables and connections before starting up1 Remove external isolation means from the device2 Switch on the circuit breaker raquo The LCD touchscreen on the front panel comes on and the energy management system (EMS) starts up

3 Switch on the residual current circuit breaker raquo The battery system starts up

763 Step 3 Switch on the PV system

1 Switch on any optional external PV isolator switches2 Set the internal DC isolator switch to ON raquo The inverter and the battery charging unit battery backup converter (BBC) are connected to the PV system raquo The device monitors the PV voltage for approx 60 seconds then optimisation of internal consumption takes

place

764 Step 4 Switch on batteries

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

765 Step 5 Activate energy management

NOTEKACO new energy cannot provide any support for problems regarding the IT infrastructure (eg router configuration IP address assignment ports etc) as the structure settings and configuration of the network environment can be complex and very different from place to place In the event of any problems please contact an IT service provider

Remote access activated 1 Please call the KACO Hotline to make an appointment for activation of energy management

Configuration and Operation

Page 28 Operating instructions Powador-gridsave_EN

Authorised electrician

8 Configuration and Operation

81 ControlsThe battery system is fitted with a touchscreen which allows it to be controlled very precisely In normal operation the display is switched off Touching the screen activates the display and after a configurable period of time without being touched the dis-play will deactivate If the screen-save function is switched off the touchscreen will be on continuously

NOTEDepending on the tolerances of the measuring elements the measured and displayed values are not always the actual values However the measuring elements ensure maximum solar yield Due to these tolerances the daily yields shown on the touchscreen may deviate from the values on the grid operatorrsquos feed-in meter by up to 15

3

1

45

2

Figure 15 Overview (home screen)

Key

1 Home button 4 Current time

2 System components 5 Menu name

3 More information

811 Information about the system

Open start screen View changesjumps to the home screen

Show component detail Parameters of the selected component

Settings Define settings for the active user

raquo Displays settings

Configuration and Operation

Operating instructions Powador-gridsave_EN Page 29

Controls Left arrow jump back to previous menu item Up and down arrows navigate through the menu or change a value

Left arrow displayed value is reduced by one increment Right arrow displayed value is increased by one increment or change to the submenu

Display fields Grey box Text or figures (not selectable) Blue box Calls up submenu for the display in question

Activate and deactivate Activate function by ticking the box

Table 6 Information about the system

812 System components

PV generator Display of the current generator data

power voltage current temperature in the inverter

Battery Display of the current battery status

power (charging or discharging) voltage current charge status available capacity temperature of battery

Grid Display of the following either fed-in or drawn from the grid

power voltage current for phase L1-L3 total output frequency

Consumer (load) Display of the consumer data

power voltage current for phase L1-L3 total output

Energy flow raquo Displays the current energy flow in the system

Table 7 Information about system components

Configuration and Operation

Page 30 Operating instructions Powador-gridsave_EN

813 Menu structure

Icons used

Display menu Submenu

Option menu

Menu Submenu Display setting

Action in this menumeaning

PV generator Details

Power Displays the current DC-side power

Voltage Displays the current DC-side voltage

Current Displays the current DC-side amperage

Temp inverter

Displays the current temperature in the inverter housing

Battery Details

Power Displays the current AC-side power

Voltage Displays the current AC-side voltage

Current Displays the current AC-side amperage

Charge status Displays the current charge status

Capacity Displays the current battery capacity

Temperature Displays the current measured temperature of the battery

Grid Details

Power Displays the current AC-side power being drawn or fed-in

Voltage Displays the AC-side voltage being applied

Current Displays the current AC-side amperage being drawn or fed-in

Total output Displays the current AC-side total output being drawn or fed-in

Frequency Displays the frequency currently being applied to the grid junction

Consumer (load) Details

Power Displays the current AC-side power being drawn

Voltage Displays the current AC-side voltage being applied

Current Displays the current AC-side amperage being drawn

Total output Displays the current AC-side total output being drawn

Configuration and Operation

Operating instructions Powador-gridsave_EN Page 31

Menu Submenu Display setting

Action in this menumeaning

Settings

Country amp directive display

Display of the country settings voltage directives and grid type

Select menu language

DateTime Specify time zone date format and date and time

Screen Activate screen-save function and set the delay period

Network settings

Display of the network settings Configure network settings Once the DHCP server becomes available the IP

address subnet mask gateway and DNS server are automatically applied and the aforemen-tioned menu items are hidden

Off DHCP deactivated make settings manually

Version Displays the installed software version and built-in HW components (inverter BBC battery)

Vendor The touchscreen shows information about the device vendor

NOTEAs changes to the software are possible after the manual has been printed the illustrations and descriptions of the functions in these operating instructions may deviate from the software Please therefore note the current Application Notes on our website

MaintenanceTroubleshooting

Page 32 Operating instructions Powador-gridsave_EN

9 MaintenanceTroubleshooting

91 Visual inspectionInspect the device and the cables for visible external damage and note the operating status display In case of damage notify your installer Repairs may only be carried out by authorised electricians

NOTEThe battery system should be checked for proper operation by a qualified electrician at regular intervals

92 Cleaning the device

DANGERLethal voltages in the battery systemSerious injuries or death can result if moisture enters the system rsaquo Only use completely dry objects to clean the battery system rsaquo Only clean the outside of the battery system

Cleaning the battery system Do not use compressed air Use a vacuum cleaner or a soft brush to remove dust from the fan cover and from the top of the inverter on a

regular basis Remove dust from the ventilation inlets if necessary

MaintenanceTroubleshooting

Operating instructions Powador-gridsave_EN Page 33

Authorised electrician

93 Maintenance

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched The device is only permitted to be opened or serviced by an authorised electrician rsaquo Observe all safety regulations and the current technical connection specifications from the relevant

power supply company rsaquo Disconnect the AC and DC sides rsaquo Secure the AC and DC sides from being inadvertently switched back on rsaquo Only then should the device be opened rsaquo After shutdown wait at least 30 minutes before working on the device

CAUTIONDestruction of the DC connectionThe connection terminals can be destroyed by arcing if disconnected while still live rsaquo It is absolutely essential that the shutdown sequence be carried out in the correct order (See sec-

tion 111 on page 35)

94 Faults

941 Procedure

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched

When a fault occurs notify an appropriately authorised and qualified electrician or KACO new energy GmbH Service

Service

Page 34 Operating instructions Powador-gridsave_EN

10 ServiceIf 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 efficientlybull Serial nobull SW version of the components (the software version can be found in the Settings menu using the EMS)bull Module type and string circuitbull Date of installation Start-up reportbull Consignment identification Delivery address Contact person (with telephone number)bull Information about the accessibility of the installation site

Any additional costs arising from unfavourable structural or mounting conditions shall be billed to the customer

You can find our warranty conditions on our websitehttpkaco-newenergycomservicewarrantyFrom there you can easily navigate to our international websites by clicking on the appropriate flag

Please use our website to register your unit immediatelyYou can also select the appropriate flag on this page to access the website for your own countryIn this manner you can assist us in providing you with the quickest service possible Note The maximum length of the warranty is based on the currently applicable national warranty conditions

We have prepared a template for complaints This can be found at httpskaco-newenergycomservicecustomer-service

Hotlines

Technical troubleshooting Technical consultation

Inverters and battery systems ()

+49 (0) 71323818-660 +49 (0) 71323818-660

Data logging and accessories +49 (0) 71323818-690 +49 (0) 71323818-690

Construction site emergency () +49 (0) 71323818-630

Customer help desk Monday to Friday from 730 am to 530 pm (CET)

() Also on Saturdays from 800 am to 200 pm (CET)

ShutdownDisassembly

Operating instructions Powador-gridsave_EN Page 35

11 ShutdownDisassembly

111 Switching off the device

DANGERLethal voltages are still present in the terminals and cables even after switching off and discon-nection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched rsaquo Complete de-energisation only occurs if the bulk power supply is switched off upstream of the bat-

tery system

DANGERDestruction of the DC plug connectorDC plug connectors can be destroyed by arcing if disconnected while still live rsaquo It is absolutely essential that the following shutdown sequence is observed

1111 Step 1 Shutting down the PV system

1 Switch off any optional external PV isolator switches2 Set the internal DC isolator switch to OFF raquo The inverter and battery charging unit battery backup converter (BBC) are disconnected

1112 Step 2 Disconnect the batteries

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

1113 Step 3 Disconnect the AC supply

1 Connect external isolation means to the device2 Switch off the circuit breaker 3 Switch off the residual current circuit breaker raquo The battery system is switched off

1114 Step 4 AC home power grid

1 Shutdown the AC home power grid using the AC main switch raquo The battery system can be uninstalled

Disposal

Page 36 Operating instructions Powador-gridsave_EN

112 Uninstalling the device

NOTETo uninstall follow the same sequence as for installation but in reverse order

Switch off the device1 Unlock and open the housing door2 Remove the upper cover3 Release the DC and AC cables from the connection terminals4 Pull out the cables raquo The battery system is uninstalled Continue with the disassembly

113 Disassembling the device

NOTETo disassemble follow the same sequence as for assembly but in reverse order

Switch off the device1 Uninstall the components2 Remove the fastening from the device3 Securely pack up the battery system if it is to be used later

or have the battery system disposed of in accordance with section 12 on page 36

12 DisposalFor the most part both the battery system and the corresponding transport packaging are made from recyclable raw materialsBatteries and components Do not dispose of faulty batteries or the components together with household waste Ensure that the old device and accessories are disposed of in a proper mannerPackaging Ensure that the transport packaging is disposed of properlyBatteriesUsed or faulty batteries must be transported in special packaging If you need such packaging please contact the KACO Hotline

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

Appendix

Operating instructions Powador-gridsave_EN Page 37

13 Appendix

EU Declaration of Conformity

Vendorrsquos name and address

KACO new energy GmbH Carl-Zeiss-Straszlige 1 74172 Neckarsulm Germany

Product description Battery system

Type designation Powador-gridsave 135 kWh 6400 Powador-gridsave 135 kWh 8000

Powador-gridsave 270 kWh 6400 Powador-gridsave 270 kWh 8000

Powador-gridsave 405 kWh 6400 Powador-gridsave 405 kWh 8000

Powador-gridsave 540 kWh 6400 Powador-gridsave 540 kWh 8000

Powador-gridsave 577 kWh 6400 Powador-gridsave 577 kWh 8000

Powador-gridsave 675 kWh 6400 Powador-gridsave 675 kWh 8000

This is to confirm that the units listed above comply with the protection requirements set forth in the Directive of the Council of the European Union of 15th December 2004 on the harmonisation of the laws of the member states relating to Electromagnetic Compatibility (2004108EC) and the Low Voltage Directive (200695EC)The units are compliant with the following standards

200695EC ldquoDirective relating to electrical equipment designed for use within specific voltage limitsrdquo

Safety of the unitIEC 62109-12010IEC 62109-22011

2004108EC ldquoDirective relating to electromagneticcompatibilityrdquo

Interference immunityEN 61000-6-22005 Emitted interferenceEN 61000-6-32007

Secondary effects on the gridEN 61000-3-112000EN 61000-3-122005

The types mentioned above are therefore labelled with the CE markUnauthorised modifications to the supplied units andor any use of the units that is contrary to their intended use render this Declaration of Conformity null and void

Neckarsulm 0711 2013KACO new energy GmbH

pp Volker DietrichEnergy systems engineering management

Disposal

Page 38 Operating instructions Powador-gridsave_EN

Carl-Zeiss-Straszlige 1 middot 74172 Neckarsulm middot Germany middot Phone +49 7132 3818-0 middot Fax +49 7132 3818-703 middot infokaco-newenergyde middot wwwkaco-newenergyde

The

text

and

figu

res

refle

ct th

e cu

rren

t tec

hnic

al s

tate

at t

he ti

me

of p

rintin

g S

ubje

ct to

tech

nica

l cha

nges

Err

ors

and

omis

sion

s ex

cept

ed

3006

856-

01-1

4030

5

  • 1General Information
    • 11About this document
    • 12Name plate
    • 13Additional information
    • 14Intended use
      • 2Safety
        • 21Protection features
          • 3Description
            • 31Mode of Operation
            • 32Summary of the components
              • 4Technical Data
                • 41Electrical data
                • 42Mechanical data
                  • 5Transportation and Delivery
                    • 51Delivery
                    • 52Storage
                    • 53Transportation
                      • 6Assembling the device
                        • 61Installation
                        • 62Installing components
                          • 7Installing the device
                            • 71Opening the connection area
                            • 72Making the electrical connection
                            • 73Connecting the interfaces
                            • 74Sealing the connection area
                            • 75Starting up
                            • 76Standard configuration
                              • 8Configuration and Operation
                                • 81Controls
                                  • 9MaintenanceTroubleshooting
                                    • 91Visual inspection
                                    • 92Cleaning the device
                                    • 93Maintenance
                                    • 94Faults
                                      • 10Service
                                      • 11ShutdownDisassembly
                                        • 111Switching off the device
                                        • 112Uninstalling the device
                                        • 113Disassembling the device
                                          • 12Disposal
                                          • 13Appendix

General Information

Operating instructions Powador-gridsave_EN Page 5

115 Instructions symbols guide

Instructions Prerequisite for the step

1 Carry out step

2 (Additional steps if applicable)

raquo Results of the step

12 Name plate The name plate is located on the inside of the cabinet door

13 Additional information

NOTEThe battery system uses lithium-based batteriesPlease check whether your insurance includes conditions for installation and operation of lithium batteries The retro-fitting of fire or smoke alarms may be necessary

NOTEThe EU Declaration of Conformity can be found in the appendixFor information on grid coupling grid protection and safety parameters along with more detailed instructions go to our web site httpkaco-newenergycomde

14 Intended useThe device is built according to the latest technological standards and safety regulations Nevertheless improper use may cause lethal hazards for the operator or third parties or may result in damage to the device and other property Operate the device only with a permanent connection to the public power grid Any other or additional use of the device is deemed improper This includes bull Mobile usebull Use in potentially explosive atmospheresbull Use in rooms where the humidity is higher than 95bull Operation outside of the specifications intended by the manufacturer

Safety

Page 6 Operating instructions Powador-gridsave_EN

2 SafetyDANGER

Lethal voltages are still present in the terminals and cables even after switching off and discon-nection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched Only authorised electricians are permitted to open install or maintain the device rsaquo Keep the device closed when in operation rsaquo Do not touch the cables or terminals when switching the unit on and off rsaquo Do not make any modifications to the device

The electrician is responsible for observing all existing standards and regulations bull Keep unauthorised persons away from the device and PV systembull Pay particular attention to the standard IEC 60364-7-7122002 ldquoRequirements for special installations or locations ndash

solar photovoltaic (PV) power supply systemsrdquobull Ensure operational safety by providing proper grounding conductor dimensioning and appropriate protection

against short circuitingbull Observe all safety instructions on the device and in these operating instructionsbull Switch off all voltage sources and secure them against being inadvertently switched back on before performing

visual inspections and maintenancebull When taking measurements while the battery system is live

ndash Do not touch the electrical connections ndash Remove all jewellery from your wrists and fingers ndash Ensure that the testing equipment is in safe operating condition

bull Stand on an insulated surface when working on the devicebull Do not place any objects on the housingbull Modifications to the surroundings of the device must comply with the applicable national and local standardsbull When working on the PV generator in addition to disconnecting this from the grid it is also necessary to switch off

the DC voltage using the DC isolator switch on the device

21 Protection featuresFor your safety the following monitoring and protection functions are integrated into the battery systembull Overvoltage conductorsvaristors to protect the power semiconductors from high-energy transients on the grid

and generator sidebull Temperature monitoring for the heat sink and batteriesbull Measurement of current in each battery modulebull Multilevel redundant overload exhaustive discharge and overcurrent protectionbull Comprehensive and regular self-testing of all componentsbull EMC filters to protect the inverter from high-frequency grid interferencebull Grid monitoring disconnection in accordance with VDE-AR-N 4105bull Overcurrent protection for the batterybull Fail-safe phase bridging

Description

Operating instructions Powador-gridsave_EN Page 7

3 Description

31 Mode of OperationThe battery system optimises internal consumption thus reducing the amount of electrical energy needed from the public grid Energy from a photovoltaic system that is not required in the home at that time is stored in a battery and supplied to the consumer as necessary Consumers are supplied with their own energy by the device in a manner which is flexible and optimised to their personal habits

311 System overview

BPM

Gridsave

Measurement

Meassurement

AC

Power Meterproduction

Grid

Distribution Box

Communication

BidirectionalPower Meter

AC circuit breaker

DC circuit breaker

Door

PV-Generator

BBC

350 - 800 VDC

3 x 400 VAC

Inverter

U [V]I [A]

P [W]

U [V]I [A]

P [W]

Powador Protect

Load

3 x 400 VAC

BMS

BatteryBattery

Battery

Power flow

Power flow

Power flow

RCD

Power supply

3 x 400 VAC

AC Main switch

3

40A

3

63A

40A

4

4

Energie- management-

System(EMS)

Figure 1 Schematic overview

Description

Page 8 Operating instructions Powador-gridsave_EN

312 Configuration

Powador-protect

CONNECTION BOX

PV INVERTER

BATTERY CONVERTER

PV-Circuit Breaker

ON

OFF

AC-Circuit Breaker

Residual-Current-Circuit Breaker

BATTERY

1

3

4

5

2

Figure 2 Configuration of the battery system

1 Connection box 4 Battery charging unit battery backup converter (BBC) 1

2 Energy management system (EMS) with LCD touchscreen

5 Battery unit with controller

3 Inverter

Description

Operating instructions Powador-gridsave_EN Page 9

32 Summary of the components

321 Connection box

ON

OFF

Powador Protect

off off off

B 32AAC-Circuit Breaker

IN=40AΔI=300mA

RCCB

off

Test

Typ A

CONNECTION BOX

1 2 3 4

Figure 3 Connection box

Key Function

1 DC isolator switch Disconnects the PV generator from the inverter battery unit

2 Measurement and control unit Powador-protect

Three-phase monitoring of the grid switches off the power supply in the event of impermissible voltage or frequency

3 Circuit breaker Disconnects the inverter from the AC grid

4 Residual current circuit breaker

Protects individuals and the installation by isolating the inverter

NOTEThe DC isolator switch circuit breaker and residual current circuit breaker will switch off the battery system Power will then be supplied from the public grid

322 Energy management system

Figure 4 Energy management system (EMS) with LCD touchscreen

NOTEThe energy management system (EMS) displays all relevant parameters in order to ensure optimum operation

Description

Page 10 Operating instructions Powador-gridsave_EN

323 Inverter

PV INVERTER

Figure 5 Inverter

NOTEThe inverter converts the DC voltage from the PV generator and the battery into AC voltage

324 Battery charging unit battery backup converter (BBC)

BATTERY CONVERTER

Figure 6 Battery charging unit battery backup converter (BBC)

NOTEThe battery charging unit battery backup converter (BBC) is the interface to the battery The high voltage from the PV generator is converted into non-hazardous safety extra low voltage (SELV) for the battery The battery charging unit battery backup converter (BBC) can transfer energy both into the battery and out of it

325 Battery management system (BMS)

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

326 Battery

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

Technical Data

Operating instructions Powador-gridsave_EN Page 11

4 Technical Data

41 Electrical data

Connection box

Home power grid

Input voltage 230V 400V 50Hz 60Hz 3-phase (3 N PE)

Grid configuration TN-C TN-S TT

Grid monitoring Powador-protect (as per VDE-AR-N 4105)

Grid isolation Double insulated 3 or 4 pin

Rated operating current [A] 75

Rated switching current AC-1 [A] 100

Rated switching current AC-3 [A] 50 (22 kW at 400 V)

Connection cross-section [mmsup2] max 25

PV input

Input voltage [V] 300 to 800

Input current [A] 30 String

Strings 2

Isolation Yes rotary switch

Inverter type 6400 8000

Input levels

Max recommended PV generator power [W] 7700 9600

Rated power peak power [VA] 6400 7000 8000 9000

DC MPP range from [V] to [V] 360 590

Open circuit voltage [V] 800

Input current [A] 190 240

cos phi 08 inductive hellip 08 capacitive

Polarity safeguard Short-circuit diode

Feed-in phases 1

Capable of stand-alone operation Yes

Efficiency [] 966

Output levels

Output voltage 230V 50Hz 60Hz 1-phase

Rated current [A] 278 35

Connection cross-section [mmsup2] max 6

Monitoring Isolation Circuit breaker residual current circuit breaker (RCD)

Table 1 Electrical data

Technical Data

Page 12 Operating instructions Powador-gridsave_EN

Battery charging unit battery backup converter (BBC)

BBC power [W] 3300

HV voltage [V] 350 to 600

Battery voltage [V] 38 to 58

Efficiency [] 970

Table 1 Electrical data

42 Mechanical data

Battery system

Display 43 LCD touchscreen

Interfaces RS485 Sym-Bus Ethernet USB digital inputsoutputs

Cable insertion Cable fitting 2x M40 2x M32 4x M25 12x M16

Ambient temperature [degC] 0 +40

Humidity [] lt95 (non-condensing)

Cooling Forced cooling temperature-controlled

Noise emission [dB] lt45

Note regarding cooling Do no cover air inletsoutlets keep clear 20 cm to the right and left

Temperature monitoring Individual monitoring of components with shutdown in the event of excess temperature

Maximum installation elevation [m above mean sea level] 2000

Protection class IP21

Housing form 19 sheet-steel control cabinet

H x W x D [mm] 1600 x 620 x 600

Weight [kg] 2435

Inverter

Ambient temperature range [degC] -20 +60

Temperature monitoring Yes

Cooling Active cooling

Connections Quick INOUT plug connector and busbar clips rear side

H x W x D [mm] 22225 x 4826 x 460

Weight [kg] 25

Table 2 Mechanical data

Technical Data

Operating instructions Powador-gridsave_EN Page 13

Battery charging unit battery backup converter (BBC)

Ambient temperature range [degC] -20 +70

Temperature monitoring Yes

Cooling Active cooling

Housing 19 plug-in module aluminium

Connections Quick INOUT plug connector and busbar clips rear side

H x W x D [mm] 13325 x 4826 x 460

Weight [kg] 15

Temperature-dependent impedance matching with shutdown if the temperature is too high

Table 2 Mechanical data

Transportation and Delivery

Page 14 Operating instructions Powador-gridsave_EN

5 Transportation and Delivery

51 DeliveryThe battery system leaves KACO new energy in fully functional electrical and mechanical condition Special packaging ensures that the units are transported safely The shipping company is responsible for any trans-port damage that occurs

511 Scope of delivery

Pallet A B

Figure Figure 7 Scope of delivery pallet A Figure 8 Scope of delivery pallet B

Contents bull Battery system Powador-gridsave (incl connection box battery management system (BMS) industrial PC Plexiglas cover and accessories)

bull Inverter bull Battery charging unit battery backup converter

(BBC)bull Battery system plug-in modules 1-5 ST (scope of

delivery can be found on the delivery document)bull Documentation

Weight (kg) 187 max 155 177 (without with Euro pool pallet)

H x W x D [mm] 1780x800x820 1200x1200x800

Packaging Cardboard box with polystyrene inserts and closures

512 Check the equipment included

bull Battery system and plug-in modules should be inspected thoroughly for transport damagebull Do not install damaged components in the control cabinetbull In the event of damage to the battery plug-in modules contact the KACO new energy Hotline immediately

Transportation and Delivery

Operating instructions Powador-gridsave_EN Page 15

Authorised electrician

DANGERRisk of fatal injury if incompatible components are usedThe battery and power electronics can be damaged if different delivery batches are combined and will carry potentially fatal voltages if connected rsaquo Assemble the system using the components provided by KACO new energy only rsaquo Check the serial numbers on the delivery document against the serial numbers of the individual

units on pallets A and B

52 StorageIncorrect storage can lead to system malfunctions Therefore please observe the following conditionsbull If storing for longer than six months store the device in an interior room in its original packaging bull If the original packaging has been removed store the device in a cool dry interior roombull Storage temperature -20 degC to +70 degCbull Relative humidity 0 to 95 (non-condensing)bull If the device is stored for a relatively long time at high humidity the device must be left for more than one day to

dry out sufficiently before connection to the power grid

53 Transportation

WARNINGImpact hazard risk of breakage to the components in the battery systemThe centre of gravity is located in the upper part of the device rsaquo Transport the device upright together with the pallet rsaquo Do not expose the device or components to any shocks rsaquo After unloading at least two people are required to transport the cabinet

WARNINGDanger due to impact and incorrect storage of the batteriesIn the event of damage batteries can release hazardous electrolyte gases which will cause irreversible burns if they come into contact with the skin rsaquo Transport the batteries in the vendors original packaging only rsaquo Remove the batteries from the original packaging shortly before installation rsaquo Do not store batteries in cars or outdoors rsaquo Check the condition of the battery before use

NOTEThe precise specifications of the UN on the transport of lithium batteries can be found under the designation Model Regulations on the transport of dangerous goods Ref STSGAC101 Recommendations on the transport of dangerous goods Part III sub-section 383 ldquoManual of Tests and Criteriardquo Ref STSGAC1011

Assembling the device

Page 16 Operating instructions Powador-gridsave_EN

Authorised electrician

6 Assembling the device

61 Installation

DANGERRisk of fatal injury from fire or explosionsFire caused by flammable or explosive materials in the vicinity of the battery system can lead to serious injuries rsaquo Do not mount the inverter in potentially explosive atmospheres or in the vicinity of highly flamma-

ble materials

CAUTIONBattery system is very heavy ndash risk of injury rsaquo Be aware of the weight of the battery system during transport rsaquo Select suitable mounting location and mounting base rsaquo Only install the battery system with the help of a second person

CAUTIONEquipment damage caused by aggressive gases in combination with humidityThe housing may be seriously damaged by aggressive gases (ammonia sulphur and other chemi-cals) in combination with ambient humidity caused by weather conditions - Installation in rooms containing aggressive gases is not permitted

NOTEAccess in the event of maintenance or serviceAny additional costs arising from unfavourable structural or mounting conditions in the event of a KACO service call-out shall be billed to the customer

611 Installation location

bull Dry well ventilated the waste heat must be conducted away from the battery systembull Unobstructed air circulationbull Easily accessible from the front top and sides without requiring additional resourcesbull Indoors protected against direct sunlight and direct water contact

612 Foundation

bull With sufficient load-bearing capacitybull Made from heat-resistant material (up to 90 degC)bull Must be flame resistant

NOTEPower reduction due to heat accumulationIf the recommended minimum clearances are not observed the device may go into power regula-tion mode due to insufficient ventilation and the resulting heat build-up rsaquo The construction and installation of the device may be performed only by a qualified electrician in

accordance with the valid standards and regulations rsaquo Maintain minimum clearances rsaquo Ensure sufficient heat dissipation

Assembling the device

Operating instructions Powador-gridsave_EN Page 17

Authorised electrician

0deg

1000 mm

200 mm 200 mm

500 mm

min carrying capacity 300 kgmsup2

200 mm200 mm

50 mm

Figure 9 Minimum clearances at the installation and assembly location

CAUTIONRisk of injury if the battery system tips overRisk of tipping due to high centre of gravity particularly with the door open rsaquo Anchor the device securely to the floor immediately after installation rsaquo Open the housing door using the enclosed cabinet key only once the device has been securely

anchored

510 mm200 mm

200 mm

400

mm

12 mmmin 110 mm

DesignationHex head wood screw 8x80 DIN571-vz Fischer dowel S12 Flat washer M8 galvanised DIN9021-vz

Units444

Figure 10 Dimensions for anchoring to the floor Table 3 Mounting parts

62 Installing components

CAUTIONAvoid improper handlingImproper handling can cause damage to components rsaquo Damaged components must not be installed rsaquo Always put the plug-in modules down horizontally to avoid damage to the components

Assembling the device

Page 18 Operating instructions Powador-gridsave_EN

Authorised electrician

WARNINGDanger caused by short circuit or sparkingSerious injury from touching or connecting live components rsaquo Damaged components must not be installed

Preparation1 Check the conditions for the installation location2 Open the housing doors using the enclosed cabinet key3 The cables should be professionally laid and prepared for connection4 Follow the installation sequence (1-4 step(s))

621 Step 1 Fit the battery (batteries)

NOTEPlease read the notes on installation and connection in the enclosed manual Features for the battery unit

622 Step 2 Connect battery (batteries) to the battery management system (BMS)

NOTEPlease read the notes on installation and connection in the enclosed manual Features for the battery unit

623 Step 3 Fit the battery charging unit battery backup converter (BBC)

Battery (batteries) connected to the battery management system (BMS)1 Carefully insert battery charging unit battery backup converter (BBC) into the compartment provided for it 2 Push in completely to establish direct contact with the rear busbars3 Secure battery charging unit battery backup converter (BBC) using the screws supplied

624 Step 4 Fit the inverter

Battery charging unit battery backup converter (BBC) is fitted1 Carefully insert inverter into the compartment provided for it 2 Push in completely to establish direct contact with the rear busbars 3 Secure inverter using the screws supplied

CAUTIONDamage to the control unit from introducing foreign objectsForeign objects can impair the function of the control unit and cause damage rsaquo Do not remove the front panel rsaquo Foreign objects should be removed immediately

Installing the device

Operating instructions Powador-gridsave_EN Page 19

Authorised electrician

7 Installing the device

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched The device may only be opened or serviced by an authorised electricianThe device must be completely assembled before being connected electrically rsaquo Observe all safety regulations and current technical connection specifications of the responsible

power supply company rsaquo De-energise the device using the DC isolator switch circuit breaker and residual current circuit

breaker rsaquo Secure both sides against being inadvertently switched back on rsaquo Ensure that the AC and DC sides are completely isolated and voltage free rsaquo Never open the plug-in modules rsaquo Hazardous voltages are present at the busbars rsaquo Disconnect from the grid and plant supply rsaquo First connect the battery system in the connection area

71 Opening the connection area

3

1

2

Figure 11 Open cover plateKey

1 Cover plate 3 Fastening screw

2 Lock

Opening the connection area You have completed assembly

1 Remove the fastening screw for the upper cover plate2 Slide the cover plate forwards out of the lock3 Lift the cover plate upward to remove raquo Make the electrical connection

Installing the device

Page 20 Operating instructions Powador-gridsave_EN

Authorised electrician

72 Making the electrical connectionMake the connection to the PV generator as well as the grid connection using the connection terminals Note the following cable cross-sections

Connection Possible cable cross-section Length of insulation to be stripped offAC home power grid 05 - 16 mmsup2 with end sleeve

05 - 25 mmsup2 without end sleeve18 mm sleeve18-20 mm

PV connection 05 - 16 mmsup2 with end sleeve05 - 25 mmsup2 without end sleeve

18 mm sleeve17-19 mm

Inverter output 05 - 4 mmsup2 with end sleeve05 - 6 mmsup2 without end sleeve

12 mm sleeve11-13 mm

Potential-free contacts 034 - 15 mmsup2 with end sleeve034 - 25 mmsup2 without end sleeve

12 mm sleeve 9-10 mm

Table 4 Cable cross-sections for connection terminals

NOTEThe threaded connections should be matched to the cable cross-section

NOTEOnly conductors and no insulation should be inserted into the connection terminals Individual wires or cables with end sleeves with the appropriate cross-section can be inserted directly into the connection terminal without a toolFine-strand cables without end sleeve or thin conductors will need a screwdriver (plain slot 35 mm) for connection To do this insert the blade of the screwdriver into the recess provided The cable can be inserted into the spring terminal by pressing downwards The spring terminal closes on removal of the screw-driver

Installing the device

Operating instructions Powador-gridsave_EN Page 21

Authorised electrician

X2X1F1 F2 X7 X4 St1

St2

St3

2 3 541 6

Figure 12 View from above of the connection area

Key

1 AC grid input (M40 cable fitting) 4 Network interface (M32 cable fitting)

2 AC grid output (M40 cable fitting) 5 Inverter input (M16 cable fitting)

3 Inverter output (M32 cable fitting) 6 Other connections (M16 cable fitting)

F1 F2 X7 X4 St1

St2

St3

L1 L2 L3 N PE L1 L2 L3 N N PE PE

X1 X2

PV+

PV-

L1 L2 L3 N PE32A 32A PEN

Cust

omer

co

nnec

tion

Figure 13 View from above of the connection area

Key

X1 AC grid input (main junction box meter) X7 PV generator input

X2 AC grid output (building electrical system) F1 F2 Phase bridging fuse

X4 Inverter output St 1-3 Potential-free contacts control outputs

Installing the device

Page 22 Operating instructions Powador-gridsave_EN

Authorised electrician

721 Connecting to the power grid

Because the device is installed between the main junction boxmeter and the buildings electrical system the maxi-mum grid current to the service line must not exceed the rated operating current of the battery system The cable cross-section must be selected in accordance with applicable standards to suit the connected load instal-lation type etc Moreover the terminal area and size of the cable fitting must be noted

NOTEThe fuse rating for the cable should be max 63A (automatic circuit breaker or safety fuse) even if the cross-section of the installed cable would permit a higher fuse rating Always follow the applicable regulations regarding the cable cross-section and installation typeThe device supports standard grid configurations such as TN-C TN-S and TT TN-SIf a TN-S grid is present directly at the power input and output of the device L1-L3 N and PE must each be connected The home power grid should have 4-pin isolationTN-C4-pin grid isolation is factory preset and disconnects L1 L2 L3 and N In a TN-C grid the N conduc-tor must not be disconnected If a TN-S grid is present directly at the power input and output of the device a cable bridge (included in delivery) must be installed between the N terminal on X1 and the N terminal on X2 N and PE must additionally be connected together To do this simply insert the enclosed terminal link into the N and PE terminals TTIn the case of a TT grid L1-L3 N and PE must each be connected The home power grid should have 4-pin isolation

NOTEPlease check with the operator of the mains grid whether there are special regulations for grid connection Grid isolation is factory preset to 4-pin is fail-safe and provided with grid and system protection as per VDE-AR-N 4105

Making the grid connection Use cables with 5 wires (L1 brown L2 black L3 grey N blue PE greenyellow) and the correct

cross-section1 Loosen cable fitting for AC connection2 Remove the outer cladding of the AC cables3 Insert the AC cables through the cable fitting into the connection area4 Strip the insulation from the AC cables5 Remove connection terminals6 Connect the cables in line with the terminal labels (Figure 13 on page 21)7 Close the connection terminals8 Check that all connected cables are securely fitted9 Tighten the cable fitting10 To meet the requirements of protection rating IP21 close the unused cable fittings with blind caps raquo The battery system is connected to the power grid

NOTEAn AC-side disconnection unit must be provided during the final installation stage This disconnec-tion unit must be installed so that it can be accessed at any time without obstruction If a residual current circuit breaker is necessary due to the installation specification a type A residual current circuit breaker must be used

Installing the device

Operating instructions Powador-gridsave_EN Page 23

Authorised electrician

7211 Output from the inverterRecommended cable cross-sections for the inverter output and fuse rating of cables for fixed wiring accord-ing to VDE 0100 part 430The fuse rating for the cable is dependent on the cable cross-section max 40A automatic circuit breaker

NOTEWhen the line resistance is high (ie long grid-side cables) the voltage at the grid terminals of the inverter will increase during feed-in to the grid The inverter monitors this voltage If the voltage exceeds the country-specific grid overvoltage limit value the inverter switches off rsaquo Ensure that the conductor cross-sections are sufficiently large or that the cable lengths are suffi-

ciently short

NOTEIn order to avoid asymmetries in the grid systems with multiple battery systems should be designed so that the inverters in the devices feed into the grid in differing phases rsaquo Follow the connection conditions for the particular type of grid and the schematic illustration

below

Country and grid-type

Grid monitoring Required monitoring

max asymmetry between phases L1L2L3

DE-NSP Three-phase or single phase phase unbalanced load 46 kVA

Table 5 Grid-type-specific connection conditions

L1

L2

L3

N

Connection X1 Connection X1 Connection X1 Connection X1

L1 L2 L3 N PE L1 L2 L3 N PE L1 L2 L3 N PE L1 L2 L3 N PE

Powador-gridsave inverter1 L1 - L1 L2 - L2 L3 - L32 L1 - L2 L2 - L3 L3 - L1 3 L1 - L3 L2 - L1 L3 - L2 4 L1 - L1 L2 - L2 L3 - L3

Figure 14 Grid-side connection for systems with multiple battery systems with three-phase grid monitoring

Installing the device

Page 24 Operating instructions Powador-gridsave_EN

Authorised electrician

722 Connecting the PV generator

Connect the PV generator on the left in the connection area (Figure 13 on page 21) Use the provided M16 cable fittings A maximum of two strings can be connected For this reason a DC string fuse can be dispensed with

DANGERRisk of fatal injury due to contact voltagesRemoving the cables from the terminals without first disconnecting the PV generator from the device can cause serious damage to health or damage to the system rsaquo During installation Electrically disconnect the DC positive and DC negative from the protective

earth (PE) rsaquo Completely de-energise the system (AC home power grid AC circuit breaker residual current circuit

breaker DC isolator switch) rsaquo Disconnect the battery system from the PV generator using the integrated DC isolator switch rsaquo Remove DC plug connectors

NOTEIn accordance with IEC 61730 Class A connected PV modules must be dimensioned for the DC system voltage provided and at least for the value of the AC grid voltage

7221 Before connecting

Ensure that there is no ground fault1 Determine the DC voltage between the

ndash protective earth (PE) and the positive cable of the PV generator and between the ndash protective earth (PE) and the negative cable of the PV generator

If stable voltages can be measured there is a ground fault in the DC generator or its wiring The ratio between the measured voltages gives an indication as to the location of this fault

2 Rectify any faults before taking further measurements3 Determine the electrical resistance between the

ndash protective earth (PE) and the positive cable of the PV generator and between the ndash protective earth (PE) and the negative cable of the PV generator

In addition ensure that the PV generator has a total insulation resistance of more than 20 MOhm since the inverter will not feed in if the insulation resistance is too low

4 Rectify any faults before connecting the DC generator

7222 Connecting the PV generator

DANGERRisk of fatal injury due to electric shockSevere injury or death will result if the live connections are touched When there is solar radiation DC voltage will be present at the open ends of the DC cables rsaquo Do not touch the exposed ends of the cables rsaquo Avoid short circuits

Installing the device

Operating instructions Powador-gridsave_EN Page 25

Authorised electrician

Connecting the PV generator Use cables with the correct cross-section

1 Remove cable fittings for DC connection2 Remove the outer cladding of the DC cables3 Insert the DC cables through the cable fittings into the connection area4 Strip the insulation from the DC cables5 Remove connection terminals6 Connect the cables in line with the terminal labels (See Figure 13 on page 21)7 Close the connection terminals8 Check that all connected cables are securely fitted9 Tighten the cable fittings10 To meet the requirements of protection rating IP21 close the unused cable fittings with blind caps raquo The PV generator is connected to the inverter

73 Connecting the interfaces

731 Ethernet interface

Pre-assembled Ethernet cables can be connected using the RJ45 socket in the connection space

Connecting the Ethernet cable1 Remove closure cap from RJ45 socket2 Connect the Ethernet cable3 The energy management system can now obtain an IP address by DHCP and is also available via this in the

network

NOTEThe network settings can be amended later in the Settings menu using the EMS

NOTEUse a suitable category 5 network cable The maximum length of a network segment is 100 m Ensure that the cable is correctly assigned The Ethernet connection of the battery system supports auto-sensing You can use both crossed and 11 configured Ethernet connection cables

74 Sealing the connection area

1 Finally check the cabling2 Ensure that all cables are firmly mounted3 Check that the cable fitting is secure and tighten if necessary4 Remove cable offcuts and particles of dirt or dust5 Fit the cover and slide back until it engages into position6 Check that the position is correct7 Screw the fastening screw onto the front of the cover

Installing the device

Page 26 Operating instructions Powador-gridsave_EN

Authorised electrician

75 Starting up

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched Only appropriately qualified and authorised electricians may open install or maintain the battery system rsaquo Keep the front doors and covers closed during operation

NOTEInitial start-up should be carried out using the available public AC grid

76 Standard configuration

Factory settingsCountry configuration Germany

Grid guidelines Low voltage directive

Language German

Time UTC +1 Central European Time

User Standard

Network parameters DHCP (network settings will be obtained automatically from the router)

NOTEPlease state the desired power limitation (60 or 70 of the PV system capacity) when you order For other variations please notify your KACO contact so that the parameters can be set at the factory prior to delivery

Installing the device

Operating instructions Powador-gridsave_EN Page 27

Authorised electrician

761 Step 1 AC home power grid

Check all cables and connections before starting up1 Switch on the AC home power grid using the AC main switch raquo Powador-protect measurement and control unit starts up and monitors the AC grid raquo Two green LEDs indicate that the grid parameters are met raquo After a further 60 seconds (shortly after the backlighting in the Powador-protect goes out) the Powador-pro-

tect will switch on the home grid2 Configure Powador-protect according to the enclosed Powador-protect instructions

(The instructions are also available on the website at wwwkaconewenergyde) raquo The AC power is supplied in the normal way by the public grid

762 Step 2 AC supply from the battery system

Check all cables and connections before starting up1 Remove external isolation means from the device2 Switch on the circuit breaker raquo The LCD touchscreen on the front panel comes on and the energy management system (EMS) starts up

3 Switch on the residual current circuit breaker raquo The battery system starts up

763 Step 3 Switch on the PV system

1 Switch on any optional external PV isolator switches2 Set the internal DC isolator switch to ON raquo The inverter and the battery charging unit battery backup converter (BBC) are connected to the PV system raquo The device monitors the PV voltage for approx 60 seconds then optimisation of internal consumption takes

place

764 Step 4 Switch on batteries

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

765 Step 5 Activate energy management

NOTEKACO new energy cannot provide any support for problems regarding the IT infrastructure (eg router configuration IP address assignment ports etc) as the structure settings and configuration of the network environment can be complex and very different from place to place In the event of any problems please contact an IT service provider

Remote access activated 1 Please call the KACO Hotline to make an appointment for activation of energy management

Configuration and Operation

Page 28 Operating instructions Powador-gridsave_EN

Authorised electrician

8 Configuration and Operation

81 ControlsThe battery system is fitted with a touchscreen which allows it to be controlled very precisely In normal operation the display is switched off Touching the screen activates the display and after a configurable period of time without being touched the dis-play will deactivate If the screen-save function is switched off the touchscreen will be on continuously

NOTEDepending on the tolerances of the measuring elements the measured and displayed values are not always the actual values However the measuring elements ensure maximum solar yield Due to these tolerances the daily yields shown on the touchscreen may deviate from the values on the grid operatorrsquos feed-in meter by up to 15

3

1

45

2

Figure 15 Overview (home screen)

Key

1 Home button 4 Current time

2 System components 5 Menu name

3 More information

811 Information about the system

Open start screen View changesjumps to the home screen

Show component detail Parameters of the selected component

Settings Define settings for the active user

raquo Displays settings

Configuration and Operation

Operating instructions Powador-gridsave_EN Page 29

Controls Left arrow jump back to previous menu item Up and down arrows navigate through the menu or change a value

Left arrow displayed value is reduced by one increment Right arrow displayed value is increased by one increment or change to the submenu

Display fields Grey box Text or figures (not selectable) Blue box Calls up submenu for the display in question

Activate and deactivate Activate function by ticking the box

Table 6 Information about the system

812 System components

PV generator Display of the current generator data

power voltage current temperature in the inverter

Battery Display of the current battery status

power (charging or discharging) voltage current charge status available capacity temperature of battery

Grid Display of the following either fed-in or drawn from the grid

power voltage current for phase L1-L3 total output frequency

Consumer (load) Display of the consumer data

power voltage current for phase L1-L3 total output

Energy flow raquo Displays the current energy flow in the system

Table 7 Information about system components

Configuration and Operation

Page 30 Operating instructions Powador-gridsave_EN

813 Menu structure

Icons used

Display menu Submenu

Option menu

Menu Submenu Display setting

Action in this menumeaning

PV generator Details

Power Displays the current DC-side power

Voltage Displays the current DC-side voltage

Current Displays the current DC-side amperage

Temp inverter

Displays the current temperature in the inverter housing

Battery Details

Power Displays the current AC-side power

Voltage Displays the current AC-side voltage

Current Displays the current AC-side amperage

Charge status Displays the current charge status

Capacity Displays the current battery capacity

Temperature Displays the current measured temperature of the battery

Grid Details

Power Displays the current AC-side power being drawn or fed-in

Voltage Displays the AC-side voltage being applied

Current Displays the current AC-side amperage being drawn or fed-in

Total output Displays the current AC-side total output being drawn or fed-in

Frequency Displays the frequency currently being applied to the grid junction

Consumer (load) Details

Power Displays the current AC-side power being drawn

Voltage Displays the current AC-side voltage being applied

Current Displays the current AC-side amperage being drawn

Total output Displays the current AC-side total output being drawn

Configuration and Operation

Operating instructions Powador-gridsave_EN Page 31

Menu Submenu Display setting

Action in this menumeaning

Settings

Country amp directive display

Display of the country settings voltage directives and grid type

Select menu language

DateTime Specify time zone date format and date and time

Screen Activate screen-save function and set the delay period

Network settings

Display of the network settings Configure network settings Once the DHCP server becomes available the IP

address subnet mask gateway and DNS server are automatically applied and the aforemen-tioned menu items are hidden

Off DHCP deactivated make settings manually

Version Displays the installed software version and built-in HW components (inverter BBC battery)

Vendor The touchscreen shows information about the device vendor

NOTEAs changes to the software are possible after the manual has been printed the illustrations and descriptions of the functions in these operating instructions may deviate from the software Please therefore note the current Application Notes on our website

MaintenanceTroubleshooting

Page 32 Operating instructions Powador-gridsave_EN

9 MaintenanceTroubleshooting

91 Visual inspectionInspect the device and the cables for visible external damage and note the operating status display In case of damage notify your installer Repairs may only be carried out by authorised electricians

NOTEThe battery system should be checked for proper operation by a qualified electrician at regular intervals

92 Cleaning the device

DANGERLethal voltages in the battery systemSerious injuries or death can result if moisture enters the system rsaquo Only use completely dry objects to clean the battery system rsaquo Only clean the outside of the battery system

Cleaning the battery system Do not use compressed air Use a vacuum cleaner or a soft brush to remove dust from the fan cover and from the top of the inverter on a

regular basis Remove dust from the ventilation inlets if necessary

MaintenanceTroubleshooting

Operating instructions Powador-gridsave_EN Page 33

Authorised electrician

93 Maintenance

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched The device is only permitted to be opened or serviced by an authorised electrician rsaquo Observe all safety regulations and the current technical connection specifications from the relevant

power supply company rsaquo Disconnect the AC and DC sides rsaquo Secure the AC and DC sides from being inadvertently switched back on rsaquo Only then should the device be opened rsaquo After shutdown wait at least 30 minutes before working on the device

CAUTIONDestruction of the DC connectionThe connection terminals can be destroyed by arcing if disconnected while still live rsaquo It is absolutely essential that the shutdown sequence be carried out in the correct order (See sec-

tion 111 on page 35)

94 Faults

941 Procedure

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched

When a fault occurs notify an appropriately authorised and qualified electrician or KACO new energy GmbH Service

Service

Page 34 Operating instructions Powador-gridsave_EN

10 ServiceIf 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 efficientlybull Serial nobull SW version of the components (the software version can be found in the Settings menu using the EMS)bull Module type and string circuitbull Date of installation Start-up reportbull Consignment identification Delivery address Contact person (with telephone number)bull Information about the accessibility of the installation site

Any additional costs arising from unfavourable structural or mounting conditions shall be billed to the customer

You can find our warranty conditions on our websitehttpkaco-newenergycomservicewarrantyFrom there you can easily navigate to our international websites by clicking on the appropriate flag

Please use our website to register your unit immediatelyYou can also select the appropriate flag on this page to access the website for your own countryIn this manner you can assist us in providing you with the quickest service possible Note The maximum length of the warranty is based on the currently applicable national warranty conditions

We have prepared a template for complaints This can be found at httpskaco-newenergycomservicecustomer-service

Hotlines

Technical troubleshooting Technical consultation

Inverters and battery systems ()

+49 (0) 71323818-660 +49 (0) 71323818-660

Data logging and accessories +49 (0) 71323818-690 +49 (0) 71323818-690

Construction site emergency () +49 (0) 71323818-630

Customer help desk Monday to Friday from 730 am to 530 pm (CET)

() Also on Saturdays from 800 am to 200 pm (CET)

ShutdownDisassembly

Operating instructions Powador-gridsave_EN Page 35

11 ShutdownDisassembly

111 Switching off the device

DANGERLethal voltages are still present in the terminals and cables even after switching off and discon-nection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched rsaquo Complete de-energisation only occurs if the bulk power supply is switched off upstream of the bat-

tery system

DANGERDestruction of the DC plug connectorDC plug connectors can be destroyed by arcing if disconnected while still live rsaquo It is absolutely essential that the following shutdown sequence is observed

1111 Step 1 Shutting down the PV system

1 Switch off any optional external PV isolator switches2 Set the internal DC isolator switch to OFF raquo The inverter and battery charging unit battery backup converter (BBC) are disconnected

1112 Step 2 Disconnect the batteries

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

1113 Step 3 Disconnect the AC supply

1 Connect external isolation means to the device2 Switch off the circuit breaker 3 Switch off the residual current circuit breaker raquo The battery system is switched off

1114 Step 4 AC home power grid

1 Shutdown the AC home power grid using the AC main switch raquo The battery system can be uninstalled

Disposal

Page 36 Operating instructions Powador-gridsave_EN

112 Uninstalling the device

NOTETo uninstall follow the same sequence as for installation but in reverse order

Switch off the device1 Unlock and open the housing door2 Remove the upper cover3 Release the DC and AC cables from the connection terminals4 Pull out the cables raquo The battery system is uninstalled Continue with the disassembly

113 Disassembling the device

NOTETo disassemble follow the same sequence as for assembly but in reverse order

Switch off the device1 Uninstall the components2 Remove the fastening from the device3 Securely pack up the battery system if it is to be used later

or have the battery system disposed of in accordance with section 12 on page 36

12 DisposalFor the most part both the battery system and the corresponding transport packaging are made from recyclable raw materialsBatteries and components Do not dispose of faulty batteries or the components together with household waste Ensure that the old device and accessories are disposed of in a proper mannerPackaging Ensure that the transport packaging is disposed of properlyBatteriesUsed or faulty batteries must be transported in special packaging If you need such packaging please contact the KACO Hotline

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

Appendix

Operating instructions Powador-gridsave_EN Page 37

13 Appendix

EU Declaration of Conformity

Vendorrsquos name and address

KACO new energy GmbH Carl-Zeiss-Straszlige 1 74172 Neckarsulm Germany

Product description Battery system

Type designation Powador-gridsave 135 kWh 6400 Powador-gridsave 135 kWh 8000

Powador-gridsave 270 kWh 6400 Powador-gridsave 270 kWh 8000

Powador-gridsave 405 kWh 6400 Powador-gridsave 405 kWh 8000

Powador-gridsave 540 kWh 6400 Powador-gridsave 540 kWh 8000

Powador-gridsave 577 kWh 6400 Powador-gridsave 577 kWh 8000

Powador-gridsave 675 kWh 6400 Powador-gridsave 675 kWh 8000

This is to confirm that the units listed above comply with the protection requirements set forth in the Directive of the Council of the European Union of 15th December 2004 on the harmonisation of the laws of the member states relating to Electromagnetic Compatibility (2004108EC) and the Low Voltage Directive (200695EC)The units are compliant with the following standards

200695EC ldquoDirective relating to electrical equipment designed for use within specific voltage limitsrdquo

Safety of the unitIEC 62109-12010IEC 62109-22011

2004108EC ldquoDirective relating to electromagneticcompatibilityrdquo

Interference immunityEN 61000-6-22005 Emitted interferenceEN 61000-6-32007

Secondary effects on the gridEN 61000-3-112000EN 61000-3-122005

The types mentioned above are therefore labelled with the CE markUnauthorised modifications to the supplied units andor any use of the units that is contrary to their intended use render this Declaration of Conformity null and void

Neckarsulm 0711 2013KACO new energy GmbH

pp Volker DietrichEnergy systems engineering management

Disposal

Page 38 Operating instructions Powador-gridsave_EN

Carl-Zeiss-Straszlige 1 middot 74172 Neckarsulm middot Germany middot Phone +49 7132 3818-0 middot Fax +49 7132 3818-703 middot infokaco-newenergyde middot wwwkaco-newenergyde

The

text

and

figu

res

refle

ct th

e cu

rren

t tec

hnic

al s

tate

at t

he ti

me

of p

rintin

g S

ubje

ct to

tech

nica

l cha

nges

Err

ors

and

omis

sion

s ex

cept

ed

3006

856-

01-1

4030

5

  • 1General Information
    • 11About this document
    • 12Name plate
    • 13Additional information
    • 14Intended use
      • 2Safety
        • 21Protection features
          • 3Description
            • 31Mode of Operation
            • 32Summary of the components
              • 4Technical Data
                • 41Electrical data
                • 42Mechanical data
                  • 5Transportation and Delivery
                    • 51Delivery
                    • 52Storage
                    • 53Transportation
                      • 6Assembling the device
                        • 61Installation
                        • 62Installing components
                          • 7Installing the device
                            • 71Opening the connection area
                            • 72Making the electrical connection
                            • 73Connecting the interfaces
                            • 74Sealing the connection area
                            • 75Starting up
                            • 76Standard configuration
                              • 8Configuration and Operation
                                • 81Controls
                                  • 9MaintenanceTroubleshooting
                                    • 91Visual inspection
                                    • 92Cleaning the device
                                    • 93Maintenance
                                    • 94Faults
                                      • 10Service
                                      • 11ShutdownDisassembly
                                        • 111Switching off the device
                                        • 112Uninstalling the device
                                        • 113Disassembling the device
                                          • 12Disposal
                                          • 13Appendix

Safety

Page 6 Operating instructions Powador-gridsave_EN

2 SafetyDANGER

Lethal voltages are still present in the terminals and cables even after switching off and discon-nection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched Only authorised electricians are permitted to open install or maintain the device rsaquo Keep the device closed when in operation rsaquo Do not touch the cables or terminals when switching the unit on and off rsaquo Do not make any modifications to the device

The electrician is responsible for observing all existing standards and regulations bull Keep unauthorised persons away from the device and PV systembull Pay particular attention to the standard IEC 60364-7-7122002 ldquoRequirements for special installations or locations ndash

solar photovoltaic (PV) power supply systemsrdquobull Ensure operational safety by providing proper grounding conductor dimensioning and appropriate protection

against short circuitingbull Observe all safety instructions on the device and in these operating instructionsbull Switch off all voltage sources and secure them against being inadvertently switched back on before performing

visual inspections and maintenancebull When taking measurements while the battery system is live

ndash Do not touch the electrical connections ndash Remove all jewellery from your wrists and fingers ndash Ensure that the testing equipment is in safe operating condition

bull Stand on an insulated surface when working on the devicebull Do not place any objects on the housingbull Modifications to the surroundings of the device must comply with the applicable national and local standardsbull When working on the PV generator in addition to disconnecting this from the grid it is also necessary to switch off

the DC voltage using the DC isolator switch on the device

21 Protection featuresFor your safety the following monitoring and protection functions are integrated into the battery systembull Overvoltage conductorsvaristors to protect the power semiconductors from high-energy transients on the grid

and generator sidebull Temperature monitoring for the heat sink and batteriesbull Measurement of current in each battery modulebull Multilevel redundant overload exhaustive discharge and overcurrent protectionbull Comprehensive and regular self-testing of all componentsbull EMC filters to protect the inverter from high-frequency grid interferencebull Grid monitoring disconnection in accordance with VDE-AR-N 4105bull Overcurrent protection for the batterybull Fail-safe phase bridging

Description

Operating instructions Powador-gridsave_EN Page 7

3 Description

31 Mode of OperationThe battery system optimises internal consumption thus reducing the amount of electrical energy needed from the public grid Energy from a photovoltaic system that is not required in the home at that time is stored in a battery and supplied to the consumer as necessary Consumers are supplied with their own energy by the device in a manner which is flexible and optimised to their personal habits

311 System overview

BPM

Gridsave

Measurement

Meassurement

AC

Power Meterproduction

Grid

Distribution Box

Communication

BidirectionalPower Meter

AC circuit breaker

DC circuit breaker

Door

PV-Generator

BBC

350 - 800 VDC

3 x 400 VAC

Inverter

U [V]I [A]

P [W]

U [V]I [A]

P [W]

Powador Protect

Load

3 x 400 VAC

BMS

BatteryBattery

Battery

Power flow

Power flow

Power flow

RCD

Power supply

3 x 400 VAC

AC Main switch

3

40A

3

63A

40A

4

4

Energie- management-

System(EMS)

Figure 1 Schematic overview

Description

Page 8 Operating instructions Powador-gridsave_EN

312 Configuration

Powador-protect

CONNECTION BOX

PV INVERTER

BATTERY CONVERTER

PV-Circuit Breaker

ON

OFF

AC-Circuit Breaker

Residual-Current-Circuit Breaker

BATTERY

1

3

4

5

2

Figure 2 Configuration of the battery system

1 Connection box 4 Battery charging unit battery backup converter (BBC) 1

2 Energy management system (EMS) with LCD touchscreen

5 Battery unit with controller

3 Inverter

Description

Operating instructions Powador-gridsave_EN Page 9

32 Summary of the components

321 Connection box

ON

OFF

Powador Protect

off off off

B 32AAC-Circuit Breaker

IN=40AΔI=300mA

RCCB

off

Test

Typ A

CONNECTION BOX

1 2 3 4

Figure 3 Connection box

Key Function

1 DC isolator switch Disconnects the PV generator from the inverter battery unit

2 Measurement and control unit Powador-protect

Three-phase monitoring of the grid switches off the power supply in the event of impermissible voltage or frequency

3 Circuit breaker Disconnects the inverter from the AC grid

4 Residual current circuit breaker

Protects individuals and the installation by isolating the inverter

NOTEThe DC isolator switch circuit breaker and residual current circuit breaker will switch off the battery system Power will then be supplied from the public grid

322 Energy management system

Figure 4 Energy management system (EMS) with LCD touchscreen

NOTEThe energy management system (EMS) displays all relevant parameters in order to ensure optimum operation

Description

Page 10 Operating instructions Powador-gridsave_EN

323 Inverter

PV INVERTER

Figure 5 Inverter

NOTEThe inverter converts the DC voltage from the PV generator and the battery into AC voltage

324 Battery charging unit battery backup converter (BBC)

BATTERY CONVERTER

Figure 6 Battery charging unit battery backup converter (BBC)

NOTEThe battery charging unit battery backup converter (BBC) is the interface to the battery The high voltage from the PV generator is converted into non-hazardous safety extra low voltage (SELV) for the battery The battery charging unit battery backup converter (BBC) can transfer energy both into the battery and out of it

325 Battery management system (BMS)

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

326 Battery

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

Technical Data

Operating instructions Powador-gridsave_EN Page 11

4 Technical Data

41 Electrical data

Connection box

Home power grid

Input voltage 230V 400V 50Hz 60Hz 3-phase (3 N PE)

Grid configuration TN-C TN-S TT

Grid monitoring Powador-protect (as per VDE-AR-N 4105)

Grid isolation Double insulated 3 or 4 pin

Rated operating current [A] 75

Rated switching current AC-1 [A] 100

Rated switching current AC-3 [A] 50 (22 kW at 400 V)

Connection cross-section [mmsup2] max 25

PV input

Input voltage [V] 300 to 800

Input current [A] 30 String

Strings 2

Isolation Yes rotary switch

Inverter type 6400 8000

Input levels

Max recommended PV generator power [W] 7700 9600

Rated power peak power [VA] 6400 7000 8000 9000

DC MPP range from [V] to [V] 360 590

Open circuit voltage [V] 800

Input current [A] 190 240

cos phi 08 inductive hellip 08 capacitive

Polarity safeguard Short-circuit diode

Feed-in phases 1

Capable of stand-alone operation Yes

Efficiency [] 966

Output levels

Output voltage 230V 50Hz 60Hz 1-phase

Rated current [A] 278 35

Connection cross-section [mmsup2] max 6

Monitoring Isolation Circuit breaker residual current circuit breaker (RCD)

Table 1 Electrical data

Technical Data

Page 12 Operating instructions Powador-gridsave_EN

Battery charging unit battery backup converter (BBC)

BBC power [W] 3300

HV voltage [V] 350 to 600

Battery voltage [V] 38 to 58

Efficiency [] 970

Table 1 Electrical data

42 Mechanical data

Battery system

Display 43 LCD touchscreen

Interfaces RS485 Sym-Bus Ethernet USB digital inputsoutputs

Cable insertion Cable fitting 2x M40 2x M32 4x M25 12x M16

Ambient temperature [degC] 0 +40

Humidity [] lt95 (non-condensing)

Cooling Forced cooling temperature-controlled

Noise emission [dB] lt45

Note regarding cooling Do no cover air inletsoutlets keep clear 20 cm to the right and left

Temperature monitoring Individual monitoring of components with shutdown in the event of excess temperature

Maximum installation elevation [m above mean sea level] 2000

Protection class IP21

Housing form 19 sheet-steel control cabinet

H x W x D [mm] 1600 x 620 x 600

Weight [kg] 2435

Inverter

Ambient temperature range [degC] -20 +60

Temperature monitoring Yes

Cooling Active cooling

Connections Quick INOUT plug connector and busbar clips rear side

H x W x D [mm] 22225 x 4826 x 460

Weight [kg] 25

Table 2 Mechanical data

Technical Data

Operating instructions Powador-gridsave_EN Page 13

Battery charging unit battery backup converter (BBC)

Ambient temperature range [degC] -20 +70

Temperature monitoring Yes

Cooling Active cooling

Housing 19 plug-in module aluminium

Connections Quick INOUT plug connector and busbar clips rear side

H x W x D [mm] 13325 x 4826 x 460

Weight [kg] 15

Temperature-dependent impedance matching with shutdown if the temperature is too high

Table 2 Mechanical data

Transportation and Delivery

Page 14 Operating instructions Powador-gridsave_EN

5 Transportation and Delivery

51 DeliveryThe battery system leaves KACO new energy in fully functional electrical and mechanical condition Special packaging ensures that the units are transported safely The shipping company is responsible for any trans-port damage that occurs

511 Scope of delivery

Pallet A B

Figure Figure 7 Scope of delivery pallet A Figure 8 Scope of delivery pallet B

Contents bull Battery system Powador-gridsave (incl connection box battery management system (BMS) industrial PC Plexiglas cover and accessories)

bull Inverter bull Battery charging unit battery backup converter

(BBC)bull Battery system plug-in modules 1-5 ST (scope of

delivery can be found on the delivery document)bull Documentation

Weight (kg) 187 max 155 177 (without with Euro pool pallet)

H x W x D [mm] 1780x800x820 1200x1200x800

Packaging Cardboard box with polystyrene inserts and closures

512 Check the equipment included

bull Battery system and plug-in modules should be inspected thoroughly for transport damagebull Do not install damaged components in the control cabinetbull In the event of damage to the battery plug-in modules contact the KACO new energy Hotline immediately

Transportation and Delivery

Operating instructions Powador-gridsave_EN Page 15

Authorised electrician

DANGERRisk of fatal injury if incompatible components are usedThe battery and power electronics can be damaged if different delivery batches are combined and will carry potentially fatal voltages if connected rsaquo Assemble the system using the components provided by KACO new energy only rsaquo Check the serial numbers on the delivery document against the serial numbers of the individual

units on pallets A and B

52 StorageIncorrect storage can lead to system malfunctions Therefore please observe the following conditionsbull If storing for longer than six months store the device in an interior room in its original packaging bull If the original packaging has been removed store the device in a cool dry interior roombull Storage temperature -20 degC to +70 degCbull Relative humidity 0 to 95 (non-condensing)bull If the device is stored for a relatively long time at high humidity the device must be left for more than one day to

dry out sufficiently before connection to the power grid

53 Transportation

WARNINGImpact hazard risk of breakage to the components in the battery systemThe centre of gravity is located in the upper part of the device rsaquo Transport the device upright together with the pallet rsaquo Do not expose the device or components to any shocks rsaquo After unloading at least two people are required to transport the cabinet

WARNINGDanger due to impact and incorrect storage of the batteriesIn the event of damage batteries can release hazardous electrolyte gases which will cause irreversible burns if they come into contact with the skin rsaquo Transport the batteries in the vendors original packaging only rsaquo Remove the batteries from the original packaging shortly before installation rsaquo Do not store batteries in cars or outdoors rsaquo Check the condition of the battery before use

NOTEThe precise specifications of the UN on the transport of lithium batteries can be found under the designation Model Regulations on the transport of dangerous goods Ref STSGAC101 Recommendations on the transport of dangerous goods Part III sub-section 383 ldquoManual of Tests and Criteriardquo Ref STSGAC1011

Assembling the device

Page 16 Operating instructions Powador-gridsave_EN

Authorised electrician

6 Assembling the device

61 Installation

DANGERRisk of fatal injury from fire or explosionsFire caused by flammable or explosive materials in the vicinity of the battery system can lead to serious injuries rsaquo Do not mount the inverter in potentially explosive atmospheres or in the vicinity of highly flamma-

ble materials

CAUTIONBattery system is very heavy ndash risk of injury rsaquo Be aware of the weight of the battery system during transport rsaquo Select suitable mounting location and mounting base rsaquo Only install the battery system with the help of a second person

CAUTIONEquipment damage caused by aggressive gases in combination with humidityThe housing may be seriously damaged by aggressive gases (ammonia sulphur and other chemi-cals) in combination with ambient humidity caused by weather conditions - Installation in rooms containing aggressive gases is not permitted

NOTEAccess in the event of maintenance or serviceAny additional costs arising from unfavourable structural or mounting conditions in the event of a KACO service call-out shall be billed to the customer

611 Installation location

bull Dry well ventilated the waste heat must be conducted away from the battery systembull Unobstructed air circulationbull Easily accessible from the front top and sides without requiring additional resourcesbull Indoors protected against direct sunlight and direct water contact

612 Foundation

bull With sufficient load-bearing capacitybull Made from heat-resistant material (up to 90 degC)bull Must be flame resistant

NOTEPower reduction due to heat accumulationIf the recommended minimum clearances are not observed the device may go into power regula-tion mode due to insufficient ventilation and the resulting heat build-up rsaquo The construction and installation of the device may be performed only by a qualified electrician in

accordance with the valid standards and regulations rsaquo Maintain minimum clearances rsaquo Ensure sufficient heat dissipation

Assembling the device

Operating instructions Powador-gridsave_EN Page 17

Authorised electrician

0deg

1000 mm

200 mm 200 mm

500 mm

min carrying capacity 300 kgmsup2

200 mm200 mm

50 mm

Figure 9 Minimum clearances at the installation and assembly location

CAUTIONRisk of injury if the battery system tips overRisk of tipping due to high centre of gravity particularly with the door open rsaquo Anchor the device securely to the floor immediately after installation rsaquo Open the housing door using the enclosed cabinet key only once the device has been securely

anchored

510 mm200 mm

200 mm

400

mm

12 mmmin 110 mm

DesignationHex head wood screw 8x80 DIN571-vz Fischer dowel S12 Flat washer M8 galvanised DIN9021-vz

Units444

Figure 10 Dimensions for anchoring to the floor Table 3 Mounting parts

62 Installing components

CAUTIONAvoid improper handlingImproper handling can cause damage to components rsaquo Damaged components must not be installed rsaquo Always put the plug-in modules down horizontally to avoid damage to the components

Assembling the device

Page 18 Operating instructions Powador-gridsave_EN

Authorised electrician

WARNINGDanger caused by short circuit or sparkingSerious injury from touching or connecting live components rsaquo Damaged components must not be installed

Preparation1 Check the conditions for the installation location2 Open the housing doors using the enclosed cabinet key3 The cables should be professionally laid and prepared for connection4 Follow the installation sequence (1-4 step(s))

621 Step 1 Fit the battery (batteries)

NOTEPlease read the notes on installation and connection in the enclosed manual Features for the battery unit

622 Step 2 Connect battery (batteries) to the battery management system (BMS)

NOTEPlease read the notes on installation and connection in the enclosed manual Features for the battery unit

623 Step 3 Fit the battery charging unit battery backup converter (BBC)

Battery (batteries) connected to the battery management system (BMS)1 Carefully insert battery charging unit battery backup converter (BBC) into the compartment provided for it 2 Push in completely to establish direct contact with the rear busbars3 Secure battery charging unit battery backup converter (BBC) using the screws supplied

624 Step 4 Fit the inverter

Battery charging unit battery backup converter (BBC) is fitted1 Carefully insert inverter into the compartment provided for it 2 Push in completely to establish direct contact with the rear busbars 3 Secure inverter using the screws supplied

CAUTIONDamage to the control unit from introducing foreign objectsForeign objects can impair the function of the control unit and cause damage rsaquo Do not remove the front panel rsaquo Foreign objects should be removed immediately

Installing the device

Operating instructions Powador-gridsave_EN Page 19

Authorised electrician

7 Installing the device

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched The device may only be opened or serviced by an authorised electricianThe device must be completely assembled before being connected electrically rsaquo Observe all safety regulations and current technical connection specifications of the responsible

power supply company rsaquo De-energise the device using the DC isolator switch circuit breaker and residual current circuit

breaker rsaquo Secure both sides against being inadvertently switched back on rsaquo Ensure that the AC and DC sides are completely isolated and voltage free rsaquo Never open the plug-in modules rsaquo Hazardous voltages are present at the busbars rsaquo Disconnect from the grid and plant supply rsaquo First connect the battery system in the connection area

71 Opening the connection area

3

1

2

Figure 11 Open cover plateKey

1 Cover plate 3 Fastening screw

2 Lock

Opening the connection area You have completed assembly

1 Remove the fastening screw for the upper cover plate2 Slide the cover plate forwards out of the lock3 Lift the cover plate upward to remove raquo Make the electrical connection

Installing the device

Page 20 Operating instructions Powador-gridsave_EN

Authorised electrician

72 Making the electrical connectionMake the connection to the PV generator as well as the grid connection using the connection terminals Note the following cable cross-sections

Connection Possible cable cross-section Length of insulation to be stripped offAC home power grid 05 - 16 mmsup2 with end sleeve

05 - 25 mmsup2 without end sleeve18 mm sleeve18-20 mm

PV connection 05 - 16 mmsup2 with end sleeve05 - 25 mmsup2 without end sleeve

18 mm sleeve17-19 mm

Inverter output 05 - 4 mmsup2 with end sleeve05 - 6 mmsup2 without end sleeve

12 mm sleeve11-13 mm

Potential-free contacts 034 - 15 mmsup2 with end sleeve034 - 25 mmsup2 without end sleeve

12 mm sleeve 9-10 mm

Table 4 Cable cross-sections for connection terminals

NOTEThe threaded connections should be matched to the cable cross-section

NOTEOnly conductors and no insulation should be inserted into the connection terminals Individual wires or cables with end sleeves with the appropriate cross-section can be inserted directly into the connection terminal without a toolFine-strand cables without end sleeve or thin conductors will need a screwdriver (plain slot 35 mm) for connection To do this insert the blade of the screwdriver into the recess provided The cable can be inserted into the spring terminal by pressing downwards The spring terminal closes on removal of the screw-driver

Installing the device

Operating instructions Powador-gridsave_EN Page 21

Authorised electrician

X2X1F1 F2 X7 X4 St1

St2

St3

2 3 541 6

Figure 12 View from above of the connection area

Key

1 AC grid input (M40 cable fitting) 4 Network interface (M32 cable fitting)

2 AC grid output (M40 cable fitting) 5 Inverter input (M16 cable fitting)

3 Inverter output (M32 cable fitting) 6 Other connections (M16 cable fitting)

F1 F2 X7 X4 St1

St2

St3

L1 L2 L3 N PE L1 L2 L3 N N PE PE

X1 X2

PV+

PV-

L1 L2 L3 N PE32A 32A PEN

Cust

omer

co

nnec

tion

Figure 13 View from above of the connection area

Key

X1 AC grid input (main junction box meter) X7 PV generator input

X2 AC grid output (building electrical system) F1 F2 Phase bridging fuse

X4 Inverter output St 1-3 Potential-free contacts control outputs

Installing the device

Page 22 Operating instructions Powador-gridsave_EN

Authorised electrician

721 Connecting to the power grid

Because the device is installed between the main junction boxmeter and the buildings electrical system the maxi-mum grid current to the service line must not exceed the rated operating current of the battery system The cable cross-section must be selected in accordance with applicable standards to suit the connected load instal-lation type etc Moreover the terminal area and size of the cable fitting must be noted

NOTEThe fuse rating for the cable should be max 63A (automatic circuit breaker or safety fuse) even if the cross-section of the installed cable would permit a higher fuse rating Always follow the applicable regulations regarding the cable cross-section and installation typeThe device supports standard grid configurations such as TN-C TN-S and TT TN-SIf a TN-S grid is present directly at the power input and output of the device L1-L3 N and PE must each be connected The home power grid should have 4-pin isolationTN-C4-pin grid isolation is factory preset and disconnects L1 L2 L3 and N In a TN-C grid the N conduc-tor must not be disconnected If a TN-S grid is present directly at the power input and output of the device a cable bridge (included in delivery) must be installed between the N terminal on X1 and the N terminal on X2 N and PE must additionally be connected together To do this simply insert the enclosed terminal link into the N and PE terminals TTIn the case of a TT grid L1-L3 N and PE must each be connected The home power grid should have 4-pin isolation

NOTEPlease check with the operator of the mains grid whether there are special regulations for grid connection Grid isolation is factory preset to 4-pin is fail-safe and provided with grid and system protection as per VDE-AR-N 4105

Making the grid connection Use cables with 5 wires (L1 brown L2 black L3 grey N blue PE greenyellow) and the correct

cross-section1 Loosen cable fitting for AC connection2 Remove the outer cladding of the AC cables3 Insert the AC cables through the cable fitting into the connection area4 Strip the insulation from the AC cables5 Remove connection terminals6 Connect the cables in line with the terminal labels (Figure 13 on page 21)7 Close the connection terminals8 Check that all connected cables are securely fitted9 Tighten the cable fitting10 To meet the requirements of protection rating IP21 close the unused cable fittings with blind caps raquo The battery system is connected to the power grid

NOTEAn AC-side disconnection unit must be provided during the final installation stage This disconnec-tion unit must be installed so that it can be accessed at any time without obstruction If a residual current circuit breaker is necessary due to the installation specification a type A residual current circuit breaker must be used

Installing the device

Operating instructions Powador-gridsave_EN Page 23

Authorised electrician

7211 Output from the inverterRecommended cable cross-sections for the inverter output and fuse rating of cables for fixed wiring accord-ing to VDE 0100 part 430The fuse rating for the cable is dependent on the cable cross-section max 40A automatic circuit breaker

NOTEWhen the line resistance is high (ie long grid-side cables) the voltage at the grid terminals of the inverter will increase during feed-in to the grid The inverter monitors this voltage If the voltage exceeds the country-specific grid overvoltage limit value the inverter switches off rsaquo Ensure that the conductor cross-sections are sufficiently large or that the cable lengths are suffi-

ciently short

NOTEIn order to avoid asymmetries in the grid systems with multiple battery systems should be designed so that the inverters in the devices feed into the grid in differing phases rsaquo Follow the connection conditions for the particular type of grid and the schematic illustration

below

Country and grid-type

Grid monitoring Required monitoring

max asymmetry between phases L1L2L3

DE-NSP Three-phase or single phase phase unbalanced load 46 kVA

Table 5 Grid-type-specific connection conditions

L1

L2

L3

N

Connection X1 Connection X1 Connection X1 Connection X1

L1 L2 L3 N PE L1 L2 L3 N PE L1 L2 L3 N PE L1 L2 L3 N PE

Powador-gridsave inverter1 L1 - L1 L2 - L2 L3 - L32 L1 - L2 L2 - L3 L3 - L1 3 L1 - L3 L2 - L1 L3 - L2 4 L1 - L1 L2 - L2 L3 - L3

Figure 14 Grid-side connection for systems with multiple battery systems with three-phase grid monitoring

Installing the device

Page 24 Operating instructions Powador-gridsave_EN

Authorised electrician

722 Connecting the PV generator

Connect the PV generator on the left in the connection area (Figure 13 on page 21) Use the provided M16 cable fittings A maximum of two strings can be connected For this reason a DC string fuse can be dispensed with

DANGERRisk of fatal injury due to contact voltagesRemoving the cables from the terminals without first disconnecting the PV generator from the device can cause serious damage to health or damage to the system rsaquo During installation Electrically disconnect the DC positive and DC negative from the protective

earth (PE) rsaquo Completely de-energise the system (AC home power grid AC circuit breaker residual current circuit

breaker DC isolator switch) rsaquo Disconnect the battery system from the PV generator using the integrated DC isolator switch rsaquo Remove DC plug connectors

NOTEIn accordance with IEC 61730 Class A connected PV modules must be dimensioned for the DC system voltage provided and at least for the value of the AC grid voltage

7221 Before connecting

Ensure that there is no ground fault1 Determine the DC voltage between the

ndash protective earth (PE) and the positive cable of the PV generator and between the ndash protective earth (PE) and the negative cable of the PV generator

If stable voltages can be measured there is a ground fault in the DC generator or its wiring The ratio between the measured voltages gives an indication as to the location of this fault

2 Rectify any faults before taking further measurements3 Determine the electrical resistance between the

ndash protective earth (PE) and the positive cable of the PV generator and between the ndash protective earth (PE) and the negative cable of the PV generator

In addition ensure that the PV generator has a total insulation resistance of more than 20 MOhm since the inverter will not feed in if the insulation resistance is too low

4 Rectify any faults before connecting the DC generator

7222 Connecting the PV generator

DANGERRisk of fatal injury due to electric shockSevere injury or death will result if the live connections are touched When there is solar radiation DC voltage will be present at the open ends of the DC cables rsaquo Do not touch the exposed ends of the cables rsaquo Avoid short circuits

Installing the device

Operating instructions Powador-gridsave_EN Page 25

Authorised electrician

Connecting the PV generator Use cables with the correct cross-section

1 Remove cable fittings for DC connection2 Remove the outer cladding of the DC cables3 Insert the DC cables through the cable fittings into the connection area4 Strip the insulation from the DC cables5 Remove connection terminals6 Connect the cables in line with the terminal labels (See Figure 13 on page 21)7 Close the connection terminals8 Check that all connected cables are securely fitted9 Tighten the cable fittings10 To meet the requirements of protection rating IP21 close the unused cable fittings with blind caps raquo The PV generator is connected to the inverter

73 Connecting the interfaces

731 Ethernet interface

Pre-assembled Ethernet cables can be connected using the RJ45 socket in the connection space

Connecting the Ethernet cable1 Remove closure cap from RJ45 socket2 Connect the Ethernet cable3 The energy management system can now obtain an IP address by DHCP and is also available via this in the

network

NOTEThe network settings can be amended later in the Settings menu using the EMS

NOTEUse a suitable category 5 network cable The maximum length of a network segment is 100 m Ensure that the cable is correctly assigned The Ethernet connection of the battery system supports auto-sensing You can use both crossed and 11 configured Ethernet connection cables

74 Sealing the connection area

1 Finally check the cabling2 Ensure that all cables are firmly mounted3 Check that the cable fitting is secure and tighten if necessary4 Remove cable offcuts and particles of dirt or dust5 Fit the cover and slide back until it engages into position6 Check that the position is correct7 Screw the fastening screw onto the front of the cover

Installing the device

Page 26 Operating instructions Powador-gridsave_EN

Authorised electrician

75 Starting up

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched Only appropriately qualified and authorised electricians may open install or maintain the battery system rsaquo Keep the front doors and covers closed during operation

NOTEInitial start-up should be carried out using the available public AC grid

76 Standard configuration

Factory settingsCountry configuration Germany

Grid guidelines Low voltage directive

Language German

Time UTC +1 Central European Time

User Standard

Network parameters DHCP (network settings will be obtained automatically from the router)

NOTEPlease state the desired power limitation (60 or 70 of the PV system capacity) when you order For other variations please notify your KACO contact so that the parameters can be set at the factory prior to delivery

Installing the device

Operating instructions Powador-gridsave_EN Page 27

Authorised electrician

761 Step 1 AC home power grid

Check all cables and connections before starting up1 Switch on the AC home power grid using the AC main switch raquo Powador-protect measurement and control unit starts up and monitors the AC grid raquo Two green LEDs indicate that the grid parameters are met raquo After a further 60 seconds (shortly after the backlighting in the Powador-protect goes out) the Powador-pro-

tect will switch on the home grid2 Configure Powador-protect according to the enclosed Powador-protect instructions

(The instructions are also available on the website at wwwkaconewenergyde) raquo The AC power is supplied in the normal way by the public grid

762 Step 2 AC supply from the battery system

Check all cables and connections before starting up1 Remove external isolation means from the device2 Switch on the circuit breaker raquo The LCD touchscreen on the front panel comes on and the energy management system (EMS) starts up

3 Switch on the residual current circuit breaker raquo The battery system starts up

763 Step 3 Switch on the PV system

1 Switch on any optional external PV isolator switches2 Set the internal DC isolator switch to ON raquo The inverter and the battery charging unit battery backup converter (BBC) are connected to the PV system raquo The device monitors the PV voltage for approx 60 seconds then optimisation of internal consumption takes

place

764 Step 4 Switch on batteries

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

765 Step 5 Activate energy management

NOTEKACO new energy cannot provide any support for problems regarding the IT infrastructure (eg router configuration IP address assignment ports etc) as the structure settings and configuration of the network environment can be complex and very different from place to place In the event of any problems please contact an IT service provider

Remote access activated 1 Please call the KACO Hotline to make an appointment for activation of energy management

Configuration and Operation

Page 28 Operating instructions Powador-gridsave_EN

Authorised electrician

8 Configuration and Operation

81 ControlsThe battery system is fitted with a touchscreen which allows it to be controlled very precisely In normal operation the display is switched off Touching the screen activates the display and after a configurable period of time without being touched the dis-play will deactivate If the screen-save function is switched off the touchscreen will be on continuously

NOTEDepending on the tolerances of the measuring elements the measured and displayed values are not always the actual values However the measuring elements ensure maximum solar yield Due to these tolerances the daily yields shown on the touchscreen may deviate from the values on the grid operatorrsquos feed-in meter by up to 15

3

1

45

2

Figure 15 Overview (home screen)

Key

1 Home button 4 Current time

2 System components 5 Menu name

3 More information

811 Information about the system

Open start screen View changesjumps to the home screen

Show component detail Parameters of the selected component

Settings Define settings for the active user

raquo Displays settings

Configuration and Operation

Operating instructions Powador-gridsave_EN Page 29

Controls Left arrow jump back to previous menu item Up and down arrows navigate through the menu or change a value

Left arrow displayed value is reduced by one increment Right arrow displayed value is increased by one increment or change to the submenu

Display fields Grey box Text or figures (not selectable) Blue box Calls up submenu for the display in question

Activate and deactivate Activate function by ticking the box

Table 6 Information about the system

812 System components

PV generator Display of the current generator data

power voltage current temperature in the inverter

Battery Display of the current battery status

power (charging or discharging) voltage current charge status available capacity temperature of battery

Grid Display of the following either fed-in or drawn from the grid

power voltage current for phase L1-L3 total output frequency

Consumer (load) Display of the consumer data

power voltage current for phase L1-L3 total output

Energy flow raquo Displays the current energy flow in the system

Table 7 Information about system components

Configuration and Operation

Page 30 Operating instructions Powador-gridsave_EN

813 Menu structure

Icons used

Display menu Submenu

Option menu

Menu Submenu Display setting

Action in this menumeaning

PV generator Details

Power Displays the current DC-side power

Voltage Displays the current DC-side voltage

Current Displays the current DC-side amperage

Temp inverter

Displays the current temperature in the inverter housing

Battery Details

Power Displays the current AC-side power

Voltage Displays the current AC-side voltage

Current Displays the current AC-side amperage

Charge status Displays the current charge status

Capacity Displays the current battery capacity

Temperature Displays the current measured temperature of the battery

Grid Details

Power Displays the current AC-side power being drawn or fed-in

Voltage Displays the AC-side voltage being applied

Current Displays the current AC-side amperage being drawn or fed-in

Total output Displays the current AC-side total output being drawn or fed-in

Frequency Displays the frequency currently being applied to the grid junction

Consumer (load) Details

Power Displays the current AC-side power being drawn

Voltage Displays the current AC-side voltage being applied

Current Displays the current AC-side amperage being drawn

Total output Displays the current AC-side total output being drawn

Configuration and Operation

Operating instructions Powador-gridsave_EN Page 31

Menu Submenu Display setting

Action in this menumeaning

Settings

Country amp directive display

Display of the country settings voltage directives and grid type

Select menu language

DateTime Specify time zone date format and date and time

Screen Activate screen-save function and set the delay period

Network settings

Display of the network settings Configure network settings Once the DHCP server becomes available the IP

address subnet mask gateway and DNS server are automatically applied and the aforemen-tioned menu items are hidden

Off DHCP deactivated make settings manually

Version Displays the installed software version and built-in HW components (inverter BBC battery)

Vendor The touchscreen shows information about the device vendor

NOTEAs changes to the software are possible after the manual has been printed the illustrations and descriptions of the functions in these operating instructions may deviate from the software Please therefore note the current Application Notes on our website

MaintenanceTroubleshooting

Page 32 Operating instructions Powador-gridsave_EN

9 MaintenanceTroubleshooting

91 Visual inspectionInspect the device and the cables for visible external damage and note the operating status display In case of damage notify your installer Repairs may only be carried out by authorised electricians

NOTEThe battery system should be checked for proper operation by a qualified electrician at regular intervals

92 Cleaning the device

DANGERLethal voltages in the battery systemSerious injuries or death can result if moisture enters the system rsaquo Only use completely dry objects to clean the battery system rsaquo Only clean the outside of the battery system

Cleaning the battery system Do not use compressed air Use a vacuum cleaner or a soft brush to remove dust from the fan cover and from the top of the inverter on a

regular basis Remove dust from the ventilation inlets if necessary

MaintenanceTroubleshooting

Operating instructions Powador-gridsave_EN Page 33

Authorised electrician

93 Maintenance

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched The device is only permitted to be opened or serviced by an authorised electrician rsaquo Observe all safety regulations and the current technical connection specifications from the relevant

power supply company rsaquo Disconnect the AC and DC sides rsaquo Secure the AC and DC sides from being inadvertently switched back on rsaquo Only then should the device be opened rsaquo After shutdown wait at least 30 minutes before working on the device

CAUTIONDestruction of the DC connectionThe connection terminals can be destroyed by arcing if disconnected while still live rsaquo It is absolutely essential that the shutdown sequence be carried out in the correct order (See sec-

tion 111 on page 35)

94 Faults

941 Procedure

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched

When a fault occurs notify an appropriately authorised and qualified electrician or KACO new energy GmbH Service

Service

Page 34 Operating instructions Powador-gridsave_EN

10 ServiceIf 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 efficientlybull Serial nobull SW version of the components (the software version can be found in the Settings menu using the EMS)bull Module type and string circuitbull Date of installation Start-up reportbull Consignment identification Delivery address Contact person (with telephone number)bull Information about the accessibility of the installation site

Any additional costs arising from unfavourable structural or mounting conditions shall be billed to the customer

You can find our warranty conditions on our websitehttpkaco-newenergycomservicewarrantyFrom there you can easily navigate to our international websites by clicking on the appropriate flag

Please use our website to register your unit immediatelyYou can also select the appropriate flag on this page to access the website for your own countryIn this manner you can assist us in providing you with the quickest service possible Note The maximum length of the warranty is based on the currently applicable national warranty conditions

We have prepared a template for complaints This can be found at httpskaco-newenergycomservicecustomer-service

Hotlines

Technical troubleshooting Technical consultation

Inverters and battery systems ()

+49 (0) 71323818-660 +49 (0) 71323818-660

Data logging and accessories +49 (0) 71323818-690 +49 (0) 71323818-690

Construction site emergency () +49 (0) 71323818-630

Customer help desk Monday to Friday from 730 am to 530 pm (CET)

() Also on Saturdays from 800 am to 200 pm (CET)

ShutdownDisassembly

Operating instructions Powador-gridsave_EN Page 35

11 ShutdownDisassembly

111 Switching off the device

DANGERLethal voltages are still present in the terminals and cables even after switching off and discon-nection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched rsaquo Complete de-energisation only occurs if the bulk power supply is switched off upstream of the bat-

tery system

DANGERDestruction of the DC plug connectorDC plug connectors can be destroyed by arcing if disconnected while still live rsaquo It is absolutely essential that the following shutdown sequence is observed

1111 Step 1 Shutting down the PV system

1 Switch off any optional external PV isolator switches2 Set the internal DC isolator switch to OFF raquo The inverter and battery charging unit battery backup converter (BBC) are disconnected

1112 Step 2 Disconnect the batteries

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

1113 Step 3 Disconnect the AC supply

1 Connect external isolation means to the device2 Switch off the circuit breaker 3 Switch off the residual current circuit breaker raquo The battery system is switched off

1114 Step 4 AC home power grid

1 Shutdown the AC home power grid using the AC main switch raquo The battery system can be uninstalled

Disposal

Page 36 Operating instructions Powador-gridsave_EN

112 Uninstalling the device

NOTETo uninstall follow the same sequence as for installation but in reverse order

Switch off the device1 Unlock and open the housing door2 Remove the upper cover3 Release the DC and AC cables from the connection terminals4 Pull out the cables raquo The battery system is uninstalled Continue with the disassembly

113 Disassembling the device

NOTETo disassemble follow the same sequence as for assembly but in reverse order

Switch off the device1 Uninstall the components2 Remove the fastening from the device3 Securely pack up the battery system if it is to be used later

or have the battery system disposed of in accordance with section 12 on page 36

12 DisposalFor the most part both the battery system and the corresponding transport packaging are made from recyclable raw materialsBatteries and components Do not dispose of faulty batteries or the components together with household waste Ensure that the old device and accessories are disposed of in a proper mannerPackaging Ensure that the transport packaging is disposed of properlyBatteriesUsed or faulty batteries must be transported in special packaging If you need such packaging please contact the KACO Hotline

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

Appendix

Operating instructions Powador-gridsave_EN Page 37

13 Appendix

EU Declaration of Conformity

Vendorrsquos name and address

KACO new energy GmbH Carl-Zeiss-Straszlige 1 74172 Neckarsulm Germany

Product description Battery system

Type designation Powador-gridsave 135 kWh 6400 Powador-gridsave 135 kWh 8000

Powador-gridsave 270 kWh 6400 Powador-gridsave 270 kWh 8000

Powador-gridsave 405 kWh 6400 Powador-gridsave 405 kWh 8000

Powador-gridsave 540 kWh 6400 Powador-gridsave 540 kWh 8000

Powador-gridsave 577 kWh 6400 Powador-gridsave 577 kWh 8000

Powador-gridsave 675 kWh 6400 Powador-gridsave 675 kWh 8000

This is to confirm that the units listed above comply with the protection requirements set forth in the Directive of the Council of the European Union of 15th December 2004 on the harmonisation of the laws of the member states relating to Electromagnetic Compatibility (2004108EC) and the Low Voltage Directive (200695EC)The units are compliant with the following standards

200695EC ldquoDirective relating to electrical equipment designed for use within specific voltage limitsrdquo

Safety of the unitIEC 62109-12010IEC 62109-22011

2004108EC ldquoDirective relating to electromagneticcompatibilityrdquo

Interference immunityEN 61000-6-22005 Emitted interferenceEN 61000-6-32007

Secondary effects on the gridEN 61000-3-112000EN 61000-3-122005

The types mentioned above are therefore labelled with the CE markUnauthorised modifications to the supplied units andor any use of the units that is contrary to their intended use render this Declaration of Conformity null and void

Neckarsulm 0711 2013KACO new energy GmbH

pp Volker DietrichEnergy systems engineering management

Disposal

Page 38 Operating instructions Powador-gridsave_EN

Carl-Zeiss-Straszlige 1 middot 74172 Neckarsulm middot Germany middot Phone +49 7132 3818-0 middot Fax +49 7132 3818-703 middot infokaco-newenergyde middot wwwkaco-newenergyde

The

text

and

figu

res

refle

ct th

e cu

rren

t tec

hnic

al s

tate

at t

he ti

me

of p

rintin

g S

ubje

ct to

tech

nica

l cha

nges

Err

ors

and

omis

sion

s ex

cept

ed

3006

856-

01-1

4030

5

  • 1General Information
    • 11About this document
    • 12Name plate
    • 13Additional information
    • 14Intended use
      • 2Safety
        • 21Protection features
          • 3Description
            • 31Mode of Operation
            • 32Summary of the components
              • 4Technical Data
                • 41Electrical data
                • 42Mechanical data
                  • 5Transportation and Delivery
                    • 51Delivery
                    • 52Storage
                    • 53Transportation
                      • 6Assembling the device
                        • 61Installation
                        • 62Installing components
                          • 7Installing the device
                            • 71Opening the connection area
                            • 72Making the electrical connection
                            • 73Connecting the interfaces
                            • 74Sealing the connection area
                            • 75Starting up
                            • 76Standard configuration
                              • 8Configuration and Operation
                                • 81Controls
                                  • 9MaintenanceTroubleshooting
                                    • 91Visual inspection
                                    • 92Cleaning the device
                                    • 93Maintenance
                                    • 94Faults
                                      • 10Service
                                      • 11ShutdownDisassembly
                                        • 111Switching off the device
                                        • 112Uninstalling the device
                                        • 113Disassembling the device
                                          • 12Disposal
                                          • 13Appendix

Description

Operating instructions Powador-gridsave_EN Page 7

3 Description

31 Mode of OperationThe battery system optimises internal consumption thus reducing the amount of electrical energy needed from the public grid Energy from a photovoltaic system that is not required in the home at that time is stored in a battery and supplied to the consumer as necessary Consumers are supplied with their own energy by the device in a manner which is flexible and optimised to their personal habits

311 System overview

BPM

Gridsave

Measurement

Meassurement

AC

Power Meterproduction

Grid

Distribution Box

Communication

BidirectionalPower Meter

AC circuit breaker

DC circuit breaker

Door

PV-Generator

BBC

350 - 800 VDC

3 x 400 VAC

Inverter

U [V]I [A]

P [W]

U [V]I [A]

P [W]

Powador Protect

Load

3 x 400 VAC

BMS

BatteryBattery

Battery

Power flow

Power flow

Power flow

RCD

Power supply

3 x 400 VAC

AC Main switch

3

40A

3

63A

40A

4

4

Energie- management-

System(EMS)

Figure 1 Schematic overview

Description

Page 8 Operating instructions Powador-gridsave_EN

312 Configuration

Powador-protect

CONNECTION BOX

PV INVERTER

BATTERY CONVERTER

PV-Circuit Breaker

ON

OFF

AC-Circuit Breaker

Residual-Current-Circuit Breaker

BATTERY

1

3

4

5

2

Figure 2 Configuration of the battery system

1 Connection box 4 Battery charging unit battery backup converter (BBC) 1

2 Energy management system (EMS) with LCD touchscreen

5 Battery unit with controller

3 Inverter

Description

Operating instructions Powador-gridsave_EN Page 9

32 Summary of the components

321 Connection box

ON

OFF

Powador Protect

off off off

B 32AAC-Circuit Breaker

IN=40AΔI=300mA

RCCB

off

Test

Typ A

CONNECTION BOX

1 2 3 4

Figure 3 Connection box

Key Function

1 DC isolator switch Disconnects the PV generator from the inverter battery unit

2 Measurement and control unit Powador-protect

Three-phase monitoring of the grid switches off the power supply in the event of impermissible voltage or frequency

3 Circuit breaker Disconnects the inverter from the AC grid

4 Residual current circuit breaker

Protects individuals and the installation by isolating the inverter

NOTEThe DC isolator switch circuit breaker and residual current circuit breaker will switch off the battery system Power will then be supplied from the public grid

322 Energy management system

Figure 4 Energy management system (EMS) with LCD touchscreen

NOTEThe energy management system (EMS) displays all relevant parameters in order to ensure optimum operation

Description

Page 10 Operating instructions Powador-gridsave_EN

323 Inverter

PV INVERTER

Figure 5 Inverter

NOTEThe inverter converts the DC voltage from the PV generator and the battery into AC voltage

324 Battery charging unit battery backup converter (BBC)

BATTERY CONVERTER

Figure 6 Battery charging unit battery backup converter (BBC)

NOTEThe battery charging unit battery backup converter (BBC) is the interface to the battery The high voltage from the PV generator is converted into non-hazardous safety extra low voltage (SELV) for the battery The battery charging unit battery backup converter (BBC) can transfer energy both into the battery and out of it

325 Battery management system (BMS)

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

326 Battery

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

Technical Data

Operating instructions Powador-gridsave_EN Page 11

4 Technical Data

41 Electrical data

Connection box

Home power grid

Input voltage 230V 400V 50Hz 60Hz 3-phase (3 N PE)

Grid configuration TN-C TN-S TT

Grid monitoring Powador-protect (as per VDE-AR-N 4105)

Grid isolation Double insulated 3 or 4 pin

Rated operating current [A] 75

Rated switching current AC-1 [A] 100

Rated switching current AC-3 [A] 50 (22 kW at 400 V)

Connection cross-section [mmsup2] max 25

PV input

Input voltage [V] 300 to 800

Input current [A] 30 String

Strings 2

Isolation Yes rotary switch

Inverter type 6400 8000

Input levels

Max recommended PV generator power [W] 7700 9600

Rated power peak power [VA] 6400 7000 8000 9000

DC MPP range from [V] to [V] 360 590

Open circuit voltage [V] 800

Input current [A] 190 240

cos phi 08 inductive hellip 08 capacitive

Polarity safeguard Short-circuit diode

Feed-in phases 1

Capable of stand-alone operation Yes

Efficiency [] 966

Output levels

Output voltage 230V 50Hz 60Hz 1-phase

Rated current [A] 278 35

Connection cross-section [mmsup2] max 6

Monitoring Isolation Circuit breaker residual current circuit breaker (RCD)

Table 1 Electrical data

Technical Data

Page 12 Operating instructions Powador-gridsave_EN

Battery charging unit battery backup converter (BBC)

BBC power [W] 3300

HV voltage [V] 350 to 600

Battery voltage [V] 38 to 58

Efficiency [] 970

Table 1 Electrical data

42 Mechanical data

Battery system

Display 43 LCD touchscreen

Interfaces RS485 Sym-Bus Ethernet USB digital inputsoutputs

Cable insertion Cable fitting 2x M40 2x M32 4x M25 12x M16

Ambient temperature [degC] 0 +40

Humidity [] lt95 (non-condensing)

Cooling Forced cooling temperature-controlled

Noise emission [dB] lt45

Note regarding cooling Do no cover air inletsoutlets keep clear 20 cm to the right and left

Temperature monitoring Individual monitoring of components with shutdown in the event of excess temperature

Maximum installation elevation [m above mean sea level] 2000

Protection class IP21

Housing form 19 sheet-steel control cabinet

H x W x D [mm] 1600 x 620 x 600

Weight [kg] 2435

Inverter

Ambient temperature range [degC] -20 +60

Temperature monitoring Yes

Cooling Active cooling

Connections Quick INOUT plug connector and busbar clips rear side

H x W x D [mm] 22225 x 4826 x 460

Weight [kg] 25

Table 2 Mechanical data

Technical Data

Operating instructions Powador-gridsave_EN Page 13

Battery charging unit battery backup converter (BBC)

Ambient temperature range [degC] -20 +70

Temperature monitoring Yes

Cooling Active cooling

Housing 19 plug-in module aluminium

Connections Quick INOUT plug connector and busbar clips rear side

H x W x D [mm] 13325 x 4826 x 460

Weight [kg] 15

Temperature-dependent impedance matching with shutdown if the temperature is too high

Table 2 Mechanical data

Transportation and Delivery

Page 14 Operating instructions Powador-gridsave_EN

5 Transportation and Delivery

51 DeliveryThe battery system leaves KACO new energy in fully functional electrical and mechanical condition Special packaging ensures that the units are transported safely The shipping company is responsible for any trans-port damage that occurs

511 Scope of delivery

Pallet A B

Figure Figure 7 Scope of delivery pallet A Figure 8 Scope of delivery pallet B

Contents bull Battery system Powador-gridsave (incl connection box battery management system (BMS) industrial PC Plexiglas cover and accessories)

bull Inverter bull Battery charging unit battery backup converter

(BBC)bull Battery system plug-in modules 1-5 ST (scope of

delivery can be found on the delivery document)bull Documentation

Weight (kg) 187 max 155 177 (without with Euro pool pallet)

H x W x D [mm] 1780x800x820 1200x1200x800

Packaging Cardboard box with polystyrene inserts and closures

512 Check the equipment included

bull Battery system and plug-in modules should be inspected thoroughly for transport damagebull Do not install damaged components in the control cabinetbull In the event of damage to the battery plug-in modules contact the KACO new energy Hotline immediately

Transportation and Delivery

Operating instructions Powador-gridsave_EN Page 15

Authorised electrician

DANGERRisk of fatal injury if incompatible components are usedThe battery and power electronics can be damaged if different delivery batches are combined and will carry potentially fatal voltages if connected rsaquo Assemble the system using the components provided by KACO new energy only rsaquo Check the serial numbers on the delivery document against the serial numbers of the individual

units on pallets A and B

52 StorageIncorrect storage can lead to system malfunctions Therefore please observe the following conditionsbull If storing for longer than six months store the device in an interior room in its original packaging bull If the original packaging has been removed store the device in a cool dry interior roombull Storage temperature -20 degC to +70 degCbull Relative humidity 0 to 95 (non-condensing)bull If the device is stored for a relatively long time at high humidity the device must be left for more than one day to

dry out sufficiently before connection to the power grid

53 Transportation

WARNINGImpact hazard risk of breakage to the components in the battery systemThe centre of gravity is located in the upper part of the device rsaquo Transport the device upright together with the pallet rsaquo Do not expose the device or components to any shocks rsaquo After unloading at least two people are required to transport the cabinet

WARNINGDanger due to impact and incorrect storage of the batteriesIn the event of damage batteries can release hazardous electrolyte gases which will cause irreversible burns if they come into contact with the skin rsaquo Transport the batteries in the vendors original packaging only rsaquo Remove the batteries from the original packaging shortly before installation rsaquo Do not store batteries in cars or outdoors rsaquo Check the condition of the battery before use

NOTEThe precise specifications of the UN on the transport of lithium batteries can be found under the designation Model Regulations on the transport of dangerous goods Ref STSGAC101 Recommendations on the transport of dangerous goods Part III sub-section 383 ldquoManual of Tests and Criteriardquo Ref STSGAC1011

Assembling the device

Page 16 Operating instructions Powador-gridsave_EN

Authorised electrician

6 Assembling the device

61 Installation

DANGERRisk of fatal injury from fire or explosionsFire caused by flammable or explosive materials in the vicinity of the battery system can lead to serious injuries rsaquo Do not mount the inverter in potentially explosive atmospheres or in the vicinity of highly flamma-

ble materials

CAUTIONBattery system is very heavy ndash risk of injury rsaquo Be aware of the weight of the battery system during transport rsaquo Select suitable mounting location and mounting base rsaquo Only install the battery system with the help of a second person

CAUTIONEquipment damage caused by aggressive gases in combination with humidityThe housing may be seriously damaged by aggressive gases (ammonia sulphur and other chemi-cals) in combination with ambient humidity caused by weather conditions - Installation in rooms containing aggressive gases is not permitted

NOTEAccess in the event of maintenance or serviceAny additional costs arising from unfavourable structural or mounting conditions in the event of a KACO service call-out shall be billed to the customer

611 Installation location

bull Dry well ventilated the waste heat must be conducted away from the battery systembull Unobstructed air circulationbull Easily accessible from the front top and sides without requiring additional resourcesbull Indoors protected against direct sunlight and direct water contact

612 Foundation

bull With sufficient load-bearing capacitybull Made from heat-resistant material (up to 90 degC)bull Must be flame resistant

NOTEPower reduction due to heat accumulationIf the recommended minimum clearances are not observed the device may go into power regula-tion mode due to insufficient ventilation and the resulting heat build-up rsaquo The construction and installation of the device may be performed only by a qualified electrician in

accordance with the valid standards and regulations rsaquo Maintain minimum clearances rsaquo Ensure sufficient heat dissipation

Assembling the device

Operating instructions Powador-gridsave_EN Page 17

Authorised electrician

0deg

1000 mm

200 mm 200 mm

500 mm

min carrying capacity 300 kgmsup2

200 mm200 mm

50 mm

Figure 9 Minimum clearances at the installation and assembly location

CAUTIONRisk of injury if the battery system tips overRisk of tipping due to high centre of gravity particularly with the door open rsaquo Anchor the device securely to the floor immediately after installation rsaquo Open the housing door using the enclosed cabinet key only once the device has been securely

anchored

510 mm200 mm

200 mm

400

mm

12 mmmin 110 mm

DesignationHex head wood screw 8x80 DIN571-vz Fischer dowel S12 Flat washer M8 galvanised DIN9021-vz

Units444

Figure 10 Dimensions for anchoring to the floor Table 3 Mounting parts

62 Installing components

CAUTIONAvoid improper handlingImproper handling can cause damage to components rsaquo Damaged components must not be installed rsaquo Always put the plug-in modules down horizontally to avoid damage to the components

Assembling the device

Page 18 Operating instructions Powador-gridsave_EN

Authorised electrician

WARNINGDanger caused by short circuit or sparkingSerious injury from touching or connecting live components rsaquo Damaged components must not be installed

Preparation1 Check the conditions for the installation location2 Open the housing doors using the enclosed cabinet key3 The cables should be professionally laid and prepared for connection4 Follow the installation sequence (1-4 step(s))

621 Step 1 Fit the battery (batteries)

NOTEPlease read the notes on installation and connection in the enclosed manual Features for the battery unit

622 Step 2 Connect battery (batteries) to the battery management system (BMS)

NOTEPlease read the notes on installation and connection in the enclosed manual Features for the battery unit

623 Step 3 Fit the battery charging unit battery backup converter (BBC)

Battery (batteries) connected to the battery management system (BMS)1 Carefully insert battery charging unit battery backup converter (BBC) into the compartment provided for it 2 Push in completely to establish direct contact with the rear busbars3 Secure battery charging unit battery backup converter (BBC) using the screws supplied

624 Step 4 Fit the inverter

Battery charging unit battery backup converter (BBC) is fitted1 Carefully insert inverter into the compartment provided for it 2 Push in completely to establish direct contact with the rear busbars 3 Secure inverter using the screws supplied

CAUTIONDamage to the control unit from introducing foreign objectsForeign objects can impair the function of the control unit and cause damage rsaquo Do not remove the front panel rsaquo Foreign objects should be removed immediately

Installing the device

Operating instructions Powador-gridsave_EN Page 19

Authorised electrician

7 Installing the device

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched The device may only be opened or serviced by an authorised electricianThe device must be completely assembled before being connected electrically rsaquo Observe all safety regulations and current technical connection specifications of the responsible

power supply company rsaquo De-energise the device using the DC isolator switch circuit breaker and residual current circuit

breaker rsaquo Secure both sides against being inadvertently switched back on rsaquo Ensure that the AC and DC sides are completely isolated and voltage free rsaquo Never open the plug-in modules rsaquo Hazardous voltages are present at the busbars rsaquo Disconnect from the grid and plant supply rsaquo First connect the battery system in the connection area

71 Opening the connection area

3

1

2

Figure 11 Open cover plateKey

1 Cover plate 3 Fastening screw

2 Lock

Opening the connection area You have completed assembly

1 Remove the fastening screw for the upper cover plate2 Slide the cover plate forwards out of the lock3 Lift the cover plate upward to remove raquo Make the electrical connection

Installing the device

Page 20 Operating instructions Powador-gridsave_EN

Authorised electrician

72 Making the electrical connectionMake the connection to the PV generator as well as the grid connection using the connection terminals Note the following cable cross-sections

Connection Possible cable cross-section Length of insulation to be stripped offAC home power grid 05 - 16 mmsup2 with end sleeve

05 - 25 mmsup2 without end sleeve18 mm sleeve18-20 mm

PV connection 05 - 16 mmsup2 with end sleeve05 - 25 mmsup2 without end sleeve

18 mm sleeve17-19 mm

Inverter output 05 - 4 mmsup2 with end sleeve05 - 6 mmsup2 without end sleeve

12 mm sleeve11-13 mm

Potential-free contacts 034 - 15 mmsup2 with end sleeve034 - 25 mmsup2 without end sleeve

12 mm sleeve 9-10 mm

Table 4 Cable cross-sections for connection terminals

NOTEThe threaded connections should be matched to the cable cross-section

NOTEOnly conductors and no insulation should be inserted into the connection terminals Individual wires or cables with end sleeves with the appropriate cross-section can be inserted directly into the connection terminal without a toolFine-strand cables without end sleeve or thin conductors will need a screwdriver (plain slot 35 mm) for connection To do this insert the blade of the screwdriver into the recess provided The cable can be inserted into the spring terminal by pressing downwards The spring terminal closes on removal of the screw-driver

Installing the device

Operating instructions Powador-gridsave_EN Page 21

Authorised electrician

X2X1F1 F2 X7 X4 St1

St2

St3

2 3 541 6

Figure 12 View from above of the connection area

Key

1 AC grid input (M40 cable fitting) 4 Network interface (M32 cable fitting)

2 AC grid output (M40 cable fitting) 5 Inverter input (M16 cable fitting)

3 Inverter output (M32 cable fitting) 6 Other connections (M16 cable fitting)

F1 F2 X7 X4 St1

St2

St3

L1 L2 L3 N PE L1 L2 L3 N N PE PE

X1 X2

PV+

PV-

L1 L2 L3 N PE32A 32A PEN

Cust

omer

co

nnec

tion

Figure 13 View from above of the connection area

Key

X1 AC grid input (main junction box meter) X7 PV generator input

X2 AC grid output (building electrical system) F1 F2 Phase bridging fuse

X4 Inverter output St 1-3 Potential-free contacts control outputs

Installing the device

Page 22 Operating instructions Powador-gridsave_EN

Authorised electrician

721 Connecting to the power grid

Because the device is installed between the main junction boxmeter and the buildings electrical system the maxi-mum grid current to the service line must not exceed the rated operating current of the battery system The cable cross-section must be selected in accordance with applicable standards to suit the connected load instal-lation type etc Moreover the terminal area and size of the cable fitting must be noted

NOTEThe fuse rating for the cable should be max 63A (automatic circuit breaker or safety fuse) even if the cross-section of the installed cable would permit a higher fuse rating Always follow the applicable regulations regarding the cable cross-section and installation typeThe device supports standard grid configurations such as TN-C TN-S and TT TN-SIf a TN-S grid is present directly at the power input and output of the device L1-L3 N and PE must each be connected The home power grid should have 4-pin isolationTN-C4-pin grid isolation is factory preset and disconnects L1 L2 L3 and N In a TN-C grid the N conduc-tor must not be disconnected If a TN-S grid is present directly at the power input and output of the device a cable bridge (included in delivery) must be installed between the N terminal on X1 and the N terminal on X2 N and PE must additionally be connected together To do this simply insert the enclosed terminal link into the N and PE terminals TTIn the case of a TT grid L1-L3 N and PE must each be connected The home power grid should have 4-pin isolation

NOTEPlease check with the operator of the mains grid whether there are special regulations for grid connection Grid isolation is factory preset to 4-pin is fail-safe and provided with grid and system protection as per VDE-AR-N 4105

Making the grid connection Use cables with 5 wires (L1 brown L2 black L3 grey N blue PE greenyellow) and the correct

cross-section1 Loosen cable fitting for AC connection2 Remove the outer cladding of the AC cables3 Insert the AC cables through the cable fitting into the connection area4 Strip the insulation from the AC cables5 Remove connection terminals6 Connect the cables in line with the terminal labels (Figure 13 on page 21)7 Close the connection terminals8 Check that all connected cables are securely fitted9 Tighten the cable fitting10 To meet the requirements of protection rating IP21 close the unused cable fittings with blind caps raquo The battery system is connected to the power grid

NOTEAn AC-side disconnection unit must be provided during the final installation stage This disconnec-tion unit must be installed so that it can be accessed at any time without obstruction If a residual current circuit breaker is necessary due to the installation specification a type A residual current circuit breaker must be used

Installing the device

Operating instructions Powador-gridsave_EN Page 23

Authorised electrician

7211 Output from the inverterRecommended cable cross-sections for the inverter output and fuse rating of cables for fixed wiring accord-ing to VDE 0100 part 430The fuse rating for the cable is dependent on the cable cross-section max 40A automatic circuit breaker

NOTEWhen the line resistance is high (ie long grid-side cables) the voltage at the grid terminals of the inverter will increase during feed-in to the grid The inverter monitors this voltage If the voltage exceeds the country-specific grid overvoltage limit value the inverter switches off rsaquo Ensure that the conductor cross-sections are sufficiently large or that the cable lengths are suffi-

ciently short

NOTEIn order to avoid asymmetries in the grid systems with multiple battery systems should be designed so that the inverters in the devices feed into the grid in differing phases rsaquo Follow the connection conditions for the particular type of grid and the schematic illustration

below

Country and grid-type

Grid monitoring Required monitoring

max asymmetry between phases L1L2L3

DE-NSP Three-phase or single phase phase unbalanced load 46 kVA

Table 5 Grid-type-specific connection conditions

L1

L2

L3

N

Connection X1 Connection X1 Connection X1 Connection X1

L1 L2 L3 N PE L1 L2 L3 N PE L1 L2 L3 N PE L1 L2 L3 N PE

Powador-gridsave inverter1 L1 - L1 L2 - L2 L3 - L32 L1 - L2 L2 - L3 L3 - L1 3 L1 - L3 L2 - L1 L3 - L2 4 L1 - L1 L2 - L2 L3 - L3

Figure 14 Grid-side connection for systems with multiple battery systems with three-phase grid monitoring

Installing the device

Page 24 Operating instructions Powador-gridsave_EN

Authorised electrician

722 Connecting the PV generator

Connect the PV generator on the left in the connection area (Figure 13 on page 21) Use the provided M16 cable fittings A maximum of two strings can be connected For this reason a DC string fuse can be dispensed with

DANGERRisk of fatal injury due to contact voltagesRemoving the cables from the terminals without first disconnecting the PV generator from the device can cause serious damage to health or damage to the system rsaquo During installation Electrically disconnect the DC positive and DC negative from the protective

earth (PE) rsaquo Completely de-energise the system (AC home power grid AC circuit breaker residual current circuit

breaker DC isolator switch) rsaquo Disconnect the battery system from the PV generator using the integrated DC isolator switch rsaquo Remove DC plug connectors

NOTEIn accordance with IEC 61730 Class A connected PV modules must be dimensioned for the DC system voltage provided and at least for the value of the AC grid voltage

7221 Before connecting

Ensure that there is no ground fault1 Determine the DC voltage between the

ndash protective earth (PE) and the positive cable of the PV generator and between the ndash protective earth (PE) and the negative cable of the PV generator

If stable voltages can be measured there is a ground fault in the DC generator or its wiring The ratio between the measured voltages gives an indication as to the location of this fault

2 Rectify any faults before taking further measurements3 Determine the electrical resistance between the

ndash protective earth (PE) and the positive cable of the PV generator and between the ndash protective earth (PE) and the negative cable of the PV generator

In addition ensure that the PV generator has a total insulation resistance of more than 20 MOhm since the inverter will not feed in if the insulation resistance is too low

4 Rectify any faults before connecting the DC generator

7222 Connecting the PV generator

DANGERRisk of fatal injury due to electric shockSevere injury or death will result if the live connections are touched When there is solar radiation DC voltage will be present at the open ends of the DC cables rsaquo Do not touch the exposed ends of the cables rsaquo Avoid short circuits

Installing the device

Operating instructions Powador-gridsave_EN Page 25

Authorised electrician

Connecting the PV generator Use cables with the correct cross-section

1 Remove cable fittings for DC connection2 Remove the outer cladding of the DC cables3 Insert the DC cables through the cable fittings into the connection area4 Strip the insulation from the DC cables5 Remove connection terminals6 Connect the cables in line with the terminal labels (See Figure 13 on page 21)7 Close the connection terminals8 Check that all connected cables are securely fitted9 Tighten the cable fittings10 To meet the requirements of protection rating IP21 close the unused cable fittings with blind caps raquo The PV generator is connected to the inverter

73 Connecting the interfaces

731 Ethernet interface

Pre-assembled Ethernet cables can be connected using the RJ45 socket in the connection space

Connecting the Ethernet cable1 Remove closure cap from RJ45 socket2 Connect the Ethernet cable3 The energy management system can now obtain an IP address by DHCP and is also available via this in the

network

NOTEThe network settings can be amended later in the Settings menu using the EMS

NOTEUse a suitable category 5 network cable The maximum length of a network segment is 100 m Ensure that the cable is correctly assigned The Ethernet connection of the battery system supports auto-sensing You can use both crossed and 11 configured Ethernet connection cables

74 Sealing the connection area

1 Finally check the cabling2 Ensure that all cables are firmly mounted3 Check that the cable fitting is secure and tighten if necessary4 Remove cable offcuts and particles of dirt or dust5 Fit the cover and slide back until it engages into position6 Check that the position is correct7 Screw the fastening screw onto the front of the cover

Installing the device

Page 26 Operating instructions Powador-gridsave_EN

Authorised electrician

75 Starting up

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched Only appropriately qualified and authorised electricians may open install or maintain the battery system rsaquo Keep the front doors and covers closed during operation

NOTEInitial start-up should be carried out using the available public AC grid

76 Standard configuration

Factory settingsCountry configuration Germany

Grid guidelines Low voltage directive

Language German

Time UTC +1 Central European Time

User Standard

Network parameters DHCP (network settings will be obtained automatically from the router)

NOTEPlease state the desired power limitation (60 or 70 of the PV system capacity) when you order For other variations please notify your KACO contact so that the parameters can be set at the factory prior to delivery

Installing the device

Operating instructions Powador-gridsave_EN Page 27

Authorised electrician

761 Step 1 AC home power grid

Check all cables and connections before starting up1 Switch on the AC home power grid using the AC main switch raquo Powador-protect measurement and control unit starts up and monitors the AC grid raquo Two green LEDs indicate that the grid parameters are met raquo After a further 60 seconds (shortly after the backlighting in the Powador-protect goes out) the Powador-pro-

tect will switch on the home grid2 Configure Powador-protect according to the enclosed Powador-protect instructions

(The instructions are also available on the website at wwwkaconewenergyde) raquo The AC power is supplied in the normal way by the public grid

762 Step 2 AC supply from the battery system

Check all cables and connections before starting up1 Remove external isolation means from the device2 Switch on the circuit breaker raquo The LCD touchscreen on the front panel comes on and the energy management system (EMS) starts up

3 Switch on the residual current circuit breaker raquo The battery system starts up

763 Step 3 Switch on the PV system

1 Switch on any optional external PV isolator switches2 Set the internal DC isolator switch to ON raquo The inverter and the battery charging unit battery backup converter (BBC) are connected to the PV system raquo The device monitors the PV voltage for approx 60 seconds then optimisation of internal consumption takes

place

764 Step 4 Switch on batteries

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

765 Step 5 Activate energy management

NOTEKACO new energy cannot provide any support for problems regarding the IT infrastructure (eg router configuration IP address assignment ports etc) as the structure settings and configuration of the network environment can be complex and very different from place to place In the event of any problems please contact an IT service provider

Remote access activated 1 Please call the KACO Hotline to make an appointment for activation of energy management

Configuration and Operation

Page 28 Operating instructions Powador-gridsave_EN

Authorised electrician

8 Configuration and Operation

81 ControlsThe battery system is fitted with a touchscreen which allows it to be controlled very precisely In normal operation the display is switched off Touching the screen activates the display and after a configurable period of time without being touched the dis-play will deactivate If the screen-save function is switched off the touchscreen will be on continuously

NOTEDepending on the tolerances of the measuring elements the measured and displayed values are not always the actual values However the measuring elements ensure maximum solar yield Due to these tolerances the daily yields shown on the touchscreen may deviate from the values on the grid operatorrsquos feed-in meter by up to 15

3

1

45

2

Figure 15 Overview (home screen)

Key

1 Home button 4 Current time

2 System components 5 Menu name

3 More information

811 Information about the system

Open start screen View changesjumps to the home screen

Show component detail Parameters of the selected component

Settings Define settings for the active user

raquo Displays settings

Configuration and Operation

Operating instructions Powador-gridsave_EN Page 29

Controls Left arrow jump back to previous menu item Up and down arrows navigate through the menu or change a value

Left arrow displayed value is reduced by one increment Right arrow displayed value is increased by one increment or change to the submenu

Display fields Grey box Text or figures (not selectable) Blue box Calls up submenu for the display in question

Activate and deactivate Activate function by ticking the box

Table 6 Information about the system

812 System components

PV generator Display of the current generator data

power voltage current temperature in the inverter

Battery Display of the current battery status

power (charging or discharging) voltage current charge status available capacity temperature of battery

Grid Display of the following either fed-in or drawn from the grid

power voltage current for phase L1-L3 total output frequency

Consumer (load) Display of the consumer data

power voltage current for phase L1-L3 total output

Energy flow raquo Displays the current energy flow in the system

Table 7 Information about system components

Configuration and Operation

Page 30 Operating instructions Powador-gridsave_EN

813 Menu structure

Icons used

Display menu Submenu

Option menu

Menu Submenu Display setting

Action in this menumeaning

PV generator Details

Power Displays the current DC-side power

Voltage Displays the current DC-side voltage

Current Displays the current DC-side amperage

Temp inverter

Displays the current temperature in the inverter housing

Battery Details

Power Displays the current AC-side power

Voltage Displays the current AC-side voltage

Current Displays the current AC-side amperage

Charge status Displays the current charge status

Capacity Displays the current battery capacity

Temperature Displays the current measured temperature of the battery

Grid Details

Power Displays the current AC-side power being drawn or fed-in

Voltage Displays the AC-side voltage being applied

Current Displays the current AC-side amperage being drawn or fed-in

Total output Displays the current AC-side total output being drawn or fed-in

Frequency Displays the frequency currently being applied to the grid junction

Consumer (load) Details

Power Displays the current AC-side power being drawn

Voltage Displays the current AC-side voltage being applied

Current Displays the current AC-side amperage being drawn

Total output Displays the current AC-side total output being drawn

Configuration and Operation

Operating instructions Powador-gridsave_EN Page 31

Menu Submenu Display setting

Action in this menumeaning

Settings

Country amp directive display

Display of the country settings voltage directives and grid type

Select menu language

DateTime Specify time zone date format and date and time

Screen Activate screen-save function and set the delay period

Network settings

Display of the network settings Configure network settings Once the DHCP server becomes available the IP

address subnet mask gateway and DNS server are automatically applied and the aforemen-tioned menu items are hidden

Off DHCP deactivated make settings manually

Version Displays the installed software version and built-in HW components (inverter BBC battery)

Vendor The touchscreen shows information about the device vendor

NOTEAs changes to the software are possible after the manual has been printed the illustrations and descriptions of the functions in these operating instructions may deviate from the software Please therefore note the current Application Notes on our website

MaintenanceTroubleshooting

Page 32 Operating instructions Powador-gridsave_EN

9 MaintenanceTroubleshooting

91 Visual inspectionInspect the device and the cables for visible external damage and note the operating status display In case of damage notify your installer Repairs may only be carried out by authorised electricians

NOTEThe battery system should be checked for proper operation by a qualified electrician at regular intervals

92 Cleaning the device

DANGERLethal voltages in the battery systemSerious injuries or death can result if moisture enters the system rsaquo Only use completely dry objects to clean the battery system rsaquo Only clean the outside of the battery system

Cleaning the battery system Do not use compressed air Use a vacuum cleaner or a soft brush to remove dust from the fan cover and from the top of the inverter on a

regular basis Remove dust from the ventilation inlets if necessary

MaintenanceTroubleshooting

Operating instructions Powador-gridsave_EN Page 33

Authorised electrician

93 Maintenance

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched The device is only permitted to be opened or serviced by an authorised electrician rsaquo Observe all safety regulations and the current technical connection specifications from the relevant

power supply company rsaquo Disconnect the AC and DC sides rsaquo Secure the AC and DC sides from being inadvertently switched back on rsaquo Only then should the device be opened rsaquo After shutdown wait at least 30 minutes before working on the device

CAUTIONDestruction of the DC connectionThe connection terminals can be destroyed by arcing if disconnected while still live rsaquo It is absolutely essential that the shutdown sequence be carried out in the correct order (See sec-

tion 111 on page 35)

94 Faults

941 Procedure

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched

When a fault occurs notify an appropriately authorised and qualified electrician or KACO new energy GmbH Service

Service

Page 34 Operating instructions Powador-gridsave_EN

10 ServiceIf 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 efficientlybull Serial nobull SW version of the components (the software version can be found in the Settings menu using the EMS)bull Module type and string circuitbull Date of installation Start-up reportbull Consignment identification Delivery address Contact person (with telephone number)bull Information about the accessibility of the installation site

Any additional costs arising from unfavourable structural or mounting conditions shall be billed to the customer

You can find our warranty conditions on our websitehttpkaco-newenergycomservicewarrantyFrom there you can easily navigate to our international websites by clicking on the appropriate flag

Please use our website to register your unit immediatelyYou can also select the appropriate flag on this page to access the website for your own countryIn this manner you can assist us in providing you with the quickest service possible Note The maximum length of the warranty is based on the currently applicable national warranty conditions

We have prepared a template for complaints This can be found at httpskaco-newenergycomservicecustomer-service

Hotlines

Technical troubleshooting Technical consultation

Inverters and battery systems ()

+49 (0) 71323818-660 +49 (0) 71323818-660

Data logging and accessories +49 (0) 71323818-690 +49 (0) 71323818-690

Construction site emergency () +49 (0) 71323818-630

Customer help desk Monday to Friday from 730 am to 530 pm (CET)

() Also on Saturdays from 800 am to 200 pm (CET)

ShutdownDisassembly

Operating instructions Powador-gridsave_EN Page 35

11 ShutdownDisassembly

111 Switching off the device

DANGERLethal voltages are still present in the terminals and cables even after switching off and discon-nection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched rsaquo Complete de-energisation only occurs if the bulk power supply is switched off upstream of the bat-

tery system

DANGERDestruction of the DC plug connectorDC plug connectors can be destroyed by arcing if disconnected while still live rsaquo It is absolutely essential that the following shutdown sequence is observed

1111 Step 1 Shutting down the PV system

1 Switch off any optional external PV isolator switches2 Set the internal DC isolator switch to OFF raquo The inverter and battery charging unit battery backup converter (BBC) are disconnected

1112 Step 2 Disconnect the batteries

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

1113 Step 3 Disconnect the AC supply

1 Connect external isolation means to the device2 Switch off the circuit breaker 3 Switch off the residual current circuit breaker raquo The battery system is switched off

1114 Step 4 AC home power grid

1 Shutdown the AC home power grid using the AC main switch raquo The battery system can be uninstalled

Disposal

Page 36 Operating instructions Powador-gridsave_EN

112 Uninstalling the device

NOTETo uninstall follow the same sequence as for installation but in reverse order

Switch off the device1 Unlock and open the housing door2 Remove the upper cover3 Release the DC and AC cables from the connection terminals4 Pull out the cables raquo The battery system is uninstalled Continue with the disassembly

113 Disassembling the device

NOTETo disassemble follow the same sequence as for assembly but in reverse order

Switch off the device1 Uninstall the components2 Remove the fastening from the device3 Securely pack up the battery system if it is to be used later

or have the battery system disposed of in accordance with section 12 on page 36

12 DisposalFor the most part both the battery system and the corresponding transport packaging are made from recyclable raw materialsBatteries and components Do not dispose of faulty batteries or the components together with household waste Ensure that the old device and accessories are disposed of in a proper mannerPackaging Ensure that the transport packaging is disposed of properlyBatteriesUsed or faulty batteries must be transported in special packaging If you need such packaging please contact the KACO Hotline

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

Appendix

Operating instructions Powador-gridsave_EN Page 37

13 Appendix

EU Declaration of Conformity

Vendorrsquos name and address

KACO new energy GmbH Carl-Zeiss-Straszlige 1 74172 Neckarsulm Germany

Product description Battery system

Type designation Powador-gridsave 135 kWh 6400 Powador-gridsave 135 kWh 8000

Powador-gridsave 270 kWh 6400 Powador-gridsave 270 kWh 8000

Powador-gridsave 405 kWh 6400 Powador-gridsave 405 kWh 8000

Powador-gridsave 540 kWh 6400 Powador-gridsave 540 kWh 8000

Powador-gridsave 577 kWh 6400 Powador-gridsave 577 kWh 8000

Powador-gridsave 675 kWh 6400 Powador-gridsave 675 kWh 8000

This is to confirm that the units listed above comply with the protection requirements set forth in the Directive of the Council of the European Union of 15th December 2004 on the harmonisation of the laws of the member states relating to Electromagnetic Compatibility (2004108EC) and the Low Voltage Directive (200695EC)The units are compliant with the following standards

200695EC ldquoDirective relating to electrical equipment designed for use within specific voltage limitsrdquo

Safety of the unitIEC 62109-12010IEC 62109-22011

2004108EC ldquoDirective relating to electromagneticcompatibilityrdquo

Interference immunityEN 61000-6-22005 Emitted interferenceEN 61000-6-32007

Secondary effects on the gridEN 61000-3-112000EN 61000-3-122005

The types mentioned above are therefore labelled with the CE markUnauthorised modifications to the supplied units andor any use of the units that is contrary to their intended use render this Declaration of Conformity null and void

Neckarsulm 0711 2013KACO new energy GmbH

pp Volker DietrichEnergy systems engineering management

Disposal

Page 38 Operating instructions Powador-gridsave_EN

Carl-Zeiss-Straszlige 1 middot 74172 Neckarsulm middot Germany middot Phone +49 7132 3818-0 middot Fax +49 7132 3818-703 middot infokaco-newenergyde middot wwwkaco-newenergyde

The

text

and

figu

res

refle

ct th

e cu

rren

t tec

hnic

al s

tate

at t

he ti

me

of p

rintin

g S

ubje

ct to

tech

nica

l cha

nges

Err

ors

and

omis

sion

s ex

cept

ed

3006

856-

01-1

4030

5

  • 1General Information
    • 11About this document
    • 12Name plate
    • 13Additional information
    • 14Intended use
      • 2Safety
        • 21Protection features
          • 3Description
            • 31Mode of Operation
            • 32Summary of the components
              • 4Technical Data
                • 41Electrical data
                • 42Mechanical data
                  • 5Transportation and Delivery
                    • 51Delivery
                    • 52Storage
                    • 53Transportation
                      • 6Assembling the device
                        • 61Installation
                        • 62Installing components
                          • 7Installing the device
                            • 71Opening the connection area
                            • 72Making the electrical connection
                            • 73Connecting the interfaces
                            • 74Sealing the connection area
                            • 75Starting up
                            • 76Standard configuration
                              • 8Configuration and Operation
                                • 81Controls
                                  • 9MaintenanceTroubleshooting
                                    • 91Visual inspection
                                    • 92Cleaning the device
                                    • 93Maintenance
                                    • 94Faults
                                      • 10Service
                                      • 11ShutdownDisassembly
                                        • 111Switching off the device
                                        • 112Uninstalling the device
                                        • 113Disassembling the device
                                          • 12Disposal
                                          • 13Appendix

Description

Page 8 Operating instructions Powador-gridsave_EN

312 Configuration

Powador-protect

CONNECTION BOX

PV INVERTER

BATTERY CONVERTER

PV-Circuit Breaker

ON

OFF

AC-Circuit Breaker

Residual-Current-Circuit Breaker

BATTERY

1

3

4

5

2

Figure 2 Configuration of the battery system

1 Connection box 4 Battery charging unit battery backup converter (BBC) 1

2 Energy management system (EMS) with LCD touchscreen

5 Battery unit with controller

3 Inverter

Description

Operating instructions Powador-gridsave_EN Page 9

32 Summary of the components

321 Connection box

ON

OFF

Powador Protect

off off off

B 32AAC-Circuit Breaker

IN=40AΔI=300mA

RCCB

off

Test

Typ A

CONNECTION BOX

1 2 3 4

Figure 3 Connection box

Key Function

1 DC isolator switch Disconnects the PV generator from the inverter battery unit

2 Measurement and control unit Powador-protect

Three-phase monitoring of the grid switches off the power supply in the event of impermissible voltage or frequency

3 Circuit breaker Disconnects the inverter from the AC grid

4 Residual current circuit breaker

Protects individuals and the installation by isolating the inverter

NOTEThe DC isolator switch circuit breaker and residual current circuit breaker will switch off the battery system Power will then be supplied from the public grid

322 Energy management system

Figure 4 Energy management system (EMS) with LCD touchscreen

NOTEThe energy management system (EMS) displays all relevant parameters in order to ensure optimum operation

Description

Page 10 Operating instructions Powador-gridsave_EN

323 Inverter

PV INVERTER

Figure 5 Inverter

NOTEThe inverter converts the DC voltage from the PV generator and the battery into AC voltage

324 Battery charging unit battery backup converter (BBC)

BATTERY CONVERTER

Figure 6 Battery charging unit battery backup converter (BBC)

NOTEThe battery charging unit battery backup converter (BBC) is the interface to the battery The high voltage from the PV generator is converted into non-hazardous safety extra low voltage (SELV) for the battery The battery charging unit battery backup converter (BBC) can transfer energy both into the battery and out of it

325 Battery management system (BMS)

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

326 Battery

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

Technical Data

Operating instructions Powador-gridsave_EN Page 11

4 Technical Data

41 Electrical data

Connection box

Home power grid

Input voltage 230V 400V 50Hz 60Hz 3-phase (3 N PE)

Grid configuration TN-C TN-S TT

Grid monitoring Powador-protect (as per VDE-AR-N 4105)

Grid isolation Double insulated 3 or 4 pin

Rated operating current [A] 75

Rated switching current AC-1 [A] 100

Rated switching current AC-3 [A] 50 (22 kW at 400 V)

Connection cross-section [mmsup2] max 25

PV input

Input voltage [V] 300 to 800

Input current [A] 30 String

Strings 2

Isolation Yes rotary switch

Inverter type 6400 8000

Input levels

Max recommended PV generator power [W] 7700 9600

Rated power peak power [VA] 6400 7000 8000 9000

DC MPP range from [V] to [V] 360 590

Open circuit voltage [V] 800

Input current [A] 190 240

cos phi 08 inductive hellip 08 capacitive

Polarity safeguard Short-circuit diode

Feed-in phases 1

Capable of stand-alone operation Yes

Efficiency [] 966

Output levels

Output voltage 230V 50Hz 60Hz 1-phase

Rated current [A] 278 35

Connection cross-section [mmsup2] max 6

Monitoring Isolation Circuit breaker residual current circuit breaker (RCD)

Table 1 Electrical data

Technical Data

Page 12 Operating instructions Powador-gridsave_EN

Battery charging unit battery backup converter (BBC)

BBC power [W] 3300

HV voltage [V] 350 to 600

Battery voltage [V] 38 to 58

Efficiency [] 970

Table 1 Electrical data

42 Mechanical data

Battery system

Display 43 LCD touchscreen

Interfaces RS485 Sym-Bus Ethernet USB digital inputsoutputs

Cable insertion Cable fitting 2x M40 2x M32 4x M25 12x M16

Ambient temperature [degC] 0 +40

Humidity [] lt95 (non-condensing)

Cooling Forced cooling temperature-controlled

Noise emission [dB] lt45

Note regarding cooling Do no cover air inletsoutlets keep clear 20 cm to the right and left

Temperature monitoring Individual monitoring of components with shutdown in the event of excess temperature

Maximum installation elevation [m above mean sea level] 2000

Protection class IP21

Housing form 19 sheet-steel control cabinet

H x W x D [mm] 1600 x 620 x 600

Weight [kg] 2435

Inverter

Ambient temperature range [degC] -20 +60

Temperature monitoring Yes

Cooling Active cooling

Connections Quick INOUT plug connector and busbar clips rear side

H x W x D [mm] 22225 x 4826 x 460

Weight [kg] 25

Table 2 Mechanical data

Technical Data

Operating instructions Powador-gridsave_EN Page 13

Battery charging unit battery backup converter (BBC)

Ambient temperature range [degC] -20 +70

Temperature monitoring Yes

Cooling Active cooling

Housing 19 plug-in module aluminium

Connections Quick INOUT plug connector and busbar clips rear side

H x W x D [mm] 13325 x 4826 x 460

Weight [kg] 15

Temperature-dependent impedance matching with shutdown if the temperature is too high

Table 2 Mechanical data

Transportation and Delivery

Page 14 Operating instructions Powador-gridsave_EN

5 Transportation and Delivery

51 DeliveryThe battery system leaves KACO new energy in fully functional electrical and mechanical condition Special packaging ensures that the units are transported safely The shipping company is responsible for any trans-port damage that occurs

511 Scope of delivery

Pallet A B

Figure Figure 7 Scope of delivery pallet A Figure 8 Scope of delivery pallet B

Contents bull Battery system Powador-gridsave (incl connection box battery management system (BMS) industrial PC Plexiglas cover and accessories)

bull Inverter bull Battery charging unit battery backup converter

(BBC)bull Battery system plug-in modules 1-5 ST (scope of

delivery can be found on the delivery document)bull Documentation

Weight (kg) 187 max 155 177 (without with Euro pool pallet)

H x W x D [mm] 1780x800x820 1200x1200x800

Packaging Cardboard box with polystyrene inserts and closures

512 Check the equipment included

bull Battery system and plug-in modules should be inspected thoroughly for transport damagebull Do not install damaged components in the control cabinetbull In the event of damage to the battery plug-in modules contact the KACO new energy Hotline immediately

Transportation and Delivery

Operating instructions Powador-gridsave_EN Page 15

Authorised electrician

DANGERRisk of fatal injury if incompatible components are usedThe battery and power electronics can be damaged if different delivery batches are combined and will carry potentially fatal voltages if connected rsaquo Assemble the system using the components provided by KACO new energy only rsaquo Check the serial numbers on the delivery document against the serial numbers of the individual

units on pallets A and B

52 StorageIncorrect storage can lead to system malfunctions Therefore please observe the following conditionsbull If storing for longer than six months store the device in an interior room in its original packaging bull If the original packaging has been removed store the device in a cool dry interior roombull Storage temperature -20 degC to +70 degCbull Relative humidity 0 to 95 (non-condensing)bull If the device is stored for a relatively long time at high humidity the device must be left for more than one day to

dry out sufficiently before connection to the power grid

53 Transportation

WARNINGImpact hazard risk of breakage to the components in the battery systemThe centre of gravity is located in the upper part of the device rsaquo Transport the device upright together with the pallet rsaquo Do not expose the device or components to any shocks rsaquo After unloading at least two people are required to transport the cabinet

WARNINGDanger due to impact and incorrect storage of the batteriesIn the event of damage batteries can release hazardous electrolyte gases which will cause irreversible burns if they come into contact with the skin rsaquo Transport the batteries in the vendors original packaging only rsaquo Remove the batteries from the original packaging shortly before installation rsaquo Do not store batteries in cars or outdoors rsaquo Check the condition of the battery before use

NOTEThe precise specifications of the UN on the transport of lithium batteries can be found under the designation Model Regulations on the transport of dangerous goods Ref STSGAC101 Recommendations on the transport of dangerous goods Part III sub-section 383 ldquoManual of Tests and Criteriardquo Ref STSGAC1011

Assembling the device

Page 16 Operating instructions Powador-gridsave_EN

Authorised electrician

6 Assembling the device

61 Installation

DANGERRisk of fatal injury from fire or explosionsFire caused by flammable or explosive materials in the vicinity of the battery system can lead to serious injuries rsaquo Do not mount the inverter in potentially explosive atmospheres or in the vicinity of highly flamma-

ble materials

CAUTIONBattery system is very heavy ndash risk of injury rsaquo Be aware of the weight of the battery system during transport rsaquo Select suitable mounting location and mounting base rsaquo Only install the battery system with the help of a second person

CAUTIONEquipment damage caused by aggressive gases in combination with humidityThe housing may be seriously damaged by aggressive gases (ammonia sulphur and other chemi-cals) in combination with ambient humidity caused by weather conditions - Installation in rooms containing aggressive gases is not permitted

NOTEAccess in the event of maintenance or serviceAny additional costs arising from unfavourable structural or mounting conditions in the event of a KACO service call-out shall be billed to the customer

611 Installation location

bull Dry well ventilated the waste heat must be conducted away from the battery systembull Unobstructed air circulationbull Easily accessible from the front top and sides without requiring additional resourcesbull Indoors protected against direct sunlight and direct water contact

612 Foundation

bull With sufficient load-bearing capacitybull Made from heat-resistant material (up to 90 degC)bull Must be flame resistant

NOTEPower reduction due to heat accumulationIf the recommended minimum clearances are not observed the device may go into power regula-tion mode due to insufficient ventilation and the resulting heat build-up rsaquo The construction and installation of the device may be performed only by a qualified electrician in

accordance with the valid standards and regulations rsaquo Maintain minimum clearances rsaquo Ensure sufficient heat dissipation

Assembling the device

Operating instructions Powador-gridsave_EN Page 17

Authorised electrician

0deg

1000 mm

200 mm 200 mm

500 mm

min carrying capacity 300 kgmsup2

200 mm200 mm

50 mm

Figure 9 Minimum clearances at the installation and assembly location

CAUTIONRisk of injury if the battery system tips overRisk of tipping due to high centre of gravity particularly with the door open rsaquo Anchor the device securely to the floor immediately after installation rsaquo Open the housing door using the enclosed cabinet key only once the device has been securely

anchored

510 mm200 mm

200 mm

400

mm

12 mmmin 110 mm

DesignationHex head wood screw 8x80 DIN571-vz Fischer dowel S12 Flat washer M8 galvanised DIN9021-vz

Units444

Figure 10 Dimensions for anchoring to the floor Table 3 Mounting parts

62 Installing components

CAUTIONAvoid improper handlingImproper handling can cause damage to components rsaquo Damaged components must not be installed rsaquo Always put the plug-in modules down horizontally to avoid damage to the components

Assembling the device

Page 18 Operating instructions Powador-gridsave_EN

Authorised electrician

WARNINGDanger caused by short circuit or sparkingSerious injury from touching or connecting live components rsaquo Damaged components must not be installed

Preparation1 Check the conditions for the installation location2 Open the housing doors using the enclosed cabinet key3 The cables should be professionally laid and prepared for connection4 Follow the installation sequence (1-4 step(s))

621 Step 1 Fit the battery (batteries)

NOTEPlease read the notes on installation and connection in the enclosed manual Features for the battery unit

622 Step 2 Connect battery (batteries) to the battery management system (BMS)

NOTEPlease read the notes on installation and connection in the enclosed manual Features for the battery unit

623 Step 3 Fit the battery charging unit battery backup converter (BBC)

Battery (batteries) connected to the battery management system (BMS)1 Carefully insert battery charging unit battery backup converter (BBC) into the compartment provided for it 2 Push in completely to establish direct contact with the rear busbars3 Secure battery charging unit battery backup converter (BBC) using the screws supplied

624 Step 4 Fit the inverter

Battery charging unit battery backup converter (BBC) is fitted1 Carefully insert inverter into the compartment provided for it 2 Push in completely to establish direct contact with the rear busbars 3 Secure inverter using the screws supplied

CAUTIONDamage to the control unit from introducing foreign objectsForeign objects can impair the function of the control unit and cause damage rsaquo Do not remove the front panel rsaquo Foreign objects should be removed immediately

Installing the device

Operating instructions Powador-gridsave_EN Page 19

Authorised electrician

7 Installing the device

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched The device may only be opened or serviced by an authorised electricianThe device must be completely assembled before being connected electrically rsaquo Observe all safety regulations and current technical connection specifications of the responsible

power supply company rsaquo De-energise the device using the DC isolator switch circuit breaker and residual current circuit

breaker rsaquo Secure both sides against being inadvertently switched back on rsaquo Ensure that the AC and DC sides are completely isolated and voltage free rsaquo Never open the plug-in modules rsaquo Hazardous voltages are present at the busbars rsaquo Disconnect from the grid and plant supply rsaquo First connect the battery system in the connection area

71 Opening the connection area

3

1

2

Figure 11 Open cover plateKey

1 Cover plate 3 Fastening screw

2 Lock

Opening the connection area You have completed assembly

1 Remove the fastening screw for the upper cover plate2 Slide the cover plate forwards out of the lock3 Lift the cover plate upward to remove raquo Make the electrical connection

Installing the device

Page 20 Operating instructions Powador-gridsave_EN

Authorised electrician

72 Making the electrical connectionMake the connection to the PV generator as well as the grid connection using the connection terminals Note the following cable cross-sections

Connection Possible cable cross-section Length of insulation to be stripped offAC home power grid 05 - 16 mmsup2 with end sleeve

05 - 25 mmsup2 without end sleeve18 mm sleeve18-20 mm

PV connection 05 - 16 mmsup2 with end sleeve05 - 25 mmsup2 without end sleeve

18 mm sleeve17-19 mm

Inverter output 05 - 4 mmsup2 with end sleeve05 - 6 mmsup2 without end sleeve

12 mm sleeve11-13 mm

Potential-free contacts 034 - 15 mmsup2 with end sleeve034 - 25 mmsup2 without end sleeve

12 mm sleeve 9-10 mm

Table 4 Cable cross-sections for connection terminals

NOTEThe threaded connections should be matched to the cable cross-section

NOTEOnly conductors and no insulation should be inserted into the connection terminals Individual wires or cables with end sleeves with the appropriate cross-section can be inserted directly into the connection terminal without a toolFine-strand cables without end sleeve or thin conductors will need a screwdriver (plain slot 35 mm) for connection To do this insert the blade of the screwdriver into the recess provided The cable can be inserted into the spring terminal by pressing downwards The spring terminal closes on removal of the screw-driver

Installing the device

Operating instructions Powador-gridsave_EN Page 21

Authorised electrician

X2X1F1 F2 X7 X4 St1

St2

St3

2 3 541 6

Figure 12 View from above of the connection area

Key

1 AC grid input (M40 cable fitting) 4 Network interface (M32 cable fitting)

2 AC grid output (M40 cable fitting) 5 Inverter input (M16 cable fitting)

3 Inverter output (M32 cable fitting) 6 Other connections (M16 cable fitting)

F1 F2 X7 X4 St1

St2

St3

L1 L2 L3 N PE L1 L2 L3 N N PE PE

X1 X2

PV+

PV-

L1 L2 L3 N PE32A 32A PEN

Cust

omer

co

nnec

tion

Figure 13 View from above of the connection area

Key

X1 AC grid input (main junction box meter) X7 PV generator input

X2 AC grid output (building electrical system) F1 F2 Phase bridging fuse

X4 Inverter output St 1-3 Potential-free contacts control outputs

Installing the device

Page 22 Operating instructions Powador-gridsave_EN

Authorised electrician

721 Connecting to the power grid

Because the device is installed between the main junction boxmeter and the buildings electrical system the maxi-mum grid current to the service line must not exceed the rated operating current of the battery system The cable cross-section must be selected in accordance with applicable standards to suit the connected load instal-lation type etc Moreover the terminal area and size of the cable fitting must be noted

NOTEThe fuse rating for the cable should be max 63A (automatic circuit breaker or safety fuse) even if the cross-section of the installed cable would permit a higher fuse rating Always follow the applicable regulations regarding the cable cross-section and installation typeThe device supports standard grid configurations such as TN-C TN-S and TT TN-SIf a TN-S grid is present directly at the power input and output of the device L1-L3 N and PE must each be connected The home power grid should have 4-pin isolationTN-C4-pin grid isolation is factory preset and disconnects L1 L2 L3 and N In a TN-C grid the N conduc-tor must not be disconnected If a TN-S grid is present directly at the power input and output of the device a cable bridge (included in delivery) must be installed between the N terminal on X1 and the N terminal on X2 N and PE must additionally be connected together To do this simply insert the enclosed terminal link into the N and PE terminals TTIn the case of a TT grid L1-L3 N and PE must each be connected The home power grid should have 4-pin isolation

NOTEPlease check with the operator of the mains grid whether there are special regulations for grid connection Grid isolation is factory preset to 4-pin is fail-safe and provided with grid and system protection as per VDE-AR-N 4105

Making the grid connection Use cables with 5 wires (L1 brown L2 black L3 grey N blue PE greenyellow) and the correct

cross-section1 Loosen cable fitting for AC connection2 Remove the outer cladding of the AC cables3 Insert the AC cables through the cable fitting into the connection area4 Strip the insulation from the AC cables5 Remove connection terminals6 Connect the cables in line with the terminal labels (Figure 13 on page 21)7 Close the connection terminals8 Check that all connected cables are securely fitted9 Tighten the cable fitting10 To meet the requirements of protection rating IP21 close the unused cable fittings with blind caps raquo The battery system is connected to the power grid

NOTEAn AC-side disconnection unit must be provided during the final installation stage This disconnec-tion unit must be installed so that it can be accessed at any time without obstruction If a residual current circuit breaker is necessary due to the installation specification a type A residual current circuit breaker must be used

Installing the device

Operating instructions Powador-gridsave_EN Page 23

Authorised electrician

7211 Output from the inverterRecommended cable cross-sections for the inverter output and fuse rating of cables for fixed wiring accord-ing to VDE 0100 part 430The fuse rating for the cable is dependent on the cable cross-section max 40A automatic circuit breaker

NOTEWhen the line resistance is high (ie long grid-side cables) the voltage at the grid terminals of the inverter will increase during feed-in to the grid The inverter monitors this voltage If the voltage exceeds the country-specific grid overvoltage limit value the inverter switches off rsaquo Ensure that the conductor cross-sections are sufficiently large or that the cable lengths are suffi-

ciently short

NOTEIn order to avoid asymmetries in the grid systems with multiple battery systems should be designed so that the inverters in the devices feed into the grid in differing phases rsaquo Follow the connection conditions for the particular type of grid and the schematic illustration

below

Country and grid-type

Grid monitoring Required monitoring

max asymmetry between phases L1L2L3

DE-NSP Three-phase or single phase phase unbalanced load 46 kVA

Table 5 Grid-type-specific connection conditions

L1

L2

L3

N

Connection X1 Connection X1 Connection X1 Connection X1

L1 L2 L3 N PE L1 L2 L3 N PE L1 L2 L3 N PE L1 L2 L3 N PE

Powador-gridsave inverter1 L1 - L1 L2 - L2 L3 - L32 L1 - L2 L2 - L3 L3 - L1 3 L1 - L3 L2 - L1 L3 - L2 4 L1 - L1 L2 - L2 L3 - L3

Figure 14 Grid-side connection for systems with multiple battery systems with three-phase grid monitoring

Installing the device

Page 24 Operating instructions Powador-gridsave_EN

Authorised electrician

722 Connecting the PV generator

Connect the PV generator on the left in the connection area (Figure 13 on page 21) Use the provided M16 cable fittings A maximum of two strings can be connected For this reason a DC string fuse can be dispensed with

DANGERRisk of fatal injury due to contact voltagesRemoving the cables from the terminals without first disconnecting the PV generator from the device can cause serious damage to health or damage to the system rsaquo During installation Electrically disconnect the DC positive and DC negative from the protective

earth (PE) rsaquo Completely de-energise the system (AC home power grid AC circuit breaker residual current circuit

breaker DC isolator switch) rsaquo Disconnect the battery system from the PV generator using the integrated DC isolator switch rsaquo Remove DC plug connectors

NOTEIn accordance with IEC 61730 Class A connected PV modules must be dimensioned for the DC system voltage provided and at least for the value of the AC grid voltage

7221 Before connecting

Ensure that there is no ground fault1 Determine the DC voltage between the

ndash protective earth (PE) and the positive cable of the PV generator and between the ndash protective earth (PE) and the negative cable of the PV generator

If stable voltages can be measured there is a ground fault in the DC generator or its wiring The ratio between the measured voltages gives an indication as to the location of this fault

2 Rectify any faults before taking further measurements3 Determine the electrical resistance between the

ndash protective earth (PE) and the positive cable of the PV generator and between the ndash protective earth (PE) and the negative cable of the PV generator

In addition ensure that the PV generator has a total insulation resistance of more than 20 MOhm since the inverter will not feed in if the insulation resistance is too low

4 Rectify any faults before connecting the DC generator

7222 Connecting the PV generator

DANGERRisk of fatal injury due to electric shockSevere injury or death will result if the live connections are touched When there is solar radiation DC voltage will be present at the open ends of the DC cables rsaquo Do not touch the exposed ends of the cables rsaquo Avoid short circuits

Installing the device

Operating instructions Powador-gridsave_EN Page 25

Authorised electrician

Connecting the PV generator Use cables with the correct cross-section

1 Remove cable fittings for DC connection2 Remove the outer cladding of the DC cables3 Insert the DC cables through the cable fittings into the connection area4 Strip the insulation from the DC cables5 Remove connection terminals6 Connect the cables in line with the terminal labels (See Figure 13 on page 21)7 Close the connection terminals8 Check that all connected cables are securely fitted9 Tighten the cable fittings10 To meet the requirements of protection rating IP21 close the unused cable fittings with blind caps raquo The PV generator is connected to the inverter

73 Connecting the interfaces

731 Ethernet interface

Pre-assembled Ethernet cables can be connected using the RJ45 socket in the connection space

Connecting the Ethernet cable1 Remove closure cap from RJ45 socket2 Connect the Ethernet cable3 The energy management system can now obtain an IP address by DHCP and is also available via this in the

network

NOTEThe network settings can be amended later in the Settings menu using the EMS

NOTEUse a suitable category 5 network cable The maximum length of a network segment is 100 m Ensure that the cable is correctly assigned The Ethernet connection of the battery system supports auto-sensing You can use both crossed and 11 configured Ethernet connection cables

74 Sealing the connection area

1 Finally check the cabling2 Ensure that all cables are firmly mounted3 Check that the cable fitting is secure and tighten if necessary4 Remove cable offcuts and particles of dirt or dust5 Fit the cover and slide back until it engages into position6 Check that the position is correct7 Screw the fastening screw onto the front of the cover

Installing the device

Page 26 Operating instructions Powador-gridsave_EN

Authorised electrician

75 Starting up

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched Only appropriately qualified and authorised electricians may open install or maintain the battery system rsaquo Keep the front doors and covers closed during operation

NOTEInitial start-up should be carried out using the available public AC grid

76 Standard configuration

Factory settingsCountry configuration Germany

Grid guidelines Low voltage directive

Language German

Time UTC +1 Central European Time

User Standard

Network parameters DHCP (network settings will be obtained automatically from the router)

NOTEPlease state the desired power limitation (60 or 70 of the PV system capacity) when you order For other variations please notify your KACO contact so that the parameters can be set at the factory prior to delivery

Installing the device

Operating instructions Powador-gridsave_EN Page 27

Authorised electrician

761 Step 1 AC home power grid

Check all cables and connections before starting up1 Switch on the AC home power grid using the AC main switch raquo Powador-protect measurement and control unit starts up and monitors the AC grid raquo Two green LEDs indicate that the grid parameters are met raquo After a further 60 seconds (shortly after the backlighting in the Powador-protect goes out) the Powador-pro-

tect will switch on the home grid2 Configure Powador-protect according to the enclosed Powador-protect instructions

(The instructions are also available on the website at wwwkaconewenergyde) raquo The AC power is supplied in the normal way by the public grid

762 Step 2 AC supply from the battery system

Check all cables and connections before starting up1 Remove external isolation means from the device2 Switch on the circuit breaker raquo The LCD touchscreen on the front panel comes on and the energy management system (EMS) starts up

3 Switch on the residual current circuit breaker raquo The battery system starts up

763 Step 3 Switch on the PV system

1 Switch on any optional external PV isolator switches2 Set the internal DC isolator switch to ON raquo The inverter and the battery charging unit battery backup converter (BBC) are connected to the PV system raquo The device monitors the PV voltage for approx 60 seconds then optimisation of internal consumption takes

place

764 Step 4 Switch on batteries

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

765 Step 5 Activate energy management

NOTEKACO new energy cannot provide any support for problems regarding the IT infrastructure (eg router configuration IP address assignment ports etc) as the structure settings and configuration of the network environment can be complex and very different from place to place In the event of any problems please contact an IT service provider

Remote access activated 1 Please call the KACO Hotline to make an appointment for activation of energy management

Configuration and Operation

Page 28 Operating instructions Powador-gridsave_EN

Authorised electrician

8 Configuration and Operation

81 ControlsThe battery system is fitted with a touchscreen which allows it to be controlled very precisely In normal operation the display is switched off Touching the screen activates the display and after a configurable period of time without being touched the dis-play will deactivate If the screen-save function is switched off the touchscreen will be on continuously

NOTEDepending on the tolerances of the measuring elements the measured and displayed values are not always the actual values However the measuring elements ensure maximum solar yield Due to these tolerances the daily yields shown on the touchscreen may deviate from the values on the grid operatorrsquos feed-in meter by up to 15

3

1

45

2

Figure 15 Overview (home screen)

Key

1 Home button 4 Current time

2 System components 5 Menu name

3 More information

811 Information about the system

Open start screen View changesjumps to the home screen

Show component detail Parameters of the selected component

Settings Define settings for the active user

raquo Displays settings

Configuration and Operation

Operating instructions Powador-gridsave_EN Page 29

Controls Left arrow jump back to previous menu item Up and down arrows navigate through the menu or change a value

Left arrow displayed value is reduced by one increment Right arrow displayed value is increased by one increment or change to the submenu

Display fields Grey box Text or figures (not selectable) Blue box Calls up submenu for the display in question

Activate and deactivate Activate function by ticking the box

Table 6 Information about the system

812 System components

PV generator Display of the current generator data

power voltage current temperature in the inverter

Battery Display of the current battery status

power (charging or discharging) voltage current charge status available capacity temperature of battery

Grid Display of the following either fed-in or drawn from the grid

power voltage current for phase L1-L3 total output frequency

Consumer (load) Display of the consumer data

power voltage current for phase L1-L3 total output

Energy flow raquo Displays the current energy flow in the system

Table 7 Information about system components

Configuration and Operation

Page 30 Operating instructions Powador-gridsave_EN

813 Menu structure

Icons used

Display menu Submenu

Option menu

Menu Submenu Display setting

Action in this menumeaning

PV generator Details

Power Displays the current DC-side power

Voltage Displays the current DC-side voltage

Current Displays the current DC-side amperage

Temp inverter

Displays the current temperature in the inverter housing

Battery Details

Power Displays the current AC-side power

Voltage Displays the current AC-side voltage

Current Displays the current AC-side amperage

Charge status Displays the current charge status

Capacity Displays the current battery capacity

Temperature Displays the current measured temperature of the battery

Grid Details

Power Displays the current AC-side power being drawn or fed-in

Voltage Displays the AC-side voltage being applied

Current Displays the current AC-side amperage being drawn or fed-in

Total output Displays the current AC-side total output being drawn or fed-in

Frequency Displays the frequency currently being applied to the grid junction

Consumer (load) Details

Power Displays the current AC-side power being drawn

Voltage Displays the current AC-side voltage being applied

Current Displays the current AC-side amperage being drawn

Total output Displays the current AC-side total output being drawn

Configuration and Operation

Operating instructions Powador-gridsave_EN Page 31

Menu Submenu Display setting

Action in this menumeaning

Settings

Country amp directive display

Display of the country settings voltage directives and grid type

Select menu language

DateTime Specify time zone date format and date and time

Screen Activate screen-save function and set the delay period

Network settings

Display of the network settings Configure network settings Once the DHCP server becomes available the IP

address subnet mask gateway and DNS server are automatically applied and the aforemen-tioned menu items are hidden

Off DHCP deactivated make settings manually

Version Displays the installed software version and built-in HW components (inverter BBC battery)

Vendor The touchscreen shows information about the device vendor

NOTEAs changes to the software are possible after the manual has been printed the illustrations and descriptions of the functions in these operating instructions may deviate from the software Please therefore note the current Application Notes on our website

MaintenanceTroubleshooting

Page 32 Operating instructions Powador-gridsave_EN

9 MaintenanceTroubleshooting

91 Visual inspectionInspect the device and the cables for visible external damage and note the operating status display In case of damage notify your installer Repairs may only be carried out by authorised electricians

NOTEThe battery system should be checked for proper operation by a qualified electrician at regular intervals

92 Cleaning the device

DANGERLethal voltages in the battery systemSerious injuries or death can result if moisture enters the system rsaquo Only use completely dry objects to clean the battery system rsaquo Only clean the outside of the battery system

Cleaning the battery system Do not use compressed air Use a vacuum cleaner or a soft brush to remove dust from the fan cover and from the top of the inverter on a

regular basis Remove dust from the ventilation inlets if necessary

MaintenanceTroubleshooting

Operating instructions Powador-gridsave_EN Page 33

Authorised electrician

93 Maintenance

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched The device is only permitted to be opened or serviced by an authorised electrician rsaquo Observe all safety regulations and the current technical connection specifications from the relevant

power supply company rsaquo Disconnect the AC and DC sides rsaquo Secure the AC and DC sides from being inadvertently switched back on rsaquo Only then should the device be opened rsaquo After shutdown wait at least 30 minutes before working on the device

CAUTIONDestruction of the DC connectionThe connection terminals can be destroyed by arcing if disconnected while still live rsaquo It is absolutely essential that the shutdown sequence be carried out in the correct order (See sec-

tion 111 on page 35)

94 Faults

941 Procedure

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched

When a fault occurs notify an appropriately authorised and qualified electrician or KACO new energy GmbH Service

Service

Page 34 Operating instructions Powador-gridsave_EN

10 ServiceIf 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 efficientlybull Serial nobull SW version of the components (the software version can be found in the Settings menu using the EMS)bull Module type and string circuitbull Date of installation Start-up reportbull Consignment identification Delivery address Contact person (with telephone number)bull Information about the accessibility of the installation site

Any additional costs arising from unfavourable structural or mounting conditions shall be billed to the customer

You can find our warranty conditions on our websitehttpkaco-newenergycomservicewarrantyFrom there you can easily navigate to our international websites by clicking on the appropriate flag

Please use our website to register your unit immediatelyYou can also select the appropriate flag on this page to access the website for your own countryIn this manner you can assist us in providing you with the quickest service possible Note The maximum length of the warranty is based on the currently applicable national warranty conditions

We have prepared a template for complaints This can be found at httpskaco-newenergycomservicecustomer-service

Hotlines

Technical troubleshooting Technical consultation

Inverters and battery systems ()

+49 (0) 71323818-660 +49 (0) 71323818-660

Data logging and accessories +49 (0) 71323818-690 +49 (0) 71323818-690

Construction site emergency () +49 (0) 71323818-630

Customer help desk Monday to Friday from 730 am to 530 pm (CET)

() Also on Saturdays from 800 am to 200 pm (CET)

ShutdownDisassembly

Operating instructions Powador-gridsave_EN Page 35

11 ShutdownDisassembly

111 Switching off the device

DANGERLethal voltages are still present in the terminals and cables even after switching off and discon-nection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched rsaquo Complete de-energisation only occurs if the bulk power supply is switched off upstream of the bat-

tery system

DANGERDestruction of the DC plug connectorDC plug connectors can be destroyed by arcing if disconnected while still live rsaquo It is absolutely essential that the following shutdown sequence is observed

1111 Step 1 Shutting down the PV system

1 Switch off any optional external PV isolator switches2 Set the internal DC isolator switch to OFF raquo The inverter and battery charging unit battery backup converter (BBC) are disconnected

1112 Step 2 Disconnect the batteries

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

1113 Step 3 Disconnect the AC supply

1 Connect external isolation means to the device2 Switch off the circuit breaker 3 Switch off the residual current circuit breaker raquo The battery system is switched off

1114 Step 4 AC home power grid

1 Shutdown the AC home power grid using the AC main switch raquo The battery system can be uninstalled

Disposal

Page 36 Operating instructions Powador-gridsave_EN

112 Uninstalling the device

NOTETo uninstall follow the same sequence as for installation but in reverse order

Switch off the device1 Unlock and open the housing door2 Remove the upper cover3 Release the DC and AC cables from the connection terminals4 Pull out the cables raquo The battery system is uninstalled Continue with the disassembly

113 Disassembling the device

NOTETo disassemble follow the same sequence as for assembly but in reverse order

Switch off the device1 Uninstall the components2 Remove the fastening from the device3 Securely pack up the battery system if it is to be used later

or have the battery system disposed of in accordance with section 12 on page 36

12 DisposalFor the most part both the battery system and the corresponding transport packaging are made from recyclable raw materialsBatteries and components Do not dispose of faulty batteries or the components together with household waste Ensure that the old device and accessories are disposed of in a proper mannerPackaging Ensure that the transport packaging is disposed of properlyBatteriesUsed or faulty batteries must be transported in special packaging If you need such packaging please contact the KACO Hotline

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

Appendix

Operating instructions Powador-gridsave_EN Page 37

13 Appendix

EU Declaration of Conformity

Vendorrsquos name and address

KACO new energy GmbH Carl-Zeiss-Straszlige 1 74172 Neckarsulm Germany

Product description Battery system

Type designation Powador-gridsave 135 kWh 6400 Powador-gridsave 135 kWh 8000

Powador-gridsave 270 kWh 6400 Powador-gridsave 270 kWh 8000

Powador-gridsave 405 kWh 6400 Powador-gridsave 405 kWh 8000

Powador-gridsave 540 kWh 6400 Powador-gridsave 540 kWh 8000

Powador-gridsave 577 kWh 6400 Powador-gridsave 577 kWh 8000

Powador-gridsave 675 kWh 6400 Powador-gridsave 675 kWh 8000

This is to confirm that the units listed above comply with the protection requirements set forth in the Directive of the Council of the European Union of 15th December 2004 on the harmonisation of the laws of the member states relating to Electromagnetic Compatibility (2004108EC) and the Low Voltage Directive (200695EC)The units are compliant with the following standards

200695EC ldquoDirective relating to electrical equipment designed for use within specific voltage limitsrdquo

Safety of the unitIEC 62109-12010IEC 62109-22011

2004108EC ldquoDirective relating to electromagneticcompatibilityrdquo

Interference immunityEN 61000-6-22005 Emitted interferenceEN 61000-6-32007

Secondary effects on the gridEN 61000-3-112000EN 61000-3-122005

The types mentioned above are therefore labelled with the CE markUnauthorised modifications to the supplied units andor any use of the units that is contrary to their intended use render this Declaration of Conformity null and void

Neckarsulm 0711 2013KACO new energy GmbH

pp Volker DietrichEnergy systems engineering management

Disposal

Page 38 Operating instructions Powador-gridsave_EN

Carl-Zeiss-Straszlige 1 middot 74172 Neckarsulm middot Germany middot Phone +49 7132 3818-0 middot Fax +49 7132 3818-703 middot infokaco-newenergyde middot wwwkaco-newenergyde

The

text

and

figu

res

refle

ct th

e cu

rren

t tec

hnic

al s

tate

at t

he ti

me

of p

rintin

g S

ubje

ct to

tech

nica

l cha

nges

Err

ors

and

omis

sion

s ex

cept

ed

3006

856-

01-1

4030

5

  • 1General Information
    • 11About this document
    • 12Name plate
    • 13Additional information
    • 14Intended use
      • 2Safety
        • 21Protection features
          • 3Description
            • 31Mode of Operation
            • 32Summary of the components
              • 4Technical Data
                • 41Electrical data
                • 42Mechanical data
                  • 5Transportation and Delivery
                    • 51Delivery
                    • 52Storage
                    • 53Transportation
                      • 6Assembling the device
                        • 61Installation
                        • 62Installing components
                          • 7Installing the device
                            • 71Opening the connection area
                            • 72Making the electrical connection
                            • 73Connecting the interfaces
                            • 74Sealing the connection area
                            • 75Starting up
                            • 76Standard configuration
                              • 8Configuration and Operation
                                • 81Controls
                                  • 9MaintenanceTroubleshooting
                                    • 91Visual inspection
                                    • 92Cleaning the device
                                    • 93Maintenance
                                    • 94Faults
                                      • 10Service
                                      • 11ShutdownDisassembly
                                        • 111Switching off the device
                                        • 112Uninstalling the device
                                        • 113Disassembling the device
                                          • 12Disposal
                                          • 13Appendix

Description

Operating instructions Powador-gridsave_EN Page 9

32 Summary of the components

321 Connection box

ON

OFF

Powador Protect

off off off

B 32AAC-Circuit Breaker

IN=40AΔI=300mA

RCCB

off

Test

Typ A

CONNECTION BOX

1 2 3 4

Figure 3 Connection box

Key Function

1 DC isolator switch Disconnects the PV generator from the inverter battery unit

2 Measurement and control unit Powador-protect

Three-phase monitoring of the grid switches off the power supply in the event of impermissible voltage or frequency

3 Circuit breaker Disconnects the inverter from the AC grid

4 Residual current circuit breaker

Protects individuals and the installation by isolating the inverter

NOTEThe DC isolator switch circuit breaker and residual current circuit breaker will switch off the battery system Power will then be supplied from the public grid

322 Energy management system

Figure 4 Energy management system (EMS) with LCD touchscreen

NOTEThe energy management system (EMS) displays all relevant parameters in order to ensure optimum operation

Description

Page 10 Operating instructions Powador-gridsave_EN

323 Inverter

PV INVERTER

Figure 5 Inverter

NOTEThe inverter converts the DC voltage from the PV generator and the battery into AC voltage

324 Battery charging unit battery backup converter (BBC)

BATTERY CONVERTER

Figure 6 Battery charging unit battery backup converter (BBC)

NOTEThe battery charging unit battery backup converter (BBC) is the interface to the battery The high voltage from the PV generator is converted into non-hazardous safety extra low voltage (SELV) for the battery The battery charging unit battery backup converter (BBC) can transfer energy both into the battery and out of it

325 Battery management system (BMS)

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

326 Battery

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

Technical Data

Operating instructions Powador-gridsave_EN Page 11

4 Technical Data

41 Electrical data

Connection box

Home power grid

Input voltage 230V 400V 50Hz 60Hz 3-phase (3 N PE)

Grid configuration TN-C TN-S TT

Grid monitoring Powador-protect (as per VDE-AR-N 4105)

Grid isolation Double insulated 3 or 4 pin

Rated operating current [A] 75

Rated switching current AC-1 [A] 100

Rated switching current AC-3 [A] 50 (22 kW at 400 V)

Connection cross-section [mmsup2] max 25

PV input

Input voltage [V] 300 to 800

Input current [A] 30 String

Strings 2

Isolation Yes rotary switch

Inverter type 6400 8000

Input levels

Max recommended PV generator power [W] 7700 9600

Rated power peak power [VA] 6400 7000 8000 9000

DC MPP range from [V] to [V] 360 590

Open circuit voltage [V] 800

Input current [A] 190 240

cos phi 08 inductive hellip 08 capacitive

Polarity safeguard Short-circuit diode

Feed-in phases 1

Capable of stand-alone operation Yes

Efficiency [] 966

Output levels

Output voltage 230V 50Hz 60Hz 1-phase

Rated current [A] 278 35

Connection cross-section [mmsup2] max 6

Monitoring Isolation Circuit breaker residual current circuit breaker (RCD)

Table 1 Electrical data

Technical Data

Page 12 Operating instructions Powador-gridsave_EN

Battery charging unit battery backup converter (BBC)

BBC power [W] 3300

HV voltage [V] 350 to 600

Battery voltage [V] 38 to 58

Efficiency [] 970

Table 1 Electrical data

42 Mechanical data

Battery system

Display 43 LCD touchscreen

Interfaces RS485 Sym-Bus Ethernet USB digital inputsoutputs

Cable insertion Cable fitting 2x M40 2x M32 4x M25 12x M16

Ambient temperature [degC] 0 +40

Humidity [] lt95 (non-condensing)

Cooling Forced cooling temperature-controlled

Noise emission [dB] lt45

Note regarding cooling Do no cover air inletsoutlets keep clear 20 cm to the right and left

Temperature monitoring Individual monitoring of components with shutdown in the event of excess temperature

Maximum installation elevation [m above mean sea level] 2000

Protection class IP21

Housing form 19 sheet-steel control cabinet

H x W x D [mm] 1600 x 620 x 600

Weight [kg] 2435

Inverter

Ambient temperature range [degC] -20 +60

Temperature monitoring Yes

Cooling Active cooling

Connections Quick INOUT plug connector and busbar clips rear side

H x W x D [mm] 22225 x 4826 x 460

Weight [kg] 25

Table 2 Mechanical data

Technical Data

Operating instructions Powador-gridsave_EN Page 13

Battery charging unit battery backup converter (BBC)

Ambient temperature range [degC] -20 +70

Temperature monitoring Yes

Cooling Active cooling

Housing 19 plug-in module aluminium

Connections Quick INOUT plug connector and busbar clips rear side

H x W x D [mm] 13325 x 4826 x 460

Weight [kg] 15

Temperature-dependent impedance matching with shutdown if the temperature is too high

Table 2 Mechanical data

Transportation and Delivery

Page 14 Operating instructions Powador-gridsave_EN

5 Transportation and Delivery

51 DeliveryThe battery system leaves KACO new energy in fully functional electrical and mechanical condition Special packaging ensures that the units are transported safely The shipping company is responsible for any trans-port damage that occurs

511 Scope of delivery

Pallet A B

Figure Figure 7 Scope of delivery pallet A Figure 8 Scope of delivery pallet B

Contents bull Battery system Powador-gridsave (incl connection box battery management system (BMS) industrial PC Plexiglas cover and accessories)

bull Inverter bull Battery charging unit battery backup converter

(BBC)bull Battery system plug-in modules 1-5 ST (scope of

delivery can be found on the delivery document)bull Documentation

Weight (kg) 187 max 155 177 (without with Euro pool pallet)

H x W x D [mm] 1780x800x820 1200x1200x800

Packaging Cardboard box with polystyrene inserts and closures

512 Check the equipment included

bull Battery system and plug-in modules should be inspected thoroughly for transport damagebull Do not install damaged components in the control cabinetbull In the event of damage to the battery plug-in modules contact the KACO new energy Hotline immediately

Transportation and Delivery

Operating instructions Powador-gridsave_EN Page 15

Authorised electrician

DANGERRisk of fatal injury if incompatible components are usedThe battery and power electronics can be damaged if different delivery batches are combined and will carry potentially fatal voltages if connected rsaquo Assemble the system using the components provided by KACO new energy only rsaquo Check the serial numbers on the delivery document against the serial numbers of the individual

units on pallets A and B

52 StorageIncorrect storage can lead to system malfunctions Therefore please observe the following conditionsbull If storing for longer than six months store the device in an interior room in its original packaging bull If the original packaging has been removed store the device in a cool dry interior roombull Storage temperature -20 degC to +70 degCbull Relative humidity 0 to 95 (non-condensing)bull If the device is stored for a relatively long time at high humidity the device must be left for more than one day to

dry out sufficiently before connection to the power grid

53 Transportation

WARNINGImpact hazard risk of breakage to the components in the battery systemThe centre of gravity is located in the upper part of the device rsaquo Transport the device upright together with the pallet rsaquo Do not expose the device or components to any shocks rsaquo After unloading at least two people are required to transport the cabinet

WARNINGDanger due to impact and incorrect storage of the batteriesIn the event of damage batteries can release hazardous electrolyte gases which will cause irreversible burns if they come into contact with the skin rsaquo Transport the batteries in the vendors original packaging only rsaquo Remove the batteries from the original packaging shortly before installation rsaquo Do not store batteries in cars or outdoors rsaquo Check the condition of the battery before use

NOTEThe precise specifications of the UN on the transport of lithium batteries can be found under the designation Model Regulations on the transport of dangerous goods Ref STSGAC101 Recommendations on the transport of dangerous goods Part III sub-section 383 ldquoManual of Tests and Criteriardquo Ref STSGAC1011

Assembling the device

Page 16 Operating instructions Powador-gridsave_EN

Authorised electrician

6 Assembling the device

61 Installation

DANGERRisk of fatal injury from fire or explosionsFire caused by flammable or explosive materials in the vicinity of the battery system can lead to serious injuries rsaquo Do not mount the inverter in potentially explosive atmospheres or in the vicinity of highly flamma-

ble materials

CAUTIONBattery system is very heavy ndash risk of injury rsaquo Be aware of the weight of the battery system during transport rsaquo Select suitable mounting location and mounting base rsaquo Only install the battery system with the help of a second person

CAUTIONEquipment damage caused by aggressive gases in combination with humidityThe housing may be seriously damaged by aggressive gases (ammonia sulphur and other chemi-cals) in combination with ambient humidity caused by weather conditions - Installation in rooms containing aggressive gases is not permitted

NOTEAccess in the event of maintenance or serviceAny additional costs arising from unfavourable structural or mounting conditions in the event of a KACO service call-out shall be billed to the customer

611 Installation location

bull Dry well ventilated the waste heat must be conducted away from the battery systembull Unobstructed air circulationbull Easily accessible from the front top and sides without requiring additional resourcesbull Indoors protected against direct sunlight and direct water contact

612 Foundation

bull With sufficient load-bearing capacitybull Made from heat-resistant material (up to 90 degC)bull Must be flame resistant

NOTEPower reduction due to heat accumulationIf the recommended minimum clearances are not observed the device may go into power regula-tion mode due to insufficient ventilation and the resulting heat build-up rsaquo The construction and installation of the device may be performed only by a qualified electrician in

accordance with the valid standards and regulations rsaquo Maintain minimum clearances rsaquo Ensure sufficient heat dissipation

Assembling the device

Operating instructions Powador-gridsave_EN Page 17

Authorised electrician

0deg

1000 mm

200 mm 200 mm

500 mm

min carrying capacity 300 kgmsup2

200 mm200 mm

50 mm

Figure 9 Minimum clearances at the installation and assembly location

CAUTIONRisk of injury if the battery system tips overRisk of tipping due to high centre of gravity particularly with the door open rsaquo Anchor the device securely to the floor immediately after installation rsaquo Open the housing door using the enclosed cabinet key only once the device has been securely

anchored

510 mm200 mm

200 mm

400

mm

12 mmmin 110 mm

DesignationHex head wood screw 8x80 DIN571-vz Fischer dowel S12 Flat washer M8 galvanised DIN9021-vz

Units444

Figure 10 Dimensions for anchoring to the floor Table 3 Mounting parts

62 Installing components

CAUTIONAvoid improper handlingImproper handling can cause damage to components rsaquo Damaged components must not be installed rsaquo Always put the plug-in modules down horizontally to avoid damage to the components

Assembling the device

Page 18 Operating instructions Powador-gridsave_EN

Authorised electrician

WARNINGDanger caused by short circuit or sparkingSerious injury from touching or connecting live components rsaquo Damaged components must not be installed

Preparation1 Check the conditions for the installation location2 Open the housing doors using the enclosed cabinet key3 The cables should be professionally laid and prepared for connection4 Follow the installation sequence (1-4 step(s))

621 Step 1 Fit the battery (batteries)

NOTEPlease read the notes on installation and connection in the enclosed manual Features for the battery unit

622 Step 2 Connect battery (batteries) to the battery management system (BMS)

NOTEPlease read the notes on installation and connection in the enclosed manual Features for the battery unit

623 Step 3 Fit the battery charging unit battery backup converter (BBC)

Battery (batteries) connected to the battery management system (BMS)1 Carefully insert battery charging unit battery backup converter (BBC) into the compartment provided for it 2 Push in completely to establish direct contact with the rear busbars3 Secure battery charging unit battery backup converter (BBC) using the screws supplied

624 Step 4 Fit the inverter

Battery charging unit battery backup converter (BBC) is fitted1 Carefully insert inverter into the compartment provided for it 2 Push in completely to establish direct contact with the rear busbars 3 Secure inverter using the screws supplied

CAUTIONDamage to the control unit from introducing foreign objectsForeign objects can impair the function of the control unit and cause damage rsaquo Do not remove the front panel rsaquo Foreign objects should be removed immediately

Installing the device

Operating instructions Powador-gridsave_EN Page 19

Authorised electrician

7 Installing the device

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched The device may only be opened or serviced by an authorised electricianThe device must be completely assembled before being connected electrically rsaquo Observe all safety regulations and current technical connection specifications of the responsible

power supply company rsaquo De-energise the device using the DC isolator switch circuit breaker and residual current circuit

breaker rsaquo Secure both sides against being inadvertently switched back on rsaquo Ensure that the AC and DC sides are completely isolated and voltage free rsaquo Never open the plug-in modules rsaquo Hazardous voltages are present at the busbars rsaquo Disconnect from the grid and plant supply rsaquo First connect the battery system in the connection area

71 Opening the connection area

3

1

2

Figure 11 Open cover plateKey

1 Cover plate 3 Fastening screw

2 Lock

Opening the connection area You have completed assembly

1 Remove the fastening screw for the upper cover plate2 Slide the cover plate forwards out of the lock3 Lift the cover plate upward to remove raquo Make the electrical connection

Installing the device

Page 20 Operating instructions Powador-gridsave_EN

Authorised electrician

72 Making the electrical connectionMake the connection to the PV generator as well as the grid connection using the connection terminals Note the following cable cross-sections

Connection Possible cable cross-section Length of insulation to be stripped offAC home power grid 05 - 16 mmsup2 with end sleeve

05 - 25 mmsup2 without end sleeve18 mm sleeve18-20 mm

PV connection 05 - 16 mmsup2 with end sleeve05 - 25 mmsup2 without end sleeve

18 mm sleeve17-19 mm

Inverter output 05 - 4 mmsup2 with end sleeve05 - 6 mmsup2 without end sleeve

12 mm sleeve11-13 mm

Potential-free contacts 034 - 15 mmsup2 with end sleeve034 - 25 mmsup2 without end sleeve

12 mm sleeve 9-10 mm

Table 4 Cable cross-sections for connection terminals

NOTEThe threaded connections should be matched to the cable cross-section

NOTEOnly conductors and no insulation should be inserted into the connection terminals Individual wires or cables with end sleeves with the appropriate cross-section can be inserted directly into the connection terminal without a toolFine-strand cables without end sleeve or thin conductors will need a screwdriver (plain slot 35 mm) for connection To do this insert the blade of the screwdriver into the recess provided The cable can be inserted into the spring terminal by pressing downwards The spring terminal closes on removal of the screw-driver

Installing the device

Operating instructions Powador-gridsave_EN Page 21

Authorised electrician

X2X1F1 F2 X7 X4 St1

St2

St3

2 3 541 6

Figure 12 View from above of the connection area

Key

1 AC grid input (M40 cable fitting) 4 Network interface (M32 cable fitting)

2 AC grid output (M40 cable fitting) 5 Inverter input (M16 cable fitting)

3 Inverter output (M32 cable fitting) 6 Other connections (M16 cable fitting)

F1 F2 X7 X4 St1

St2

St3

L1 L2 L3 N PE L1 L2 L3 N N PE PE

X1 X2

PV+

PV-

L1 L2 L3 N PE32A 32A PEN

Cust

omer

co

nnec

tion

Figure 13 View from above of the connection area

Key

X1 AC grid input (main junction box meter) X7 PV generator input

X2 AC grid output (building electrical system) F1 F2 Phase bridging fuse

X4 Inverter output St 1-3 Potential-free contacts control outputs

Installing the device

Page 22 Operating instructions Powador-gridsave_EN

Authorised electrician

721 Connecting to the power grid

Because the device is installed between the main junction boxmeter and the buildings electrical system the maxi-mum grid current to the service line must not exceed the rated operating current of the battery system The cable cross-section must be selected in accordance with applicable standards to suit the connected load instal-lation type etc Moreover the terminal area and size of the cable fitting must be noted

NOTEThe fuse rating for the cable should be max 63A (automatic circuit breaker or safety fuse) even if the cross-section of the installed cable would permit a higher fuse rating Always follow the applicable regulations regarding the cable cross-section and installation typeThe device supports standard grid configurations such as TN-C TN-S and TT TN-SIf a TN-S grid is present directly at the power input and output of the device L1-L3 N and PE must each be connected The home power grid should have 4-pin isolationTN-C4-pin grid isolation is factory preset and disconnects L1 L2 L3 and N In a TN-C grid the N conduc-tor must not be disconnected If a TN-S grid is present directly at the power input and output of the device a cable bridge (included in delivery) must be installed between the N terminal on X1 and the N terminal on X2 N and PE must additionally be connected together To do this simply insert the enclosed terminal link into the N and PE terminals TTIn the case of a TT grid L1-L3 N and PE must each be connected The home power grid should have 4-pin isolation

NOTEPlease check with the operator of the mains grid whether there are special regulations for grid connection Grid isolation is factory preset to 4-pin is fail-safe and provided with grid and system protection as per VDE-AR-N 4105

Making the grid connection Use cables with 5 wires (L1 brown L2 black L3 grey N blue PE greenyellow) and the correct

cross-section1 Loosen cable fitting for AC connection2 Remove the outer cladding of the AC cables3 Insert the AC cables through the cable fitting into the connection area4 Strip the insulation from the AC cables5 Remove connection terminals6 Connect the cables in line with the terminal labels (Figure 13 on page 21)7 Close the connection terminals8 Check that all connected cables are securely fitted9 Tighten the cable fitting10 To meet the requirements of protection rating IP21 close the unused cable fittings with blind caps raquo The battery system is connected to the power grid

NOTEAn AC-side disconnection unit must be provided during the final installation stage This disconnec-tion unit must be installed so that it can be accessed at any time without obstruction If a residual current circuit breaker is necessary due to the installation specification a type A residual current circuit breaker must be used

Installing the device

Operating instructions Powador-gridsave_EN Page 23

Authorised electrician

7211 Output from the inverterRecommended cable cross-sections for the inverter output and fuse rating of cables for fixed wiring accord-ing to VDE 0100 part 430The fuse rating for the cable is dependent on the cable cross-section max 40A automatic circuit breaker

NOTEWhen the line resistance is high (ie long grid-side cables) the voltage at the grid terminals of the inverter will increase during feed-in to the grid The inverter monitors this voltage If the voltage exceeds the country-specific grid overvoltage limit value the inverter switches off rsaquo Ensure that the conductor cross-sections are sufficiently large or that the cable lengths are suffi-

ciently short

NOTEIn order to avoid asymmetries in the grid systems with multiple battery systems should be designed so that the inverters in the devices feed into the grid in differing phases rsaquo Follow the connection conditions for the particular type of grid and the schematic illustration

below

Country and grid-type

Grid monitoring Required monitoring

max asymmetry between phases L1L2L3

DE-NSP Three-phase or single phase phase unbalanced load 46 kVA

Table 5 Grid-type-specific connection conditions

L1

L2

L3

N

Connection X1 Connection X1 Connection X1 Connection X1

L1 L2 L3 N PE L1 L2 L3 N PE L1 L2 L3 N PE L1 L2 L3 N PE

Powador-gridsave inverter1 L1 - L1 L2 - L2 L3 - L32 L1 - L2 L2 - L3 L3 - L1 3 L1 - L3 L2 - L1 L3 - L2 4 L1 - L1 L2 - L2 L3 - L3

Figure 14 Grid-side connection for systems with multiple battery systems with three-phase grid monitoring

Installing the device

Page 24 Operating instructions Powador-gridsave_EN

Authorised electrician

722 Connecting the PV generator

Connect the PV generator on the left in the connection area (Figure 13 on page 21) Use the provided M16 cable fittings A maximum of two strings can be connected For this reason a DC string fuse can be dispensed with

DANGERRisk of fatal injury due to contact voltagesRemoving the cables from the terminals without first disconnecting the PV generator from the device can cause serious damage to health or damage to the system rsaquo During installation Electrically disconnect the DC positive and DC negative from the protective

earth (PE) rsaquo Completely de-energise the system (AC home power grid AC circuit breaker residual current circuit

breaker DC isolator switch) rsaquo Disconnect the battery system from the PV generator using the integrated DC isolator switch rsaquo Remove DC plug connectors

NOTEIn accordance with IEC 61730 Class A connected PV modules must be dimensioned for the DC system voltage provided and at least for the value of the AC grid voltage

7221 Before connecting

Ensure that there is no ground fault1 Determine the DC voltage between the

ndash protective earth (PE) and the positive cable of the PV generator and between the ndash protective earth (PE) and the negative cable of the PV generator

If stable voltages can be measured there is a ground fault in the DC generator or its wiring The ratio between the measured voltages gives an indication as to the location of this fault

2 Rectify any faults before taking further measurements3 Determine the electrical resistance between the

ndash protective earth (PE) and the positive cable of the PV generator and between the ndash protective earth (PE) and the negative cable of the PV generator

In addition ensure that the PV generator has a total insulation resistance of more than 20 MOhm since the inverter will not feed in if the insulation resistance is too low

4 Rectify any faults before connecting the DC generator

7222 Connecting the PV generator

DANGERRisk of fatal injury due to electric shockSevere injury or death will result if the live connections are touched When there is solar radiation DC voltage will be present at the open ends of the DC cables rsaquo Do not touch the exposed ends of the cables rsaquo Avoid short circuits

Installing the device

Operating instructions Powador-gridsave_EN Page 25

Authorised electrician

Connecting the PV generator Use cables with the correct cross-section

1 Remove cable fittings for DC connection2 Remove the outer cladding of the DC cables3 Insert the DC cables through the cable fittings into the connection area4 Strip the insulation from the DC cables5 Remove connection terminals6 Connect the cables in line with the terminal labels (See Figure 13 on page 21)7 Close the connection terminals8 Check that all connected cables are securely fitted9 Tighten the cable fittings10 To meet the requirements of protection rating IP21 close the unused cable fittings with blind caps raquo The PV generator is connected to the inverter

73 Connecting the interfaces

731 Ethernet interface

Pre-assembled Ethernet cables can be connected using the RJ45 socket in the connection space

Connecting the Ethernet cable1 Remove closure cap from RJ45 socket2 Connect the Ethernet cable3 The energy management system can now obtain an IP address by DHCP and is also available via this in the

network

NOTEThe network settings can be amended later in the Settings menu using the EMS

NOTEUse a suitable category 5 network cable The maximum length of a network segment is 100 m Ensure that the cable is correctly assigned The Ethernet connection of the battery system supports auto-sensing You can use both crossed and 11 configured Ethernet connection cables

74 Sealing the connection area

1 Finally check the cabling2 Ensure that all cables are firmly mounted3 Check that the cable fitting is secure and tighten if necessary4 Remove cable offcuts and particles of dirt or dust5 Fit the cover and slide back until it engages into position6 Check that the position is correct7 Screw the fastening screw onto the front of the cover

Installing the device

Page 26 Operating instructions Powador-gridsave_EN

Authorised electrician

75 Starting up

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched Only appropriately qualified and authorised electricians may open install or maintain the battery system rsaquo Keep the front doors and covers closed during operation

NOTEInitial start-up should be carried out using the available public AC grid

76 Standard configuration

Factory settingsCountry configuration Germany

Grid guidelines Low voltage directive

Language German

Time UTC +1 Central European Time

User Standard

Network parameters DHCP (network settings will be obtained automatically from the router)

NOTEPlease state the desired power limitation (60 or 70 of the PV system capacity) when you order For other variations please notify your KACO contact so that the parameters can be set at the factory prior to delivery

Installing the device

Operating instructions Powador-gridsave_EN Page 27

Authorised electrician

761 Step 1 AC home power grid

Check all cables and connections before starting up1 Switch on the AC home power grid using the AC main switch raquo Powador-protect measurement and control unit starts up and monitors the AC grid raquo Two green LEDs indicate that the grid parameters are met raquo After a further 60 seconds (shortly after the backlighting in the Powador-protect goes out) the Powador-pro-

tect will switch on the home grid2 Configure Powador-protect according to the enclosed Powador-protect instructions

(The instructions are also available on the website at wwwkaconewenergyde) raquo The AC power is supplied in the normal way by the public grid

762 Step 2 AC supply from the battery system

Check all cables and connections before starting up1 Remove external isolation means from the device2 Switch on the circuit breaker raquo The LCD touchscreen on the front panel comes on and the energy management system (EMS) starts up

3 Switch on the residual current circuit breaker raquo The battery system starts up

763 Step 3 Switch on the PV system

1 Switch on any optional external PV isolator switches2 Set the internal DC isolator switch to ON raquo The inverter and the battery charging unit battery backup converter (BBC) are connected to the PV system raquo The device monitors the PV voltage for approx 60 seconds then optimisation of internal consumption takes

place

764 Step 4 Switch on batteries

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

765 Step 5 Activate energy management

NOTEKACO new energy cannot provide any support for problems regarding the IT infrastructure (eg router configuration IP address assignment ports etc) as the structure settings and configuration of the network environment can be complex and very different from place to place In the event of any problems please contact an IT service provider

Remote access activated 1 Please call the KACO Hotline to make an appointment for activation of energy management

Configuration and Operation

Page 28 Operating instructions Powador-gridsave_EN

Authorised electrician

8 Configuration and Operation

81 ControlsThe battery system is fitted with a touchscreen which allows it to be controlled very precisely In normal operation the display is switched off Touching the screen activates the display and after a configurable period of time without being touched the dis-play will deactivate If the screen-save function is switched off the touchscreen will be on continuously

NOTEDepending on the tolerances of the measuring elements the measured and displayed values are not always the actual values However the measuring elements ensure maximum solar yield Due to these tolerances the daily yields shown on the touchscreen may deviate from the values on the grid operatorrsquos feed-in meter by up to 15

3

1

45

2

Figure 15 Overview (home screen)

Key

1 Home button 4 Current time

2 System components 5 Menu name

3 More information

811 Information about the system

Open start screen View changesjumps to the home screen

Show component detail Parameters of the selected component

Settings Define settings for the active user

raquo Displays settings

Configuration and Operation

Operating instructions Powador-gridsave_EN Page 29

Controls Left arrow jump back to previous menu item Up and down arrows navigate through the menu or change a value

Left arrow displayed value is reduced by one increment Right arrow displayed value is increased by one increment or change to the submenu

Display fields Grey box Text or figures (not selectable) Blue box Calls up submenu for the display in question

Activate and deactivate Activate function by ticking the box

Table 6 Information about the system

812 System components

PV generator Display of the current generator data

power voltage current temperature in the inverter

Battery Display of the current battery status

power (charging or discharging) voltage current charge status available capacity temperature of battery

Grid Display of the following either fed-in or drawn from the grid

power voltage current for phase L1-L3 total output frequency

Consumer (load) Display of the consumer data

power voltage current for phase L1-L3 total output

Energy flow raquo Displays the current energy flow in the system

Table 7 Information about system components

Configuration and Operation

Page 30 Operating instructions Powador-gridsave_EN

813 Menu structure

Icons used

Display menu Submenu

Option menu

Menu Submenu Display setting

Action in this menumeaning

PV generator Details

Power Displays the current DC-side power

Voltage Displays the current DC-side voltage

Current Displays the current DC-side amperage

Temp inverter

Displays the current temperature in the inverter housing

Battery Details

Power Displays the current AC-side power

Voltage Displays the current AC-side voltage

Current Displays the current AC-side amperage

Charge status Displays the current charge status

Capacity Displays the current battery capacity

Temperature Displays the current measured temperature of the battery

Grid Details

Power Displays the current AC-side power being drawn or fed-in

Voltage Displays the AC-side voltage being applied

Current Displays the current AC-side amperage being drawn or fed-in

Total output Displays the current AC-side total output being drawn or fed-in

Frequency Displays the frequency currently being applied to the grid junction

Consumer (load) Details

Power Displays the current AC-side power being drawn

Voltage Displays the current AC-side voltage being applied

Current Displays the current AC-side amperage being drawn

Total output Displays the current AC-side total output being drawn

Configuration and Operation

Operating instructions Powador-gridsave_EN Page 31

Menu Submenu Display setting

Action in this menumeaning

Settings

Country amp directive display

Display of the country settings voltage directives and grid type

Select menu language

DateTime Specify time zone date format and date and time

Screen Activate screen-save function and set the delay period

Network settings

Display of the network settings Configure network settings Once the DHCP server becomes available the IP

address subnet mask gateway and DNS server are automatically applied and the aforemen-tioned menu items are hidden

Off DHCP deactivated make settings manually

Version Displays the installed software version and built-in HW components (inverter BBC battery)

Vendor The touchscreen shows information about the device vendor

NOTEAs changes to the software are possible after the manual has been printed the illustrations and descriptions of the functions in these operating instructions may deviate from the software Please therefore note the current Application Notes on our website

MaintenanceTroubleshooting

Page 32 Operating instructions Powador-gridsave_EN

9 MaintenanceTroubleshooting

91 Visual inspectionInspect the device and the cables for visible external damage and note the operating status display In case of damage notify your installer Repairs may only be carried out by authorised electricians

NOTEThe battery system should be checked for proper operation by a qualified electrician at regular intervals

92 Cleaning the device

DANGERLethal voltages in the battery systemSerious injuries or death can result if moisture enters the system rsaquo Only use completely dry objects to clean the battery system rsaquo Only clean the outside of the battery system

Cleaning the battery system Do not use compressed air Use a vacuum cleaner or a soft brush to remove dust from the fan cover and from the top of the inverter on a

regular basis Remove dust from the ventilation inlets if necessary

MaintenanceTroubleshooting

Operating instructions Powador-gridsave_EN Page 33

Authorised electrician

93 Maintenance

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched The device is only permitted to be opened or serviced by an authorised electrician rsaquo Observe all safety regulations and the current technical connection specifications from the relevant

power supply company rsaquo Disconnect the AC and DC sides rsaquo Secure the AC and DC sides from being inadvertently switched back on rsaquo Only then should the device be opened rsaquo After shutdown wait at least 30 minutes before working on the device

CAUTIONDestruction of the DC connectionThe connection terminals can be destroyed by arcing if disconnected while still live rsaquo It is absolutely essential that the shutdown sequence be carried out in the correct order (See sec-

tion 111 on page 35)

94 Faults

941 Procedure

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched

When a fault occurs notify an appropriately authorised and qualified electrician or KACO new energy GmbH Service

Service

Page 34 Operating instructions Powador-gridsave_EN

10 ServiceIf 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 efficientlybull Serial nobull SW version of the components (the software version can be found in the Settings menu using the EMS)bull Module type and string circuitbull Date of installation Start-up reportbull Consignment identification Delivery address Contact person (with telephone number)bull Information about the accessibility of the installation site

Any additional costs arising from unfavourable structural or mounting conditions shall be billed to the customer

You can find our warranty conditions on our websitehttpkaco-newenergycomservicewarrantyFrom there you can easily navigate to our international websites by clicking on the appropriate flag

Please use our website to register your unit immediatelyYou can also select the appropriate flag on this page to access the website for your own countryIn this manner you can assist us in providing you with the quickest service possible Note The maximum length of the warranty is based on the currently applicable national warranty conditions

We have prepared a template for complaints This can be found at httpskaco-newenergycomservicecustomer-service

Hotlines

Technical troubleshooting Technical consultation

Inverters and battery systems ()

+49 (0) 71323818-660 +49 (0) 71323818-660

Data logging and accessories +49 (0) 71323818-690 +49 (0) 71323818-690

Construction site emergency () +49 (0) 71323818-630

Customer help desk Monday to Friday from 730 am to 530 pm (CET)

() Also on Saturdays from 800 am to 200 pm (CET)

ShutdownDisassembly

Operating instructions Powador-gridsave_EN Page 35

11 ShutdownDisassembly

111 Switching off the device

DANGERLethal voltages are still present in the terminals and cables even after switching off and discon-nection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched rsaquo Complete de-energisation only occurs if the bulk power supply is switched off upstream of the bat-

tery system

DANGERDestruction of the DC plug connectorDC plug connectors can be destroyed by arcing if disconnected while still live rsaquo It is absolutely essential that the following shutdown sequence is observed

1111 Step 1 Shutting down the PV system

1 Switch off any optional external PV isolator switches2 Set the internal DC isolator switch to OFF raquo The inverter and battery charging unit battery backup converter (BBC) are disconnected

1112 Step 2 Disconnect the batteries

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

1113 Step 3 Disconnect the AC supply

1 Connect external isolation means to the device2 Switch off the circuit breaker 3 Switch off the residual current circuit breaker raquo The battery system is switched off

1114 Step 4 AC home power grid

1 Shutdown the AC home power grid using the AC main switch raquo The battery system can be uninstalled

Disposal

Page 36 Operating instructions Powador-gridsave_EN

112 Uninstalling the device

NOTETo uninstall follow the same sequence as for installation but in reverse order

Switch off the device1 Unlock and open the housing door2 Remove the upper cover3 Release the DC and AC cables from the connection terminals4 Pull out the cables raquo The battery system is uninstalled Continue with the disassembly

113 Disassembling the device

NOTETo disassemble follow the same sequence as for assembly but in reverse order

Switch off the device1 Uninstall the components2 Remove the fastening from the device3 Securely pack up the battery system if it is to be used later

or have the battery system disposed of in accordance with section 12 on page 36

12 DisposalFor the most part both the battery system and the corresponding transport packaging are made from recyclable raw materialsBatteries and components Do not dispose of faulty batteries or the components together with household waste Ensure that the old device and accessories are disposed of in a proper mannerPackaging Ensure that the transport packaging is disposed of properlyBatteriesUsed or faulty batteries must be transported in special packaging If you need such packaging please contact the KACO Hotline

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

Appendix

Operating instructions Powador-gridsave_EN Page 37

13 Appendix

EU Declaration of Conformity

Vendorrsquos name and address

KACO new energy GmbH Carl-Zeiss-Straszlige 1 74172 Neckarsulm Germany

Product description Battery system

Type designation Powador-gridsave 135 kWh 6400 Powador-gridsave 135 kWh 8000

Powador-gridsave 270 kWh 6400 Powador-gridsave 270 kWh 8000

Powador-gridsave 405 kWh 6400 Powador-gridsave 405 kWh 8000

Powador-gridsave 540 kWh 6400 Powador-gridsave 540 kWh 8000

Powador-gridsave 577 kWh 6400 Powador-gridsave 577 kWh 8000

Powador-gridsave 675 kWh 6400 Powador-gridsave 675 kWh 8000

This is to confirm that the units listed above comply with the protection requirements set forth in the Directive of the Council of the European Union of 15th December 2004 on the harmonisation of the laws of the member states relating to Electromagnetic Compatibility (2004108EC) and the Low Voltage Directive (200695EC)The units are compliant with the following standards

200695EC ldquoDirective relating to electrical equipment designed for use within specific voltage limitsrdquo

Safety of the unitIEC 62109-12010IEC 62109-22011

2004108EC ldquoDirective relating to electromagneticcompatibilityrdquo

Interference immunityEN 61000-6-22005 Emitted interferenceEN 61000-6-32007

Secondary effects on the gridEN 61000-3-112000EN 61000-3-122005

The types mentioned above are therefore labelled with the CE markUnauthorised modifications to the supplied units andor any use of the units that is contrary to their intended use render this Declaration of Conformity null and void

Neckarsulm 0711 2013KACO new energy GmbH

pp Volker DietrichEnergy systems engineering management

Disposal

Page 38 Operating instructions Powador-gridsave_EN

Carl-Zeiss-Straszlige 1 middot 74172 Neckarsulm middot Germany middot Phone +49 7132 3818-0 middot Fax +49 7132 3818-703 middot infokaco-newenergyde middot wwwkaco-newenergyde

The

text

and

figu

res

refle

ct th

e cu

rren

t tec

hnic

al s

tate

at t

he ti

me

of p

rintin

g S

ubje

ct to

tech

nica

l cha

nges

Err

ors

and

omis

sion

s ex

cept

ed

3006

856-

01-1

4030

5

  • 1General Information
    • 11About this document
    • 12Name plate
    • 13Additional information
    • 14Intended use
      • 2Safety
        • 21Protection features
          • 3Description
            • 31Mode of Operation
            • 32Summary of the components
              • 4Technical Data
                • 41Electrical data
                • 42Mechanical data
                  • 5Transportation and Delivery
                    • 51Delivery
                    • 52Storage
                    • 53Transportation
                      • 6Assembling the device
                        • 61Installation
                        • 62Installing components
                          • 7Installing the device
                            • 71Opening the connection area
                            • 72Making the electrical connection
                            • 73Connecting the interfaces
                            • 74Sealing the connection area
                            • 75Starting up
                            • 76Standard configuration
                              • 8Configuration and Operation
                                • 81Controls
                                  • 9MaintenanceTroubleshooting
                                    • 91Visual inspection
                                    • 92Cleaning the device
                                    • 93Maintenance
                                    • 94Faults
                                      • 10Service
                                      • 11ShutdownDisassembly
                                        • 111Switching off the device
                                        • 112Uninstalling the device
                                        • 113Disassembling the device
                                          • 12Disposal
                                          • 13Appendix

Description

Page 10 Operating instructions Powador-gridsave_EN

323 Inverter

PV INVERTER

Figure 5 Inverter

NOTEThe inverter converts the DC voltage from the PV generator and the battery into AC voltage

324 Battery charging unit battery backup converter (BBC)

BATTERY CONVERTER

Figure 6 Battery charging unit battery backup converter (BBC)

NOTEThe battery charging unit battery backup converter (BBC) is the interface to the battery The high voltage from the PV generator is converted into non-hazardous safety extra low voltage (SELV) for the battery The battery charging unit battery backup converter (BBC) can transfer energy both into the battery and out of it

325 Battery management system (BMS)

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

326 Battery

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

Technical Data

Operating instructions Powador-gridsave_EN Page 11

4 Technical Data

41 Electrical data

Connection box

Home power grid

Input voltage 230V 400V 50Hz 60Hz 3-phase (3 N PE)

Grid configuration TN-C TN-S TT

Grid monitoring Powador-protect (as per VDE-AR-N 4105)

Grid isolation Double insulated 3 or 4 pin

Rated operating current [A] 75

Rated switching current AC-1 [A] 100

Rated switching current AC-3 [A] 50 (22 kW at 400 V)

Connection cross-section [mmsup2] max 25

PV input

Input voltage [V] 300 to 800

Input current [A] 30 String

Strings 2

Isolation Yes rotary switch

Inverter type 6400 8000

Input levels

Max recommended PV generator power [W] 7700 9600

Rated power peak power [VA] 6400 7000 8000 9000

DC MPP range from [V] to [V] 360 590

Open circuit voltage [V] 800

Input current [A] 190 240

cos phi 08 inductive hellip 08 capacitive

Polarity safeguard Short-circuit diode

Feed-in phases 1

Capable of stand-alone operation Yes

Efficiency [] 966

Output levels

Output voltage 230V 50Hz 60Hz 1-phase

Rated current [A] 278 35

Connection cross-section [mmsup2] max 6

Monitoring Isolation Circuit breaker residual current circuit breaker (RCD)

Table 1 Electrical data

Technical Data

Page 12 Operating instructions Powador-gridsave_EN

Battery charging unit battery backup converter (BBC)

BBC power [W] 3300

HV voltage [V] 350 to 600

Battery voltage [V] 38 to 58

Efficiency [] 970

Table 1 Electrical data

42 Mechanical data

Battery system

Display 43 LCD touchscreen

Interfaces RS485 Sym-Bus Ethernet USB digital inputsoutputs

Cable insertion Cable fitting 2x M40 2x M32 4x M25 12x M16

Ambient temperature [degC] 0 +40

Humidity [] lt95 (non-condensing)

Cooling Forced cooling temperature-controlled

Noise emission [dB] lt45

Note regarding cooling Do no cover air inletsoutlets keep clear 20 cm to the right and left

Temperature monitoring Individual monitoring of components with shutdown in the event of excess temperature

Maximum installation elevation [m above mean sea level] 2000

Protection class IP21

Housing form 19 sheet-steel control cabinet

H x W x D [mm] 1600 x 620 x 600

Weight [kg] 2435

Inverter

Ambient temperature range [degC] -20 +60

Temperature monitoring Yes

Cooling Active cooling

Connections Quick INOUT plug connector and busbar clips rear side

H x W x D [mm] 22225 x 4826 x 460

Weight [kg] 25

Table 2 Mechanical data

Technical Data

Operating instructions Powador-gridsave_EN Page 13

Battery charging unit battery backup converter (BBC)

Ambient temperature range [degC] -20 +70

Temperature monitoring Yes

Cooling Active cooling

Housing 19 plug-in module aluminium

Connections Quick INOUT plug connector and busbar clips rear side

H x W x D [mm] 13325 x 4826 x 460

Weight [kg] 15

Temperature-dependent impedance matching with shutdown if the temperature is too high

Table 2 Mechanical data

Transportation and Delivery

Page 14 Operating instructions Powador-gridsave_EN

5 Transportation and Delivery

51 DeliveryThe battery system leaves KACO new energy in fully functional electrical and mechanical condition Special packaging ensures that the units are transported safely The shipping company is responsible for any trans-port damage that occurs

511 Scope of delivery

Pallet A B

Figure Figure 7 Scope of delivery pallet A Figure 8 Scope of delivery pallet B

Contents bull Battery system Powador-gridsave (incl connection box battery management system (BMS) industrial PC Plexiglas cover and accessories)

bull Inverter bull Battery charging unit battery backup converter

(BBC)bull Battery system plug-in modules 1-5 ST (scope of

delivery can be found on the delivery document)bull Documentation

Weight (kg) 187 max 155 177 (without with Euro pool pallet)

H x W x D [mm] 1780x800x820 1200x1200x800

Packaging Cardboard box with polystyrene inserts and closures

512 Check the equipment included

bull Battery system and plug-in modules should be inspected thoroughly for transport damagebull Do not install damaged components in the control cabinetbull In the event of damage to the battery plug-in modules contact the KACO new energy Hotline immediately

Transportation and Delivery

Operating instructions Powador-gridsave_EN Page 15

Authorised electrician

DANGERRisk of fatal injury if incompatible components are usedThe battery and power electronics can be damaged if different delivery batches are combined and will carry potentially fatal voltages if connected rsaquo Assemble the system using the components provided by KACO new energy only rsaquo Check the serial numbers on the delivery document against the serial numbers of the individual

units on pallets A and B

52 StorageIncorrect storage can lead to system malfunctions Therefore please observe the following conditionsbull If storing for longer than six months store the device in an interior room in its original packaging bull If the original packaging has been removed store the device in a cool dry interior roombull Storage temperature -20 degC to +70 degCbull Relative humidity 0 to 95 (non-condensing)bull If the device is stored for a relatively long time at high humidity the device must be left for more than one day to

dry out sufficiently before connection to the power grid

53 Transportation

WARNINGImpact hazard risk of breakage to the components in the battery systemThe centre of gravity is located in the upper part of the device rsaquo Transport the device upright together with the pallet rsaquo Do not expose the device or components to any shocks rsaquo After unloading at least two people are required to transport the cabinet

WARNINGDanger due to impact and incorrect storage of the batteriesIn the event of damage batteries can release hazardous electrolyte gases which will cause irreversible burns if they come into contact with the skin rsaquo Transport the batteries in the vendors original packaging only rsaquo Remove the batteries from the original packaging shortly before installation rsaquo Do not store batteries in cars or outdoors rsaquo Check the condition of the battery before use

NOTEThe precise specifications of the UN on the transport of lithium batteries can be found under the designation Model Regulations on the transport of dangerous goods Ref STSGAC101 Recommendations on the transport of dangerous goods Part III sub-section 383 ldquoManual of Tests and Criteriardquo Ref STSGAC1011

Assembling the device

Page 16 Operating instructions Powador-gridsave_EN

Authorised electrician

6 Assembling the device

61 Installation

DANGERRisk of fatal injury from fire or explosionsFire caused by flammable or explosive materials in the vicinity of the battery system can lead to serious injuries rsaquo Do not mount the inverter in potentially explosive atmospheres or in the vicinity of highly flamma-

ble materials

CAUTIONBattery system is very heavy ndash risk of injury rsaquo Be aware of the weight of the battery system during transport rsaquo Select suitable mounting location and mounting base rsaquo Only install the battery system with the help of a second person

CAUTIONEquipment damage caused by aggressive gases in combination with humidityThe housing may be seriously damaged by aggressive gases (ammonia sulphur and other chemi-cals) in combination with ambient humidity caused by weather conditions - Installation in rooms containing aggressive gases is not permitted

NOTEAccess in the event of maintenance or serviceAny additional costs arising from unfavourable structural or mounting conditions in the event of a KACO service call-out shall be billed to the customer

611 Installation location

bull Dry well ventilated the waste heat must be conducted away from the battery systembull Unobstructed air circulationbull Easily accessible from the front top and sides without requiring additional resourcesbull Indoors protected against direct sunlight and direct water contact

612 Foundation

bull With sufficient load-bearing capacitybull Made from heat-resistant material (up to 90 degC)bull Must be flame resistant

NOTEPower reduction due to heat accumulationIf the recommended minimum clearances are not observed the device may go into power regula-tion mode due to insufficient ventilation and the resulting heat build-up rsaquo The construction and installation of the device may be performed only by a qualified electrician in

accordance with the valid standards and regulations rsaquo Maintain minimum clearances rsaquo Ensure sufficient heat dissipation

Assembling the device

Operating instructions Powador-gridsave_EN Page 17

Authorised electrician

0deg

1000 mm

200 mm 200 mm

500 mm

min carrying capacity 300 kgmsup2

200 mm200 mm

50 mm

Figure 9 Minimum clearances at the installation and assembly location

CAUTIONRisk of injury if the battery system tips overRisk of tipping due to high centre of gravity particularly with the door open rsaquo Anchor the device securely to the floor immediately after installation rsaquo Open the housing door using the enclosed cabinet key only once the device has been securely

anchored

510 mm200 mm

200 mm

400

mm

12 mmmin 110 mm

DesignationHex head wood screw 8x80 DIN571-vz Fischer dowel S12 Flat washer M8 galvanised DIN9021-vz

Units444

Figure 10 Dimensions for anchoring to the floor Table 3 Mounting parts

62 Installing components

CAUTIONAvoid improper handlingImproper handling can cause damage to components rsaquo Damaged components must not be installed rsaquo Always put the plug-in modules down horizontally to avoid damage to the components

Assembling the device

Page 18 Operating instructions Powador-gridsave_EN

Authorised electrician

WARNINGDanger caused by short circuit or sparkingSerious injury from touching or connecting live components rsaquo Damaged components must not be installed

Preparation1 Check the conditions for the installation location2 Open the housing doors using the enclosed cabinet key3 The cables should be professionally laid and prepared for connection4 Follow the installation sequence (1-4 step(s))

621 Step 1 Fit the battery (batteries)

NOTEPlease read the notes on installation and connection in the enclosed manual Features for the battery unit

622 Step 2 Connect battery (batteries) to the battery management system (BMS)

NOTEPlease read the notes on installation and connection in the enclosed manual Features for the battery unit

623 Step 3 Fit the battery charging unit battery backup converter (BBC)

Battery (batteries) connected to the battery management system (BMS)1 Carefully insert battery charging unit battery backup converter (BBC) into the compartment provided for it 2 Push in completely to establish direct contact with the rear busbars3 Secure battery charging unit battery backup converter (BBC) using the screws supplied

624 Step 4 Fit the inverter

Battery charging unit battery backup converter (BBC) is fitted1 Carefully insert inverter into the compartment provided for it 2 Push in completely to establish direct contact with the rear busbars 3 Secure inverter using the screws supplied

CAUTIONDamage to the control unit from introducing foreign objectsForeign objects can impair the function of the control unit and cause damage rsaquo Do not remove the front panel rsaquo Foreign objects should be removed immediately

Installing the device

Operating instructions Powador-gridsave_EN Page 19

Authorised electrician

7 Installing the device

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched The device may only be opened or serviced by an authorised electricianThe device must be completely assembled before being connected electrically rsaquo Observe all safety regulations and current technical connection specifications of the responsible

power supply company rsaquo De-energise the device using the DC isolator switch circuit breaker and residual current circuit

breaker rsaquo Secure both sides against being inadvertently switched back on rsaquo Ensure that the AC and DC sides are completely isolated and voltage free rsaquo Never open the plug-in modules rsaquo Hazardous voltages are present at the busbars rsaquo Disconnect from the grid and plant supply rsaquo First connect the battery system in the connection area

71 Opening the connection area

3

1

2

Figure 11 Open cover plateKey

1 Cover plate 3 Fastening screw

2 Lock

Opening the connection area You have completed assembly

1 Remove the fastening screw for the upper cover plate2 Slide the cover plate forwards out of the lock3 Lift the cover plate upward to remove raquo Make the electrical connection

Installing the device

Page 20 Operating instructions Powador-gridsave_EN

Authorised electrician

72 Making the electrical connectionMake the connection to the PV generator as well as the grid connection using the connection terminals Note the following cable cross-sections

Connection Possible cable cross-section Length of insulation to be stripped offAC home power grid 05 - 16 mmsup2 with end sleeve

05 - 25 mmsup2 without end sleeve18 mm sleeve18-20 mm

PV connection 05 - 16 mmsup2 with end sleeve05 - 25 mmsup2 without end sleeve

18 mm sleeve17-19 mm

Inverter output 05 - 4 mmsup2 with end sleeve05 - 6 mmsup2 without end sleeve

12 mm sleeve11-13 mm

Potential-free contacts 034 - 15 mmsup2 with end sleeve034 - 25 mmsup2 without end sleeve

12 mm sleeve 9-10 mm

Table 4 Cable cross-sections for connection terminals

NOTEThe threaded connections should be matched to the cable cross-section

NOTEOnly conductors and no insulation should be inserted into the connection terminals Individual wires or cables with end sleeves with the appropriate cross-section can be inserted directly into the connection terminal without a toolFine-strand cables without end sleeve or thin conductors will need a screwdriver (plain slot 35 mm) for connection To do this insert the blade of the screwdriver into the recess provided The cable can be inserted into the spring terminal by pressing downwards The spring terminal closes on removal of the screw-driver

Installing the device

Operating instructions Powador-gridsave_EN Page 21

Authorised electrician

X2X1F1 F2 X7 X4 St1

St2

St3

2 3 541 6

Figure 12 View from above of the connection area

Key

1 AC grid input (M40 cable fitting) 4 Network interface (M32 cable fitting)

2 AC grid output (M40 cable fitting) 5 Inverter input (M16 cable fitting)

3 Inverter output (M32 cable fitting) 6 Other connections (M16 cable fitting)

F1 F2 X7 X4 St1

St2

St3

L1 L2 L3 N PE L1 L2 L3 N N PE PE

X1 X2

PV+

PV-

L1 L2 L3 N PE32A 32A PEN

Cust

omer

co

nnec

tion

Figure 13 View from above of the connection area

Key

X1 AC grid input (main junction box meter) X7 PV generator input

X2 AC grid output (building electrical system) F1 F2 Phase bridging fuse

X4 Inverter output St 1-3 Potential-free contacts control outputs

Installing the device

Page 22 Operating instructions Powador-gridsave_EN

Authorised electrician

721 Connecting to the power grid

Because the device is installed between the main junction boxmeter and the buildings electrical system the maxi-mum grid current to the service line must not exceed the rated operating current of the battery system The cable cross-section must be selected in accordance with applicable standards to suit the connected load instal-lation type etc Moreover the terminal area and size of the cable fitting must be noted

NOTEThe fuse rating for the cable should be max 63A (automatic circuit breaker or safety fuse) even if the cross-section of the installed cable would permit a higher fuse rating Always follow the applicable regulations regarding the cable cross-section and installation typeThe device supports standard grid configurations such as TN-C TN-S and TT TN-SIf a TN-S grid is present directly at the power input and output of the device L1-L3 N and PE must each be connected The home power grid should have 4-pin isolationTN-C4-pin grid isolation is factory preset and disconnects L1 L2 L3 and N In a TN-C grid the N conduc-tor must not be disconnected If a TN-S grid is present directly at the power input and output of the device a cable bridge (included in delivery) must be installed between the N terminal on X1 and the N terminal on X2 N and PE must additionally be connected together To do this simply insert the enclosed terminal link into the N and PE terminals TTIn the case of a TT grid L1-L3 N and PE must each be connected The home power grid should have 4-pin isolation

NOTEPlease check with the operator of the mains grid whether there are special regulations for grid connection Grid isolation is factory preset to 4-pin is fail-safe and provided with grid and system protection as per VDE-AR-N 4105

Making the grid connection Use cables with 5 wires (L1 brown L2 black L3 grey N blue PE greenyellow) and the correct

cross-section1 Loosen cable fitting for AC connection2 Remove the outer cladding of the AC cables3 Insert the AC cables through the cable fitting into the connection area4 Strip the insulation from the AC cables5 Remove connection terminals6 Connect the cables in line with the terminal labels (Figure 13 on page 21)7 Close the connection terminals8 Check that all connected cables are securely fitted9 Tighten the cable fitting10 To meet the requirements of protection rating IP21 close the unused cable fittings with blind caps raquo The battery system is connected to the power grid

NOTEAn AC-side disconnection unit must be provided during the final installation stage This disconnec-tion unit must be installed so that it can be accessed at any time without obstruction If a residual current circuit breaker is necessary due to the installation specification a type A residual current circuit breaker must be used

Installing the device

Operating instructions Powador-gridsave_EN Page 23

Authorised electrician

7211 Output from the inverterRecommended cable cross-sections for the inverter output and fuse rating of cables for fixed wiring accord-ing to VDE 0100 part 430The fuse rating for the cable is dependent on the cable cross-section max 40A automatic circuit breaker

NOTEWhen the line resistance is high (ie long grid-side cables) the voltage at the grid terminals of the inverter will increase during feed-in to the grid The inverter monitors this voltage If the voltage exceeds the country-specific grid overvoltage limit value the inverter switches off rsaquo Ensure that the conductor cross-sections are sufficiently large or that the cable lengths are suffi-

ciently short

NOTEIn order to avoid asymmetries in the grid systems with multiple battery systems should be designed so that the inverters in the devices feed into the grid in differing phases rsaquo Follow the connection conditions for the particular type of grid and the schematic illustration

below

Country and grid-type

Grid monitoring Required monitoring

max asymmetry between phases L1L2L3

DE-NSP Three-phase or single phase phase unbalanced load 46 kVA

Table 5 Grid-type-specific connection conditions

L1

L2

L3

N

Connection X1 Connection X1 Connection X1 Connection X1

L1 L2 L3 N PE L1 L2 L3 N PE L1 L2 L3 N PE L1 L2 L3 N PE

Powador-gridsave inverter1 L1 - L1 L2 - L2 L3 - L32 L1 - L2 L2 - L3 L3 - L1 3 L1 - L3 L2 - L1 L3 - L2 4 L1 - L1 L2 - L2 L3 - L3

Figure 14 Grid-side connection for systems with multiple battery systems with three-phase grid monitoring

Installing the device

Page 24 Operating instructions Powador-gridsave_EN

Authorised electrician

722 Connecting the PV generator

Connect the PV generator on the left in the connection area (Figure 13 on page 21) Use the provided M16 cable fittings A maximum of two strings can be connected For this reason a DC string fuse can be dispensed with

DANGERRisk of fatal injury due to contact voltagesRemoving the cables from the terminals without first disconnecting the PV generator from the device can cause serious damage to health or damage to the system rsaquo During installation Electrically disconnect the DC positive and DC negative from the protective

earth (PE) rsaquo Completely de-energise the system (AC home power grid AC circuit breaker residual current circuit

breaker DC isolator switch) rsaquo Disconnect the battery system from the PV generator using the integrated DC isolator switch rsaquo Remove DC plug connectors

NOTEIn accordance with IEC 61730 Class A connected PV modules must be dimensioned for the DC system voltage provided and at least for the value of the AC grid voltage

7221 Before connecting

Ensure that there is no ground fault1 Determine the DC voltage between the

ndash protective earth (PE) and the positive cable of the PV generator and between the ndash protective earth (PE) and the negative cable of the PV generator

If stable voltages can be measured there is a ground fault in the DC generator or its wiring The ratio between the measured voltages gives an indication as to the location of this fault

2 Rectify any faults before taking further measurements3 Determine the electrical resistance between the

ndash protective earth (PE) and the positive cable of the PV generator and between the ndash protective earth (PE) and the negative cable of the PV generator

In addition ensure that the PV generator has a total insulation resistance of more than 20 MOhm since the inverter will not feed in if the insulation resistance is too low

4 Rectify any faults before connecting the DC generator

7222 Connecting the PV generator

DANGERRisk of fatal injury due to electric shockSevere injury or death will result if the live connections are touched When there is solar radiation DC voltage will be present at the open ends of the DC cables rsaquo Do not touch the exposed ends of the cables rsaquo Avoid short circuits

Installing the device

Operating instructions Powador-gridsave_EN Page 25

Authorised electrician

Connecting the PV generator Use cables with the correct cross-section

1 Remove cable fittings for DC connection2 Remove the outer cladding of the DC cables3 Insert the DC cables through the cable fittings into the connection area4 Strip the insulation from the DC cables5 Remove connection terminals6 Connect the cables in line with the terminal labels (See Figure 13 on page 21)7 Close the connection terminals8 Check that all connected cables are securely fitted9 Tighten the cable fittings10 To meet the requirements of protection rating IP21 close the unused cable fittings with blind caps raquo The PV generator is connected to the inverter

73 Connecting the interfaces

731 Ethernet interface

Pre-assembled Ethernet cables can be connected using the RJ45 socket in the connection space

Connecting the Ethernet cable1 Remove closure cap from RJ45 socket2 Connect the Ethernet cable3 The energy management system can now obtain an IP address by DHCP and is also available via this in the

network

NOTEThe network settings can be amended later in the Settings menu using the EMS

NOTEUse a suitable category 5 network cable The maximum length of a network segment is 100 m Ensure that the cable is correctly assigned The Ethernet connection of the battery system supports auto-sensing You can use both crossed and 11 configured Ethernet connection cables

74 Sealing the connection area

1 Finally check the cabling2 Ensure that all cables are firmly mounted3 Check that the cable fitting is secure and tighten if necessary4 Remove cable offcuts and particles of dirt or dust5 Fit the cover and slide back until it engages into position6 Check that the position is correct7 Screw the fastening screw onto the front of the cover

Installing the device

Page 26 Operating instructions Powador-gridsave_EN

Authorised electrician

75 Starting up

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched Only appropriately qualified and authorised electricians may open install or maintain the battery system rsaquo Keep the front doors and covers closed during operation

NOTEInitial start-up should be carried out using the available public AC grid

76 Standard configuration

Factory settingsCountry configuration Germany

Grid guidelines Low voltage directive

Language German

Time UTC +1 Central European Time

User Standard

Network parameters DHCP (network settings will be obtained automatically from the router)

NOTEPlease state the desired power limitation (60 or 70 of the PV system capacity) when you order For other variations please notify your KACO contact so that the parameters can be set at the factory prior to delivery

Installing the device

Operating instructions Powador-gridsave_EN Page 27

Authorised electrician

761 Step 1 AC home power grid

Check all cables and connections before starting up1 Switch on the AC home power grid using the AC main switch raquo Powador-protect measurement and control unit starts up and monitors the AC grid raquo Two green LEDs indicate that the grid parameters are met raquo After a further 60 seconds (shortly after the backlighting in the Powador-protect goes out) the Powador-pro-

tect will switch on the home grid2 Configure Powador-protect according to the enclosed Powador-protect instructions

(The instructions are also available on the website at wwwkaconewenergyde) raquo The AC power is supplied in the normal way by the public grid

762 Step 2 AC supply from the battery system

Check all cables and connections before starting up1 Remove external isolation means from the device2 Switch on the circuit breaker raquo The LCD touchscreen on the front panel comes on and the energy management system (EMS) starts up

3 Switch on the residual current circuit breaker raquo The battery system starts up

763 Step 3 Switch on the PV system

1 Switch on any optional external PV isolator switches2 Set the internal DC isolator switch to ON raquo The inverter and the battery charging unit battery backup converter (BBC) are connected to the PV system raquo The device monitors the PV voltage for approx 60 seconds then optimisation of internal consumption takes

place

764 Step 4 Switch on batteries

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

765 Step 5 Activate energy management

NOTEKACO new energy cannot provide any support for problems regarding the IT infrastructure (eg router configuration IP address assignment ports etc) as the structure settings and configuration of the network environment can be complex and very different from place to place In the event of any problems please contact an IT service provider

Remote access activated 1 Please call the KACO Hotline to make an appointment for activation of energy management

Configuration and Operation

Page 28 Operating instructions Powador-gridsave_EN

Authorised electrician

8 Configuration and Operation

81 ControlsThe battery system is fitted with a touchscreen which allows it to be controlled very precisely In normal operation the display is switched off Touching the screen activates the display and after a configurable period of time without being touched the dis-play will deactivate If the screen-save function is switched off the touchscreen will be on continuously

NOTEDepending on the tolerances of the measuring elements the measured and displayed values are not always the actual values However the measuring elements ensure maximum solar yield Due to these tolerances the daily yields shown on the touchscreen may deviate from the values on the grid operatorrsquos feed-in meter by up to 15

3

1

45

2

Figure 15 Overview (home screen)

Key

1 Home button 4 Current time

2 System components 5 Menu name

3 More information

811 Information about the system

Open start screen View changesjumps to the home screen

Show component detail Parameters of the selected component

Settings Define settings for the active user

raquo Displays settings

Configuration and Operation

Operating instructions Powador-gridsave_EN Page 29

Controls Left arrow jump back to previous menu item Up and down arrows navigate through the menu or change a value

Left arrow displayed value is reduced by one increment Right arrow displayed value is increased by one increment or change to the submenu

Display fields Grey box Text or figures (not selectable) Blue box Calls up submenu for the display in question

Activate and deactivate Activate function by ticking the box

Table 6 Information about the system

812 System components

PV generator Display of the current generator data

power voltage current temperature in the inverter

Battery Display of the current battery status

power (charging or discharging) voltage current charge status available capacity temperature of battery

Grid Display of the following either fed-in or drawn from the grid

power voltage current for phase L1-L3 total output frequency

Consumer (load) Display of the consumer data

power voltage current for phase L1-L3 total output

Energy flow raquo Displays the current energy flow in the system

Table 7 Information about system components

Configuration and Operation

Page 30 Operating instructions Powador-gridsave_EN

813 Menu structure

Icons used

Display menu Submenu

Option menu

Menu Submenu Display setting

Action in this menumeaning

PV generator Details

Power Displays the current DC-side power

Voltage Displays the current DC-side voltage

Current Displays the current DC-side amperage

Temp inverter

Displays the current temperature in the inverter housing

Battery Details

Power Displays the current AC-side power

Voltage Displays the current AC-side voltage

Current Displays the current AC-side amperage

Charge status Displays the current charge status

Capacity Displays the current battery capacity

Temperature Displays the current measured temperature of the battery

Grid Details

Power Displays the current AC-side power being drawn or fed-in

Voltage Displays the AC-side voltage being applied

Current Displays the current AC-side amperage being drawn or fed-in

Total output Displays the current AC-side total output being drawn or fed-in

Frequency Displays the frequency currently being applied to the grid junction

Consumer (load) Details

Power Displays the current AC-side power being drawn

Voltage Displays the current AC-side voltage being applied

Current Displays the current AC-side amperage being drawn

Total output Displays the current AC-side total output being drawn

Configuration and Operation

Operating instructions Powador-gridsave_EN Page 31

Menu Submenu Display setting

Action in this menumeaning

Settings

Country amp directive display

Display of the country settings voltage directives and grid type

Select menu language

DateTime Specify time zone date format and date and time

Screen Activate screen-save function and set the delay period

Network settings

Display of the network settings Configure network settings Once the DHCP server becomes available the IP

address subnet mask gateway and DNS server are automatically applied and the aforemen-tioned menu items are hidden

Off DHCP deactivated make settings manually

Version Displays the installed software version and built-in HW components (inverter BBC battery)

Vendor The touchscreen shows information about the device vendor

NOTEAs changes to the software are possible after the manual has been printed the illustrations and descriptions of the functions in these operating instructions may deviate from the software Please therefore note the current Application Notes on our website

MaintenanceTroubleshooting

Page 32 Operating instructions Powador-gridsave_EN

9 MaintenanceTroubleshooting

91 Visual inspectionInspect the device and the cables for visible external damage and note the operating status display In case of damage notify your installer Repairs may only be carried out by authorised electricians

NOTEThe battery system should be checked for proper operation by a qualified electrician at regular intervals

92 Cleaning the device

DANGERLethal voltages in the battery systemSerious injuries or death can result if moisture enters the system rsaquo Only use completely dry objects to clean the battery system rsaquo Only clean the outside of the battery system

Cleaning the battery system Do not use compressed air Use a vacuum cleaner or a soft brush to remove dust from the fan cover and from the top of the inverter on a

regular basis Remove dust from the ventilation inlets if necessary

MaintenanceTroubleshooting

Operating instructions Powador-gridsave_EN Page 33

Authorised electrician

93 Maintenance

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched The device is only permitted to be opened or serviced by an authorised electrician rsaquo Observe all safety regulations and the current technical connection specifications from the relevant

power supply company rsaquo Disconnect the AC and DC sides rsaquo Secure the AC and DC sides from being inadvertently switched back on rsaquo Only then should the device be opened rsaquo After shutdown wait at least 30 minutes before working on the device

CAUTIONDestruction of the DC connectionThe connection terminals can be destroyed by arcing if disconnected while still live rsaquo It is absolutely essential that the shutdown sequence be carried out in the correct order (See sec-

tion 111 on page 35)

94 Faults

941 Procedure

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched

When a fault occurs notify an appropriately authorised and qualified electrician or KACO new energy GmbH Service

Service

Page 34 Operating instructions Powador-gridsave_EN

10 ServiceIf 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 efficientlybull Serial nobull SW version of the components (the software version can be found in the Settings menu using the EMS)bull Module type and string circuitbull Date of installation Start-up reportbull Consignment identification Delivery address Contact person (with telephone number)bull Information about the accessibility of the installation site

Any additional costs arising from unfavourable structural or mounting conditions shall be billed to the customer

You can find our warranty conditions on our websitehttpkaco-newenergycomservicewarrantyFrom there you can easily navigate to our international websites by clicking on the appropriate flag

Please use our website to register your unit immediatelyYou can also select the appropriate flag on this page to access the website for your own countryIn this manner you can assist us in providing you with the quickest service possible Note The maximum length of the warranty is based on the currently applicable national warranty conditions

We have prepared a template for complaints This can be found at httpskaco-newenergycomservicecustomer-service

Hotlines

Technical troubleshooting Technical consultation

Inverters and battery systems ()

+49 (0) 71323818-660 +49 (0) 71323818-660

Data logging and accessories +49 (0) 71323818-690 +49 (0) 71323818-690

Construction site emergency () +49 (0) 71323818-630

Customer help desk Monday to Friday from 730 am to 530 pm (CET)

() Also on Saturdays from 800 am to 200 pm (CET)

ShutdownDisassembly

Operating instructions Powador-gridsave_EN Page 35

11 ShutdownDisassembly

111 Switching off the device

DANGERLethal voltages are still present in the terminals and cables even after switching off and discon-nection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched rsaquo Complete de-energisation only occurs if the bulk power supply is switched off upstream of the bat-

tery system

DANGERDestruction of the DC plug connectorDC plug connectors can be destroyed by arcing if disconnected while still live rsaquo It is absolutely essential that the following shutdown sequence is observed

1111 Step 1 Shutting down the PV system

1 Switch off any optional external PV isolator switches2 Set the internal DC isolator switch to OFF raquo The inverter and battery charging unit battery backup converter (BBC) are disconnected

1112 Step 2 Disconnect the batteries

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

1113 Step 3 Disconnect the AC supply

1 Connect external isolation means to the device2 Switch off the circuit breaker 3 Switch off the residual current circuit breaker raquo The battery system is switched off

1114 Step 4 AC home power grid

1 Shutdown the AC home power grid using the AC main switch raquo The battery system can be uninstalled

Disposal

Page 36 Operating instructions Powador-gridsave_EN

112 Uninstalling the device

NOTETo uninstall follow the same sequence as for installation but in reverse order

Switch off the device1 Unlock and open the housing door2 Remove the upper cover3 Release the DC and AC cables from the connection terminals4 Pull out the cables raquo The battery system is uninstalled Continue with the disassembly

113 Disassembling the device

NOTETo disassemble follow the same sequence as for assembly but in reverse order

Switch off the device1 Uninstall the components2 Remove the fastening from the device3 Securely pack up the battery system if it is to be used later

or have the battery system disposed of in accordance with section 12 on page 36

12 DisposalFor the most part both the battery system and the corresponding transport packaging are made from recyclable raw materialsBatteries and components Do not dispose of faulty batteries or the components together with household waste Ensure that the old device and accessories are disposed of in a proper mannerPackaging Ensure that the transport packaging is disposed of properlyBatteriesUsed or faulty batteries must be transported in special packaging If you need such packaging please contact the KACO Hotline

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

Appendix

Operating instructions Powador-gridsave_EN Page 37

13 Appendix

EU Declaration of Conformity

Vendorrsquos name and address

KACO new energy GmbH Carl-Zeiss-Straszlige 1 74172 Neckarsulm Germany

Product description Battery system

Type designation Powador-gridsave 135 kWh 6400 Powador-gridsave 135 kWh 8000

Powador-gridsave 270 kWh 6400 Powador-gridsave 270 kWh 8000

Powador-gridsave 405 kWh 6400 Powador-gridsave 405 kWh 8000

Powador-gridsave 540 kWh 6400 Powador-gridsave 540 kWh 8000

Powador-gridsave 577 kWh 6400 Powador-gridsave 577 kWh 8000

Powador-gridsave 675 kWh 6400 Powador-gridsave 675 kWh 8000

This is to confirm that the units listed above comply with the protection requirements set forth in the Directive of the Council of the European Union of 15th December 2004 on the harmonisation of the laws of the member states relating to Electromagnetic Compatibility (2004108EC) and the Low Voltage Directive (200695EC)The units are compliant with the following standards

200695EC ldquoDirective relating to electrical equipment designed for use within specific voltage limitsrdquo

Safety of the unitIEC 62109-12010IEC 62109-22011

2004108EC ldquoDirective relating to electromagneticcompatibilityrdquo

Interference immunityEN 61000-6-22005 Emitted interferenceEN 61000-6-32007

Secondary effects on the gridEN 61000-3-112000EN 61000-3-122005

The types mentioned above are therefore labelled with the CE markUnauthorised modifications to the supplied units andor any use of the units that is contrary to their intended use render this Declaration of Conformity null and void

Neckarsulm 0711 2013KACO new energy GmbH

pp Volker DietrichEnergy systems engineering management

Disposal

Page 38 Operating instructions Powador-gridsave_EN

Carl-Zeiss-Straszlige 1 middot 74172 Neckarsulm middot Germany middot Phone +49 7132 3818-0 middot Fax +49 7132 3818-703 middot infokaco-newenergyde middot wwwkaco-newenergyde

The

text

and

figu

res

refle

ct th

e cu

rren

t tec

hnic

al s

tate

at t

he ti

me

of p

rintin

g S

ubje

ct to

tech

nica

l cha

nges

Err

ors

and

omis

sion

s ex

cept

ed

3006

856-

01-1

4030

5

  • 1General Information
    • 11About this document
    • 12Name plate
    • 13Additional information
    • 14Intended use
      • 2Safety
        • 21Protection features
          • 3Description
            • 31Mode of Operation
            • 32Summary of the components
              • 4Technical Data
                • 41Electrical data
                • 42Mechanical data
                  • 5Transportation and Delivery
                    • 51Delivery
                    • 52Storage
                    • 53Transportation
                      • 6Assembling the device
                        • 61Installation
                        • 62Installing components
                          • 7Installing the device
                            • 71Opening the connection area
                            • 72Making the electrical connection
                            • 73Connecting the interfaces
                            • 74Sealing the connection area
                            • 75Starting up
                            • 76Standard configuration
                              • 8Configuration and Operation
                                • 81Controls
                                  • 9MaintenanceTroubleshooting
                                    • 91Visual inspection
                                    • 92Cleaning the device
                                    • 93Maintenance
                                    • 94Faults
                                      • 10Service
                                      • 11ShutdownDisassembly
                                        • 111Switching off the device
                                        • 112Uninstalling the device
                                        • 113Disassembling the device
                                          • 12Disposal
                                          • 13Appendix

Technical Data

Operating instructions Powador-gridsave_EN Page 11

4 Technical Data

41 Electrical data

Connection box

Home power grid

Input voltage 230V 400V 50Hz 60Hz 3-phase (3 N PE)

Grid configuration TN-C TN-S TT

Grid monitoring Powador-protect (as per VDE-AR-N 4105)

Grid isolation Double insulated 3 or 4 pin

Rated operating current [A] 75

Rated switching current AC-1 [A] 100

Rated switching current AC-3 [A] 50 (22 kW at 400 V)

Connection cross-section [mmsup2] max 25

PV input

Input voltage [V] 300 to 800

Input current [A] 30 String

Strings 2

Isolation Yes rotary switch

Inverter type 6400 8000

Input levels

Max recommended PV generator power [W] 7700 9600

Rated power peak power [VA] 6400 7000 8000 9000

DC MPP range from [V] to [V] 360 590

Open circuit voltage [V] 800

Input current [A] 190 240

cos phi 08 inductive hellip 08 capacitive

Polarity safeguard Short-circuit diode

Feed-in phases 1

Capable of stand-alone operation Yes

Efficiency [] 966

Output levels

Output voltage 230V 50Hz 60Hz 1-phase

Rated current [A] 278 35

Connection cross-section [mmsup2] max 6

Monitoring Isolation Circuit breaker residual current circuit breaker (RCD)

Table 1 Electrical data

Technical Data

Page 12 Operating instructions Powador-gridsave_EN

Battery charging unit battery backup converter (BBC)

BBC power [W] 3300

HV voltage [V] 350 to 600

Battery voltage [V] 38 to 58

Efficiency [] 970

Table 1 Electrical data

42 Mechanical data

Battery system

Display 43 LCD touchscreen

Interfaces RS485 Sym-Bus Ethernet USB digital inputsoutputs

Cable insertion Cable fitting 2x M40 2x M32 4x M25 12x M16

Ambient temperature [degC] 0 +40

Humidity [] lt95 (non-condensing)

Cooling Forced cooling temperature-controlled

Noise emission [dB] lt45

Note regarding cooling Do no cover air inletsoutlets keep clear 20 cm to the right and left

Temperature monitoring Individual monitoring of components with shutdown in the event of excess temperature

Maximum installation elevation [m above mean sea level] 2000

Protection class IP21

Housing form 19 sheet-steel control cabinet

H x W x D [mm] 1600 x 620 x 600

Weight [kg] 2435

Inverter

Ambient temperature range [degC] -20 +60

Temperature monitoring Yes

Cooling Active cooling

Connections Quick INOUT plug connector and busbar clips rear side

H x W x D [mm] 22225 x 4826 x 460

Weight [kg] 25

Table 2 Mechanical data

Technical Data

Operating instructions Powador-gridsave_EN Page 13

Battery charging unit battery backup converter (BBC)

Ambient temperature range [degC] -20 +70

Temperature monitoring Yes

Cooling Active cooling

Housing 19 plug-in module aluminium

Connections Quick INOUT plug connector and busbar clips rear side

H x W x D [mm] 13325 x 4826 x 460

Weight [kg] 15

Temperature-dependent impedance matching with shutdown if the temperature is too high

Table 2 Mechanical data

Transportation and Delivery

Page 14 Operating instructions Powador-gridsave_EN

5 Transportation and Delivery

51 DeliveryThe battery system leaves KACO new energy in fully functional electrical and mechanical condition Special packaging ensures that the units are transported safely The shipping company is responsible for any trans-port damage that occurs

511 Scope of delivery

Pallet A B

Figure Figure 7 Scope of delivery pallet A Figure 8 Scope of delivery pallet B

Contents bull Battery system Powador-gridsave (incl connection box battery management system (BMS) industrial PC Plexiglas cover and accessories)

bull Inverter bull Battery charging unit battery backup converter

(BBC)bull Battery system plug-in modules 1-5 ST (scope of

delivery can be found on the delivery document)bull Documentation

Weight (kg) 187 max 155 177 (without with Euro pool pallet)

H x W x D [mm] 1780x800x820 1200x1200x800

Packaging Cardboard box with polystyrene inserts and closures

512 Check the equipment included

bull Battery system and plug-in modules should be inspected thoroughly for transport damagebull Do not install damaged components in the control cabinetbull In the event of damage to the battery plug-in modules contact the KACO new energy Hotline immediately

Transportation and Delivery

Operating instructions Powador-gridsave_EN Page 15

Authorised electrician

DANGERRisk of fatal injury if incompatible components are usedThe battery and power electronics can be damaged if different delivery batches are combined and will carry potentially fatal voltages if connected rsaquo Assemble the system using the components provided by KACO new energy only rsaquo Check the serial numbers on the delivery document against the serial numbers of the individual

units on pallets A and B

52 StorageIncorrect storage can lead to system malfunctions Therefore please observe the following conditionsbull If storing for longer than six months store the device in an interior room in its original packaging bull If the original packaging has been removed store the device in a cool dry interior roombull Storage temperature -20 degC to +70 degCbull Relative humidity 0 to 95 (non-condensing)bull If the device is stored for a relatively long time at high humidity the device must be left for more than one day to

dry out sufficiently before connection to the power grid

53 Transportation

WARNINGImpact hazard risk of breakage to the components in the battery systemThe centre of gravity is located in the upper part of the device rsaquo Transport the device upright together with the pallet rsaquo Do not expose the device or components to any shocks rsaquo After unloading at least two people are required to transport the cabinet

WARNINGDanger due to impact and incorrect storage of the batteriesIn the event of damage batteries can release hazardous electrolyte gases which will cause irreversible burns if they come into contact with the skin rsaquo Transport the batteries in the vendors original packaging only rsaquo Remove the batteries from the original packaging shortly before installation rsaquo Do not store batteries in cars or outdoors rsaquo Check the condition of the battery before use

NOTEThe precise specifications of the UN on the transport of lithium batteries can be found under the designation Model Regulations on the transport of dangerous goods Ref STSGAC101 Recommendations on the transport of dangerous goods Part III sub-section 383 ldquoManual of Tests and Criteriardquo Ref STSGAC1011

Assembling the device

Page 16 Operating instructions Powador-gridsave_EN

Authorised electrician

6 Assembling the device

61 Installation

DANGERRisk of fatal injury from fire or explosionsFire caused by flammable or explosive materials in the vicinity of the battery system can lead to serious injuries rsaquo Do not mount the inverter in potentially explosive atmospheres or in the vicinity of highly flamma-

ble materials

CAUTIONBattery system is very heavy ndash risk of injury rsaquo Be aware of the weight of the battery system during transport rsaquo Select suitable mounting location and mounting base rsaquo Only install the battery system with the help of a second person

CAUTIONEquipment damage caused by aggressive gases in combination with humidityThe housing may be seriously damaged by aggressive gases (ammonia sulphur and other chemi-cals) in combination with ambient humidity caused by weather conditions - Installation in rooms containing aggressive gases is not permitted

NOTEAccess in the event of maintenance or serviceAny additional costs arising from unfavourable structural or mounting conditions in the event of a KACO service call-out shall be billed to the customer

611 Installation location

bull Dry well ventilated the waste heat must be conducted away from the battery systembull Unobstructed air circulationbull Easily accessible from the front top and sides without requiring additional resourcesbull Indoors protected against direct sunlight and direct water contact

612 Foundation

bull With sufficient load-bearing capacitybull Made from heat-resistant material (up to 90 degC)bull Must be flame resistant

NOTEPower reduction due to heat accumulationIf the recommended minimum clearances are not observed the device may go into power regula-tion mode due to insufficient ventilation and the resulting heat build-up rsaquo The construction and installation of the device may be performed only by a qualified electrician in

accordance with the valid standards and regulations rsaquo Maintain minimum clearances rsaquo Ensure sufficient heat dissipation

Assembling the device

Operating instructions Powador-gridsave_EN Page 17

Authorised electrician

0deg

1000 mm

200 mm 200 mm

500 mm

min carrying capacity 300 kgmsup2

200 mm200 mm

50 mm

Figure 9 Minimum clearances at the installation and assembly location

CAUTIONRisk of injury if the battery system tips overRisk of tipping due to high centre of gravity particularly with the door open rsaquo Anchor the device securely to the floor immediately after installation rsaquo Open the housing door using the enclosed cabinet key only once the device has been securely

anchored

510 mm200 mm

200 mm

400

mm

12 mmmin 110 mm

DesignationHex head wood screw 8x80 DIN571-vz Fischer dowel S12 Flat washer M8 galvanised DIN9021-vz

Units444

Figure 10 Dimensions for anchoring to the floor Table 3 Mounting parts

62 Installing components

CAUTIONAvoid improper handlingImproper handling can cause damage to components rsaquo Damaged components must not be installed rsaquo Always put the plug-in modules down horizontally to avoid damage to the components

Assembling the device

Page 18 Operating instructions Powador-gridsave_EN

Authorised electrician

WARNINGDanger caused by short circuit or sparkingSerious injury from touching or connecting live components rsaquo Damaged components must not be installed

Preparation1 Check the conditions for the installation location2 Open the housing doors using the enclosed cabinet key3 The cables should be professionally laid and prepared for connection4 Follow the installation sequence (1-4 step(s))

621 Step 1 Fit the battery (batteries)

NOTEPlease read the notes on installation and connection in the enclosed manual Features for the battery unit

622 Step 2 Connect battery (batteries) to the battery management system (BMS)

NOTEPlease read the notes on installation and connection in the enclosed manual Features for the battery unit

623 Step 3 Fit the battery charging unit battery backup converter (BBC)

Battery (batteries) connected to the battery management system (BMS)1 Carefully insert battery charging unit battery backup converter (BBC) into the compartment provided for it 2 Push in completely to establish direct contact with the rear busbars3 Secure battery charging unit battery backup converter (BBC) using the screws supplied

624 Step 4 Fit the inverter

Battery charging unit battery backup converter (BBC) is fitted1 Carefully insert inverter into the compartment provided for it 2 Push in completely to establish direct contact with the rear busbars 3 Secure inverter using the screws supplied

CAUTIONDamage to the control unit from introducing foreign objectsForeign objects can impair the function of the control unit and cause damage rsaquo Do not remove the front panel rsaquo Foreign objects should be removed immediately

Installing the device

Operating instructions Powador-gridsave_EN Page 19

Authorised electrician

7 Installing the device

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched The device may only be opened or serviced by an authorised electricianThe device must be completely assembled before being connected electrically rsaquo Observe all safety regulations and current technical connection specifications of the responsible

power supply company rsaquo De-energise the device using the DC isolator switch circuit breaker and residual current circuit

breaker rsaquo Secure both sides against being inadvertently switched back on rsaquo Ensure that the AC and DC sides are completely isolated and voltage free rsaquo Never open the plug-in modules rsaquo Hazardous voltages are present at the busbars rsaquo Disconnect from the grid and plant supply rsaquo First connect the battery system in the connection area

71 Opening the connection area

3

1

2

Figure 11 Open cover plateKey

1 Cover plate 3 Fastening screw

2 Lock

Opening the connection area You have completed assembly

1 Remove the fastening screw for the upper cover plate2 Slide the cover plate forwards out of the lock3 Lift the cover plate upward to remove raquo Make the electrical connection

Installing the device

Page 20 Operating instructions Powador-gridsave_EN

Authorised electrician

72 Making the electrical connectionMake the connection to the PV generator as well as the grid connection using the connection terminals Note the following cable cross-sections

Connection Possible cable cross-section Length of insulation to be stripped offAC home power grid 05 - 16 mmsup2 with end sleeve

05 - 25 mmsup2 without end sleeve18 mm sleeve18-20 mm

PV connection 05 - 16 mmsup2 with end sleeve05 - 25 mmsup2 without end sleeve

18 mm sleeve17-19 mm

Inverter output 05 - 4 mmsup2 with end sleeve05 - 6 mmsup2 without end sleeve

12 mm sleeve11-13 mm

Potential-free contacts 034 - 15 mmsup2 with end sleeve034 - 25 mmsup2 without end sleeve

12 mm sleeve 9-10 mm

Table 4 Cable cross-sections for connection terminals

NOTEThe threaded connections should be matched to the cable cross-section

NOTEOnly conductors and no insulation should be inserted into the connection terminals Individual wires or cables with end sleeves with the appropriate cross-section can be inserted directly into the connection terminal without a toolFine-strand cables without end sleeve or thin conductors will need a screwdriver (plain slot 35 mm) for connection To do this insert the blade of the screwdriver into the recess provided The cable can be inserted into the spring terminal by pressing downwards The spring terminal closes on removal of the screw-driver

Installing the device

Operating instructions Powador-gridsave_EN Page 21

Authorised electrician

X2X1F1 F2 X7 X4 St1

St2

St3

2 3 541 6

Figure 12 View from above of the connection area

Key

1 AC grid input (M40 cable fitting) 4 Network interface (M32 cable fitting)

2 AC grid output (M40 cable fitting) 5 Inverter input (M16 cable fitting)

3 Inverter output (M32 cable fitting) 6 Other connections (M16 cable fitting)

F1 F2 X7 X4 St1

St2

St3

L1 L2 L3 N PE L1 L2 L3 N N PE PE

X1 X2

PV+

PV-

L1 L2 L3 N PE32A 32A PEN

Cust

omer

co

nnec

tion

Figure 13 View from above of the connection area

Key

X1 AC grid input (main junction box meter) X7 PV generator input

X2 AC grid output (building electrical system) F1 F2 Phase bridging fuse

X4 Inverter output St 1-3 Potential-free contacts control outputs

Installing the device

Page 22 Operating instructions Powador-gridsave_EN

Authorised electrician

721 Connecting to the power grid

Because the device is installed between the main junction boxmeter and the buildings electrical system the maxi-mum grid current to the service line must not exceed the rated operating current of the battery system The cable cross-section must be selected in accordance with applicable standards to suit the connected load instal-lation type etc Moreover the terminal area and size of the cable fitting must be noted

NOTEThe fuse rating for the cable should be max 63A (automatic circuit breaker or safety fuse) even if the cross-section of the installed cable would permit a higher fuse rating Always follow the applicable regulations regarding the cable cross-section and installation typeThe device supports standard grid configurations such as TN-C TN-S and TT TN-SIf a TN-S grid is present directly at the power input and output of the device L1-L3 N and PE must each be connected The home power grid should have 4-pin isolationTN-C4-pin grid isolation is factory preset and disconnects L1 L2 L3 and N In a TN-C grid the N conduc-tor must not be disconnected If a TN-S grid is present directly at the power input and output of the device a cable bridge (included in delivery) must be installed between the N terminal on X1 and the N terminal on X2 N and PE must additionally be connected together To do this simply insert the enclosed terminal link into the N and PE terminals TTIn the case of a TT grid L1-L3 N and PE must each be connected The home power grid should have 4-pin isolation

NOTEPlease check with the operator of the mains grid whether there are special regulations for grid connection Grid isolation is factory preset to 4-pin is fail-safe and provided with grid and system protection as per VDE-AR-N 4105

Making the grid connection Use cables with 5 wires (L1 brown L2 black L3 grey N blue PE greenyellow) and the correct

cross-section1 Loosen cable fitting for AC connection2 Remove the outer cladding of the AC cables3 Insert the AC cables through the cable fitting into the connection area4 Strip the insulation from the AC cables5 Remove connection terminals6 Connect the cables in line with the terminal labels (Figure 13 on page 21)7 Close the connection terminals8 Check that all connected cables are securely fitted9 Tighten the cable fitting10 To meet the requirements of protection rating IP21 close the unused cable fittings with blind caps raquo The battery system is connected to the power grid

NOTEAn AC-side disconnection unit must be provided during the final installation stage This disconnec-tion unit must be installed so that it can be accessed at any time without obstruction If a residual current circuit breaker is necessary due to the installation specification a type A residual current circuit breaker must be used

Installing the device

Operating instructions Powador-gridsave_EN Page 23

Authorised electrician

7211 Output from the inverterRecommended cable cross-sections for the inverter output and fuse rating of cables for fixed wiring accord-ing to VDE 0100 part 430The fuse rating for the cable is dependent on the cable cross-section max 40A automatic circuit breaker

NOTEWhen the line resistance is high (ie long grid-side cables) the voltage at the grid terminals of the inverter will increase during feed-in to the grid The inverter monitors this voltage If the voltage exceeds the country-specific grid overvoltage limit value the inverter switches off rsaquo Ensure that the conductor cross-sections are sufficiently large or that the cable lengths are suffi-

ciently short

NOTEIn order to avoid asymmetries in the grid systems with multiple battery systems should be designed so that the inverters in the devices feed into the grid in differing phases rsaquo Follow the connection conditions for the particular type of grid and the schematic illustration

below

Country and grid-type

Grid monitoring Required monitoring

max asymmetry between phases L1L2L3

DE-NSP Three-phase or single phase phase unbalanced load 46 kVA

Table 5 Grid-type-specific connection conditions

L1

L2

L3

N

Connection X1 Connection X1 Connection X1 Connection X1

L1 L2 L3 N PE L1 L2 L3 N PE L1 L2 L3 N PE L1 L2 L3 N PE

Powador-gridsave inverter1 L1 - L1 L2 - L2 L3 - L32 L1 - L2 L2 - L3 L3 - L1 3 L1 - L3 L2 - L1 L3 - L2 4 L1 - L1 L2 - L2 L3 - L3

Figure 14 Grid-side connection for systems with multiple battery systems with three-phase grid monitoring

Installing the device

Page 24 Operating instructions Powador-gridsave_EN

Authorised electrician

722 Connecting the PV generator

Connect the PV generator on the left in the connection area (Figure 13 on page 21) Use the provided M16 cable fittings A maximum of two strings can be connected For this reason a DC string fuse can be dispensed with

DANGERRisk of fatal injury due to contact voltagesRemoving the cables from the terminals without first disconnecting the PV generator from the device can cause serious damage to health or damage to the system rsaquo During installation Electrically disconnect the DC positive and DC negative from the protective

earth (PE) rsaquo Completely de-energise the system (AC home power grid AC circuit breaker residual current circuit

breaker DC isolator switch) rsaquo Disconnect the battery system from the PV generator using the integrated DC isolator switch rsaquo Remove DC plug connectors

NOTEIn accordance with IEC 61730 Class A connected PV modules must be dimensioned for the DC system voltage provided and at least for the value of the AC grid voltage

7221 Before connecting

Ensure that there is no ground fault1 Determine the DC voltage between the

ndash protective earth (PE) and the positive cable of the PV generator and between the ndash protective earth (PE) and the negative cable of the PV generator

If stable voltages can be measured there is a ground fault in the DC generator or its wiring The ratio between the measured voltages gives an indication as to the location of this fault

2 Rectify any faults before taking further measurements3 Determine the electrical resistance between the

ndash protective earth (PE) and the positive cable of the PV generator and between the ndash protective earth (PE) and the negative cable of the PV generator

In addition ensure that the PV generator has a total insulation resistance of more than 20 MOhm since the inverter will not feed in if the insulation resistance is too low

4 Rectify any faults before connecting the DC generator

7222 Connecting the PV generator

DANGERRisk of fatal injury due to electric shockSevere injury or death will result if the live connections are touched When there is solar radiation DC voltage will be present at the open ends of the DC cables rsaquo Do not touch the exposed ends of the cables rsaquo Avoid short circuits

Installing the device

Operating instructions Powador-gridsave_EN Page 25

Authorised electrician

Connecting the PV generator Use cables with the correct cross-section

1 Remove cable fittings for DC connection2 Remove the outer cladding of the DC cables3 Insert the DC cables through the cable fittings into the connection area4 Strip the insulation from the DC cables5 Remove connection terminals6 Connect the cables in line with the terminal labels (See Figure 13 on page 21)7 Close the connection terminals8 Check that all connected cables are securely fitted9 Tighten the cable fittings10 To meet the requirements of protection rating IP21 close the unused cable fittings with blind caps raquo The PV generator is connected to the inverter

73 Connecting the interfaces

731 Ethernet interface

Pre-assembled Ethernet cables can be connected using the RJ45 socket in the connection space

Connecting the Ethernet cable1 Remove closure cap from RJ45 socket2 Connect the Ethernet cable3 The energy management system can now obtain an IP address by DHCP and is also available via this in the

network

NOTEThe network settings can be amended later in the Settings menu using the EMS

NOTEUse a suitable category 5 network cable The maximum length of a network segment is 100 m Ensure that the cable is correctly assigned The Ethernet connection of the battery system supports auto-sensing You can use both crossed and 11 configured Ethernet connection cables

74 Sealing the connection area

1 Finally check the cabling2 Ensure that all cables are firmly mounted3 Check that the cable fitting is secure and tighten if necessary4 Remove cable offcuts and particles of dirt or dust5 Fit the cover and slide back until it engages into position6 Check that the position is correct7 Screw the fastening screw onto the front of the cover

Installing the device

Page 26 Operating instructions Powador-gridsave_EN

Authorised electrician

75 Starting up

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched Only appropriately qualified and authorised electricians may open install or maintain the battery system rsaquo Keep the front doors and covers closed during operation

NOTEInitial start-up should be carried out using the available public AC grid

76 Standard configuration

Factory settingsCountry configuration Germany

Grid guidelines Low voltage directive

Language German

Time UTC +1 Central European Time

User Standard

Network parameters DHCP (network settings will be obtained automatically from the router)

NOTEPlease state the desired power limitation (60 or 70 of the PV system capacity) when you order For other variations please notify your KACO contact so that the parameters can be set at the factory prior to delivery

Installing the device

Operating instructions Powador-gridsave_EN Page 27

Authorised electrician

761 Step 1 AC home power grid

Check all cables and connections before starting up1 Switch on the AC home power grid using the AC main switch raquo Powador-protect measurement and control unit starts up and monitors the AC grid raquo Two green LEDs indicate that the grid parameters are met raquo After a further 60 seconds (shortly after the backlighting in the Powador-protect goes out) the Powador-pro-

tect will switch on the home grid2 Configure Powador-protect according to the enclosed Powador-protect instructions

(The instructions are also available on the website at wwwkaconewenergyde) raquo The AC power is supplied in the normal way by the public grid

762 Step 2 AC supply from the battery system

Check all cables and connections before starting up1 Remove external isolation means from the device2 Switch on the circuit breaker raquo The LCD touchscreen on the front panel comes on and the energy management system (EMS) starts up

3 Switch on the residual current circuit breaker raquo The battery system starts up

763 Step 3 Switch on the PV system

1 Switch on any optional external PV isolator switches2 Set the internal DC isolator switch to ON raquo The inverter and the battery charging unit battery backup converter (BBC) are connected to the PV system raquo The device monitors the PV voltage for approx 60 seconds then optimisation of internal consumption takes

place

764 Step 4 Switch on batteries

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

765 Step 5 Activate energy management

NOTEKACO new energy cannot provide any support for problems regarding the IT infrastructure (eg router configuration IP address assignment ports etc) as the structure settings and configuration of the network environment can be complex and very different from place to place In the event of any problems please contact an IT service provider

Remote access activated 1 Please call the KACO Hotline to make an appointment for activation of energy management

Configuration and Operation

Page 28 Operating instructions Powador-gridsave_EN

Authorised electrician

8 Configuration and Operation

81 ControlsThe battery system is fitted with a touchscreen which allows it to be controlled very precisely In normal operation the display is switched off Touching the screen activates the display and after a configurable period of time without being touched the dis-play will deactivate If the screen-save function is switched off the touchscreen will be on continuously

NOTEDepending on the tolerances of the measuring elements the measured and displayed values are not always the actual values However the measuring elements ensure maximum solar yield Due to these tolerances the daily yields shown on the touchscreen may deviate from the values on the grid operatorrsquos feed-in meter by up to 15

3

1

45

2

Figure 15 Overview (home screen)

Key

1 Home button 4 Current time

2 System components 5 Menu name

3 More information

811 Information about the system

Open start screen View changesjumps to the home screen

Show component detail Parameters of the selected component

Settings Define settings for the active user

raquo Displays settings

Configuration and Operation

Operating instructions Powador-gridsave_EN Page 29

Controls Left arrow jump back to previous menu item Up and down arrows navigate through the menu or change a value

Left arrow displayed value is reduced by one increment Right arrow displayed value is increased by one increment or change to the submenu

Display fields Grey box Text or figures (not selectable) Blue box Calls up submenu for the display in question

Activate and deactivate Activate function by ticking the box

Table 6 Information about the system

812 System components

PV generator Display of the current generator data

power voltage current temperature in the inverter

Battery Display of the current battery status

power (charging or discharging) voltage current charge status available capacity temperature of battery

Grid Display of the following either fed-in or drawn from the grid

power voltage current for phase L1-L3 total output frequency

Consumer (load) Display of the consumer data

power voltage current for phase L1-L3 total output

Energy flow raquo Displays the current energy flow in the system

Table 7 Information about system components

Configuration and Operation

Page 30 Operating instructions Powador-gridsave_EN

813 Menu structure

Icons used

Display menu Submenu

Option menu

Menu Submenu Display setting

Action in this menumeaning

PV generator Details

Power Displays the current DC-side power

Voltage Displays the current DC-side voltage

Current Displays the current DC-side amperage

Temp inverter

Displays the current temperature in the inverter housing

Battery Details

Power Displays the current AC-side power

Voltage Displays the current AC-side voltage

Current Displays the current AC-side amperage

Charge status Displays the current charge status

Capacity Displays the current battery capacity

Temperature Displays the current measured temperature of the battery

Grid Details

Power Displays the current AC-side power being drawn or fed-in

Voltage Displays the AC-side voltage being applied

Current Displays the current AC-side amperage being drawn or fed-in

Total output Displays the current AC-side total output being drawn or fed-in

Frequency Displays the frequency currently being applied to the grid junction

Consumer (load) Details

Power Displays the current AC-side power being drawn

Voltage Displays the current AC-side voltage being applied

Current Displays the current AC-side amperage being drawn

Total output Displays the current AC-side total output being drawn

Configuration and Operation

Operating instructions Powador-gridsave_EN Page 31

Menu Submenu Display setting

Action in this menumeaning

Settings

Country amp directive display

Display of the country settings voltage directives and grid type

Select menu language

DateTime Specify time zone date format and date and time

Screen Activate screen-save function and set the delay period

Network settings

Display of the network settings Configure network settings Once the DHCP server becomes available the IP

address subnet mask gateway and DNS server are automatically applied and the aforemen-tioned menu items are hidden

Off DHCP deactivated make settings manually

Version Displays the installed software version and built-in HW components (inverter BBC battery)

Vendor The touchscreen shows information about the device vendor

NOTEAs changes to the software are possible after the manual has been printed the illustrations and descriptions of the functions in these operating instructions may deviate from the software Please therefore note the current Application Notes on our website

MaintenanceTroubleshooting

Page 32 Operating instructions Powador-gridsave_EN

9 MaintenanceTroubleshooting

91 Visual inspectionInspect the device and the cables for visible external damage and note the operating status display In case of damage notify your installer Repairs may only be carried out by authorised electricians

NOTEThe battery system should be checked for proper operation by a qualified electrician at regular intervals

92 Cleaning the device

DANGERLethal voltages in the battery systemSerious injuries or death can result if moisture enters the system rsaquo Only use completely dry objects to clean the battery system rsaquo Only clean the outside of the battery system

Cleaning the battery system Do not use compressed air Use a vacuum cleaner or a soft brush to remove dust from the fan cover and from the top of the inverter on a

regular basis Remove dust from the ventilation inlets if necessary

MaintenanceTroubleshooting

Operating instructions Powador-gridsave_EN Page 33

Authorised electrician

93 Maintenance

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched The device is only permitted to be opened or serviced by an authorised electrician rsaquo Observe all safety regulations and the current technical connection specifications from the relevant

power supply company rsaquo Disconnect the AC and DC sides rsaquo Secure the AC and DC sides from being inadvertently switched back on rsaquo Only then should the device be opened rsaquo After shutdown wait at least 30 minutes before working on the device

CAUTIONDestruction of the DC connectionThe connection terminals can be destroyed by arcing if disconnected while still live rsaquo It is absolutely essential that the shutdown sequence be carried out in the correct order (See sec-

tion 111 on page 35)

94 Faults

941 Procedure

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched

When a fault occurs notify an appropriately authorised and qualified electrician or KACO new energy GmbH Service

Service

Page 34 Operating instructions Powador-gridsave_EN

10 ServiceIf 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 efficientlybull Serial nobull SW version of the components (the software version can be found in the Settings menu using the EMS)bull Module type and string circuitbull Date of installation Start-up reportbull Consignment identification Delivery address Contact person (with telephone number)bull Information about the accessibility of the installation site

Any additional costs arising from unfavourable structural or mounting conditions shall be billed to the customer

You can find our warranty conditions on our websitehttpkaco-newenergycomservicewarrantyFrom there you can easily navigate to our international websites by clicking on the appropriate flag

Please use our website to register your unit immediatelyYou can also select the appropriate flag on this page to access the website for your own countryIn this manner you can assist us in providing you with the quickest service possible Note The maximum length of the warranty is based on the currently applicable national warranty conditions

We have prepared a template for complaints This can be found at httpskaco-newenergycomservicecustomer-service

Hotlines

Technical troubleshooting Technical consultation

Inverters and battery systems ()

+49 (0) 71323818-660 +49 (0) 71323818-660

Data logging and accessories +49 (0) 71323818-690 +49 (0) 71323818-690

Construction site emergency () +49 (0) 71323818-630

Customer help desk Monday to Friday from 730 am to 530 pm (CET)

() Also on Saturdays from 800 am to 200 pm (CET)

ShutdownDisassembly

Operating instructions Powador-gridsave_EN Page 35

11 ShutdownDisassembly

111 Switching off the device

DANGERLethal voltages are still present in the terminals and cables even after switching off and discon-nection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched rsaquo Complete de-energisation only occurs if the bulk power supply is switched off upstream of the bat-

tery system

DANGERDestruction of the DC plug connectorDC plug connectors can be destroyed by arcing if disconnected while still live rsaquo It is absolutely essential that the following shutdown sequence is observed

1111 Step 1 Shutting down the PV system

1 Switch off any optional external PV isolator switches2 Set the internal DC isolator switch to OFF raquo The inverter and battery charging unit battery backup converter (BBC) are disconnected

1112 Step 2 Disconnect the batteries

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

1113 Step 3 Disconnect the AC supply

1 Connect external isolation means to the device2 Switch off the circuit breaker 3 Switch off the residual current circuit breaker raquo The battery system is switched off

1114 Step 4 AC home power grid

1 Shutdown the AC home power grid using the AC main switch raquo The battery system can be uninstalled

Disposal

Page 36 Operating instructions Powador-gridsave_EN

112 Uninstalling the device

NOTETo uninstall follow the same sequence as for installation but in reverse order

Switch off the device1 Unlock and open the housing door2 Remove the upper cover3 Release the DC and AC cables from the connection terminals4 Pull out the cables raquo The battery system is uninstalled Continue with the disassembly

113 Disassembling the device

NOTETo disassemble follow the same sequence as for assembly but in reverse order

Switch off the device1 Uninstall the components2 Remove the fastening from the device3 Securely pack up the battery system if it is to be used later

or have the battery system disposed of in accordance with section 12 on page 36

12 DisposalFor the most part both the battery system and the corresponding transport packaging are made from recyclable raw materialsBatteries and components Do not dispose of faulty batteries or the components together with household waste Ensure that the old device and accessories are disposed of in a proper mannerPackaging Ensure that the transport packaging is disposed of properlyBatteriesUsed or faulty batteries must be transported in special packaging If you need such packaging please contact the KACO Hotline

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

Appendix

Operating instructions Powador-gridsave_EN Page 37

13 Appendix

EU Declaration of Conformity

Vendorrsquos name and address

KACO new energy GmbH Carl-Zeiss-Straszlige 1 74172 Neckarsulm Germany

Product description Battery system

Type designation Powador-gridsave 135 kWh 6400 Powador-gridsave 135 kWh 8000

Powador-gridsave 270 kWh 6400 Powador-gridsave 270 kWh 8000

Powador-gridsave 405 kWh 6400 Powador-gridsave 405 kWh 8000

Powador-gridsave 540 kWh 6400 Powador-gridsave 540 kWh 8000

Powador-gridsave 577 kWh 6400 Powador-gridsave 577 kWh 8000

Powador-gridsave 675 kWh 6400 Powador-gridsave 675 kWh 8000

This is to confirm that the units listed above comply with the protection requirements set forth in the Directive of the Council of the European Union of 15th December 2004 on the harmonisation of the laws of the member states relating to Electromagnetic Compatibility (2004108EC) and the Low Voltage Directive (200695EC)The units are compliant with the following standards

200695EC ldquoDirective relating to electrical equipment designed for use within specific voltage limitsrdquo

Safety of the unitIEC 62109-12010IEC 62109-22011

2004108EC ldquoDirective relating to electromagneticcompatibilityrdquo

Interference immunityEN 61000-6-22005 Emitted interferenceEN 61000-6-32007

Secondary effects on the gridEN 61000-3-112000EN 61000-3-122005

The types mentioned above are therefore labelled with the CE markUnauthorised modifications to the supplied units andor any use of the units that is contrary to their intended use render this Declaration of Conformity null and void

Neckarsulm 0711 2013KACO new energy GmbH

pp Volker DietrichEnergy systems engineering management

Disposal

Page 38 Operating instructions Powador-gridsave_EN

Carl-Zeiss-Straszlige 1 middot 74172 Neckarsulm middot Germany middot Phone +49 7132 3818-0 middot Fax +49 7132 3818-703 middot infokaco-newenergyde middot wwwkaco-newenergyde

The

text

and

figu

res

refle

ct th

e cu

rren

t tec

hnic

al s

tate

at t

he ti

me

of p

rintin

g S

ubje

ct to

tech

nica

l cha

nges

Err

ors

and

omis

sion

s ex

cept

ed

3006

856-

01-1

4030

5

  • 1General Information
    • 11About this document
    • 12Name plate
    • 13Additional information
    • 14Intended use
      • 2Safety
        • 21Protection features
          • 3Description
            • 31Mode of Operation
            • 32Summary of the components
              • 4Technical Data
                • 41Electrical data
                • 42Mechanical data
                  • 5Transportation and Delivery
                    • 51Delivery
                    • 52Storage
                    • 53Transportation
                      • 6Assembling the device
                        • 61Installation
                        • 62Installing components
                          • 7Installing the device
                            • 71Opening the connection area
                            • 72Making the electrical connection
                            • 73Connecting the interfaces
                            • 74Sealing the connection area
                            • 75Starting up
                            • 76Standard configuration
                              • 8Configuration and Operation
                                • 81Controls
                                  • 9MaintenanceTroubleshooting
                                    • 91Visual inspection
                                    • 92Cleaning the device
                                    • 93Maintenance
                                    • 94Faults
                                      • 10Service
                                      • 11ShutdownDisassembly
                                        • 111Switching off the device
                                        • 112Uninstalling the device
                                        • 113Disassembling the device
                                          • 12Disposal
                                          • 13Appendix

Technical Data

Page 12 Operating instructions Powador-gridsave_EN

Battery charging unit battery backup converter (BBC)

BBC power [W] 3300

HV voltage [V] 350 to 600

Battery voltage [V] 38 to 58

Efficiency [] 970

Table 1 Electrical data

42 Mechanical data

Battery system

Display 43 LCD touchscreen

Interfaces RS485 Sym-Bus Ethernet USB digital inputsoutputs

Cable insertion Cable fitting 2x M40 2x M32 4x M25 12x M16

Ambient temperature [degC] 0 +40

Humidity [] lt95 (non-condensing)

Cooling Forced cooling temperature-controlled

Noise emission [dB] lt45

Note regarding cooling Do no cover air inletsoutlets keep clear 20 cm to the right and left

Temperature monitoring Individual monitoring of components with shutdown in the event of excess temperature

Maximum installation elevation [m above mean sea level] 2000

Protection class IP21

Housing form 19 sheet-steel control cabinet

H x W x D [mm] 1600 x 620 x 600

Weight [kg] 2435

Inverter

Ambient temperature range [degC] -20 +60

Temperature monitoring Yes

Cooling Active cooling

Connections Quick INOUT plug connector and busbar clips rear side

H x W x D [mm] 22225 x 4826 x 460

Weight [kg] 25

Table 2 Mechanical data

Technical Data

Operating instructions Powador-gridsave_EN Page 13

Battery charging unit battery backup converter (BBC)

Ambient temperature range [degC] -20 +70

Temperature monitoring Yes

Cooling Active cooling

Housing 19 plug-in module aluminium

Connections Quick INOUT plug connector and busbar clips rear side

H x W x D [mm] 13325 x 4826 x 460

Weight [kg] 15

Temperature-dependent impedance matching with shutdown if the temperature is too high

Table 2 Mechanical data

Transportation and Delivery

Page 14 Operating instructions Powador-gridsave_EN

5 Transportation and Delivery

51 DeliveryThe battery system leaves KACO new energy in fully functional electrical and mechanical condition Special packaging ensures that the units are transported safely The shipping company is responsible for any trans-port damage that occurs

511 Scope of delivery

Pallet A B

Figure Figure 7 Scope of delivery pallet A Figure 8 Scope of delivery pallet B

Contents bull Battery system Powador-gridsave (incl connection box battery management system (BMS) industrial PC Plexiglas cover and accessories)

bull Inverter bull Battery charging unit battery backup converter

(BBC)bull Battery system plug-in modules 1-5 ST (scope of

delivery can be found on the delivery document)bull Documentation

Weight (kg) 187 max 155 177 (without with Euro pool pallet)

H x W x D [mm] 1780x800x820 1200x1200x800

Packaging Cardboard box with polystyrene inserts and closures

512 Check the equipment included

bull Battery system and plug-in modules should be inspected thoroughly for transport damagebull Do not install damaged components in the control cabinetbull In the event of damage to the battery plug-in modules contact the KACO new energy Hotline immediately

Transportation and Delivery

Operating instructions Powador-gridsave_EN Page 15

Authorised electrician

DANGERRisk of fatal injury if incompatible components are usedThe battery and power electronics can be damaged if different delivery batches are combined and will carry potentially fatal voltages if connected rsaquo Assemble the system using the components provided by KACO new energy only rsaquo Check the serial numbers on the delivery document against the serial numbers of the individual

units on pallets A and B

52 StorageIncorrect storage can lead to system malfunctions Therefore please observe the following conditionsbull If storing for longer than six months store the device in an interior room in its original packaging bull If the original packaging has been removed store the device in a cool dry interior roombull Storage temperature -20 degC to +70 degCbull Relative humidity 0 to 95 (non-condensing)bull If the device is stored for a relatively long time at high humidity the device must be left for more than one day to

dry out sufficiently before connection to the power grid

53 Transportation

WARNINGImpact hazard risk of breakage to the components in the battery systemThe centre of gravity is located in the upper part of the device rsaquo Transport the device upright together with the pallet rsaquo Do not expose the device or components to any shocks rsaquo After unloading at least two people are required to transport the cabinet

WARNINGDanger due to impact and incorrect storage of the batteriesIn the event of damage batteries can release hazardous electrolyte gases which will cause irreversible burns if they come into contact with the skin rsaquo Transport the batteries in the vendors original packaging only rsaquo Remove the batteries from the original packaging shortly before installation rsaquo Do not store batteries in cars or outdoors rsaquo Check the condition of the battery before use

NOTEThe precise specifications of the UN on the transport of lithium batteries can be found under the designation Model Regulations on the transport of dangerous goods Ref STSGAC101 Recommendations on the transport of dangerous goods Part III sub-section 383 ldquoManual of Tests and Criteriardquo Ref STSGAC1011

Assembling the device

Page 16 Operating instructions Powador-gridsave_EN

Authorised electrician

6 Assembling the device

61 Installation

DANGERRisk of fatal injury from fire or explosionsFire caused by flammable or explosive materials in the vicinity of the battery system can lead to serious injuries rsaquo Do not mount the inverter in potentially explosive atmospheres or in the vicinity of highly flamma-

ble materials

CAUTIONBattery system is very heavy ndash risk of injury rsaquo Be aware of the weight of the battery system during transport rsaquo Select suitable mounting location and mounting base rsaquo Only install the battery system with the help of a second person

CAUTIONEquipment damage caused by aggressive gases in combination with humidityThe housing may be seriously damaged by aggressive gases (ammonia sulphur and other chemi-cals) in combination with ambient humidity caused by weather conditions - Installation in rooms containing aggressive gases is not permitted

NOTEAccess in the event of maintenance or serviceAny additional costs arising from unfavourable structural or mounting conditions in the event of a KACO service call-out shall be billed to the customer

611 Installation location

bull Dry well ventilated the waste heat must be conducted away from the battery systembull Unobstructed air circulationbull Easily accessible from the front top and sides without requiring additional resourcesbull Indoors protected against direct sunlight and direct water contact

612 Foundation

bull With sufficient load-bearing capacitybull Made from heat-resistant material (up to 90 degC)bull Must be flame resistant

NOTEPower reduction due to heat accumulationIf the recommended minimum clearances are not observed the device may go into power regula-tion mode due to insufficient ventilation and the resulting heat build-up rsaquo The construction and installation of the device may be performed only by a qualified electrician in

accordance with the valid standards and regulations rsaquo Maintain minimum clearances rsaquo Ensure sufficient heat dissipation

Assembling the device

Operating instructions Powador-gridsave_EN Page 17

Authorised electrician

0deg

1000 mm

200 mm 200 mm

500 mm

min carrying capacity 300 kgmsup2

200 mm200 mm

50 mm

Figure 9 Minimum clearances at the installation and assembly location

CAUTIONRisk of injury if the battery system tips overRisk of tipping due to high centre of gravity particularly with the door open rsaquo Anchor the device securely to the floor immediately after installation rsaquo Open the housing door using the enclosed cabinet key only once the device has been securely

anchored

510 mm200 mm

200 mm

400

mm

12 mmmin 110 mm

DesignationHex head wood screw 8x80 DIN571-vz Fischer dowel S12 Flat washer M8 galvanised DIN9021-vz

Units444

Figure 10 Dimensions for anchoring to the floor Table 3 Mounting parts

62 Installing components

CAUTIONAvoid improper handlingImproper handling can cause damage to components rsaquo Damaged components must not be installed rsaquo Always put the plug-in modules down horizontally to avoid damage to the components

Assembling the device

Page 18 Operating instructions Powador-gridsave_EN

Authorised electrician

WARNINGDanger caused by short circuit or sparkingSerious injury from touching or connecting live components rsaquo Damaged components must not be installed

Preparation1 Check the conditions for the installation location2 Open the housing doors using the enclosed cabinet key3 The cables should be professionally laid and prepared for connection4 Follow the installation sequence (1-4 step(s))

621 Step 1 Fit the battery (batteries)

NOTEPlease read the notes on installation and connection in the enclosed manual Features for the battery unit

622 Step 2 Connect battery (batteries) to the battery management system (BMS)

NOTEPlease read the notes on installation and connection in the enclosed manual Features for the battery unit

623 Step 3 Fit the battery charging unit battery backup converter (BBC)

Battery (batteries) connected to the battery management system (BMS)1 Carefully insert battery charging unit battery backup converter (BBC) into the compartment provided for it 2 Push in completely to establish direct contact with the rear busbars3 Secure battery charging unit battery backup converter (BBC) using the screws supplied

624 Step 4 Fit the inverter

Battery charging unit battery backup converter (BBC) is fitted1 Carefully insert inverter into the compartment provided for it 2 Push in completely to establish direct contact with the rear busbars 3 Secure inverter using the screws supplied

CAUTIONDamage to the control unit from introducing foreign objectsForeign objects can impair the function of the control unit and cause damage rsaquo Do not remove the front panel rsaquo Foreign objects should be removed immediately

Installing the device

Operating instructions Powador-gridsave_EN Page 19

Authorised electrician

7 Installing the device

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched The device may only be opened or serviced by an authorised electricianThe device must be completely assembled before being connected electrically rsaquo Observe all safety regulations and current technical connection specifications of the responsible

power supply company rsaquo De-energise the device using the DC isolator switch circuit breaker and residual current circuit

breaker rsaquo Secure both sides against being inadvertently switched back on rsaquo Ensure that the AC and DC sides are completely isolated and voltage free rsaquo Never open the plug-in modules rsaquo Hazardous voltages are present at the busbars rsaquo Disconnect from the grid and plant supply rsaquo First connect the battery system in the connection area

71 Opening the connection area

3

1

2

Figure 11 Open cover plateKey

1 Cover plate 3 Fastening screw

2 Lock

Opening the connection area You have completed assembly

1 Remove the fastening screw for the upper cover plate2 Slide the cover plate forwards out of the lock3 Lift the cover plate upward to remove raquo Make the electrical connection

Installing the device

Page 20 Operating instructions Powador-gridsave_EN

Authorised electrician

72 Making the electrical connectionMake the connection to the PV generator as well as the grid connection using the connection terminals Note the following cable cross-sections

Connection Possible cable cross-section Length of insulation to be stripped offAC home power grid 05 - 16 mmsup2 with end sleeve

05 - 25 mmsup2 without end sleeve18 mm sleeve18-20 mm

PV connection 05 - 16 mmsup2 with end sleeve05 - 25 mmsup2 without end sleeve

18 mm sleeve17-19 mm

Inverter output 05 - 4 mmsup2 with end sleeve05 - 6 mmsup2 without end sleeve

12 mm sleeve11-13 mm

Potential-free contacts 034 - 15 mmsup2 with end sleeve034 - 25 mmsup2 without end sleeve

12 mm sleeve 9-10 mm

Table 4 Cable cross-sections for connection terminals

NOTEThe threaded connections should be matched to the cable cross-section

NOTEOnly conductors and no insulation should be inserted into the connection terminals Individual wires or cables with end sleeves with the appropriate cross-section can be inserted directly into the connection terminal without a toolFine-strand cables without end sleeve or thin conductors will need a screwdriver (plain slot 35 mm) for connection To do this insert the blade of the screwdriver into the recess provided The cable can be inserted into the spring terminal by pressing downwards The spring terminal closes on removal of the screw-driver

Installing the device

Operating instructions Powador-gridsave_EN Page 21

Authorised electrician

X2X1F1 F2 X7 X4 St1

St2

St3

2 3 541 6

Figure 12 View from above of the connection area

Key

1 AC grid input (M40 cable fitting) 4 Network interface (M32 cable fitting)

2 AC grid output (M40 cable fitting) 5 Inverter input (M16 cable fitting)

3 Inverter output (M32 cable fitting) 6 Other connections (M16 cable fitting)

F1 F2 X7 X4 St1

St2

St3

L1 L2 L3 N PE L1 L2 L3 N N PE PE

X1 X2

PV+

PV-

L1 L2 L3 N PE32A 32A PEN

Cust

omer

co

nnec

tion

Figure 13 View from above of the connection area

Key

X1 AC grid input (main junction box meter) X7 PV generator input

X2 AC grid output (building electrical system) F1 F2 Phase bridging fuse

X4 Inverter output St 1-3 Potential-free contacts control outputs

Installing the device

Page 22 Operating instructions Powador-gridsave_EN

Authorised electrician

721 Connecting to the power grid

Because the device is installed between the main junction boxmeter and the buildings electrical system the maxi-mum grid current to the service line must not exceed the rated operating current of the battery system The cable cross-section must be selected in accordance with applicable standards to suit the connected load instal-lation type etc Moreover the terminal area and size of the cable fitting must be noted

NOTEThe fuse rating for the cable should be max 63A (automatic circuit breaker or safety fuse) even if the cross-section of the installed cable would permit a higher fuse rating Always follow the applicable regulations regarding the cable cross-section and installation typeThe device supports standard grid configurations such as TN-C TN-S and TT TN-SIf a TN-S grid is present directly at the power input and output of the device L1-L3 N and PE must each be connected The home power grid should have 4-pin isolationTN-C4-pin grid isolation is factory preset and disconnects L1 L2 L3 and N In a TN-C grid the N conduc-tor must not be disconnected If a TN-S grid is present directly at the power input and output of the device a cable bridge (included in delivery) must be installed between the N terminal on X1 and the N terminal on X2 N and PE must additionally be connected together To do this simply insert the enclosed terminal link into the N and PE terminals TTIn the case of a TT grid L1-L3 N and PE must each be connected The home power grid should have 4-pin isolation

NOTEPlease check with the operator of the mains grid whether there are special regulations for grid connection Grid isolation is factory preset to 4-pin is fail-safe and provided with grid and system protection as per VDE-AR-N 4105

Making the grid connection Use cables with 5 wires (L1 brown L2 black L3 grey N blue PE greenyellow) and the correct

cross-section1 Loosen cable fitting for AC connection2 Remove the outer cladding of the AC cables3 Insert the AC cables through the cable fitting into the connection area4 Strip the insulation from the AC cables5 Remove connection terminals6 Connect the cables in line with the terminal labels (Figure 13 on page 21)7 Close the connection terminals8 Check that all connected cables are securely fitted9 Tighten the cable fitting10 To meet the requirements of protection rating IP21 close the unused cable fittings with blind caps raquo The battery system is connected to the power grid

NOTEAn AC-side disconnection unit must be provided during the final installation stage This disconnec-tion unit must be installed so that it can be accessed at any time without obstruction If a residual current circuit breaker is necessary due to the installation specification a type A residual current circuit breaker must be used

Installing the device

Operating instructions Powador-gridsave_EN Page 23

Authorised electrician

7211 Output from the inverterRecommended cable cross-sections for the inverter output and fuse rating of cables for fixed wiring accord-ing to VDE 0100 part 430The fuse rating for the cable is dependent on the cable cross-section max 40A automatic circuit breaker

NOTEWhen the line resistance is high (ie long grid-side cables) the voltage at the grid terminals of the inverter will increase during feed-in to the grid The inverter monitors this voltage If the voltage exceeds the country-specific grid overvoltage limit value the inverter switches off rsaquo Ensure that the conductor cross-sections are sufficiently large or that the cable lengths are suffi-

ciently short

NOTEIn order to avoid asymmetries in the grid systems with multiple battery systems should be designed so that the inverters in the devices feed into the grid in differing phases rsaquo Follow the connection conditions for the particular type of grid and the schematic illustration

below

Country and grid-type

Grid monitoring Required monitoring

max asymmetry between phases L1L2L3

DE-NSP Three-phase or single phase phase unbalanced load 46 kVA

Table 5 Grid-type-specific connection conditions

L1

L2

L3

N

Connection X1 Connection X1 Connection X1 Connection X1

L1 L2 L3 N PE L1 L2 L3 N PE L1 L2 L3 N PE L1 L2 L3 N PE

Powador-gridsave inverter1 L1 - L1 L2 - L2 L3 - L32 L1 - L2 L2 - L3 L3 - L1 3 L1 - L3 L2 - L1 L3 - L2 4 L1 - L1 L2 - L2 L3 - L3

Figure 14 Grid-side connection for systems with multiple battery systems with three-phase grid monitoring

Installing the device

Page 24 Operating instructions Powador-gridsave_EN

Authorised electrician

722 Connecting the PV generator

Connect the PV generator on the left in the connection area (Figure 13 on page 21) Use the provided M16 cable fittings A maximum of two strings can be connected For this reason a DC string fuse can be dispensed with

DANGERRisk of fatal injury due to contact voltagesRemoving the cables from the terminals without first disconnecting the PV generator from the device can cause serious damage to health or damage to the system rsaquo During installation Electrically disconnect the DC positive and DC negative from the protective

earth (PE) rsaquo Completely de-energise the system (AC home power grid AC circuit breaker residual current circuit

breaker DC isolator switch) rsaquo Disconnect the battery system from the PV generator using the integrated DC isolator switch rsaquo Remove DC plug connectors

NOTEIn accordance with IEC 61730 Class A connected PV modules must be dimensioned for the DC system voltage provided and at least for the value of the AC grid voltage

7221 Before connecting

Ensure that there is no ground fault1 Determine the DC voltage between the

ndash protective earth (PE) and the positive cable of the PV generator and between the ndash protective earth (PE) and the negative cable of the PV generator

If stable voltages can be measured there is a ground fault in the DC generator or its wiring The ratio between the measured voltages gives an indication as to the location of this fault

2 Rectify any faults before taking further measurements3 Determine the electrical resistance between the

ndash protective earth (PE) and the positive cable of the PV generator and between the ndash protective earth (PE) and the negative cable of the PV generator

In addition ensure that the PV generator has a total insulation resistance of more than 20 MOhm since the inverter will not feed in if the insulation resistance is too low

4 Rectify any faults before connecting the DC generator

7222 Connecting the PV generator

DANGERRisk of fatal injury due to electric shockSevere injury or death will result if the live connections are touched When there is solar radiation DC voltage will be present at the open ends of the DC cables rsaquo Do not touch the exposed ends of the cables rsaquo Avoid short circuits

Installing the device

Operating instructions Powador-gridsave_EN Page 25

Authorised electrician

Connecting the PV generator Use cables with the correct cross-section

1 Remove cable fittings for DC connection2 Remove the outer cladding of the DC cables3 Insert the DC cables through the cable fittings into the connection area4 Strip the insulation from the DC cables5 Remove connection terminals6 Connect the cables in line with the terminal labels (See Figure 13 on page 21)7 Close the connection terminals8 Check that all connected cables are securely fitted9 Tighten the cable fittings10 To meet the requirements of protection rating IP21 close the unused cable fittings with blind caps raquo The PV generator is connected to the inverter

73 Connecting the interfaces

731 Ethernet interface

Pre-assembled Ethernet cables can be connected using the RJ45 socket in the connection space

Connecting the Ethernet cable1 Remove closure cap from RJ45 socket2 Connect the Ethernet cable3 The energy management system can now obtain an IP address by DHCP and is also available via this in the

network

NOTEThe network settings can be amended later in the Settings menu using the EMS

NOTEUse a suitable category 5 network cable The maximum length of a network segment is 100 m Ensure that the cable is correctly assigned The Ethernet connection of the battery system supports auto-sensing You can use both crossed and 11 configured Ethernet connection cables

74 Sealing the connection area

1 Finally check the cabling2 Ensure that all cables are firmly mounted3 Check that the cable fitting is secure and tighten if necessary4 Remove cable offcuts and particles of dirt or dust5 Fit the cover and slide back until it engages into position6 Check that the position is correct7 Screw the fastening screw onto the front of the cover

Installing the device

Page 26 Operating instructions Powador-gridsave_EN

Authorised electrician

75 Starting up

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched Only appropriately qualified and authorised electricians may open install or maintain the battery system rsaquo Keep the front doors and covers closed during operation

NOTEInitial start-up should be carried out using the available public AC grid

76 Standard configuration

Factory settingsCountry configuration Germany

Grid guidelines Low voltage directive

Language German

Time UTC +1 Central European Time

User Standard

Network parameters DHCP (network settings will be obtained automatically from the router)

NOTEPlease state the desired power limitation (60 or 70 of the PV system capacity) when you order For other variations please notify your KACO contact so that the parameters can be set at the factory prior to delivery

Installing the device

Operating instructions Powador-gridsave_EN Page 27

Authorised electrician

761 Step 1 AC home power grid

Check all cables and connections before starting up1 Switch on the AC home power grid using the AC main switch raquo Powador-protect measurement and control unit starts up and monitors the AC grid raquo Two green LEDs indicate that the grid parameters are met raquo After a further 60 seconds (shortly after the backlighting in the Powador-protect goes out) the Powador-pro-

tect will switch on the home grid2 Configure Powador-protect according to the enclosed Powador-protect instructions

(The instructions are also available on the website at wwwkaconewenergyde) raquo The AC power is supplied in the normal way by the public grid

762 Step 2 AC supply from the battery system

Check all cables and connections before starting up1 Remove external isolation means from the device2 Switch on the circuit breaker raquo The LCD touchscreen on the front panel comes on and the energy management system (EMS) starts up

3 Switch on the residual current circuit breaker raquo The battery system starts up

763 Step 3 Switch on the PV system

1 Switch on any optional external PV isolator switches2 Set the internal DC isolator switch to ON raquo The inverter and the battery charging unit battery backup converter (BBC) are connected to the PV system raquo The device monitors the PV voltage for approx 60 seconds then optimisation of internal consumption takes

place

764 Step 4 Switch on batteries

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

765 Step 5 Activate energy management

NOTEKACO new energy cannot provide any support for problems regarding the IT infrastructure (eg router configuration IP address assignment ports etc) as the structure settings and configuration of the network environment can be complex and very different from place to place In the event of any problems please contact an IT service provider

Remote access activated 1 Please call the KACO Hotline to make an appointment for activation of energy management

Configuration and Operation

Page 28 Operating instructions Powador-gridsave_EN

Authorised electrician

8 Configuration and Operation

81 ControlsThe battery system is fitted with a touchscreen which allows it to be controlled very precisely In normal operation the display is switched off Touching the screen activates the display and after a configurable period of time without being touched the dis-play will deactivate If the screen-save function is switched off the touchscreen will be on continuously

NOTEDepending on the tolerances of the measuring elements the measured and displayed values are not always the actual values However the measuring elements ensure maximum solar yield Due to these tolerances the daily yields shown on the touchscreen may deviate from the values on the grid operatorrsquos feed-in meter by up to 15

3

1

45

2

Figure 15 Overview (home screen)

Key

1 Home button 4 Current time

2 System components 5 Menu name

3 More information

811 Information about the system

Open start screen View changesjumps to the home screen

Show component detail Parameters of the selected component

Settings Define settings for the active user

raquo Displays settings

Configuration and Operation

Operating instructions Powador-gridsave_EN Page 29

Controls Left arrow jump back to previous menu item Up and down arrows navigate through the menu or change a value

Left arrow displayed value is reduced by one increment Right arrow displayed value is increased by one increment or change to the submenu

Display fields Grey box Text or figures (not selectable) Blue box Calls up submenu for the display in question

Activate and deactivate Activate function by ticking the box

Table 6 Information about the system

812 System components

PV generator Display of the current generator data

power voltage current temperature in the inverter

Battery Display of the current battery status

power (charging or discharging) voltage current charge status available capacity temperature of battery

Grid Display of the following either fed-in or drawn from the grid

power voltage current for phase L1-L3 total output frequency

Consumer (load) Display of the consumer data

power voltage current for phase L1-L3 total output

Energy flow raquo Displays the current energy flow in the system

Table 7 Information about system components

Configuration and Operation

Page 30 Operating instructions Powador-gridsave_EN

813 Menu structure

Icons used

Display menu Submenu

Option menu

Menu Submenu Display setting

Action in this menumeaning

PV generator Details

Power Displays the current DC-side power

Voltage Displays the current DC-side voltage

Current Displays the current DC-side amperage

Temp inverter

Displays the current temperature in the inverter housing

Battery Details

Power Displays the current AC-side power

Voltage Displays the current AC-side voltage

Current Displays the current AC-side amperage

Charge status Displays the current charge status

Capacity Displays the current battery capacity

Temperature Displays the current measured temperature of the battery

Grid Details

Power Displays the current AC-side power being drawn or fed-in

Voltage Displays the AC-side voltage being applied

Current Displays the current AC-side amperage being drawn or fed-in

Total output Displays the current AC-side total output being drawn or fed-in

Frequency Displays the frequency currently being applied to the grid junction

Consumer (load) Details

Power Displays the current AC-side power being drawn

Voltage Displays the current AC-side voltage being applied

Current Displays the current AC-side amperage being drawn

Total output Displays the current AC-side total output being drawn

Configuration and Operation

Operating instructions Powador-gridsave_EN Page 31

Menu Submenu Display setting

Action in this menumeaning

Settings

Country amp directive display

Display of the country settings voltage directives and grid type

Select menu language

DateTime Specify time zone date format and date and time

Screen Activate screen-save function and set the delay period

Network settings

Display of the network settings Configure network settings Once the DHCP server becomes available the IP

address subnet mask gateway and DNS server are automatically applied and the aforemen-tioned menu items are hidden

Off DHCP deactivated make settings manually

Version Displays the installed software version and built-in HW components (inverter BBC battery)

Vendor The touchscreen shows information about the device vendor

NOTEAs changes to the software are possible after the manual has been printed the illustrations and descriptions of the functions in these operating instructions may deviate from the software Please therefore note the current Application Notes on our website

MaintenanceTroubleshooting

Page 32 Operating instructions Powador-gridsave_EN

9 MaintenanceTroubleshooting

91 Visual inspectionInspect the device and the cables for visible external damage and note the operating status display In case of damage notify your installer Repairs may only be carried out by authorised electricians

NOTEThe battery system should be checked for proper operation by a qualified electrician at regular intervals

92 Cleaning the device

DANGERLethal voltages in the battery systemSerious injuries or death can result if moisture enters the system rsaquo Only use completely dry objects to clean the battery system rsaquo Only clean the outside of the battery system

Cleaning the battery system Do not use compressed air Use a vacuum cleaner or a soft brush to remove dust from the fan cover and from the top of the inverter on a

regular basis Remove dust from the ventilation inlets if necessary

MaintenanceTroubleshooting

Operating instructions Powador-gridsave_EN Page 33

Authorised electrician

93 Maintenance

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched The device is only permitted to be opened or serviced by an authorised electrician rsaquo Observe all safety regulations and the current technical connection specifications from the relevant

power supply company rsaquo Disconnect the AC and DC sides rsaquo Secure the AC and DC sides from being inadvertently switched back on rsaquo Only then should the device be opened rsaquo After shutdown wait at least 30 minutes before working on the device

CAUTIONDestruction of the DC connectionThe connection terminals can be destroyed by arcing if disconnected while still live rsaquo It is absolutely essential that the shutdown sequence be carried out in the correct order (See sec-

tion 111 on page 35)

94 Faults

941 Procedure

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched

When a fault occurs notify an appropriately authorised and qualified electrician or KACO new energy GmbH Service

Service

Page 34 Operating instructions Powador-gridsave_EN

10 ServiceIf 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 efficientlybull Serial nobull SW version of the components (the software version can be found in the Settings menu using the EMS)bull Module type and string circuitbull Date of installation Start-up reportbull Consignment identification Delivery address Contact person (with telephone number)bull Information about the accessibility of the installation site

Any additional costs arising from unfavourable structural or mounting conditions shall be billed to the customer

You can find our warranty conditions on our websitehttpkaco-newenergycomservicewarrantyFrom there you can easily navigate to our international websites by clicking on the appropriate flag

Please use our website to register your unit immediatelyYou can also select the appropriate flag on this page to access the website for your own countryIn this manner you can assist us in providing you with the quickest service possible Note The maximum length of the warranty is based on the currently applicable national warranty conditions

We have prepared a template for complaints This can be found at httpskaco-newenergycomservicecustomer-service

Hotlines

Technical troubleshooting Technical consultation

Inverters and battery systems ()

+49 (0) 71323818-660 +49 (0) 71323818-660

Data logging and accessories +49 (0) 71323818-690 +49 (0) 71323818-690

Construction site emergency () +49 (0) 71323818-630

Customer help desk Monday to Friday from 730 am to 530 pm (CET)

() Also on Saturdays from 800 am to 200 pm (CET)

ShutdownDisassembly

Operating instructions Powador-gridsave_EN Page 35

11 ShutdownDisassembly

111 Switching off the device

DANGERLethal voltages are still present in the terminals and cables even after switching off and discon-nection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched rsaquo Complete de-energisation only occurs if the bulk power supply is switched off upstream of the bat-

tery system

DANGERDestruction of the DC plug connectorDC plug connectors can be destroyed by arcing if disconnected while still live rsaquo It is absolutely essential that the following shutdown sequence is observed

1111 Step 1 Shutting down the PV system

1 Switch off any optional external PV isolator switches2 Set the internal DC isolator switch to OFF raquo The inverter and battery charging unit battery backup converter (BBC) are disconnected

1112 Step 2 Disconnect the batteries

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

1113 Step 3 Disconnect the AC supply

1 Connect external isolation means to the device2 Switch off the circuit breaker 3 Switch off the residual current circuit breaker raquo The battery system is switched off

1114 Step 4 AC home power grid

1 Shutdown the AC home power grid using the AC main switch raquo The battery system can be uninstalled

Disposal

Page 36 Operating instructions Powador-gridsave_EN

112 Uninstalling the device

NOTETo uninstall follow the same sequence as for installation but in reverse order

Switch off the device1 Unlock and open the housing door2 Remove the upper cover3 Release the DC and AC cables from the connection terminals4 Pull out the cables raquo The battery system is uninstalled Continue with the disassembly

113 Disassembling the device

NOTETo disassemble follow the same sequence as for assembly but in reverse order

Switch off the device1 Uninstall the components2 Remove the fastening from the device3 Securely pack up the battery system if it is to be used later

or have the battery system disposed of in accordance with section 12 on page 36

12 DisposalFor the most part both the battery system and the corresponding transport packaging are made from recyclable raw materialsBatteries and components Do not dispose of faulty batteries or the components together with household waste Ensure that the old device and accessories are disposed of in a proper mannerPackaging Ensure that the transport packaging is disposed of properlyBatteriesUsed or faulty batteries must be transported in special packaging If you need such packaging please contact the KACO Hotline

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

Appendix

Operating instructions Powador-gridsave_EN Page 37

13 Appendix

EU Declaration of Conformity

Vendorrsquos name and address

KACO new energy GmbH Carl-Zeiss-Straszlige 1 74172 Neckarsulm Germany

Product description Battery system

Type designation Powador-gridsave 135 kWh 6400 Powador-gridsave 135 kWh 8000

Powador-gridsave 270 kWh 6400 Powador-gridsave 270 kWh 8000

Powador-gridsave 405 kWh 6400 Powador-gridsave 405 kWh 8000

Powador-gridsave 540 kWh 6400 Powador-gridsave 540 kWh 8000

Powador-gridsave 577 kWh 6400 Powador-gridsave 577 kWh 8000

Powador-gridsave 675 kWh 6400 Powador-gridsave 675 kWh 8000

This is to confirm that the units listed above comply with the protection requirements set forth in the Directive of the Council of the European Union of 15th December 2004 on the harmonisation of the laws of the member states relating to Electromagnetic Compatibility (2004108EC) and the Low Voltage Directive (200695EC)The units are compliant with the following standards

200695EC ldquoDirective relating to electrical equipment designed for use within specific voltage limitsrdquo

Safety of the unitIEC 62109-12010IEC 62109-22011

2004108EC ldquoDirective relating to electromagneticcompatibilityrdquo

Interference immunityEN 61000-6-22005 Emitted interferenceEN 61000-6-32007

Secondary effects on the gridEN 61000-3-112000EN 61000-3-122005

The types mentioned above are therefore labelled with the CE markUnauthorised modifications to the supplied units andor any use of the units that is contrary to their intended use render this Declaration of Conformity null and void

Neckarsulm 0711 2013KACO new energy GmbH

pp Volker DietrichEnergy systems engineering management

Disposal

Page 38 Operating instructions Powador-gridsave_EN

Carl-Zeiss-Straszlige 1 middot 74172 Neckarsulm middot Germany middot Phone +49 7132 3818-0 middot Fax +49 7132 3818-703 middot infokaco-newenergyde middot wwwkaco-newenergyde

The

text

and

figu

res

refle

ct th

e cu

rren

t tec

hnic

al s

tate

at t

he ti

me

of p

rintin

g S

ubje

ct to

tech

nica

l cha

nges

Err

ors

and

omis

sion

s ex

cept

ed

3006

856-

01-1

4030

5

  • 1General Information
    • 11About this document
    • 12Name plate
    • 13Additional information
    • 14Intended use
      • 2Safety
        • 21Protection features
          • 3Description
            • 31Mode of Operation
            • 32Summary of the components
              • 4Technical Data
                • 41Electrical data
                • 42Mechanical data
                  • 5Transportation and Delivery
                    • 51Delivery
                    • 52Storage
                    • 53Transportation
                      • 6Assembling the device
                        • 61Installation
                        • 62Installing components
                          • 7Installing the device
                            • 71Opening the connection area
                            • 72Making the electrical connection
                            • 73Connecting the interfaces
                            • 74Sealing the connection area
                            • 75Starting up
                            • 76Standard configuration
                              • 8Configuration and Operation
                                • 81Controls
                                  • 9MaintenanceTroubleshooting
                                    • 91Visual inspection
                                    • 92Cleaning the device
                                    • 93Maintenance
                                    • 94Faults
                                      • 10Service
                                      • 11ShutdownDisassembly
                                        • 111Switching off the device
                                        • 112Uninstalling the device
                                        • 113Disassembling the device
                                          • 12Disposal
                                          • 13Appendix

Technical Data

Operating instructions Powador-gridsave_EN Page 13

Battery charging unit battery backup converter (BBC)

Ambient temperature range [degC] -20 +70

Temperature monitoring Yes

Cooling Active cooling

Housing 19 plug-in module aluminium

Connections Quick INOUT plug connector and busbar clips rear side

H x W x D [mm] 13325 x 4826 x 460

Weight [kg] 15

Temperature-dependent impedance matching with shutdown if the temperature is too high

Table 2 Mechanical data

Transportation and Delivery

Page 14 Operating instructions Powador-gridsave_EN

5 Transportation and Delivery

51 DeliveryThe battery system leaves KACO new energy in fully functional electrical and mechanical condition Special packaging ensures that the units are transported safely The shipping company is responsible for any trans-port damage that occurs

511 Scope of delivery

Pallet A B

Figure Figure 7 Scope of delivery pallet A Figure 8 Scope of delivery pallet B

Contents bull Battery system Powador-gridsave (incl connection box battery management system (BMS) industrial PC Plexiglas cover and accessories)

bull Inverter bull Battery charging unit battery backup converter

(BBC)bull Battery system plug-in modules 1-5 ST (scope of

delivery can be found on the delivery document)bull Documentation

Weight (kg) 187 max 155 177 (without with Euro pool pallet)

H x W x D [mm] 1780x800x820 1200x1200x800

Packaging Cardboard box with polystyrene inserts and closures

512 Check the equipment included

bull Battery system and plug-in modules should be inspected thoroughly for transport damagebull Do not install damaged components in the control cabinetbull In the event of damage to the battery plug-in modules contact the KACO new energy Hotline immediately

Transportation and Delivery

Operating instructions Powador-gridsave_EN Page 15

Authorised electrician

DANGERRisk of fatal injury if incompatible components are usedThe battery and power electronics can be damaged if different delivery batches are combined and will carry potentially fatal voltages if connected rsaquo Assemble the system using the components provided by KACO new energy only rsaquo Check the serial numbers on the delivery document against the serial numbers of the individual

units on pallets A and B

52 StorageIncorrect storage can lead to system malfunctions Therefore please observe the following conditionsbull If storing for longer than six months store the device in an interior room in its original packaging bull If the original packaging has been removed store the device in a cool dry interior roombull Storage temperature -20 degC to +70 degCbull Relative humidity 0 to 95 (non-condensing)bull If the device is stored for a relatively long time at high humidity the device must be left for more than one day to

dry out sufficiently before connection to the power grid

53 Transportation

WARNINGImpact hazard risk of breakage to the components in the battery systemThe centre of gravity is located in the upper part of the device rsaquo Transport the device upright together with the pallet rsaquo Do not expose the device or components to any shocks rsaquo After unloading at least two people are required to transport the cabinet

WARNINGDanger due to impact and incorrect storage of the batteriesIn the event of damage batteries can release hazardous electrolyte gases which will cause irreversible burns if they come into contact with the skin rsaquo Transport the batteries in the vendors original packaging only rsaquo Remove the batteries from the original packaging shortly before installation rsaquo Do not store batteries in cars or outdoors rsaquo Check the condition of the battery before use

NOTEThe precise specifications of the UN on the transport of lithium batteries can be found under the designation Model Regulations on the transport of dangerous goods Ref STSGAC101 Recommendations on the transport of dangerous goods Part III sub-section 383 ldquoManual of Tests and Criteriardquo Ref STSGAC1011

Assembling the device

Page 16 Operating instructions Powador-gridsave_EN

Authorised electrician

6 Assembling the device

61 Installation

DANGERRisk of fatal injury from fire or explosionsFire caused by flammable or explosive materials in the vicinity of the battery system can lead to serious injuries rsaquo Do not mount the inverter in potentially explosive atmospheres or in the vicinity of highly flamma-

ble materials

CAUTIONBattery system is very heavy ndash risk of injury rsaquo Be aware of the weight of the battery system during transport rsaquo Select suitable mounting location and mounting base rsaquo Only install the battery system with the help of a second person

CAUTIONEquipment damage caused by aggressive gases in combination with humidityThe housing may be seriously damaged by aggressive gases (ammonia sulphur and other chemi-cals) in combination with ambient humidity caused by weather conditions - Installation in rooms containing aggressive gases is not permitted

NOTEAccess in the event of maintenance or serviceAny additional costs arising from unfavourable structural or mounting conditions in the event of a KACO service call-out shall be billed to the customer

611 Installation location

bull Dry well ventilated the waste heat must be conducted away from the battery systembull Unobstructed air circulationbull Easily accessible from the front top and sides without requiring additional resourcesbull Indoors protected against direct sunlight and direct water contact

612 Foundation

bull With sufficient load-bearing capacitybull Made from heat-resistant material (up to 90 degC)bull Must be flame resistant

NOTEPower reduction due to heat accumulationIf the recommended minimum clearances are not observed the device may go into power regula-tion mode due to insufficient ventilation and the resulting heat build-up rsaquo The construction and installation of the device may be performed only by a qualified electrician in

accordance with the valid standards and regulations rsaquo Maintain minimum clearances rsaquo Ensure sufficient heat dissipation

Assembling the device

Operating instructions Powador-gridsave_EN Page 17

Authorised electrician

0deg

1000 mm

200 mm 200 mm

500 mm

min carrying capacity 300 kgmsup2

200 mm200 mm

50 mm

Figure 9 Minimum clearances at the installation and assembly location

CAUTIONRisk of injury if the battery system tips overRisk of tipping due to high centre of gravity particularly with the door open rsaquo Anchor the device securely to the floor immediately after installation rsaquo Open the housing door using the enclosed cabinet key only once the device has been securely

anchored

510 mm200 mm

200 mm

400

mm

12 mmmin 110 mm

DesignationHex head wood screw 8x80 DIN571-vz Fischer dowel S12 Flat washer M8 galvanised DIN9021-vz

Units444

Figure 10 Dimensions for anchoring to the floor Table 3 Mounting parts

62 Installing components

CAUTIONAvoid improper handlingImproper handling can cause damage to components rsaquo Damaged components must not be installed rsaquo Always put the plug-in modules down horizontally to avoid damage to the components

Assembling the device

Page 18 Operating instructions Powador-gridsave_EN

Authorised electrician

WARNINGDanger caused by short circuit or sparkingSerious injury from touching or connecting live components rsaquo Damaged components must not be installed

Preparation1 Check the conditions for the installation location2 Open the housing doors using the enclosed cabinet key3 The cables should be professionally laid and prepared for connection4 Follow the installation sequence (1-4 step(s))

621 Step 1 Fit the battery (batteries)

NOTEPlease read the notes on installation and connection in the enclosed manual Features for the battery unit

622 Step 2 Connect battery (batteries) to the battery management system (BMS)

NOTEPlease read the notes on installation and connection in the enclosed manual Features for the battery unit

623 Step 3 Fit the battery charging unit battery backup converter (BBC)

Battery (batteries) connected to the battery management system (BMS)1 Carefully insert battery charging unit battery backup converter (BBC) into the compartment provided for it 2 Push in completely to establish direct contact with the rear busbars3 Secure battery charging unit battery backup converter (BBC) using the screws supplied

624 Step 4 Fit the inverter

Battery charging unit battery backup converter (BBC) is fitted1 Carefully insert inverter into the compartment provided for it 2 Push in completely to establish direct contact with the rear busbars 3 Secure inverter using the screws supplied

CAUTIONDamage to the control unit from introducing foreign objectsForeign objects can impair the function of the control unit and cause damage rsaquo Do not remove the front panel rsaquo Foreign objects should be removed immediately

Installing the device

Operating instructions Powador-gridsave_EN Page 19

Authorised electrician

7 Installing the device

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched The device may only be opened or serviced by an authorised electricianThe device must be completely assembled before being connected electrically rsaquo Observe all safety regulations and current technical connection specifications of the responsible

power supply company rsaquo De-energise the device using the DC isolator switch circuit breaker and residual current circuit

breaker rsaquo Secure both sides against being inadvertently switched back on rsaquo Ensure that the AC and DC sides are completely isolated and voltage free rsaquo Never open the plug-in modules rsaquo Hazardous voltages are present at the busbars rsaquo Disconnect from the grid and plant supply rsaquo First connect the battery system in the connection area

71 Opening the connection area

3

1

2

Figure 11 Open cover plateKey

1 Cover plate 3 Fastening screw

2 Lock

Opening the connection area You have completed assembly

1 Remove the fastening screw for the upper cover plate2 Slide the cover plate forwards out of the lock3 Lift the cover plate upward to remove raquo Make the electrical connection

Installing the device

Page 20 Operating instructions Powador-gridsave_EN

Authorised electrician

72 Making the electrical connectionMake the connection to the PV generator as well as the grid connection using the connection terminals Note the following cable cross-sections

Connection Possible cable cross-section Length of insulation to be stripped offAC home power grid 05 - 16 mmsup2 with end sleeve

05 - 25 mmsup2 without end sleeve18 mm sleeve18-20 mm

PV connection 05 - 16 mmsup2 with end sleeve05 - 25 mmsup2 without end sleeve

18 mm sleeve17-19 mm

Inverter output 05 - 4 mmsup2 with end sleeve05 - 6 mmsup2 without end sleeve

12 mm sleeve11-13 mm

Potential-free contacts 034 - 15 mmsup2 with end sleeve034 - 25 mmsup2 without end sleeve

12 mm sleeve 9-10 mm

Table 4 Cable cross-sections for connection terminals

NOTEThe threaded connections should be matched to the cable cross-section

NOTEOnly conductors and no insulation should be inserted into the connection terminals Individual wires or cables with end sleeves with the appropriate cross-section can be inserted directly into the connection terminal without a toolFine-strand cables without end sleeve or thin conductors will need a screwdriver (plain slot 35 mm) for connection To do this insert the blade of the screwdriver into the recess provided The cable can be inserted into the spring terminal by pressing downwards The spring terminal closes on removal of the screw-driver

Installing the device

Operating instructions Powador-gridsave_EN Page 21

Authorised electrician

X2X1F1 F2 X7 X4 St1

St2

St3

2 3 541 6

Figure 12 View from above of the connection area

Key

1 AC grid input (M40 cable fitting) 4 Network interface (M32 cable fitting)

2 AC grid output (M40 cable fitting) 5 Inverter input (M16 cable fitting)

3 Inverter output (M32 cable fitting) 6 Other connections (M16 cable fitting)

F1 F2 X7 X4 St1

St2

St3

L1 L2 L3 N PE L1 L2 L3 N N PE PE

X1 X2

PV+

PV-

L1 L2 L3 N PE32A 32A PEN

Cust

omer

co

nnec

tion

Figure 13 View from above of the connection area

Key

X1 AC grid input (main junction box meter) X7 PV generator input

X2 AC grid output (building electrical system) F1 F2 Phase bridging fuse

X4 Inverter output St 1-3 Potential-free contacts control outputs

Installing the device

Page 22 Operating instructions Powador-gridsave_EN

Authorised electrician

721 Connecting to the power grid

Because the device is installed between the main junction boxmeter and the buildings electrical system the maxi-mum grid current to the service line must not exceed the rated operating current of the battery system The cable cross-section must be selected in accordance with applicable standards to suit the connected load instal-lation type etc Moreover the terminal area and size of the cable fitting must be noted

NOTEThe fuse rating for the cable should be max 63A (automatic circuit breaker or safety fuse) even if the cross-section of the installed cable would permit a higher fuse rating Always follow the applicable regulations regarding the cable cross-section and installation typeThe device supports standard grid configurations such as TN-C TN-S and TT TN-SIf a TN-S grid is present directly at the power input and output of the device L1-L3 N and PE must each be connected The home power grid should have 4-pin isolationTN-C4-pin grid isolation is factory preset and disconnects L1 L2 L3 and N In a TN-C grid the N conduc-tor must not be disconnected If a TN-S grid is present directly at the power input and output of the device a cable bridge (included in delivery) must be installed between the N terminal on X1 and the N terminal on X2 N and PE must additionally be connected together To do this simply insert the enclosed terminal link into the N and PE terminals TTIn the case of a TT grid L1-L3 N and PE must each be connected The home power grid should have 4-pin isolation

NOTEPlease check with the operator of the mains grid whether there are special regulations for grid connection Grid isolation is factory preset to 4-pin is fail-safe and provided with grid and system protection as per VDE-AR-N 4105

Making the grid connection Use cables with 5 wires (L1 brown L2 black L3 grey N blue PE greenyellow) and the correct

cross-section1 Loosen cable fitting for AC connection2 Remove the outer cladding of the AC cables3 Insert the AC cables through the cable fitting into the connection area4 Strip the insulation from the AC cables5 Remove connection terminals6 Connect the cables in line with the terminal labels (Figure 13 on page 21)7 Close the connection terminals8 Check that all connected cables are securely fitted9 Tighten the cable fitting10 To meet the requirements of protection rating IP21 close the unused cable fittings with blind caps raquo The battery system is connected to the power grid

NOTEAn AC-side disconnection unit must be provided during the final installation stage This disconnec-tion unit must be installed so that it can be accessed at any time without obstruction If a residual current circuit breaker is necessary due to the installation specification a type A residual current circuit breaker must be used

Installing the device

Operating instructions Powador-gridsave_EN Page 23

Authorised electrician

7211 Output from the inverterRecommended cable cross-sections for the inverter output and fuse rating of cables for fixed wiring accord-ing to VDE 0100 part 430The fuse rating for the cable is dependent on the cable cross-section max 40A automatic circuit breaker

NOTEWhen the line resistance is high (ie long grid-side cables) the voltage at the grid terminals of the inverter will increase during feed-in to the grid The inverter monitors this voltage If the voltage exceeds the country-specific grid overvoltage limit value the inverter switches off rsaquo Ensure that the conductor cross-sections are sufficiently large or that the cable lengths are suffi-

ciently short

NOTEIn order to avoid asymmetries in the grid systems with multiple battery systems should be designed so that the inverters in the devices feed into the grid in differing phases rsaquo Follow the connection conditions for the particular type of grid and the schematic illustration

below

Country and grid-type

Grid monitoring Required monitoring

max asymmetry between phases L1L2L3

DE-NSP Three-phase or single phase phase unbalanced load 46 kVA

Table 5 Grid-type-specific connection conditions

L1

L2

L3

N

Connection X1 Connection X1 Connection X1 Connection X1

L1 L2 L3 N PE L1 L2 L3 N PE L1 L2 L3 N PE L1 L2 L3 N PE

Powador-gridsave inverter1 L1 - L1 L2 - L2 L3 - L32 L1 - L2 L2 - L3 L3 - L1 3 L1 - L3 L2 - L1 L3 - L2 4 L1 - L1 L2 - L2 L3 - L3

Figure 14 Grid-side connection for systems with multiple battery systems with three-phase grid monitoring

Installing the device

Page 24 Operating instructions Powador-gridsave_EN

Authorised electrician

722 Connecting the PV generator

Connect the PV generator on the left in the connection area (Figure 13 on page 21) Use the provided M16 cable fittings A maximum of two strings can be connected For this reason a DC string fuse can be dispensed with

DANGERRisk of fatal injury due to contact voltagesRemoving the cables from the terminals without first disconnecting the PV generator from the device can cause serious damage to health or damage to the system rsaquo During installation Electrically disconnect the DC positive and DC negative from the protective

earth (PE) rsaquo Completely de-energise the system (AC home power grid AC circuit breaker residual current circuit

breaker DC isolator switch) rsaquo Disconnect the battery system from the PV generator using the integrated DC isolator switch rsaquo Remove DC plug connectors

NOTEIn accordance with IEC 61730 Class A connected PV modules must be dimensioned for the DC system voltage provided and at least for the value of the AC grid voltage

7221 Before connecting

Ensure that there is no ground fault1 Determine the DC voltage between the

ndash protective earth (PE) and the positive cable of the PV generator and between the ndash protective earth (PE) and the negative cable of the PV generator

If stable voltages can be measured there is a ground fault in the DC generator or its wiring The ratio between the measured voltages gives an indication as to the location of this fault

2 Rectify any faults before taking further measurements3 Determine the electrical resistance between the

ndash protective earth (PE) and the positive cable of the PV generator and between the ndash protective earth (PE) and the negative cable of the PV generator

In addition ensure that the PV generator has a total insulation resistance of more than 20 MOhm since the inverter will not feed in if the insulation resistance is too low

4 Rectify any faults before connecting the DC generator

7222 Connecting the PV generator

DANGERRisk of fatal injury due to electric shockSevere injury or death will result if the live connections are touched When there is solar radiation DC voltage will be present at the open ends of the DC cables rsaquo Do not touch the exposed ends of the cables rsaquo Avoid short circuits

Installing the device

Operating instructions Powador-gridsave_EN Page 25

Authorised electrician

Connecting the PV generator Use cables with the correct cross-section

1 Remove cable fittings for DC connection2 Remove the outer cladding of the DC cables3 Insert the DC cables through the cable fittings into the connection area4 Strip the insulation from the DC cables5 Remove connection terminals6 Connect the cables in line with the terminal labels (See Figure 13 on page 21)7 Close the connection terminals8 Check that all connected cables are securely fitted9 Tighten the cable fittings10 To meet the requirements of protection rating IP21 close the unused cable fittings with blind caps raquo The PV generator is connected to the inverter

73 Connecting the interfaces

731 Ethernet interface

Pre-assembled Ethernet cables can be connected using the RJ45 socket in the connection space

Connecting the Ethernet cable1 Remove closure cap from RJ45 socket2 Connect the Ethernet cable3 The energy management system can now obtain an IP address by DHCP and is also available via this in the

network

NOTEThe network settings can be amended later in the Settings menu using the EMS

NOTEUse a suitable category 5 network cable The maximum length of a network segment is 100 m Ensure that the cable is correctly assigned The Ethernet connection of the battery system supports auto-sensing You can use both crossed and 11 configured Ethernet connection cables

74 Sealing the connection area

1 Finally check the cabling2 Ensure that all cables are firmly mounted3 Check that the cable fitting is secure and tighten if necessary4 Remove cable offcuts and particles of dirt or dust5 Fit the cover and slide back until it engages into position6 Check that the position is correct7 Screw the fastening screw onto the front of the cover

Installing the device

Page 26 Operating instructions Powador-gridsave_EN

Authorised electrician

75 Starting up

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched Only appropriately qualified and authorised electricians may open install or maintain the battery system rsaquo Keep the front doors and covers closed during operation

NOTEInitial start-up should be carried out using the available public AC grid

76 Standard configuration

Factory settingsCountry configuration Germany

Grid guidelines Low voltage directive

Language German

Time UTC +1 Central European Time

User Standard

Network parameters DHCP (network settings will be obtained automatically from the router)

NOTEPlease state the desired power limitation (60 or 70 of the PV system capacity) when you order For other variations please notify your KACO contact so that the parameters can be set at the factory prior to delivery

Installing the device

Operating instructions Powador-gridsave_EN Page 27

Authorised electrician

761 Step 1 AC home power grid

Check all cables and connections before starting up1 Switch on the AC home power grid using the AC main switch raquo Powador-protect measurement and control unit starts up and monitors the AC grid raquo Two green LEDs indicate that the grid parameters are met raquo After a further 60 seconds (shortly after the backlighting in the Powador-protect goes out) the Powador-pro-

tect will switch on the home grid2 Configure Powador-protect according to the enclosed Powador-protect instructions

(The instructions are also available on the website at wwwkaconewenergyde) raquo The AC power is supplied in the normal way by the public grid

762 Step 2 AC supply from the battery system

Check all cables and connections before starting up1 Remove external isolation means from the device2 Switch on the circuit breaker raquo The LCD touchscreen on the front panel comes on and the energy management system (EMS) starts up

3 Switch on the residual current circuit breaker raquo The battery system starts up

763 Step 3 Switch on the PV system

1 Switch on any optional external PV isolator switches2 Set the internal DC isolator switch to ON raquo The inverter and the battery charging unit battery backup converter (BBC) are connected to the PV system raquo The device monitors the PV voltage for approx 60 seconds then optimisation of internal consumption takes

place

764 Step 4 Switch on batteries

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

765 Step 5 Activate energy management

NOTEKACO new energy cannot provide any support for problems regarding the IT infrastructure (eg router configuration IP address assignment ports etc) as the structure settings and configuration of the network environment can be complex and very different from place to place In the event of any problems please contact an IT service provider

Remote access activated 1 Please call the KACO Hotline to make an appointment for activation of energy management

Configuration and Operation

Page 28 Operating instructions Powador-gridsave_EN

Authorised electrician

8 Configuration and Operation

81 ControlsThe battery system is fitted with a touchscreen which allows it to be controlled very precisely In normal operation the display is switched off Touching the screen activates the display and after a configurable period of time without being touched the dis-play will deactivate If the screen-save function is switched off the touchscreen will be on continuously

NOTEDepending on the tolerances of the measuring elements the measured and displayed values are not always the actual values However the measuring elements ensure maximum solar yield Due to these tolerances the daily yields shown on the touchscreen may deviate from the values on the grid operatorrsquos feed-in meter by up to 15

3

1

45

2

Figure 15 Overview (home screen)

Key

1 Home button 4 Current time

2 System components 5 Menu name

3 More information

811 Information about the system

Open start screen View changesjumps to the home screen

Show component detail Parameters of the selected component

Settings Define settings for the active user

raquo Displays settings

Configuration and Operation

Operating instructions Powador-gridsave_EN Page 29

Controls Left arrow jump back to previous menu item Up and down arrows navigate through the menu or change a value

Left arrow displayed value is reduced by one increment Right arrow displayed value is increased by one increment or change to the submenu

Display fields Grey box Text or figures (not selectable) Blue box Calls up submenu for the display in question

Activate and deactivate Activate function by ticking the box

Table 6 Information about the system

812 System components

PV generator Display of the current generator data

power voltage current temperature in the inverter

Battery Display of the current battery status

power (charging or discharging) voltage current charge status available capacity temperature of battery

Grid Display of the following either fed-in or drawn from the grid

power voltage current for phase L1-L3 total output frequency

Consumer (load) Display of the consumer data

power voltage current for phase L1-L3 total output

Energy flow raquo Displays the current energy flow in the system

Table 7 Information about system components

Configuration and Operation

Page 30 Operating instructions Powador-gridsave_EN

813 Menu structure

Icons used

Display menu Submenu

Option menu

Menu Submenu Display setting

Action in this menumeaning

PV generator Details

Power Displays the current DC-side power

Voltage Displays the current DC-side voltage

Current Displays the current DC-side amperage

Temp inverter

Displays the current temperature in the inverter housing

Battery Details

Power Displays the current AC-side power

Voltage Displays the current AC-side voltage

Current Displays the current AC-side amperage

Charge status Displays the current charge status

Capacity Displays the current battery capacity

Temperature Displays the current measured temperature of the battery

Grid Details

Power Displays the current AC-side power being drawn or fed-in

Voltage Displays the AC-side voltage being applied

Current Displays the current AC-side amperage being drawn or fed-in

Total output Displays the current AC-side total output being drawn or fed-in

Frequency Displays the frequency currently being applied to the grid junction

Consumer (load) Details

Power Displays the current AC-side power being drawn

Voltage Displays the current AC-side voltage being applied

Current Displays the current AC-side amperage being drawn

Total output Displays the current AC-side total output being drawn

Configuration and Operation

Operating instructions Powador-gridsave_EN Page 31

Menu Submenu Display setting

Action in this menumeaning

Settings

Country amp directive display

Display of the country settings voltage directives and grid type

Select menu language

DateTime Specify time zone date format and date and time

Screen Activate screen-save function and set the delay period

Network settings

Display of the network settings Configure network settings Once the DHCP server becomes available the IP

address subnet mask gateway and DNS server are automatically applied and the aforemen-tioned menu items are hidden

Off DHCP deactivated make settings manually

Version Displays the installed software version and built-in HW components (inverter BBC battery)

Vendor The touchscreen shows information about the device vendor

NOTEAs changes to the software are possible after the manual has been printed the illustrations and descriptions of the functions in these operating instructions may deviate from the software Please therefore note the current Application Notes on our website

MaintenanceTroubleshooting

Page 32 Operating instructions Powador-gridsave_EN

9 MaintenanceTroubleshooting

91 Visual inspectionInspect the device and the cables for visible external damage and note the operating status display In case of damage notify your installer Repairs may only be carried out by authorised electricians

NOTEThe battery system should be checked for proper operation by a qualified electrician at regular intervals

92 Cleaning the device

DANGERLethal voltages in the battery systemSerious injuries or death can result if moisture enters the system rsaquo Only use completely dry objects to clean the battery system rsaquo Only clean the outside of the battery system

Cleaning the battery system Do not use compressed air Use a vacuum cleaner or a soft brush to remove dust from the fan cover and from the top of the inverter on a

regular basis Remove dust from the ventilation inlets if necessary

MaintenanceTroubleshooting

Operating instructions Powador-gridsave_EN Page 33

Authorised electrician

93 Maintenance

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched The device is only permitted to be opened or serviced by an authorised electrician rsaquo Observe all safety regulations and the current technical connection specifications from the relevant

power supply company rsaquo Disconnect the AC and DC sides rsaquo Secure the AC and DC sides from being inadvertently switched back on rsaquo Only then should the device be opened rsaquo After shutdown wait at least 30 minutes before working on the device

CAUTIONDestruction of the DC connectionThe connection terminals can be destroyed by arcing if disconnected while still live rsaquo It is absolutely essential that the shutdown sequence be carried out in the correct order (See sec-

tion 111 on page 35)

94 Faults

941 Procedure

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched

When a fault occurs notify an appropriately authorised and qualified electrician or KACO new energy GmbH Service

Service

Page 34 Operating instructions Powador-gridsave_EN

10 ServiceIf 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 efficientlybull Serial nobull SW version of the components (the software version can be found in the Settings menu using the EMS)bull Module type and string circuitbull Date of installation Start-up reportbull Consignment identification Delivery address Contact person (with telephone number)bull Information about the accessibility of the installation site

Any additional costs arising from unfavourable structural or mounting conditions shall be billed to the customer

You can find our warranty conditions on our websitehttpkaco-newenergycomservicewarrantyFrom there you can easily navigate to our international websites by clicking on the appropriate flag

Please use our website to register your unit immediatelyYou can also select the appropriate flag on this page to access the website for your own countryIn this manner you can assist us in providing you with the quickest service possible Note The maximum length of the warranty is based on the currently applicable national warranty conditions

We have prepared a template for complaints This can be found at httpskaco-newenergycomservicecustomer-service

Hotlines

Technical troubleshooting Technical consultation

Inverters and battery systems ()

+49 (0) 71323818-660 +49 (0) 71323818-660

Data logging and accessories +49 (0) 71323818-690 +49 (0) 71323818-690

Construction site emergency () +49 (0) 71323818-630

Customer help desk Monday to Friday from 730 am to 530 pm (CET)

() Also on Saturdays from 800 am to 200 pm (CET)

ShutdownDisassembly

Operating instructions Powador-gridsave_EN Page 35

11 ShutdownDisassembly

111 Switching off the device

DANGERLethal voltages are still present in the terminals and cables even after switching off and discon-nection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched rsaquo Complete de-energisation only occurs if the bulk power supply is switched off upstream of the bat-

tery system

DANGERDestruction of the DC plug connectorDC plug connectors can be destroyed by arcing if disconnected while still live rsaquo It is absolutely essential that the following shutdown sequence is observed

1111 Step 1 Shutting down the PV system

1 Switch off any optional external PV isolator switches2 Set the internal DC isolator switch to OFF raquo The inverter and battery charging unit battery backup converter (BBC) are disconnected

1112 Step 2 Disconnect the batteries

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

1113 Step 3 Disconnect the AC supply

1 Connect external isolation means to the device2 Switch off the circuit breaker 3 Switch off the residual current circuit breaker raquo The battery system is switched off

1114 Step 4 AC home power grid

1 Shutdown the AC home power grid using the AC main switch raquo The battery system can be uninstalled

Disposal

Page 36 Operating instructions Powador-gridsave_EN

112 Uninstalling the device

NOTETo uninstall follow the same sequence as for installation but in reverse order

Switch off the device1 Unlock and open the housing door2 Remove the upper cover3 Release the DC and AC cables from the connection terminals4 Pull out the cables raquo The battery system is uninstalled Continue with the disassembly

113 Disassembling the device

NOTETo disassemble follow the same sequence as for assembly but in reverse order

Switch off the device1 Uninstall the components2 Remove the fastening from the device3 Securely pack up the battery system if it is to be used later

or have the battery system disposed of in accordance with section 12 on page 36

12 DisposalFor the most part both the battery system and the corresponding transport packaging are made from recyclable raw materialsBatteries and components Do not dispose of faulty batteries or the components together with household waste Ensure that the old device and accessories are disposed of in a proper mannerPackaging Ensure that the transport packaging is disposed of properlyBatteriesUsed or faulty batteries must be transported in special packaging If you need such packaging please contact the KACO Hotline

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

Appendix

Operating instructions Powador-gridsave_EN Page 37

13 Appendix

EU Declaration of Conformity

Vendorrsquos name and address

KACO new energy GmbH Carl-Zeiss-Straszlige 1 74172 Neckarsulm Germany

Product description Battery system

Type designation Powador-gridsave 135 kWh 6400 Powador-gridsave 135 kWh 8000

Powador-gridsave 270 kWh 6400 Powador-gridsave 270 kWh 8000

Powador-gridsave 405 kWh 6400 Powador-gridsave 405 kWh 8000

Powador-gridsave 540 kWh 6400 Powador-gridsave 540 kWh 8000

Powador-gridsave 577 kWh 6400 Powador-gridsave 577 kWh 8000

Powador-gridsave 675 kWh 6400 Powador-gridsave 675 kWh 8000

This is to confirm that the units listed above comply with the protection requirements set forth in the Directive of the Council of the European Union of 15th December 2004 on the harmonisation of the laws of the member states relating to Electromagnetic Compatibility (2004108EC) and the Low Voltage Directive (200695EC)The units are compliant with the following standards

200695EC ldquoDirective relating to electrical equipment designed for use within specific voltage limitsrdquo

Safety of the unitIEC 62109-12010IEC 62109-22011

2004108EC ldquoDirective relating to electromagneticcompatibilityrdquo

Interference immunityEN 61000-6-22005 Emitted interferenceEN 61000-6-32007

Secondary effects on the gridEN 61000-3-112000EN 61000-3-122005

The types mentioned above are therefore labelled with the CE markUnauthorised modifications to the supplied units andor any use of the units that is contrary to their intended use render this Declaration of Conformity null and void

Neckarsulm 0711 2013KACO new energy GmbH

pp Volker DietrichEnergy systems engineering management

Disposal

Page 38 Operating instructions Powador-gridsave_EN

Carl-Zeiss-Straszlige 1 middot 74172 Neckarsulm middot Germany middot Phone +49 7132 3818-0 middot Fax +49 7132 3818-703 middot infokaco-newenergyde middot wwwkaco-newenergyde

The

text

and

figu

res

refle

ct th

e cu

rren

t tec

hnic

al s

tate

at t

he ti

me

of p

rintin

g S

ubje

ct to

tech

nica

l cha

nges

Err

ors

and

omis

sion

s ex

cept

ed

3006

856-

01-1

4030

5

  • 1General Information
    • 11About this document
    • 12Name plate
    • 13Additional information
    • 14Intended use
      • 2Safety
        • 21Protection features
          • 3Description
            • 31Mode of Operation
            • 32Summary of the components
              • 4Technical Data
                • 41Electrical data
                • 42Mechanical data
                  • 5Transportation and Delivery
                    • 51Delivery
                    • 52Storage
                    • 53Transportation
                      • 6Assembling the device
                        • 61Installation
                        • 62Installing components
                          • 7Installing the device
                            • 71Opening the connection area
                            • 72Making the electrical connection
                            • 73Connecting the interfaces
                            • 74Sealing the connection area
                            • 75Starting up
                            • 76Standard configuration
                              • 8Configuration and Operation
                                • 81Controls
                                  • 9MaintenanceTroubleshooting
                                    • 91Visual inspection
                                    • 92Cleaning the device
                                    • 93Maintenance
                                    • 94Faults
                                      • 10Service
                                      • 11ShutdownDisassembly
                                        • 111Switching off the device
                                        • 112Uninstalling the device
                                        • 113Disassembling the device
                                          • 12Disposal
                                          • 13Appendix

Transportation and Delivery

Page 14 Operating instructions Powador-gridsave_EN

5 Transportation and Delivery

51 DeliveryThe battery system leaves KACO new energy in fully functional electrical and mechanical condition Special packaging ensures that the units are transported safely The shipping company is responsible for any trans-port damage that occurs

511 Scope of delivery

Pallet A B

Figure Figure 7 Scope of delivery pallet A Figure 8 Scope of delivery pallet B

Contents bull Battery system Powador-gridsave (incl connection box battery management system (BMS) industrial PC Plexiglas cover and accessories)

bull Inverter bull Battery charging unit battery backup converter

(BBC)bull Battery system plug-in modules 1-5 ST (scope of

delivery can be found on the delivery document)bull Documentation

Weight (kg) 187 max 155 177 (without with Euro pool pallet)

H x W x D [mm] 1780x800x820 1200x1200x800

Packaging Cardboard box with polystyrene inserts and closures

512 Check the equipment included

bull Battery system and plug-in modules should be inspected thoroughly for transport damagebull Do not install damaged components in the control cabinetbull In the event of damage to the battery plug-in modules contact the KACO new energy Hotline immediately

Transportation and Delivery

Operating instructions Powador-gridsave_EN Page 15

Authorised electrician

DANGERRisk of fatal injury if incompatible components are usedThe battery and power electronics can be damaged if different delivery batches are combined and will carry potentially fatal voltages if connected rsaquo Assemble the system using the components provided by KACO new energy only rsaquo Check the serial numbers on the delivery document against the serial numbers of the individual

units on pallets A and B

52 StorageIncorrect storage can lead to system malfunctions Therefore please observe the following conditionsbull If storing for longer than six months store the device in an interior room in its original packaging bull If the original packaging has been removed store the device in a cool dry interior roombull Storage temperature -20 degC to +70 degCbull Relative humidity 0 to 95 (non-condensing)bull If the device is stored for a relatively long time at high humidity the device must be left for more than one day to

dry out sufficiently before connection to the power grid

53 Transportation

WARNINGImpact hazard risk of breakage to the components in the battery systemThe centre of gravity is located in the upper part of the device rsaquo Transport the device upright together with the pallet rsaquo Do not expose the device or components to any shocks rsaquo After unloading at least two people are required to transport the cabinet

WARNINGDanger due to impact and incorrect storage of the batteriesIn the event of damage batteries can release hazardous electrolyte gases which will cause irreversible burns if they come into contact with the skin rsaquo Transport the batteries in the vendors original packaging only rsaquo Remove the batteries from the original packaging shortly before installation rsaquo Do not store batteries in cars or outdoors rsaquo Check the condition of the battery before use

NOTEThe precise specifications of the UN on the transport of lithium batteries can be found under the designation Model Regulations on the transport of dangerous goods Ref STSGAC101 Recommendations on the transport of dangerous goods Part III sub-section 383 ldquoManual of Tests and Criteriardquo Ref STSGAC1011

Assembling the device

Page 16 Operating instructions Powador-gridsave_EN

Authorised electrician

6 Assembling the device

61 Installation

DANGERRisk of fatal injury from fire or explosionsFire caused by flammable or explosive materials in the vicinity of the battery system can lead to serious injuries rsaquo Do not mount the inverter in potentially explosive atmospheres or in the vicinity of highly flamma-

ble materials

CAUTIONBattery system is very heavy ndash risk of injury rsaquo Be aware of the weight of the battery system during transport rsaquo Select suitable mounting location and mounting base rsaquo Only install the battery system with the help of a second person

CAUTIONEquipment damage caused by aggressive gases in combination with humidityThe housing may be seriously damaged by aggressive gases (ammonia sulphur and other chemi-cals) in combination with ambient humidity caused by weather conditions - Installation in rooms containing aggressive gases is not permitted

NOTEAccess in the event of maintenance or serviceAny additional costs arising from unfavourable structural or mounting conditions in the event of a KACO service call-out shall be billed to the customer

611 Installation location

bull Dry well ventilated the waste heat must be conducted away from the battery systembull Unobstructed air circulationbull Easily accessible from the front top and sides without requiring additional resourcesbull Indoors protected against direct sunlight and direct water contact

612 Foundation

bull With sufficient load-bearing capacitybull Made from heat-resistant material (up to 90 degC)bull Must be flame resistant

NOTEPower reduction due to heat accumulationIf the recommended minimum clearances are not observed the device may go into power regula-tion mode due to insufficient ventilation and the resulting heat build-up rsaquo The construction and installation of the device may be performed only by a qualified electrician in

accordance with the valid standards and regulations rsaquo Maintain minimum clearances rsaquo Ensure sufficient heat dissipation

Assembling the device

Operating instructions Powador-gridsave_EN Page 17

Authorised electrician

0deg

1000 mm

200 mm 200 mm

500 mm

min carrying capacity 300 kgmsup2

200 mm200 mm

50 mm

Figure 9 Minimum clearances at the installation and assembly location

CAUTIONRisk of injury if the battery system tips overRisk of tipping due to high centre of gravity particularly with the door open rsaquo Anchor the device securely to the floor immediately after installation rsaquo Open the housing door using the enclosed cabinet key only once the device has been securely

anchored

510 mm200 mm

200 mm

400

mm

12 mmmin 110 mm

DesignationHex head wood screw 8x80 DIN571-vz Fischer dowel S12 Flat washer M8 galvanised DIN9021-vz

Units444

Figure 10 Dimensions for anchoring to the floor Table 3 Mounting parts

62 Installing components

CAUTIONAvoid improper handlingImproper handling can cause damage to components rsaquo Damaged components must not be installed rsaquo Always put the plug-in modules down horizontally to avoid damage to the components

Assembling the device

Page 18 Operating instructions Powador-gridsave_EN

Authorised electrician

WARNINGDanger caused by short circuit or sparkingSerious injury from touching or connecting live components rsaquo Damaged components must not be installed

Preparation1 Check the conditions for the installation location2 Open the housing doors using the enclosed cabinet key3 The cables should be professionally laid and prepared for connection4 Follow the installation sequence (1-4 step(s))

621 Step 1 Fit the battery (batteries)

NOTEPlease read the notes on installation and connection in the enclosed manual Features for the battery unit

622 Step 2 Connect battery (batteries) to the battery management system (BMS)

NOTEPlease read the notes on installation and connection in the enclosed manual Features for the battery unit

623 Step 3 Fit the battery charging unit battery backup converter (BBC)

Battery (batteries) connected to the battery management system (BMS)1 Carefully insert battery charging unit battery backup converter (BBC) into the compartment provided for it 2 Push in completely to establish direct contact with the rear busbars3 Secure battery charging unit battery backup converter (BBC) using the screws supplied

624 Step 4 Fit the inverter

Battery charging unit battery backup converter (BBC) is fitted1 Carefully insert inverter into the compartment provided for it 2 Push in completely to establish direct contact with the rear busbars 3 Secure inverter using the screws supplied

CAUTIONDamage to the control unit from introducing foreign objectsForeign objects can impair the function of the control unit and cause damage rsaquo Do not remove the front panel rsaquo Foreign objects should be removed immediately

Installing the device

Operating instructions Powador-gridsave_EN Page 19

Authorised electrician

7 Installing the device

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched The device may only be opened or serviced by an authorised electricianThe device must be completely assembled before being connected electrically rsaquo Observe all safety regulations and current technical connection specifications of the responsible

power supply company rsaquo De-energise the device using the DC isolator switch circuit breaker and residual current circuit

breaker rsaquo Secure both sides against being inadvertently switched back on rsaquo Ensure that the AC and DC sides are completely isolated and voltage free rsaquo Never open the plug-in modules rsaquo Hazardous voltages are present at the busbars rsaquo Disconnect from the grid and plant supply rsaquo First connect the battery system in the connection area

71 Opening the connection area

3

1

2

Figure 11 Open cover plateKey

1 Cover plate 3 Fastening screw

2 Lock

Opening the connection area You have completed assembly

1 Remove the fastening screw for the upper cover plate2 Slide the cover plate forwards out of the lock3 Lift the cover plate upward to remove raquo Make the electrical connection

Installing the device

Page 20 Operating instructions Powador-gridsave_EN

Authorised electrician

72 Making the electrical connectionMake the connection to the PV generator as well as the grid connection using the connection terminals Note the following cable cross-sections

Connection Possible cable cross-section Length of insulation to be stripped offAC home power grid 05 - 16 mmsup2 with end sleeve

05 - 25 mmsup2 without end sleeve18 mm sleeve18-20 mm

PV connection 05 - 16 mmsup2 with end sleeve05 - 25 mmsup2 without end sleeve

18 mm sleeve17-19 mm

Inverter output 05 - 4 mmsup2 with end sleeve05 - 6 mmsup2 without end sleeve

12 mm sleeve11-13 mm

Potential-free contacts 034 - 15 mmsup2 with end sleeve034 - 25 mmsup2 without end sleeve

12 mm sleeve 9-10 mm

Table 4 Cable cross-sections for connection terminals

NOTEThe threaded connections should be matched to the cable cross-section

NOTEOnly conductors and no insulation should be inserted into the connection terminals Individual wires or cables with end sleeves with the appropriate cross-section can be inserted directly into the connection terminal without a toolFine-strand cables without end sleeve or thin conductors will need a screwdriver (plain slot 35 mm) for connection To do this insert the blade of the screwdriver into the recess provided The cable can be inserted into the spring terminal by pressing downwards The spring terminal closes on removal of the screw-driver

Installing the device

Operating instructions Powador-gridsave_EN Page 21

Authorised electrician

X2X1F1 F2 X7 X4 St1

St2

St3

2 3 541 6

Figure 12 View from above of the connection area

Key

1 AC grid input (M40 cable fitting) 4 Network interface (M32 cable fitting)

2 AC grid output (M40 cable fitting) 5 Inverter input (M16 cable fitting)

3 Inverter output (M32 cable fitting) 6 Other connections (M16 cable fitting)

F1 F2 X7 X4 St1

St2

St3

L1 L2 L3 N PE L1 L2 L3 N N PE PE

X1 X2

PV+

PV-

L1 L2 L3 N PE32A 32A PEN

Cust

omer

co

nnec

tion

Figure 13 View from above of the connection area

Key

X1 AC grid input (main junction box meter) X7 PV generator input

X2 AC grid output (building electrical system) F1 F2 Phase bridging fuse

X4 Inverter output St 1-3 Potential-free contacts control outputs

Installing the device

Page 22 Operating instructions Powador-gridsave_EN

Authorised electrician

721 Connecting to the power grid

Because the device is installed between the main junction boxmeter and the buildings electrical system the maxi-mum grid current to the service line must not exceed the rated operating current of the battery system The cable cross-section must be selected in accordance with applicable standards to suit the connected load instal-lation type etc Moreover the terminal area and size of the cable fitting must be noted

NOTEThe fuse rating for the cable should be max 63A (automatic circuit breaker or safety fuse) even if the cross-section of the installed cable would permit a higher fuse rating Always follow the applicable regulations regarding the cable cross-section and installation typeThe device supports standard grid configurations such as TN-C TN-S and TT TN-SIf a TN-S grid is present directly at the power input and output of the device L1-L3 N and PE must each be connected The home power grid should have 4-pin isolationTN-C4-pin grid isolation is factory preset and disconnects L1 L2 L3 and N In a TN-C grid the N conduc-tor must not be disconnected If a TN-S grid is present directly at the power input and output of the device a cable bridge (included in delivery) must be installed between the N terminal on X1 and the N terminal on X2 N and PE must additionally be connected together To do this simply insert the enclosed terminal link into the N and PE terminals TTIn the case of a TT grid L1-L3 N and PE must each be connected The home power grid should have 4-pin isolation

NOTEPlease check with the operator of the mains grid whether there are special regulations for grid connection Grid isolation is factory preset to 4-pin is fail-safe and provided with grid and system protection as per VDE-AR-N 4105

Making the grid connection Use cables with 5 wires (L1 brown L2 black L3 grey N blue PE greenyellow) and the correct

cross-section1 Loosen cable fitting for AC connection2 Remove the outer cladding of the AC cables3 Insert the AC cables through the cable fitting into the connection area4 Strip the insulation from the AC cables5 Remove connection terminals6 Connect the cables in line with the terminal labels (Figure 13 on page 21)7 Close the connection terminals8 Check that all connected cables are securely fitted9 Tighten the cable fitting10 To meet the requirements of protection rating IP21 close the unused cable fittings with blind caps raquo The battery system is connected to the power grid

NOTEAn AC-side disconnection unit must be provided during the final installation stage This disconnec-tion unit must be installed so that it can be accessed at any time without obstruction If a residual current circuit breaker is necessary due to the installation specification a type A residual current circuit breaker must be used

Installing the device

Operating instructions Powador-gridsave_EN Page 23

Authorised electrician

7211 Output from the inverterRecommended cable cross-sections for the inverter output and fuse rating of cables for fixed wiring accord-ing to VDE 0100 part 430The fuse rating for the cable is dependent on the cable cross-section max 40A automatic circuit breaker

NOTEWhen the line resistance is high (ie long grid-side cables) the voltage at the grid terminals of the inverter will increase during feed-in to the grid The inverter monitors this voltage If the voltage exceeds the country-specific grid overvoltage limit value the inverter switches off rsaquo Ensure that the conductor cross-sections are sufficiently large or that the cable lengths are suffi-

ciently short

NOTEIn order to avoid asymmetries in the grid systems with multiple battery systems should be designed so that the inverters in the devices feed into the grid in differing phases rsaquo Follow the connection conditions for the particular type of grid and the schematic illustration

below

Country and grid-type

Grid monitoring Required monitoring

max asymmetry between phases L1L2L3

DE-NSP Three-phase or single phase phase unbalanced load 46 kVA

Table 5 Grid-type-specific connection conditions

L1

L2

L3

N

Connection X1 Connection X1 Connection X1 Connection X1

L1 L2 L3 N PE L1 L2 L3 N PE L1 L2 L3 N PE L1 L2 L3 N PE

Powador-gridsave inverter1 L1 - L1 L2 - L2 L3 - L32 L1 - L2 L2 - L3 L3 - L1 3 L1 - L3 L2 - L1 L3 - L2 4 L1 - L1 L2 - L2 L3 - L3

Figure 14 Grid-side connection for systems with multiple battery systems with three-phase grid monitoring

Installing the device

Page 24 Operating instructions Powador-gridsave_EN

Authorised electrician

722 Connecting the PV generator

Connect the PV generator on the left in the connection area (Figure 13 on page 21) Use the provided M16 cable fittings A maximum of two strings can be connected For this reason a DC string fuse can be dispensed with

DANGERRisk of fatal injury due to contact voltagesRemoving the cables from the terminals without first disconnecting the PV generator from the device can cause serious damage to health or damage to the system rsaquo During installation Electrically disconnect the DC positive and DC negative from the protective

earth (PE) rsaquo Completely de-energise the system (AC home power grid AC circuit breaker residual current circuit

breaker DC isolator switch) rsaquo Disconnect the battery system from the PV generator using the integrated DC isolator switch rsaquo Remove DC plug connectors

NOTEIn accordance with IEC 61730 Class A connected PV modules must be dimensioned for the DC system voltage provided and at least for the value of the AC grid voltage

7221 Before connecting

Ensure that there is no ground fault1 Determine the DC voltage between the

ndash protective earth (PE) and the positive cable of the PV generator and between the ndash protective earth (PE) and the negative cable of the PV generator

If stable voltages can be measured there is a ground fault in the DC generator or its wiring The ratio between the measured voltages gives an indication as to the location of this fault

2 Rectify any faults before taking further measurements3 Determine the electrical resistance between the

ndash protective earth (PE) and the positive cable of the PV generator and between the ndash protective earth (PE) and the negative cable of the PV generator

In addition ensure that the PV generator has a total insulation resistance of more than 20 MOhm since the inverter will not feed in if the insulation resistance is too low

4 Rectify any faults before connecting the DC generator

7222 Connecting the PV generator

DANGERRisk of fatal injury due to electric shockSevere injury or death will result if the live connections are touched When there is solar radiation DC voltage will be present at the open ends of the DC cables rsaquo Do not touch the exposed ends of the cables rsaquo Avoid short circuits

Installing the device

Operating instructions Powador-gridsave_EN Page 25

Authorised electrician

Connecting the PV generator Use cables with the correct cross-section

1 Remove cable fittings for DC connection2 Remove the outer cladding of the DC cables3 Insert the DC cables through the cable fittings into the connection area4 Strip the insulation from the DC cables5 Remove connection terminals6 Connect the cables in line with the terminal labels (See Figure 13 on page 21)7 Close the connection terminals8 Check that all connected cables are securely fitted9 Tighten the cable fittings10 To meet the requirements of protection rating IP21 close the unused cable fittings with blind caps raquo The PV generator is connected to the inverter

73 Connecting the interfaces

731 Ethernet interface

Pre-assembled Ethernet cables can be connected using the RJ45 socket in the connection space

Connecting the Ethernet cable1 Remove closure cap from RJ45 socket2 Connect the Ethernet cable3 The energy management system can now obtain an IP address by DHCP and is also available via this in the

network

NOTEThe network settings can be amended later in the Settings menu using the EMS

NOTEUse a suitable category 5 network cable The maximum length of a network segment is 100 m Ensure that the cable is correctly assigned The Ethernet connection of the battery system supports auto-sensing You can use both crossed and 11 configured Ethernet connection cables

74 Sealing the connection area

1 Finally check the cabling2 Ensure that all cables are firmly mounted3 Check that the cable fitting is secure and tighten if necessary4 Remove cable offcuts and particles of dirt or dust5 Fit the cover and slide back until it engages into position6 Check that the position is correct7 Screw the fastening screw onto the front of the cover

Installing the device

Page 26 Operating instructions Powador-gridsave_EN

Authorised electrician

75 Starting up

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched Only appropriately qualified and authorised electricians may open install or maintain the battery system rsaquo Keep the front doors and covers closed during operation

NOTEInitial start-up should be carried out using the available public AC grid

76 Standard configuration

Factory settingsCountry configuration Germany

Grid guidelines Low voltage directive

Language German

Time UTC +1 Central European Time

User Standard

Network parameters DHCP (network settings will be obtained automatically from the router)

NOTEPlease state the desired power limitation (60 or 70 of the PV system capacity) when you order For other variations please notify your KACO contact so that the parameters can be set at the factory prior to delivery

Installing the device

Operating instructions Powador-gridsave_EN Page 27

Authorised electrician

761 Step 1 AC home power grid

Check all cables and connections before starting up1 Switch on the AC home power grid using the AC main switch raquo Powador-protect measurement and control unit starts up and monitors the AC grid raquo Two green LEDs indicate that the grid parameters are met raquo After a further 60 seconds (shortly after the backlighting in the Powador-protect goes out) the Powador-pro-

tect will switch on the home grid2 Configure Powador-protect according to the enclosed Powador-protect instructions

(The instructions are also available on the website at wwwkaconewenergyde) raquo The AC power is supplied in the normal way by the public grid

762 Step 2 AC supply from the battery system

Check all cables and connections before starting up1 Remove external isolation means from the device2 Switch on the circuit breaker raquo The LCD touchscreen on the front panel comes on and the energy management system (EMS) starts up

3 Switch on the residual current circuit breaker raquo The battery system starts up

763 Step 3 Switch on the PV system

1 Switch on any optional external PV isolator switches2 Set the internal DC isolator switch to ON raquo The inverter and the battery charging unit battery backup converter (BBC) are connected to the PV system raquo The device monitors the PV voltage for approx 60 seconds then optimisation of internal consumption takes

place

764 Step 4 Switch on batteries

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

765 Step 5 Activate energy management

NOTEKACO new energy cannot provide any support for problems regarding the IT infrastructure (eg router configuration IP address assignment ports etc) as the structure settings and configuration of the network environment can be complex and very different from place to place In the event of any problems please contact an IT service provider

Remote access activated 1 Please call the KACO Hotline to make an appointment for activation of energy management

Configuration and Operation

Page 28 Operating instructions Powador-gridsave_EN

Authorised electrician

8 Configuration and Operation

81 ControlsThe battery system is fitted with a touchscreen which allows it to be controlled very precisely In normal operation the display is switched off Touching the screen activates the display and after a configurable period of time without being touched the dis-play will deactivate If the screen-save function is switched off the touchscreen will be on continuously

NOTEDepending on the tolerances of the measuring elements the measured and displayed values are not always the actual values However the measuring elements ensure maximum solar yield Due to these tolerances the daily yields shown on the touchscreen may deviate from the values on the grid operatorrsquos feed-in meter by up to 15

3

1

45

2

Figure 15 Overview (home screen)

Key

1 Home button 4 Current time

2 System components 5 Menu name

3 More information

811 Information about the system

Open start screen View changesjumps to the home screen

Show component detail Parameters of the selected component

Settings Define settings for the active user

raquo Displays settings

Configuration and Operation

Operating instructions Powador-gridsave_EN Page 29

Controls Left arrow jump back to previous menu item Up and down arrows navigate through the menu or change a value

Left arrow displayed value is reduced by one increment Right arrow displayed value is increased by one increment or change to the submenu

Display fields Grey box Text or figures (not selectable) Blue box Calls up submenu for the display in question

Activate and deactivate Activate function by ticking the box

Table 6 Information about the system

812 System components

PV generator Display of the current generator data

power voltage current temperature in the inverter

Battery Display of the current battery status

power (charging or discharging) voltage current charge status available capacity temperature of battery

Grid Display of the following either fed-in or drawn from the grid

power voltage current for phase L1-L3 total output frequency

Consumer (load) Display of the consumer data

power voltage current for phase L1-L3 total output

Energy flow raquo Displays the current energy flow in the system

Table 7 Information about system components

Configuration and Operation

Page 30 Operating instructions Powador-gridsave_EN

813 Menu structure

Icons used

Display menu Submenu

Option menu

Menu Submenu Display setting

Action in this menumeaning

PV generator Details

Power Displays the current DC-side power

Voltage Displays the current DC-side voltage

Current Displays the current DC-side amperage

Temp inverter

Displays the current temperature in the inverter housing

Battery Details

Power Displays the current AC-side power

Voltage Displays the current AC-side voltage

Current Displays the current AC-side amperage

Charge status Displays the current charge status

Capacity Displays the current battery capacity

Temperature Displays the current measured temperature of the battery

Grid Details

Power Displays the current AC-side power being drawn or fed-in

Voltage Displays the AC-side voltage being applied

Current Displays the current AC-side amperage being drawn or fed-in

Total output Displays the current AC-side total output being drawn or fed-in

Frequency Displays the frequency currently being applied to the grid junction

Consumer (load) Details

Power Displays the current AC-side power being drawn

Voltage Displays the current AC-side voltage being applied

Current Displays the current AC-side amperage being drawn

Total output Displays the current AC-side total output being drawn

Configuration and Operation

Operating instructions Powador-gridsave_EN Page 31

Menu Submenu Display setting

Action in this menumeaning

Settings

Country amp directive display

Display of the country settings voltage directives and grid type

Select menu language

DateTime Specify time zone date format and date and time

Screen Activate screen-save function and set the delay period

Network settings

Display of the network settings Configure network settings Once the DHCP server becomes available the IP

address subnet mask gateway and DNS server are automatically applied and the aforemen-tioned menu items are hidden

Off DHCP deactivated make settings manually

Version Displays the installed software version and built-in HW components (inverter BBC battery)

Vendor The touchscreen shows information about the device vendor

NOTEAs changes to the software are possible after the manual has been printed the illustrations and descriptions of the functions in these operating instructions may deviate from the software Please therefore note the current Application Notes on our website

MaintenanceTroubleshooting

Page 32 Operating instructions Powador-gridsave_EN

9 MaintenanceTroubleshooting

91 Visual inspectionInspect the device and the cables for visible external damage and note the operating status display In case of damage notify your installer Repairs may only be carried out by authorised electricians

NOTEThe battery system should be checked for proper operation by a qualified electrician at regular intervals

92 Cleaning the device

DANGERLethal voltages in the battery systemSerious injuries or death can result if moisture enters the system rsaquo Only use completely dry objects to clean the battery system rsaquo Only clean the outside of the battery system

Cleaning the battery system Do not use compressed air Use a vacuum cleaner or a soft brush to remove dust from the fan cover and from the top of the inverter on a

regular basis Remove dust from the ventilation inlets if necessary

MaintenanceTroubleshooting

Operating instructions Powador-gridsave_EN Page 33

Authorised electrician

93 Maintenance

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched The device is only permitted to be opened or serviced by an authorised electrician rsaquo Observe all safety regulations and the current technical connection specifications from the relevant

power supply company rsaquo Disconnect the AC and DC sides rsaquo Secure the AC and DC sides from being inadvertently switched back on rsaquo Only then should the device be opened rsaquo After shutdown wait at least 30 minutes before working on the device

CAUTIONDestruction of the DC connectionThe connection terminals can be destroyed by arcing if disconnected while still live rsaquo It is absolutely essential that the shutdown sequence be carried out in the correct order (See sec-

tion 111 on page 35)

94 Faults

941 Procedure

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched

When a fault occurs notify an appropriately authorised and qualified electrician or KACO new energy GmbH Service

Service

Page 34 Operating instructions Powador-gridsave_EN

10 ServiceIf 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 efficientlybull Serial nobull SW version of the components (the software version can be found in the Settings menu using the EMS)bull Module type and string circuitbull Date of installation Start-up reportbull Consignment identification Delivery address Contact person (with telephone number)bull Information about the accessibility of the installation site

Any additional costs arising from unfavourable structural or mounting conditions shall be billed to the customer

You can find our warranty conditions on our websitehttpkaco-newenergycomservicewarrantyFrom there you can easily navigate to our international websites by clicking on the appropriate flag

Please use our website to register your unit immediatelyYou can also select the appropriate flag on this page to access the website for your own countryIn this manner you can assist us in providing you with the quickest service possible Note The maximum length of the warranty is based on the currently applicable national warranty conditions

We have prepared a template for complaints This can be found at httpskaco-newenergycomservicecustomer-service

Hotlines

Technical troubleshooting Technical consultation

Inverters and battery systems ()

+49 (0) 71323818-660 +49 (0) 71323818-660

Data logging and accessories +49 (0) 71323818-690 +49 (0) 71323818-690

Construction site emergency () +49 (0) 71323818-630

Customer help desk Monday to Friday from 730 am to 530 pm (CET)

() Also on Saturdays from 800 am to 200 pm (CET)

ShutdownDisassembly

Operating instructions Powador-gridsave_EN Page 35

11 ShutdownDisassembly

111 Switching off the device

DANGERLethal voltages are still present in the terminals and cables even after switching off and discon-nection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched rsaquo Complete de-energisation only occurs if the bulk power supply is switched off upstream of the bat-

tery system

DANGERDestruction of the DC plug connectorDC plug connectors can be destroyed by arcing if disconnected while still live rsaquo It is absolutely essential that the following shutdown sequence is observed

1111 Step 1 Shutting down the PV system

1 Switch off any optional external PV isolator switches2 Set the internal DC isolator switch to OFF raquo The inverter and battery charging unit battery backup converter (BBC) are disconnected

1112 Step 2 Disconnect the batteries

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

1113 Step 3 Disconnect the AC supply

1 Connect external isolation means to the device2 Switch off the circuit breaker 3 Switch off the residual current circuit breaker raquo The battery system is switched off

1114 Step 4 AC home power grid

1 Shutdown the AC home power grid using the AC main switch raquo The battery system can be uninstalled

Disposal

Page 36 Operating instructions Powador-gridsave_EN

112 Uninstalling the device

NOTETo uninstall follow the same sequence as for installation but in reverse order

Switch off the device1 Unlock and open the housing door2 Remove the upper cover3 Release the DC and AC cables from the connection terminals4 Pull out the cables raquo The battery system is uninstalled Continue with the disassembly

113 Disassembling the device

NOTETo disassemble follow the same sequence as for assembly but in reverse order

Switch off the device1 Uninstall the components2 Remove the fastening from the device3 Securely pack up the battery system if it is to be used later

or have the battery system disposed of in accordance with section 12 on page 36

12 DisposalFor the most part both the battery system and the corresponding transport packaging are made from recyclable raw materialsBatteries and components Do not dispose of faulty batteries or the components together with household waste Ensure that the old device and accessories are disposed of in a proper mannerPackaging Ensure that the transport packaging is disposed of properlyBatteriesUsed or faulty batteries must be transported in special packaging If you need such packaging please contact the KACO Hotline

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

Appendix

Operating instructions Powador-gridsave_EN Page 37

13 Appendix

EU Declaration of Conformity

Vendorrsquos name and address

KACO new energy GmbH Carl-Zeiss-Straszlige 1 74172 Neckarsulm Germany

Product description Battery system

Type designation Powador-gridsave 135 kWh 6400 Powador-gridsave 135 kWh 8000

Powador-gridsave 270 kWh 6400 Powador-gridsave 270 kWh 8000

Powador-gridsave 405 kWh 6400 Powador-gridsave 405 kWh 8000

Powador-gridsave 540 kWh 6400 Powador-gridsave 540 kWh 8000

Powador-gridsave 577 kWh 6400 Powador-gridsave 577 kWh 8000

Powador-gridsave 675 kWh 6400 Powador-gridsave 675 kWh 8000

This is to confirm that the units listed above comply with the protection requirements set forth in the Directive of the Council of the European Union of 15th December 2004 on the harmonisation of the laws of the member states relating to Electromagnetic Compatibility (2004108EC) and the Low Voltage Directive (200695EC)The units are compliant with the following standards

200695EC ldquoDirective relating to electrical equipment designed for use within specific voltage limitsrdquo

Safety of the unitIEC 62109-12010IEC 62109-22011

2004108EC ldquoDirective relating to electromagneticcompatibilityrdquo

Interference immunityEN 61000-6-22005 Emitted interferenceEN 61000-6-32007

Secondary effects on the gridEN 61000-3-112000EN 61000-3-122005

The types mentioned above are therefore labelled with the CE markUnauthorised modifications to the supplied units andor any use of the units that is contrary to their intended use render this Declaration of Conformity null and void

Neckarsulm 0711 2013KACO new energy GmbH

pp Volker DietrichEnergy systems engineering management

Disposal

Page 38 Operating instructions Powador-gridsave_EN

Carl-Zeiss-Straszlige 1 middot 74172 Neckarsulm middot Germany middot Phone +49 7132 3818-0 middot Fax +49 7132 3818-703 middot infokaco-newenergyde middot wwwkaco-newenergyde

The

text

and

figu

res

refle

ct th

e cu

rren

t tec

hnic

al s

tate

at t

he ti

me

of p

rintin

g S

ubje

ct to

tech

nica

l cha

nges

Err

ors

and

omis

sion

s ex

cept

ed

3006

856-

01-1

4030

5

  • 1General Information
    • 11About this document
    • 12Name plate
    • 13Additional information
    • 14Intended use
      • 2Safety
        • 21Protection features
          • 3Description
            • 31Mode of Operation
            • 32Summary of the components
              • 4Technical Data
                • 41Electrical data
                • 42Mechanical data
                  • 5Transportation and Delivery
                    • 51Delivery
                    • 52Storage
                    • 53Transportation
                      • 6Assembling the device
                        • 61Installation
                        • 62Installing components
                          • 7Installing the device
                            • 71Opening the connection area
                            • 72Making the electrical connection
                            • 73Connecting the interfaces
                            • 74Sealing the connection area
                            • 75Starting up
                            • 76Standard configuration
                              • 8Configuration and Operation
                                • 81Controls
                                  • 9MaintenanceTroubleshooting
                                    • 91Visual inspection
                                    • 92Cleaning the device
                                    • 93Maintenance
                                    • 94Faults
                                      • 10Service
                                      • 11ShutdownDisassembly
                                        • 111Switching off the device
                                        • 112Uninstalling the device
                                        • 113Disassembling the device
                                          • 12Disposal
                                          • 13Appendix

Transportation and Delivery

Operating instructions Powador-gridsave_EN Page 15

Authorised electrician

DANGERRisk of fatal injury if incompatible components are usedThe battery and power electronics can be damaged if different delivery batches are combined and will carry potentially fatal voltages if connected rsaquo Assemble the system using the components provided by KACO new energy only rsaquo Check the serial numbers on the delivery document against the serial numbers of the individual

units on pallets A and B

52 StorageIncorrect storage can lead to system malfunctions Therefore please observe the following conditionsbull If storing for longer than six months store the device in an interior room in its original packaging bull If the original packaging has been removed store the device in a cool dry interior roombull Storage temperature -20 degC to +70 degCbull Relative humidity 0 to 95 (non-condensing)bull If the device is stored for a relatively long time at high humidity the device must be left for more than one day to

dry out sufficiently before connection to the power grid

53 Transportation

WARNINGImpact hazard risk of breakage to the components in the battery systemThe centre of gravity is located in the upper part of the device rsaquo Transport the device upright together with the pallet rsaquo Do not expose the device or components to any shocks rsaquo After unloading at least two people are required to transport the cabinet

WARNINGDanger due to impact and incorrect storage of the batteriesIn the event of damage batteries can release hazardous electrolyte gases which will cause irreversible burns if they come into contact with the skin rsaquo Transport the batteries in the vendors original packaging only rsaquo Remove the batteries from the original packaging shortly before installation rsaquo Do not store batteries in cars or outdoors rsaquo Check the condition of the battery before use

NOTEThe precise specifications of the UN on the transport of lithium batteries can be found under the designation Model Regulations on the transport of dangerous goods Ref STSGAC101 Recommendations on the transport of dangerous goods Part III sub-section 383 ldquoManual of Tests and Criteriardquo Ref STSGAC1011

Assembling the device

Page 16 Operating instructions Powador-gridsave_EN

Authorised electrician

6 Assembling the device

61 Installation

DANGERRisk of fatal injury from fire or explosionsFire caused by flammable or explosive materials in the vicinity of the battery system can lead to serious injuries rsaquo Do not mount the inverter in potentially explosive atmospheres or in the vicinity of highly flamma-

ble materials

CAUTIONBattery system is very heavy ndash risk of injury rsaquo Be aware of the weight of the battery system during transport rsaquo Select suitable mounting location and mounting base rsaquo Only install the battery system with the help of a second person

CAUTIONEquipment damage caused by aggressive gases in combination with humidityThe housing may be seriously damaged by aggressive gases (ammonia sulphur and other chemi-cals) in combination with ambient humidity caused by weather conditions - Installation in rooms containing aggressive gases is not permitted

NOTEAccess in the event of maintenance or serviceAny additional costs arising from unfavourable structural or mounting conditions in the event of a KACO service call-out shall be billed to the customer

611 Installation location

bull Dry well ventilated the waste heat must be conducted away from the battery systembull Unobstructed air circulationbull Easily accessible from the front top and sides without requiring additional resourcesbull Indoors protected against direct sunlight and direct water contact

612 Foundation

bull With sufficient load-bearing capacitybull Made from heat-resistant material (up to 90 degC)bull Must be flame resistant

NOTEPower reduction due to heat accumulationIf the recommended minimum clearances are not observed the device may go into power regula-tion mode due to insufficient ventilation and the resulting heat build-up rsaquo The construction and installation of the device may be performed only by a qualified electrician in

accordance with the valid standards and regulations rsaquo Maintain minimum clearances rsaquo Ensure sufficient heat dissipation

Assembling the device

Operating instructions Powador-gridsave_EN Page 17

Authorised electrician

0deg

1000 mm

200 mm 200 mm

500 mm

min carrying capacity 300 kgmsup2

200 mm200 mm

50 mm

Figure 9 Minimum clearances at the installation and assembly location

CAUTIONRisk of injury if the battery system tips overRisk of tipping due to high centre of gravity particularly with the door open rsaquo Anchor the device securely to the floor immediately after installation rsaquo Open the housing door using the enclosed cabinet key only once the device has been securely

anchored

510 mm200 mm

200 mm

400

mm

12 mmmin 110 mm

DesignationHex head wood screw 8x80 DIN571-vz Fischer dowel S12 Flat washer M8 galvanised DIN9021-vz

Units444

Figure 10 Dimensions for anchoring to the floor Table 3 Mounting parts

62 Installing components

CAUTIONAvoid improper handlingImproper handling can cause damage to components rsaquo Damaged components must not be installed rsaquo Always put the plug-in modules down horizontally to avoid damage to the components

Assembling the device

Page 18 Operating instructions Powador-gridsave_EN

Authorised electrician

WARNINGDanger caused by short circuit or sparkingSerious injury from touching or connecting live components rsaquo Damaged components must not be installed

Preparation1 Check the conditions for the installation location2 Open the housing doors using the enclosed cabinet key3 The cables should be professionally laid and prepared for connection4 Follow the installation sequence (1-4 step(s))

621 Step 1 Fit the battery (batteries)

NOTEPlease read the notes on installation and connection in the enclosed manual Features for the battery unit

622 Step 2 Connect battery (batteries) to the battery management system (BMS)

NOTEPlease read the notes on installation and connection in the enclosed manual Features for the battery unit

623 Step 3 Fit the battery charging unit battery backup converter (BBC)

Battery (batteries) connected to the battery management system (BMS)1 Carefully insert battery charging unit battery backup converter (BBC) into the compartment provided for it 2 Push in completely to establish direct contact with the rear busbars3 Secure battery charging unit battery backup converter (BBC) using the screws supplied

624 Step 4 Fit the inverter

Battery charging unit battery backup converter (BBC) is fitted1 Carefully insert inverter into the compartment provided for it 2 Push in completely to establish direct contact with the rear busbars 3 Secure inverter using the screws supplied

CAUTIONDamage to the control unit from introducing foreign objectsForeign objects can impair the function of the control unit and cause damage rsaquo Do not remove the front panel rsaquo Foreign objects should be removed immediately

Installing the device

Operating instructions Powador-gridsave_EN Page 19

Authorised electrician

7 Installing the device

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched The device may only be opened or serviced by an authorised electricianThe device must be completely assembled before being connected electrically rsaquo Observe all safety regulations and current technical connection specifications of the responsible

power supply company rsaquo De-energise the device using the DC isolator switch circuit breaker and residual current circuit

breaker rsaquo Secure both sides against being inadvertently switched back on rsaquo Ensure that the AC and DC sides are completely isolated and voltage free rsaquo Never open the plug-in modules rsaquo Hazardous voltages are present at the busbars rsaquo Disconnect from the grid and plant supply rsaquo First connect the battery system in the connection area

71 Opening the connection area

3

1

2

Figure 11 Open cover plateKey

1 Cover plate 3 Fastening screw

2 Lock

Opening the connection area You have completed assembly

1 Remove the fastening screw for the upper cover plate2 Slide the cover plate forwards out of the lock3 Lift the cover plate upward to remove raquo Make the electrical connection

Installing the device

Page 20 Operating instructions Powador-gridsave_EN

Authorised electrician

72 Making the electrical connectionMake the connection to the PV generator as well as the grid connection using the connection terminals Note the following cable cross-sections

Connection Possible cable cross-section Length of insulation to be stripped offAC home power grid 05 - 16 mmsup2 with end sleeve

05 - 25 mmsup2 without end sleeve18 mm sleeve18-20 mm

PV connection 05 - 16 mmsup2 with end sleeve05 - 25 mmsup2 without end sleeve

18 mm sleeve17-19 mm

Inverter output 05 - 4 mmsup2 with end sleeve05 - 6 mmsup2 without end sleeve

12 mm sleeve11-13 mm

Potential-free contacts 034 - 15 mmsup2 with end sleeve034 - 25 mmsup2 without end sleeve

12 mm sleeve 9-10 mm

Table 4 Cable cross-sections for connection terminals

NOTEThe threaded connections should be matched to the cable cross-section

NOTEOnly conductors and no insulation should be inserted into the connection terminals Individual wires or cables with end sleeves with the appropriate cross-section can be inserted directly into the connection terminal without a toolFine-strand cables without end sleeve or thin conductors will need a screwdriver (plain slot 35 mm) for connection To do this insert the blade of the screwdriver into the recess provided The cable can be inserted into the spring terminal by pressing downwards The spring terminal closes on removal of the screw-driver

Installing the device

Operating instructions Powador-gridsave_EN Page 21

Authorised electrician

X2X1F1 F2 X7 X4 St1

St2

St3

2 3 541 6

Figure 12 View from above of the connection area

Key

1 AC grid input (M40 cable fitting) 4 Network interface (M32 cable fitting)

2 AC grid output (M40 cable fitting) 5 Inverter input (M16 cable fitting)

3 Inverter output (M32 cable fitting) 6 Other connections (M16 cable fitting)

F1 F2 X7 X4 St1

St2

St3

L1 L2 L3 N PE L1 L2 L3 N N PE PE

X1 X2

PV+

PV-

L1 L2 L3 N PE32A 32A PEN

Cust

omer

co

nnec

tion

Figure 13 View from above of the connection area

Key

X1 AC grid input (main junction box meter) X7 PV generator input

X2 AC grid output (building electrical system) F1 F2 Phase bridging fuse

X4 Inverter output St 1-3 Potential-free contacts control outputs

Installing the device

Page 22 Operating instructions Powador-gridsave_EN

Authorised electrician

721 Connecting to the power grid

Because the device is installed between the main junction boxmeter and the buildings electrical system the maxi-mum grid current to the service line must not exceed the rated operating current of the battery system The cable cross-section must be selected in accordance with applicable standards to suit the connected load instal-lation type etc Moreover the terminal area and size of the cable fitting must be noted

NOTEThe fuse rating for the cable should be max 63A (automatic circuit breaker or safety fuse) even if the cross-section of the installed cable would permit a higher fuse rating Always follow the applicable regulations regarding the cable cross-section and installation typeThe device supports standard grid configurations such as TN-C TN-S and TT TN-SIf a TN-S grid is present directly at the power input and output of the device L1-L3 N and PE must each be connected The home power grid should have 4-pin isolationTN-C4-pin grid isolation is factory preset and disconnects L1 L2 L3 and N In a TN-C grid the N conduc-tor must not be disconnected If a TN-S grid is present directly at the power input and output of the device a cable bridge (included in delivery) must be installed between the N terminal on X1 and the N terminal on X2 N and PE must additionally be connected together To do this simply insert the enclosed terminal link into the N and PE terminals TTIn the case of a TT grid L1-L3 N and PE must each be connected The home power grid should have 4-pin isolation

NOTEPlease check with the operator of the mains grid whether there are special regulations for grid connection Grid isolation is factory preset to 4-pin is fail-safe and provided with grid and system protection as per VDE-AR-N 4105

Making the grid connection Use cables with 5 wires (L1 brown L2 black L3 grey N blue PE greenyellow) and the correct

cross-section1 Loosen cable fitting for AC connection2 Remove the outer cladding of the AC cables3 Insert the AC cables through the cable fitting into the connection area4 Strip the insulation from the AC cables5 Remove connection terminals6 Connect the cables in line with the terminal labels (Figure 13 on page 21)7 Close the connection terminals8 Check that all connected cables are securely fitted9 Tighten the cable fitting10 To meet the requirements of protection rating IP21 close the unused cable fittings with blind caps raquo The battery system is connected to the power grid

NOTEAn AC-side disconnection unit must be provided during the final installation stage This disconnec-tion unit must be installed so that it can be accessed at any time without obstruction If a residual current circuit breaker is necessary due to the installation specification a type A residual current circuit breaker must be used

Installing the device

Operating instructions Powador-gridsave_EN Page 23

Authorised electrician

7211 Output from the inverterRecommended cable cross-sections for the inverter output and fuse rating of cables for fixed wiring accord-ing to VDE 0100 part 430The fuse rating for the cable is dependent on the cable cross-section max 40A automatic circuit breaker

NOTEWhen the line resistance is high (ie long grid-side cables) the voltage at the grid terminals of the inverter will increase during feed-in to the grid The inverter monitors this voltage If the voltage exceeds the country-specific grid overvoltage limit value the inverter switches off rsaquo Ensure that the conductor cross-sections are sufficiently large or that the cable lengths are suffi-

ciently short

NOTEIn order to avoid asymmetries in the grid systems with multiple battery systems should be designed so that the inverters in the devices feed into the grid in differing phases rsaquo Follow the connection conditions for the particular type of grid and the schematic illustration

below

Country and grid-type

Grid monitoring Required monitoring

max asymmetry between phases L1L2L3

DE-NSP Three-phase or single phase phase unbalanced load 46 kVA

Table 5 Grid-type-specific connection conditions

L1

L2

L3

N

Connection X1 Connection X1 Connection X1 Connection X1

L1 L2 L3 N PE L1 L2 L3 N PE L1 L2 L3 N PE L1 L2 L3 N PE

Powador-gridsave inverter1 L1 - L1 L2 - L2 L3 - L32 L1 - L2 L2 - L3 L3 - L1 3 L1 - L3 L2 - L1 L3 - L2 4 L1 - L1 L2 - L2 L3 - L3

Figure 14 Grid-side connection for systems with multiple battery systems with three-phase grid monitoring

Installing the device

Page 24 Operating instructions Powador-gridsave_EN

Authorised electrician

722 Connecting the PV generator

Connect the PV generator on the left in the connection area (Figure 13 on page 21) Use the provided M16 cable fittings A maximum of two strings can be connected For this reason a DC string fuse can be dispensed with

DANGERRisk of fatal injury due to contact voltagesRemoving the cables from the terminals without first disconnecting the PV generator from the device can cause serious damage to health or damage to the system rsaquo During installation Electrically disconnect the DC positive and DC negative from the protective

earth (PE) rsaquo Completely de-energise the system (AC home power grid AC circuit breaker residual current circuit

breaker DC isolator switch) rsaquo Disconnect the battery system from the PV generator using the integrated DC isolator switch rsaquo Remove DC plug connectors

NOTEIn accordance with IEC 61730 Class A connected PV modules must be dimensioned for the DC system voltage provided and at least for the value of the AC grid voltage

7221 Before connecting

Ensure that there is no ground fault1 Determine the DC voltage between the

ndash protective earth (PE) and the positive cable of the PV generator and between the ndash protective earth (PE) and the negative cable of the PV generator

If stable voltages can be measured there is a ground fault in the DC generator or its wiring The ratio between the measured voltages gives an indication as to the location of this fault

2 Rectify any faults before taking further measurements3 Determine the electrical resistance between the

ndash protective earth (PE) and the positive cable of the PV generator and between the ndash protective earth (PE) and the negative cable of the PV generator

In addition ensure that the PV generator has a total insulation resistance of more than 20 MOhm since the inverter will not feed in if the insulation resistance is too low

4 Rectify any faults before connecting the DC generator

7222 Connecting the PV generator

DANGERRisk of fatal injury due to electric shockSevere injury or death will result if the live connections are touched When there is solar radiation DC voltage will be present at the open ends of the DC cables rsaquo Do not touch the exposed ends of the cables rsaquo Avoid short circuits

Installing the device

Operating instructions Powador-gridsave_EN Page 25

Authorised electrician

Connecting the PV generator Use cables with the correct cross-section

1 Remove cable fittings for DC connection2 Remove the outer cladding of the DC cables3 Insert the DC cables through the cable fittings into the connection area4 Strip the insulation from the DC cables5 Remove connection terminals6 Connect the cables in line with the terminal labels (See Figure 13 on page 21)7 Close the connection terminals8 Check that all connected cables are securely fitted9 Tighten the cable fittings10 To meet the requirements of protection rating IP21 close the unused cable fittings with blind caps raquo The PV generator is connected to the inverter

73 Connecting the interfaces

731 Ethernet interface

Pre-assembled Ethernet cables can be connected using the RJ45 socket in the connection space

Connecting the Ethernet cable1 Remove closure cap from RJ45 socket2 Connect the Ethernet cable3 The energy management system can now obtain an IP address by DHCP and is also available via this in the

network

NOTEThe network settings can be amended later in the Settings menu using the EMS

NOTEUse a suitable category 5 network cable The maximum length of a network segment is 100 m Ensure that the cable is correctly assigned The Ethernet connection of the battery system supports auto-sensing You can use both crossed and 11 configured Ethernet connection cables

74 Sealing the connection area

1 Finally check the cabling2 Ensure that all cables are firmly mounted3 Check that the cable fitting is secure and tighten if necessary4 Remove cable offcuts and particles of dirt or dust5 Fit the cover and slide back until it engages into position6 Check that the position is correct7 Screw the fastening screw onto the front of the cover

Installing the device

Page 26 Operating instructions Powador-gridsave_EN

Authorised electrician

75 Starting up

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched Only appropriately qualified and authorised electricians may open install or maintain the battery system rsaquo Keep the front doors and covers closed during operation

NOTEInitial start-up should be carried out using the available public AC grid

76 Standard configuration

Factory settingsCountry configuration Germany

Grid guidelines Low voltage directive

Language German

Time UTC +1 Central European Time

User Standard

Network parameters DHCP (network settings will be obtained automatically from the router)

NOTEPlease state the desired power limitation (60 or 70 of the PV system capacity) when you order For other variations please notify your KACO contact so that the parameters can be set at the factory prior to delivery

Installing the device

Operating instructions Powador-gridsave_EN Page 27

Authorised electrician

761 Step 1 AC home power grid

Check all cables and connections before starting up1 Switch on the AC home power grid using the AC main switch raquo Powador-protect measurement and control unit starts up and monitors the AC grid raquo Two green LEDs indicate that the grid parameters are met raquo After a further 60 seconds (shortly after the backlighting in the Powador-protect goes out) the Powador-pro-

tect will switch on the home grid2 Configure Powador-protect according to the enclosed Powador-protect instructions

(The instructions are also available on the website at wwwkaconewenergyde) raquo The AC power is supplied in the normal way by the public grid

762 Step 2 AC supply from the battery system

Check all cables and connections before starting up1 Remove external isolation means from the device2 Switch on the circuit breaker raquo The LCD touchscreen on the front panel comes on and the energy management system (EMS) starts up

3 Switch on the residual current circuit breaker raquo The battery system starts up

763 Step 3 Switch on the PV system

1 Switch on any optional external PV isolator switches2 Set the internal DC isolator switch to ON raquo The inverter and the battery charging unit battery backup converter (BBC) are connected to the PV system raquo The device monitors the PV voltage for approx 60 seconds then optimisation of internal consumption takes

place

764 Step 4 Switch on batteries

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

765 Step 5 Activate energy management

NOTEKACO new energy cannot provide any support for problems regarding the IT infrastructure (eg router configuration IP address assignment ports etc) as the structure settings and configuration of the network environment can be complex and very different from place to place In the event of any problems please contact an IT service provider

Remote access activated 1 Please call the KACO Hotline to make an appointment for activation of energy management

Configuration and Operation

Page 28 Operating instructions Powador-gridsave_EN

Authorised electrician

8 Configuration and Operation

81 ControlsThe battery system is fitted with a touchscreen which allows it to be controlled very precisely In normal operation the display is switched off Touching the screen activates the display and after a configurable period of time without being touched the dis-play will deactivate If the screen-save function is switched off the touchscreen will be on continuously

NOTEDepending on the tolerances of the measuring elements the measured and displayed values are not always the actual values However the measuring elements ensure maximum solar yield Due to these tolerances the daily yields shown on the touchscreen may deviate from the values on the grid operatorrsquos feed-in meter by up to 15

3

1

45

2

Figure 15 Overview (home screen)

Key

1 Home button 4 Current time

2 System components 5 Menu name

3 More information

811 Information about the system

Open start screen View changesjumps to the home screen

Show component detail Parameters of the selected component

Settings Define settings for the active user

raquo Displays settings

Configuration and Operation

Operating instructions Powador-gridsave_EN Page 29

Controls Left arrow jump back to previous menu item Up and down arrows navigate through the menu or change a value

Left arrow displayed value is reduced by one increment Right arrow displayed value is increased by one increment or change to the submenu

Display fields Grey box Text or figures (not selectable) Blue box Calls up submenu for the display in question

Activate and deactivate Activate function by ticking the box

Table 6 Information about the system

812 System components

PV generator Display of the current generator data

power voltage current temperature in the inverter

Battery Display of the current battery status

power (charging or discharging) voltage current charge status available capacity temperature of battery

Grid Display of the following either fed-in or drawn from the grid

power voltage current for phase L1-L3 total output frequency

Consumer (load) Display of the consumer data

power voltage current for phase L1-L3 total output

Energy flow raquo Displays the current energy flow in the system

Table 7 Information about system components

Configuration and Operation

Page 30 Operating instructions Powador-gridsave_EN

813 Menu structure

Icons used

Display menu Submenu

Option menu

Menu Submenu Display setting

Action in this menumeaning

PV generator Details

Power Displays the current DC-side power

Voltage Displays the current DC-side voltage

Current Displays the current DC-side amperage

Temp inverter

Displays the current temperature in the inverter housing

Battery Details

Power Displays the current AC-side power

Voltage Displays the current AC-side voltage

Current Displays the current AC-side amperage

Charge status Displays the current charge status

Capacity Displays the current battery capacity

Temperature Displays the current measured temperature of the battery

Grid Details

Power Displays the current AC-side power being drawn or fed-in

Voltage Displays the AC-side voltage being applied

Current Displays the current AC-side amperage being drawn or fed-in

Total output Displays the current AC-side total output being drawn or fed-in

Frequency Displays the frequency currently being applied to the grid junction

Consumer (load) Details

Power Displays the current AC-side power being drawn

Voltage Displays the current AC-side voltage being applied

Current Displays the current AC-side amperage being drawn

Total output Displays the current AC-side total output being drawn

Configuration and Operation

Operating instructions Powador-gridsave_EN Page 31

Menu Submenu Display setting

Action in this menumeaning

Settings

Country amp directive display

Display of the country settings voltage directives and grid type

Select menu language

DateTime Specify time zone date format and date and time

Screen Activate screen-save function and set the delay period

Network settings

Display of the network settings Configure network settings Once the DHCP server becomes available the IP

address subnet mask gateway and DNS server are automatically applied and the aforemen-tioned menu items are hidden

Off DHCP deactivated make settings manually

Version Displays the installed software version and built-in HW components (inverter BBC battery)

Vendor The touchscreen shows information about the device vendor

NOTEAs changes to the software are possible after the manual has been printed the illustrations and descriptions of the functions in these operating instructions may deviate from the software Please therefore note the current Application Notes on our website

MaintenanceTroubleshooting

Page 32 Operating instructions Powador-gridsave_EN

9 MaintenanceTroubleshooting

91 Visual inspectionInspect the device and the cables for visible external damage and note the operating status display In case of damage notify your installer Repairs may only be carried out by authorised electricians

NOTEThe battery system should be checked for proper operation by a qualified electrician at regular intervals

92 Cleaning the device

DANGERLethal voltages in the battery systemSerious injuries or death can result if moisture enters the system rsaquo Only use completely dry objects to clean the battery system rsaquo Only clean the outside of the battery system

Cleaning the battery system Do not use compressed air Use a vacuum cleaner or a soft brush to remove dust from the fan cover and from the top of the inverter on a

regular basis Remove dust from the ventilation inlets if necessary

MaintenanceTroubleshooting

Operating instructions Powador-gridsave_EN Page 33

Authorised electrician

93 Maintenance

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched The device is only permitted to be opened or serviced by an authorised electrician rsaquo Observe all safety regulations and the current technical connection specifications from the relevant

power supply company rsaquo Disconnect the AC and DC sides rsaquo Secure the AC and DC sides from being inadvertently switched back on rsaquo Only then should the device be opened rsaquo After shutdown wait at least 30 minutes before working on the device

CAUTIONDestruction of the DC connectionThe connection terminals can be destroyed by arcing if disconnected while still live rsaquo It is absolutely essential that the shutdown sequence be carried out in the correct order (See sec-

tion 111 on page 35)

94 Faults

941 Procedure

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched

When a fault occurs notify an appropriately authorised and qualified electrician or KACO new energy GmbH Service

Service

Page 34 Operating instructions Powador-gridsave_EN

10 ServiceIf 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 efficientlybull Serial nobull SW version of the components (the software version can be found in the Settings menu using the EMS)bull Module type and string circuitbull Date of installation Start-up reportbull Consignment identification Delivery address Contact person (with telephone number)bull Information about the accessibility of the installation site

Any additional costs arising from unfavourable structural or mounting conditions shall be billed to the customer

You can find our warranty conditions on our websitehttpkaco-newenergycomservicewarrantyFrom there you can easily navigate to our international websites by clicking on the appropriate flag

Please use our website to register your unit immediatelyYou can also select the appropriate flag on this page to access the website for your own countryIn this manner you can assist us in providing you with the quickest service possible Note The maximum length of the warranty is based on the currently applicable national warranty conditions

We have prepared a template for complaints This can be found at httpskaco-newenergycomservicecustomer-service

Hotlines

Technical troubleshooting Technical consultation

Inverters and battery systems ()

+49 (0) 71323818-660 +49 (0) 71323818-660

Data logging and accessories +49 (0) 71323818-690 +49 (0) 71323818-690

Construction site emergency () +49 (0) 71323818-630

Customer help desk Monday to Friday from 730 am to 530 pm (CET)

() Also on Saturdays from 800 am to 200 pm (CET)

ShutdownDisassembly

Operating instructions Powador-gridsave_EN Page 35

11 ShutdownDisassembly

111 Switching off the device

DANGERLethal voltages are still present in the terminals and cables even after switching off and discon-nection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched rsaquo Complete de-energisation only occurs if the bulk power supply is switched off upstream of the bat-

tery system

DANGERDestruction of the DC plug connectorDC plug connectors can be destroyed by arcing if disconnected while still live rsaquo It is absolutely essential that the following shutdown sequence is observed

1111 Step 1 Shutting down the PV system

1 Switch off any optional external PV isolator switches2 Set the internal DC isolator switch to OFF raquo The inverter and battery charging unit battery backup converter (BBC) are disconnected

1112 Step 2 Disconnect the batteries

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

1113 Step 3 Disconnect the AC supply

1 Connect external isolation means to the device2 Switch off the circuit breaker 3 Switch off the residual current circuit breaker raquo The battery system is switched off

1114 Step 4 AC home power grid

1 Shutdown the AC home power grid using the AC main switch raquo The battery system can be uninstalled

Disposal

Page 36 Operating instructions Powador-gridsave_EN

112 Uninstalling the device

NOTETo uninstall follow the same sequence as for installation but in reverse order

Switch off the device1 Unlock and open the housing door2 Remove the upper cover3 Release the DC and AC cables from the connection terminals4 Pull out the cables raquo The battery system is uninstalled Continue with the disassembly

113 Disassembling the device

NOTETo disassemble follow the same sequence as for assembly but in reverse order

Switch off the device1 Uninstall the components2 Remove the fastening from the device3 Securely pack up the battery system if it is to be used later

or have the battery system disposed of in accordance with section 12 on page 36

12 DisposalFor the most part both the battery system and the corresponding transport packaging are made from recyclable raw materialsBatteries and components Do not dispose of faulty batteries or the components together with household waste Ensure that the old device and accessories are disposed of in a proper mannerPackaging Ensure that the transport packaging is disposed of properlyBatteriesUsed or faulty batteries must be transported in special packaging If you need such packaging please contact the KACO Hotline

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

Appendix

Operating instructions Powador-gridsave_EN Page 37

13 Appendix

EU Declaration of Conformity

Vendorrsquos name and address

KACO new energy GmbH Carl-Zeiss-Straszlige 1 74172 Neckarsulm Germany

Product description Battery system

Type designation Powador-gridsave 135 kWh 6400 Powador-gridsave 135 kWh 8000

Powador-gridsave 270 kWh 6400 Powador-gridsave 270 kWh 8000

Powador-gridsave 405 kWh 6400 Powador-gridsave 405 kWh 8000

Powador-gridsave 540 kWh 6400 Powador-gridsave 540 kWh 8000

Powador-gridsave 577 kWh 6400 Powador-gridsave 577 kWh 8000

Powador-gridsave 675 kWh 6400 Powador-gridsave 675 kWh 8000

This is to confirm that the units listed above comply with the protection requirements set forth in the Directive of the Council of the European Union of 15th December 2004 on the harmonisation of the laws of the member states relating to Electromagnetic Compatibility (2004108EC) and the Low Voltage Directive (200695EC)The units are compliant with the following standards

200695EC ldquoDirective relating to electrical equipment designed for use within specific voltage limitsrdquo

Safety of the unitIEC 62109-12010IEC 62109-22011

2004108EC ldquoDirective relating to electromagneticcompatibilityrdquo

Interference immunityEN 61000-6-22005 Emitted interferenceEN 61000-6-32007

Secondary effects on the gridEN 61000-3-112000EN 61000-3-122005

The types mentioned above are therefore labelled with the CE markUnauthorised modifications to the supplied units andor any use of the units that is contrary to their intended use render this Declaration of Conformity null and void

Neckarsulm 0711 2013KACO new energy GmbH

pp Volker DietrichEnergy systems engineering management

Disposal

Page 38 Operating instructions Powador-gridsave_EN

Carl-Zeiss-Straszlige 1 middot 74172 Neckarsulm middot Germany middot Phone +49 7132 3818-0 middot Fax +49 7132 3818-703 middot infokaco-newenergyde middot wwwkaco-newenergyde

The

text

and

figu

res

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al s

tate

at t

he ti

me

of p

rintin

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ubje

ct to

tech

nica

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nges

Err

ors

and

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cept

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3006

856-

01-1

4030

5

  • 1General Information
    • 11About this document
    • 12Name plate
    • 13Additional information
    • 14Intended use
      • 2Safety
        • 21Protection features
          • 3Description
            • 31Mode of Operation
            • 32Summary of the components
              • 4Technical Data
                • 41Electrical data
                • 42Mechanical data
                  • 5Transportation and Delivery
                    • 51Delivery
                    • 52Storage
                    • 53Transportation
                      • 6Assembling the device
                        • 61Installation
                        • 62Installing components
                          • 7Installing the device
                            • 71Opening the connection area
                            • 72Making the electrical connection
                            • 73Connecting the interfaces
                            • 74Sealing the connection area
                            • 75Starting up
                            • 76Standard configuration
                              • 8Configuration and Operation
                                • 81Controls
                                  • 9MaintenanceTroubleshooting
                                    • 91Visual inspection
                                    • 92Cleaning the device
                                    • 93Maintenance
                                    • 94Faults
                                      • 10Service
                                      • 11ShutdownDisassembly
                                        • 111Switching off the device
                                        • 112Uninstalling the device
                                        • 113Disassembling the device
                                          • 12Disposal
                                          • 13Appendix

Assembling the device

Page 16 Operating instructions Powador-gridsave_EN

Authorised electrician

6 Assembling the device

61 Installation

DANGERRisk of fatal injury from fire or explosionsFire caused by flammable or explosive materials in the vicinity of the battery system can lead to serious injuries rsaquo Do not mount the inverter in potentially explosive atmospheres or in the vicinity of highly flamma-

ble materials

CAUTIONBattery system is very heavy ndash risk of injury rsaquo Be aware of the weight of the battery system during transport rsaquo Select suitable mounting location and mounting base rsaquo Only install the battery system with the help of a second person

CAUTIONEquipment damage caused by aggressive gases in combination with humidityThe housing may be seriously damaged by aggressive gases (ammonia sulphur and other chemi-cals) in combination with ambient humidity caused by weather conditions - Installation in rooms containing aggressive gases is not permitted

NOTEAccess in the event of maintenance or serviceAny additional costs arising from unfavourable structural or mounting conditions in the event of a KACO service call-out shall be billed to the customer

611 Installation location

bull Dry well ventilated the waste heat must be conducted away from the battery systembull Unobstructed air circulationbull Easily accessible from the front top and sides without requiring additional resourcesbull Indoors protected against direct sunlight and direct water contact

612 Foundation

bull With sufficient load-bearing capacitybull Made from heat-resistant material (up to 90 degC)bull Must be flame resistant

NOTEPower reduction due to heat accumulationIf the recommended minimum clearances are not observed the device may go into power regula-tion mode due to insufficient ventilation and the resulting heat build-up rsaquo The construction and installation of the device may be performed only by a qualified electrician in

accordance with the valid standards and regulations rsaquo Maintain minimum clearances rsaquo Ensure sufficient heat dissipation

Assembling the device

Operating instructions Powador-gridsave_EN Page 17

Authorised electrician

0deg

1000 mm

200 mm 200 mm

500 mm

min carrying capacity 300 kgmsup2

200 mm200 mm

50 mm

Figure 9 Minimum clearances at the installation and assembly location

CAUTIONRisk of injury if the battery system tips overRisk of tipping due to high centre of gravity particularly with the door open rsaquo Anchor the device securely to the floor immediately after installation rsaquo Open the housing door using the enclosed cabinet key only once the device has been securely

anchored

510 mm200 mm

200 mm

400

mm

12 mmmin 110 mm

DesignationHex head wood screw 8x80 DIN571-vz Fischer dowel S12 Flat washer M8 galvanised DIN9021-vz

Units444

Figure 10 Dimensions for anchoring to the floor Table 3 Mounting parts

62 Installing components

CAUTIONAvoid improper handlingImproper handling can cause damage to components rsaquo Damaged components must not be installed rsaquo Always put the plug-in modules down horizontally to avoid damage to the components

Assembling the device

Page 18 Operating instructions Powador-gridsave_EN

Authorised electrician

WARNINGDanger caused by short circuit or sparkingSerious injury from touching or connecting live components rsaquo Damaged components must not be installed

Preparation1 Check the conditions for the installation location2 Open the housing doors using the enclosed cabinet key3 The cables should be professionally laid and prepared for connection4 Follow the installation sequence (1-4 step(s))

621 Step 1 Fit the battery (batteries)

NOTEPlease read the notes on installation and connection in the enclosed manual Features for the battery unit

622 Step 2 Connect battery (batteries) to the battery management system (BMS)

NOTEPlease read the notes on installation and connection in the enclosed manual Features for the battery unit

623 Step 3 Fit the battery charging unit battery backup converter (BBC)

Battery (batteries) connected to the battery management system (BMS)1 Carefully insert battery charging unit battery backup converter (BBC) into the compartment provided for it 2 Push in completely to establish direct contact with the rear busbars3 Secure battery charging unit battery backup converter (BBC) using the screws supplied

624 Step 4 Fit the inverter

Battery charging unit battery backup converter (BBC) is fitted1 Carefully insert inverter into the compartment provided for it 2 Push in completely to establish direct contact with the rear busbars 3 Secure inverter using the screws supplied

CAUTIONDamage to the control unit from introducing foreign objectsForeign objects can impair the function of the control unit and cause damage rsaquo Do not remove the front panel rsaquo Foreign objects should be removed immediately

Installing the device

Operating instructions Powador-gridsave_EN Page 19

Authorised electrician

7 Installing the device

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched The device may only be opened or serviced by an authorised electricianThe device must be completely assembled before being connected electrically rsaquo Observe all safety regulations and current technical connection specifications of the responsible

power supply company rsaquo De-energise the device using the DC isolator switch circuit breaker and residual current circuit

breaker rsaquo Secure both sides against being inadvertently switched back on rsaquo Ensure that the AC and DC sides are completely isolated and voltage free rsaquo Never open the plug-in modules rsaquo Hazardous voltages are present at the busbars rsaquo Disconnect from the grid and plant supply rsaquo First connect the battery system in the connection area

71 Opening the connection area

3

1

2

Figure 11 Open cover plateKey

1 Cover plate 3 Fastening screw

2 Lock

Opening the connection area You have completed assembly

1 Remove the fastening screw for the upper cover plate2 Slide the cover plate forwards out of the lock3 Lift the cover plate upward to remove raquo Make the electrical connection

Installing the device

Page 20 Operating instructions Powador-gridsave_EN

Authorised electrician

72 Making the electrical connectionMake the connection to the PV generator as well as the grid connection using the connection terminals Note the following cable cross-sections

Connection Possible cable cross-section Length of insulation to be stripped offAC home power grid 05 - 16 mmsup2 with end sleeve

05 - 25 mmsup2 without end sleeve18 mm sleeve18-20 mm

PV connection 05 - 16 mmsup2 with end sleeve05 - 25 mmsup2 without end sleeve

18 mm sleeve17-19 mm

Inverter output 05 - 4 mmsup2 with end sleeve05 - 6 mmsup2 without end sleeve

12 mm sleeve11-13 mm

Potential-free contacts 034 - 15 mmsup2 with end sleeve034 - 25 mmsup2 without end sleeve

12 mm sleeve 9-10 mm

Table 4 Cable cross-sections for connection terminals

NOTEThe threaded connections should be matched to the cable cross-section

NOTEOnly conductors and no insulation should be inserted into the connection terminals Individual wires or cables with end sleeves with the appropriate cross-section can be inserted directly into the connection terminal without a toolFine-strand cables without end sleeve or thin conductors will need a screwdriver (plain slot 35 mm) for connection To do this insert the blade of the screwdriver into the recess provided The cable can be inserted into the spring terminal by pressing downwards The spring terminal closes on removal of the screw-driver

Installing the device

Operating instructions Powador-gridsave_EN Page 21

Authorised electrician

X2X1F1 F2 X7 X4 St1

St2

St3

2 3 541 6

Figure 12 View from above of the connection area

Key

1 AC grid input (M40 cable fitting) 4 Network interface (M32 cable fitting)

2 AC grid output (M40 cable fitting) 5 Inverter input (M16 cable fitting)

3 Inverter output (M32 cable fitting) 6 Other connections (M16 cable fitting)

F1 F2 X7 X4 St1

St2

St3

L1 L2 L3 N PE L1 L2 L3 N N PE PE

X1 X2

PV+

PV-

L1 L2 L3 N PE32A 32A PEN

Cust

omer

co

nnec

tion

Figure 13 View from above of the connection area

Key

X1 AC grid input (main junction box meter) X7 PV generator input

X2 AC grid output (building electrical system) F1 F2 Phase bridging fuse

X4 Inverter output St 1-3 Potential-free contacts control outputs

Installing the device

Page 22 Operating instructions Powador-gridsave_EN

Authorised electrician

721 Connecting to the power grid

Because the device is installed between the main junction boxmeter and the buildings electrical system the maxi-mum grid current to the service line must not exceed the rated operating current of the battery system The cable cross-section must be selected in accordance with applicable standards to suit the connected load instal-lation type etc Moreover the terminal area and size of the cable fitting must be noted

NOTEThe fuse rating for the cable should be max 63A (automatic circuit breaker or safety fuse) even if the cross-section of the installed cable would permit a higher fuse rating Always follow the applicable regulations regarding the cable cross-section and installation typeThe device supports standard grid configurations such as TN-C TN-S and TT TN-SIf a TN-S grid is present directly at the power input and output of the device L1-L3 N and PE must each be connected The home power grid should have 4-pin isolationTN-C4-pin grid isolation is factory preset and disconnects L1 L2 L3 and N In a TN-C grid the N conduc-tor must not be disconnected If a TN-S grid is present directly at the power input and output of the device a cable bridge (included in delivery) must be installed between the N terminal on X1 and the N terminal on X2 N and PE must additionally be connected together To do this simply insert the enclosed terminal link into the N and PE terminals TTIn the case of a TT grid L1-L3 N and PE must each be connected The home power grid should have 4-pin isolation

NOTEPlease check with the operator of the mains grid whether there are special regulations for grid connection Grid isolation is factory preset to 4-pin is fail-safe and provided with grid and system protection as per VDE-AR-N 4105

Making the grid connection Use cables with 5 wires (L1 brown L2 black L3 grey N blue PE greenyellow) and the correct

cross-section1 Loosen cable fitting for AC connection2 Remove the outer cladding of the AC cables3 Insert the AC cables through the cable fitting into the connection area4 Strip the insulation from the AC cables5 Remove connection terminals6 Connect the cables in line with the terminal labels (Figure 13 on page 21)7 Close the connection terminals8 Check that all connected cables are securely fitted9 Tighten the cable fitting10 To meet the requirements of protection rating IP21 close the unused cable fittings with blind caps raquo The battery system is connected to the power grid

NOTEAn AC-side disconnection unit must be provided during the final installation stage This disconnec-tion unit must be installed so that it can be accessed at any time without obstruction If a residual current circuit breaker is necessary due to the installation specification a type A residual current circuit breaker must be used

Installing the device

Operating instructions Powador-gridsave_EN Page 23

Authorised electrician

7211 Output from the inverterRecommended cable cross-sections for the inverter output and fuse rating of cables for fixed wiring accord-ing to VDE 0100 part 430The fuse rating for the cable is dependent on the cable cross-section max 40A automatic circuit breaker

NOTEWhen the line resistance is high (ie long grid-side cables) the voltage at the grid terminals of the inverter will increase during feed-in to the grid The inverter monitors this voltage If the voltage exceeds the country-specific grid overvoltage limit value the inverter switches off rsaquo Ensure that the conductor cross-sections are sufficiently large or that the cable lengths are suffi-

ciently short

NOTEIn order to avoid asymmetries in the grid systems with multiple battery systems should be designed so that the inverters in the devices feed into the grid in differing phases rsaquo Follow the connection conditions for the particular type of grid and the schematic illustration

below

Country and grid-type

Grid monitoring Required monitoring

max asymmetry between phases L1L2L3

DE-NSP Three-phase or single phase phase unbalanced load 46 kVA

Table 5 Grid-type-specific connection conditions

L1

L2

L3

N

Connection X1 Connection X1 Connection X1 Connection X1

L1 L2 L3 N PE L1 L2 L3 N PE L1 L2 L3 N PE L1 L2 L3 N PE

Powador-gridsave inverter1 L1 - L1 L2 - L2 L3 - L32 L1 - L2 L2 - L3 L3 - L1 3 L1 - L3 L2 - L1 L3 - L2 4 L1 - L1 L2 - L2 L3 - L3

Figure 14 Grid-side connection for systems with multiple battery systems with three-phase grid monitoring

Installing the device

Page 24 Operating instructions Powador-gridsave_EN

Authorised electrician

722 Connecting the PV generator

Connect the PV generator on the left in the connection area (Figure 13 on page 21) Use the provided M16 cable fittings A maximum of two strings can be connected For this reason a DC string fuse can be dispensed with

DANGERRisk of fatal injury due to contact voltagesRemoving the cables from the terminals without first disconnecting the PV generator from the device can cause serious damage to health or damage to the system rsaquo During installation Electrically disconnect the DC positive and DC negative from the protective

earth (PE) rsaquo Completely de-energise the system (AC home power grid AC circuit breaker residual current circuit

breaker DC isolator switch) rsaquo Disconnect the battery system from the PV generator using the integrated DC isolator switch rsaquo Remove DC plug connectors

NOTEIn accordance with IEC 61730 Class A connected PV modules must be dimensioned for the DC system voltage provided and at least for the value of the AC grid voltage

7221 Before connecting

Ensure that there is no ground fault1 Determine the DC voltage between the

ndash protective earth (PE) and the positive cable of the PV generator and between the ndash protective earth (PE) and the negative cable of the PV generator

If stable voltages can be measured there is a ground fault in the DC generator or its wiring The ratio between the measured voltages gives an indication as to the location of this fault

2 Rectify any faults before taking further measurements3 Determine the electrical resistance between the

ndash protective earth (PE) and the positive cable of the PV generator and between the ndash protective earth (PE) and the negative cable of the PV generator

In addition ensure that the PV generator has a total insulation resistance of more than 20 MOhm since the inverter will not feed in if the insulation resistance is too low

4 Rectify any faults before connecting the DC generator

7222 Connecting the PV generator

DANGERRisk of fatal injury due to electric shockSevere injury or death will result if the live connections are touched When there is solar radiation DC voltage will be present at the open ends of the DC cables rsaquo Do not touch the exposed ends of the cables rsaquo Avoid short circuits

Installing the device

Operating instructions Powador-gridsave_EN Page 25

Authorised electrician

Connecting the PV generator Use cables with the correct cross-section

1 Remove cable fittings for DC connection2 Remove the outer cladding of the DC cables3 Insert the DC cables through the cable fittings into the connection area4 Strip the insulation from the DC cables5 Remove connection terminals6 Connect the cables in line with the terminal labels (See Figure 13 on page 21)7 Close the connection terminals8 Check that all connected cables are securely fitted9 Tighten the cable fittings10 To meet the requirements of protection rating IP21 close the unused cable fittings with blind caps raquo The PV generator is connected to the inverter

73 Connecting the interfaces

731 Ethernet interface

Pre-assembled Ethernet cables can be connected using the RJ45 socket in the connection space

Connecting the Ethernet cable1 Remove closure cap from RJ45 socket2 Connect the Ethernet cable3 The energy management system can now obtain an IP address by DHCP and is also available via this in the

network

NOTEThe network settings can be amended later in the Settings menu using the EMS

NOTEUse a suitable category 5 network cable The maximum length of a network segment is 100 m Ensure that the cable is correctly assigned The Ethernet connection of the battery system supports auto-sensing You can use both crossed and 11 configured Ethernet connection cables

74 Sealing the connection area

1 Finally check the cabling2 Ensure that all cables are firmly mounted3 Check that the cable fitting is secure and tighten if necessary4 Remove cable offcuts and particles of dirt or dust5 Fit the cover and slide back until it engages into position6 Check that the position is correct7 Screw the fastening screw onto the front of the cover

Installing the device

Page 26 Operating instructions Powador-gridsave_EN

Authorised electrician

75 Starting up

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched Only appropriately qualified and authorised electricians may open install or maintain the battery system rsaquo Keep the front doors and covers closed during operation

NOTEInitial start-up should be carried out using the available public AC grid

76 Standard configuration

Factory settingsCountry configuration Germany

Grid guidelines Low voltage directive

Language German

Time UTC +1 Central European Time

User Standard

Network parameters DHCP (network settings will be obtained automatically from the router)

NOTEPlease state the desired power limitation (60 or 70 of the PV system capacity) when you order For other variations please notify your KACO contact so that the parameters can be set at the factory prior to delivery

Installing the device

Operating instructions Powador-gridsave_EN Page 27

Authorised electrician

761 Step 1 AC home power grid

Check all cables and connections before starting up1 Switch on the AC home power grid using the AC main switch raquo Powador-protect measurement and control unit starts up and monitors the AC grid raquo Two green LEDs indicate that the grid parameters are met raquo After a further 60 seconds (shortly after the backlighting in the Powador-protect goes out) the Powador-pro-

tect will switch on the home grid2 Configure Powador-protect according to the enclosed Powador-protect instructions

(The instructions are also available on the website at wwwkaconewenergyde) raquo The AC power is supplied in the normal way by the public grid

762 Step 2 AC supply from the battery system

Check all cables and connections before starting up1 Remove external isolation means from the device2 Switch on the circuit breaker raquo The LCD touchscreen on the front panel comes on and the energy management system (EMS) starts up

3 Switch on the residual current circuit breaker raquo The battery system starts up

763 Step 3 Switch on the PV system

1 Switch on any optional external PV isolator switches2 Set the internal DC isolator switch to ON raquo The inverter and the battery charging unit battery backup converter (BBC) are connected to the PV system raquo The device monitors the PV voltage for approx 60 seconds then optimisation of internal consumption takes

place

764 Step 4 Switch on batteries

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

765 Step 5 Activate energy management

NOTEKACO new energy cannot provide any support for problems regarding the IT infrastructure (eg router configuration IP address assignment ports etc) as the structure settings and configuration of the network environment can be complex and very different from place to place In the event of any problems please contact an IT service provider

Remote access activated 1 Please call the KACO Hotline to make an appointment for activation of energy management

Configuration and Operation

Page 28 Operating instructions Powador-gridsave_EN

Authorised electrician

8 Configuration and Operation

81 ControlsThe battery system is fitted with a touchscreen which allows it to be controlled very precisely In normal operation the display is switched off Touching the screen activates the display and after a configurable period of time without being touched the dis-play will deactivate If the screen-save function is switched off the touchscreen will be on continuously

NOTEDepending on the tolerances of the measuring elements the measured and displayed values are not always the actual values However the measuring elements ensure maximum solar yield Due to these tolerances the daily yields shown on the touchscreen may deviate from the values on the grid operatorrsquos feed-in meter by up to 15

3

1

45

2

Figure 15 Overview (home screen)

Key

1 Home button 4 Current time

2 System components 5 Menu name

3 More information

811 Information about the system

Open start screen View changesjumps to the home screen

Show component detail Parameters of the selected component

Settings Define settings for the active user

raquo Displays settings

Configuration and Operation

Operating instructions Powador-gridsave_EN Page 29

Controls Left arrow jump back to previous menu item Up and down arrows navigate through the menu or change a value

Left arrow displayed value is reduced by one increment Right arrow displayed value is increased by one increment or change to the submenu

Display fields Grey box Text or figures (not selectable) Blue box Calls up submenu for the display in question

Activate and deactivate Activate function by ticking the box

Table 6 Information about the system

812 System components

PV generator Display of the current generator data

power voltage current temperature in the inverter

Battery Display of the current battery status

power (charging or discharging) voltage current charge status available capacity temperature of battery

Grid Display of the following either fed-in or drawn from the grid

power voltage current for phase L1-L3 total output frequency

Consumer (load) Display of the consumer data

power voltage current for phase L1-L3 total output

Energy flow raquo Displays the current energy flow in the system

Table 7 Information about system components

Configuration and Operation

Page 30 Operating instructions Powador-gridsave_EN

813 Menu structure

Icons used

Display menu Submenu

Option menu

Menu Submenu Display setting

Action in this menumeaning

PV generator Details

Power Displays the current DC-side power

Voltage Displays the current DC-side voltage

Current Displays the current DC-side amperage

Temp inverter

Displays the current temperature in the inverter housing

Battery Details

Power Displays the current AC-side power

Voltage Displays the current AC-side voltage

Current Displays the current AC-side amperage

Charge status Displays the current charge status

Capacity Displays the current battery capacity

Temperature Displays the current measured temperature of the battery

Grid Details

Power Displays the current AC-side power being drawn or fed-in

Voltage Displays the AC-side voltage being applied

Current Displays the current AC-side amperage being drawn or fed-in

Total output Displays the current AC-side total output being drawn or fed-in

Frequency Displays the frequency currently being applied to the grid junction

Consumer (load) Details

Power Displays the current AC-side power being drawn

Voltage Displays the current AC-side voltage being applied

Current Displays the current AC-side amperage being drawn

Total output Displays the current AC-side total output being drawn

Configuration and Operation

Operating instructions Powador-gridsave_EN Page 31

Menu Submenu Display setting

Action in this menumeaning

Settings

Country amp directive display

Display of the country settings voltage directives and grid type

Select menu language

DateTime Specify time zone date format and date and time

Screen Activate screen-save function and set the delay period

Network settings

Display of the network settings Configure network settings Once the DHCP server becomes available the IP

address subnet mask gateway and DNS server are automatically applied and the aforemen-tioned menu items are hidden

Off DHCP deactivated make settings manually

Version Displays the installed software version and built-in HW components (inverter BBC battery)

Vendor The touchscreen shows information about the device vendor

NOTEAs changes to the software are possible after the manual has been printed the illustrations and descriptions of the functions in these operating instructions may deviate from the software Please therefore note the current Application Notes on our website

MaintenanceTroubleshooting

Page 32 Operating instructions Powador-gridsave_EN

9 MaintenanceTroubleshooting

91 Visual inspectionInspect the device and the cables for visible external damage and note the operating status display In case of damage notify your installer Repairs may only be carried out by authorised electricians

NOTEThe battery system should be checked for proper operation by a qualified electrician at regular intervals

92 Cleaning the device

DANGERLethal voltages in the battery systemSerious injuries or death can result if moisture enters the system rsaquo Only use completely dry objects to clean the battery system rsaquo Only clean the outside of the battery system

Cleaning the battery system Do not use compressed air Use a vacuum cleaner or a soft brush to remove dust from the fan cover and from the top of the inverter on a

regular basis Remove dust from the ventilation inlets if necessary

MaintenanceTroubleshooting

Operating instructions Powador-gridsave_EN Page 33

Authorised electrician

93 Maintenance

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched The device is only permitted to be opened or serviced by an authorised electrician rsaquo Observe all safety regulations and the current technical connection specifications from the relevant

power supply company rsaquo Disconnect the AC and DC sides rsaquo Secure the AC and DC sides from being inadvertently switched back on rsaquo Only then should the device be opened rsaquo After shutdown wait at least 30 minutes before working on the device

CAUTIONDestruction of the DC connectionThe connection terminals can be destroyed by arcing if disconnected while still live rsaquo It is absolutely essential that the shutdown sequence be carried out in the correct order (See sec-

tion 111 on page 35)

94 Faults

941 Procedure

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched

When a fault occurs notify an appropriately authorised and qualified electrician or KACO new energy GmbH Service

Service

Page 34 Operating instructions Powador-gridsave_EN

10 ServiceIf 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 efficientlybull Serial nobull SW version of the components (the software version can be found in the Settings menu using the EMS)bull Module type and string circuitbull Date of installation Start-up reportbull Consignment identification Delivery address Contact person (with telephone number)bull Information about the accessibility of the installation site

Any additional costs arising from unfavourable structural or mounting conditions shall be billed to the customer

You can find our warranty conditions on our websitehttpkaco-newenergycomservicewarrantyFrom there you can easily navigate to our international websites by clicking on the appropriate flag

Please use our website to register your unit immediatelyYou can also select the appropriate flag on this page to access the website for your own countryIn this manner you can assist us in providing you with the quickest service possible Note The maximum length of the warranty is based on the currently applicable national warranty conditions

We have prepared a template for complaints This can be found at httpskaco-newenergycomservicecustomer-service

Hotlines

Technical troubleshooting Technical consultation

Inverters and battery systems ()

+49 (0) 71323818-660 +49 (0) 71323818-660

Data logging and accessories +49 (0) 71323818-690 +49 (0) 71323818-690

Construction site emergency () +49 (0) 71323818-630

Customer help desk Monday to Friday from 730 am to 530 pm (CET)

() Also on Saturdays from 800 am to 200 pm (CET)

ShutdownDisassembly

Operating instructions Powador-gridsave_EN Page 35

11 ShutdownDisassembly

111 Switching off the device

DANGERLethal voltages are still present in the terminals and cables even after switching off and discon-nection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched rsaquo Complete de-energisation only occurs if the bulk power supply is switched off upstream of the bat-

tery system

DANGERDestruction of the DC plug connectorDC plug connectors can be destroyed by arcing if disconnected while still live rsaquo It is absolutely essential that the following shutdown sequence is observed

1111 Step 1 Shutting down the PV system

1 Switch off any optional external PV isolator switches2 Set the internal DC isolator switch to OFF raquo The inverter and battery charging unit battery backup converter (BBC) are disconnected

1112 Step 2 Disconnect the batteries

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

1113 Step 3 Disconnect the AC supply

1 Connect external isolation means to the device2 Switch off the circuit breaker 3 Switch off the residual current circuit breaker raquo The battery system is switched off

1114 Step 4 AC home power grid

1 Shutdown the AC home power grid using the AC main switch raquo The battery system can be uninstalled

Disposal

Page 36 Operating instructions Powador-gridsave_EN

112 Uninstalling the device

NOTETo uninstall follow the same sequence as for installation but in reverse order

Switch off the device1 Unlock and open the housing door2 Remove the upper cover3 Release the DC and AC cables from the connection terminals4 Pull out the cables raquo The battery system is uninstalled Continue with the disassembly

113 Disassembling the device

NOTETo disassemble follow the same sequence as for assembly but in reverse order

Switch off the device1 Uninstall the components2 Remove the fastening from the device3 Securely pack up the battery system if it is to be used later

or have the battery system disposed of in accordance with section 12 on page 36

12 DisposalFor the most part both the battery system and the corresponding transport packaging are made from recyclable raw materialsBatteries and components Do not dispose of faulty batteries or the components together with household waste Ensure that the old device and accessories are disposed of in a proper mannerPackaging Ensure that the transport packaging is disposed of properlyBatteriesUsed or faulty batteries must be transported in special packaging If you need such packaging please contact the KACO Hotline

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

Appendix

Operating instructions Powador-gridsave_EN Page 37

13 Appendix

EU Declaration of Conformity

Vendorrsquos name and address

KACO new energy GmbH Carl-Zeiss-Straszlige 1 74172 Neckarsulm Germany

Product description Battery system

Type designation Powador-gridsave 135 kWh 6400 Powador-gridsave 135 kWh 8000

Powador-gridsave 270 kWh 6400 Powador-gridsave 270 kWh 8000

Powador-gridsave 405 kWh 6400 Powador-gridsave 405 kWh 8000

Powador-gridsave 540 kWh 6400 Powador-gridsave 540 kWh 8000

Powador-gridsave 577 kWh 6400 Powador-gridsave 577 kWh 8000

Powador-gridsave 675 kWh 6400 Powador-gridsave 675 kWh 8000

This is to confirm that the units listed above comply with the protection requirements set forth in the Directive of the Council of the European Union of 15th December 2004 on the harmonisation of the laws of the member states relating to Electromagnetic Compatibility (2004108EC) and the Low Voltage Directive (200695EC)The units are compliant with the following standards

200695EC ldquoDirective relating to electrical equipment designed for use within specific voltage limitsrdquo

Safety of the unitIEC 62109-12010IEC 62109-22011

2004108EC ldquoDirective relating to electromagneticcompatibilityrdquo

Interference immunityEN 61000-6-22005 Emitted interferenceEN 61000-6-32007

Secondary effects on the gridEN 61000-3-112000EN 61000-3-122005

The types mentioned above are therefore labelled with the CE markUnauthorised modifications to the supplied units andor any use of the units that is contrary to their intended use render this Declaration of Conformity null and void

Neckarsulm 0711 2013KACO new energy GmbH

pp Volker DietrichEnergy systems engineering management

Disposal

Page 38 Operating instructions Powador-gridsave_EN

Carl-Zeiss-Straszlige 1 middot 74172 Neckarsulm middot Germany middot Phone +49 7132 3818-0 middot Fax +49 7132 3818-703 middot infokaco-newenergyde middot wwwkaco-newenergyde

The

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3006

856-

01-1

4030

5

  • 1General Information
    • 11About this document
    • 12Name plate
    • 13Additional information
    • 14Intended use
      • 2Safety
        • 21Protection features
          • 3Description
            • 31Mode of Operation
            • 32Summary of the components
              • 4Technical Data
                • 41Electrical data
                • 42Mechanical data
                  • 5Transportation and Delivery
                    • 51Delivery
                    • 52Storage
                    • 53Transportation
                      • 6Assembling the device
                        • 61Installation
                        • 62Installing components
                          • 7Installing the device
                            • 71Opening the connection area
                            • 72Making the electrical connection
                            • 73Connecting the interfaces
                            • 74Sealing the connection area
                            • 75Starting up
                            • 76Standard configuration
                              • 8Configuration and Operation
                                • 81Controls
                                  • 9MaintenanceTroubleshooting
                                    • 91Visual inspection
                                    • 92Cleaning the device
                                    • 93Maintenance
                                    • 94Faults
                                      • 10Service
                                      • 11ShutdownDisassembly
                                        • 111Switching off the device
                                        • 112Uninstalling the device
                                        • 113Disassembling the device
                                          • 12Disposal
                                          • 13Appendix

Assembling the device

Operating instructions Powador-gridsave_EN Page 17

Authorised electrician

0deg

1000 mm

200 mm 200 mm

500 mm

min carrying capacity 300 kgmsup2

200 mm200 mm

50 mm

Figure 9 Minimum clearances at the installation and assembly location

CAUTIONRisk of injury if the battery system tips overRisk of tipping due to high centre of gravity particularly with the door open rsaquo Anchor the device securely to the floor immediately after installation rsaquo Open the housing door using the enclosed cabinet key only once the device has been securely

anchored

510 mm200 mm

200 mm

400

mm

12 mmmin 110 mm

DesignationHex head wood screw 8x80 DIN571-vz Fischer dowel S12 Flat washer M8 galvanised DIN9021-vz

Units444

Figure 10 Dimensions for anchoring to the floor Table 3 Mounting parts

62 Installing components

CAUTIONAvoid improper handlingImproper handling can cause damage to components rsaquo Damaged components must not be installed rsaquo Always put the plug-in modules down horizontally to avoid damage to the components

Assembling the device

Page 18 Operating instructions Powador-gridsave_EN

Authorised electrician

WARNINGDanger caused by short circuit or sparkingSerious injury from touching or connecting live components rsaquo Damaged components must not be installed

Preparation1 Check the conditions for the installation location2 Open the housing doors using the enclosed cabinet key3 The cables should be professionally laid and prepared for connection4 Follow the installation sequence (1-4 step(s))

621 Step 1 Fit the battery (batteries)

NOTEPlease read the notes on installation and connection in the enclosed manual Features for the battery unit

622 Step 2 Connect battery (batteries) to the battery management system (BMS)

NOTEPlease read the notes on installation and connection in the enclosed manual Features for the battery unit

623 Step 3 Fit the battery charging unit battery backup converter (BBC)

Battery (batteries) connected to the battery management system (BMS)1 Carefully insert battery charging unit battery backup converter (BBC) into the compartment provided for it 2 Push in completely to establish direct contact with the rear busbars3 Secure battery charging unit battery backup converter (BBC) using the screws supplied

624 Step 4 Fit the inverter

Battery charging unit battery backup converter (BBC) is fitted1 Carefully insert inverter into the compartment provided for it 2 Push in completely to establish direct contact with the rear busbars 3 Secure inverter using the screws supplied

CAUTIONDamage to the control unit from introducing foreign objectsForeign objects can impair the function of the control unit and cause damage rsaquo Do not remove the front panel rsaquo Foreign objects should be removed immediately

Installing the device

Operating instructions Powador-gridsave_EN Page 19

Authorised electrician

7 Installing the device

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched The device may only be opened or serviced by an authorised electricianThe device must be completely assembled before being connected electrically rsaquo Observe all safety regulations and current technical connection specifications of the responsible

power supply company rsaquo De-energise the device using the DC isolator switch circuit breaker and residual current circuit

breaker rsaquo Secure both sides against being inadvertently switched back on rsaquo Ensure that the AC and DC sides are completely isolated and voltage free rsaquo Never open the plug-in modules rsaquo Hazardous voltages are present at the busbars rsaquo Disconnect from the grid and plant supply rsaquo First connect the battery system in the connection area

71 Opening the connection area

3

1

2

Figure 11 Open cover plateKey

1 Cover plate 3 Fastening screw

2 Lock

Opening the connection area You have completed assembly

1 Remove the fastening screw for the upper cover plate2 Slide the cover plate forwards out of the lock3 Lift the cover plate upward to remove raquo Make the electrical connection

Installing the device

Page 20 Operating instructions Powador-gridsave_EN

Authorised electrician

72 Making the electrical connectionMake the connection to the PV generator as well as the grid connection using the connection terminals Note the following cable cross-sections

Connection Possible cable cross-section Length of insulation to be stripped offAC home power grid 05 - 16 mmsup2 with end sleeve

05 - 25 mmsup2 without end sleeve18 mm sleeve18-20 mm

PV connection 05 - 16 mmsup2 with end sleeve05 - 25 mmsup2 without end sleeve

18 mm sleeve17-19 mm

Inverter output 05 - 4 mmsup2 with end sleeve05 - 6 mmsup2 without end sleeve

12 mm sleeve11-13 mm

Potential-free contacts 034 - 15 mmsup2 with end sleeve034 - 25 mmsup2 without end sleeve

12 mm sleeve 9-10 mm

Table 4 Cable cross-sections for connection terminals

NOTEThe threaded connections should be matched to the cable cross-section

NOTEOnly conductors and no insulation should be inserted into the connection terminals Individual wires or cables with end sleeves with the appropriate cross-section can be inserted directly into the connection terminal without a toolFine-strand cables without end sleeve or thin conductors will need a screwdriver (plain slot 35 mm) for connection To do this insert the blade of the screwdriver into the recess provided The cable can be inserted into the spring terminal by pressing downwards The spring terminal closes on removal of the screw-driver

Installing the device

Operating instructions Powador-gridsave_EN Page 21

Authorised electrician

X2X1F1 F2 X7 X4 St1

St2

St3

2 3 541 6

Figure 12 View from above of the connection area

Key

1 AC grid input (M40 cable fitting) 4 Network interface (M32 cable fitting)

2 AC grid output (M40 cable fitting) 5 Inverter input (M16 cable fitting)

3 Inverter output (M32 cable fitting) 6 Other connections (M16 cable fitting)

F1 F2 X7 X4 St1

St2

St3

L1 L2 L3 N PE L1 L2 L3 N N PE PE

X1 X2

PV+

PV-

L1 L2 L3 N PE32A 32A PEN

Cust

omer

co

nnec

tion

Figure 13 View from above of the connection area

Key

X1 AC grid input (main junction box meter) X7 PV generator input

X2 AC grid output (building electrical system) F1 F2 Phase bridging fuse

X4 Inverter output St 1-3 Potential-free contacts control outputs

Installing the device

Page 22 Operating instructions Powador-gridsave_EN

Authorised electrician

721 Connecting to the power grid

Because the device is installed between the main junction boxmeter and the buildings electrical system the maxi-mum grid current to the service line must not exceed the rated operating current of the battery system The cable cross-section must be selected in accordance with applicable standards to suit the connected load instal-lation type etc Moreover the terminal area and size of the cable fitting must be noted

NOTEThe fuse rating for the cable should be max 63A (automatic circuit breaker or safety fuse) even if the cross-section of the installed cable would permit a higher fuse rating Always follow the applicable regulations regarding the cable cross-section and installation typeThe device supports standard grid configurations such as TN-C TN-S and TT TN-SIf a TN-S grid is present directly at the power input and output of the device L1-L3 N and PE must each be connected The home power grid should have 4-pin isolationTN-C4-pin grid isolation is factory preset and disconnects L1 L2 L3 and N In a TN-C grid the N conduc-tor must not be disconnected If a TN-S grid is present directly at the power input and output of the device a cable bridge (included in delivery) must be installed between the N terminal on X1 and the N terminal on X2 N and PE must additionally be connected together To do this simply insert the enclosed terminal link into the N and PE terminals TTIn the case of a TT grid L1-L3 N and PE must each be connected The home power grid should have 4-pin isolation

NOTEPlease check with the operator of the mains grid whether there are special regulations for grid connection Grid isolation is factory preset to 4-pin is fail-safe and provided with grid and system protection as per VDE-AR-N 4105

Making the grid connection Use cables with 5 wires (L1 brown L2 black L3 grey N blue PE greenyellow) and the correct

cross-section1 Loosen cable fitting for AC connection2 Remove the outer cladding of the AC cables3 Insert the AC cables through the cable fitting into the connection area4 Strip the insulation from the AC cables5 Remove connection terminals6 Connect the cables in line with the terminal labels (Figure 13 on page 21)7 Close the connection terminals8 Check that all connected cables are securely fitted9 Tighten the cable fitting10 To meet the requirements of protection rating IP21 close the unused cable fittings with blind caps raquo The battery system is connected to the power grid

NOTEAn AC-side disconnection unit must be provided during the final installation stage This disconnec-tion unit must be installed so that it can be accessed at any time without obstruction If a residual current circuit breaker is necessary due to the installation specification a type A residual current circuit breaker must be used

Installing the device

Operating instructions Powador-gridsave_EN Page 23

Authorised electrician

7211 Output from the inverterRecommended cable cross-sections for the inverter output and fuse rating of cables for fixed wiring accord-ing to VDE 0100 part 430The fuse rating for the cable is dependent on the cable cross-section max 40A automatic circuit breaker

NOTEWhen the line resistance is high (ie long grid-side cables) the voltage at the grid terminals of the inverter will increase during feed-in to the grid The inverter monitors this voltage If the voltage exceeds the country-specific grid overvoltage limit value the inverter switches off rsaquo Ensure that the conductor cross-sections are sufficiently large or that the cable lengths are suffi-

ciently short

NOTEIn order to avoid asymmetries in the grid systems with multiple battery systems should be designed so that the inverters in the devices feed into the grid in differing phases rsaquo Follow the connection conditions for the particular type of grid and the schematic illustration

below

Country and grid-type

Grid monitoring Required monitoring

max asymmetry between phases L1L2L3

DE-NSP Three-phase or single phase phase unbalanced load 46 kVA

Table 5 Grid-type-specific connection conditions

L1

L2

L3

N

Connection X1 Connection X1 Connection X1 Connection X1

L1 L2 L3 N PE L1 L2 L3 N PE L1 L2 L3 N PE L1 L2 L3 N PE

Powador-gridsave inverter1 L1 - L1 L2 - L2 L3 - L32 L1 - L2 L2 - L3 L3 - L1 3 L1 - L3 L2 - L1 L3 - L2 4 L1 - L1 L2 - L2 L3 - L3

Figure 14 Grid-side connection for systems with multiple battery systems with three-phase grid monitoring

Installing the device

Page 24 Operating instructions Powador-gridsave_EN

Authorised electrician

722 Connecting the PV generator

Connect the PV generator on the left in the connection area (Figure 13 on page 21) Use the provided M16 cable fittings A maximum of two strings can be connected For this reason a DC string fuse can be dispensed with

DANGERRisk of fatal injury due to contact voltagesRemoving the cables from the terminals without first disconnecting the PV generator from the device can cause serious damage to health or damage to the system rsaquo During installation Electrically disconnect the DC positive and DC negative from the protective

earth (PE) rsaquo Completely de-energise the system (AC home power grid AC circuit breaker residual current circuit

breaker DC isolator switch) rsaquo Disconnect the battery system from the PV generator using the integrated DC isolator switch rsaquo Remove DC plug connectors

NOTEIn accordance with IEC 61730 Class A connected PV modules must be dimensioned for the DC system voltage provided and at least for the value of the AC grid voltage

7221 Before connecting

Ensure that there is no ground fault1 Determine the DC voltage between the

ndash protective earth (PE) and the positive cable of the PV generator and between the ndash protective earth (PE) and the negative cable of the PV generator

If stable voltages can be measured there is a ground fault in the DC generator or its wiring The ratio between the measured voltages gives an indication as to the location of this fault

2 Rectify any faults before taking further measurements3 Determine the electrical resistance between the

ndash protective earth (PE) and the positive cable of the PV generator and between the ndash protective earth (PE) and the negative cable of the PV generator

In addition ensure that the PV generator has a total insulation resistance of more than 20 MOhm since the inverter will not feed in if the insulation resistance is too low

4 Rectify any faults before connecting the DC generator

7222 Connecting the PV generator

DANGERRisk of fatal injury due to electric shockSevere injury or death will result if the live connections are touched When there is solar radiation DC voltage will be present at the open ends of the DC cables rsaquo Do not touch the exposed ends of the cables rsaquo Avoid short circuits

Installing the device

Operating instructions Powador-gridsave_EN Page 25

Authorised electrician

Connecting the PV generator Use cables with the correct cross-section

1 Remove cable fittings for DC connection2 Remove the outer cladding of the DC cables3 Insert the DC cables through the cable fittings into the connection area4 Strip the insulation from the DC cables5 Remove connection terminals6 Connect the cables in line with the terminal labels (See Figure 13 on page 21)7 Close the connection terminals8 Check that all connected cables are securely fitted9 Tighten the cable fittings10 To meet the requirements of protection rating IP21 close the unused cable fittings with blind caps raquo The PV generator is connected to the inverter

73 Connecting the interfaces

731 Ethernet interface

Pre-assembled Ethernet cables can be connected using the RJ45 socket in the connection space

Connecting the Ethernet cable1 Remove closure cap from RJ45 socket2 Connect the Ethernet cable3 The energy management system can now obtain an IP address by DHCP and is also available via this in the

network

NOTEThe network settings can be amended later in the Settings menu using the EMS

NOTEUse a suitable category 5 network cable The maximum length of a network segment is 100 m Ensure that the cable is correctly assigned The Ethernet connection of the battery system supports auto-sensing You can use both crossed and 11 configured Ethernet connection cables

74 Sealing the connection area

1 Finally check the cabling2 Ensure that all cables are firmly mounted3 Check that the cable fitting is secure and tighten if necessary4 Remove cable offcuts and particles of dirt or dust5 Fit the cover and slide back until it engages into position6 Check that the position is correct7 Screw the fastening screw onto the front of the cover

Installing the device

Page 26 Operating instructions Powador-gridsave_EN

Authorised electrician

75 Starting up

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched Only appropriately qualified and authorised electricians may open install or maintain the battery system rsaquo Keep the front doors and covers closed during operation

NOTEInitial start-up should be carried out using the available public AC grid

76 Standard configuration

Factory settingsCountry configuration Germany

Grid guidelines Low voltage directive

Language German

Time UTC +1 Central European Time

User Standard

Network parameters DHCP (network settings will be obtained automatically from the router)

NOTEPlease state the desired power limitation (60 or 70 of the PV system capacity) when you order For other variations please notify your KACO contact so that the parameters can be set at the factory prior to delivery

Installing the device

Operating instructions Powador-gridsave_EN Page 27

Authorised electrician

761 Step 1 AC home power grid

Check all cables and connections before starting up1 Switch on the AC home power grid using the AC main switch raquo Powador-protect measurement and control unit starts up and monitors the AC grid raquo Two green LEDs indicate that the grid parameters are met raquo After a further 60 seconds (shortly after the backlighting in the Powador-protect goes out) the Powador-pro-

tect will switch on the home grid2 Configure Powador-protect according to the enclosed Powador-protect instructions

(The instructions are also available on the website at wwwkaconewenergyde) raquo The AC power is supplied in the normal way by the public grid

762 Step 2 AC supply from the battery system

Check all cables and connections before starting up1 Remove external isolation means from the device2 Switch on the circuit breaker raquo The LCD touchscreen on the front panel comes on and the energy management system (EMS) starts up

3 Switch on the residual current circuit breaker raquo The battery system starts up

763 Step 3 Switch on the PV system

1 Switch on any optional external PV isolator switches2 Set the internal DC isolator switch to ON raquo The inverter and the battery charging unit battery backup converter (BBC) are connected to the PV system raquo The device monitors the PV voltage for approx 60 seconds then optimisation of internal consumption takes

place

764 Step 4 Switch on batteries

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

765 Step 5 Activate energy management

NOTEKACO new energy cannot provide any support for problems regarding the IT infrastructure (eg router configuration IP address assignment ports etc) as the structure settings and configuration of the network environment can be complex and very different from place to place In the event of any problems please contact an IT service provider

Remote access activated 1 Please call the KACO Hotline to make an appointment for activation of energy management

Configuration and Operation

Page 28 Operating instructions Powador-gridsave_EN

Authorised electrician

8 Configuration and Operation

81 ControlsThe battery system is fitted with a touchscreen which allows it to be controlled very precisely In normal operation the display is switched off Touching the screen activates the display and after a configurable period of time without being touched the dis-play will deactivate If the screen-save function is switched off the touchscreen will be on continuously

NOTEDepending on the tolerances of the measuring elements the measured and displayed values are not always the actual values However the measuring elements ensure maximum solar yield Due to these tolerances the daily yields shown on the touchscreen may deviate from the values on the grid operatorrsquos feed-in meter by up to 15

3

1

45

2

Figure 15 Overview (home screen)

Key

1 Home button 4 Current time

2 System components 5 Menu name

3 More information

811 Information about the system

Open start screen View changesjumps to the home screen

Show component detail Parameters of the selected component

Settings Define settings for the active user

raquo Displays settings

Configuration and Operation

Operating instructions Powador-gridsave_EN Page 29

Controls Left arrow jump back to previous menu item Up and down arrows navigate through the menu or change a value

Left arrow displayed value is reduced by one increment Right arrow displayed value is increased by one increment or change to the submenu

Display fields Grey box Text or figures (not selectable) Blue box Calls up submenu for the display in question

Activate and deactivate Activate function by ticking the box

Table 6 Information about the system

812 System components

PV generator Display of the current generator data

power voltage current temperature in the inverter

Battery Display of the current battery status

power (charging or discharging) voltage current charge status available capacity temperature of battery

Grid Display of the following either fed-in or drawn from the grid

power voltage current for phase L1-L3 total output frequency

Consumer (load) Display of the consumer data

power voltage current for phase L1-L3 total output

Energy flow raquo Displays the current energy flow in the system

Table 7 Information about system components

Configuration and Operation

Page 30 Operating instructions Powador-gridsave_EN

813 Menu structure

Icons used

Display menu Submenu

Option menu

Menu Submenu Display setting

Action in this menumeaning

PV generator Details

Power Displays the current DC-side power

Voltage Displays the current DC-side voltage

Current Displays the current DC-side amperage

Temp inverter

Displays the current temperature in the inverter housing

Battery Details

Power Displays the current AC-side power

Voltage Displays the current AC-side voltage

Current Displays the current AC-side amperage

Charge status Displays the current charge status

Capacity Displays the current battery capacity

Temperature Displays the current measured temperature of the battery

Grid Details

Power Displays the current AC-side power being drawn or fed-in

Voltage Displays the AC-side voltage being applied

Current Displays the current AC-side amperage being drawn or fed-in

Total output Displays the current AC-side total output being drawn or fed-in

Frequency Displays the frequency currently being applied to the grid junction

Consumer (load) Details

Power Displays the current AC-side power being drawn

Voltage Displays the current AC-side voltage being applied

Current Displays the current AC-side amperage being drawn

Total output Displays the current AC-side total output being drawn

Configuration and Operation

Operating instructions Powador-gridsave_EN Page 31

Menu Submenu Display setting

Action in this menumeaning

Settings

Country amp directive display

Display of the country settings voltage directives and grid type

Select menu language

DateTime Specify time zone date format and date and time

Screen Activate screen-save function and set the delay period

Network settings

Display of the network settings Configure network settings Once the DHCP server becomes available the IP

address subnet mask gateway and DNS server are automatically applied and the aforemen-tioned menu items are hidden

Off DHCP deactivated make settings manually

Version Displays the installed software version and built-in HW components (inverter BBC battery)

Vendor The touchscreen shows information about the device vendor

NOTEAs changes to the software are possible after the manual has been printed the illustrations and descriptions of the functions in these operating instructions may deviate from the software Please therefore note the current Application Notes on our website

MaintenanceTroubleshooting

Page 32 Operating instructions Powador-gridsave_EN

9 MaintenanceTroubleshooting

91 Visual inspectionInspect the device and the cables for visible external damage and note the operating status display In case of damage notify your installer Repairs may only be carried out by authorised electricians

NOTEThe battery system should be checked for proper operation by a qualified electrician at regular intervals

92 Cleaning the device

DANGERLethal voltages in the battery systemSerious injuries or death can result if moisture enters the system rsaquo Only use completely dry objects to clean the battery system rsaquo Only clean the outside of the battery system

Cleaning the battery system Do not use compressed air Use a vacuum cleaner or a soft brush to remove dust from the fan cover and from the top of the inverter on a

regular basis Remove dust from the ventilation inlets if necessary

MaintenanceTroubleshooting

Operating instructions Powador-gridsave_EN Page 33

Authorised electrician

93 Maintenance

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched The device is only permitted to be opened or serviced by an authorised electrician rsaquo Observe all safety regulations and the current technical connection specifications from the relevant

power supply company rsaquo Disconnect the AC and DC sides rsaquo Secure the AC and DC sides from being inadvertently switched back on rsaquo Only then should the device be opened rsaquo After shutdown wait at least 30 minutes before working on the device

CAUTIONDestruction of the DC connectionThe connection terminals can be destroyed by arcing if disconnected while still live rsaquo It is absolutely essential that the shutdown sequence be carried out in the correct order (See sec-

tion 111 on page 35)

94 Faults

941 Procedure

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched

When a fault occurs notify an appropriately authorised and qualified electrician or KACO new energy GmbH Service

Service

Page 34 Operating instructions Powador-gridsave_EN

10 ServiceIf 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 efficientlybull Serial nobull SW version of the components (the software version can be found in the Settings menu using the EMS)bull Module type and string circuitbull Date of installation Start-up reportbull Consignment identification Delivery address Contact person (with telephone number)bull Information about the accessibility of the installation site

Any additional costs arising from unfavourable structural or mounting conditions shall be billed to the customer

You can find our warranty conditions on our websitehttpkaco-newenergycomservicewarrantyFrom there you can easily navigate to our international websites by clicking on the appropriate flag

Please use our website to register your unit immediatelyYou can also select the appropriate flag on this page to access the website for your own countryIn this manner you can assist us in providing you with the quickest service possible Note The maximum length of the warranty is based on the currently applicable national warranty conditions

We have prepared a template for complaints This can be found at httpskaco-newenergycomservicecustomer-service

Hotlines

Technical troubleshooting Technical consultation

Inverters and battery systems ()

+49 (0) 71323818-660 +49 (0) 71323818-660

Data logging and accessories +49 (0) 71323818-690 +49 (0) 71323818-690

Construction site emergency () +49 (0) 71323818-630

Customer help desk Monday to Friday from 730 am to 530 pm (CET)

() Also on Saturdays from 800 am to 200 pm (CET)

ShutdownDisassembly

Operating instructions Powador-gridsave_EN Page 35

11 ShutdownDisassembly

111 Switching off the device

DANGERLethal voltages are still present in the terminals and cables even after switching off and discon-nection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched rsaquo Complete de-energisation only occurs if the bulk power supply is switched off upstream of the bat-

tery system

DANGERDestruction of the DC plug connectorDC plug connectors can be destroyed by arcing if disconnected while still live rsaquo It is absolutely essential that the following shutdown sequence is observed

1111 Step 1 Shutting down the PV system

1 Switch off any optional external PV isolator switches2 Set the internal DC isolator switch to OFF raquo The inverter and battery charging unit battery backup converter (BBC) are disconnected

1112 Step 2 Disconnect the batteries

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

1113 Step 3 Disconnect the AC supply

1 Connect external isolation means to the device2 Switch off the circuit breaker 3 Switch off the residual current circuit breaker raquo The battery system is switched off

1114 Step 4 AC home power grid

1 Shutdown the AC home power grid using the AC main switch raquo The battery system can be uninstalled

Disposal

Page 36 Operating instructions Powador-gridsave_EN

112 Uninstalling the device

NOTETo uninstall follow the same sequence as for installation but in reverse order

Switch off the device1 Unlock and open the housing door2 Remove the upper cover3 Release the DC and AC cables from the connection terminals4 Pull out the cables raquo The battery system is uninstalled Continue with the disassembly

113 Disassembling the device

NOTETo disassemble follow the same sequence as for assembly but in reverse order

Switch off the device1 Uninstall the components2 Remove the fastening from the device3 Securely pack up the battery system if it is to be used later

or have the battery system disposed of in accordance with section 12 on page 36

12 DisposalFor the most part both the battery system and the corresponding transport packaging are made from recyclable raw materialsBatteries and components Do not dispose of faulty batteries or the components together with household waste Ensure that the old device and accessories are disposed of in a proper mannerPackaging Ensure that the transport packaging is disposed of properlyBatteriesUsed or faulty batteries must be transported in special packaging If you need such packaging please contact the KACO Hotline

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

Appendix

Operating instructions Powador-gridsave_EN Page 37

13 Appendix

EU Declaration of Conformity

Vendorrsquos name and address

KACO new energy GmbH Carl-Zeiss-Straszlige 1 74172 Neckarsulm Germany

Product description Battery system

Type designation Powador-gridsave 135 kWh 6400 Powador-gridsave 135 kWh 8000

Powador-gridsave 270 kWh 6400 Powador-gridsave 270 kWh 8000

Powador-gridsave 405 kWh 6400 Powador-gridsave 405 kWh 8000

Powador-gridsave 540 kWh 6400 Powador-gridsave 540 kWh 8000

Powador-gridsave 577 kWh 6400 Powador-gridsave 577 kWh 8000

Powador-gridsave 675 kWh 6400 Powador-gridsave 675 kWh 8000

This is to confirm that the units listed above comply with the protection requirements set forth in the Directive of the Council of the European Union of 15th December 2004 on the harmonisation of the laws of the member states relating to Electromagnetic Compatibility (2004108EC) and the Low Voltage Directive (200695EC)The units are compliant with the following standards

200695EC ldquoDirective relating to electrical equipment designed for use within specific voltage limitsrdquo

Safety of the unitIEC 62109-12010IEC 62109-22011

2004108EC ldquoDirective relating to electromagneticcompatibilityrdquo

Interference immunityEN 61000-6-22005 Emitted interferenceEN 61000-6-32007

Secondary effects on the gridEN 61000-3-112000EN 61000-3-122005

The types mentioned above are therefore labelled with the CE markUnauthorised modifications to the supplied units andor any use of the units that is contrary to their intended use render this Declaration of Conformity null and void

Neckarsulm 0711 2013KACO new energy GmbH

pp Volker DietrichEnergy systems engineering management

Disposal

Page 38 Operating instructions Powador-gridsave_EN

Carl-Zeiss-Straszlige 1 middot 74172 Neckarsulm middot Germany middot Phone +49 7132 3818-0 middot Fax +49 7132 3818-703 middot infokaco-newenergyde middot wwwkaco-newenergyde

The

text

and

figu

res

refle

ct th

e cu

rren

t tec

hnic

al s

tate

at t

he ti

me

of p

rintin

g S

ubje

ct to

tech

nica

l cha

nges

Err

ors

and

omis

sion

s ex

cept

ed

3006

856-

01-1

4030

5

  • 1General Information
    • 11About this document
    • 12Name plate
    • 13Additional information
    • 14Intended use
      • 2Safety
        • 21Protection features
          • 3Description
            • 31Mode of Operation
            • 32Summary of the components
              • 4Technical Data
                • 41Electrical data
                • 42Mechanical data
                  • 5Transportation and Delivery
                    • 51Delivery
                    • 52Storage
                    • 53Transportation
                      • 6Assembling the device
                        • 61Installation
                        • 62Installing components
                          • 7Installing the device
                            • 71Opening the connection area
                            • 72Making the electrical connection
                            • 73Connecting the interfaces
                            • 74Sealing the connection area
                            • 75Starting up
                            • 76Standard configuration
                              • 8Configuration and Operation
                                • 81Controls
                                  • 9MaintenanceTroubleshooting
                                    • 91Visual inspection
                                    • 92Cleaning the device
                                    • 93Maintenance
                                    • 94Faults
                                      • 10Service
                                      • 11ShutdownDisassembly
                                        • 111Switching off the device
                                        • 112Uninstalling the device
                                        • 113Disassembling the device
                                          • 12Disposal
                                          • 13Appendix

Assembling the device

Page 18 Operating instructions Powador-gridsave_EN

Authorised electrician

WARNINGDanger caused by short circuit or sparkingSerious injury from touching or connecting live components rsaquo Damaged components must not be installed

Preparation1 Check the conditions for the installation location2 Open the housing doors using the enclosed cabinet key3 The cables should be professionally laid and prepared for connection4 Follow the installation sequence (1-4 step(s))

621 Step 1 Fit the battery (batteries)

NOTEPlease read the notes on installation and connection in the enclosed manual Features for the battery unit

622 Step 2 Connect battery (batteries) to the battery management system (BMS)

NOTEPlease read the notes on installation and connection in the enclosed manual Features for the battery unit

623 Step 3 Fit the battery charging unit battery backup converter (BBC)

Battery (batteries) connected to the battery management system (BMS)1 Carefully insert battery charging unit battery backup converter (BBC) into the compartment provided for it 2 Push in completely to establish direct contact with the rear busbars3 Secure battery charging unit battery backup converter (BBC) using the screws supplied

624 Step 4 Fit the inverter

Battery charging unit battery backup converter (BBC) is fitted1 Carefully insert inverter into the compartment provided for it 2 Push in completely to establish direct contact with the rear busbars 3 Secure inverter using the screws supplied

CAUTIONDamage to the control unit from introducing foreign objectsForeign objects can impair the function of the control unit and cause damage rsaquo Do not remove the front panel rsaquo Foreign objects should be removed immediately

Installing the device

Operating instructions Powador-gridsave_EN Page 19

Authorised electrician

7 Installing the device

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched The device may only be opened or serviced by an authorised electricianThe device must be completely assembled before being connected electrically rsaquo Observe all safety regulations and current technical connection specifications of the responsible

power supply company rsaquo De-energise the device using the DC isolator switch circuit breaker and residual current circuit

breaker rsaquo Secure both sides against being inadvertently switched back on rsaquo Ensure that the AC and DC sides are completely isolated and voltage free rsaquo Never open the plug-in modules rsaquo Hazardous voltages are present at the busbars rsaquo Disconnect from the grid and plant supply rsaquo First connect the battery system in the connection area

71 Opening the connection area

3

1

2

Figure 11 Open cover plateKey

1 Cover plate 3 Fastening screw

2 Lock

Opening the connection area You have completed assembly

1 Remove the fastening screw for the upper cover plate2 Slide the cover plate forwards out of the lock3 Lift the cover plate upward to remove raquo Make the electrical connection

Installing the device

Page 20 Operating instructions Powador-gridsave_EN

Authorised electrician

72 Making the electrical connectionMake the connection to the PV generator as well as the grid connection using the connection terminals Note the following cable cross-sections

Connection Possible cable cross-section Length of insulation to be stripped offAC home power grid 05 - 16 mmsup2 with end sleeve

05 - 25 mmsup2 without end sleeve18 mm sleeve18-20 mm

PV connection 05 - 16 mmsup2 with end sleeve05 - 25 mmsup2 without end sleeve

18 mm sleeve17-19 mm

Inverter output 05 - 4 mmsup2 with end sleeve05 - 6 mmsup2 without end sleeve

12 mm sleeve11-13 mm

Potential-free contacts 034 - 15 mmsup2 with end sleeve034 - 25 mmsup2 without end sleeve

12 mm sleeve 9-10 mm

Table 4 Cable cross-sections for connection terminals

NOTEThe threaded connections should be matched to the cable cross-section

NOTEOnly conductors and no insulation should be inserted into the connection terminals Individual wires or cables with end sleeves with the appropriate cross-section can be inserted directly into the connection terminal without a toolFine-strand cables without end sleeve or thin conductors will need a screwdriver (plain slot 35 mm) for connection To do this insert the blade of the screwdriver into the recess provided The cable can be inserted into the spring terminal by pressing downwards The spring terminal closes on removal of the screw-driver

Installing the device

Operating instructions Powador-gridsave_EN Page 21

Authorised electrician

X2X1F1 F2 X7 X4 St1

St2

St3

2 3 541 6

Figure 12 View from above of the connection area

Key

1 AC grid input (M40 cable fitting) 4 Network interface (M32 cable fitting)

2 AC grid output (M40 cable fitting) 5 Inverter input (M16 cable fitting)

3 Inverter output (M32 cable fitting) 6 Other connections (M16 cable fitting)

F1 F2 X7 X4 St1

St2

St3

L1 L2 L3 N PE L1 L2 L3 N N PE PE

X1 X2

PV+

PV-

L1 L2 L3 N PE32A 32A PEN

Cust

omer

co

nnec

tion

Figure 13 View from above of the connection area

Key

X1 AC grid input (main junction box meter) X7 PV generator input

X2 AC grid output (building electrical system) F1 F2 Phase bridging fuse

X4 Inverter output St 1-3 Potential-free contacts control outputs

Installing the device

Page 22 Operating instructions Powador-gridsave_EN

Authorised electrician

721 Connecting to the power grid

Because the device is installed between the main junction boxmeter and the buildings electrical system the maxi-mum grid current to the service line must not exceed the rated operating current of the battery system The cable cross-section must be selected in accordance with applicable standards to suit the connected load instal-lation type etc Moreover the terminal area and size of the cable fitting must be noted

NOTEThe fuse rating for the cable should be max 63A (automatic circuit breaker or safety fuse) even if the cross-section of the installed cable would permit a higher fuse rating Always follow the applicable regulations regarding the cable cross-section and installation typeThe device supports standard grid configurations such as TN-C TN-S and TT TN-SIf a TN-S grid is present directly at the power input and output of the device L1-L3 N and PE must each be connected The home power grid should have 4-pin isolationTN-C4-pin grid isolation is factory preset and disconnects L1 L2 L3 and N In a TN-C grid the N conduc-tor must not be disconnected If a TN-S grid is present directly at the power input and output of the device a cable bridge (included in delivery) must be installed between the N terminal on X1 and the N terminal on X2 N and PE must additionally be connected together To do this simply insert the enclosed terminal link into the N and PE terminals TTIn the case of a TT grid L1-L3 N and PE must each be connected The home power grid should have 4-pin isolation

NOTEPlease check with the operator of the mains grid whether there are special regulations for grid connection Grid isolation is factory preset to 4-pin is fail-safe and provided with grid and system protection as per VDE-AR-N 4105

Making the grid connection Use cables with 5 wires (L1 brown L2 black L3 grey N blue PE greenyellow) and the correct

cross-section1 Loosen cable fitting for AC connection2 Remove the outer cladding of the AC cables3 Insert the AC cables through the cable fitting into the connection area4 Strip the insulation from the AC cables5 Remove connection terminals6 Connect the cables in line with the terminal labels (Figure 13 on page 21)7 Close the connection terminals8 Check that all connected cables are securely fitted9 Tighten the cable fitting10 To meet the requirements of protection rating IP21 close the unused cable fittings with blind caps raquo The battery system is connected to the power grid

NOTEAn AC-side disconnection unit must be provided during the final installation stage This disconnec-tion unit must be installed so that it can be accessed at any time without obstruction If a residual current circuit breaker is necessary due to the installation specification a type A residual current circuit breaker must be used

Installing the device

Operating instructions Powador-gridsave_EN Page 23

Authorised electrician

7211 Output from the inverterRecommended cable cross-sections for the inverter output and fuse rating of cables for fixed wiring accord-ing to VDE 0100 part 430The fuse rating for the cable is dependent on the cable cross-section max 40A automatic circuit breaker

NOTEWhen the line resistance is high (ie long grid-side cables) the voltage at the grid terminals of the inverter will increase during feed-in to the grid The inverter monitors this voltage If the voltage exceeds the country-specific grid overvoltage limit value the inverter switches off rsaquo Ensure that the conductor cross-sections are sufficiently large or that the cable lengths are suffi-

ciently short

NOTEIn order to avoid asymmetries in the grid systems with multiple battery systems should be designed so that the inverters in the devices feed into the grid in differing phases rsaquo Follow the connection conditions for the particular type of grid and the schematic illustration

below

Country and grid-type

Grid monitoring Required monitoring

max asymmetry between phases L1L2L3

DE-NSP Three-phase or single phase phase unbalanced load 46 kVA

Table 5 Grid-type-specific connection conditions

L1

L2

L3

N

Connection X1 Connection X1 Connection X1 Connection X1

L1 L2 L3 N PE L1 L2 L3 N PE L1 L2 L3 N PE L1 L2 L3 N PE

Powador-gridsave inverter1 L1 - L1 L2 - L2 L3 - L32 L1 - L2 L2 - L3 L3 - L1 3 L1 - L3 L2 - L1 L3 - L2 4 L1 - L1 L2 - L2 L3 - L3

Figure 14 Grid-side connection for systems with multiple battery systems with three-phase grid monitoring

Installing the device

Page 24 Operating instructions Powador-gridsave_EN

Authorised electrician

722 Connecting the PV generator

Connect the PV generator on the left in the connection area (Figure 13 on page 21) Use the provided M16 cable fittings A maximum of two strings can be connected For this reason a DC string fuse can be dispensed with

DANGERRisk of fatal injury due to contact voltagesRemoving the cables from the terminals without first disconnecting the PV generator from the device can cause serious damage to health or damage to the system rsaquo During installation Electrically disconnect the DC positive and DC negative from the protective

earth (PE) rsaquo Completely de-energise the system (AC home power grid AC circuit breaker residual current circuit

breaker DC isolator switch) rsaquo Disconnect the battery system from the PV generator using the integrated DC isolator switch rsaquo Remove DC plug connectors

NOTEIn accordance with IEC 61730 Class A connected PV modules must be dimensioned for the DC system voltage provided and at least for the value of the AC grid voltage

7221 Before connecting

Ensure that there is no ground fault1 Determine the DC voltage between the

ndash protective earth (PE) and the positive cable of the PV generator and between the ndash protective earth (PE) and the negative cable of the PV generator

If stable voltages can be measured there is a ground fault in the DC generator or its wiring The ratio between the measured voltages gives an indication as to the location of this fault

2 Rectify any faults before taking further measurements3 Determine the electrical resistance between the

ndash protective earth (PE) and the positive cable of the PV generator and between the ndash protective earth (PE) and the negative cable of the PV generator

In addition ensure that the PV generator has a total insulation resistance of more than 20 MOhm since the inverter will not feed in if the insulation resistance is too low

4 Rectify any faults before connecting the DC generator

7222 Connecting the PV generator

DANGERRisk of fatal injury due to electric shockSevere injury or death will result if the live connections are touched When there is solar radiation DC voltage will be present at the open ends of the DC cables rsaquo Do not touch the exposed ends of the cables rsaquo Avoid short circuits

Installing the device

Operating instructions Powador-gridsave_EN Page 25

Authorised electrician

Connecting the PV generator Use cables with the correct cross-section

1 Remove cable fittings for DC connection2 Remove the outer cladding of the DC cables3 Insert the DC cables through the cable fittings into the connection area4 Strip the insulation from the DC cables5 Remove connection terminals6 Connect the cables in line with the terminal labels (See Figure 13 on page 21)7 Close the connection terminals8 Check that all connected cables are securely fitted9 Tighten the cable fittings10 To meet the requirements of protection rating IP21 close the unused cable fittings with blind caps raquo The PV generator is connected to the inverter

73 Connecting the interfaces

731 Ethernet interface

Pre-assembled Ethernet cables can be connected using the RJ45 socket in the connection space

Connecting the Ethernet cable1 Remove closure cap from RJ45 socket2 Connect the Ethernet cable3 The energy management system can now obtain an IP address by DHCP and is also available via this in the

network

NOTEThe network settings can be amended later in the Settings menu using the EMS

NOTEUse a suitable category 5 network cable The maximum length of a network segment is 100 m Ensure that the cable is correctly assigned The Ethernet connection of the battery system supports auto-sensing You can use both crossed and 11 configured Ethernet connection cables

74 Sealing the connection area

1 Finally check the cabling2 Ensure that all cables are firmly mounted3 Check that the cable fitting is secure and tighten if necessary4 Remove cable offcuts and particles of dirt or dust5 Fit the cover and slide back until it engages into position6 Check that the position is correct7 Screw the fastening screw onto the front of the cover

Installing the device

Page 26 Operating instructions Powador-gridsave_EN

Authorised electrician

75 Starting up

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched Only appropriately qualified and authorised electricians may open install or maintain the battery system rsaquo Keep the front doors and covers closed during operation

NOTEInitial start-up should be carried out using the available public AC grid

76 Standard configuration

Factory settingsCountry configuration Germany

Grid guidelines Low voltage directive

Language German

Time UTC +1 Central European Time

User Standard

Network parameters DHCP (network settings will be obtained automatically from the router)

NOTEPlease state the desired power limitation (60 or 70 of the PV system capacity) when you order For other variations please notify your KACO contact so that the parameters can be set at the factory prior to delivery

Installing the device

Operating instructions Powador-gridsave_EN Page 27

Authorised electrician

761 Step 1 AC home power grid

Check all cables and connections before starting up1 Switch on the AC home power grid using the AC main switch raquo Powador-protect measurement and control unit starts up and monitors the AC grid raquo Two green LEDs indicate that the grid parameters are met raquo After a further 60 seconds (shortly after the backlighting in the Powador-protect goes out) the Powador-pro-

tect will switch on the home grid2 Configure Powador-protect according to the enclosed Powador-protect instructions

(The instructions are also available on the website at wwwkaconewenergyde) raquo The AC power is supplied in the normal way by the public grid

762 Step 2 AC supply from the battery system

Check all cables and connections before starting up1 Remove external isolation means from the device2 Switch on the circuit breaker raquo The LCD touchscreen on the front panel comes on and the energy management system (EMS) starts up

3 Switch on the residual current circuit breaker raquo The battery system starts up

763 Step 3 Switch on the PV system

1 Switch on any optional external PV isolator switches2 Set the internal DC isolator switch to ON raquo The inverter and the battery charging unit battery backup converter (BBC) are connected to the PV system raquo The device monitors the PV voltage for approx 60 seconds then optimisation of internal consumption takes

place

764 Step 4 Switch on batteries

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

765 Step 5 Activate energy management

NOTEKACO new energy cannot provide any support for problems regarding the IT infrastructure (eg router configuration IP address assignment ports etc) as the structure settings and configuration of the network environment can be complex and very different from place to place In the event of any problems please contact an IT service provider

Remote access activated 1 Please call the KACO Hotline to make an appointment for activation of energy management

Configuration and Operation

Page 28 Operating instructions Powador-gridsave_EN

Authorised electrician

8 Configuration and Operation

81 ControlsThe battery system is fitted with a touchscreen which allows it to be controlled very precisely In normal operation the display is switched off Touching the screen activates the display and after a configurable period of time without being touched the dis-play will deactivate If the screen-save function is switched off the touchscreen will be on continuously

NOTEDepending on the tolerances of the measuring elements the measured and displayed values are not always the actual values However the measuring elements ensure maximum solar yield Due to these tolerances the daily yields shown on the touchscreen may deviate from the values on the grid operatorrsquos feed-in meter by up to 15

3

1

45

2

Figure 15 Overview (home screen)

Key

1 Home button 4 Current time

2 System components 5 Menu name

3 More information

811 Information about the system

Open start screen View changesjumps to the home screen

Show component detail Parameters of the selected component

Settings Define settings for the active user

raquo Displays settings

Configuration and Operation

Operating instructions Powador-gridsave_EN Page 29

Controls Left arrow jump back to previous menu item Up and down arrows navigate through the menu or change a value

Left arrow displayed value is reduced by one increment Right arrow displayed value is increased by one increment or change to the submenu

Display fields Grey box Text or figures (not selectable) Blue box Calls up submenu for the display in question

Activate and deactivate Activate function by ticking the box

Table 6 Information about the system

812 System components

PV generator Display of the current generator data

power voltage current temperature in the inverter

Battery Display of the current battery status

power (charging or discharging) voltage current charge status available capacity temperature of battery

Grid Display of the following either fed-in or drawn from the grid

power voltage current for phase L1-L3 total output frequency

Consumer (load) Display of the consumer data

power voltage current for phase L1-L3 total output

Energy flow raquo Displays the current energy flow in the system

Table 7 Information about system components

Configuration and Operation

Page 30 Operating instructions Powador-gridsave_EN

813 Menu structure

Icons used

Display menu Submenu

Option menu

Menu Submenu Display setting

Action in this menumeaning

PV generator Details

Power Displays the current DC-side power

Voltage Displays the current DC-side voltage

Current Displays the current DC-side amperage

Temp inverter

Displays the current temperature in the inverter housing

Battery Details

Power Displays the current AC-side power

Voltage Displays the current AC-side voltage

Current Displays the current AC-side amperage

Charge status Displays the current charge status

Capacity Displays the current battery capacity

Temperature Displays the current measured temperature of the battery

Grid Details

Power Displays the current AC-side power being drawn or fed-in

Voltage Displays the AC-side voltage being applied

Current Displays the current AC-side amperage being drawn or fed-in

Total output Displays the current AC-side total output being drawn or fed-in

Frequency Displays the frequency currently being applied to the grid junction

Consumer (load) Details

Power Displays the current AC-side power being drawn

Voltage Displays the current AC-side voltage being applied

Current Displays the current AC-side amperage being drawn

Total output Displays the current AC-side total output being drawn

Configuration and Operation

Operating instructions Powador-gridsave_EN Page 31

Menu Submenu Display setting

Action in this menumeaning

Settings

Country amp directive display

Display of the country settings voltage directives and grid type

Select menu language

DateTime Specify time zone date format and date and time

Screen Activate screen-save function and set the delay period

Network settings

Display of the network settings Configure network settings Once the DHCP server becomes available the IP

address subnet mask gateway and DNS server are automatically applied and the aforemen-tioned menu items are hidden

Off DHCP deactivated make settings manually

Version Displays the installed software version and built-in HW components (inverter BBC battery)

Vendor The touchscreen shows information about the device vendor

NOTEAs changes to the software are possible after the manual has been printed the illustrations and descriptions of the functions in these operating instructions may deviate from the software Please therefore note the current Application Notes on our website

MaintenanceTroubleshooting

Page 32 Operating instructions Powador-gridsave_EN

9 MaintenanceTroubleshooting

91 Visual inspectionInspect the device and the cables for visible external damage and note the operating status display In case of damage notify your installer Repairs may only be carried out by authorised electricians

NOTEThe battery system should be checked for proper operation by a qualified electrician at regular intervals

92 Cleaning the device

DANGERLethal voltages in the battery systemSerious injuries or death can result if moisture enters the system rsaquo Only use completely dry objects to clean the battery system rsaquo Only clean the outside of the battery system

Cleaning the battery system Do not use compressed air Use a vacuum cleaner or a soft brush to remove dust from the fan cover and from the top of the inverter on a

regular basis Remove dust from the ventilation inlets if necessary

MaintenanceTroubleshooting

Operating instructions Powador-gridsave_EN Page 33

Authorised electrician

93 Maintenance

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched The device is only permitted to be opened or serviced by an authorised electrician rsaquo Observe all safety regulations and the current technical connection specifications from the relevant

power supply company rsaquo Disconnect the AC and DC sides rsaquo Secure the AC and DC sides from being inadvertently switched back on rsaquo Only then should the device be opened rsaquo After shutdown wait at least 30 minutes before working on the device

CAUTIONDestruction of the DC connectionThe connection terminals can be destroyed by arcing if disconnected while still live rsaquo It is absolutely essential that the shutdown sequence be carried out in the correct order (See sec-

tion 111 on page 35)

94 Faults

941 Procedure

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched

When a fault occurs notify an appropriately authorised and qualified electrician or KACO new energy GmbH Service

Service

Page 34 Operating instructions Powador-gridsave_EN

10 ServiceIf 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 efficientlybull Serial nobull SW version of the components (the software version can be found in the Settings menu using the EMS)bull Module type and string circuitbull Date of installation Start-up reportbull Consignment identification Delivery address Contact person (with telephone number)bull Information about the accessibility of the installation site

Any additional costs arising from unfavourable structural or mounting conditions shall be billed to the customer

You can find our warranty conditions on our websitehttpkaco-newenergycomservicewarrantyFrom there you can easily navigate to our international websites by clicking on the appropriate flag

Please use our website to register your unit immediatelyYou can also select the appropriate flag on this page to access the website for your own countryIn this manner you can assist us in providing you with the quickest service possible Note The maximum length of the warranty is based on the currently applicable national warranty conditions

We have prepared a template for complaints This can be found at httpskaco-newenergycomservicecustomer-service

Hotlines

Technical troubleshooting Technical consultation

Inverters and battery systems ()

+49 (0) 71323818-660 +49 (0) 71323818-660

Data logging and accessories +49 (0) 71323818-690 +49 (0) 71323818-690

Construction site emergency () +49 (0) 71323818-630

Customer help desk Monday to Friday from 730 am to 530 pm (CET)

() Also on Saturdays from 800 am to 200 pm (CET)

ShutdownDisassembly

Operating instructions Powador-gridsave_EN Page 35

11 ShutdownDisassembly

111 Switching off the device

DANGERLethal voltages are still present in the terminals and cables even after switching off and discon-nection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched rsaquo Complete de-energisation only occurs if the bulk power supply is switched off upstream of the bat-

tery system

DANGERDestruction of the DC plug connectorDC plug connectors can be destroyed by arcing if disconnected while still live rsaquo It is absolutely essential that the following shutdown sequence is observed

1111 Step 1 Shutting down the PV system

1 Switch off any optional external PV isolator switches2 Set the internal DC isolator switch to OFF raquo The inverter and battery charging unit battery backup converter (BBC) are disconnected

1112 Step 2 Disconnect the batteries

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

1113 Step 3 Disconnect the AC supply

1 Connect external isolation means to the device2 Switch off the circuit breaker 3 Switch off the residual current circuit breaker raquo The battery system is switched off

1114 Step 4 AC home power grid

1 Shutdown the AC home power grid using the AC main switch raquo The battery system can be uninstalled

Disposal

Page 36 Operating instructions Powador-gridsave_EN

112 Uninstalling the device

NOTETo uninstall follow the same sequence as for installation but in reverse order

Switch off the device1 Unlock and open the housing door2 Remove the upper cover3 Release the DC and AC cables from the connection terminals4 Pull out the cables raquo The battery system is uninstalled Continue with the disassembly

113 Disassembling the device

NOTETo disassemble follow the same sequence as for assembly but in reverse order

Switch off the device1 Uninstall the components2 Remove the fastening from the device3 Securely pack up the battery system if it is to be used later

or have the battery system disposed of in accordance with section 12 on page 36

12 DisposalFor the most part both the battery system and the corresponding transport packaging are made from recyclable raw materialsBatteries and components Do not dispose of faulty batteries or the components together with household waste Ensure that the old device and accessories are disposed of in a proper mannerPackaging Ensure that the transport packaging is disposed of properlyBatteriesUsed or faulty batteries must be transported in special packaging If you need such packaging please contact the KACO Hotline

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

Appendix

Operating instructions Powador-gridsave_EN Page 37

13 Appendix

EU Declaration of Conformity

Vendorrsquos name and address

KACO new energy GmbH Carl-Zeiss-Straszlige 1 74172 Neckarsulm Germany

Product description Battery system

Type designation Powador-gridsave 135 kWh 6400 Powador-gridsave 135 kWh 8000

Powador-gridsave 270 kWh 6400 Powador-gridsave 270 kWh 8000

Powador-gridsave 405 kWh 6400 Powador-gridsave 405 kWh 8000

Powador-gridsave 540 kWh 6400 Powador-gridsave 540 kWh 8000

Powador-gridsave 577 kWh 6400 Powador-gridsave 577 kWh 8000

Powador-gridsave 675 kWh 6400 Powador-gridsave 675 kWh 8000

This is to confirm that the units listed above comply with the protection requirements set forth in the Directive of the Council of the European Union of 15th December 2004 on the harmonisation of the laws of the member states relating to Electromagnetic Compatibility (2004108EC) and the Low Voltage Directive (200695EC)The units are compliant with the following standards

200695EC ldquoDirective relating to electrical equipment designed for use within specific voltage limitsrdquo

Safety of the unitIEC 62109-12010IEC 62109-22011

2004108EC ldquoDirective relating to electromagneticcompatibilityrdquo

Interference immunityEN 61000-6-22005 Emitted interferenceEN 61000-6-32007

Secondary effects on the gridEN 61000-3-112000EN 61000-3-122005

The types mentioned above are therefore labelled with the CE markUnauthorised modifications to the supplied units andor any use of the units that is contrary to their intended use render this Declaration of Conformity null and void

Neckarsulm 0711 2013KACO new energy GmbH

pp Volker DietrichEnergy systems engineering management

Disposal

Page 38 Operating instructions Powador-gridsave_EN

Carl-Zeiss-Straszlige 1 middot 74172 Neckarsulm middot Germany middot Phone +49 7132 3818-0 middot Fax +49 7132 3818-703 middot infokaco-newenergyde middot wwwkaco-newenergyde

The

text

and

figu

res

refle

ct th

e cu

rren

t tec

hnic

al s

tate

at t

he ti

me

of p

rintin

g S

ubje

ct to

tech

nica

l cha

nges

Err

ors

and

omis

sion

s ex

cept

ed

3006

856-

01-1

4030

5

  • 1General Information
    • 11About this document
    • 12Name plate
    • 13Additional information
    • 14Intended use
      • 2Safety
        • 21Protection features
          • 3Description
            • 31Mode of Operation
            • 32Summary of the components
              • 4Technical Data
                • 41Electrical data
                • 42Mechanical data
                  • 5Transportation and Delivery
                    • 51Delivery
                    • 52Storage
                    • 53Transportation
                      • 6Assembling the device
                        • 61Installation
                        • 62Installing components
                          • 7Installing the device
                            • 71Opening the connection area
                            • 72Making the electrical connection
                            • 73Connecting the interfaces
                            • 74Sealing the connection area
                            • 75Starting up
                            • 76Standard configuration
                              • 8Configuration and Operation
                                • 81Controls
                                  • 9MaintenanceTroubleshooting
                                    • 91Visual inspection
                                    • 92Cleaning the device
                                    • 93Maintenance
                                    • 94Faults
                                      • 10Service
                                      • 11ShutdownDisassembly
                                        • 111Switching off the device
                                        • 112Uninstalling the device
                                        • 113Disassembling the device
                                          • 12Disposal
                                          • 13Appendix

Installing the device

Operating instructions Powador-gridsave_EN Page 19

Authorised electrician

7 Installing the device

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched The device may only be opened or serviced by an authorised electricianThe device must be completely assembled before being connected electrically rsaquo Observe all safety regulations and current technical connection specifications of the responsible

power supply company rsaquo De-energise the device using the DC isolator switch circuit breaker and residual current circuit

breaker rsaquo Secure both sides against being inadvertently switched back on rsaquo Ensure that the AC and DC sides are completely isolated and voltage free rsaquo Never open the plug-in modules rsaquo Hazardous voltages are present at the busbars rsaquo Disconnect from the grid and plant supply rsaquo First connect the battery system in the connection area

71 Opening the connection area

3

1

2

Figure 11 Open cover plateKey

1 Cover plate 3 Fastening screw

2 Lock

Opening the connection area You have completed assembly

1 Remove the fastening screw for the upper cover plate2 Slide the cover plate forwards out of the lock3 Lift the cover plate upward to remove raquo Make the electrical connection

Installing the device

Page 20 Operating instructions Powador-gridsave_EN

Authorised electrician

72 Making the electrical connectionMake the connection to the PV generator as well as the grid connection using the connection terminals Note the following cable cross-sections

Connection Possible cable cross-section Length of insulation to be stripped offAC home power grid 05 - 16 mmsup2 with end sleeve

05 - 25 mmsup2 without end sleeve18 mm sleeve18-20 mm

PV connection 05 - 16 mmsup2 with end sleeve05 - 25 mmsup2 without end sleeve

18 mm sleeve17-19 mm

Inverter output 05 - 4 mmsup2 with end sleeve05 - 6 mmsup2 without end sleeve

12 mm sleeve11-13 mm

Potential-free contacts 034 - 15 mmsup2 with end sleeve034 - 25 mmsup2 without end sleeve

12 mm sleeve 9-10 mm

Table 4 Cable cross-sections for connection terminals

NOTEThe threaded connections should be matched to the cable cross-section

NOTEOnly conductors and no insulation should be inserted into the connection terminals Individual wires or cables with end sleeves with the appropriate cross-section can be inserted directly into the connection terminal without a toolFine-strand cables without end sleeve or thin conductors will need a screwdriver (plain slot 35 mm) for connection To do this insert the blade of the screwdriver into the recess provided The cable can be inserted into the spring terminal by pressing downwards The spring terminal closes on removal of the screw-driver

Installing the device

Operating instructions Powador-gridsave_EN Page 21

Authorised electrician

X2X1F1 F2 X7 X4 St1

St2

St3

2 3 541 6

Figure 12 View from above of the connection area

Key

1 AC grid input (M40 cable fitting) 4 Network interface (M32 cable fitting)

2 AC grid output (M40 cable fitting) 5 Inverter input (M16 cable fitting)

3 Inverter output (M32 cable fitting) 6 Other connections (M16 cable fitting)

F1 F2 X7 X4 St1

St2

St3

L1 L2 L3 N PE L1 L2 L3 N N PE PE

X1 X2

PV+

PV-

L1 L2 L3 N PE32A 32A PEN

Cust

omer

co

nnec

tion

Figure 13 View from above of the connection area

Key

X1 AC grid input (main junction box meter) X7 PV generator input

X2 AC grid output (building electrical system) F1 F2 Phase bridging fuse

X4 Inverter output St 1-3 Potential-free contacts control outputs

Installing the device

Page 22 Operating instructions Powador-gridsave_EN

Authorised electrician

721 Connecting to the power grid

Because the device is installed between the main junction boxmeter and the buildings electrical system the maxi-mum grid current to the service line must not exceed the rated operating current of the battery system The cable cross-section must be selected in accordance with applicable standards to suit the connected load instal-lation type etc Moreover the terminal area and size of the cable fitting must be noted

NOTEThe fuse rating for the cable should be max 63A (automatic circuit breaker or safety fuse) even if the cross-section of the installed cable would permit a higher fuse rating Always follow the applicable regulations regarding the cable cross-section and installation typeThe device supports standard grid configurations such as TN-C TN-S and TT TN-SIf a TN-S grid is present directly at the power input and output of the device L1-L3 N and PE must each be connected The home power grid should have 4-pin isolationTN-C4-pin grid isolation is factory preset and disconnects L1 L2 L3 and N In a TN-C grid the N conduc-tor must not be disconnected If a TN-S grid is present directly at the power input and output of the device a cable bridge (included in delivery) must be installed between the N terminal on X1 and the N terminal on X2 N and PE must additionally be connected together To do this simply insert the enclosed terminal link into the N and PE terminals TTIn the case of a TT grid L1-L3 N and PE must each be connected The home power grid should have 4-pin isolation

NOTEPlease check with the operator of the mains grid whether there are special regulations for grid connection Grid isolation is factory preset to 4-pin is fail-safe and provided with grid and system protection as per VDE-AR-N 4105

Making the grid connection Use cables with 5 wires (L1 brown L2 black L3 grey N blue PE greenyellow) and the correct

cross-section1 Loosen cable fitting for AC connection2 Remove the outer cladding of the AC cables3 Insert the AC cables through the cable fitting into the connection area4 Strip the insulation from the AC cables5 Remove connection terminals6 Connect the cables in line with the terminal labels (Figure 13 on page 21)7 Close the connection terminals8 Check that all connected cables are securely fitted9 Tighten the cable fitting10 To meet the requirements of protection rating IP21 close the unused cable fittings with blind caps raquo The battery system is connected to the power grid

NOTEAn AC-side disconnection unit must be provided during the final installation stage This disconnec-tion unit must be installed so that it can be accessed at any time without obstruction If a residual current circuit breaker is necessary due to the installation specification a type A residual current circuit breaker must be used

Installing the device

Operating instructions Powador-gridsave_EN Page 23

Authorised electrician

7211 Output from the inverterRecommended cable cross-sections for the inverter output and fuse rating of cables for fixed wiring accord-ing to VDE 0100 part 430The fuse rating for the cable is dependent on the cable cross-section max 40A automatic circuit breaker

NOTEWhen the line resistance is high (ie long grid-side cables) the voltage at the grid terminals of the inverter will increase during feed-in to the grid The inverter monitors this voltage If the voltage exceeds the country-specific grid overvoltage limit value the inverter switches off rsaquo Ensure that the conductor cross-sections are sufficiently large or that the cable lengths are suffi-

ciently short

NOTEIn order to avoid asymmetries in the grid systems with multiple battery systems should be designed so that the inverters in the devices feed into the grid in differing phases rsaquo Follow the connection conditions for the particular type of grid and the schematic illustration

below

Country and grid-type

Grid monitoring Required monitoring

max asymmetry between phases L1L2L3

DE-NSP Three-phase or single phase phase unbalanced load 46 kVA

Table 5 Grid-type-specific connection conditions

L1

L2

L3

N

Connection X1 Connection X1 Connection X1 Connection X1

L1 L2 L3 N PE L1 L2 L3 N PE L1 L2 L3 N PE L1 L2 L3 N PE

Powador-gridsave inverter1 L1 - L1 L2 - L2 L3 - L32 L1 - L2 L2 - L3 L3 - L1 3 L1 - L3 L2 - L1 L3 - L2 4 L1 - L1 L2 - L2 L3 - L3

Figure 14 Grid-side connection for systems with multiple battery systems with three-phase grid monitoring

Installing the device

Page 24 Operating instructions Powador-gridsave_EN

Authorised electrician

722 Connecting the PV generator

Connect the PV generator on the left in the connection area (Figure 13 on page 21) Use the provided M16 cable fittings A maximum of two strings can be connected For this reason a DC string fuse can be dispensed with

DANGERRisk of fatal injury due to contact voltagesRemoving the cables from the terminals without first disconnecting the PV generator from the device can cause serious damage to health or damage to the system rsaquo During installation Electrically disconnect the DC positive and DC negative from the protective

earth (PE) rsaquo Completely de-energise the system (AC home power grid AC circuit breaker residual current circuit

breaker DC isolator switch) rsaquo Disconnect the battery system from the PV generator using the integrated DC isolator switch rsaquo Remove DC plug connectors

NOTEIn accordance with IEC 61730 Class A connected PV modules must be dimensioned for the DC system voltage provided and at least for the value of the AC grid voltage

7221 Before connecting

Ensure that there is no ground fault1 Determine the DC voltage between the

ndash protective earth (PE) and the positive cable of the PV generator and between the ndash protective earth (PE) and the negative cable of the PV generator

If stable voltages can be measured there is a ground fault in the DC generator or its wiring The ratio between the measured voltages gives an indication as to the location of this fault

2 Rectify any faults before taking further measurements3 Determine the electrical resistance between the

ndash protective earth (PE) and the positive cable of the PV generator and between the ndash protective earth (PE) and the negative cable of the PV generator

In addition ensure that the PV generator has a total insulation resistance of more than 20 MOhm since the inverter will not feed in if the insulation resistance is too low

4 Rectify any faults before connecting the DC generator

7222 Connecting the PV generator

DANGERRisk of fatal injury due to electric shockSevere injury or death will result if the live connections are touched When there is solar radiation DC voltage will be present at the open ends of the DC cables rsaquo Do not touch the exposed ends of the cables rsaquo Avoid short circuits

Installing the device

Operating instructions Powador-gridsave_EN Page 25

Authorised electrician

Connecting the PV generator Use cables with the correct cross-section

1 Remove cable fittings for DC connection2 Remove the outer cladding of the DC cables3 Insert the DC cables through the cable fittings into the connection area4 Strip the insulation from the DC cables5 Remove connection terminals6 Connect the cables in line with the terminal labels (See Figure 13 on page 21)7 Close the connection terminals8 Check that all connected cables are securely fitted9 Tighten the cable fittings10 To meet the requirements of protection rating IP21 close the unused cable fittings with blind caps raquo The PV generator is connected to the inverter

73 Connecting the interfaces

731 Ethernet interface

Pre-assembled Ethernet cables can be connected using the RJ45 socket in the connection space

Connecting the Ethernet cable1 Remove closure cap from RJ45 socket2 Connect the Ethernet cable3 The energy management system can now obtain an IP address by DHCP and is also available via this in the

network

NOTEThe network settings can be amended later in the Settings menu using the EMS

NOTEUse a suitable category 5 network cable The maximum length of a network segment is 100 m Ensure that the cable is correctly assigned The Ethernet connection of the battery system supports auto-sensing You can use both crossed and 11 configured Ethernet connection cables

74 Sealing the connection area

1 Finally check the cabling2 Ensure that all cables are firmly mounted3 Check that the cable fitting is secure and tighten if necessary4 Remove cable offcuts and particles of dirt or dust5 Fit the cover and slide back until it engages into position6 Check that the position is correct7 Screw the fastening screw onto the front of the cover

Installing the device

Page 26 Operating instructions Powador-gridsave_EN

Authorised electrician

75 Starting up

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched Only appropriately qualified and authorised electricians may open install or maintain the battery system rsaquo Keep the front doors and covers closed during operation

NOTEInitial start-up should be carried out using the available public AC grid

76 Standard configuration

Factory settingsCountry configuration Germany

Grid guidelines Low voltage directive

Language German

Time UTC +1 Central European Time

User Standard

Network parameters DHCP (network settings will be obtained automatically from the router)

NOTEPlease state the desired power limitation (60 or 70 of the PV system capacity) when you order For other variations please notify your KACO contact so that the parameters can be set at the factory prior to delivery

Installing the device

Operating instructions Powador-gridsave_EN Page 27

Authorised electrician

761 Step 1 AC home power grid

Check all cables and connections before starting up1 Switch on the AC home power grid using the AC main switch raquo Powador-protect measurement and control unit starts up and monitors the AC grid raquo Two green LEDs indicate that the grid parameters are met raquo After a further 60 seconds (shortly after the backlighting in the Powador-protect goes out) the Powador-pro-

tect will switch on the home grid2 Configure Powador-protect according to the enclosed Powador-protect instructions

(The instructions are also available on the website at wwwkaconewenergyde) raquo The AC power is supplied in the normal way by the public grid

762 Step 2 AC supply from the battery system

Check all cables and connections before starting up1 Remove external isolation means from the device2 Switch on the circuit breaker raquo The LCD touchscreen on the front panel comes on and the energy management system (EMS) starts up

3 Switch on the residual current circuit breaker raquo The battery system starts up

763 Step 3 Switch on the PV system

1 Switch on any optional external PV isolator switches2 Set the internal DC isolator switch to ON raquo The inverter and the battery charging unit battery backup converter (BBC) are connected to the PV system raquo The device monitors the PV voltage for approx 60 seconds then optimisation of internal consumption takes

place

764 Step 4 Switch on batteries

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

765 Step 5 Activate energy management

NOTEKACO new energy cannot provide any support for problems regarding the IT infrastructure (eg router configuration IP address assignment ports etc) as the structure settings and configuration of the network environment can be complex and very different from place to place In the event of any problems please contact an IT service provider

Remote access activated 1 Please call the KACO Hotline to make an appointment for activation of energy management

Configuration and Operation

Page 28 Operating instructions Powador-gridsave_EN

Authorised electrician

8 Configuration and Operation

81 ControlsThe battery system is fitted with a touchscreen which allows it to be controlled very precisely In normal operation the display is switched off Touching the screen activates the display and after a configurable period of time without being touched the dis-play will deactivate If the screen-save function is switched off the touchscreen will be on continuously

NOTEDepending on the tolerances of the measuring elements the measured and displayed values are not always the actual values However the measuring elements ensure maximum solar yield Due to these tolerances the daily yields shown on the touchscreen may deviate from the values on the grid operatorrsquos feed-in meter by up to 15

3

1

45

2

Figure 15 Overview (home screen)

Key

1 Home button 4 Current time

2 System components 5 Menu name

3 More information

811 Information about the system

Open start screen View changesjumps to the home screen

Show component detail Parameters of the selected component

Settings Define settings for the active user

raquo Displays settings

Configuration and Operation

Operating instructions Powador-gridsave_EN Page 29

Controls Left arrow jump back to previous menu item Up and down arrows navigate through the menu or change a value

Left arrow displayed value is reduced by one increment Right arrow displayed value is increased by one increment or change to the submenu

Display fields Grey box Text or figures (not selectable) Blue box Calls up submenu for the display in question

Activate and deactivate Activate function by ticking the box

Table 6 Information about the system

812 System components

PV generator Display of the current generator data

power voltage current temperature in the inverter

Battery Display of the current battery status

power (charging or discharging) voltage current charge status available capacity temperature of battery

Grid Display of the following either fed-in or drawn from the grid

power voltage current for phase L1-L3 total output frequency

Consumer (load) Display of the consumer data

power voltage current for phase L1-L3 total output

Energy flow raquo Displays the current energy flow in the system

Table 7 Information about system components

Configuration and Operation

Page 30 Operating instructions Powador-gridsave_EN

813 Menu structure

Icons used

Display menu Submenu

Option menu

Menu Submenu Display setting

Action in this menumeaning

PV generator Details

Power Displays the current DC-side power

Voltage Displays the current DC-side voltage

Current Displays the current DC-side amperage

Temp inverter

Displays the current temperature in the inverter housing

Battery Details

Power Displays the current AC-side power

Voltage Displays the current AC-side voltage

Current Displays the current AC-side amperage

Charge status Displays the current charge status

Capacity Displays the current battery capacity

Temperature Displays the current measured temperature of the battery

Grid Details

Power Displays the current AC-side power being drawn or fed-in

Voltage Displays the AC-side voltage being applied

Current Displays the current AC-side amperage being drawn or fed-in

Total output Displays the current AC-side total output being drawn or fed-in

Frequency Displays the frequency currently being applied to the grid junction

Consumer (load) Details

Power Displays the current AC-side power being drawn

Voltage Displays the current AC-side voltage being applied

Current Displays the current AC-side amperage being drawn

Total output Displays the current AC-side total output being drawn

Configuration and Operation

Operating instructions Powador-gridsave_EN Page 31

Menu Submenu Display setting

Action in this menumeaning

Settings

Country amp directive display

Display of the country settings voltage directives and grid type

Select menu language

DateTime Specify time zone date format and date and time

Screen Activate screen-save function and set the delay period

Network settings

Display of the network settings Configure network settings Once the DHCP server becomes available the IP

address subnet mask gateway and DNS server are automatically applied and the aforemen-tioned menu items are hidden

Off DHCP deactivated make settings manually

Version Displays the installed software version and built-in HW components (inverter BBC battery)

Vendor The touchscreen shows information about the device vendor

NOTEAs changes to the software are possible after the manual has been printed the illustrations and descriptions of the functions in these operating instructions may deviate from the software Please therefore note the current Application Notes on our website

MaintenanceTroubleshooting

Page 32 Operating instructions Powador-gridsave_EN

9 MaintenanceTroubleshooting

91 Visual inspectionInspect the device and the cables for visible external damage and note the operating status display In case of damage notify your installer Repairs may only be carried out by authorised electricians

NOTEThe battery system should be checked for proper operation by a qualified electrician at regular intervals

92 Cleaning the device

DANGERLethal voltages in the battery systemSerious injuries or death can result if moisture enters the system rsaquo Only use completely dry objects to clean the battery system rsaquo Only clean the outside of the battery system

Cleaning the battery system Do not use compressed air Use a vacuum cleaner or a soft brush to remove dust from the fan cover and from the top of the inverter on a

regular basis Remove dust from the ventilation inlets if necessary

MaintenanceTroubleshooting

Operating instructions Powador-gridsave_EN Page 33

Authorised electrician

93 Maintenance

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched The device is only permitted to be opened or serviced by an authorised electrician rsaquo Observe all safety regulations and the current technical connection specifications from the relevant

power supply company rsaquo Disconnect the AC and DC sides rsaquo Secure the AC and DC sides from being inadvertently switched back on rsaquo Only then should the device be opened rsaquo After shutdown wait at least 30 minutes before working on the device

CAUTIONDestruction of the DC connectionThe connection terminals can be destroyed by arcing if disconnected while still live rsaquo It is absolutely essential that the shutdown sequence be carried out in the correct order (See sec-

tion 111 on page 35)

94 Faults

941 Procedure

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched

When a fault occurs notify an appropriately authorised and qualified electrician or KACO new energy GmbH Service

Service

Page 34 Operating instructions Powador-gridsave_EN

10 ServiceIf 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 efficientlybull Serial nobull SW version of the components (the software version can be found in the Settings menu using the EMS)bull Module type and string circuitbull Date of installation Start-up reportbull Consignment identification Delivery address Contact person (with telephone number)bull Information about the accessibility of the installation site

Any additional costs arising from unfavourable structural or mounting conditions shall be billed to the customer

You can find our warranty conditions on our websitehttpkaco-newenergycomservicewarrantyFrom there you can easily navigate to our international websites by clicking on the appropriate flag

Please use our website to register your unit immediatelyYou can also select the appropriate flag on this page to access the website for your own countryIn this manner you can assist us in providing you with the quickest service possible Note The maximum length of the warranty is based on the currently applicable national warranty conditions

We have prepared a template for complaints This can be found at httpskaco-newenergycomservicecustomer-service

Hotlines

Technical troubleshooting Technical consultation

Inverters and battery systems ()

+49 (0) 71323818-660 +49 (0) 71323818-660

Data logging and accessories +49 (0) 71323818-690 +49 (0) 71323818-690

Construction site emergency () +49 (0) 71323818-630

Customer help desk Monday to Friday from 730 am to 530 pm (CET)

() Also on Saturdays from 800 am to 200 pm (CET)

ShutdownDisassembly

Operating instructions Powador-gridsave_EN Page 35

11 ShutdownDisassembly

111 Switching off the device

DANGERLethal voltages are still present in the terminals and cables even after switching off and discon-nection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched rsaquo Complete de-energisation only occurs if the bulk power supply is switched off upstream of the bat-

tery system

DANGERDestruction of the DC plug connectorDC plug connectors can be destroyed by arcing if disconnected while still live rsaquo It is absolutely essential that the following shutdown sequence is observed

1111 Step 1 Shutting down the PV system

1 Switch off any optional external PV isolator switches2 Set the internal DC isolator switch to OFF raquo The inverter and battery charging unit battery backup converter (BBC) are disconnected

1112 Step 2 Disconnect the batteries

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

1113 Step 3 Disconnect the AC supply

1 Connect external isolation means to the device2 Switch off the circuit breaker 3 Switch off the residual current circuit breaker raquo The battery system is switched off

1114 Step 4 AC home power grid

1 Shutdown the AC home power grid using the AC main switch raquo The battery system can be uninstalled

Disposal

Page 36 Operating instructions Powador-gridsave_EN

112 Uninstalling the device

NOTETo uninstall follow the same sequence as for installation but in reverse order

Switch off the device1 Unlock and open the housing door2 Remove the upper cover3 Release the DC and AC cables from the connection terminals4 Pull out the cables raquo The battery system is uninstalled Continue with the disassembly

113 Disassembling the device

NOTETo disassemble follow the same sequence as for assembly but in reverse order

Switch off the device1 Uninstall the components2 Remove the fastening from the device3 Securely pack up the battery system if it is to be used later

or have the battery system disposed of in accordance with section 12 on page 36

12 DisposalFor the most part both the battery system and the corresponding transport packaging are made from recyclable raw materialsBatteries and components Do not dispose of faulty batteries or the components together with household waste Ensure that the old device and accessories are disposed of in a proper mannerPackaging Ensure that the transport packaging is disposed of properlyBatteriesUsed or faulty batteries must be transported in special packaging If you need such packaging please contact the KACO Hotline

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

Appendix

Operating instructions Powador-gridsave_EN Page 37

13 Appendix

EU Declaration of Conformity

Vendorrsquos name and address

KACO new energy GmbH Carl-Zeiss-Straszlige 1 74172 Neckarsulm Germany

Product description Battery system

Type designation Powador-gridsave 135 kWh 6400 Powador-gridsave 135 kWh 8000

Powador-gridsave 270 kWh 6400 Powador-gridsave 270 kWh 8000

Powador-gridsave 405 kWh 6400 Powador-gridsave 405 kWh 8000

Powador-gridsave 540 kWh 6400 Powador-gridsave 540 kWh 8000

Powador-gridsave 577 kWh 6400 Powador-gridsave 577 kWh 8000

Powador-gridsave 675 kWh 6400 Powador-gridsave 675 kWh 8000

This is to confirm that the units listed above comply with the protection requirements set forth in the Directive of the Council of the European Union of 15th December 2004 on the harmonisation of the laws of the member states relating to Electromagnetic Compatibility (2004108EC) and the Low Voltage Directive (200695EC)The units are compliant with the following standards

200695EC ldquoDirective relating to electrical equipment designed for use within specific voltage limitsrdquo

Safety of the unitIEC 62109-12010IEC 62109-22011

2004108EC ldquoDirective relating to electromagneticcompatibilityrdquo

Interference immunityEN 61000-6-22005 Emitted interferenceEN 61000-6-32007

Secondary effects on the gridEN 61000-3-112000EN 61000-3-122005

The types mentioned above are therefore labelled with the CE markUnauthorised modifications to the supplied units andor any use of the units that is contrary to their intended use render this Declaration of Conformity null and void

Neckarsulm 0711 2013KACO new energy GmbH

pp Volker DietrichEnergy systems engineering management

Disposal

Page 38 Operating instructions Powador-gridsave_EN

Carl-Zeiss-Straszlige 1 middot 74172 Neckarsulm middot Germany middot Phone +49 7132 3818-0 middot Fax +49 7132 3818-703 middot infokaco-newenergyde middot wwwkaco-newenergyde

The

text

and

figu

res

refle

ct th

e cu

rren

t tec

hnic

al s

tate

at t

he ti

me

of p

rintin

g S

ubje

ct to

tech

nica

l cha

nges

Err

ors

and

omis

sion

s ex

cept

ed

3006

856-

01-1

4030

5

  • 1General Information
    • 11About this document
    • 12Name plate
    • 13Additional information
    • 14Intended use
      • 2Safety
        • 21Protection features
          • 3Description
            • 31Mode of Operation
            • 32Summary of the components
              • 4Technical Data
                • 41Electrical data
                • 42Mechanical data
                  • 5Transportation and Delivery
                    • 51Delivery
                    • 52Storage
                    • 53Transportation
                      • 6Assembling the device
                        • 61Installation
                        • 62Installing components
                          • 7Installing the device
                            • 71Opening the connection area
                            • 72Making the electrical connection
                            • 73Connecting the interfaces
                            • 74Sealing the connection area
                            • 75Starting up
                            • 76Standard configuration
                              • 8Configuration and Operation
                                • 81Controls
                                  • 9MaintenanceTroubleshooting
                                    • 91Visual inspection
                                    • 92Cleaning the device
                                    • 93Maintenance
                                    • 94Faults
                                      • 10Service
                                      • 11ShutdownDisassembly
                                        • 111Switching off the device
                                        • 112Uninstalling the device
                                        • 113Disassembling the device
                                          • 12Disposal
                                          • 13Appendix

Installing the device

Page 20 Operating instructions Powador-gridsave_EN

Authorised electrician

72 Making the electrical connectionMake the connection to the PV generator as well as the grid connection using the connection terminals Note the following cable cross-sections

Connection Possible cable cross-section Length of insulation to be stripped offAC home power grid 05 - 16 mmsup2 with end sleeve

05 - 25 mmsup2 without end sleeve18 mm sleeve18-20 mm

PV connection 05 - 16 mmsup2 with end sleeve05 - 25 mmsup2 without end sleeve

18 mm sleeve17-19 mm

Inverter output 05 - 4 mmsup2 with end sleeve05 - 6 mmsup2 without end sleeve

12 mm sleeve11-13 mm

Potential-free contacts 034 - 15 mmsup2 with end sleeve034 - 25 mmsup2 without end sleeve

12 mm sleeve 9-10 mm

Table 4 Cable cross-sections for connection terminals

NOTEThe threaded connections should be matched to the cable cross-section

NOTEOnly conductors and no insulation should be inserted into the connection terminals Individual wires or cables with end sleeves with the appropriate cross-section can be inserted directly into the connection terminal without a toolFine-strand cables without end sleeve or thin conductors will need a screwdriver (plain slot 35 mm) for connection To do this insert the blade of the screwdriver into the recess provided The cable can be inserted into the spring terminal by pressing downwards The spring terminal closes on removal of the screw-driver

Installing the device

Operating instructions Powador-gridsave_EN Page 21

Authorised electrician

X2X1F1 F2 X7 X4 St1

St2

St3

2 3 541 6

Figure 12 View from above of the connection area

Key

1 AC grid input (M40 cable fitting) 4 Network interface (M32 cable fitting)

2 AC grid output (M40 cable fitting) 5 Inverter input (M16 cable fitting)

3 Inverter output (M32 cable fitting) 6 Other connections (M16 cable fitting)

F1 F2 X7 X4 St1

St2

St3

L1 L2 L3 N PE L1 L2 L3 N N PE PE

X1 X2

PV+

PV-

L1 L2 L3 N PE32A 32A PEN

Cust

omer

co

nnec

tion

Figure 13 View from above of the connection area

Key

X1 AC grid input (main junction box meter) X7 PV generator input

X2 AC grid output (building electrical system) F1 F2 Phase bridging fuse

X4 Inverter output St 1-3 Potential-free contacts control outputs

Installing the device

Page 22 Operating instructions Powador-gridsave_EN

Authorised electrician

721 Connecting to the power grid

Because the device is installed between the main junction boxmeter and the buildings electrical system the maxi-mum grid current to the service line must not exceed the rated operating current of the battery system The cable cross-section must be selected in accordance with applicable standards to suit the connected load instal-lation type etc Moreover the terminal area and size of the cable fitting must be noted

NOTEThe fuse rating for the cable should be max 63A (automatic circuit breaker or safety fuse) even if the cross-section of the installed cable would permit a higher fuse rating Always follow the applicable regulations regarding the cable cross-section and installation typeThe device supports standard grid configurations such as TN-C TN-S and TT TN-SIf a TN-S grid is present directly at the power input and output of the device L1-L3 N and PE must each be connected The home power grid should have 4-pin isolationTN-C4-pin grid isolation is factory preset and disconnects L1 L2 L3 and N In a TN-C grid the N conduc-tor must not be disconnected If a TN-S grid is present directly at the power input and output of the device a cable bridge (included in delivery) must be installed between the N terminal on X1 and the N terminal on X2 N and PE must additionally be connected together To do this simply insert the enclosed terminal link into the N and PE terminals TTIn the case of a TT grid L1-L3 N and PE must each be connected The home power grid should have 4-pin isolation

NOTEPlease check with the operator of the mains grid whether there are special regulations for grid connection Grid isolation is factory preset to 4-pin is fail-safe and provided with grid and system protection as per VDE-AR-N 4105

Making the grid connection Use cables with 5 wires (L1 brown L2 black L3 grey N blue PE greenyellow) and the correct

cross-section1 Loosen cable fitting for AC connection2 Remove the outer cladding of the AC cables3 Insert the AC cables through the cable fitting into the connection area4 Strip the insulation from the AC cables5 Remove connection terminals6 Connect the cables in line with the terminal labels (Figure 13 on page 21)7 Close the connection terminals8 Check that all connected cables are securely fitted9 Tighten the cable fitting10 To meet the requirements of protection rating IP21 close the unused cable fittings with blind caps raquo The battery system is connected to the power grid

NOTEAn AC-side disconnection unit must be provided during the final installation stage This disconnec-tion unit must be installed so that it can be accessed at any time without obstruction If a residual current circuit breaker is necessary due to the installation specification a type A residual current circuit breaker must be used

Installing the device

Operating instructions Powador-gridsave_EN Page 23

Authorised electrician

7211 Output from the inverterRecommended cable cross-sections for the inverter output and fuse rating of cables for fixed wiring accord-ing to VDE 0100 part 430The fuse rating for the cable is dependent on the cable cross-section max 40A automatic circuit breaker

NOTEWhen the line resistance is high (ie long grid-side cables) the voltage at the grid terminals of the inverter will increase during feed-in to the grid The inverter monitors this voltage If the voltage exceeds the country-specific grid overvoltage limit value the inverter switches off rsaquo Ensure that the conductor cross-sections are sufficiently large or that the cable lengths are suffi-

ciently short

NOTEIn order to avoid asymmetries in the grid systems with multiple battery systems should be designed so that the inverters in the devices feed into the grid in differing phases rsaquo Follow the connection conditions for the particular type of grid and the schematic illustration

below

Country and grid-type

Grid monitoring Required monitoring

max asymmetry between phases L1L2L3

DE-NSP Three-phase or single phase phase unbalanced load 46 kVA

Table 5 Grid-type-specific connection conditions

L1

L2

L3

N

Connection X1 Connection X1 Connection X1 Connection X1

L1 L2 L3 N PE L1 L2 L3 N PE L1 L2 L3 N PE L1 L2 L3 N PE

Powador-gridsave inverter1 L1 - L1 L2 - L2 L3 - L32 L1 - L2 L2 - L3 L3 - L1 3 L1 - L3 L2 - L1 L3 - L2 4 L1 - L1 L2 - L2 L3 - L3

Figure 14 Grid-side connection for systems with multiple battery systems with three-phase grid monitoring

Installing the device

Page 24 Operating instructions Powador-gridsave_EN

Authorised electrician

722 Connecting the PV generator

Connect the PV generator on the left in the connection area (Figure 13 on page 21) Use the provided M16 cable fittings A maximum of two strings can be connected For this reason a DC string fuse can be dispensed with

DANGERRisk of fatal injury due to contact voltagesRemoving the cables from the terminals without first disconnecting the PV generator from the device can cause serious damage to health or damage to the system rsaquo During installation Electrically disconnect the DC positive and DC negative from the protective

earth (PE) rsaquo Completely de-energise the system (AC home power grid AC circuit breaker residual current circuit

breaker DC isolator switch) rsaquo Disconnect the battery system from the PV generator using the integrated DC isolator switch rsaquo Remove DC plug connectors

NOTEIn accordance with IEC 61730 Class A connected PV modules must be dimensioned for the DC system voltage provided and at least for the value of the AC grid voltage

7221 Before connecting

Ensure that there is no ground fault1 Determine the DC voltage between the

ndash protective earth (PE) and the positive cable of the PV generator and between the ndash protective earth (PE) and the negative cable of the PV generator

If stable voltages can be measured there is a ground fault in the DC generator or its wiring The ratio between the measured voltages gives an indication as to the location of this fault

2 Rectify any faults before taking further measurements3 Determine the electrical resistance between the

ndash protective earth (PE) and the positive cable of the PV generator and between the ndash protective earth (PE) and the negative cable of the PV generator

In addition ensure that the PV generator has a total insulation resistance of more than 20 MOhm since the inverter will not feed in if the insulation resistance is too low

4 Rectify any faults before connecting the DC generator

7222 Connecting the PV generator

DANGERRisk of fatal injury due to electric shockSevere injury or death will result if the live connections are touched When there is solar radiation DC voltage will be present at the open ends of the DC cables rsaquo Do not touch the exposed ends of the cables rsaquo Avoid short circuits

Installing the device

Operating instructions Powador-gridsave_EN Page 25

Authorised electrician

Connecting the PV generator Use cables with the correct cross-section

1 Remove cable fittings for DC connection2 Remove the outer cladding of the DC cables3 Insert the DC cables through the cable fittings into the connection area4 Strip the insulation from the DC cables5 Remove connection terminals6 Connect the cables in line with the terminal labels (See Figure 13 on page 21)7 Close the connection terminals8 Check that all connected cables are securely fitted9 Tighten the cable fittings10 To meet the requirements of protection rating IP21 close the unused cable fittings with blind caps raquo The PV generator is connected to the inverter

73 Connecting the interfaces

731 Ethernet interface

Pre-assembled Ethernet cables can be connected using the RJ45 socket in the connection space

Connecting the Ethernet cable1 Remove closure cap from RJ45 socket2 Connect the Ethernet cable3 The energy management system can now obtain an IP address by DHCP and is also available via this in the

network

NOTEThe network settings can be amended later in the Settings menu using the EMS

NOTEUse a suitable category 5 network cable The maximum length of a network segment is 100 m Ensure that the cable is correctly assigned The Ethernet connection of the battery system supports auto-sensing You can use both crossed and 11 configured Ethernet connection cables

74 Sealing the connection area

1 Finally check the cabling2 Ensure that all cables are firmly mounted3 Check that the cable fitting is secure and tighten if necessary4 Remove cable offcuts and particles of dirt or dust5 Fit the cover and slide back until it engages into position6 Check that the position is correct7 Screw the fastening screw onto the front of the cover

Installing the device

Page 26 Operating instructions Powador-gridsave_EN

Authorised electrician

75 Starting up

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched Only appropriately qualified and authorised electricians may open install or maintain the battery system rsaquo Keep the front doors and covers closed during operation

NOTEInitial start-up should be carried out using the available public AC grid

76 Standard configuration

Factory settingsCountry configuration Germany

Grid guidelines Low voltage directive

Language German

Time UTC +1 Central European Time

User Standard

Network parameters DHCP (network settings will be obtained automatically from the router)

NOTEPlease state the desired power limitation (60 or 70 of the PV system capacity) when you order For other variations please notify your KACO contact so that the parameters can be set at the factory prior to delivery

Installing the device

Operating instructions Powador-gridsave_EN Page 27

Authorised electrician

761 Step 1 AC home power grid

Check all cables and connections before starting up1 Switch on the AC home power grid using the AC main switch raquo Powador-protect measurement and control unit starts up and monitors the AC grid raquo Two green LEDs indicate that the grid parameters are met raquo After a further 60 seconds (shortly after the backlighting in the Powador-protect goes out) the Powador-pro-

tect will switch on the home grid2 Configure Powador-protect according to the enclosed Powador-protect instructions

(The instructions are also available on the website at wwwkaconewenergyde) raquo The AC power is supplied in the normal way by the public grid

762 Step 2 AC supply from the battery system

Check all cables and connections before starting up1 Remove external isolation means from the device2 Switch on the circuit breaker raquo The LCD touchscreen on the front panel comes on and the energy management system (EMS) starts up

3 Switch on the residual current circuit breaker raquo The battery system starts up

763 Step 3 Switch on the PV system

1 Switch on any optional external PV isolator switches2 Set the internal DC isolator switch to ON raquo The inverter and the battery charging unit battery backup converter (BBC) are connected to the PV system raquo The device monitors the PV voltage for approx 60 seconds then optimisation of internal consumption takes

place

764 Step 4 Switch on batteries

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

765 Step 5 Activate energy management

NOTEKACO new energy cannot provide any support for problems regarding the IT infrastructure (eg router configuration IP address assignment ports etc) as the structure settings and configuration of the network environment can be complex and very different from place to place In the event of any problems please contact an IT service provider

Remote access activated 1 Please call the KACO Hotline to make an appointment for activation of energy management

Configuration and Operation

Page 28 Operating instructions Powador-gridsave_EN

Authorised electrician

8 Configuration and Operation

81 ControlsThe battery system is fitted with a touchscreen which allows it to be controlled very precisely In normal operation the display is switched off Touching the screen activates the display and after a configurable period of time without being touched the dis-play will deactivate If the screen-save function is switched off the touchscreen will be on continuously

NOTEDepending on the tolerances of the measuring elements the measured and displayed values are not always the actual values However the measuring elements ensure maximum solar yield Due to these tolerances the daily yields shown on the touchscreen may deviate from the values on the grid operatorrsquos feed-in meter by up to 15

3

1

45

2

Figure 15 Overview (home screen)

Key

1 Home button 4 Current time

2 System components 5 Menu name

3 More information

811 Information about the system

Open start screen View changesjumps to the home screen

Show component detail Parameters of the selected component

Settings Define settings for the active user

raquo Displays settings

Configuration and Operation

Operating instructions Powador-gridsave_EN Page 29

Controls Left arrow jump back to previous menu item Up and down arrows navigate through the menu or change a value

Left arrow displayed value is reduced by one increment Right arrow displayed value is increased by one increment or change to the submenu

Display fields Grey box Text or figures (not selectable) Blue box Calls up submenu for the display in question

Activate and deactivate Activate function by ticking the box

Table 6 Information about the system

812 System components

PV generator Display of the current generator data

power voltage current temperature in the inverter

Battery Display of the current battery status

power (charging or discharging) voltage current charge status available capacity temperature of battery

Grid Display of the following either fed-in or drawn from the grid

power voltage current for phase L1-L3 total output frequency

Consumer (load) Display of the consumer data

power voltage current for phase L1-L3 total output

Energy flow raquo Displays the current energy flow in the system

Table 7 Information about system components

Configuration and Operation

Page 30 Operating instructions Powador-gridsave_EN

813 Menu structure

Icons used

Display menu Submenu

Option menu

Menu Submenu Display setting

Action in this menumeaning

PV generator Details

Power Displays the current DC-side power

Voltage Displays the current DC-side voltage

Current Displays the current DC-side amperage

Temp inverter

Displays the current temperature in the inverter housing

Battery Details

Power Displays the current AC-side power

Voltage Displays the current AC-side voltage

Current Displays the current AC-side amperage

Charge status Displays the current charge status

Capacity Displays the current battery capacity

Temperature Displays the current measured temperature of the battery

Grid Details

Power Displays the current AC-side power being drawn or fed-in

Voltage Displays the AC-side voltage being applied

Current Displays the current AC-side amperage being drawn or fed-in

Total output Displays the current AC-side total output being drawn or fed-in

Frequency Displays the frequency currently being applied to the grid junction

Consumer (load) Details

Power Displays the current AC-side power being drawn

Voltage Displays the current AC-side voltage being applied

Current Displays the current AC-side amperage being drawn

Total output Displays the current AC-side total output being drawn

Configuration and Operation

Operating instructions Powador-gridsave_EN Page 31

Menu Submenu Display setting

Action in this menumeaning

Settings

Country amp directive display

Display of the country settings voltage directives and grid type

Select menu language

DateTime Specify time zone date format and date and time

Screen Activate screen-save function and set the delay period

Network settings

Display of the network settings Configure network settings Once the DHCP server becomes available the IP

address subnet mask gateway and DNS server are automatically applied and the aforemen-tioned menu items are hidden

Off DHCP deactivated make settings manually

Version Displays the installed software version and built-in HW components (inverter BBC battery)

Vendor The touchscreen shows information about the device vendor

NOTEAs changes to the software are possible after the manual has been printed the illustrations and descriptions of the functions in these operating instructions may deviate from the software Please therefore note the current Application Notes on our website

MaintenanceTroubleshooting

Page 32 Operating instructions Powador-gridsave_EN

9 MaintenanceTroubleshooting

91 Visual inspectionInspect the device and the cables for visible external damage and note the operating status display In case of damage notify your installer Repairs may only be carried out by authorised electricians

NOTEThe battery system should be checked for proper operation by a qualified electrician at regular intervals

92 Cleaning the device

DANGERLethal voltages in the battery systemSerious injuries or death can result if moisture enters the system rsaquo Only use completely dry objects to clean the battery system rsaquo Only clean the outside of the battery system

Cleaning the battery system Do not use compressed air Use a vacuum cleaner or a soft brush to remove dust from the fan cover and from the top of the inverter on a

regular basis Remove dust from the ventilation inlets if necessary

MaintenanceTroubleshooting

Operating instructions Powador-gridsave_EN Page 33

Authorised electrician

93 Maintenance

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched The device is only permitted to be opened or serviced by an authorised electrician rsaquo Observe all safety regulations and the current technical connection specifications from the relevant

power supply company rsaquo Disconnect the AC and DC sides rsaquo Secure the AC and DC sides from being inadvertently switched back on rsaquo Only then should the device be opened rsaquo After shutdown wait at least 30 minutes before working on the device

CAUTIONDestruction of the DC connectionThe connection terminals can be destroyed by arcing if disconnected while still live rsaquo It is absolutely essential that the shutdown sequence be carried out in the correct order (See sec-

tion 111 on page 35)

94 Faults

941 Procedure

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched

When a fault occurs notify an appropriately authorised and qualified electrician or KACO new energy GmbH Service

Service

Page 34 Operating instructions Powador-gridsave_EN

10 ServiceIf 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 efficientlybull Serial nobull SW version of the components (the software version can be found in the Settings menu using the EMS)bull Module type and string circuitbull Date of installation Start-up reportbull Consignment identification Delivery address Contact person (with telephone number)bull Information about the accessibility of the installation site

Any additional costs arising from unfavourable structural or mounting conditions shall be billed to the customer

You can find our warranty conditions on our websitehttpkaco-newenergycomservicewarrantyFrom there you can easily navigate to our international websites by clicking on the appropriate flag

Please use our website to register your unit immediatelyYou can also select the appropriate flag on this page to access the website for your own countryIn this manner you can assist us in providing you with the quickest service possible Note The maximum length of the warranty is based on the currently applicable national warranty conditions

We have prepared a template for complaints This can be found at httpskaco-newenergycomservicecustomer-service

Hotlines

Technical troubleshooting Technical consultation

Inverters and battery systems ()

+49 (0) 71323818-660 +49 (0) 71323818-660

Data logging and accessories +49 (0) 71323818-690 +49 (0) 71323818-690

Construction site emergency () +49 (0) 71323818-630

Customer help desk Monday to Friday from 730 am to 530 pm (CET)

() Also on Saturdays from 800 am to 200 pm (CET)

ShutdownDisassembly

Operating instructions Powador-gridsave_EN Page 35

11 ShutdownDisassembly

111 Switching off the device

DANGERLethal voltages are still present in the terminals and cables even after switching off and discon-nection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched rsaquo Complete de-energisation only occurs if the bulk power supply is switched off upstream of the bat-

tery system

DANGERDestruction of the DC plug connectorDC plug connectors can be destroyed by arcing if disconnected while still live rsaquo It is absolutely essential that the following shutdown sequence is observed

1111 Step 1 Shutting down the PV system

1 Switch off any optional external PV isolator switches2 Set the internal DC isolator switch to OFF raquo The inverter and battery charging unit battery backup converter (BBC) are disconnected

1112 Step 2 Disconnect the batteries

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

1113 Step 3 Disconnect the AC supply

1 Connect external isolation means to the device2 Switch off the circuit breaker 3 Switch off the residual current circuit breaker raquo The battery system is switched off

1114 Step 4 AC home power grid

1 Shutdown the AC home power grid using the AC main switch raquo The battery system can be uninstalled

Disposal

Page 36 Operating instructions Powador-gridsave_EN

112 Uninstalling the device

NOTETo uninstall follow the same sequence as for installation but in reverse order

Switch off the device1 Unlock and open the housing door2 Remove the upper cover3 Release the DC and AC cables from the connection terminals4 Pull out the cables raquo The battery system is uninstalled Continue with the disassembly

113 Disassembling the device

NOTETo disassemble follow the same sequence as for assembly but in reverse order

Switch off the device1 Uninstall the components2 Remove the fastening from the device3 Securely pack up the battery system if it is to be used later

or have the battery system disposed of in accordance with section 12 on page 36

12 DisposalFor the most part both the battery system and the corresponding transport packaging are made from recyclable raw materialsBatteries and components Do not dispose of faulty batteries or the components together with household waste Ensure that the old device and accessories are disposed of in a proper mannerPackaging Ensure that the transport packaging is disposed of properlyBatteriesUsed or faulty batteries must be transported in special packaging If you need such packaging please contact the KACO Hotline

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

Appendix

Operating instructions Powador-gridsave_EN Page 37

13 Appendix

EU Declaration of Conformity

Vendorrsquos name and address

KACO new energy GmbH Carl-Zeiss-Straszlige 1 74172 Neckarsulm Germany

Product description Battery system

Type designation Powador-gridsave 135 kWh 6400 Powador-gridsave 135 kWh 8000

Powador-gridsave 270 kWh 6400 Powador-gridsave 270 kWh 8000

Powador-gridsave 405 kWh 6400 Powador-gridsave 405 kWh 8000

Powador-gridsave 540 kWh 6400 Powador-gridsave 540 kWh 8000

Powador-gridsave 577 kWh 6400 Powador-gridsave 577 kWh 8000

Powador-gridsave 675 kWh 6400 Powador-gridsave 675 kWh 8000

This is to confirm that the units listed above comply with the protection requirements set forth in the Directive of the Council of the European Union of 15th December 2004 on the harmonisation of the laws of the member states relating to Electromagnetic Compatibility (2004108EC) and the Low Voltage Directive (200695EC)The units are compliant with the following standards

200695EC ldquoDirective relating to electrical equipment designed for use within specific voltage limitsrdquo

Safety of the unitIEC 62109-12010IEC 62109-22011

2004108EC ldquoDirective relating to electromagneticcompatibilityrdquo

Interference immunityEN 61000-6-22005 Emitted interferenceEN 61000-6-32007

Secondary effects on the gridEN 61000-3-112000EN 61000-3-122005

The types mentioned above are therefore labelled with the CE markUnauthorised modifications to the supplied units andor any use of the units that is contrary to their intended use render this Declaration of Conformity null and void

Neckarsulm 0711 2013KACO new energy GmbH

pp Volker DietrichEnergy systems engineering management

Disposal

Page 38 Operating instructions Powador-gridsave_EN

Carl-Zeiss-Straszlige 1 middot 74172 Neckarsulm middot Germany middot Phone +49 7132 3818-0 middot Fax +49 7132 3818-703 middot infokaco-newenergyde middot wwwkaco-newenergyde

The

text

and

figu

res

refle

ct th

e cu

rren

t tec

hnic

al s

tate

at t

he ti

me

of p

rintin

g S

ubje

ct to

tech

nica

l cha

nges

Err

ors

and

omis

sion

s ex

cept

ed

3006

856-

01-1

4030

5

  • 1General Information
    • 11About this document
    • 12Name plate
    • 13Additional information
    • 14Intended use
      • 2Safety
        • 21Protection features
          • 3Description
            • 31Mode of Operation
            • 32Summary of the components
              • 4Technical Data
                • 41Electrical data
                • 42Mechanical data
                  • 5Transportation and Delivery
                    • 51Delivery
                    • 52Storage
                    • 53Transportation
                      • 6Assembling the device
                        • 61Installation
                        • 62Installing components
                          • 7Installing the device
                            • 71Opening the connection area
                            • 72Making the electrical connection
                            • 73Connecting the interfaces
                            • 74Sealing the connection area
                            • 75Starting up
                            • 76Standard configuration
                              • 8Configuration and Operation
                                • 81Controls
                                  • 9MaintenanceTroubleshooting
                                    • 91Visual inspection
                                    • 92Cleaning the device
                                    • 93Maintenance
                                    • 94Faults
                                      • 10Service
                                      • 11ShutdownDisassembly
                                        • 111Switching off the device
                                        • 112Uninstalling the device
                                        • 113Disassembling the device
                                          • 12Disposal
                                          • 13Appendix

Installing the device

Operating instructions Powador-gridsave_EN Page 21

Authorised electrician

X2X1F1 F2 X7 X4 St1

St2

St3

2 3 541 6

Figure 12 View from above of the connection area

Key

1 AC grid input (M40 cable fitting) 4 Network interface (M32 cable fitting)

2 AC grid output (M40 cable fitting) 5 Inverter input (M16 cable fitting)

3 Inverter output (M32 cable fitting) 6 Other connections (M16 cable fitting)

F1 F2 X7 X4 St1

St2

St3

L1 L2 L3 N PE L1 L2 L3 N N PE PE

X1 X2

PV+

PV-

L1 L2 L3 N PE32A 32A PEN

Cust

omer

co

nnec

tion

Figure 13 View from above of the connection area

Key

X1 AC grid input (main junction box meter) X7 PV generator input

X2 AC grid output (building electrical system) F1 F2 Phase bridging fuse

X4 Inverter output St 1-3 Potential-free contacts control outputs

Installing the device

Page 22 Operating instructions Powador-gridsave_EN

Authorised electrician

721 Connecting to the power grid

Because the device is installed between the main junction boxmeter and the buildings electrical system the maxi-mum grid current to the service line must not exceed the rated operating current of the battery system The cable cross-section must be selected in accordance with applicable standards to suit the connected load instal-lation type etc Moreover the terminal area and size of the cable fitting must be noted

NOTEThe fuse rating for the cable should be max 63A (automatic circuit breaker or safety fuse) even if the cross-section of the installed cable would permit a higher fuse rating Always follow the applicable regulations regarding the cable cross-section and installation typeThe device supports standard grid configurations such as TN-C TN-S and TT TN-SIf a TN-S grid is present directly at the power input and output of the device L1-L3 N and PE must each be connected The home power grid should have 4-pin isolationTN-C4-pin grid isolation is factory preset and disconnects L1 L2 L3 and N In a TN-C grid the N conduc-tor must not be disconnected If a TN-S grid is present directly at the power input and output of the device a cable bridge (included in delivery) must be installed between the N terminal on X1 and the N terminal on X2 N and PE must additionally be connected together To do this simply insert the enclosed terminal link into the N and PE terminals TTIn the case of a TT grid L1-L3 N and PE must each be connected The home power grid should have 4-pin isolation

NOTEPlease check with the operator of the mains grid whether there are special regulations for grid connection Grid isolation is factory preset to 4-pin is fail-safe and provided with grid and system protection as per VDE-AR-N 4105

Making the grid connection Use cables with 5 wires (L1 brown L2 black L3 grey N blue PE greenyellow) and the correct

cross-section1 Loosen cable fitting for AC connection2 Remove the outer cladding of the AC cables3 Insert the AC cables through the cable fitting into the connection area4 Strip the insulation from the AC cables5 Remove connection terminals6 Connect the cables in line with the terminal labels (Figure 13 on page 21)7 Close the connection terminals8 Check that all connected cables are securely fitted9 Tighten the cable fitting10 To meet the requirements of protection rating IP21 close the unused cable fittings with blind caps raquo The battery system is connected to the power grid

NOTEAn AC-side disconnection unit must be provided during the final installation stage This disconnec-tion unit must be installed so that it can be accessed at any time without obstruction If a residual current circuit breaker is necessary due to the installation specification a type A residual current circuit breaker must be used

Installing the device

Operating instructions Powador-gridsave_EN Page 23

Authorised electrician

7211 Output from the inverterRecommended cable cross-sections for the inverter output and fuse rating of cables for fixed wiring accord-ing to VDE 0100 part 430The fuse rating for the cable is dependent on the cable cross-section max 40A automatic circuit breaker

NOTEWhen the line resistance is high (ie long grid-side cables) the voltage at the grid terminals of the inverter will increase during feed-in to the grid The inverter monitors this voltage If the voltage exceeds the country-specific grid overvoltage limit value the inverter switches off rsaquo Ensure that the conductor cross-sections are sufficiently large or that the cable lengths are suffi-

ciently short

NOTEIn order to avoid asymmetries in the grid systems with multiple battery systems should be designed so that the inverters in the devices feed into the grid in differing phases rsaquo Follow the connection conditions for the particular type of grid and the schematic illustration

below

Country and grid-type

Grid monitoring Required monitoring

max asymmetry between phases L1L2L3

DE-NSP Three-phase or single phase phase unbalanced load 46 kVA

Table 5 Grid-type-specific connection conditions

L1

L2

L3

N

Connection X1 Connection X1 Connection X1 Connection X1

L1 L2 L3 N PE L1 L2 L3 N PE L1 L2 L3 N PE L1 L2 L3 N PE

Powador-gridsave inverter1 L1 - L1 L2 - L2 L3 - L32 L1 - L2 L2 - L3 L3 - L1 3 L1 - L3 L2 - L1 L3 - L2 4 L1 - L1 L2 - L2 L3 - L3

Figure 14 Grid-side connection for systems with multiple battery systems with three-phase grid monitoring

Installing the device

Page 24 Operating instructions Powador-gridsave_EN

Authorised electrician

722 Connecting the PV generator

Connect the PV generator on the left in the connection area (Figure 13 on page 21) Use the provided M16 cable fittings A maximum of two strings can be connected For this reason a DC string fuse can be dispensed with

DANGERRisk of fatal injury due to contact voltagesRemoving the cables from the terminals without first disconnecting the PV generator from the device can cause serious damage to health or damage to the system rsaquo During installation Electrically disconnect the DC positive and DC negative from the protective

earth (PE) rsaquo Completely de-energise the system (AC home power grid AC circuit breaker residual current circuit

breaker DC isolator switch) rsaquo Disconnect the battery system from the PV generator using the integrated DC isolator switch rsaquo Remove DC plug connectors

NOTEIn accordance with IEC 61730 Class A connected PV modules must be dimensioned for the DC system voltage provided and at least for the value of the AC grid voltage

7221 Before connecting

Ensure that there is no ground fault1 Determine the DC voltage between the

ndash protective earth (PE) and the positive cable of the PV generator and between the ndash protective earth (PE) and the negative cable of the PV generator

If stable voltages can be measured there is a ground fault in the DC generator or its wiring The ratio between the measured voltages gives an indication as to the location of this fault

2 Rectify any faults before taking further measurements3 Determine the electrical resistance between the

ndash protective earth (PE) and the positive cable of the PV generator and between the ndash protective earth (PE) and the negative cable of the PV generator

In addition ensure that the PV generator has a total insulation resistance of more than 20 MOhm since the inverter will not feed in if the insulation resistance is too low

4 Rectify any faults before connecting the DC generator

7222 Connecting the PV generator

DANGERRisk of fatal injury due to electric shockSevere injury or death will result if the live connections are touched When there is solar radiation DC voltage will be present at the open ends of the DC cables rsaquo Do not touch the exposed ends of the cables rsaquo Avoid short circuits

Installing the device

Operating instructions Powador-gridsave_EN Page 25

Authorised electrician

Connecting the PV generator Use cables with the correct cross-section

1 Remove cable fittings for DC connection2 Remove the outer cladding of the DC cables3 Insert the DC cables through the cable fittings into the connection area4 Strip the insulation from the DC cables5 Remove connection terminals6 Connect the cables in line with the terminal labels (See Figure 13 on page 21)7 Close the connection terminals8 Check that all connected cables are securely fitted9 Tighten the cable fittings10 To meet the requirements of protection rating IP21 close the unused cable fittings with blind caps raquo The PV generator is connected to the inverter

73 Connecting the interfaces

731 Ethernet interface

Pre-assembled Ethernet cables can be connected using the RJ45 socket in the connection space

Connecting the Ethernet cable1 Remove closure cap from RJ45 socket2 Connect the Ethernet cable3 The energy management system can now obtain an IP address by DHCP and is also available via this in the

network

NOTEThe network settings can be amended later in the Settings menu using the EMS

NOTEUse a suitable category 5 network cable The maximum length of a network segment is 100 m Ensure that the cable is correctly assigned The Ethernet connection of the battery system supports auto-sensing You can use both crossed and 11 configured Ethernet connection cables

74 Sealing the connection area

1 Finally check the cabling2 Ensure that all cables are firmly mounted3 Check that the cable fitting is secure and tighten if necessary4 Remove cable offcuts and particles of dirt or dust5 Fit the cover and slide back until it engages into position6 Check that the position is correct7 Screw the fastening screw onto the front of the cover

Installing the device

Page 26 Operating instructions Powador-gridsave_EN

Authorised electrician

75 Starting up

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched Only appropriately qualified and authorised electricians may open install or maintain the battery system rsaquo Keep the front doors and covers closed during operation

NOTEInitial start-up should be carried out using the available public AC grid

76 Standard configuration

Factory settingsCountry configuration Germany

Grid guidelines Low voltage directive

Language German

Time UTC +1 Central European Time

User Standard

Network parameters DHCP (network settings will be obtained automatically from the router)

NOTEPlease state the desired power limitation (60 or 70 of the PV system capacity) when you order For other variations please notify your KACO contact so that the parameters can be set at the factory prior to delivery

Installing the device

Operating instructions Powador-gridsave_EN Page 27

Authorised electrician

761 Step 1 AC home power grid

Check all cables and connections before starting up1 Switch on the AC home power grid using the AC main switch raquo Powador-protect measurement and control unit starts up and monitors the AC grid raquo Two green LEDs indicate that the grid parameters are met raquo After a further 60 seconds (shortly after the backlighting in the Powador-protect goes out) the Powador-pro-

tect will switch on the home grid2 Configure Powador-protect according to the enclosed Powador-protect instructions

(The instructions are also available on the website at wwwkaconewenergyde) raquo The AC power is supplied in the normal way by the public grid

762 Step 2 AC supply from the battery system

Check all cables and connections before starting up1 Remove external isolation means from the device2 Switch on the circuit breaker raquo The LCD touchscreen on the front panel comes on and the energy management system (EMS) starts up

3 Switch on the residual current circuit breaker raquo The battery system starts up

763 Step 3 Switch on the PV system

1 Switch on any optional external PV isolator switches2 Set the internal DC isolator switch to ON raquo The inverter and the battery charging unit battery backup converter (BBC) are connected to the PV system raquo The device monitors the PV voltage for approx 60 seconds then optimisation of internal consumption takes

place

764 Step 4 Switch on batteries

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

765 Step 5 Activate energy management

NOTEKACO new energy cannot provide any support for problems regarding the IT infrastructure (eg router configuration IP address assignment ports etc) as the structure settings and configuration of the network environment can be complex and very different from place to place In the event of any problems please contact an IT service provider

Remote access activated 1 Please call the KACO Hotline to make an appointment for activation of energy management

Configuration and Operation

Page 28 Operating instructions Powador-gridsave_EN

Authorised electrician

8 Configuration and Operation

81 ControlsThe battery system is fitted with a touchscreen which allows it to be controlled very precisely In normal operation the display is switched off Touching the screen activates the display and after a configurable period of time without being touched the dis-play will deactivate If the screen-save function is switched off the touchscreen will be on continuously

NOTEDepending on the tolerances of the measuring elements the measured and displayed values are not always the actual values However the measuring elements ensure maximum solar yield Due to these tolerances the daily yields shown on the touchscreen may deviate from the values on the grid operatorrsquos feed-in meter by up to 15

3

1

45

2

Figure 15 Overview (home screen)

Key

1 Home button 4 Current time

2 System components 5 Menu name

3 More information

811 Information about the system

Open start screen View changesjumps to the home screen

Show component detail Parameters of the selected component

Settings Define settings for the active user

raquo Displays settings

Configuration and Operation

Operating instructions Powador-gridsave_EN Page 29

Controls Left arrow jump back to previous menu item Up and down arrows navigate through the menu or change a value

Left arrow displayed value is reduced by one increment Right arrow displayed value is increased by one increment or change to the submenu

Display fields Grey box Text or figures (not selectable) Blue box Calls up submenu for the display in question

Activate and deactivate Activate function by ticking the box

Table 6 Information about the system

812 System components

PV generator Display of the current generator data

power voltage current temperature in the inverter

Battery Display of the current battery status

power (charging or discharging) voltage current charge status available capacity temperature of battery

Grid Display of the following either fed-in or drawn from the grid

power voltage current for phase L1-L3 total output frequency

Consumer (load) Display of the consumer data

power voltage current for phase L1-L3 total output

Energy flow raquo Displays the current energy flow in the system

Table 7 Information about system components

Configuration and Operation

Page 30 Operating instructions Powador-gridsave_EN

813 Menu structure

Icons used

Display menu Submenu

Option menu

Menu Submenu Display setting

Action in this menumeaning

PV generator Details

Power Displays the current DC-side power

Voltage Displays the current DC-side voltage

Current Displays the current DC-side amperage

Temp inverter

Displays the current temperature in the inverter housing

Battery Details

Power Displays the current AC-side power

Voltage Displays the current AC-side voltage

Current Displays the current AC-side amperage

Charge status Displays the current charge status

Capacity Displays the current battery capacity

Temperature Displays the current measured temperature of the battery

Grid Details

Power Displays the current AC-side power being drawn or fed-in

Voltage Displays the AC-side voltage being applied

Current Displays the current AC-side amperage being drawn or fed-in

Total output Displays the current AC-side total output being drawn or fed-in

Frequency Displays the frequency currently being applied to the grid junction

Consumer (load) Details

Power Displays the current AC-side power being drawn

Voltage Displays the current AC-side voltage being applied

Current Displays the current AC-side amperage being drawn

Total output Displays the current AC-side total output being drawn

Configuration and Operation

Operating instructions Powador-gridsave_EN Page 31

Menu Submenu Display setting

Action in this menumeaning

Settings

Country amp directive display

Display of the country settings voltage directives and grid type

Select menu language

DateTime Specify time zone date format and date and time

Screen Activate screen-save function and set the delay period

Network settings

Display of the network settings Configure network settings Once the DHCP server becomes available the IP

address subnet mask gateway and DNS server are automatically applied and the aforemen-tioned menu items are hidden

Off DHCP deactivated make settings manually

Version Displays the installed software version and built-in HW components (inverter BBC battery)

Vendor The touchscreen shows information about the device vendor

NOTEAs changes to the software are possible after the manual has been printed the illustrations and descriptions of the functions in these operating instructions may deviate from the software Please therefore note the current Application Notes on our website

MaintenanceTroubleshooting

Page 32 Operating instructions Powador-gridsave_EN

9 MaintenanceTroubleshooting

91 Visual inspectionInspect the device and the cables for visible external damage and note the operating status display In case of damage notify your installer Repairs may only be carried out by authorised electricians

NOTEThe battery system should be checked for proper operation by a qualified electrician at regular intervals

92 Cleaning the device

DANGERLethal voltages in the battery systemSerious injuries or death can result if moisture enters the system rsaquo Only use completely dry objects to clean the battery system rsaquo Only clean the outside of the battery system

Cleaning the battery system Do not use compressed air Use a vacuum cleaner or a soft brush to remove dust from the fan cover and from the top of the inverter on a

regular basis Remove dust from the ventilation inlets if necessary

MaintenanceTroubleshooting

Operating instructions Powador-gridsave_EN Page 33

Authorised electrician

93 Maintenance

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched The device is only permitted to be opened or serviced by an authorised electrician rsaquo Observe all safety regulations and the current technical connection specifications from the relevant

power supply company rsaquo Disconnect the AC and DC sides rsaquo Secure the AC and DC sides from being inadvertently switched back on rsaquo Only then should the device be opened rsaquo After shutdown wait at least 30 minutes before working on the device

CAUTIONDestruction of the DC connectionThe connection terminals can be destroyed by arcing if disconnected while still live rsaquo It is absolutely essential that the shutdown sequence be carried out in the correct order (See sec-

tion 111 on page 35)

94 Faults

941 Procedure

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched

When a fault occurs notify an appropriately authorised and qualified electrician or KACO new energy GmbH Service

Service

Page 34 Operating instructions Powador-gridsave_EN

10 ServiceIf 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 efficientlybull Serial nobull SW version of the components (the software version can be found in the Settings menu using the EMS)bull Module type and string circuitbull Date of installation Start-up reportbull Consignment identification Delivery address Contact person (with telephone number)bull Information about the accessibility of the installation site

Any additional costs arising from unfavourable structural or mounting conditions shall be billed to the customer

You can find our warranty conditions on our websitehttpkaco-newenergycomservicewarrantyFrom there you can easily navigate to our international websites by clicking on the appropriate flag

Please use our website to register your unit immediatelyYou can also select the appropriate flag on this page to access the website for your own countryIn this manner you can assist us in providing you with the quickest service possible Note The maximum length of the warranty is based on the currently applicable national warranty conditions

We have prepared a template for complaints This can be found at httpskaco-newenergycomservicecustomer-service

Hotlines

Technical troubleshooting Technical consultation

Inverters and battery systems ()

+49 (0) 71323818-660 +49 (0) 71323818-660

Data logging and accessories +49 (0) 71323818-690 +49 (0) 71323818-690

Construction site emergency () +49 (0) 71323818-630

Customer help desk Monday to Friday from 730 am to 530 pm (CET)

() Also on Saturdays from 800 am to 200 pm (CET)

ShutdownDisassembly

Operating instructions Powador-gridsave_EN Page 35

11 ShutdownDisassembly

111 Switching off the device

DANGERLethal voltages are still present in the terminals and cables even after switching off and discon-nection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched rsaquo Complete de-energisation only occurs if the bulk power supply is switched off upstream of the bat-

tery system

DANGERDestruction of the DC plug connectorDC plug connectors can be destroyed by arcing if disconnected while still live rsaquo It is absolutely essential that the following shutdown sequence is observed

1111 Step 1 Shutting down the PV system

1 Switch off any optional external PV isolator switches2 Set the internal DC isolator switch to OFF raquo The inverter and battery charging unit battery backup converter (BBC) are disconnected

1112 Step 2 Disconnect the batteries

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

1113 Step 3 Disconnect the AC supply

1 Connect external isolation means to the device2 Switch off the circuit breaker 3 Switch off the residual current circuit breaker raquo The battery system is switched off

1114 Step 4 AC home power grid

1 Shutdown the AC home power grid using the AC main switch raquo The battery system can be uninstalled

Disposal

Page 36 Operating instructions Powador-gridsave_EN

112 Uninstalling the device

NOTETo uninstall follow the same sequence as for installation but in reverse order

Switch off the device1 Unlock and open the housing door2 Remove the upper cover3 Release the DC and AC cables from the connection terminals4 Pull out the cables raquo The battery system is uninstalled Continue with the disassembly

113 Disassembling the device

NOTETo disassemble follow the same sequence as for assembly but in reverse order

Switch off the device1 Uninstall the components2 Remove the fastening from the device3 Securely pack up the battery system if it is to be used later

or have the battery system disposed of in accordance with section 12 on page 36

12 DisposalFor the most part both the battery system and the corresponding transport packaging are made from recyclable raw materialsBatteries and components Do not dispose of faulty batteries or the components together with household waste Ensure that the old device and accessories are disposed of in a proper mannerPackaging Ensure that the transport packaging is disposed of properlyBatteriesUsed or faulty batteries must be transported in special packaging If you need such packaging please contact the KACO Hotline

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

Appendix

Operating instructions Powador-gridsave_EN Page 37

13 Appendix

EU Declaration of Conformity

Vendorrsquos name and address

KACO new energy GmbH Carl-Zeiss-Straszlige 1 74172 Neckarsulm Germany

Product description Battery system

Type designation Powador-gridsave 135 kWh 6400 Powador-gridsave 135 kWh 8000

Powador-gridsave 270 kWh 6400 Powador-gridsave 270 kWh 8000

Powador-gridsave 405 kWh 6400 Powador-gridsave 405 kWh 8000

Powador-gridsave 540 kWh 6400 Powador-gridsave 540 kWh 8000

Powador-gridsave 577 kWh 6400 Powador-gridsave 577 kWh 8000

Powador-gridsave 675 kWh 6400 Powador-gridsave 675 kWh 8000

This is to confirm that the units listed above comply with the protection requirements set forth in the Directive of the Council of the European Union of 15th December 2004 on the harmonisation of the laws of the member states relating to Electromagnetic Compatibility (2004108EC) and the Low Voltage Directive (200695EC)The units are compliant with the following standards

200695EC ldquoDirective relating to electrical equipment designed for use within specific voltage limitsrdquo

Safety of the unitIEC 62109-12010IEC 62109-22011

2004108EC ldquoDirective relating to electromagneticcompatibilityrdquo

Interference immunityEN 61000-6-22005 Emitted interferenceEN 61000-6-32007

Secondary effects on the gridEN 61000-3-112000EN 61000-3-122005

The types mentioned above are therefore labelled with the CE markUnauthorised modifications to the supplied units andor any use of the units that is contrary to their intended use render this Declaration of Conformity null and void

Neckarsulm 0711 2013KACO new energy GmbH

pp Volker DietrichEnergy systems engineering management

Disposal

Page 38 Operating instructions Powador-gridsave_EN

Carl-Zeiss-Straszlige 1 middot 74172 Neckarsulm middot Germany middot Phone +49 7132 3818-0 middot Fax +49 7132 3818-703 middot infokaco-newenergyde middot wwwkaco-newenergyde

The

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Err

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and

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3006

856-

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4030

5

  • 1General Information
    • 11About this document
    • 12Name plate
    • 13Additional information
    • 14Intended use
      • 2Safety
        • 21Protection features
          • 3Description
            • 31Mode of Operation
            • 32Summary of the components
              • 4Technical Data
                • 41Electrical data
                • 42Mechanical data
                  • 5Transportation and Delivery
                    • 51Delivery
                    • 52Storage
                    • 53Transportation
                      • 6Assembling the device
                        • 61Installation
                        • 62Installing components
                          • 7Installing the device
                            • 71Opening the connection area
                            • 72Making the electrical connection
                            • 73Connecting the interfaces
                            • 74Sealing the connection area
                            • 75Starting up
                            • 76Standard configuration
                              • 8Configuration and Operation
                                • 81Controls
                                  • 9MaintenanceTroubleshooting
                                    • 91Visual inspection
                                    • 92Cleaning the device
                                    • 93Maintenance
                                    • 94Faults
                                      • 10Service
                                      • 11ShutdownDisassembly
                                        • 111Switching off the device
                                        • 112Uninstalling the device
                                        • 113Disassembling the device
                                          • 12Disposal
                                          • 13Appendix

Installing the device

Page 22 Operating instructions Powador-gridsave_EN

Authorised electrician

721 Connecting to the power grid

Because the device is installed between the main junction boxmeter and the buildings electrical system the maxi-mum grid current to the service line must not exceed the rated operating current of the battery system The cable cross-section must be selected in accordance with applicable standards to suit the connected load instal-lation type etc Moreover the terminal area and size of the cable fitting must be noted

NOTEThe fuse rating for the cable should be max 63A (automatic circuit breaker or safety fuse) even if the cross-section of the installed cable would permit a higher fuse rating Always follow the applicable regulations regarding the cable cross-section and installation typeThe device supports standard grid configurations such as TN-C TN-S and TT TN-SIf a TN-S grid is present directly at the power input and output of the device L1-L3 N and PE must each be connected The home power grid should have 4-pin isolationTN-C4-pin grid isolation is factory preset and disconnects L1 L2 L3 and N In a TN-C grid the N conduc-tor must not be disconnected If a TN-S grid is present directly at the power input and output of the device a cable bridge (included in delivery) must be installed between the N terminal on X1 and the N terminal on X2 N and PE must additionally be connected together To do this simply insert the enclosed terminal link into the N and PE terminals TTIn the case of a TT grid L1-L3 N and PE must each be connected The home power grid should have 4-pin isolation

NOTEPlease check with the operator of the mains grid whether there are special regulations for grid connection Grid isolation is factory preset to 4-pin is fail-safe and provided with grid and system protection as per VDE-AR-N 4105

Making the grid connection Use cables with 5 wires (L1 brown L2 black L3 grey N blue PE greenyellow) and the correct

cross-section1 Loosen cable fitting for AC connection2 Remove the outer cladding of the AC cables3 Insert the AC cables through the cable fitting into the connection area4 Strip the insulation from the AC cables5 Remove connection terminals6 Connect the cables in line with the terminal labels (Figure 13 on page 21)7 Close the connection terminals8 Check that all connected cables are securely fitted9 Tighten the cable fitting10 To meet the requirements of protection rating IP21 close the unused cable fittings with blind caps raquo The battery system is connected to the power grid

NOTEAn AC-side disconnection unit must be provided during the final installation stage This disconnec-tion unit must be installed so that it can be accessed at any time without obstruction If a residual current circuit breaker is necessary due to the installation specification a type A residual current circuit breaker must be used

Installing the device

Operating instructions Powador-gridsave_EN Page 23

Authorised electrician

7211 Output from the inverterRecommended cable cross-sections for the inverter output and fuse rating of cables for fixed wiring accord-ing to VDE 0100 part 430The fuse rating for the cable is dependent on the cable cross-section max 40A automatic circuit breaker

NOTEWhen the line resistance is high (ie long grid-side cables) the voltage at the grid terminals of the inverter will increase during feed-in to the grid The inverter monitors this voltage If the voltage exceeds the country-specific grid overvoltage limit value the inverter switches off rsaquo Ensure that the conductor cross-sections are sufficiently large or that the cable lengths are suffi-

ciently short

NOTEIn order to avoid asymmetries in the grid systems with multiple battery systems should be designed so that the inverters in the devices feed into the grid in differing phases rsaquo Follow the connection conditions for the particular type of grid and the schematic illustration

below

Country and grid-type

Grid monitoring Required monitoring

max asymmetry between phases L1L2L3

DE-NSP Three-phase or single phase phase unbalanced load 46 kVA

Table 5 Grid-type-specific connection conditions

L1

L2

L3

N

Connection X1 Connection X1 Connection X1 Connection X1

L1 L2 L3 N PE L1 L2 L3 N PE L1 L2 L3 N PE L1 L2 L3 N PE

Powador-gridsave inverter1 L1 - L1 L2 - L2 L3 - L32 L1 - L2 L2 - L3 L3 - L1 3 L1 - L3 L2 - L1 L3 - L2 4 L1 - L1 L2 - L2 L3 - L3

Figure 14 Grid-side connection for systems with multiple battery systems with three-phase grid monitoring

Installing the device

Page 24 Operating instructions Powador-gridsave_EN

Authorised electrician

722 Connecting the PV generator

Connect the PV generator on the left in the connection area (Figure 13 on page 21) Use the provided M16 cable fittings A maximum of two strings can be connected For this reason a DC string fuse can be dispensed with

DANGERRisk of fatal injury due to contact voltagesRemoving the cables from the terminals without first disconnecting the PV generator from the device can cause serious damage to health or damage to the system rsaquo During installation Electrically disconnect the DC positive and DC negative from the protective

earth (PE) rsaquo Completely de-energise the system (AC home power grid AC circuit breaker residual current circuit

breaker DC isolator switch) rsaquo Disconnect the battery system from the PV generator using the integrated DC isolator switch rsaquo Remove DC plug connectors

NOTEIn accordance with IEC 61730 Class A connected PV modules must be dimensioned for the DC system voltage provided and at least for the value of the AC grid voltage

7221 Before connecting

Ensure that there is no ground fault1 Determine the DC voltage between the

ndash protective earth (PE) and the positive cable of the PV generator and between the ndash protective earth (PE) and the negative cable of the PV generator

If stable voltages can be measured there is a ground fault in the DC generator or its wiring The ratio between the measured voltages gives an indication as to the location of this fault

2 Rectify any faults before taking further measurements3 Determine the electrical resistance between the

ndash protective earth (PE) and the positive cable of the PV generator and between the ndash protective earth (PE) and the negative cable of the PV generator

In addition ensure that the PV generator has a total insulation resistance of more than 20 MOhm since the inverter will not feed in if the insulation resistance is too low

4 Rectify any faults before connecting the DC generator

7222 Connecting the PV generator

DANGERRisk of fatal injury due to electric shockSevere injury or death will result if the live connections are touched When there is solar radiation DC voltage will be present at the open ends of the DC cables rsaquo Do not touch the exposed ends of the cables rsaquo Avoid short circuits

Installing the device

Operating instructions Powador-gridsave_EN Page 25

Authorised electrician

Connecting the PV generator Use cables with the correct cross-section

1 Remove cable fittings for DC connection2 Remove the outer cladding of the DC cables3 Insert the DC cables through the cable fittings into the connection area4 Strip the insulation from the DC cables5 Remove connection terminals6 Connect the cables in line with the terminal labels (See Figure 13 on page 21)7 Close the connection terminals8 Check that all connected cables are securely fitted9 Tighten the cable fittings10 To meet the requirements of protection rating IP21 close the unused cable fittings with blind caps raquo The PV generator is connected to the inverter

73 Connecting the interfaces

731 Ethernet interface

Pre-assembled Ethernet cables can be connected using the RJ45 socket in the connection space

Connecting the Ethernet cable1 Remove closure cap from RJ45 socket2 Connect the Ethernet cable3 The energy management system can now obtain an IP address by DHCP and is also available via this in the

network

NOTEThe network settings can be amended later in the Settings menu using the EMS

NOTEUse a suitable category 5 network cable The maximum length of a network segment is 100 m Ensure that the cable is correctly assigned The Ethernet connection of the battery system supports auto-sensing You can use both crossed and 11 configured Ethernet connection cables

74 Sealing the connection area

1 Finally check the cabling2 Ensure that all cables are firmly mounted3 Check that the cable fitting is secure and tighten if necessary4 Remove cable offcuts and particles of dirt or dust5 Fit the cover and slide back until it engages into position6 Check that the position is correct7 Screw the fastening screw onto the front of the cover

Installing the device

Page 26 Operating instructions Powador-gridsave_EN

Authorised electrician

75 Starting up

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched Only appropriately qualified and authorised electricians may open install or maintain the battery system rsaquo Keep the front doors and covers closed during operation

NOTEInitial start-up should be carried out using the available public AC grid

76 Standard configuration

Factory settingsCountry configuration Germany

Grid guidelines Low voltage directive

Language German

Time UTC +1 Central European Time

User Standard

Network parameters DHCP (network settings will be obtained automatically from the router)

NOTEPlease state the desired power limitation (60 or 70 of the PV system capacity) when you order For other variations please notify your KACO contact so that the parameters can be set at the factory prior to delivery

Installing the device

Operating instructions Powador-gridsave_EN Page 27

Authorised electrician

761 Step 1 AC home power grid

Check all cables and connections before starting up1 Switch on the AC home power grid using the AC main switch raquo Powador-protect measurement and control unit starts up and monitors the AC grid raquo Two green LEDs indicate that the grid parameters are met raquo After a further 60 seconds (shortly after the backlighting in the Powador-protect goes out) the Powador-pro-

tect will switch on the home grid2 Configure Powador-protect according to the enclosed Powador-protect instructions

(The instructions are also available on the website at wwwkaconewenergyde) raquo The AC power is supplied in the normal way by the public grid

762 Step 2 AC supply from the battery system

Check all cables and connections before starting up1 Remove external isolation means from the device2 Switch on the circuit breaker raquo The LCD touchscreen on the front panel comes on and the energy management system (EMS) starts up

3 Switch on the residual current circuit breaker raquo The battery system starts up

763 Step 3 Switch on the PV system

1 Switch on any optional external PV isolator switches2 Set the internal DC isolator switch to ON raquo The inverter and the battery charging unit battery backup converter (BBC) are connected to the PV system raquo The device monitors the PV voltage for approx 60 seconds then optimisation of internal consumption takes

place

764 Step 4 Switch on batteries

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

765 Step 5 Activate energy management

NOTEKACO new energy cannot provide any support for problems regarding the IT infrastructure (eg router configuration IP address assignment ports etc) as the structure settings and configuration of the network environment can be complex and very different from place to place In the event of any problems please contact an IT service provider

Remote access activated 1 Please call the KACO Hotline to make an appointment for activation of energy management

Configuration and Operation

Page 28 Operating instructions Powador-gridsave_EN

Authorised electrician

8 Configuration and Operation

81 ControlsThe battery system is fitted with a touchscreen which allows it to be controlled very precisely In normal operation the display is switched off Touching the screen activates the display and after a configurable period of time without being touched the dis-play will deactivate If the screen-save function is switched off the touchscreen will be on continuously

NOTEDepending on the tolerances of the measuring elements the measured and displayed values are not always the actual values However the measuring elements ensure maximum solar yield Due to these tolerances the daily yields shown on the touchscreen may deviate from the values on the grid operatorrsquos feed-in meter by up to 15

3

1

45

2

Figure 15 Overview (home screen)

Key

1 Home button 4 Current time

2 System components 5 Menu name

3 More information

811 Information about the system

Open start screen View changesjumps to the home screen

Show component detail Parameters of the selected component

Settings Define settings for the active user

raquo Displays settings

Configuration and Operation

Operating instructions Powador-gridsave_EN Page 29

Controls Left arrow jump back to previous menu item Up and down arrows navigate through the menu or change a value

Left arrow displayed value is reduced by one increment Right arrow displayed value is increased by one increment or change to the submenu

Display fields Grey box Text or figures (not selectable) Blue box Calls up submenu for the display in question

Activate and deactivate Activate function by ticking the box

Table 6 Information about the system

812 System components

PV generator Display of the current generator data

power voltage current temperature in the inverter

Battery Display of the current battery status

power (charging or discharging) voltage current charge status available capacity temperature of battery

Grid Display of the following either fed-in or drawn from the grid

power voltage current for phase L1-L3 total output frequency

Consumer (load) Display of the consumer data

power voltage current for phase L1-L3 total output

Energy flow raquo Displays the current energy flow in the system

Table 7 Information about system components

Configuration and Operation

Page 30 Operating instructions Powador-gridsave_EN

813 Menu structure

Icons used

Display menu Submenu

Option menu

Menu Submenu Display setting

Action in this menumeaning

PV generator Details

Power Displays the current DC-side power

Voltage Displays the current DC-side voltage

Current Displays the current DC-side amperage

Temp inverter

Displays the current temperature in the inverter housing

Battery Details

Power Displays the current AC-side power

Voltage Displays the current AC-side voltage

Current Displays the current AC-side amperage

Charge status Displays the current charge status

Capacity Displays the current battery capacity

Temperature Displays the current measured temperature of the battery

Grid Details

Power Displays the current AC-side power being drawn or fed-in

Voltage Displays the AC-side voltage being applied

Current Displays the current AC-side amperage being drawn or fed-in

Total output Displays the current AC-side total output being drawn or fed-in

Frequency Displays the frequency currently being applied to the grid junction

Consumer (load) Details

Power Displays the current AC-side power being drawn

Voltage Displays the current AC-side voltage being applied

Current Displays the current AC-side amperage being drawn

Total output Displays the current AC-side total output being drawn

Configuration and Operation

Operating instructions Powador-gridsave_EN Page 31

Menu Submenu Display setting

Action in this menumeaning

Settings

Country amp directive display

Display of the country settings voltage directives and grid type

Select menu language

DateTime Specify time zone date format and date and time

Screen Activate screen-save function and set the delay period

Network settings

Display of the network settings Configure network settings Once the DHCP server becomes available the IP

address subnet mask gateway and DNS server are automatically applied and the aforemen-tioned menu items are hidden

Off DHCP deactivated make settings manually

Version Displays the installed software version and built-in HW components (inverter BBC battery)

Vendor The touchscreen shows information about the device vendor

NOTEAs changes to the software are possible after the manual has been printed the illustrations and descriptions of the functions in these operating instructions may deviate from the software Please therefore note the current Application Notes on our website

MaintenanceTroubleshooting

Page 32 Operating instructions Powador-gridsave_EN

9 MaintenanceTroubleshooting

91 Visual inspectionInspect the device and the cables for visible external damage and note the operating status display In case of damage notify your installer Repairs may only be carried out by authorised electricians

NOTEThe battery system should be checked for proper operation by a qualified electrician at regular intervals

92 Cleaning the device

DANGERLethal voltages in the battery systemSerious injuries or death can result if moisture enters the system rsaquo Only use completely dry objects to clean the battery system rsaquo Only clean the outside of the battery system

Cleaning the battery system Do not use compressed air Use a vacuum cleaner or a soft brush to remove dust from the fan cover and from the top of the inverter on a

regular basis Remove dust from the ventilation inlets if necessary

MaintenanceTroubleshooting

Operating instructions Powador-gridsave_EN Page 33

Authorised electrician

93 Maintenance

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched The device is only permitted to be opened or serviced by an authorised electrician rsaquo Observe all safety regulations and the current technical connection specifications from the relevant

power supply company rsaquo Disconnect the AC and DC sides rsaquo Secure the AC and DC sides from being inadvertently switched back on rsaquo Only then should the device be opened rsaquo After shutdown wait at least 30 minutes before working on the device

CAUTIONDestruction of the DC connectionThe connection terminals can be destroyed by arcing if disconnected while still live rsaquo It is absolutely essential that the shutdown sequence be carried out in the correct order (See sec-

tion 111 on page 35)

94 Faults

941 Procedure

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched

When a fault occurs notify an appropriately authorised and qualified electrician or KACO new energy GmbH Service

Service

Page 34 Operating instructions Powador-gridsave_EN

10 ServiceIf 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 efficientlybull Serial nobull SW version of the components (the software version can be found in the Settings menu using the EMS)bull Module type and string circuitbull Date of installation Start-up reportbull Consignment identification Delivery address Contact person (with telephone number)bull Information about the accessibility of the installation site

Any additional costs arising from unfavourable structural or mounting conditions shall be billed to the customer

You can find our warranty conditions on our websitehttpkaco-newenergycomservicewarrantyFrom there you can easily navigate to our international websites by clicking on the appropriate flag

Please use our website to register your unit immediatelyYou can also select the appropriate flag on this page to access the website for your own countryIn this manner you can assist us in providing you with the quickest service possible Note The maximum length of the warranty is based on the currently applicable national warranty conditions

We have prepared a template for complaints This can be found at httpskaco-newenergycomservicecustomer-service

Hotlines

Technical troubleshooting Technical consultation

Inverters and battery systems ()

+49 (0) 71323818-660 +49 (0) 71323818-660

Data logging and accessories +49 (0) 71323818-690 +49 (0) 71323818-690

Construction site emergency () +49 (0) 71323818-630

Customer help desk Monday to Friday from 730 am to 530 pm (CET)

() Also on Saturdays from 800 am to 200 pm (CET)

ShutdownDisassembly

Operating instructions Powador-gridsave_EN Page 35

11 ShutdownDisassembly

111 Switching off the device

DANGERLethal voltages are still present in the terminals and cables even after switching off and discon-nection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched rsaquo Complete de-energisation only occurs if the bulk power supply is switched off upstream of the bat-

tery system

DANGERDestruction of the DC plug connectorDC plug connectors can be destroyed by arcing if disconnected while still live rsaquo It is absolutely essential that the following shutdown sequence is observed

1111 Step 1 Shutting down the PV system

1 Switch off any optional external PV isolator switches2 Set the internal DC isolator switch to OFF raquo The inverter and battery charging unit battery backup converter (BBC) are disconnected

1112 Step 2 Disconnect the batteries

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

1113 Step 3 Disconnect the AC supply

1 Connect external isolation means to the device2 Switch off the circuit breaker 3 Switch off the residual current circuit breaker raquo The battery system is switched off

1114 Step 4 AC home power grid

1 Shutdown the AC home power grid using the AC main switch raquo The battery system can be uninstalled

Disposal

Page 36 Operating instructions Powador-gridsave_EN

112 Uninstalling the device

NOTETo uninstall follow the same sequence as for installation but in reverse order

Switch off the device1 Unlock and open the housing door2 Remove the upper cover3 Release the DC and AC cables from the connection terminals4 Pull out the cables raquo The battery system is uninstalled Continue with the disassembly

113 Disassembling the device

NOTETo disassemble follow the same sequence as for assembly but in reverse order

Switch off the device1 Uninstall the components2 Remove the fastening from the device3 Securely pack up the battery system if it is to be used later

or have the battery system disposed of in accordance with section 12 on page 36

12 DisposalFor the most part both the battery system and the corresponding transport packaging are made from recyclable raw materialsBatteries and components Do not dispose of faulty batteries or the components together with household waste Ensure that the old device and accessories are disposed of in a proper mannerPackaging Ensure that the transport packaging is disposed of properlyBatteriesUsed or faulty batteries must be transported in special packaging If you need such packaging please contact the KACO Hotline

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

Appendix

Operating instructions Powador-gridsave_EN Page 37

13 Appendix

EU Declaration of Conformity

Vendorrsquos name and address

KACO new energy GmbH Carl-Zeiss-Straszlige 1 74172 Neckarsulm Germany

Product description Battery system

Type designation Powador-gridsave 135 kWh 6400 Powador-gridsave 135 kWh 8000

Powador-gridsave 270 kWh 6400 Powador-gridsave 270 kWh 8000

Powador-gridsave 405 kWh 6400 Powador-gridsave 405 kWh 8000

Powador-gridsave 540 kWh 6400 Powador-gridsave 540 kWh 8000

Powador-gridsave 577 kWh 6400 Powador-gridsave 577 kWh 8000

Powador-gridsave 675 kWh 6400 Powador-gridsave 675 kWh 8000

This is to confirm that the units listed above comply with the protection requirements set forth in the Directive of the Council of the European Union of 15th December 2004 on the harmonisation of the laws of the member states relating to Electromagnetic Compatibility (2004108EC) and the Low Voltage Directive (200695EC)The units are compliant with the following standards

200695EC ldquoDirective relating to electrical equipment designed for use within specific voltage limitsrdquo

Safety of the unitIEC 62109-12010IEC 62109-22011

2004108EC ldquoDirective relating to electromagneticcompatibilityrdquo

Interference immunityEN 61000-6-22005 Emitted interferenceEN 61000-6-32007

Secondary effects on the gridEN 61000-3-112000EN 61000-3-122005

The types mentioned above are therefore labelled with the CE markUnauthorised modifications to the supplied units andor any use of the units that is contrary to their intended use render this Declaration of Conformity null and void

Neckarsulm 0711 2013KACO new energy GmbH

pp Volker DietrichEnergy systems engineering management

Disposal

Page 38 Operating instructions Powador-gridsave_EN

Carl-Zeiss-Straszlige 1 middot 74172 Neckarsulm middot Germany middot Phone +49 7132 3818-0 middot Fax +49 7132 3818-703 middot infokaco-newenergyde middot wwwkaco-newenergyde

The

text

and

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ct th

e cu

rren

t tec

hnic

al s

tate

at t

he ti

me

of p

rintin

g S

ubje

ct to

tech

nica

l cha

nges

Err

ors

and

omis

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cept

ed

3006

856-

01-1

4030

5

  • 1General Information
    • 11About this document
    • 12Name plate
    • 13Additional information
    • 14Intended use
      • 2Safety
        • 21Protection features
          • 3Description
            • 31Mode of Operation
            • 32Summary of the components
              • 4Technical Data
                • 41Electrical data
                • 42Mechanical data
                  • 5Transportation and Delivery
                    • 51Delivery
                    • 52Storage
                    • 53Transportation
                      • 6Assembling the device
                        • 61Installation
                        • 62Installing components
                          • 7Installing the device
                            • 71Opening the connection area
                            • 72Making the electrical connection
                            • 73Connecting the interfaces
                            • 74Sealing the connection area
                            • 75Starting up
                            • 76Standard configuration
                              • 8Configuration and Operation
                                • 81Controls
                                  • 9MaintenanceTroubleshooting
                                    • 91Visual inspection
                                    • 92Cleaning the device
                                    • 93Maintenance
                                    • 94Faults
                                      • 10Service
                                      • 11ShutdownDisassembly
                                        • 111Switching off the device
                                        • 112Uninstalling the device
                                        • 113Disassembling the device
                                          • 12Disposal
                                          • 13Appendix

Installing the device

Operating instructions Powador-gridsave_EN Page 23

Authorised electrician

7211 Output from the inverterRecommended cable cross-sections for the inverter output and fuse rating of cables for fixed wiring accord-ing to VDE 0100 part 430The fuse rating for the cable is dependent on the cable cross-section max 40A automatic circuit breaker

NOTEWhen the line resistance is high (ie long grid-side cables) the voltage at the grid terminals of the inverter will increase during feed-in to the grid The inverter monitors this voltage If the voltage exceeds the country-specific grid overvoltage limit value the inverter switches off rsaquo Ensure that the conductor cross-sections are sufficiently large or that the cable lengths are suffi-

ciently short

NOTEIn order to avoid asymmetries in the grid systems with multiple battery systems should be designed so that the inverters in the devices feed into the grid in differing phases rsaquo Follow the connection conditions for the particular type of grid and the schematic illustration

below

Country and grid-type

Grid monitoring Required monitoring

max asymmetry between phases L1L2L3

DE-NSP Three-phase or single phase phase unbalanced load 46 kVA

Table 5 Grid-type-specific connection conditions

L1

L2

L3

N

Connection X1 Connection X1 Connection X1 Connection X1

L1 L2 L3 N PE L1 L2 L3 N PE L1 L2 L3 N PE L1 L2 L3 N PE

Powador-gridsave inverter1 L1 - L1 L2 - L2 L3 - L32 L1 - L2 L2 - L3 L3 - L1 3 L1 - L3 L2 - L1 L3 - L2 4 L1 - L1 L2 - L2 L3 - L3

Figure 14 Grid-side connection for systems with multiple battery systems with three-phase grid monitoring

Installing the device

Page 24 Operating instructions Powador-gridsave_EN

Authorised electrician

722 Connecting the PV generator

Connect the PV generator on the left in the connection area (Figure 13 on page 21) Use the provided M16 cable fittings A maximum of two strings can be connected For this reason a DC string fuse can be dispensed with

DANGERRisk of fatal injury due to contact voltagesRemoving the cables from the terminals without first disconnecting the PV generator from the device can cause serious damage to health or damage to the system rsaquo During installation Electrically disconnect the DC positive and DC negative from the protective

earth (PE) rsaquo Completely de-energise the system (AC home power grid AC circuit breaker residual current circuit

breaker DC isolator switch) rsaquo Disconnect the battery system from the PV generator using the integrated DC isolator switch rsaquo Remove DC plug connectors

NOTEIn accordance with IEC 61730 Class A connected PV modules must be dimensioned for the DC system voltage provided and at least for the value of the AC grid voltage

7221 Before connecting

Ensure that there is no ground fault1 Determine the DC voltage between the

ndash protective earth (PE) and the positive cable of the PV generator and between the ndash protective earth (PE) and the negative cable of the PV generator

If stable voltages can be measured there is a ground fault in the DC generator or its wiring The ratio between the measured voltages gives an indication as to the location of this fault

2 Rectify any faults before taking further measurements3 Determine the electrical resistance between the

ndash protective earth (PE) and the positive cable of the PV generator and between the ndash protective earth (PE) and the negative cable of the PV generator

In addition ensure that the PV generator has a total insulation resistance of more than 20 MOhm since the inverter will not feed in if the insulation resistance is too low

4 Rectify any faults before connecting the DC generator

7222 Connecting the PV generator

DANGERRisk of fatal injury due to electric shockSevere injury or death will result if the live connections are touched When there is solar radiation DC voltage will be present at the open ends of the DC cables rsaquo Do not touch the exposed ends of the cables rsaquo Avoid short circuits

Installing the device

Operating instructions Powador-gridsave_EN Page 25

Authorised electrician

Connecting the PV generator Use cables with the correct cross-section

1 Remove cable fittings for DC connection2 Remove the outer cladding of the DC cables3 Insert the DC cables through the cable fittings into the connection area4 Strip the insulation from the DC cables5 Remove connection terminals6 Connect the cables in line with the terminal labels (See Figure 13 on page 21)7 Close the connection terminals8 Check that all connected cables are securely fitted9 Tighten the cable fittings10 To meet the requirements of protection rating IP21 close the unused cable fittings with blind caps raquo The PV generator is connected to the inverter

73 Connecting the interfaces

731 Ethernet interface

Pre-assembled Ethernet cables can be connected using the RJ45 socket in the connection space

Connecting the Ethernet cable1 Remove closure cap from RJ45 socket2 Connect the Ethernet cable3 The energy management system can now obtain an IP address by DHCP and is also available via this in the

network

NOTEThe network settings can be amended later in the Settings menu using the EMS

NOTEUse a suitable category 5 network cable The maximum length of a network segment is 100 m Ensure that the cable is correctly assigned The Ethernet connection of the battery system supports auto-sensing You can use both crossed and 11 configured Ethernet connection cables

74 Sealing the connection area

1 Finally check the cabling2 Ensure that all cables are firmly mounted3 Check that the cable fitting is secure and tighten if necessary4 Remove cable offcuts and particles of dirt or dust5 Fit the cover and slide back until it engages into position6 Check that the position is correct7 Screw the fastening screw onto the front of the cover

Installing the device

Page 26 Operating instructions Powador-gridsave_EN

Authorised electrician

75 Starting up

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched Only appropriately qualified and authorised electricians may open install or maintain the battery system rsaquo Keep the front doors and covers closed during operation

NOTEInitial start-up should be carried out using the available public AC grid

76 Standard configuration

Factory settingsCountry configuration Germany

Grid guidelines Low voltage directive

Language German

Time UTC +1 Central European Time

User Standard

Network parameters DHCP (network settings will be obtained automatically from the router)

NOTEPlease state the desired power limitation (60 or 70 of the PV system capacity) when you order For other variations please notify your KACO contact so that the parameters can be set at the factory prior to delivery

Installing the device

Operating instructions Powador-gridsave_EN Page 27

Authorised electrician

761 Step 1 AC home power grid

Check all cables and connections before starting up1 Switch on the AC home power grid using the AC main switch raquo Powador-protect measurement and control unit starts up and monitors the AC grid raquo Two green LEDs indicate that the grid parameters are met raquo After a further 60 seconds (shortly after the backlighting in the Powador-protect goes out) the Powador-pro-

tect will switch on the home grid2 Configure Powador-protect according to the enclosed Powador-protect instructions

(The instructions are also available on the website at wwwkaconewenergyde) raquo The AC power is supplied in the normal way by the public grid

762 Step 2 AC supply from the battery system

Check all cables and connections before starting up1 Remove external isolation means from the device2 Switch on the circuit breaker raquo The LCD touchscreen on the front panel comes on and the energy management system (EMS) starts up

3 Switch on the residual current circuit breaker raquo The battery system starts up

763 Step 3 Switch on the PV system

1 Switch on any optional external PV isolator switches2 Set the internal DC isolator switch to ON raquo The inverter and the battery charging unit battery backup converter (BBC) are connected to the PV system raquo The device monitors the PV voltage for approx 60 seconds then optimisation of internal consumption takes

place

764 Step 4 Switch on batteries

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

765 Step 5 Activate energy management

NOTEKACO new energy cannot provide any support for problems regarding the IT infrastructure (eg router configuration IP address assignment ports etc) as the structure settings and configuration of the network environment can be complex and very different from place to place In the event of any problems please contact an IT service provider

Remote access activated 1 Please call the KACO Hotline to make an appointment for activation of energy management

Configuration and Operation

Page 28 Operating instructions Powador-gridsave_EN

Authorised electrician

8 Configuration and Operation

81 ControlsThe battery system is fitted with a touchscreen which allows it to be controlled very precisely In normal operation the display is switched off Touching the screen activates the display and after a configurable period of time without being touched the dis-play will deactivate If the screen-save function is switched off the touchscreen will be on continuously

NOTEDepending on the tolerances of the measuring elements the measured and displayed values are not always the actual values However the measuring elements ensure maximum solar yield Due to these tolerances the daily yields shown on the touchscreen may deviate from the values on the grid operatorrsquos feed-in meter by up to 15

3

1

45

2

Figure 15 Overview (home screen)

Key

1 Home button 4 Current time

2 System components 5 Menu name

3 More information

811 Information about the system

Open start screen View changesjumps to the home screen

Show component detail Parameters of the selected component

Settings Define settings for the active user

raquo Displays settings

Configuration and Operation

Operating instructions Powador-gridsave_EN Page 29

Controls Left arrow jump back to previous menu item Up and down arrows navigate through the menu or change a value

Left arrow displayed value is reduced by one increment Right arrow displayed value is increased by one increment or change to the submenu

Display fields Grey box Text or figures (not selectable) Blue box Calls up submenu for the display in question

Activate and deactivate Activate function by ticking the box

Table 6 Information about the system

812 System components

PV generator Display of the current generator data

power voltage current temperature in the inverter

Battery Display of the current battery status

power (charging or discharging) voltage current charge status available capacity temperature of battery

Grid Display of the following either fed-in or drawn from the grid

power voltage current for phase L1-L3 total output frequency

Consumer (load) Display of the consumer data

power voltage current for phase L1-L3 total output

Energy flow raquo Displays the current energy flow in the system

Table 7 Information about system components

Configuration and Operation

Page 30 Operating instructions Powador-gridsave_EN

813 Menu structure

Icons used

Display menu Submenu

Option menu

Menu Submenu Display setting

Action in this menumeaning

PV generator Details

Power Displays the current DC-side power

Voltage Displays the current DC-side voltage

Current Displays the current DC-side amperage

Temp inverter

Displays the current temperature in the inverter housing

Battery Details

Power Displays the current AC-side power

Voltage Displays the current AC-side voltage

Current Displays the current AC-side amperage

Charge status Displays the current charge status

Capacity Displays the current battery capacity

Temperature Displays the current measured temperature of the battery

Grid Details

Power Displays the current AC-side power being drawn or fed-in

Voltage Displays the AC-side voltage being applied

Current Displays the current AC-side amperage being drawn or fed-in

Total output Displays the current AC-side total output being drawn or fed-in

Frequency Displays the frequency currently being applied to the grid junction

Consumer (load) Details

Power Displays the current AC-side power being drawn

Voltage Displays the current AC-side voltage being applied

Current Displays the current AC-side amperage being drawn

Total output Displays the current AC-side total output being drawn

Configuration and Operation

Operating instructions Powador-gridsave_EN Page 31

Menu Submenu Display setting

Action in this menumeaning

Settings

Country amp directive display

Display of the country settings voltage directives and grid type

Select menu language

DateTime Specify time zone date format and date and time

Screen Activate screen-save function and set the delay period

Network settings

Display of the network settings Configure network settings Once the DHCP server becomes available the IP

address subnet mask gateway and DNS server are automatically applied and the aforemen-tioned menu items are hidden

Off DHCP deactivated make settings manually

Version Displays the installed software version and built-in HW components (inverter BBC battery)

Vendor The touchscreen shows information about the device vendor

NOTEAs changes to the software are possible after the manual has been printed the illustrations and descriptions of the functions in these operating instructions may deviate from the software Please therefore note the current Application Notes on our website

MaintenanceTroubleshooting

Page 32 Operating instructions Powador-gridsave_EN

9 MaintenanceTroubleshooting

91 Visual inspectionInspect the device and the cables for visible external damage and note the operating status display In case of damage notify your installer Repairs may only be carried out by authorised electricians

NOTEThe battery system should be checked for proper operation by a qualified electrician at regular intervals

92 Cleaning the device

DANGERLethal voltages in the battery systemSerious injuries or death can result if moisture enters the system rsaquo Only use completely dry objects to clean the battery system rsaquo Only clean the outside of the battery system

Cleaning the battery system Do not use compressed air Use a vacuum cleaner or a soft brush to remove dust from the fan cover and from the top of the inverter on a

regular basis Remove dust from the ventilation inlets if necessary

MaintenanceTroubleshooting

Operating instructions Powador-gridsave_EN Page 33

Authorised electrician

93 Maintenance

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched The device is only permitted to be opened or serviced by an authorised electrician rsaquo Observe all safety regulations and the current technical connection specifications from the relevant

power supply company rsaquo Disconnect the AC and DC sides rsaquo Secure the AC and DC sides from being inadvertently switched back on rsaquo Only then should the device be opened rsaquo After shutdown wait at least 30 minutes before working on the device

CAUTIONDestruction of the DC connectionThe connection terminals can be destroyed by arcing if disconnected while still live rsaquo It is absolutely essential that the shutdown sequence be carried out in the correct order (See sec-

tion 111 on page 35)

94 Faults

941 Procedure

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched

When a fault occurs notify an appropriately authorised and qualified electrician or KACO new energy GmbH Service

Service

Page 34 Operating instructions Powador-gridsave_EN

10 ServiceIf 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 efficientlybull Serial nobull SW version of the components (the software version can be found in the Settings menu using the EMS)bull Module type and string circuitbull Date of installation Start-up reportbull Consignment identification Delivery address Contact person (with telephone number)bull Information about the accessibility of the installation site

Any additional costs arising from unfavourable structural or mounting conditions shall be billed to the customer

You can find our warranty conditions on our websitehttpkaco-newenergycomservicewarrantyFrom there you can easily navigate to our international websites by clicking on the appropriate flag

Please use our website to register your unit immediatelyYou can also select the appropriate flag on this page to access the website for your own countryIn this manner you can assist us in providing you with the quickest service possible Note The maximum length of the warranty is based on the currently applicable national warranty conditions

We have prepared a template for complaints This can be found at httpskaco-newenergycomservicecustomer-service

Hotlines

Technical troubleshooting Technical consultation

Inverters and battery systems ()

+49 (0) 71323818-660 +49 (0) 71323818-660

Data logging and accessories +49 (0) 71323818-690 +49 (0) 71323818-690

Construction site emergency () +49 (0) 71323818-630

Customer help desk Monday to Friday from 730 am to 530 pm (CET)

() Also on Saturdays from 800 am to 200 pm (CET)

ShutdownDisassembly

Operating instructions Powador-gridsave_EN Page 35

11 ShutdownDisassembly

111 Switching off the device

DANGERLethal voltages are still present in the terminals and cables even after switching off and discon-nection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched rsaquo Complete de-energisation only occurs if the bulk power supply is switched off upstream of the bat-

tery system

DANGERDestruction of the DC plug connectorDC plug connectors can be destroyed by arcing if disconnected while still live rsaquo It is absolutely essential that the following shutdown sequence is observed

1111 Step 1 Shutting down the PV system

1 Switch off any optional external PV isolator switches2 Set the internal DC isolator switch to OFF raquo The inverter and battery charging unit battery backup converter (BBC) are disconnected

1112 Step 2 Disconnect the batteries

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

1113 Step 3 Disconnect the AC supply

1 Connect external isolation means to the device2 Switch off the circuit breaker 3 Switch off the residual current circuit breaker raquo The battery system is switched off

1114 Step 4 AC home power grid

1 Shutdown the AC home power grid using the AC main switch raquo The battery system can be uninstalled

Disposal

Page 36 Operating instructions Powador-gridsave_EN

112 Uninstalling the device

NOTETo uninstall follow the same sequence as for installation but in reverse order

Switch off the device1 Unlock and open the housing door2 Remove the upper cover3 Release the DC and AC cables from the connection terminals4 Pull out the cables raquo The battery system is uninstalled Continue with the disassembly

113 Disassembling the device

NOTETo disassemble follow the same sequence as for assembly but in reverse order

Switch off the device1 Uninstall the components2 Remove the fastening from the device3 Securely pack up the battery system if it is to be used later

or have the battery system disposed of in accordance with section 12 on page 36

12 DisposalFor the most part both the battery system and the corresponding transport packaging are made from recyclable raw materialsBatteries and components Do not dispose of faulty batteries or the components together with household waste Ensure that the old device and accessories are disposed of in a proper mannerPackaging Ensure that the transport packaging is disposed of properlyBatteriesUsed or faulty batteries must be transported in special packaging If you need such packaging please contact the KACO Hotline

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

Appendix

Operating instructions Powador-gridsave_EN Page 37

13 Appendix

EU Declaration of Conformity

Vendorrsquos name and address

KACO new energy GmbH Carl-Zeiss-Straszlige 1 74172 Neckarsulm Germany

Product description Battery system

Type designation Powador-gridsave 135 kWh 6400 Powador-gridsave 135 kWh 8000

Powador-gridsave 270 kWh 6400 Powador-gridsave 270 kWh 8000

Powador-gridsave 405 kWh 6400 Powador-gridsave 405 kWh 8000

Powador-gridsave 540 kWh 6400 Powador-gridsave 540 kWh 8000

Powador-gridsave 577 kWh 6400 Powador-gridsave 577 kWh 8000

Powador-gridsave 675 kWh 6400 Powador-gridsave 675 kWh 8000

This is to confirm that the units listed above comply with the protection requirements set forth in the Directive of the Council of the European Union of 15th December 2004 on the harmonisation of the laws of the member states relating to Electromagnetic Compatibility (2004108EC) and the Low Voltage Directive (200695EC)The units are compliant with the following standards

200695EC ldquoDirective relating to electrical equipment designed for use within specific voltage limitsrdquo

Safety of the unitIEC 62109-12010IEC 62109-22011

2004108EC ldquoDirective relating to electromagneticcompatibilityrdquo

Interference immunityEN 61000-6-22005 Emitted interferenceEN 61000-6-32007

Secondary effects on the gridEN 61000-3-112000EN 61000-3-122005

The types mentioned above are therefore labelled with the CE markUnauthorised modifications to the supplied units andor any use of the units that is contrary to their intended use render this Declaration of Conformity null and void

Neckarsulm 0711 2013KACO new energy GmbH

pp Volker DietrichEnergy systems engineering management

Disposal

Page 38 Operating instructions Powador-gridsave_EN

Carl-Zeiss-Straszlige 1 middot 74172 Neckarsulm middot Germany middot Phone +49 7132 3818-0 middot Fax +49 7132 3818-703 middot infokaco-newenergyde middot wwwkaco-newenergyde

The

text

and

figu

res

refle

ct th

e cu

rren

t tec

hnic

al s

tate

at t

he ti

me

of p

rintin

g S

ubje

ct to

tech

nica

l cha

nges

Err

ors

and

omis

sion

s ex

cept

ed

3006

856-

01-1

4030

5

  • 1General Information
    • 11About this document
    • 12Name plate
    • 13Additional information
    • 14Intended use
      • 2Safety
        • 21Protection features
          • 3Description
            • 31Mode of Operation
            • 32Summary of the components
              • 4Technical Data
                • 41Electrical data
                • 42Mechanical data
                  • 5Transportation and Delivery
                    • 51Delivery
                    • 52Storage
                    • 53Transportation
                      • 6Assembling the device
                        • 61Installation
                        • 62Installing components
                          • 7Installing the device
                            • 71Opening the connection area
                            • 72Making the electrical connection
                            • 73Connecting the interfaces
                            • 74Sealing the connection area
                            • 75Starting up
                            • 76Standard configuration
                              • 8Configuration and Operation
                                • 81Controls
                                  • 9MaintenanceTroubleshooting
                                    • 91Visual inspection
                                    • 92Cleaning the device
                                    • 93Maintenance
                                    • 94Faults
                                      • 10Service
                                      • 11ShutdownDisassembly
                                        • 111Switching off the device
                                        • 112Uninstalling the device
                                        • 113Disassembling the device
                                          • 12Disposal
                                          • 13Appendix

Installing the device

Page 24 Operating instructions Powador-gridsave_EN

Authorised electrician

722 Connecting the PV generator

Connect the PV generator on the left in the connection area (Figure 13 on page 21) Use the provided M16 cable fittings A maximum of two strings can be connected For this reason a DC string fuse can be dispensed with

DANGERRisk of fatal injury due to contact voltagesRemoving the cables from the terminals without first disconnecting the PV generator from the device can cause serious damage to health or damage to the system rsaquo During installation Electrically disconnect the DC positive and DC negative from the protective

earth (PE) rsaquo Completely de-energise the system (AC home power grid AC circuit breaker residual current circuit

breaker DC isolator switch) rsaquo Disconnect the battery system from the PV generator using the integrated DC isolator switch rsaquo Remove DC plug connectors

NOTEIn accordance with IEC 61730 Class A connected PV modules must be dimensioned for the DC system voltage provided and at least for the value of the AC grid voltage

7221 Before connecting

Ensure that there is no ground fault1 Determine the DC voltage between the

ndash protective earth (PE) and the positive cable of the PV generator and between the ndash protective earth (PE) and the negative cable of the PV generator

If stable voltages can be measured there is a ground fault in the DC generator or its wiring The ratio between the measured voltages gives an indication as to the location of this fault

2 Rectify any faults before taking further measurements3 Determine the electrical resistance between the

ndash protective earth (PE) and the positive cable of the PV generator and between the ndash protective earth (PE) and the negative cable of the PV generator

In addition ensure that the PV generator has a total insulation resistance of more than 20 MOhm since the inverter will not feed in if the insulation resistance is too low

4 Rectify any faults before connecting the DC generator

7222 Connecting the PV generator

DANGERRisk of fatal injury due to electric shockSevere injury or death will result if the live connections are touched When there is solar radiation DC voltage will be present at the open ends of the DC cables rsaquo Do not touch the exposed ends of the cables rsaquo Avoid short circuits

Installing the device

Operating instructions Powador-gridsave_EN Page 25

Authorised electrician

Connecting the PV generator Use cables with the correct cross-section

1 Remove cable fittings for DC connection2 Remove the outer cladding of the DC cables3 Insert the DC cables through the cable fittings into the connection area4 Strip the insulation from the DC cables5 Remove connection terminals6 Connect the cables in line with the terminal labels (See Figure 13 on page 21)7 Close the connection terminals8 Check that all connected cables are securely fitted9 Tighten the cable fittings10 To meet the requirements of protection rating IP21 close the unused cable fittings with blind caps raquo The PV generator is connected to the inverter

73 Connecting the interfaces

731 Ethernet interface

Pre-assembled Ethernet cables can be connected using the RJ45 socket in the connection space

Connecting the Ethernet cable1 Remove closure cap from RJ45 socket2 Connect the Ethernet cable3 The energy management system can now obtain an IP address by DHCP and is also available via this in the

network

NOTEThe network settings can be amended later in the Settings menu using the EMS

NOTEUse a suitable category 5 network cable The maximum length of a network segment is 100 m Ensure that the cable is correctly assigned The Ethernet connection of the battery system supports auto-sensing You can use both crossed and 11 configured Ethernet connection cables

74 Sealing the connection area

1 Finally check the cabling2 Ensure that all cables are firmly mounted3 Check that the cable fitting is secure and tighten if necessary4 Remove cable offcuts and particles of dirt or dust5 Fit the cover and slide back until it engages into position6 Check that the position is correct7 Screw the fastening screw onto the front of the cover

Installing the device

Page 26 Operating instructions Powador-gridsave_EN

Authorised electrician

75 Starting up

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched Only appropriately qualified and authorised electricians may open install or maintain the battery system rsaquo Keep the front doors and covers closed during operation

NOTEInitial start-up should be carried out using the available public AC grid

76 Standard configuration

Factory settingsCountry configuration Germany

Grid guidelines Low voltage directive

Language German

Time UTC +1 Central European Time

User Standard

Network parameters DHCP (network settings will be obtained automatically from the router)

NOTEPlease state the desired power limitation (60 or 70 of the PV system capacity) when you order For other variations please notify your KACO contact so that the parameters can be set at the factory prior to delivery

Installing the device

Operating instructions Powador-gridsave_EN Page 27

Authorised electrician

761 Step 1 AC home power grid

Check all cables and connections before starting up1 Switch on the AC home power grid using the AC main switch raquo Powador-protect measurement and control unit starts up and monitors the AC grid raquo Two green LEDs indicate that the grid parameters are met raquo After a further 60 seconds (shortly after the backlighting in the Powador-protect goes out) the Powador-pro-

tect will switch on the home grid2 Configure Powador-protect according to the enclosed Powador-protect instructions

(The instructions are also available on the website at wwwkaconewenergyde) raquo The AC power is supplied in the normal way by the public grid

762 Step 2 AC supply from the battery system

Check all cables and connections before starting up1 Remove external isolation means from the device2 Switch on the circuit breaker raquo The LCD touchscreen on the front panel comes on and the energy management system (EMS) starts up

3 Switch on the residual current circuit breaker raquo The battery system starts up

763 Step 3 Switch on the PV system

1 Switch on any optional external PV isolator switches2 Set the internal DC isolator switch to ON raquo The inverter and the battery charging unit battery backup converter (BBC) are connected to the PV system raquo The device monitors the PV voltage for approx 60 seconds then optimisation of internal consumption takes

place

764 Step 4 Switch on batteries

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

765 Step 5 Activate energy management

NOTEKACO new energy cannot provide any support for problems regarding the IT infrastructure (eg router configuration IP address assignment ports etc) as the structure settings and configuration of the network environment can be complex and very different from place to place In the event of any problems please contact an IT service provider

Remote access activated 1 Please call the KACO Hotline to make an appointment for activation of energy management

Configuration and Operation

Page 28 Operating instructions Powador-gridsave_EN

Authorised electrician

8 Configuration and Operation

81 ControlsThe battery system is fitted with a touchscreen which allows it to be controlled very precisely In normal operation the display is switched off Touching the screen activates the display and after a configurable period of time without being touched the dis-play will deactivate If the screen-save function is switched off the touchscreen will be on continuously

NOTEDepending on the tolerances of the measuring elements the measured and displayed values are not always the actual values However the measuring elements ensure maximum solar yield Due to these tolerances the daily yields shown on the touchscreen may deviate from the values on the grid operatorrsquos feed-in meter by up to 15

3

1

45

2

Figure 15 Overview (home screen)

Key

1 Home button 4 Current time

2 System components 5 Menu name

3 More information

811 Information about the system

Open start screen View changesjumps to the home screen

Show component detail Parameters of the selected component

Settings Define settings for the active user

raquo Displays settings

Configuration and Operation

Operating instructions Powador-gridsave_EN Page 29

Controls Left arrow jump back to previous menu item Up and down arrows navigate through the menu or change a value

Left arrow displayed value is reduced by one increment Right arrow displayed value is increased by one increment or change to the submenu

Display fields Grey box Text or figures (not selectable) Blue box Calls up submenu for the display in question

Activate and deactivate Activate function by ticking the box

Table 6 Information about the system

812 System components

PV generator Display of the current generator data

power voltage current temperature in the inverter

Battery Display of the current battery status

power (charging or discharging) voltage current charge status available capacity temperature of battery

Grid Display of the following either fed-in or drawn from the grid

power voltage current for phase L1-L3 total output frequency

Consumer (load) Display of the consumer data

power voltage current for phase L1-L3 total output

Energy flow raquo Displays the current energy flow in the system

Table 7 Information about system components

Configuration and Operation

Page 30 Operating instructions Powador-gridsave_EN

813 Menu structure

Icons used

Display menu Submenu

Option menu

Menu Submenu Display setting

Action in this menumeaning

PV generator Details

Power Displays the current DC-side power

Voltage Displays the current DC-side voltage

Current Displays the current DC-side amperage

Temp inverter

Displays the current temperature in the inverter housing

Battery Details

Power Displays the current AC-side power

Voltage Displays the current AC-side voltage

Current Displays the current AC-side amperage

Charge status Displays the current charge status

Capacity Displays the current battery capacity

Temperature Displays the current measured temperature of the battery

Grid Details

Power Displays the current AC-side power being drawn or fed-in

Voltage Displays the AC-side voltage being applied

Current Displays the current AC-side amperage being drawn or fed-in

Total output Displays the current AC-side total output being drawn or fed-in

Frequency Displays the frequency currently being applied to the grid junction

Consumer (load) Details

Power Displays the current AC-side power being drawn

Voltage Displays the current AC-side voltage being applied

Current Displays the current AC-side amperage being drawn

Total output Displays the current AC-side total output being drawn

Configuration and Operation

Operating instructions Powador-gridsave_EN Page 31

Menu Submenu Display setting

Action in this menumeaning

Settings

Country amp directive display

Display of the country settings voltage directives and grid type

Select menu language

DateTime Specify time zone date format and date and time

Screen Activate screen-save function and set the delay period

Network settings

Display of the network settings Configure network settings Once the DHCP server becomes available the IP

address subnet mask gateway and DNS server are automatically applied and the aforemen-tioned menu items are hidden

Off DHCP deactivated make settings manually

Version Displays the installed software version and built-in HW components (inverter BBC battery)

Vendor The touchscreen shows information about the device vendor

NOTEAs changes to the software are possible after the manual has been printed the illustrations and descriptions of the functions in these operating instructions may deviate from the software Please therefore note the current Application Notes on our website

MaintenanceTroubleshooting

Page 32 Operating instructions Powador-gridsave_EN

9 MaintenanceTroubleshooting

91 Visual inspectionInspect the device and the cables for visible external damage and note the operating status display In case of damage notify your installer Repairs may only be carried out by authorised electricians

NOTEThe battery system should be checked for proper operation by a qualified electrician at regular intervals

92 Cleaning the device

DANGERLethal voltages in the battery systemSerious injuries or death can result if moisture enters the system rsaquo Only use completely dry objects to clean the battery system rsaquo Only clean the outside of the battery system

Cleaning the battery system Do not use compressed air Use a vacuum cleaner or a soft brush to remove dust from the fan cover and from the top of the inverter on a

regular basis Remove dust from the ventilation inlets if necessary

MaintenanceTroubleshooting

Operating instructions Powador-gridsave_EN Page 33

Authorised electrician

93 Maintenance

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched The device is only permitted to be opened or serviced by an authorised electrician rsaquo Observe all safety regulations and the current technical connection specifications from the relevant

power supply company rsaquo Disconnect the AC and DC sides rsaquo Secure the AC and DC sides from being inadvertently switched back on rsaquo Only then should the device be opened rsaquo After shutdown wait at least 30 minutes before working on the device

CAUTIONDestruction of the DC connectionThe connection terminals can be destroyed by arcing if disconnected while still live rsaquo It is absolutely essential that the shutdown sequence be carried out in the correct order (See sec-

tion 111 on page 35)

94 Faults

941 Procedure

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched

When a fault occurs notify an appropriately authorised and qualified electrician or KACO new energy GmbH Service

Service

Page 34 Operating instructions Powador-gridsave_EN

10 ServiceIf 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 efficientlybull Serial nobull SW version of the components (the software version can be found in the Settings menu using the EMS)bull Module type and string circuitbull Date of installation Start-up reportbull Consignment identification Delivery address Contact person (with telephone number)bull Information about the accessibility of the installation site

Any additional costs arising from unfavourable structural or mounting conditions shall be billed to the customer

You can find our warranty conditions on our websitehttpkaco-newenergycomservicewarrantyFrom there you can easily navigate to our international websites by clicking on the appropriate flag

Please use our website to register your unit immediatelyYou can also select the appropriate flag on this page to access the website for your own countryIn this manner you can assist us in providing you with the quickest service possible Note The maximum length of the warranty is based on the currently applicable national warranty conditions

We have prepared a template for complaints This can be found at httpskaco-newenergycomservicecustomer-service

Hotlines

Technical troubleshooting Technical consultation

Inverters and battery systems ()

+49 (0) 71323818-660 +49 (0) 71323818-660

Data logging and accessories +49 (0) 71323818-690 +49 (0) 71323818-690

Construction site emergency () +49 (0) 71323818-630

Customer help desk Monday to Friday from 730 am to 530 pm (CET)

() Also on Saturdays from 800 am to 200 pm (CET)

ShutdownDisassembly

Operating instructions Powador-gridsave_EN Page 35

11 ShutdownDisassembly

111 Switching off the device

DANGERLethal voltages are still present in the terminals and cables even after switching off and discon-nection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched rsaquo Complete de-energisation only occurs if the bulk power supply is switched off upstream of the bat-

tery system

DANGERDestruction of the DC plug connectorDC plug connectors can be destroyed by arcing if disconnected while still live rsaquo It is absolutely essential that the following shutdown sequence is observed

1111 Step 1 Shutting down the PV system

1 Switch off any optional external PV isolator switches2 Set the internal DC isolator switch to OFF raquo The inverter and battery charging unit battery backup converter (BBC) are disconnected

1112 Step 2 Disconnect the batteries

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

1113 Step 3 Disconnect the AC supply

1 Connect external isolation means to the device2 Switch off the circuit breaker 3 Switch off the residual current circuit breaker raquo The battery system is switched off

1114 Step 4 AC home power grid

1 Shutdown the AC home power grid using the AC main switch raquo The battery system can be uninstalled

Disposal

Page 36 Operating instructions Powador-gridsave_EN

112 Uninstalling the device

NOTETo uninstall follow the same sequence as for installation but in reverse order

Switch off the device1 Unlock and open the housing door2 Remove the upper cover3 Release the DC and AC cables from the connection terminals4 Pull out the cables raquo The battery system is uninstalled Continue with the disassembly

113 Disassembling the device

NOTETo disassemble follow the same sequence as for assembly but in reverse order

Switch off the device1 Uninstall the components2 Remove the fastening from the device3 Securely pack up the battery system if it is to be used later

or have the battery system disposed of in accordance with section 12 on page 36

12 DisposalFor the most part both the battery system and the corresponding transport packaging are made from recyclable raw materialsBatteries and components Do not dispose of faulty batteries or the components together with household waste Ensure that the old device and accessories are disposed of in a proper mannerPackaging Ensure that the transport packaging is disposed of properlyBatteriesUsed or faulty batteries must be transported in special packaging If you need such packaging please contact the KACO Hotline

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

Appendix

Operating instructions Powador-gridsave_EN Page 37

13 Appendix

EU Declaration of Conformity

Vendorrsquos name and address

KACO new energy GmbH Carl-Zeiss-Straszlige 1 74172 Neckarsulm Germany

Product description Battery system

Type designation Powador-gridsave 135 kWh 6400 Powador-gridsave 135 kWh 8000

Powador-gridsave 270 kWh 6400 Powador-gridsave 270 kWh 8000

Powador-gridsave 405 kWh 6400 Powador-gridsave 405 kWh 8000

Powador-gridsave 540 kWh 6400 Powador-gridsave 540 kWh 8000

Powador-gridsave 577 kWh 6400 Powador-gridsave 577 kWh 8000

Powador-gridsave 675 kWh 6400 Powador-gridsave 675 kWh 8000

This is to confirm that the units listed above comply with the protection requirements set forth in the Directive of the Council of the European Union of 15th December 2004 on the harmonisation of the laws of the member states relating to Electromagnetic Compatibility (2004108EC) and the Low Voltage Directive (200695EC)The units are compliant with the following standards

200695EC ldquoDirective relating to electrical equipment designed for use within specific voltage limitsrdquo

Safety of the unitIEC 62109-12010IEC 62109-22011

2004108EC ldquoDirective relating to electromagneticcompatibilityrdquo

Interference immunityEN 61000-6-22005 Emitted interferenceEN 61000-6-32007

Secondary effects on the gridEN 61000-3-112000EN 61000-3-122005

The types mentioned above are therefore labelled with the CE markUnauthorised modifications to the supplied units andor any use of the units that is contrary to their intended use render this Declaration of Conformity null and void

Neckarsulm 0711 2013KACO new energy GmbH

pp Volker DietrichEnergy systems engineering management

Disposal

Page 38 Operating instructions Powador-gridsave_EN

Carl-Zeiss-Straszlige 1 middot 74172 Neckarsulm middot Germany middot Phone +49 7132 3818-0 middot Fax +49 7132 3818-703 middot infokaco-newenergyde middot wwwkaco-newenergyde

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Err

ors

and

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3006

856-

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4030

5

  • 1General Information
    • 11About this document
    • 12Name plate
    • 13Additional information
    • 14Intended use
      • 2Safety
        • 21Protection features
          • 3Description
            • 31Mode of Operation
            • 32Summary of the components
              • 4Technical Data
                • 41Electrical data
                • 42Mechanical data
                  • 5Transportation and Delivery
                    • 51Delivery
                    • 52Storage
                    • 53Transportation
                      • 6Assembling the device
                        • 61Installation
                        • 62Installing components
                          • 7Installing the device
                            • 71Opening the connection area
                            • 72Making the electrical connection
                            • 73Connecting the interfaces
                            • 74Sealing the connection area
                            • 75Starting up
                            • 76Standard configuration
                              • 8Configuration and Operation
                                • 81Controls
                                  • 9MaintenanceTroubleshooting
                                    • 91Visual inspection
                                    • 92Cleaning the device
                                    • 93Maintenance
                                    • 94Faults
                                      • 10Service
                                      • 11ShutdownDisassembly
                                        • 111Switching off the device
                                        • 112Uninstalling the device
                                        • 113Disassembling the device
                                          • 12Disposal
                                          • 13Appendix

Installing the device

Operating instructions Powador-gridsave_EN Page 25

Authorised electrician

Connecting the PV generator Use cables with the correct cross-section

1 Remove cable fittings for DC connection2 Remove the outer cladding of the DC cables3 Insert the DC cables through the cable fittings into the connection area4 Strip the insulation from the DC cables5 Remove connection terminals6 Connect the cables in line with the terminal labels (See Figure 13 on page 21)7 Close the connection terminals8 Check that all connected cables are securely fitted9 Tighten the cable fittings10 To meet the requirements of protection rating IP21 close the unused cable fittings with blind caps raquo The PV generator is connected to the inverter

73 Connecting the interfaces

731 Ethernet interface

Pre-assembled Ethernet cables can be connected using the RJ45 socket in the connection space

Connecting the Ethernet cable1 Remove closure cap from RJ45 socket2 Connect the Ethernet cable3 The energy management system can now obtain an IP address by DHCP and is also available via this in the

network

NOTEThe network settings can be amended later in the Settings menu using the EMS

NOTEUse a suitable category 5 network cable The maximum length of a network segment is 100 m Ensure that the cable is correctly assigned The Ethernet connection of the battery system supports auto-sensing You can use both crossed and 11 configured Ethernet connection cables

74 Sealing the connection area

1 Finally check the cabling2 Ensure that all cables are firmly mounted3 Check that the cable fitting is secure and tighten if necessary4 Remove cable offcuts and particles of dirt or dust5 Fit the cover and slide back until it engages into position6 Check that the position is correct7 Screw the fastening screw onto the front of the cover

Installing the device

Page 26 Operating instructions Powador-gridsave_EN

Authorised electrician

75 Starting up

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched Only appropriately qualified and authorised electricians may open install or maintain the battery system rsaquo Keep the front doors and covers closed during operation

NOTEInitial start-up should be carried out using the available public AC grid

76 Standard configuration

Factory settingsCountry configuration Germany

Grid guidelines Low voltage directive

Language German

Time UTC +1 Central European Time

User Standard

Network parameters DHCP (network settings will be obtained automatically from the router)

NOTEPlease state the desired power limitation (60 or 70 of the PV system capacity) when you order For other variations please notify your KACO contact so that the parameters can be set at the factory prior to delivery

Installing the device

Operating instructions Powador-gridsave_EN Page 27

Authorised electrician

761 Step 1 AC home power grid

Check all cables and connections before starting up1 Switch on the AC home power grid using the AC main switch raquo Powador-protect measurement and control unit starts up and monitors the AC grid raquo Two green LEDs indicate that the grid parameters are met raquo After a further 60 seconds (shortly after the backlighting in the Powador-protect goes out) the Powador-pro-

tect will switch on the home grid2 Configure Powador-protect according to the enclosed Powador-protect instructions

(The instructions are also available on the website at wwwkaconewenergyde) raquo The AC power is supplied in the normal way by the public grid

762 Step 2 AC supply from the battery system

Check all cables and connections before starting up1 Remove external isolation means from the device2 Switch on the circuit breaker raquo The LCD touchscreen on the front panel comes on and the energy management system (EMS) starts up

3 Switch on the residual current circuit breaker raquo The battery system starts up

763 Step 3 Switch on the PV system

1 Switch on any optional external PV isolator switches2 Set the internal DC isolator switch to ON raquo The inverter and the battery charging unit battery backup converter (BBC) are connected to the PV system raquo The device monitors the PV voltage for approx 60 seconds then optimisation of internal consumption takes

place

764 Step 4 Switch on batteries

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

765 Step 5 Activate energy management

NOTEKACO new energy cannot provide any support for problems regarding the IT infrastructure (eg router configuration IP address assignment ports etc) as the structure settings and configuration of the network environment can be complex and very different from place to place In the event of any problems please contact an IT service provider

Remote access activated 1 Please call the KACO Hotline to make an appointment for activation of energy management

Configuration and Operation

Page 28 Operating instructions Powador-gridsave_EN

Authorised electrician

8 Configuration and Operation

81 ControlsThe battery system is fitted with a touchscreen which allows it to be controlled very precisely In normal operation the display is switched off Touching the screen activates the display and after a configurable period of time without being touched the dis-play will deactivate If the screen-save function is switched off the touchscreen will be on continuously

NOTEDepending on the tolerances of the measuring elements the measured and displayed values are not always the actual values However the measuring elements ensure maximum solar yield Due to these tolerances the daily yields shown on the touchscreen may deviate from the values on the grid operatorrsquos feed-in meter by up to 15

3

1

45

2

Figure 15 Overview (home screen)

Key

1 Home button 4 Current time

2 System components 5 Menu name

3 More information

811 Information about the system

Open start screen View changesjumps to the home screen

Show component detail Parameters of the selected component

Settings Define settings for the active user

raquo Displays settings

Configuration and Operation

Operating instructions Powador-gridsave_EN Page 29

Controls Left arrow jump back to previous menu item Up and down arrows navigate through the menu or change a value

Left arrow displayed value is reduced by one increment Right arrow displayed value is increased by one increment or change to the submenu

Display fields Grey box Text or figures (not selectable) Blue box Calls up submenu for the display in question

Activate and deactivate Activate function by ticking the box

Table 6 Information about the system

812 System components

PV generator Display of the current generator data

power voltage current temperature in the inverter

Battery Display of the current battery status

power (charging or discharging) voltage current charge status available capacity temperature of battery

Grid Display of the following either fed-in or drawn from the grid

power voltage current for phase L1-L3 total output frequency

Consumer (load) Display of the consumer data

power voltage current for phase L1-L3 total output

Energy flow raquo Displays the current energy flow in the system

Table 7 Information about system components

Configuration and Operation

Page 30 Operating instructions Powador-gridsave_EN

813 Menu structure

Icons used

Display menu Submenu

Option menu

Menu Submenu Display setting

Action in this menumeaning

PV generator Details

Power Displays the current DC-side power

Voltage Displays the current DC-side voltage

Current Displays the current DC-side amperage

Temp inverter

Displays the current temperature in the inverter housing

Battery Details

Power Displays the current AC-side power

Voltage Displays the current AC-side voltage

Current Displays the current AC-side amperage

Charge status Displays the current charge status

Capacity Displays the current battery capacity

Temperature Displays the current measured temperature of the battery

Grid Details

Power Displays the current AC-side power being drawn or fed-in

Voltage Displays the AC-side voltage being applied

Current Displays the current AC-side amperage being drawn or fed-in

Total output Displays the current AC-side total output being drawn or fed-in

Frequency Displays the frequency currently being applied to the grid junction

Consumer (load) Details

Power Displays the current AC-side power being drawn

Voltage Displays the current AC-side voltage being applied

Current Displays the current AC-side amperage being drawn

Total output Displays the current AC-side total output being drawn

Configuration and Operation

Operating instructions Powador-gridsave_EN Page 31

Menu Submenu Display setting

Action in this menumeaning

Settings

Country amp directive display

Display of the country settings voltage directives and grid type

Select menu language

DateTime Specify time zone date format and date and time

Screen Activate screen-save function and set the delay period

Network settings

Display of the network settings Configure network settings Once the DHCP server becomes available the IP

address subnet mask gateway and DNS server are automatically applied and the aforemen-tioned menu items are hidden

Off DHCP deactivated make settings manually

Version Displays the installed software version and built-in HW components (inverter BBC battery)

Vendor The touchscreen shows information about the device vendor

NOTEAs changes to the software are possible after the manual has been printed the illustrations and descriptions of the functions in these operating instructions may deviate from the software Please therefore note the current Application Notes on our website

MaintenanceTroubleshooting

Page 32 Operating instructions Powador-gridsave_EN

9 MaintenanceTroubleshooting

91 Visual inspectionInspect the device and the cables for visible external damage and note the operating status display In case of damage notify your installer Repairs may only be carried out by authorised electricians

NOTEThe battery system should be checked for proper operation by a qualified electrician at regular intervals

92 Cleaning the device

DANGERLethal voltages in the battery systemSerious injuries or death can result if moisture enters the system rsaquo Only use completely dry objects to clean the battery system rsaquo Only clean the outside of the battery system

Cleaning the battery system Do not use compressed air Use a vacuum cleaner or a soft brush to remove dust from the fan cover and from the top of the inverter on a

regular basis Remove dust from the ventilation inlets if necessary

MaintenanceTroubleshooting

Operating instructions Powador-gridsave_EN Page 33

Authorised electrician

93 Maintenance

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched The device is only permitted to be opened or serviced by an authorised electrician rsaquo Observe all safety regulations and the current technical connection specifications from the relevant

power supply company rsaquo Disconnect the AC and DC sides rsaquo Secure the AC and DC sides from being inadvertently switched back on rsaquo Only then should the device be opened rsaquo After shutdown wait at least 30 minutes before working on the device

CAUTIONDestruction of the DC connectionThe connection terminals can be destroyed by arcing if disconnected while still live rsaquo It is absolutely essential that the shutdown sequence be carried out in the correct order (See sec-

tion 111 on page 35)

94 Faults

941 Procedure

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched

When a fault occurs notify an appropriately authorised and qualified electrician or KACO new energy GmbH Service

Service

Page 34 Operating instructions Powador-gridsave_EN

10 ServiceIf 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 efficientlybull Serial nobull SW version of the components (the software version can be found in the Settings menu using the EMS)bull Module type and string circuitbull Date of installation Start-up reportbull Consignment identification Delivery address Contact person (with telephone number)bull Information about the accessibility of the installation site

Any additional costs arising from unfavourable structural or mounting conditions shall be billed to the customer

You can find our warranty conditions on our websitehttpkaco-newenergycomservicewarrantyFrom there you can easily navigate to our international websites by clicking on the appropriate flag

Please use our website to register your unit immediatelyYou can also select the appropriate flag on this page to access the website for your own countryIn this manner you can assist us in providing you with the quickest service possible Note The maximum length of the warranty is based on the currently applicable national warranty conditions

We have prepared a template for complaints This can be found at httpskaco-newenergycomservicecustomer-service

Hotlines

Technical troubleshooting Technical consultation

Inverters and battery systems ()

+49 (0) 71323818-660 +49 (0) 71323818-660

Data logging and accessories +49 (0) 71323818-690 +49 (0) 71323818-690

Construction site emergency () +49 (0) 71323818-630

Customer help desk Monday to Friday from 730 am to 530 pm (CET)

() Also on Saturdays from 800 am to 200 pm (CET)

ShutdownDisassembly

Operating instructions Powador-gridsave_EN Page 35

11 ShutdownDisassembly

111 Switching off the device

DANGERLethal voltages are still present in the terminals and cables even after switching off and discon-nection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched rsaquo Complete de-energisation only occurs if the bulk power supply is switched off upstream of the bat-

tery system

DANGERDestruction of the DC plug connectorDC plug connectors can be destroyed by arcing if disconnected while still live rsaquo It is absolutely essential that the following shutdown sequence is observed

1111 Step 1 Shutting down the PV system

1 Switch off any optional external PV isolator switches2 Set the internal DC isolator switch to OFF raquo The inverter and battery charging unit battery backup converter (BBC) are disconnected

1112 Step 2 Disconnect the batteries

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

1113 Step 3 Disconnect the AC supply

1 Connect external isolation means to the device2 Switch off the circuit breaker 3 Switch off the residual current circuit breaker raquo The battery system is switched off

1114 Step 4 AC home power grid

1 Shutdown the AC home power grid using the AC main switch raquo The battery system can be uninstalled

Disposal

Page 36 Operating instructions Powador-gridsave_EN

112 Uninstalling the device

NOTETo uninstall follow the same sequence as for installation but in reverse order

Switch off the device1 Unlock and open the housing door2 Remove the upper cover3 Release the DC and AC cables from the connection terminals4 Pull out the cables raquo The battery system is uninstalled Continue with the disassembly

113 Disassembling the device

NOTETo disassemble follow the same sequence as for assembly but in reverse order

Switch off the device1 Uninstall the components2 Remove the fastening from the device3 Securely pack up the battery system if it is to be used later

or have the battery system disposed of in accordance with section 12 on page 36

12 DisposalFor the most part both the battery system and the corresponding transport packaging are made from recyclable raw materialsBatteries and components Do not dispose of faulty batteries or the components together with household waste Ensure that the old device and accessories are disposed of in a proper mannerPackaging Ensure that the transport packaging is disposed of properlyBatteriesUsed or faulty batteries must be transported in special packaging If you need such packaging please contact the KACO Hotline

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

Appendix

Operating instructions Powador-gridsave_EN Page 37

13 Appendix

EU Declaration of Conformity

Vendorrsquos name and address

KACO new energy GmbH Carl-Zeiss-Straszlige 1 74172 Neckarsulm Germany

Product description Battery system

Type designation Powador-gridsave 135 kWh 6400 Powador-gridsave 135 kWh 8000

Powador-gridsave 270 kWh 6400 Powador-gridsave 270 kWh 8000

Powador-gridsave 405 kWh 6400 Powador-gridsave 405 kWh 8000

Powador-gridsave 540 kWh 6400 Powador-gridsave 540 kWh 8000

Powador-gridsave 577 kWh 6400 Powador-gridsave 577 kWh 8000

Powador-gridsave 675 kWh 6400 Powador-gridsave 675 kWh 8000

This is to confirm that the units listed above comply with the protection requirements set forth in the Directive of the Council of the European Union of 15th December 2004 on the harmonisation of the laws of the member states relating to Electromagnetic Compatibility (2004108EC) and the Low Voltage Directive (200695EC)The units are compliant with the following standards

200695EC ldquoDirective relating to electrical equipment designed for use within specific voltage limitsrdquo

Safety of the unitIEC 62109-12010IEC 62109-22011

2004108EC ldquoDirective relating to electromagneticcompatibilityrdquo

Interference immunityEN 61000-6-22005 Emitted interferenceEN 61000-6-32007

Secondary effects on the gridEN 61000-3-112000EN 61000-3-122005

The types mentioned above are therefore labelled with the CE markUnauthorised modifications to the supplied units andor any use of the units that is contrary to their intended use render this Declaration of Conformity null and void

Neckarsulm 0711 2013KACO new energy GmbH

pp Volker DietrichEnergy systems engineering management

Disposal

Page 38 Operating instructions Powador-gridsave_EN

Carl-Zeiss-Straszlige 1 middot 74172 Neckarsulm middot Germany middot Phone +49 7132 3818-0 middot Fax +49 7132 3818-703 middot infokaco-newenergyde middot wwwkaco-newenergyde

The

text

and

figu

res

refle

ct th

e cu

rren

t tec

hnic

al s

tate

at t

he ti

me

of p

rintin

g S

ubje

ct to

tech

nica

l cha

nges

Err

ors

and

omis

sion

s ex

cept

ed

3006

856-

01-1

4030

5

  • 1General Information
    • 11About this document
    • 12Name plate
    • 13Additional information
    • 14Intended use
      • 2Safety
        • 21Protection features
          • 3Description
            • 31Mode of Operation
            • 32Summary of the components
              • 4Technical Data
                • 41Electrical data
                • 42Mechanical data
                  • 5Transportation and Delivery
                    • 51Delivery
                    • 52Storage
                    • 53Transportation
                      • 6Assembling the device
                        • 61Installation
                        • 62Installing components
                          • 7Installing the device
                            • 71Opening the connection area
                            • 72Making the electrical connection
                            • 73Connecting the interfaces
                            • 74Sealing the connection area
                            • 75Starting up
                            • 76Standard configuration
                              • 8Configuration and Operation
                                • 81Controls
                                  • 9MaintenanceTroubleshooting
                                    • 91Visual inspection
                                    • 92Cleaning the device
                                    • 93Maintenance
                                    • 94Faults
                                      • 10Service
                                      • 11ShutdownDisassembly
                                        • 111Switching off the device
                                        • 112Uninstalling the device
                                        • 113Disassembling the device
                                          • 12Disposal
                                          • 13Appendix

Installing the device

Page 26 Operating instructions Powador-gridsave_EN

Authorised electrician

75 Starting up

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched Only appropriately qualified and authorised electricians may open install or maintain the battery system rsaquo Keep the front doors and covers closed during operation

NOTEInitial start-up should be carried out using the available public AC grid

76 Standard configuration

Factory settingsCountry configuration Germany

Grid guidelines Low voltage directive

Language German

Time UTC +1 Central European Time

User Standard

Network parameters DHCP (network settings will be obtained automatically from the router)

NOTEPlease state the desired power limitation (60 or 70 of the PV system capacity) when you order For other variations please notify your KACO contact so that the parameters can be set at the factory prior to delivery

Installing the device

Operating instructions Powador-gridsave_EN Page 27

Authorised electrician

761 Step 1 AC home power grid

Check all cables and connections before starting up1 Switch on the AC home power grid using the AC main switch raquo Powador-protect measurement and control unit starts up and monitors the AC grid raquo Two green LEDs indicate that the grid parameters are met raquo After a further 60 seconds (shortly after the backlighting in the Powador-protect goes out) the Powador-pro-

tect will switch on the home grid2 Configure Powador-protect according to the enclosed Powador-protect instructions

(The instructions are also available on the website at wwwkaconewenergyde) raquo The AC power is supplied in the normal way by the public grid

762 Step 2 AC supply from the battery system

Check all cables and connections before starting up1 Remove external isolation means from the device2 Switch on the circuit breaker raquo The LCD touchscreen on the front panel comes on and the energy management system (EMS) starts up

3 Switch on the residual current circuit breaker raquo The battery system starts up

763 Step 3 Switch on the PV system

1 Switch on any optional external PV isolator switches2 Set the internal DC isolator switch to ON raquo The inverter and the battery charging unit battery backup converter (BBC) are connected to the PV system raquo The device monitors the PV voltage for approx 60 seconds then optimisation of internal consumption takes

place

764 Step 4 Switch on batteries

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

765 Step 5 Activate energy management

NOTEKACO new energy cannot provide any support for problems regarding the IT infrastructure (eg router configuration IP address assignment ports etc) as the structure settings and configuration of the network environment can be complex and very different from place to place In the event of any problems please contact an IT service provider

Remote access activated 1 Please call the KACO Hotline to make an appointment for activation of energy management

Configuration and Operation

Page 28 Operating instructions Powador-gridsave_EN

Authorised electrician

8 Configuration and Operation

81 ControlsThe battery system is fitted with a touchscreen which allows it to be controlled very precisely In normal operation the display is switched off Touching the screen activates the display and after a configurable period of time without being touched the dis-play will deactivate If the screen-save function is switched off the touchscreen will be on continuously

NOTEDepending on the tolerances of the measuring elements the measured and displayed values are not always the actual values However the measuring elements ensure maximum solar yield Due to these tolerances the daily yields shown on the touchscreen may deviate from the values on the grid operatorrsquos feed-in meter by up to 15

3

1

45

2

Figure 15 Overview (home screen)

Key

1 Home button 4 Current time

2 System components 5 Menu name

3 More information

811 Information about the system

Open start screen View changesjumps to the home screen

Show component detail Parameters of the selected component

Settings Define settings for the active user

raquo Displays settings

Configuration and Operation

Operating instructions Powador-gridsave_EN Page 29

Controls Left arrow jump back to previous menu item Up and down arrows navigate through the menu or change a value

Left arrow displayed value is reduced by one increment Right arrow displayed value is increased by one increment or change to the submenu

Display fields Grey box Text or figures (not selectable) Blue box Calls up submenu for the display in question

Activate and deactivate Activate function by ticking the box

Table 6 Information about the system

812 System components

PV generator Display of the current generator data

power voltage current temperature in the inverter

Battery Display of the current battery status

power (charging or discharging) voltage current charge status available capacity temperature of battery

Grid Display of the following either fed-in or drawn from the grid

power voltage current for phase L1-L3 total output frequency

Consumer (load) Display of the consumer data

power voltage current for phase L1-L3 total output

Energy flow raquo Displays the current energy flow in the system

Table 7 Information about system components

Configuration and Operation

Page 30 Operating instructions Powador-gridsave_EN

813 Menu structure

Icons used

Display menu Submenu

Option menu

Menu Submenu Display setting

Action in this menumeaning

PV generator Details

Power Displays the current DC-side power

Voltage Displays the current DC-side voltage

Current Displays the current DC-side amperage

Temp inverter

Displays the current temperature in the inverter housing

Battery Details

Power Displays the current AC-side power

Voltage Displays the current AC-side voltage

Current Displays the current AC-side amperage

Charge status Displays the current charge status

Capacity Displays the current battery capacity

Temperature Displays the current measured temperature of the battery

Grid Details

Power Displays the current AC-side power being drawn or fed-in

Voltage Displays the AC-side voltage being applied

Current Displays the current AC-side amperage being drawn or fed-in

Total output Displays the current AC-side total output being drawn or fed-in

Frequency Displays the frequency currently being applied to the grid junction

Consumer (load) Details

Power Displays the current AC-side power being drawn

Voltage Displays the current AC-side voltage being applied

Current Displays the current AC-side amperage being drawn

Total output Displays the current AC-side total output being drawn

Configuration and Operation

Operating instructions Powador-gridsave_EN Page 31

Menu Submenu Display setting

Action in this menumeaning

Settings

Country amp directive display

Display of the country settings voltage directives and grid type

Select menu language

DateTime Specify time zone date format and date and time

Screen Activate screen-save function and set the delay period

Network settings

Display of the network settings Configure network settings Once the DHCP server becomes available the IP

address subnet mask gateway and DNS server are automatically applied and the aforemen-tioned menu items are hidden

Off DHCP deactivated make settings manually

Version Displays the installed software version and built-in HW components (inverter BBC battery)

Vendor The touchscreen shows information about the device vendor

NOTEAs changes to the software are possible after the manual has been printed the illustrations and descriptions of the functions in these operating instructions may deviate from the software Please therefore note the current Application Notes on our website

MaintenanceTroubleshooting

Page 32 Operating instructions Powador-gridsave_EN

9 MaintenanceTroubleshooting

91 Visual inspectionInspect the device and the cables for visible external damage and note the operating status display In case of damage notify your installer Repairs may only be carried out by authorised electricians

NOTEThe battery system should be checked for proper operation by a qualified electrician at regular intervals

92 Cleaning the device

DANGERLethal voltages in the battery systemSerious injuries or death can result if moisture enters the system rsaquo Only use completely dry objects to clean the battery system rsaquo Only clean the outside of the battery system

Cleaning the battery system Do not use compressed air Use a vacuum cleaner or a soft brush to remove dust from the fan cover and from the top of the inverter on a

regular basis Remove dust from the ventilation inlets if necessary

MaintenanceTroubleshooting

Operating instructions Powador-gridsave_EN Page 33

Authorised electrician

93 Maintenance

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched The device is only permitted to be opened or serviced by an authorised electrician rsaquo Observe all safety regulations and the current technical connection specifications from the relevant

power supply company rsaquo Disconnect the AC and DC sides rsaquo Secure the AC and DC sides from being inadvertently switched back on rsaquo Only then should the device be opened rsaquo After shutdown wait at least 30 minutes before working on the device

CAUTIONDestruction of the DC connectionThe connection terminals can be destroyed by arcing if disconnected while still live rsaquo It is absolutely essential that the shutdown sequence be carried out in the correct order (See sec-

tion 111 on page 35)

94 Faults

941 Procedure

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched

When a fault occurs notify an appropriately authorised and qualified electrician or KACO new energy GmbH Service

Service

Page 34 Operating instructions Powador-gridsave_EN

10 ServiceIf 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 efficientlybull Serial nobull SW version of the components (the software version can be found in the Settings menu using the EMS)bull Module type and string circuitbull Date of installation Start-up reportbull Consignment identification Delivery address Contact person (with telephone number)bull Information about the accessibility of the installation site

Any additional costs arising from unfavourable structural or mounting conditions shall be billed to the customer

You can find our warranty conditions on our websitehttpkaco-newenergycomservicewarrantyFrom there you can easily navigate to our international websites by clicking on the appropriate flag

Please use our website to register your unit immediatelyYou can also select the appropriate flag on this page to access the website for your own countryIn this manner you can assist us in providing you with the quickest service possible Note The maximum length of the warranty is based on the currently applicable national warranty conditions

We have prepared a template for complaints This can be found at httpskaco-newenergycomservicecustomer-service

Hotlines

Technical troubleshooting Technical consultation

Inverters and battery systems ()

+49 (0) 71323818-660 +49 (0) 71323818-660

Data logging and accessories +49 (0) 71323818-690 +49 (0) 71323818-690

Construction site emergency () +49 (0) 71323818-630

Customer help desk Monday to Friday from 730 am to 530 pm (CET)

() Also on Saturdays from 800 am to 200 pm (CET)

ShutdownDisassembly

Operating instructions Powador-gridsave_EN Page 35

11 ShutdownDisassembly

111 Switching off the device

DANGERLethal voltages are still present in the terminals and cables even after switching off and discon-nection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched rsaquo Complete de-energisation only occurs if the bulk power supply is switched off upstream of the bat-

tery system

DANGERDestruction of the DC plug connectorDC plug connectors can be destroyed by arcing if disconnected while still live rsaquo It is absolutely essential that the following shutdown sequence is observed

1111 Step 1 Shutting down the PV system

1 Switch off any optional external PV isolator switches2 Set the internal DC isolator switch to OFF raquo The inverter and battery charging unit battery backup converter (BBC) are disconnected

1112 Step 2 Disconnect the batteries

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

1113 Step 3 Disconnect the AC supply

1 Connect external isolation means to the device2 Switch off the circuit breaker 3 Switch off the residual current circuit breaker raquo The battery system is switched off

1114 Step 4 AC home power grid

1 Shutdown the AC home power grid using the AC main switch raquo The battery system can be uninstalled

Disposal

Page 36 Operating instructions Powador-gridsave_EN

112 Uninstalling the device

NOTETo uninstall follow the same sequence as for installation but in reverse order

Switch off the device1 Unlock and open the housing door2 Remove the upper cover3 Release the DC and AC cables from the connection terminals4 Pull out the cables raquo The battery system is uninstalled Continue with the disassembly

113 Disassembling the device

NOTETo disassemble follow the same sequence as for assembly but in reverse order

Switch off the device1 Uninstall the components2 Remove the fastening from the device3 Securely pack up the battery system if it is to be used later

or have the battery system disposed of in accordance with section 12 on page 36

12 DisposalFor the most part both the battery system and the corresponding transport packaging are made from recyclable raw materialsBatteries and components Do not dispose of faulty batteries or the components together with household waste Ensure that the old device and accessories are disposed of in a proper mannerPackaging Ensure that the transport packaging is disposed of properlyBatteriesUsed or faulty batteries must be transported in special packaging If you need such packaging please contact the KACO Hotline

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

Appendix

Operating instructions Powador-gridsave_EN Page 37

13 Appendix

EU Declaration of Conformity

Vendorrsquos name and address

KACO new energy GmbH Carl-Zeiss-Straszlige 1 74172 Neckarsulm Germany

Product description Battery system

Type designation Powador-gridsave 135 kWh 6400 Powador-gridsave 135 kWh 8000

Powador-gridsave 270 kWh 6400 Powador-gridsave 270 kWh 8000

Powador-gridsave 405 kWh 6400 Powador-gridsave 405 kWh 8000

Powador-gridsave 540 kWh 6400 Powador-gridsave 540 kWh 8000

Powador-gridsave 577 kWh 6400 Powador-gridsave 577 kWh 8000

Powador-gridsave 675 kWh 6400 Powador-gridsave 675 kWh 8000

This is to confirm that the units listed above comply with the protection requirements set forth in the Directive of the Council of the European Union of 15th December 2004 on the harmonisation of the laws of the member states relating to Electromagnetic Compatibility (2004108EC) and the Low Voltage Directive (200695EC)The units are compliant with the following standards

200695EC ldquoDirective relating to electrical equipment designed for use within specific voltage limitsrdquo

Safety of the unitIEC 62109-12010IEC 62109-22011

2004108EC ldquoDirective relating to electromagneticcompatibilityrdquo

Interference immunityEN 61000-6-22005 Emitted interferenceEN 61000-6-32007

Secondary effects on the gridEN 61000-3-112000EN 61000-3-122005

The types mentioned above are therefore labelled with the CE markUnauthorised modifications to the supplied units andor any use of the units that is contrary to their intended use render this Declaration of Conformity null and void

Neckarsulm 0711 2013KACO new energy GmbH

pp Volker DietrichEnergy systems engineering management

Disposal

Page 38 Operating instructions Powador-gridsave_EN

Carl-Zeiss-Straszlige 1 middot 74172 Neckarsulm middot Germany middot Phone +49 7132 3818-0 middot Fax +49 7132 3818-703 middot infokaco-newenergyde middot wwwkaco-newenergyde

The

text

and

figu

res

refle

ct th

e cu

rren

t tec

hnic

al s

tate

at t

he ti

me

of p

rintin

g S

ubje

ct to

tech

nica

l cha

nges

Err

ors

and

omis

sion

s ex

cept

ed

3006

856-

01-1

4030

5

  • 1General Information
    • 11About this document
    • 12Name plate
    • 13Additional information
    • 14Intended use
      • 2Safety
        • 21Protection features
          • 3Description
            • 31Mode of Operation
            • 32Summary of the components
              • 4Technical Data
                • 41Electrical data
                • 42Mechanical data
                  • 5Transportation and Delivery
                    • 51Delivery
                    • 52Storage
                    • 53Transportation
                      • 6Assembling the device
                        • 61Installation
                        • 62Installing components
                          • 7Installing the device
                            • 71Opening the connection area
                            • 72Making the electrical connection
                            • 73Connecting the interfaces
                            • 74Sealing the connection area
                            • 75Starting up
                            • 76Standard configuration
                              • 8Configuration and Operation
                                • 81Controls
                                  • 9MaintenanceTroubleshooting
                                    • 91Visual inspection
                                    • 92Cleaning the device
                                    • 93Maintenance
                                    • 94Faults
                                      • 10Service
                                      • 11ShutdownDisassembly
                                        • 111Switching off the device
                                        • 112Uninstalling the device
                                        • 113Disassembling the device
                                          • 12Disposal
                                          • 13Appendix

Installing the device

Operating instructions Powador-gridsave_EN Page 27

Authorised electrician

761 Step 1 AC home power grid

Check all cables and connections before starting up1 Switch on the AC home power grid using the AC main switch raquo Powador-protect measurement and control unit starts up and monitors the AC grid raquo Two green LEDs indicate that the grid parameters are met raquo After a further 60 seconds (shortly after the backlighting in the Powador-protect goes out) the Powador-pro-

tect will switch on the home grid2 Configure Powador-protect according to the enclosed Powador-protect instructions

(The instructions are also available on the website at wwwkaconewenergyde) raquo The AC power is supplied in the normal way by the public grid

762 Step 2 AC supply from the battery system

Check all cables and connections before starting up1 Remove external isolation means from the device2 Switch on the circuit breaker raquo The LCD touchscreen on the front panel comes on and the energy management system (EMS) starts up

3 Switch on the residual current circuit breaker raquo The battery system starts up

763 Step 3 Switch on the PV system

1 Switch on any optional external PV isolator switches2 Set the internal DC isolator switch to ON raquo The inverter and the battery charging unit battery backup converter (BBC) are connected to the PV system raquo The device monitors the PV voltage for approx 60 seconds then optimisation of internal consumption takes

place

764 Step 4 Switch on batteries

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

765 Step 5 Activate energy management

NOTEKACO new energy cannot provide any support for problems regarding the IT infrastructure (eg router configuration IP address assignment ports etc) as the structure settings and configuration of the network environment can be complex and very different from place to place In the event of any problems please contact an IT service provider

Remote access activated 1 Please call the KACO Hotline to make an appointment for activation of energy management

Configuration and Operation

Page 28 Operating instructions Powador-gridsave_EN

Authorised electrician

8 Configuration and Operation

81 ControlsThe battery system is fitted with a touchscreen which allows it to be controlled very precisely In normal operation the display is switched off Touching the screen activates the display and after a configurable period of time without being touched the dis-play will deactivate If the screen-save function is switched off the touchscreen will be on continuously

NOTEDepending on the tolerances of the measuring elements the measured and displayed values are not always the actual values However the measuring elements ensure maximum solar yield Due to these tolerances the daily yields shown on the touchscreen may deviate from the values on the grid operatorrsquos feed-in meter by up to 15

3

1

45

2

Figure 15 Overview (home screen)

Key

1 Home button 4 Current time

2 System components 5 Menu name

3 More information

811 Information about the system

Open start screen View changesjumps to the home screen

Show component detail Parameters of the selected component

Settings Define settings for the active user

raquo Displays settings

Configuration and Operation

Operating instructions Powador-gridsave_EN Page 29

Controls Left arrow jump back to previous menu item Up and down arrows navigate through the menu or change a value

Left arrow displayed value is reduced by one increment Right arrow displayed value is increased by one increment or change to the submenu

Display fields Grey box Text or figures (not selectable) Blue box Calls up submenu for the display in question

Activate and deactivate Activate function by ticking the box

Table 6 Information about the system

812 System components

PV generator Display of the current generator data

power voltage current temperature in the inverter

Battery Display of the current battery status

power (charging or discharging) voltage current charge status available capacity temperature of battery

Grid Display of the following either fed-in or drawn from the grid

power voltage current for phase L1-L3 total output frequency

Consumer (load) Display of the consumer data

power voltage current for phase L1-L3 total output

Energy flow raquo Displays the current energy flow in the system

Table 7 Information about system components

Configuration and Operation

Page 30 Operating instructions Powador-gridsave_EN

813 Menu structure

Icons used

Display menu Submenu

Option menu

Menu Submenu Display setting

Action in this menumeaning

PV generator Details

Power Displays the current DC-side power

Voltage Displays the current DC-side voltage

Current Displays the current DC-side amperage

Temp inverter

Displays the current temperature in the inverter housing

Battery Details

Power Displays the current AC-side power

Voltage Displays the current AC-side voltage

Current Displays the current AC-side amperage

Charge status Displays the current charge status

Capacity Displays the current battery capacity

Temperature Displays the current measured temperature of the battery

Grid Details

Power Displays the current AC-side power being drawn or fed-in

Voltage Displays the AC-side voltage being applied

Current Displays the current AC-side amperage being drawn or fed-in

Total output Displays the current AC-side total output being drawn or fed-in

Frequency Displays the frequency currently being applied to the grid junction

Consumer (load) Details

Power Displays the current AC-side power being drawn

Voltage Displays the current AC-side voltage being applied

Current Displays the current AC-side amperage being drawn

Total output Displays the current AC-side total output being drawn

Configuration and Operation

Operating instructions Powador-gridsave_EN Page 31

Menu Submenu Display setting

Action in this menumeaning

Settings

Country amp directive display

Display of the country settings voltage directives and grid type

Select menu language

DateTime Specify time zone date format and date and time

Screen Activate screen-save function and set the delay period

Network settings

Display of the network settings Configure network settings Once the DHCP server becomes available the IP

address subnet mask gateway and DNS server are automatically applied and the aforemen-tioned menu items are hidden

Off DHCP deactivated make settings manually

Version Displays the installed software version and built-in HW components (inverter BBC battery)

Vendor The touchscreen shows information about the device vendor

NOTEAs changes to the software are possible after the manual has been printed the illustrations and descriptions of the functions in these operating instructions may deviate from the software Please therefore note the current Application Notes on our website

MaintenanceTroubleshooting

Page 32 Operating instructions Powador-gridsave_EN

9 MaintenanceTroubleshooting

91 Visual inspectionInspect the device and the cables for visible external damage and note the operating status display In case of damage notify your installer Repairs may only be carried out by authorised electricians

NOTEThe battery system should be checked for proper operation by a qualified electrician at regular intervals

92 Cleaning the device

DANGERLethal voltages in the battery systemSerious injuries or death can result if moisture enters the system rsaquo Only use completely dry objects to clean the battery system rsaquo Only clean the outside of the battery system

Cleaning the battery system Do not use compressed air Use a vacuum cleaner or a soft brush to remove dust from the fan cover and from the top of the inverter on a

regular basis Remove dust from the ventilation inlets if necessary

MaintenanceTroubleshooting

Operating instructions Powador-gridsave_EN Page 33

Authorised electrician

93 Maintenance

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched The device is only permitted to be opened or serviced by an authorised electrician rsaquo Observe all safety regulations and the current technical connection specifications from the relevant

power supply company rsaquo Disconnect the AC and DC sides rsaquo Secure the AC and DC sides from being inadvertently switched back on rsaquo Only then should the device be opened rsaquo After shutdown wait at least 30 minutes before working on the device

CAUTIONDestruction of the DC connectionThe connection terminals can be destroyed by arcing if disconnected while still live rsaquo It is absolutely essential that the shutdown sequence be carried out in the correct order (See sec-

tion 111 on page 35)

94 Faults

941 Procedure

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched

When a fault occurs notify an appropriately authorised and qualified electrician or KACO new energy GmbH Service

Service

Page 34 Operating instructions Powador-gridsave_EN

10 ServiceIf 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 efficientlybull Serial nobull SW version of the components (the software version can be found in the Settings menu using the EMS)bull Module type and string circuitbull Date of installation Start-up reportbull Consignment identification Delivery address Contact person (with telephone number)bull Information about the accessibility of the installation site

Any additional costs arising from unfavourable structural or mounting conditions shall be billed to the customer

You can find our warranty conditions on our websitehttpkaco-newenergycomservicewarrantyFrom there you can easily navigate to our international websites by clicking on the appropriate flag

Please use our website to register your unit immediatelyYou can also select the appropriate flag on this page to access the website for your own countryIn this manner you can assist us in providing you with the quickest service possible Note The maximum length of the warranty is based on the currently applicable national warranty conditions

We have prepared a template for complaints This can be found at httpskaco-newenergycomservicecustomer-service

Hotlines

Technical troubleshooting Technical consultation

Inverters and battery systems ()

+49 (0) 71323818-660 +49 (0) 71323818-660

Data logging and accessories +49 (0) 71323818-690 +49 (0) 71323818-690

Construction site emergency () +49 (0) 71323818-630

Customer help desk Monday to Friday from 730 am to 530 pm (CET)

() Also on Saturdays from 800 am to 200 pm (CET)

ShutdownDisassembly

Operating instructions Powador-gridsave_EN Page 35

11 ShutdownDisassembly

111 Switching off the device

DANGERLethal voltages are still present in the terminals and cables even after switching off and discon-nection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched rsaquo Complete de-energisation only occurs if the bulk power supply is switched off upstream of the bat-

tery system

DANGERDestruction of the DC plug connectorDC plug connectors can be destroyed by arcing if disconnected while still live rsaquo It is absolutely essential that the following shutdown sequence is observed

1111 Step 1 Shutting down the PV system

1 Switch off any optional external PV isolator switches2 Set the internal DC isolator switch to OFF raquo The inverter and battery charging unit battery backup converter (BBC) are disconnected

1112 Step 2 Disconnect the batteries

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

1113 Step 3 Disconnect the AC supply

1 Connect external isolation means to the device2 Switch off the circuit breaker 3 Switch off the residual current circuit breaker raquo The battery system is switched off

1114 Step 4 AC home power grid

1 Shutdown the AC home power grid using the AC main switch raquo The battery system can be uninstalled

Disposal

Page 36 Operating instructions Powador-gridsave_EN

112 Uninstalling the device

NOTETo uninstall follow the same sequence as for installation but in reverse order

Switch off the device1 Unlock and open the housing door2 Remove the upper cover3 Release the DC and AC cables from the connection terminals4 Pull out the cables raquo The battery system is uninstalled Continue with the disassembly

113 Disassembling the device

NOTETo disassemble follow the same sequence as for assembly but in reverse order

Switch off the device1 Uninstall the components2 Remove the fastening from the device3 Securely pack up the battery system if it is to be used later

or have the battery system disposed of in accordance with section 12 on page 36

12 DisposalFor the most part both the battery system and the corresponding transport packaging are made from recyclable raw materialsBatteries and components Do not dispose of faulty batteries or the components together with household waste Ensure that the old device and accessories are disposed of in a proper mannerPackaging Ensure that the transport packaging is disposed of properlyBatteriesUsed or faulty batteries must be transported in special packaging If you need such packaging please contact the KACO Hotline

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

Appendix

Operating instructions Powador-gridsave_EN Page 37

13 Appendix

EU Declaration of Conformity

Vendorrsquos name and address

KACO new energy GmbH Carl-Zeiss-Straszlige 1 74172 Neckarsulm Germany

Product description Battery system

Type designation Powador-gridsave 135 kWh 6400 Powador-gridsave 135 kWh 8000

Powador-gridsave 270 kWh 6400 Powador-gridsave 270 kWh 8000

Powador-gridsave 405 kWh 6400 Powador-gridsave 405 kWh 8000

Powador-gridsave 540 kWh 6400 Powador-gridsave 540 kWh 8000

Powador-gridsave 577 kWh 6400 Powador-gridsave 577 kWh 8000

Powador-gridsave 675 kWh 6400 Powador-gridsave 675 kWh 8000

This is to confirm that the units listed above comply with the protection requirements set forth in the Directive of the Council of the European Union of 15th December 2004 on the harmonisation of the laws of the member states relating to Electromagnetic Compatibility (2004108EC) and the Low Voltage Directive (200695EC)The units are compliant with the following standards

200695EC ldquoDirective relating to electrical equipment designed for use within specific voltage limitsrdquo

Safety of the unitIEC 62109-12010IEC 62109-22011

2004108EC ldquoDirective relating to electromagneticcompatibilityrdquo

Interference immunityEN 61000-6-22005 Emitted interferenceEN 61000-6-32007

Secondary effects on the gridEN 61000-3-112000EN 61000-3-122005

The types mentioned above are therefore labelled with the CE markUnauthorised modifications to the supplied units andor any use of the units that is contrary to their intended use render this Declaration of Conformity null and void

Neckarsulm 0711 2013KACO new energy GmbH

pp Volker DietrichEnergy systems engineering management

Disposal

Page 38 Operating instructions Powador-gridsave_EN

Carl-Zeiss-Straszlige 1 middot 74172 Neckarsulm middot Germany middot Phone +49 7132 3818-0 middot Fax +49 7132 3818-703 middot infokaco-newenergyde middot wwwkaco-newenergyde

The

text

and

figu

res

refle

ct th

e cu

rren

t tec

hnic

al s

tate

at t

he ti

me

of p

rintin

g S

ubje

ct to

tech

nica

l cha

nges

Err

ors

and

omis

sion

s ex

cept

ed

3006

856-

01-1

4030

5

  • 1General Information
    • 11About this document
    • 12Name plate
    • 13Additional information
    • 14Intended use
      • 2Safety
        • 21Protection features
          • 3Description
            • 31Mode of Operation
            • 32Summary of the components
              • 4Technical Data
                • 41Electrical data
                • 42Mechanical data
                  • 5Transportation and Delivery
                    • 51Delivery
                    • 52Storage
                    • 53Transportation
                      • 6Assembling the device
                        • 61Installation
                        • 62Installing components
                          • 7Installing the device
                            • 71Opening the connection area
                            • 72Making the electrical connection
                            • 73Connecting the interfaces
                            • 74Sealing the connection area
                            • 75Starting up
                            • 76Standard configuration
                              • 8Configuration and Operation
                                • 81Controls
                                  • 9MaintenanceTroubleshooting
                                    • 91Visual inspection
                                    • 92Cleaning the device
                                    • 93Maintenance
                                    • 94Faults
                                      • 10Service
                                      • 11ShutdownDisassembly
                                        • 111Switching off the device
                                        • 112Uninstalling the device
                                        • 113Disassembling the device
                                          • 12Disposal
                                          • 13Appendix

Configuration and Operation

Page 28 Operating instructions Powador-gridsave_EN

Authorised electrician

8 Configuration and Operation

81 ControlsThe battery system is fitted with a touchscreen which allows it to be controlled very precisely In normal operation the display is switched off Touching the screen activates the display and after a configurable period of time without being touched the dis-play will deactivate If the screen-save function is switched off the touchscreen will be on continuously

NOTEDepending on the tolerances of the measuring elements the measured and displayed values are not always the actual values However the measuring elements ensure maximum solar yield Due to these tolerances the daily yields shown on the touchscreen may deviate from the values on the grid operatorrsquos feed-in meter by up to 15

3

1

45

2

Figure 15 Overview (home screen)

Key

1 Home button 4 Current time

2 System components 5 Menu name

3 More information

811 Information about the system

Open start screen View changesjumps to the home screen

Show component detail Parameters of the selected component

Settings Define settings for the active user

raquo Displays settings

Configuration and Operation

Operating instructions Powador-gridsave_EN Page 29

Controls Left arrow jump back to previous menu item Up and down arrows navigate through the menu or change a value

Left arrow displayed value is reduced by one increment Right arrow displayed value is increased by one increment or change to the submenu

Display fields Grey box Text or figures (not selectable) Blue box Calls up submenu for the display in question

Activate and deactivate Activate function by ticking the box

Table 6 Information about the system

812 System components

PV generator Display of the current generator data

power voltage current temperature in the inverter

Battery Display of the current battery status

power (charging or discharging) voltage current charge status available capacity temperature of battery

Grid Display of the following either fed-in or drawn from the grid

power voltage current for phase L1-L3 total output frequency

Consumer (load) Display of the consumer data

power voltage current for phase L1-L3 total output

Energy flow raquo Displays the current energy flow in the system

Table 7 Information about system components

Configuration and Operation

Page 30 Operating instructions Powador-gridsave_EN

813 Menu structure

Icons used

Display menu Submenu

Option menu

Menu Submenu Display setting

Action in this menumeaning

PV generator Details

Power Displays the current DC-side power

Voltage Displays the current DC-side voltage

Current Displays the current DC-side amperage

Temp inverter

Displays the current temperature in the inverter housing

Battery Details

Power Displays the current AC-side power

Voltage Displays the current AC-side voltage

Current Displays the current AC-side amperage

Charge status Displays the current charge status

Capacity Displays the current battery capacity

Temperature Displays the current measured temperature of the battery

Grid Details

Power Displays the current AC-side power being drawn or fed-in

Voltage Displays the AC-side voltage being applied

Current Displays the current AC-side amperage being drawn or fed-in

Total output Displays the current AC-side total output being drawn or fed-in

Frequency Displays the frequency currently being applied to the grid junction

Consumer (load) Details

Power Displays the current AC-side power being drawn

Voltage Displays the current AC-side voltage being applied

Current Displays the current AC-side amperage being drawn

Total output Displays the current AC-side total output being drawn

Configuration and Operation

Operating instructions Powador-gridsave_EN Page 31

Menu Submenu Display setting

Action in this menumeaning

Settings

Country amp directive display

Display of the country settings voltage directives and grid type

Select menu language

DateTime Specify time zone date format and date and time

Screen Activate screen-save function and set the delay period

Network settings

Display of the network settings Configure network settings Once the DHCP server becomes available the IP

address subnet mask gateway and DNS server are automatically applied and the aforemen-tioned menu items are hidden

Off DHCP deactivated make settings manually

Version Displays the installed software version and built-in HW components (inverter BBC battery)

Vendor The touchscreen shows information about the device vendor

NOTEAs changes to the software are possible after the manual has been printed the illustrations and descriptions of the functions in these operating instructions may deviate from the software Please therefore note the current Application Notes on our website

MaintenanceTroubleshooting

Page 32 Operating instructions Powador-gridsave_EN

9 MaintenanceTroubleshooting

91 Visual inspectionInspect the device and the cables for visible external damage and note the operating status display In case of damage notify your installer Repairs may only be carried out by authorised electricians

NOTEThe battery system should be checked for proper operation by a qualified electrician at regular intervals

92 Cleaning the device

DANGERLethal voltages in the battery systemSerious injuries or death can result if moisture enters the system rsaquo Only use completely dry objects to clean the battery system rsaquo Only clean the outside of the battery system

Cleaning the battery system Do not use compressed air Use a vacuum cleaner or a soft brush to remove dust from the fan cover and from the top of the inverter on a

regular basis Remove dust from the ventilation inlets if necessary

MaintenanceTroubleshooting

Operating instructions Powador-gridsave_EN Page 33

Authorised electrician

93 Maintenance

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched The device is only permitted to be opened or serviced by an authorised electrician rsaquo Observe all safety regulations and the current technical connection specifications from the relevant

power supply company rsaquo Disconnect the AC and DC sides rsaquo Secure the AC and DC sides from being inadvertently switched back on rsaquo Only then should the device be opened rsaquo After shutdown wait at least 30 minutes before working on the device

CAUTIONDestruction of the DC connectionThe connection terminals can be destroyed by arcing if disconnected while still live rsaquo It is absolutely essential that the shutdown sequence be carried out in the correct order (See sec-

tion 111 on page 35)

94 Faults

941 Procedure

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched

When a fault occurs notify an appropriately authorised and qualified electrician or KACO new energy GmbH Service

Service

Page 34 Operating instructions Powador-gridsave_EN

10 ServiceIf 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 efficientlybull Serial nobull SW version of the components (the software version can be found in the Settings menu using the EMS)bull Module type and string circuitbull Date of installation Start-up reportbull Consignment identification Delivery address Contact person (with telephone number)bull Information about the accessibility of the installation site

Any additional costs arising from unfavourable structural or mounting conditions shall be billed to the customer

You can find our warranty conditions on our websitehttpkaco-newenergycomservicewarrantyFrom there you can easily navigate to our international websites by clicking on the appropriate flag

Please use our website to register your unit immediatelyYou can also select the appropriate flag on this page to access the website for your own countryIn this manner you can assist us in providing you with the quickest service possible Note The maximum length of the warranty is based on the currently applicable national warranty conditions

We have prepared a template for complaints This can be found at httpskaco-newenergycomservicecustomer-service

Hotlines

Technical troubleshooting Technical consultation

Inverters and battery systems ()

+49 (0) 71323818-660 +49 (0) 71323818-660

Data logging and accessories +49 (0) 71323818-690 +49 (0) 71323818-690

Construction site emergency () +49 (0) 71323818-630

Customer help desk Monday to Friday from 730 am to 530 pm (CET)

() Also on Saturdays from 800 am to 200 pm (CET)

ShutdownDisassembly

Operating instructions Powador-gridsave_EN Page 35

11 ShutdownDisassembly

111 Switching off the device

DANGERLethal voltages are still present in the terminals and cables even after switching off and discon-nection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched rsaquo Complete de-energisation only occurs if the bulk power supply is switched off upstream of the bat-

tery system

DANGERDestruction of the DC plug connectorDC plug connectors can be destroyed by arcing if disconnected while still live rsaquo It is absolutely essential that the following shutdown sequence is observed

1111 Step 1 Shutting down the PV system

1 Switch off any optional external PV isolator switches2 Set the internal DC isolator switch to OFF raquo The inverter and battery charging unit battery backup converter (BBC) are disconnected

1112 Step 2 Disconnect the batteries

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

1113 Step 3 Disconnect the AC supply

1 Connect external isolation means to the device2 Switch off the circuit breaker 3 Switch off the residual current circuit breaker raquo The battery system is switched off

1114 Step 4 AC home power grid

1 Shutdown the AC home power grid using the AC main switch raquo The battery system can be uninstalled

Disposal

Page 36 Operating instructions Powador-gridsave_EN

112 Uninstalling the device

NOTETo uninstall follow the same sequence as for installation but in reverse order

Switch off the device1 Unlock and open the housing door2 Remove the upper cover3 Release the DC and AC cables from the connection terminals4 Pull out the cables raquo The battery system is uninstalled Continue with the disassembly

113 Disassembling the device

NOTETo disassemble follow the same sequence as for assembly but in reverse order

Switch off the device1 Uninstall the components2 Remove the fastening from the device3 Securely pack up the battery system if it is to be used later

or have the battery system disposed of in accordance with section 12 on page 36

12 DisposalFor the most part both the battery system and the corresponding transport packaging are made from recyclable raw materialsBatteries and components Do not dispose of faulty batteries or the components together with household waste Ensure that the old device and accessories are disposed of in a proper mannerPackaging Ensure that the transport packaging is disposed of properlyBatteriesUsed or faulty batteries must be transported in special packaging If you need such packaging please contact the KACO Hotline

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

Appendix

Operating instructions Powador-gridsave_EN Page 37

13 Appendix

EU Declaration of Conformity

Vendorrsquos name and address

KACO new energy GmbH Carl-Zeiss-Straszlige 1 74172 Neckarsulm Germany

Product description Battery system

Type designation Powador-gridsave 135 kWh 6400 Powador-gridsave 135 kWh 8000

Powador-gridsave 270 kWh 6400 Powador-gridsave 270 kWh 8000

Powador-gridsave 405 kWh 6400 Powador-gridsave 405 kWh 8000

Powador-gridsave 540 kWh 6400 Powador-gridsave 540 kWh 8000

Powador-gridsave 577 kWh 6400 Powador-gridsave 577 kWh 8000

Powador-gridsave 675 kWh 6400 Powador-gridsave 675 kWh 8000

This is to confirm that the units listed above comply with the protection requirements set forth in the Directive of the Council of the European Union of 15th December 2004 on the harmonisation of the laws of the member states relating to Electromagnetic Compatibility (2004108EC) and the Low Voltage Directive (200695EC)The units are compliant with the following standards

200695EC ldquoDirective relating to electrical equipment designed for use within specific voltage limitsrdquo

Safety of the unitIEC 62109-12010IEC 62109-22011

2004108EC ldquoDirective relating to electromagneticcompatibilityrdquo

Interference immunityEN 61000-6-22005 Emitted interferenceEN 61000-6-32007

Secondary effects on the gridEN 61000-3-112000EN 61000-3-122005

The types mentioned above are therefore labelled with the CE markUnauthorised modifications to the supplied units andor any use of the units that is contrary to their intended use render this Declaration of Conformity null and void

Neckarsulm 0711 2013KACO new energy GmbH

pp Volker DietrichEnergy systems engineering management

Disposal

Page 38 Operating instructions Powador-gridsave_EN

Carl-Zeiss-Straszlige 1 middot 74172 Neckarsulm middot Germany middot Phone +49 7132 3818-0 middot Fax +49 7132 3818-703 middot infokaco-newenergyde middot wwwkaco-newenergyde

The

text

and

figu

res

refle

ct th

e cu

rren

t tec

hnic

al s

tate

at t

he ti

me

of p

rintin

g S

ubje

ct to

tech

nica

l cha

nges

Err

ors

and

omis

sion

s ex

cept

ed

3006

856-

01-1

4030

5

  • 1General Information
    • 11About this document
    • 12Name plate
    • 13Additional information
    • 14Intended use
      • 2Safety
        • 21Protection features
          • 3Description
            • 31Mode of Operation
            • 32Summary of the components
              • 4Technical Data
                • 41Electrical data
                • 42Mechanical data
                  • 5Transportation and Delivery
                    • 51Delivery
                    • 52Storage
                    • 53Transportation
                      • 6Assembling the device
                        • 61Installation
                        • 62Installing components
                          • 7Installing the device
                            • 71Opening the connection area
                            • 72Making the electrical connection
                            • 73Connecting the interfaces
                            • 74Sealing the connection area
                            • 75Starting up
                            • 76Standard configuration
                              • 8Configuration and Operation
                                • 81Controls
                                  • 9MaintenanceTroubleshooting
                                    • 91Visual inspection
                                    • 92Cleaning the device
                                    • 93Maintenance
                                    • 94Faults
                                      • 10Service
                                      • 11ShutdownDisassembly
                                        • 111Switching off the device
                                        • 112Uninstalling the device
                                        • 113Disassembling the device
                                          • 12Disposal
                                          • 13Appendix

Configuration and Operation

Operating instructions Powador-gridsave_EN Page 29

Controls Left arrow jump back to previous menu item Up and down arrows navigate through the menu or change a value

Left arrow displayed value is reduced by one increment Right arrow displayed value is increased by one increment or change to the submenu

Display fields Grey box Text or figures (not selectable) Blue box Calls up submenu for the display in question

Activate and deactivate Activate function by ticking the box

Table 6 Information about the system

812 System components

PV generator Display of the current generator data

power voltage current temperature in the inverter

Battery Display of the current battery status

power (charging or discharging) voltage current charge status available capacity temperature of battery

Grid Display of the following either fed-in or drawn from the grid

power voltage current for phase L1-L3 total output frequency

Consumer (load) Display of the consumer data

power voltage current for phase L1-L3 total output

Energy flow raquo Displays the current energy flow in the system

Table 7 Information about system components

Configuration and Operation

Page 30 Operating instructions Powador-gridsave_EN

813 Menu structure

Icons used

Display menu Submenu

Option menu

Menu Submenu Display setting

Action in this menumeaning

PV generator Details

Power Displays the current DC-side power

Voltage Displays the current DC-side voltage

Current Displays the current DC-side amperage

Temp inverter

Displays the current temperature in the inverter housing

Battery Details

Power Displays the current AC-side power

Voltage Displays the current AC-side voltage

Current Displays the current AC-side amperage

Charge status Displays the current charge status

Capacity Displays the current battery capacity

Temperature Displays the current measured temperature of the battery

Grid Details

Power Displays the current AC-side power being drawn or fed-in

Voltage Displays the AC-side voltage being applied

Current Displays the current AC-side amperage being drawn or fed-in

Total output Displays the current AC-side total output being drawn or fed-in

Frequency Displays the frequency currently being applied to the grid junction

Consumer (load) Details

Power Displays the current AC-side power being drawn

Voltage Displays the current AC-side voltage being applied

Current Displays the current AC-side amperage being drawn

Total output Displays the current AC-side total output being drawn

Configuration and Operation

Operating instructions Powador-gridsave_EN Page 31

Menu Submenu Display setting

Action in this menumeaning

Settings

Country amp directive display

Display of the country settings voltage directives and grid type

Select menu language

DateTime Specify time zone date format and date and time

Screen Activate screen-save function and set the delay period

Network settings

Display of the network settings Configure network settings Once the DHCP server becomes available the IP

address subnet mask gateway and DNS server are automatically applied and the aforemen-tioned menu items are hidden

Off DHCP deactivated make settings manually

Version Displays the installed software version and built-in HW components (inverter BBC battery)

Vendor The touchscreen shows information about the device vendor

NOTEAs changes to the software are possible after the manual has been printed the illustrations and descriptions of the functions in these operating instructions may deviate from the software Please therefore note the current Application Notes on our website

MaintenanceTroubleshooting

Page 32 Operating instructions Powador-gridsave_EN

9 MaintenanceTroubleshooting

91 Visual inspectionInspect the device and the cables for visible external damage and note the operating status display In case of damage notify your installer Repairs may only be carried out by authorised electricians

NOTEThe battery system should be checked for proper operation by a qualified electrician at regular intervals

92 Cleaning the device

DANGERLethal voltages in the battery systemSerious injuries or death can result if moisture enters the system rsaquo Only use completely dry objects to clean the battery system rsaquo Only clean the outside of the battery system

Cleaning the battery system Do not use compressed air Use a vacuum cleaner or a soft brush to remove dust from the fan cover and from the top of the inverter on a

regular basis Remove dust from the ventilation inlets if necessary

MaintenanceTroubleshooting

Operating instructions Powador-gridsave_EN Page 33

Authorised electrician

93 Maintenance

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched The device is only permitted to be opened or serviced by an authorised electrician rsaquo Observe all safety regulations and the current technical connection specifications from the relevant

power supply company rsaquo Disconnect the AC and DC sides rsaquo Secure the AC and DC sides from being inadvertently switched back on rsaquo Only then should the device be opened rsaquo After shutdown wait at least 30 minutes before working on the device

CAUTIONDestruction of the DC connectionThe connection terminals can be destroyed by arcing if disconnected while still live rsaquo It is absolutely essential that the shutdown sequence be carried out in the correct order (See sec-

tion 111 on page 35)

94 Faults

941 Procedure

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched

When a fault occurs notify an appropriately authorised and qualified electrician or KACO new energy GmbH Service

Service

Page 34 Operating instructions Powador-gridsave_EN

10 ServiceIf 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 efficientlybull Serial nobull SW version of the components (the software version can be found in the Settings menu using the EMS)bull Module type and string circuitbull Date of installation Start-up reportbull Consignment identification Delivery address Contact person (with telephone number)bull Information about the accessibility of the installation site

Any additional costs arising from unfavourable structural or mounting conditions shall be billed to the customer

You can find our warranty conditions on our websitehttpkaco-newenergycomservicewarrantyFrom there you can easily navigate to our international websites by clicking on the appropriate flag

Please use our website to register your unit immediatelyYou can also select the appropriate flag on this page to access the website for your own countryIn this manner you can assist us in providing you with the quickest service possible Note The maximum length of the warranty is based on the currently applicable national warranty conditions

We have prepared a template for complaints This can be found at httpskaco-newenergycomservicecustomer-service

Hotlines

Technical troubleshooting Technical consultation

Inverters and battery systems ()

+49 (0) 71323818-660 +49 (0) 71323818-660

Data logging and accessories +49 (0) 71323818-690 +49 (0) 71323818-690

Construction site emergency () +49 (0) 71323818-630

Customer help desk Monday to Friday from 730 am to 530 pm (CET)

() Also on Saturdays from 800 am to 200 pm (CET)

ShutdownDisassembly

Operating instructions Powador-gridsave_EN Page 35

11 ShutdownDisassembly

111 Switching off the device

DANGERLethal voltages are still present in the terminals and cables even after switching off and discon-nection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched rsaquo Complete de-energisation only occurs if the bulk power supply is switched off upstream of the bat-

tery system

DANGERDestruction of the DC plug connectorDC plug connectors can be destroyed by arcing if disconnected while still live rsaquo It is absolutely essential that the following shutdown sequence is observed

1111 Step 1 Shutting down the PV system

1 Switch off any optional external PV isolator switches2 Set the internal DC isolator switch to OFF raquo The inverter and battery charging unit battery backup converter (BBC) are disconnected

1112 Step 2 Disconnect the batteries

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

1113 Step 3 Disconnect the AC supply

1 Connect external isolation means to the device2 Switch off the circuit breaker 3 Switch off the residual current circuit breaker raquo The battery system is switched off

1114 Step 4 AC home power grid

1 Shutdown the AC home power grid using the AC main switch raquo The battery system can be uninstalled

Disposal

Page 36 Operating instructions Powador-gridsave_EN

112 Uninstalling the device

NOTETo uninstall follow the same sequence as for installation but in reverse order

Switch off the device1 Unlock and open the housing door2 Remove the upper cover3 Release the DC and AC cables from the connection terminals4 Pull out the cables raquo The battery system is uninstalled Continue with the disassembly

113 Disassembling the device

NOTETo disassemble follow the same sequence as for assembly but in reverse order

Switch off the device1 Uninstall the components2 Remove the fastening from the device3 Securely pack up the battery system if it is to be used later

or have the battery system disposed of in accordance with section 12 on page 36

12 DisposalFor the most part both the battery system and the corresponding transport packaging are made from recyclable raw materialsBatteries and components Do not dispose of faulty batteries or the components together with household waste Ensure that the old device and accessories are disposed of in a proper mannerPackaging Ensure that the transport packaging is disposed of properlyBatteriesUsed or faulty batteries must be transported in special packaging If you need such packaging please contact the KACO Hotline

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

Appendix

Operating instructions Powador-gridsave_EN Page 37

13 Appendix

EU Declaration of Conformity

Vendorrsquos name and address

KACO new energy GmbH Carl-Zeiss-Straszlige 1 74172 Neckarsulm Germany

Product description Battery system

Type designation Powador-gridsave 135 kWh 6400 Powador-gridsave 135 kWh 8000

Powador-gridsave 270 kWh 6400 Powador-gridsave 270 kWh 8000

Powador-gridsave 405 kWh 6400 Powador-gridsave 405 kWh 8000

Powador-gridsave 540 kWh 6400 Powador-gridsave 540 kWh 8000

Powador-gridsave 577 kWh 6400 Powador-gridsave 577 kWh 8000

Powador-gridsave 675 kWh 6400 Powador-gridsave 675 kWh 8000

This is to confirm that the units listed above comply with the protection requirements set forth in the Directive of the Council of the European Union of 15th December 2004 on the harmonisation of the laws of the member states relating to Electromagnetic Compatibility (2004108EC) and the Low Voltage Directive (200695EC)The units are compliant with the following standards

200695EC ldquoDirective relating to electrical equipment designed for use within specific voltage limitsrdquo

Safety of the unitIEC 62109-12010IEC 62109-22011

2004108EC ldquoDirective relating to electromagneticcompatibilityrdquo

Interference immunityEN 61000-6-22005 Emitted interferenceEN 61000-6-32007

Secondary effects on the gridEN 61000-3-112000EN 61000-3-122005

The types mentioned above are therefore labelled with the CE markUnauthorised modifications to the supplied units andor any use of the units that is contrary to their intended use render this Declaration of Conformity null and void

Neckarsulm 0711 2013KACO new energy GmbH

pp Volker DietrichEnergy systems engineering management

Disposal

Page 38 Operating instructions Powador-gridsave_EN

Carl-Zeiss-Straszlige 1 middot 74172 Neckarsulm middot Germany middot Phone +49 7132 3818-0 middot Fax +49 7132 3818-703 middot infokaco-newenergyde middot wwwkaco-newenergyde

The

text

and

figu

res

refle

ct th

e cu

rren

t tec

hnic

al s

tate

at t

he ti

me

of p

rintin

g S

ubje

ct to

tech

nica

l cha

nges

Err

ors

and

omis

sion

s ex

cept

ed

3006

856-

01-1

4030

5

  • 1General Information
    • 11About this document
    • 12Name plate
    • 13Additional information
    • 14Intended use
      • 2Safety
        • 21Protection features
          • 3Description
            • 31Mode of Operation
            • 32Summary of the components
              • 4Technical Data
                • 41Electrical data
                • 42Mechanical data
                  • 5Transportation and Delivery
                    • 51Delivery
                    • 52Storage
                    • 53Transportation
                      • 6Assembling the device
                        • 61Installation
                        • 62Installing components
                          • 7Installing the device
                            • 71Opening the connection area
                            • 72Making the electrical connection
                            • 73Connecting the interfaces
                            • 74Sealing the connection area
                            • 75Starting up
                            • 76Standard configuration
                              • 8Configuration and Operation
                                • 81Controls
                                  • 9MaintenanceTroubleshooting
                                    • 91Visual inspection
                                    • 92Cleaning the device
                                    • 93Maintenance
                                    • 94Faults
                                      • 10Service
                                      • 11ShutdownDisassembly
                                        • 111Switching off the device
                                        • 112Uninstalling the device
                                        • 113Disassembling the device
                                          • 12Disposal
                                          • 13Appendix

Configuration and Operation

Page 30 Operating instructions Powador-gridsave_EN

813 Menu structure

Icons used

Display menu Submenu

Option menu

Menu Submenu Display setting

Action in this menumeaning

PV generator Details

Power Displays the current DC-side power

Voltage Displays the current DC-side voltage

Current Displays the current DC-side amperage

Temp inverter

Displays the current temperature in the inverter housing

Battery Details

Power Displays the current AC-side power

Voltage Displays the current AC-side voltage

Current Displays the current AC-side amperage

Charge status Displays the current charge status

Capacity Displays the current battery capacity

Temperature Displays the current measured temperature of the battery

Grid Details

Power Displays the current AC-side power being drawn or fed-in

Voltage Displays the AC-side voltage being applied

Current Displays the current AC-side amperage being drawn or fed-in

Total output Displays the current AC-side total output being drawn or fed-in

Frequency Displays the frequency currently being applied to the grid junction

Consumer (load) Details

Power Displays the current AC-side power being drawn

Voltage Displays the current AC-side voltage being applied

Current Displays the current AC-side amperage being drawn

Total output Displays the current AC-side total output being drawn

Configuration and Operation

Operating instructions Powador-gridsave_EN Page 31

Menu Submenu Display setting

Action in this menumeaning

Settings

Country amp directive display

Display of the country settings voltage directives and grid type

Select menu language

DateTime Specify time zone date format and date and time

Screen Activate screen-save function and set the delay period

Network settings

Display of the network settings Configure network settings Once the DHCP server becomes available the IP

address subnet mask gateway and DNS server are automatically applied and the aforemen-tioned menu items are hidden

Off DHCP deactivated make settings manually

Version Displays the installed software version and built-in HW components (inverter BBC battery)

Vendor The touchscreen shows information about the device vendor

NOTEAs changes to the software are possible after the manual has been printed the illustrations and descriptions of the functions in these operating instructions may deviate from the software Please therefore note the current Application Notes on our website

MaintenanceTroubleshooting

Page 32 Operating instructions Powador-gridsave_EN

9 MaintenanceTroubleshooting

91 Visual inspectionInspect the device and the cables for visible external damage and note the operating status display In case of damage notify your installer Repairs may only be carried out by authorised electricians

NOTEThe battery system should be checked for proper operation by a qualified electrician at regular intervals

92 Cleaning the device

DANGERLethal voltages in the battery systemSerious injuries or death can result if moisture enters the system rsaquo Only use completely dry objects to clean the battery system rsaquo Only clean the outside of the battery system

Cleaning the battery system Do not use compressed air Use a vacuum cleaner or a soft brush to remove dust from the fan cover and from the top of the inverter on a

regular basis Remove dust from the ventilation inlets if necessary

MaintenanceTroubleshooting

Operating instructions Powador-gridsave_EN Page 33

Authorised electrician

93 Maintenance

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched The device is only permitted to be opened or serviced by an authorised electrician rsaquo Observe all safety regulations and the current technical connection specifications from the relevant

power supply company rsaquo Disconnect the AC and DC sides rsaquo Secure the AC and DC sides from being inadvertently switched back on rsaquo Only then should the device be opened rsaquo After shutdown wait at least 30 minutes before working on the device

CAUTIONDestruction of the DC connectionThe connection terminals can be destroyed by arcing if disconnected while still live rsaquo It is absolutely essential that the shutdown sequence be carried out in the correct order (See sec-

tion 111 on page 35)

94 Faults

941 Procedure

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched

When a fault occurs notify an appropriately authorised and qualified electrician or KACO new energy GmbH Service

Service

Page 34 Operating instructions Powador-gridsave_EN

10 ServiceIf 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 efficientlybull Serial nobull SW version of the components (the software version can be found in the Settings menu using the EMS)bull Module type and string circuitbull Date of installation Start-up reportbull Consignment identification Delivery address Contact person (with telephone number)bull Information about the accessibility of the installation site

Any additional costs arising from unfavourable structural or mounting conditions shall be billed to the customer

You can find our warranty conditions on our websitehttpkaco-newenergycomservicewarrantyFrom there you can easily navigate to our international websites by clicking on the appropriate flag

Please use our website to register your unit immediatelyYou can also select the appropriate flag on this page to access the website for your own countryIn this manner you can assist us in providing you with the quickest service possible Note The maximum length of the warranty is based on the currently applicable national warranty conditions

We have prepared a template for complaints This can be found at httpskaco-newenergycomservicecustomer-service

Hotlines

Technical troubleshooting Technical consultation

Inverters and battery systems ()

+49 (0) 71323818-660 +49 (0) 71323818-660

Data logging and accessories +49 (0) 71323818-690 +49 (0) 71323818-690

Construction site emergency () +49 (0) 71323818-630

Customer help desk Monday to Friday from 730 am to 530 pm (CET)

() Also on Saturdays from 800 am to 200 pm (CET)

ShutdownDisassembly

Operating instructions Powador-gridsave_EN Page 35

11 ShutdownDisassembly

111 Switching off the device

DANGERLethal voltages are still present in the terminals and cables even after switching off and discon-nection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched rsaquo Complete de-energisation only occurs if the bulk power supply is switched off upstream of the bat-

tery system

DANGERDestruction of the DC plug connectorDC plug connectors can be destroyed by arcing if disconnected while still live rsaquo It is absolutely essential that the following shutdown sequence is observed

1111 Step 1 Shutting down the PV system

1 Switch off any optional external PV isolator switches2 Set the internal DC isolator switch to OFF raquo The inverter and battery charging unit battery backup converter (BBC) are disconnected

1112 Step 2 Disconnect the batteries

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

1113 Step 3 Disconnect the AC supply

1 Connect external isolation means to the device2 Switch off the circuit breaker 3 Switch off the residual current circuit breaker raquo The battery system is switched off

1114 Step 4 AC home power grid

1 Shutdown the AC home power grid using the AC main switch raquo The battery system can be uninstalled

Disposal

Page 36 Operating instructions Powador-gridsave_EN

112 Uninstalling the device

NOTETo uninstall follow the same sequence as for installation but in reverse order

Switch off the device1 Unlock and open the housing door2 Remove the upper cover3 Release the DC and AC cables from the connection terminals4 Pull out the cables raquo The battery system is uninstalled Continue with the disassembly

113 Disassembling the device

NOTETo disassemble follow the same sequence as for assembly but in reverse order

Switch off the device1 Uninstall the components2 Remove the fastening from the device3 Securely pack up the battery system if it is to be used later

or have the battery system disposed of in accordance with section 12 on page 36

12 DisposalFor the most part both the battery system and the corresponding transport packaging are made from recyclable raw materialsBatteries and components Do not dispose of faulty batteries or the components together with household waste Ensure that the old device and accessories are disposed of in a proper mannerPackaging Ensure that the transport packaging is disposed of properlyBatteriesUsed or faulty batteries must be transported in special packaging If you need such packaging please contact the KACO Hotline

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

Appendix

Operating instructions Powador-gridsave_EN Page 37

13 Appendix

EU Declaration of Conformity

Vendorrsquos name and address

KACO new energy GmbH Carl-Zeiss-Straszlige 1 74172 Neckarsulm Germany

Product description Battery system

Type designation Powador-gridsave 135 kWh 6400 Powador-gridsave 135 kWh 8000

Powador-gridsave 270 kWh 6400 Powador-gridsave 270 kWh 8000

Powador-gridsave 405 kWh 6400 Powador-gridsave 405 kWh 8000

Powador-gridsave 540 kWh 6400 Powador-gridsave 540 kWh 8000

Powador-gridsave 577 kWh 6400 Powador-gridsave 577 kWh 8000

Powador-gridsave 675 kWh 6400 Powador-gridsave 675 kWh 8000

This is to confirm that the units listed above comply with the protection requirements set forth in the Directive of the Council of the European Union of 15th December 2004 on the harmonisation of the laws of the member states relating to Electromagnetic Compatibility (2004108EC) and the Low Voltage Directive (200695EC)The units are compliant with the following standards

200695EC ldquoDirective relating to electrical equipment designed for use within specific voltage limitsrdquo

Safety of the unitIEC 62109-12010IEC 62109-22011

2004108EC ldquoDirective relating to electromagneticcompatibilityrdquo

Interference immunityEN 61000-6-22005 Emitted interferenceEN 61000-6-32007

Secondary effects on the gridEN 61000-3-112000EN 61000-3-122005

The types mentioned above are therefore labelled with the CE markUnauthorised modifications to the supplied units andor any use of the units that is contrary to their intended use render this Declaration of Conformity null and void

Neckarsulm 0711 2013KACO new energy GmbH

pp Volker DietrichEnergy systems engineering management

Disposal

Page 38 Operating instructions Powador-gridsave_EN

Carl-Zeiss-Straszlige 1 middot 74172 Neckarsulm middot Germany middot Phone +49 7132 3818-0 middot Fax +49 7132 3818-703 middot infokaco-newenergyde middot wwwkaco-newenergyde

The

text

and

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res

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ct th

e cu

rren

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hnic

al s

tate

at t

he ti

me

of p

rintin

g S

ubje

ct to

tech

nica

l cha

nges

Err

ors

and

omis

sion

s ex

cept

ed

3006

856-

01-1

4030

5

  • 1General Information
    • 11About this document
    • 12Name plate
    • 13Additional information
    • 14Intended use
      • 2Safety
        • 21Protection features
          • 3Description
            • 31Mode of Operation
            • 32Summary of the components
              • 4Technical Data
                • 41Electrical data
                • 42Mechanical data
                  • 5Transportation and Delivery
                    • 51Delivery
                    • 52Storage
                    • 53Transportation
                      • 6Assembling the device
                        • 61Installation
                        • 62Installing components
                          • 7Installing the device
                            • 71Opening the connection area
                            • 72Making the electrical connection
                            • 73Connecting the interfaces
                            • 74Sealing the connection area
                            • 75Starting up
                            • 76Standard configuration
                              • 8Configuration and Operation
                                • 81Controls
                                  • 9MaintenanceTroubleshooting
                                    • 91Visual inspection
                                    • 92Cleaning the device
                                    • 93Maintenance
                                    • 94Faults
                                      • 10Service
                                      • 11ShutdownDisassembly
                                        • 111Switching off the device
                                        • 112Uninstalling the device
                                        • 113Disassembling the device
                                          • 12Disposal
                                          • 13Appendix

Configuration and Operation

Operating instructions Powador-gridsave_EN Page 31

Menu Submenu Display setting

Action in this menumeaning

Settings

Country amp directive display

Display of the country settings voltage directives and grid type

Select menu language

DateTime Specify time zone date format and date and time

Screen Activate screen-save function and set the delay period

Network settings

Display of the network settings Configure network settings Once the DHCP server becomes available the IP

address subnet mask gateway and DNS server are automatically applied and the aforemen-tioned menu items are hidden

Off DHCP deactivated make settings manually

Version Displays the installed software version and built-in HW components (inverter BBC battery)

Vendor The touchscreen shows information about the device vendor

NOTEAs changes to the software are possible after the manual has been printed the illustrations and descriptions of the functions in these operating instructions may deviate from the software Please therefore note the current Application Notes on our website

MaintenanceTroubleshooting

Page 32 Operating instructions Powador-gridsave_EN

9 MaintenanceTroubleshooting

91 Visual inspectionInspect the device and the cables for visible external damage and note the operating status display In case of damage notify your installer Repairs may only be carried out by authorised electricians

NOTEThe battery system should be checked for proper operation by a qualified electrician at regular intervals

92 Cleaning the device

DANGERLethal voltages in the battery systemSerious injuries or death can result if moisture enters the system rsaquo Only use completely dry objects to clean the battery system rsaquo Only clean the outside of the battery system

Cleaning the battery system Do not use compressed air Use a vacuum cleaner or a soft brush to remove dust from the fan cover and from the top of the inverter on a

regular basis Remove dust from the ventilation inlets if necessary

MaintenanceTroubleshooting

Operating instructions Powador-gridsave_EN Page 33

Authorised electrician

93 Maintenance

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched The device is only permitted to be opened or serviced by an authorised electrician rsaquo Observe all safety regulations and the current technical connection specifications from the relevant

power supply company rsaquo Disconnect the AC and DC sides rsaquo Secure the AC and DC sides from being inadvertently switched back on rsaquo Only then should the device be opened rsaquo After shutdown wait at least 30 minutes before working on the device

CAUTIONDestruction of the DC connectionThe connection terminals can be destroyed by arcing if disconnected while still live rsaquo It is absolutely essential that the shutdown sequence be carried out in the correct order (See sec-

tion 111 on page 35)

94 Faults

941 Procedure

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched

When a fault occurs notify an appropriately authorised and qualified electrician or KACO new energy GmbH Service

Service

Page 34 Operating instructions Powador-gridsave_EN

10 ServiceIf 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 efficientlybull Serial nobull SW version of the components (the software version can be found in the Settings menu using the EMS)bull Module type and string circuitbull Date of installation Start-up reportbull Consignment identification Delivery address Contact person (with telephone number)bull Information about the accessibility of the installation site

Any additional costs arising from unfavourable structural or mounting conditions shall be billed to the customer

You can find our warranty conditions on our websitehttpkaco-newenergycomservicewarrantyFrom there you can easily navigate to our international websites by clicking on the appropriate flag

Please use our website to register your unit immediatelyYou can also select the appropriate flag on this page to access the website for your own countryIn this manner you can assist us in providing you with the quickest service possible Note The maximum length of the warranty is based on the currently applicable national warranty conditions

We have prepared a template for complaints This can be found at httpskaco-newenergycomservicecustomer-service

Hotlines

Technical troubleshooting Technical consultation

Inverters and battery systems ()

+49 (0) 71323818-660 +49 (0) 71323818-660

Data logging and accessories +49 (0) 71323818-690 +49 (0) 71323818-690

Construction site emergency () +49 (0) 71323818-630

Customer help desk Monday to Friday from 730 am to 530 pm (CET)

() Also on Saturdays from 800 am to 200 pm (CET)

ShutdownDisassembly

Operating instructions Powador-gridsave_EN Page 35

11 ShutdownDisassembly

111 Switching off the device

DANGERLethal voltages are still present in the terminals and cables even after switching off and discon-nection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched rsaquo Complete de-energisation only occurs if the bulk power supply is switched off upstream of the bat-

tery system

DANGERDestruction of the DC plug connectorDC plug connectors can be destroyed by arcing if disconnected while still live rsaquo It is absolutely essential that the following shutdown sequence is observed

1111 Step 1 Shutting down the PV system

1 Switch off any optional external PV isolator switches2 Set the internal DC isolator switch to OFF raquo The inverter and battery charging unit battery backup converter (BBC) are disconnected

1112 Step 2 Disconnect the batteries

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

1113 Step 3 Disconnect the AC supply

1 Connect external isolation means to the device2 Switch off the circuit breaker 3 Switch off the residual current circuit breaker raquo The battery system is switched off

1114 Step 4 AC home power grid

1 Shutdown the AC home power grid using the AC main switch raquo The battery system can be uninstalled

Disposal

Page 36 Operating instructions Powador-gridsave_EN

112 Uninstalling the device

NOTETo uninstall follow the same sequence as for installation but in reverse order

Switch off the device1 Unlock and open the housing door2 Remove the upper cover3 Release the DC and AC cables from the connection terminals4 Pull out the cables raquo The battery system is uninstalled Continue with the disassembly

113 Disassembling the device

NOTETo disassemble follow the same sequence as for assembly but in reverse order

Switch off the device1 Uninstall the components2 Remove the fastening from the device3 Securely pack up the battery system if it is to be used later

or have the battery system disposed of in accordance with section 12 on page 36

12 DisposalFor the most part both the battery system and the corresponding transport packaging are made from recyclable raw materialsBatteries and components Do not dispose of faulty batteries or the components together with household waste Ensure that the old device and accessories are disposed of in a proper mannerPackaging Ensure that the transport packaging is disposed of properlyBatteriesUsed or faulty batteries must be transported in special packaging If you need such packaging please contact the KACO Hotline

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

Appendix

Operating instructions Powador-gridsave_EN Page 37

13 Appendix

EU Declaration of Conformity

Vendorrsquos name and address

KACO new energy GmbH Carl-Zeiss-Straszlige 1 74172 Neckarsulm Germany

Product description Battery system

Type designation Powador-gridsave 135 kWh 6400 Powador-gridsave 135 kWh 8000

Powador-gridsave 270 kWh 6400 Powador-gridsave 270 kWh 8000

Powador-gridsave 405 kWh 6400 Powador-gridsave 405 kWh 8000

Powador-gridsave 540 kWh 6400 Powador-gridsave 540 kWh 8000

Powador-gridsave 577 kWh 6400 Powador-gridsave 577 kWh 8000

Powador-gridsave 675 kWh 6400 Powador-gridsave 675 kWh 8000

This is to confirm that the units listed above comply with the protection requirements set forth in the Directive of the Council of the European Union of 15th December 2004 on the harmonisation of the laws of the member states relating to Electromagnetic Compatibility (2004108EC) and the Low Voltage Directive (200695EC)The units are compliant with the following standards

200695EC ldquoDirective relating to electrical equipment designed for use within specific voltage limitsrdquo

Safety of the unitIEC 62109-12010IEC 62109-22011

2004108EC ldquoDirective relating to electromagneticcompatibilityrdquo

Interference immunityEN 61000-6-22005 Emitted interferenceEN 61000-6-32007

Secondary effects on the gridEN 61000-3-112000EN 61000-3-122005

The types mentioned above are therefore labelled with the CE markUnauthorised modifications to the supplied units andor any use of the units that is contrary to their intended use render this Declaration of Conformity null and void

Neckarsulm 0711 2013KACO new energy GmbH

pp Volker DietrichEnergy systems engineering management

Disposal

Page 38 Operating instructions Powador-gridsave_EN

Carl-Zeiss-Straszlige 1 middot 74172 Neckarsulm middot Germany middot Phone +49 7132 3818-0 middot Fax +49 7132 3818-703 middot infokaco-newenergyde middot wwwkaco-newenergyde

The

text

and

figu

res

refle

ct th

e cu

rren

t tec

hnic

al s

tate

at t

he ti

me

of p

rintin

g S

ubje

ct to

tech

nica

l cha

nges

Err

ors

and

omis

sion

s ex

cept

ed

3006

856-

01-1

4030

5

  • 1General Information
    • 11About this document
    • 12Name plate
    • 13Additional information
    • 14Intended use
      • 2Safety
        • 21Protection features
          • 3Description
            • 31Mode of Operation
            • 32Summary of the components
              • 4Technical Data
                • 41Electrical data
                • 42Mechanical data
                  • 5Transportation and Delivery
                    • 51Delivery
                    • 52Storage
                    • 53Transportation
                      • 6Assembling the device
                        • 61Installation
                        • 62Installing components
                          • 7Installing the device
                            • 71Opening the connection area
                            • 72Making the electrical connection
                            • 73Connecting the interfaces
                            • 74Sealing the connection area
                            • 75Starting up
                            • 76Standard configuration
                              • 8Configuration and Operation
                                • 81Controls
                                  • 9MaintenanceTroubleshooting
                                    • 91Visual inspection
                                    • 92Cleaning the device
                                    • 93Maintenance
                                    • 94Faults
                                      • 10Service
                                      • 11ShutdownDisassembly
                                        • 111Switching off the device
                                        • 112Uninstalling the device
                                        • 113Disassembling the device
                                          • 12Disposal
                                          • 13Appendix

MaintenanceTroubleshooting

Page 32 Operating instructions Powador-gridsave_EN

9 MaintenanceTroubleshooting

91 Visual inspectionInspect the device and the cables for visible external damage and note the operating status display In case of damage notify your installer Repairs may only be carried out by authorised electricians

NOTEThe battery system should be checked for proper operation by a qualified electrician at regular intervals

92 Cleaning the device

DANGERLethal voltages in the battery systemSerious injuries or death can result if moisture enters the system rsaquo Only use completely dry objects to clean the battery system rsaquo Only clean the outside of the battery system

Cleaning the battery system Do not use compressed air Use a vacuum cleaner or a soft brush to remove dust from the fan cover and from the top of the inverter on a

regular basis Remove dust from the ventilation inlets if necessary

MaintenanceTroubleshooting

Operating instructions Powador-gridsave_EN Page 33

Authorised electrician

93 Maintenance

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched The device is only permitted to be opened or serviced by an authorised electrician rsaquo Observe all safety regulations and the current technical connection specifications from the relevant

power supply company rsaquo Disconnect the AC and DC sides rsaquo Secure the AC and DC sides from being inadvertently switched back on rsaquo Only then should the device be opened rsaquo After shutdown wait at least 30 minutes before working on the device

CAUTIONDestruction of the DC connectionThe connection terminals can be destroyed by arcing if disconnected while still live rsaquo It is absolutely essential that the shutdown sequence be carried out in the correct order (See sec-

tion 111 on page 35)

94 Faults

941 Procedure

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched

When a fault occurs notify an appropriately authorised and qualified electrician or KACO new energy GmbH Service

Service

Page 34 Operating instructions Powador-gridsave_EN

10 ServiceIf 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 efficientlybull Serial nobull SW version of the components (the software version can be found in the Settings menu using the EMS)bull Module type and string circuitbull Date of installation Start-up reportbull Consignment identification Delivery address Contact person (with telephone number)bull Information about the accessibility of the installation site

Any additional costs arising from unfavourable structural or mounting conditions shall be billed to the customer

You can find our warranty conditions on our websitehttpkaco-newenergycomservicewarrantyFrom there you can easily navigate to our international websites by clicking on the appropriate flag

Please use our website to register your unit immediatelyYou can also select the appropriate flag on this page to access the website for your own countryIn this manner you can assist us in providing you with the quickest service possible Note The maximum length of the warranty is based on the currently applicable national warranty conditions

We have prepared a template for complaints This can be found at httpskaco-newenergycomservicecustomer-service

Hotlines

Technical troubleshooting Technical consultation

Inverters and battery systems ()

+49 (0) 71323818-660 +49 (0) 71323818-660

Data logging and accessories +49 (0) 71323818-690 +49 (0) 71323818-690

Construction site emergency () +49 (0) 71323818-630

Customer help desk Monday to Friday from 730 am to 530 pm (CET)

() Also on Saturdays from 800 am to 200 pm (CET)

ShutdownDisassembly

Operating instructions Powador-gridsave_EN Page 35

11 ShutdownDisassembly

111 Switching off the device

DANGERLethal voltages are still present in the terminals and cables even after switching off and discon-nection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched rsaquo Complete de-energisation only occurs if the bulk power supply is switched off upstream of the bat-

tery system

DANGERDestruction of the DC plug connectorDC plug connectors can be destroyed by arcing if disconnected while still live rsaquo It is absolutely essential that the following shutdown sequence is observed

1111 Step 1 Shutting down the PV system

1 Switch off any optional external PV isolator switches2 Set the internal DC isolator switch to OFF raquo The inverter and battery charging unit battery backup converter (BBC) are disconnected

1112 Step 2 Disconnect the batteries

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

1113 Step 3 Disconnect the AC supply

1 Connect external isolation means to the device2 Switch off the circuit breaker 3 Switch off the residual current circuit breaker raquo The battery system is switched off

1114 Step 4 AC home power grid

1 Shutdown the AC home power grid using the AC main switch raquo The battery system can be uninstalled

Disposal

Page 36 Operating instructions Powador-gridsave_EN

112 Uninstalling the device

NOTETo uninstall follow the same sequence as for installation but in reverse order

Switch off the device1 Unlock and open the housing door2 Remove the upper cover3 Release the DC and AC cables from the connection terminals4 Pull out the cables raquo The battery system is uninstalled Continue with the disassembly

113 Disassembling the device

NOTETo disassemble follow the same sequence as for assembly but in reverse order

Switch off the device1 Uninstall the components2 Remove the fastening from the device3 Securely pack up the battery system if it is to be used later

or have the battery system disposed of in accordance with section 12 on page 36

12 DisposalFor the most part both the battery system and the corresponding transport packaging are made from recyclable raw materialsBatteries and components Do not dispose of faulty batteries or the components together with household waste Ensure that the old device and accessories are disposed of in a proper mannerPackaging Ensure that the transport packaging is disposed of properlyBatteriesUsed or faulty batteries must be transported in special packaging If you need such packaging please contact the KACO Hotline

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

Appendix

Operating instructions Powador-gridsave_EN Page 37

13 Appendix

EU Declaration of Conformity

Vendorrsquos name and address

KACO new energy GmbH Carl-Zeiss-Straszlige 1 74172 Neckarsulm Germany

Product description Battery system

Type designation Powador-gridsave 135 kWh 6400 Powador-gridsave 135 kWh 8000

Powador-gridsave 270 kWh 6400 Powador-gridsave 270 kWh 8000

Powador-gridsave 405 kWh 6400 Powador-gridsave 405 kWh 8000

Powador-gridsave 540 kWh 6400 Powador-gridsave 540 kWh 8000

Powador-gridsave 577 kWh 6400 Powador-gridsave 577 kWh 8000

Powador-gridsave 675 kWh 6400 Powador-gridsave 675 kWh 8000

This is to confirm that the units listed above comply with the protection requirements set forth in the Directive of the Council of the European Union of 15th December 2004 on the harmonisation of the laws of the member states relating to Electromagnetic Compatibility (2004108EC) and the Low Voltage Directive (200695EC)The units are compliant with the following standards

200695EC ldquoDirective relating to electrical equipment designed for use within specific voltage limitsrdquo

Safety of the unitIEC 62109-12010IEC 62109-22011

2004108EC ldquoDirective relating to electromagneticcompatibilityrdquo

Interference immunityEN 61000-6-22005 Emitted interferenceEN 61000-6-32007

Secondary effects on the gridEN 61000-3-112000EN 61000-3-122005

The types mentioned above are therefore labelled with the CE markUnauthorised modifications to the supplied units andor any use of the units that is contrary to their intended use render this Declaration of Conformity null and void

Neckarsulm 0711 2013KACO new energy GmbH

pp Volker DietrichEnergy systems engineering management

Disposal

Page 38 Operating instructions Powador-gridsave_EN

Carl-Zeiss-Straszlige 1 middot 74172 Neckarsulm middot Germany middot Phone +49 7132 3818-0 middot Fax +49 7132 3818-703 middot infokaco-newenergyde middot wwwkaco-newenergyde

The

text

and

figu

res

refle

ct th

e cu

rren

t tec

hnic

al s

tate

at t

he ti

me

of p

rintin

g S

ubje

ct to

tech

nica

l cha

nges

Err

ors

and

omis

sion

s ex

cept

ed

3006

856-

01-1

4030

5

  • 1General Information
    • 11About this document
    • 12Name plate
    • 13Additional information
    • 14Intended use
      • 2Safety
        • 21Protection features
          • 3Description
            • 31Mode of Operation
            • 32Summary of the components
              • 4Technical Data
                • 41Electrical data
                • 42Mechanical data
                  • 5Transportation and Delivery
                    • 51Delivery
                    • 52Storage
                    • 53Transportation
                      • 6Assembling the device
                        • 61Installation
                        • 62Installing components
                          • 7Installing the device
                            • 71Opening the connection area
                            • 72Making the electrical connection
                            • 73Connecting the interfaces
                            • 74Sealing the connection area
                            • 75Starting up
                            • 76Standard configuration
                              • 8Configuration and Operation
                                • 81Controls
                                  • 9MaintenanceTroubleshooting
                                    • 91Visual inspection
                                    • 92Cleaning the device
                                    • 93Maintenance
                                    • 94Faults
                                      • 10Service
                                      • 11ShutdownDisassembly
                                        • 111Switching off the device
                                        • 112Uninstalling the device
                                        • 113Disassembling the device
                                          • 12Disposal
                                          • 13Appendix

MaintenanceTroubleshooting

Operating instructions Powador-gridsave_EN Page 33

Authorised electrician

93 Maintenance

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched The device is only permitted to be opened or serviced by an authorised electrician rsaquo Observe all safety regulations and the current technical connection specifications from the relevant

power supply company rsaquo Disconnect the AC and DC sides rsaquo Secure the AC and DC sides from being inadvertently switched back on rsaquo Only then should the device be opened rsaquo After shutdown wait at least 30 minutes before working on the device

CAUTIONDestruction of the DC connectionThe connection terminals can be destroyed by arcing if disconnected while still live rsaquo It is absolutely essential that the shutdown sequence be carried out in the correct order (See sec-

tion 111 on page 35)

94 Faults

941 Procedure

DANGERLethal voltages are still present in the terminals and cables in the device even after switching off and disconnection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched

When a fault occurs notify an appropriately authorised and qualified electrician or KACO new energy GmbH Service

Service

Page 34 Operating instructions Powador-gridsave_EN

10 ServiceIf 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 efficientlybull Serial nobull SW version of the components (the software version can be found in the Settings menu using the EMS)bull Module type and string circuitbull Date of installation Start-up reportbull Consignment identification Delivery address Contact person (with telephone number)bull Information about the accessibility of the installation site

Any additional costs arising from unfavourable structural or mounting conditions shall be billed to the customer

You can find our warranty conditions on our websitehttpkaco-newenergycomservicewarrantyFrom there you can easily navigate to our international websites by clicking on the appropriate flag

Please use our website to register your unit immediatelyYou can also select the appropriate flag on this page to access the website for your own countryIn this manner you can assist us in providing you with the quickest service possible Note The maximum length of the warranty is based on the currently applicable national warranty conditions

We have prepared a template for complaints This can be found at httpskaco-newenergycomservicecustomer-service

Hotlines

Technical troubleshooting Technical consultation

Inverters and battery systems ()

+49 (0) 71323818-660 +49 (0) 71323818-660

Data logging and accessories +49 (0) 71323818-690 +49 (0) 71323818-690

Construction site emergency () +49 (0) 71323818-630

Customer help desk Monday to Friday from 730 am to 530 pm (CET)

() Also on Saturdays from 800 am to 200 pm (CET)

ShutdownDisassembly

Operating instructions Powador-gridsave_EN Page 35

11 ShutdownDisassembly

111 Switching off the device

DANGERLethal voltages are still present in the terminals and cables even after switching off and discon-nection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched rsaquo Complete de-energisation only occurs if the bulk power supply is switched off upstream of the bat-

tery system

DANGERDestruction of the DC plug connectorDC plug connectors can be destroyed by arcing if disconnected while still live rsaquo It is absolutely essential that the following shutdown sequence is observed

1111 Step 1 Shutting down the PV system

1 Switch off any optional external PV isolator switches2 Set the internal DC isolator switch to OFF raquo The inverter and battery charging unit battery backup converter (BBC) are disconnected

1112 Step 2 Disconnect the batteries

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

1113 Step 3 Disconnect the AC supply

1 Connect external isolation means to the device2 Switch off the circuit breaker 3 Switch off the residual current circuit breaker raquo The battery system is switched off

1114 Step 4 AC home power grid

1 Shutdown the AC home power grid using the AC main switch raquo The battery system can be uninstalled

Disposal

Page 36 Operating instructions Powador-gridsave_EN

112 Uninstalling the device

NOTETo uninstall follow the same sequence as for installation but in reverse order

Switch off the device1 Unlock and open the housing door2 Remove the upper cover3 Release the DC and AC cables from the connection terminals4 Pull out the cables raquo The battery system is uninstalled Continue with the disassembly

113 Disassembling the device

NOTETo disassemble follow the same sequence as for assembly but in reverse order

Switch off the device1 Uninstall the components2 Remove the fastening from the device3 Securely pack up the battery system if it is to be used later

or have the battery system disposed of in accordance with section 12 on page 36

12 DisposalFor the most part both the battery system and the corresponding transport packaging are made from recyclable raw materialsBatteries and components Do not dispose of faulty batteries or the components together with household waste Ensure that the old device and accessories are disposed of in a proper mannerPackaging Ensure that the transport packaging is disposed of properlyBatteriesUsed or faulty batteries must be transported in special packaging If you need such packaging please contact the KACO Hotline

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

Appendix

Operating instructions Powador-gridsave_EN Page 37

13 Appendix

EU Declaration of Conformity

Vendorrsquos name and address

KACO new energy GmbH Carl-Zeiss-Straszlige 1 74172 Neckarsulm Germany

Product description Battery system

Type designation Powador-gridsave 135 kWh 6400 Powador-gridsave 135 kWh 8000

Powador-gridsave 270 kWh 6400 Powador-gridsave 270 kWh 8000

Powador-gridsave 405 kWh 6400 Powador-gridsave 405 kWh 8000

Powador-gridsave 540 kWh 6400 Powador-gridsave 540 kWh 8000

Powador-gridsave 577 kWh 6400 Powador-gridsave 577 kWh 8000

Powador-gridsave 675 kWh 6400 Powador-gridsave 675 kWh 8000

This is to confirm that the units listed above comply with the protection requirements set forth in the Directive of the Council of the European Union of 15th December 2004 on the harmonisation of the laws of the member states relating to Electromagnetic Compatibility (2004108EC) and the Low Voltage Directive (200695EC)The units are compliant with the following standards

200695EC ldquoDirective relating to electrical equipment designed for use within specific voltage limitsrdquo

Safety of the unitIEC 62109-12010IEC 62109-22011

2004108EC ldquoDirective relating to electromagneticcompatibilityrdquo

Interference immunityEN 61000-6-22005 Emitted interferenceEN 61000-6-32007

Secondary effects on the gridEN 61000-3-112000EN 61000-3-122005

The types mentioned above are therefore labelled with the CE markUnauthorised modifications to the supplied units andor any use of the units that is contrary to their intended use render this Declaration of Conformity null and void

Neckarsulm 0711 2013KACO new energy GmbH

pp Volker DietrichEnergy systems engineering management

Disposal

Page 38 Operating instructions Powador-gridsave_EN

Carl-Zeiss-Straszlige 1 middot 74172 Neckarsulm middot Germany middot Phone +49 7132 3818-0 middot Fax +49 7132 3818-703 middot infokaco-newenergyde middot wwwkaco-newenergyde

The

text

and

figu

res

refle

ct th

e cu

rren

t tec

hnic

al s

tate

at t

he ti

me

of p

rintin

g S

ubje

ct to

tech

nica

l cha

nges

Err

ors

and

omis

sion

s ex

cept

ed

3006

856-

01-1

4030

5

  • 1General Information
    • 11About this document
    • 12Name plate
    • 13Additional information
    • 14Intended use
      • 2Safety
        • 21Protection features
          • 3Description
            • 31Mode of Operation
            • 32Summary of the components
              • 4Technical Data
                • 41Electrical data
                • 42Mechanical data
                  • 5Transportation and Delivery
                    • 51Delivery
                    • 52Storage
                    • 53Transportation
                      • 6Assembling the device
                        • 61Installation
                        • 62Installing components
                          • 7Installing the device
                            • 71Opening the connection area
                            • 72Making the electrical connection
                            • 73Connecting the interfaces
                            • 74Sealing the connection area
                            • 75Starting up
                            • 76Standard configuration
                              • 8Configuration and Operation
                                • 81Controls
                                  • 9MaintenanceTroubleshooting
                                    • 91Visual inspection
                                    • 92Cleaning the device
                                    • 93Maintenance
                                    • 94Faults
                                      • 10Service
                                      • 11ShutdownDisassembly
                                        • 111Switching off the device
                                        • 112Uninstalling the device
                                        • 113Disassembling the device
                                          • 12Disposal
                                          • 13Appendix

Service

Page 34 Operating instructions Powador-gridsave_EN

10 ServiceIf 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 efficientlybull Serial nobull SW version of the components (the software version can be found in the Settings menu using the EMS)bull Module type and string circuitbull Date of installation Start-up reportbull Consignment identification Delivery address Contact person (with telephone number)bull Information about the accessibility of the installation site

Any additional costs arising from unfavourable structural or mounting conditions shall be billed to the customer

You can find our warranty conditions on our websitehttpkaco-newenergycomservicewarrantyFrom there you can easily navigate to our international websites by clicking on the appropriate flag

Please use our website to register your unit immediatelyYou can also select the appropriate flag on this page to access the website for your own countryIn this manner you can assist us in providing you with the quickest service possible Note The maximum length of the warranty is based on the currently applicable national warranty conditions

We have prepared a template for complaints This can be found at httpskaco-newenergycomservicecustomer-service

Hotlines

Technical troubleshooting Technical consultation

Inverters and battery systems ()

+49 (0) 71323818-660 +49 (0) 71323818-660

Data logging and accessories +49 (0) 71323818-690 +49 (0) 71323818-690

Construction site emergency () +49 (0) 71323818-630

Customer help desk Monday to Friday from 730 am to 530 pm (CET)

() Also on Saturdays from 800 am to 200 pm (CET)

ShutdownDisassembly

Operating instructions Powador-gridsave_EN Page 35

11 ShutdownDisassembly

111 Switching off the device

DANGERLethal voltages are still present in the terminals and cables even after switching off and discon-nection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched rsaquo Complete de-energisation only occurs if the bulk power supply is switched off upstream of the bat-

tery system

DANGERDestruction of the DC plug connectorDC plug connectors can be destroyed by arcing if disconnected while still live rsaquo It is absolutely essential that the following shutdown sequence is observed

1111 Step 1 Shutting down the PV system

1 Switch off any optional external PV isolator switches2 Set the internal DC isolator switch to OFF raquo The inverter and battery charging unit battery backup converter (BBC) are disconnected

1112 Step 2 Disconnect the batteries

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

1113 Step 3 Disconnect the AC supply

1 Connect external isolation means to the device2 Switch off the circuit breaker 3 Switch off the residual current circuit breaker raquo The battery system is switched off

1114 Step 4 AC home power grid

1 Shutdown the AC home power grid using the AC main switch raquo The battery system can be uninstalled

Disposal

Page 36 Operating instructions Powador-gridsave_EN

112 Uninstalling the device

NOTETo uninstall follow the same sequence as for installation but in reverse order

Switch off the device1 Unlock and open the housing door2 Remove the upper cover3 Release the DC and AC cables from the connection terminals4 Pull out the cables raquo The battery system is uninstalled Continue with the disassembly

113 Disassembling the device

NOTETo disassemble follow the same sequence as for assembly but in reverse order

Switch off the device1 Uninstall the components2 Remove the fastening from the device3 Securely pack up the battery system if it is to be used later

or have the battery system disposed of in accordance with section 12 on page 36

12 DisposalFor the most part both the battery system and the corresponding transport packaging are made from recyclable raw materialsBatteries and components Do not dispose of faulty batteries or the components together with household waste Ensure that the old device and accessories are disposed of in a proper mannerPackaging Ensure that the transport packaging is disposed of properlyBatteriesUsed or faulty batteries must be transported in special packaging If you need such packaging please contact the KACO Hotline

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

Appendix

Operating instructions Powador-gridsave_EN Page 37

13 Appendix

EU Declaration of Conformity

Vendorrsquos name and address

KACO new energy GmbH Carl-Zeiss-Straszlige 1 74172 Neckarsulm Germany

Product description Battery system

Type designation Powador-gridsave 135 kWh 6400 Powador-gridsave 135 kWh 8000

Powador-gridsave 270 kWh 6400 Powador-gridsave 270 kWh 8000

Powador-gridsave 405 kWh 6400 Powador-gridsave 405 kWh 8000

Powador-gridsave 540 kWh 6400 Powador-gridsave 540 kWh 8000

Powador-gridsave 577 kWh 6400 Powador-gridsave 577 kWh 8000

Powador-gridsave 675 kWh 6400 Powador-gridsave 675 kWh 8000

This is to confirm that the units listed above comply with the protection requirements set forth in the Directive of the Council of the European Union of 15th December 2004 on the harmonisation of the laws of the member states relating to Electromagnetic Compatibility (2004108EC) and the Low Voltage Directive (200695EC)The units are compliant with the following standards

200695EC ldquoDirective relating to electrical equipment designed for use within specific voltage limitsrdquo

Safety of the unitIEC 62109-12010IEC 62109-22011

2004108EC ldquoDirective relating to electromagneticcompatibilityrdquo

Interference immunityEN 61000-6-22005 Emitted interferenceEN 61000-6-32007

Secondary effects on the gridEN 61000-3-112000EN 61000-3-122005

The types mentioned above are therefore labelled with the CE markUnauthorised modifications to the supplied units andor any use of the units that is contrary to their intended use render this Declaration of Conformity null and void

Neckarsulm 0711 2013KACO new energy GmbH

pp Volker DietrichEnergy systems engineering management

Disposal

Page 38 Operating instructions Powador-gridsave_EN

Carl-Zeiss-Straszlige 1 middot 74172 Neckarsulm middot Germany middot Phone +49 7132 3818-0 middot Fax +49 7132 3818-703 middot infokaco-newenergyde middot wwwkaco-newenergyde

The

text

and

figu

res

refle

ct th

e cu

rren

t tec

hnic

al s

tate

at t

he ti

me

of p

rintin

g S

ubje

ct to

tech

nica

l cha

nges

Err

ors

and

omis

sion

s ex

cept

ed

3006

856-

01-1

4030

5

  • 1General Information
    • 11About this document
    • 12Name plate
    • 13Additional information
    • 14Intended use
      • 2Safety
        • 21Protection features
          • 3Description
            • 31Mode of Operation
            • 32Summary of the components
              • 4Technical Data
                • 41Electrical data
                • 42Mechanical data
                  • 5Transportation and Delivery
                    • 51Delivery
                    • 52Storage
                    • 53Transportation
                      • 6Assembling the device
                        • 61Installation
                        • 62Installing components
                          • 7Installing the device
                            • 71Opening the connection area
                            • 72Making the electrical connection
                            • 73Connecting the interfaces
                            • 74Sealing the connection area
                            • 75Starting up
                            • 76Standard configuration
                              • 8Configuration and Operation
                                • 81Controls
                                  • 9MaintenanceTroubleshooting
                                    • 91Visual inspection
                                    • 92Cleaning the device
                                    • 93Maintenance
                                    • 94Faults
                                      • 10Service
                                      • 11ShutdownDisassembly
                                        • 111Switching off the device
                                        • 112Uninstalling the device
                                        • 113Disassembling the device
                                          • 12Disposal
                                          • 13Appendix

ShutdownDisassembly

Operating instructions Powador-gridsave_EN Page 35

11 ShutdownDisassembly

111 Switching off the device

DANGERLethal voltages are still present in the terminals and cables even after switching off and discon-nection of the battery systemSevere injuries or death may occur if the cables and terminals in the device are touched rsaquo Complete de-energisation only occurs if the bulk power supply is switched off upstream of the bat-

tery system

DANGERDestruction of the DC plug connectorDC plug connectors can be destroyed by arcing if disconnected while still live rsaquo It is absolutely essential that the following shutdown sequence is observed

1111 Step 1 Shutting down the PV system

1 Switch off any optional external PV isolator switches2 Set the internal DC isolator switch to OFF raquo The inverter and battery charging unit battery backup converter (BBC) are disconnected

1112 Step 2 Disconnect the batteries

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

1113 Step 3 Disconnect the AC supply

1 Connect external isolation means to the device2 Switch off the circuit breaker 3 Switch off the residual current circuit breaker raquo The battery system is switched off

1114 Step 4 AC home power grid

1 Shutdown the AC home power grid using the AC main switch raquo The battery system can be uninstalled

Disposal

Page 36 Operating instructions Powador-gridsave_EN

112 Uninstalling the device

NOTETo uninstall follow the same sequence as for installation but in reverse order

Switch off the device1 Unlock and open the housing door2 Remove the upper cover3 Release the DC and AC cables from the connection terminals4 Pull out the cables raquo The battery system is uninstalled Continue with the disassembly

113 Disassembling the device

NOTETo disassemble follow the same sequence as for assembly but in reverse order

Switch off the device1 Uninstall the components2 Remove the fastening from the device3 Securely pack up the battery system if it is to be used later

or have the battery system disposed of in accordance with section 12 on page 36

12 DisposalFor the most part both the battery system and the corresponding transport packaging are made from recyclable raw materialsBatteries and components Do not dispose of faulty batteries or the components together with household waste Ensure that the old device and accessories are disposed of in a proper mannerPackaging Ensure that the transport packaging is disposed of properlyBatteriesUsed or faulty batteries must be transported in special packaging If you need such packaging please contact the KACO Hotline

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

Appendix

Operating instructions Powador-gridsave_EN Page 37

13 Appendix

EU Declaration of Conformity

Vendorrsquos name and address

KACO new energy GmbH Carl-Zeiss-Straszlige 1 74172 Neckarsulm Germany

Product description Battery system

Type designation Powador-gridsave 135 kWh 6400 Powador-gridsave 135 kWh 8000

Powador-gridsave 270 kWh 6400 Powador-gridsave 270 kWh 8000

Powador-gridsave 405 kWh 6400 Powador-gridsave 405 kWh 8000

Powador-gridsave 540 kWh 6400 Powador-gridsave 540 kWh 8000

Powador-gridsave 577 kWh 6400 Powador-gridsave 577 kWh 8000

Powador-gridsave 675 kWh 6400 Powador-gridsave 675 kWh 8000

This is to confirm that the units listed above comply with the protection requirements set forth in the Directive of the Council of the European Union of 15th December 2004 on the harmonisation of the laws of the member states relating to Electromagnetic Compatibility (2004108EC) and the Low Voltage Directive (200695EC)The units are compliant with the following standards

200695EC ldquoDirective relating to electrical equipment designed for use within specific voltage limitsrdquo

Safety of the unitIEC 62109-12010IEC 62109-22011

2004108EC ldquoDirective relating to electromagneticcompatibilityrdquo

Interference immunityEN 61000-6-22005 Emitted interferenceEN 61000-6-32007

Secondary effects on the gridEN 61000-3-112000EN 61000-3-122005

The types mentioned above are therefore labelled with the CE markUnauthorised modifications to the supplied units andor any use of the units that is contrary to their intended use render this Declaration of Conformity null and void

Neckarsulm 0711 2013KACO new energy GmbH

pp Volker DietrichEnergy systems engineering management

Disposal

Page 38 Operating instructions Powador-gridsave_EN

Carl-Zeiss-Straszlige 1 middot 74172 Neckarsulm middot Germany middot Phone +49 7132 3818-0 middot Fax +49 7132 3818-703 middot infokaco-newenergyde middot wwwkaco-newenergyde

The

text

and

figu

res

refle

ct th

e cu

rren

t tec

hnic

al s

tate

at t

he ti

me

of p

rintin

g S

ubje

ct to

tech

nica

l cha

nges

Err

ors

and

omis

sion

s ex

cept

ed

3006

856-

01-1

4030

5

  • 1General Information
    • 11About this document
    • 12Name plate
    • 13Additional information
    • 14Intended use
      • 2Safety
        • 21Protection features
          • 3Description
            • 31Mode of Operation
            • 32Summary of the components
              • 4Technical Data
                • 41Electrical data
                • 42Mechanical data
                  • 5Transportation and Delivery
                    • 51Delivery
                    • 52Storage
                    • 53Transportation
                      • 6Assembling the device
                        • 61Installation
                        • 62Installing components
                          • 7Installing the device
                            • 71Opening the connection area
                            • 72Making the electrical connection
                            • 73Connecting the interfaces
                            • 74Sealing the connection area
                            • 75Starting up
                            • 76Standard configuration
                              • 8Configuration and Operation
                                • 81Controls
                                  • 9MaintenanceTroubleshooting
                                    • 91Visual inspection
                                    • 92Cleaning the device
                                    • 93Maintenance
                                    • 94Faults
                                      • 10Service
                                      • 11ShutdownDisassembly
                                        • 111Switching off the device
                                        • 112Uninstalling the device
                                        • 113Disassembling the device
                                          • 12Disposal
                                          • 13Appendix

Disposal

Page 36 Operating instructions Powador-gridsave_EN

112 Uninstalling the device

NOTETo uninstall follow the same sequence as for installation but in reverse order

Switch off the device1 Unlock and open the housing door2 Remove the upper cover3 Release the DC and AC cables from the connection terminals4 Pull out the cables raquo The battery system is uninstalled Continue with the disassembly

113 Disassembling the device

NOTETo disassemble follow the same sequence as for assembly but in reverse order

Switch off the device1 Uninstall the components2 Remove the fastening from the device3 Securely pack up the battery system if it is to be used later

or have the battery system disposed of in accordance with section 12 on page 36

12 DisposalFor the most part both the battery system and the corresponding transport packaging are made from recyclable raw materialsBatteries and components Do not dispose of faulty batteries or the components together with household waste Ensure that the old device and accessories are disposed of in a proper mannerPackaging Ensure that the transport packaging is disposed of properlyBatteriesUsed or faulty batteries must be transported in special packaging If you need such packaging please contact the KACO Hotline

NOTEPlease read the additional information in the enclosed manual Features for the battery unit

Appendix

Operating instructions Powador-gridsave_EN Page 37

13 Appendix

EU Declaration of Conformity

Vendorrsquos name and address

KACO new energy GmbH Carl-Zeiss-Straszlige 1 74172 Neckarsulm Germany

Product description Battery system

Type designation Powador-gridsave 135 kWh 6400 Powador-gridsave 135 kWh 8000

Powador-gridsave 270 kWh 6400 Powador-gridsave 270 kWh 8000

Powador-gridsave 405 kWh 6400 Powador-gridsave 405 kWh 8000

Powador-gridsave 540 kWh 6400 Powador-gridsave 540 kWh 8000

Powador-gridsave 577 kWh 6400 Powador-gridsave 577 kWh 8000

Powador-gridsave 675 kWh 6400 Powador-gridsave 675 kWh 8000

This is to confirm that the units listed above comply with the protection requirements set forth in the Directive of the Council of the European Union of 15th December 2004 on the harmonisation of the laws of the member states relating to Electromagnetic Compatibility (2004108EC) and the Low Voltage Directive (200695EC)The units are compliant with the following standards

200695EC ldquoDirective relating to electrical equipment designed for use within specific voltage limitsrdquo

Safety of the unitIEC 62109-12010IEC 62109-22011

2004108EC ldquoDirective relating to electromagneticcompatibilityrdquo

Interference immunityEN 61000-6-22005 Emitted interferenceEN 61000-6-32007

Secondary effects on the gridEN 61000-3-112000EN 61000-3-122005

The types mentioned above are therefore labelled with the CE markUnauthorised modifications to the supplied units andor any use of the units that is contrary to their intended use render this Declaration of Conformity null and void

Neckarsulm 0711 2013KACO new energy GmbH

pp Volker DietrichEnergy systems engineering management

Disposal

Page 38 Operating instructions Powador-gridsave_EN

Carl-Zeiss-Straszlige 1 middot 74172 Neckarsulm middot Germany middot Phone +49 7132 3818-0 middot Fax +49 7132 3818-703 middot infokaco-newenergyde middot wwwkaco-newenergyde

The

text

and

figu

res

refle

ct th

e cu

rren

t tec

hnic

al s

tate

at t

he ti

me

of p

rintin

g S

ubje

ct to

tech

nica

l cha

nges

Err

ors

and

omis

sion

s ex

cept

ed

3006

856-

01-1

4030

5

  • 1General Information
    • 11About this document
    • 12Name plate
    • 13Additional information
    • 14Intended use
      • 2Safety
        • 21Protection features
          • 3Description
            • 31Mode of Operation
            • 32Summary of the components
              • 4Technical Data
                • 41Electrical data
                • 42Mechanical data
                  • 5Transportation and Delivery
                    • 51Delivery
                    • 52Storage
                    • 53Transportation
                      • 6Assembling the device
                        • 61Installation
                        • 62Installing components
                          • 7Installing the device
                            • 71Opening the connection area
                            • 72Making the electrical connection
                            • 73Connecting the interfaces
                            • 74Sealing the connection area
                            • 75Starting up
                            • 76Standard configuration
                              • 8Configuration and Operation
                                • 81Controls
                                  • 9MaintenanceTroubleshooting
                                    • 91Visual inspection
                                    • 92Cleaning the device
                                    • 93Maintenance
                                    • 94Faults
                                      • 10Service
                                      • 11ShutdownDisassembly
                                        • 111Switching off the device
                                        • 112Uninstalling the device
                                        • 113Disassembling the device
                                          • 12Disposal
                                          • 13Appendix

Appendix

Operating instructions Powador-gridsave_EN Page 37

13 Appendix

EU Declaration of Conformity

Vendorrsquos name and address

KACO new energy GmbH Carl-Zeiss-Straszlige 1 74172 Neckarsulm Germany

Product description Battery system

Type designation Powador-gridsave 135 kWh 6400 Powador-gridsave 135 kWh 8000

Powador-gridsave 270 kWh 6400 Powador-gridsave 270 kWh 8000

Powador-gridsave 405 kWh 6400 Powador-gridsave 405 kWh 8000

Powador-gridsave 540 kWh 6400 Powador-gridsave 540 kWh 8000

Powador-gridsave 577 kWh 6400 Powador-gridsave 577 kWh 8000

Powador-gridsave 675 kWh 6400 Powador-gridsave 675 kWh 8000

This is to confirm that the units listed above comply with the protection requirements set forth in the Directive of the Council of the European Union of 15th December 2004 on the harmonisation of the laws of the member states relating to Electromagnetic Compatibility (2004108EC) and the Low Voltage Directive (200695EC)The units are compliant with the following standards

200695EC ldquoDirective relating to electrical equipment designed for use within specific voltage limitsrdquo

Safety of the unitIEC 62109-12010IEC 62109-22011

2004108EC ldquoDirective relating to electromagneticcompatibilityrdquo

Interference immunityEN 61000-6-22005 Emitted interferenceEN 61000-6-32007

Secondary effects on the gridEN 61000-3-112000EN 61000-3-122005

The types mentioned above are therefore labelled with the CE markUnauthorised modifications to the supplied units andor any use of the units that is contrary to their intended use render this Declaration of Conformity null and void

Neckarsulm 0711 2013KACO new energy GmbH

pp Volker DietrichEnergy systems engineering management

Disposal

Page 38 Operating instructions Powador-gridsave_EN

Carl-Zeiss-Straszlige 1 middot 74172 Neckarsulm middot Germany middot Phone +49 7132 3818-0 middot Fax +49 7132 3818-703 middot infokaco-newenergyde middot wwwkaco-newenergyde

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3006

856-

01-1

4030

5

  • 1General Information
    • 11About this document
    • 12Name plate
    • 13Additional information
    • 14Intended use
      • 2Safety
        • 21Protection features
          • 3Description
            • 31Mode of Operation
            • 32Summary of the components
              • 4Technical Data
                • 41Electrical data
                • 42Mechanical data
                  • 5Transportation and Delivery
                    • 51Delivery
                    • 52Storage
                    • 53Transportation
                      • 6Assembling the device
                        • 61Installation
                        • 62Installing components
                          • 7Installing the device
                            • 71Opening the connection area
                            • 72Making the electrical connection
                            • 73Connecting the interfaces
                            • 74Sealing the connection area
                            • 75Starting up
                            • 76Standard configuration
                              • 8Configuration and Operation
                                • 81Controls
                                  • 9MaintenanceTroubleshooting
                                    • 91Visual inspection
                                    • 92Cleaning the device
                                    • 93Maintenance
                                    • 94Faults
                                      • 10Service
                                      • 11ShutdownDisassembly
                                        • 111Switching off the device
                                        • 112Uninstalling the device
                                        • 113Disassembling the device
                                          • 12Disposal
                                          • 13Appendix

Disposal

Page 38 Operating instructions Powador-gridsave_EN

Carl-Zeiss-Straszlige 1 middot 74172 Neckarsulm middot Germany middot Phone +49 7132 3818-0 middot Fax +49 7132 3818-703 middot infokaco-newenergyde middot wwwkaco-newenergyde

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3006

856-

01-1

4030

5

  • 1General Information
    • 11About this document
    • 12Name plate
    • 13Additional information
    • 14Intended use
      • 2Safety
        • 21Protection features
          • 3Description
            • 31Mode of Operation
            • 32Summary of the components
              • 4Technical Data
                • 41Electrical data
                • 42Mechanical data
                  • 5Transportation and Delivery
                    • 51Delivery
                    • 52Storage
                    • 53Transportation
                      • 6Assembling the device
                        • 61Installation
                        • 62Installing components
                          • 7Installing the device
                            • 71Opening the connection area
                            • 72Making the electrical connection
                            • 73Connecting the interfaces
                            • 74Sealing the connection area
                            • 75Starting up
                            • 76Standard configuration
                              • 8Configuration and Operation
                                • 81Controls
                                  • 9MaintenanceTroubleshooting
                                    • 91Visual inspection
                                    • 92Cleaning the device
                                    • 93Maintenance
                                    • 94Faults
                                      • 10Service
                                      • 11ShutdownDisassembly
                                        • 111Switching off the device
                                        • 112Uninstalling the device
                                        • 113Disassembling the device
                                          • 12Disposal
                                          • 13Appendix

Carl-Zeiss-Straszlige 1 middot 74172 Neckarsulm middot Germany middot Phone +49 7132 3818-0 middot Fax +49 7132 3818-703 middot infokaco-newenergyde middot wwwkaco-newenergyde

The

text

and

figu

res

refle

ct th

e cu

rren

t tec

hnic

al s

tate

at t

he ti

me

of p

rintin

g S

ubje

ct to

tech

nica

l cha

nges

Err

ors

and

omis

sion

s ex

cept

ed

3006

856-

01-1

4030

5

  • 1General Information
    • 11About this document
    • 12Name plate
    • 13Additional information
    • 14Intended use
      • 2Safety
        • 21Protection features
          • 3Description
            • 31Mode of Operation
            • 32Summary of the components
              • 4Technical Data
                • 41Electrical data
                • 42Mechanical data
                  • 5Transportation and Delivery
                    • 51Delivery
                    • 52Storage
                    • 53Transportation
                      • 6Assembling the device
                        • 61Installation
                        • 62Installing components
                          • 7Installing the device
                            • 71Opening the connection area
                            • 72Making the electrical connection
                            • 73Connecting the interfaces
                            • 74Sealing the connection area
                            • 75Starting up
                            • 76Standard configuration
                              • 8Configuration and Operation
                                • 81Controls
                                  • 9MaintenanceTroubleshooting
                                    • 91Visual inspection
                                    • 92Cleaning the device
                                    • 93Maintenance
                                    • 94Faults
                                      • 10Service
                                      • 11ShutdownDisassembly
                                        • 111Switching off the device
                                        • 112Uninstalling the device
                                        • 113Disassembling the device
                                          • 12Disposal
                                          • 13Appendix