Wireless RS485 for KACO Link Introduction The SP PRO KACO Managed AC Coupling provides a method of linking the KACO Powador xx00 and Powador xx02 series grid tie inverters to the SP PRO AU or GO Series (SP PRO) via the AC Load supply so that regardless of whether the grid or a generator is connected, the SP PRO can manage and control the KACO grid tie inverters. Each SP PRO can manage a maximum of five KACO grid tie inverters by commanding each grid tie inverter to output the required amount of power. This is done via either a wireless or wired communications link which also serves to retrieve all the operational data from the KACO inverters for display and logging by the SP PRO. This document details the additional steps needed to install a Wireless RS485 link into a SP PRO KACO Managed AC Coupled system. The SP PRO and KACO inverters are installed as per their individual installation instructions with the additional allowance of communications cables and a Wireless RS485 linking communications between all of the inverters. Note: This document needs to be read in conjunction with IN00018-Installaion of Managed AC coupling, the SP PRO AU or GO Series Instruction Manual and the KACO xx02 Series or KACO xx00 Series Instruction Manual. Overview The diagram below (fig. 1) shows a typical single phase managed AC coupled system with five KACO inverters (Two direct connected and three via the wireless link). Fig. 1 Overview of single phase system using the Wireless RS485 IN0029 Revision 03 (005074) 1 of 15 POWER PERFORMANCE PASSION
The diagram below (fig. 2) shows a typical three phase managed AC coupled system with three KACO inverters per phase (one direct connected and two via the wireless link). A separate pair of wireless devices must be used for each phase. NOTE: When using multiple Wireless RS485 device pairs it is recommended that Patch Antennas be used on each of the devices at the local end of the system (SP PRO end). This will reduce the interference between devices and ensure trouble free operation. Fig. 2 Overview of three phase system using the Wireless RS485 IN0029 Revision 03 (005074) 2 of 15
The diagram below (fig. 3) shows a typical single phase managed AC coupled system with three separate remote locations. In this scenario each remote location is separated by a distance that cannot accommodate a hard wired connection between them. A separate pair of wireless devices must be used for each remote location. NOTE: When using multiple Wireless RS485 device pairs it is recommended that Patch Antennas be used on each of the devices at the local end of the system (SP PRO end). This will reduce the interference between devices and ensure trouble free operation. Fig. 3 Overview of single phase system using multiple Wireless RS485 IN0029 Revision 03 (005074) 3 of 15 POWER PERFORMANCE PASSION
Wireless link restrictions The wireless link uses the same frequency band as WiFi (2.4GHz). Any obstructions between the two devices or interference from other devices using the same frequency band (other blue tooth or WiFi devices) will have a significant impact on their range. To achieve the maximum range of 200m there must be line of sight between the two devices and no interference. As a rule of thumb each obstruction that is equivalent to a stud wall will reduce the distance by about 20%. Mud brick walls, double brick or concrete walls will have a much larger impact on the range. Any obstruction from the landscape such as levy banks, hills or undulation land will totally block the signal and the wireless link will not work. If more than one wireless link is required within the same installation (such as a three phase system or multiple remote sites) then the interference between the devices will further reduce the distance. In this case it is recommended that a patch antenna be used on all local Wireless devices Extending the Wireless Range If the required distance is longer than the specified 200m clear line of site, or there is multiple devices being used then the range of the devices can be extended by replacing the dipole antenna with a patch antenna. The table 1 below gives an indication of the expected range when using a combination of dipole and patch antennas: Table 1: Maximum Line of site distance between Wireless RS485 device pairs. Local Wireless device antenna Remote wireless device antenna Max distance, one pair of devices (line of sight) Max. distance, multiple pair of devices (line of sight) Dipole (supplied) Dipole (supplied) 200m Not recommended Patch Optional (stock code 004810) Patch Optional (stock code 004810) Dipole (supplied) 300m 150m Patch Optional (stock code 004810) 500m 250m Optional Patch Antenna to extend the range of the wireless devices. Please order Selectronic Stock code 004810. Note: Patch Antenna is directional and must be mounted in a fixed position that is directly facing the antenna of the other wireless device. IN0029 Revision 03 (005074) 4 of 15
Installation SP PRO, LOCAL WIRELESS RS485 DEVICE AND LOCAL KACO COMMUNICATIONS LINK (RS485) The communications link always starts at the SP PRO, then connects to all the Local KACO inverters then to the Local Wireless RS485 device in a daisy chain arrangement. There is no need to connect the local KACO inverters in any particular order. The Local Wireless RS485 device is always connected last (see fig. 4 and 5). The termination resistor is always set in the SP PRO. The termination resistor is not set in any of the KACO inverters. Fig. 4 Communications wiring for local KACO inverters and Wireless RS485 Fig. 5 Communications wiring with ONLY Wireless RS485 (no Local KACO inverters) Using the supplied CAT5 network cable, plug one end into the SP PRO RS485 port and the other end onto the RS485 wireless adaptor as shown below. If a longer cable is required then this can be any Cat 5 cable (network patch lead). If there are local KACO inverters installed then cut off the connector on one end of the CAT 5 cable from the SP PRO, strip the wires and connect the ORANGE wire (RJ45 pin 6) to the A terminal on the KACO and the ORANGE/WHITE wire (RJ45 pin 3) to the B terminal on the KACO. See table 2 below. IN0029 Revision 03 (005074) 5 of 15 POWER PERFORMANCE PASSION
MULTIPLE WIRELESS RS485 DEVICES AND LOCAL KACO INVERTERS This configuration is used in a Managed AC coupling system that has two or three remote wireless sites where each of these is too far apart for hard wired inter-connection. The diagram below (fig. 6) shows a system with local KACO inverters. Where no local KACO inverters are installed, connect directly from the SP PRO to the first Wireless RS485 adaptor. The intermediate adaptors use an additional plug adaptor (included) to convert the single RJ45 socket into a dual RJ45 socket. This allows standard patch leads to be used to connect between each Wireless RS485 device. NOTE: When using multiple Wireless RS485 device pairs it is recommended that Patch Antennas be used on each of the devices at the local end of the system (SP PRO end). This will reduce the interference between devices and ensure trouble free operation. Fig. 6 - Communications wiring with multiple Wireless RS485 on single phase All intermediate Wireless RS485 adaptors need to have their termination resistors set to OFF. See fig. 7 below. The last Wireless RS485 Adaptor does NOT change. Fig. 7 Setting Termination Resistor for intermediate Wireless RS485 Adaptors IN0029 Revision 03 (005074) 6 of 15
MULTI PHASE INSTALLATION: SP PRO, LOCAL WIRELESS RS485 DEVICE AND LOCAL KACO To incorporate the Wireless RS485 devices in a multi-phase (three phase or split phase) Managed AC coupled system, one Wireless RS485 device pair is installed per phase. In this configuration there will be one Wireless RS485 device attached to each of the SP PRO inverters and any local KACO inverters attached to that phase. At the remote end, the matching Wireless RS485 device will only be connected to the KACO inverters for that phase. NOTE: When using multiple Wireless RS485 device pairs it is recommended that Patch Antennas be used on each of the devices at the local end of the system (SP PRO end). This will reduce the interference between devices and ensure trouble free operation. Fig. 8 Communications wiring for local Wireless RS485 Adaptors in a three phase system. IN0029 Revision 03 (005074) 7 of 15 POWER PERFORMANCE PASSION
REMOTE WIRELESS RS485 DEVICE AND KACO INVERTERS The remote communications link always starts with the RS485 device, then connects to all the remote KACO inverters in a daisy chain arrangement. There is no need to connect the local KACO inverters in any particular order. The Local Wireless RS485 device is always connected first (see fig. 9 and 10). The termination resistor is always set in the last KACO inverter. Fig. 9 Remote Wireless RS485 and Multiple Remote Kaco inverters. Fig. 10 Remote Wireless RS485 and One Remote KACO inverter. IN0029 Revision 03 (005074) 8 of 15
POWER FOR THE WIRELESS RS485 DEVICES The RS485 devices are powered from the supplied plug packs. The plug packs must be connected to the same AC power circuit as the connected KACO inverters. This is normally the AC load side of the SP PRO. Fig 11 - Wireless RS485 device connections CONNECTION DETAILS FOR THE COMMS CABLES ON EACH OF THE DEVICES The following section gives detailed connection information for the SP PRO, the KACO 00 and 02 inverters and the RS485 wireless adaptor. PLEASE NOTE: The wire colours in the table 2 below may vary between different CAT5 cables. To ensure correct connections please check that the SP PRO RS485 RJ45 pins corresponds to the KACO RS485 Connector connection by buzzing out the lead before connecting it to the KACO or the SP PRO inverter. Pin 1 Fig 12 - RS485 RJ45 Adaptor Pin 1 designation IN0029 Revision 03 (005074) 9 of 15 POWER PERFORMANCE PASSION
SP PRO RS485 RJ45 pin Signal Typical Wire Colour (May vary with different CAT5 leads) Wireless RS485 device connector KACO xx00 Series RS485 Connector 1 GND Green/White Pin 5-2 GND Green Pin 5 - KACO xx02 Series RS485 Connector GND 3 RS485 - B Orange/White Pin 7 B B 4 GND Blue - - - 5 GND Blue/White - - - 6 RS485 - A Orange Pin 3 A A 7 GND Brown/White - - - 8 GND Brown - - - Table 2 - SP PRO to Local Wireless RS485 device and Local KACO connections Note: Only the wires connected to Pins 1,2,3,and 6 (on the RJ45) are used. Connect the RJ45 connector to the SP PRO RS485 Port 2 connection Fig 13 - SP PRO Connections (inside unit) RS485 Port 2 RJ45 connector IN0029 Revision 03 (005074) 10 of 15
KACO Powador xx00 Series RS485 Connections Fig. 14 - KACO xx00 Series RS485 Connections (inside unit) double plug in socket. On the KACO inverter there are two parallel connection sockets allowing looping through of the wiring to additional inverters. Either connection point is suitable. Green mating plugs are provided with each KACO unit included with mounting hardware plastic bag. When looped to another KACO, the termination switch position 2 should be set to OFF (away from ON). For the last KACO inverter on the Communications Link (RS485) (or when only one KACO inverter is used), the termination switch position 2 must be set to ON Fig 15 - Last KACO on Communications Link (RS485), or when only 1 KACO is used: SW 2 ON (Terminator ON) Notes: 1. Green mating connector show is provided in plastic bag with mounting hardware 2. Wire colours may vary with different CAT5 cables. 3. The Ground wire (GND) from the SP PRO RS485 communication link is not connected. IN0029 Revision 03 (005074) 11 of 15 POWER PERFORMANCE PASSION
KACO Powador xx02 Series Fig 16 - KACO xx02 Series RS485 Connections (inside unit) spring loaded terminals On the KACO inverter there are two parallel sets of connections allowing looping through of the wiring to additional inverters. Either connection point is suitable. When looped to another KACO, the termination switch position 1 should be set to OFF (away from ON). For the last KACO inverter on the Communications Link (RS485) (or when only one KACO inverter is used), the termination switch position 1 must be set to ON Last KACO on Communications Link (RS485), or when only 1 KACO is used: SW 1 ON (Terminator ON) Fig. 17 Fig 18 Notes: 1. Wire colours may vary with different CAT5 cables. KACO loop-through: SW 1 OFF (Terminator OFF) IN0029 Revision 03 (005074) 12 of 15
WIRELESS RS485 DEVICE AND REMOTE KACO COMMUNICATIONS LINK (RS485) The communications link starts at the remote Wireless RS485 device then to all the Remote KACO inverters in a daisy chain arrangement and finishes at the last Remote KACO inverter. There is no need to connect the Wireless RS485 device and the Remote KACO inverters in any particular order. The remote Wireless RS485 devices and the Remote KACO connections are detailed in the table 3 below: Signal Typical Wire Colour (May vary with different CAT5 cables) Wireless RS485 device RJ45 pinout KACO xx00 Series RS485 Connector GND Green/White Pin 1 - GND Green Pin 2 - KACO xx02 Series RS485 Connector GND RS485 - B Orange/White Pin 3 B B GND Blue - - - GND Blue/White - - - RS485 - A Orange Pin 6 A A GND Brown/White - - - GND Brown - - - Table 3 - Remote Wireless RS485 device and Remote KACO connections Configuration settings for SP PRO / KACO managed AC coupling Refer to the installation instructions IN0018 SP PRO KACO managed AC coupling installation for information on setting up and commissioning the inverters. Configuration Additional settings when using wireless. It is recommended when using wireless RS485 that Fall back power mode be programmed into the SP PRO and the KACO inverters. This is a fail safe mode that will cause the KACO inverter output power to drop to zero during a period of lost communications with the SP PRO. IN0029 Revision 03 (005074) 13 of 15 POWER PERFORMANCE PASSION
PROGRAMMING FALLBACK POWER INTO THE KACO POWADOR INVERTERS This section details the process for programming the KACO inverters in the system to enable fallback power mode. Details for setting the SP PRO to fallback power mode are provided in the next section. WARNING: It is important that both the SP PRO and ALL the connected KACO inverters are set to fallback Power mode to ensure correct system operation. The set fallback power mode in the KACO inverters follow the instructions below. 1. Isolate the DC solar from the KACO inverter(s) (via the appropriate DC circuit breaker). 2. Disconnect the RS485 connection from the SP PRO. The KACO parameter settings cannot be accessed when the communications link is active between the SP PRO and the KACO(s). 3. Ensuring that the SP PRO AC Load supply is present at the KACO inverter, switch on the AC supply to the KACO inverter. 4. Wake up the KACO inverter by pressing and holding the Night Switch for 10 seconds. Fig. 19 5. Once the display is active on the KACO, enter parameter settings mode (level 2 menu) by pressing keys 1 and 2 together. The firmware version will be displayed. Check that the firmware version is greater than or equal to the following: o ARM: V5.34 o DSP: V5.32 6. Press keys 1 and 2 together to return to main menu (level 1). Hold down key 2 for 20 seconds to get to the level 3 menu. Select Country is displayed 7. Keep pressing key 1 until Config. fallback power is displayed. Press key 2 to select yes. Press key 1 and the Fallback Power screen is displayed. 8. Press key 2 to change fallback power to 0000/1000 (see fig. 20). Press key 1 until Timeout setting appears. Adjust the setting to 000005 s (see fig. 21) using key 2 to change digit and key 1 to move to next digit. Fig. 20 Fig. 21 Press keys 1 and 2 together to save settings and return to main menu IN0029 Revision 03 (005074) 14 of 15
PROGRAMMING FALLBACK POWER INTO THE KACO POWADOR INVERTERS This section details the process for programming the SP PRO inverter in the system to enable fallback power mode. Details for setting the KACO inverters to fallback power mode are provided in the previous section. WARNING: It is important that both the SP PRO and ALL the connected KACO inverters are set to fallback Power mode to ensure correct system operation. Check that the firmware revision of the SP PRO is 7.07 or greater. Click on the Configuration Settings tab then System tab. Set the Fallback Power setting to Enable. When the configuration is complete then Save Site to file (File / Site information / save). Once the site has been saved then connect to the SP PRO using the Connect button or the Connection Menu. Once connected the configuration is sent to the SP PRO using the Configure SP PRO button in the Configuration Settings tab. Selectronic web site http://www.selectronic.com.au or contact the Selectronic Sales Team. +61 3 9727 6600 www.selectronic.com.au IN0029 Revision 03 (005074) 15 of 15 POWER PERFORMANCE PASSION