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Electrical Connection

SMA America, LLC

38

SB50US-80US-IA-en-36

Installation Manual

6.2.1 Wiring with DC disconnect

Procedure and Order

1. Switch off all energy sources. Open all AC and DC disconnect switches and breakers.
2. Wiring from AC breaker to DC disconnect.
3. AC wiring from DC disconnect to Sunny Boy.
4. Wiring from PV array to DC disconnect.
5. DC wiring from DC disconnect to Sunny Boy.
6. Switch DC disconnect to position "1".
7. Switch on AC breaker.

Removing Sunny Boy from Wiring

• Disconnect all AC disconnect switches.
• Switch DC disconnect to position "0".
• Always disconnect the AC side before the DC side.
• When the Sunny Boy is switched off, remove the wiring in reverse order.

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Summary of Contents for SUNNY BOY 5000-US

Page 1: ...SB50US 80US IA en 36 TBUS SB50_60_70US Version 3 6 CA US PV Inverter SUNNY BOY 5000 US 6000 US 7000 US 8000 US Installation Manual...

Page 2: ......

Page 3: ...f implied warranties may not apply in all cases under some statutes and thus the above exclusion may not apply Specifications are subject to change without notice Every attempt has been made to make t...

Page 4: ...t carefully read and follow all instructions cautions and warnings in this installation guide Warnings in this document A warning describes a hazard to equipment or personnel It calls attention to a p...

Page 5: ...cumentation of the product Beware of hot surface The product can become hot during operation Do not touch the product during operation Observe the operating instructions Read the documentation of the...

Page 6: ...e jurisdiction of installation SMA assumes no responsibility for the compliance or noncompliance with such laws or codes in connection with the installation of the inverter The Sunny Boy contains no u...

Page 7: ...tion 16 3 1 Scope of Delivery 16 4 AC Voltage Configuration 17 4 1 Opening the Sunny Boy 17 4 2 Locating Internal Component Parts 18 4 3 AC Voltage Configuration 19 4 4 Jumper for System Configuration...

Page 8: ...C Connection 46 6 6 1 DC Connection Requirements 47 6 6 2 DC Input Grounding 48 6 6 3 Connecting the DC Cables in the DC disconnect 49 6 6 4 DC Connection with Additional DC Distribution 54 6 7 Commun...

Page 9: ...83 10 5 Exchanging the Fuses 85 10 5 1 Exchanging the GFDI Fuse within the Sunny Boy 85 10 5 2 Exchanging PV String Fuses within the DC disconnect 86 10 6 Testing and Replacing the DC Varistors 88 11...

Page 10: ......

Page 11: ...e connected devices is available from the manufacturers of the devices 1 2 Target Group This manual is for qualified personnel Qualified personnel have received training and have demonstrated skills a...

Page 12: ...he electric utility company depending on the interconnection agreement Principle of a PV Plant with a Sunny Boy Ground Fault Detection and Interruption in the PV Array All Sunny Boy inverters have a s...

Page 13: ...istribution grid is switched off and the Sunny Boy is in operation For this to happen the remaining load must be resonant at 60 Hz and exactly match the power of the Sunny Boy Although the appearance...

Page 14: ...is connected to the power distribution grid The Sunny Boy is also certified according to Canadian Electrical Code CSA C22 2 N0 107 1 01 General Use Power Supplies 2 2 Safety Instructions Prior to sett...

Page 15: ...ne cross section safety measures and warnings to prevent injuries and or damage to the device and step by step instructions for connecting the Sunny Boy to a PV array to an electric circuit in the hom...

Page 16: ...3 3 1 Scope of Delivery only SB 5000US 12 SB 6000US 12 SB 7000US 12 SB 8000US 12 Position Quantity Description A 1 Sunny Boy B 1 Wall mounting bracket C 1 Replacement screw and replacement conical spr...

Page 17: ...For inserting the conduits into the enclosure and the DC Disconnect only use UL certified rainproof sleeves or waterproof sleeves that fulfill UL 514B Do not open the Sunny Boy in the event of rain or...

Page 18: ...for optional communication Piggy Back RS485 or wireless B Display C Status LEDs D Jumpers for configuring the AC voltage and the fan test E Terminal blocks for configuring the AC voltage F Ground ter...

Page 19: ...the AC voltage select the cable with the correct voltage at the right terminal block C Connect the selected cable to the left side of the left terminal block A 3 Secure all screw terminals If spring...

Page 20: ...ve the procedure in 4 4 Jumper for System Configuration page 22 To connect a neutral conductor to the Sunny Boy observe section 6 5 2 AC Connection in the DC Disconnect page 42 or section AC Connectio...

Page 21: ...C Voltage Configuration SB50US 80US IA en 36 SB50US 80US IA en 36 21 The Sunny Boy 8000 US must not be connected to a 208 V grid When using grounded 240 V or 208 V Delta grids Connect terminal L2 to t...

Page 22: ...possible The following figure provides an overview of the standard settings the settings for grids without neutral conductors and the settings for the fan test The Sunny Boy 8000 US must not be conne...

Page 23: ...er in which the inverters are connected to the phases Configuration Examples for Jumpers with 240 V Delta 120 V Stinger Configuration Examples for Jumpers with 240 V Delta Grounded When using grounded...

Page 24: ...ng Contusions or bone fractures due to the heavy weight of the Sunny Boy When mounting the Sunny Boy take its weight of 148 lb 67 kg into consideration Use appropriate mounting material for the mounti...

Page 25: ...surface The mounting location must be accessible at all times Mount vertically or tilted backward at max 45 The connection area must point downward Do not install the inverter tilting forward Do not i...

Page 26: ...will prevent the inverter power from being reduced due to too high temperatures Recommended clearances The National Electrical Code may stipulate greater clearances see National Electrical Code Sectio...

Page 27: ...nting with Wall Mounting Bracket The Sunny Boy is supplied with a T shaped wall mounting bracket that is suitable for most walls The wall must be vertical and stable enough to carry a weight of 145 lb...

Page 28: ...LLC 28 SB50US 80US IA en 36 Installation Manual Dimensions of the Wall Mounting Bracket 2 in 50 mm 2 in 50 mm 2 in 50 mm 2 in 50 mm 2 in 50 mm 2 in 50 mm 2 in 50 mm 2 in 50 mm 23 in 584 mm 11 in 280...

Page 29: ...Pillar Secure the wall mounting bracket with at least 3 screws The position of the screws on the wall mounting bracket is as follows 2 screws at the upper middle 1 screw below Mount the wall mounting...

Page 30: ...nting the DC Disconnect Inserting the DC varistors WARNING Electric shock due to damaged electric cables Electric cables may be located behind the installation points which can be damaged when mountin...

Page 31: ...tors Insert the insertion tool into the rectangular opening of the terminal Insert the DC varistor into the terminal Pull the insertion tool out of the rectangular opening of the terminal 3 Ensure tha...

Page 32: ...oles of the wall mounting bracket using the two screws and washers provided 1 Insert the screws with the washers through the holes of the anchorage brackets of the DC disconnect The teeth of the washe...

Page 33: ...e opening above and transport it between two people 2 Hook the Sunny Boy with the enclosure opening onto the rear panel in the wall mounting bracket The Sunny Boy must be seated on the middle of the w...

Page 34: ...Sunny Boy during frost the seal of the enclosure lid can be damaged There may be an ingress of moisture damaging the Sunny Boy Do not open the Sunny Boy when the outdoor temperature is below 23 F 5 C...

Page 35: ...y be required by the Authority Having Jurisdiction AHJ Use the connecting terminal plate for the PV grounding conductor and DC grounding conductor see section 4 2 Locating Internal Component Parts pag...

Page 36: ...ribution grid are connected inside the enclosure The internal AC and DC connecting terminal plates are designed for a maximum size of 6 AWG Suitable enclosure openings are on the underside of the Sunn...

Page 37: ...p 50 Amp N L1 L2 Betrieb Operation Betrieb Operation Erdschluss Earth Fault Erdschluss Earth Fault St rung Failure St rung Failure PV Ungrounded PV Grounded SMA DC Disconnect SUNNY BOY SMA SOLAR TECHN...

Page 38: ...breaker to DC disconnect 3 AC wiring from DC disconnect to Sunny Boy 4 Wiring from PV array to DC disconnect 5 DC wiring from DC disconnect to Sunny Boy 6 Switch DC disconnect to position 1 7 Switch o...

Page 39: ...njury due to electric shock Only open the Sunny Boy in the order described as follows NOTICE Moisture can penetrate the open Sunny Boy Potential damage to the Sunny Boy Do not open the Sunny Boy in th...

Page 40: ...r on the underside of the DC disconnect 4 Remove the rotary switch 5 Remove the cover of the DC disconnect Pull the cover on the underside forward In the process simultaneously remove it from the encl...

Page 41: ...allations according to all of the applicable on site electrical standards and the National Electrical Code NE ANSI NFPA 70 See National Electrical Code Section 690 64 b 2 For installations in Canada o...

Page 42: ...n which you are working Open terminals fully before feeding through the cables 5 Connect the AC device grounding conductor to the PE terminal labeled in the DC disconnect 208 V and 240 V System Config...

Page 43: ...Configuration 11 Tighten the cables with a torque of 15 in lb 1 7 Nm 12 Check that all terminals have the correct wiring and that the cables are secure 9 Connect conductor L1 AC conductor 1 or UNGROU...

Page 44: ...rommet in the inverter 2 Remove the rubber membrane 3 Feed the cable through the rubber grommet into the inverter 4 Pull the cable back slightly so as to seal the rubber grommet 5 Connect the green ye...

Page 45: ...tion 8 Connect the white cable of the DC disconnect to the terminal labeled N Connect the black insulated conductor of the DC disconnect to the terminal labeled L1 9 Connect the red insulated conducto...

Page 46: ...onnect the DC cable from the PV module to the inverter as described in this manual NOTICE Potential damage to the inverter due to overvoltage The DC input voltage of the PV modules must not exceed the...

Page 47: ...he Canadian Electrical Code CSA C22 1 and the applicable standards in Canada When selecting the cable type and the line cross section observe the following requirements depending on the type of instal...

Page 48: ...n dimensioning the fuses observe the National Electrical Code 690 8 and 690 9 6 6 2 DC Input Grounding The Sunny Boy is configured ex works for plants with negative PV array grounding Certain types of...

Page 49: ...cable conduit between the enclosure of the DC disconnect and the PV array 4 Pull the DC cables the grounding cables of the PV array and the grounding conductor through the cable conduit and inside th...

Page 50: ...your inverter is grounded as intended observe section 6 6 2 DC Input Grounding page 48 7 Connect the positive DC cables to the terminal A labeled PV UNGROUNDED in the DC disconnect 8 Connect the negat...

Page 51: ...C cables from the SMA DC disconnect inside the Sunny Boy 13 Pull the cable back slightly so as to seal the sealing grommet 14 Connect the black cable PV UNGROUNDED to the terminal labeled DC in the Su...

Page 52: ...r your inverter is grounded as intended observe section 6 6 2 DC Input Grounding page 48 1 Connect the negative DC cable to the terminal labeled PV UNGROUNDED A in the DC disconnect 2 Connect the posi...

Page 53: ...the DC cables from the SMA DC disconnect inside the Sunny Boy 7 Pull the cable back slightly so as to seal the sealing grommet 8 Connect the white cable PV GROUNDED to the terminal labeled DC in the S...

Page 54: ...ded 2 Press the screwdriver upward The spring terminal is open 3 Feed the stripped cable into the spring terminal 4 Pull the screwdriver back into its original position 5 Remove the screwdriver The sp...

Page 55: ...nication The Sunny Boy can be equipped with a communication interface in order to communicate with SMA communication products You will find further information and a list of applicable communication p...

Page 56: ...he seal between the enclosure lid and the enclosure There may be an ingress of moisture Potential damage to the Sunny Boy Handle the enclosure lid with care Check the seal on the inner side of the enc...

Page 57: ...a cross head screwdriver screw used UNC no 5x3 4 in cross head flat head 3 Insert the screw and conical spring washer of the DC disconnect into the underside Tighten the screw with a torque of 44 in l...

Page 58: ...ition 1 The Sunny Boy performs an AFCI self test DANGER High voltages in the PV plant when exposed to sunlight Risk of death or serious injuries due to incorrect commissioning Only commission the Sunn...

Page 59: ...1 Check whether the input voltage is sufficient For the input voltage values see 11 Technical Data page 91 2 If the input voltage is not sufficient perform troubleshooting in the PV array and rectify...

Page 60: ...ircuit voltage 3 After the fault is rectified restart the Sunny Boy Turn the DC disconnect to position 1 The Sunny Box starts and performs another AFCI self test 4 If the following message appears on...

Page 61: ...the AFCI self test continues to fail Turn the DC disconnect to position 0 and switch off the AC disconnect switch to the inverter The Message EarthCurrentMax Is Displayed A ground fault is present in...

Page 62: ...inverter The red LED indicates the status of the GFDI fuse located inside the Sunny Boy If this LED lights up the GFDI fuse has cleared or is not present The inverter does not feed into the power dist...

Page 63: ...smission is not possible during initialization If the yellow LED and the red LED light up simultaneously the inverter has a ground fault The ground fault may also trip the GFDI fuse Observe section 8...

Page 64: ...TOP mode this status is displayed as well Waiting The inverter checks the grid requirements and whether enough voltage from the array is available to feed into the power distribution grid If the feed...

Page 65: ...for using the inverter with fuel cells or small hydroelectric power plants Turbine mode This mode is suitable for using the inverter with a rectified DC generator and dynamic power characteristic curv...

Page 66: ...GFDI fuse was cleared or is not present This fuse protects the PV plant if a ground fault is present in the PV array Locate and rectify the ground fault Observe section 9 Troubleshooting page 77 Then...

Page 67: ...sequence is repeated 3 times As long as a grid failure continues to be present this flashing code will repeat itself The flashing code can be caused by one of the following conditions Grid undervoltag...

Page 68: ...put voltage that is too high for safe operation Inverter Interference The yellow LED lights up for 5 seconds goes out for 3 seconds then flashes 5 times The message is repeated 3 times If the status d...

Page 69: ...onds the installed firmware versions of the operation control unit OCU and the current control system SRR are displayed Operation Messages The LCD scrolls consecutively through all operation messages...

Page 70: ...display shows the value of the fault at as well as the current value for the corresponding parameter present Warning The GFDI fuse is cleared Warning messages display a plant status that must be inves...

Page 71: ...d language as shown below 3 Close the Sunny Boy as described in Section 6 8 Closing the Sunny Boy page 56 The display language is set 8 5 Measuring Channels and Parameters The communication options su...

Page 72: ...ax PV input voltage I dif Fault current Vfan Fan voltage E Total Total energy yield h Total Total operating hours h on h on displays how long sufficient DC voltage has been applied at the Sunny Boy an...

Page 73: ...tus relating to the grid As soon as the cause of the fault is no longer present this fault will be reset automatically Error Inverter fault user interaction required Warning System warning advising fu...

Page 74: ...and below 60 Hz Standard value is optimal for plants 30 kW Fac delta Hz 0 4 5 0 49 for country setting USA UL1741 2005 Electrically qualified person Fac MinTripTime s 0 16 300 0 16 Electrically qualif...

Page 75: ...of 88 as the list of trip limits shows Vac Max 0 20 10 Electrically qualified person Values are used to calculate the upper limit of permissible AC voltage Standard value is optimal for plants 30 kW S...

Page 76: ...ly qualified person Minimum DC voltage for the Sunny Boy to connect to the grid Name Unit Range Standard Description Plimit V fixed SB 5000 US 5100 SB 6000 US 6100 SB 7000 US 7100 SB 8000 US 8100 Uppe...

Page 77: ...maintenance use the original box in order to prevent shipping damage 9 2 Error Messages Error type Error code Description Interference Ocu Srr Communication between micro controllers is interrupted W...

Page 78: ...eason for this may be severe grid interference If Imax appears frequently check the AC grid If you require help contact SMA Interference K1 Close Relay test failed Contact SMA Error K1 Open K2 Open In...

Page 79: ...riggered Interference XFMR The transformer is connected to the wrong grid Check the connection of the transformer For grounded Delta grids Monitor whether the grid grounding conductor is connected to...

Page 80: ...Disconnect the Sunny Boy on the AC and DC sides 2 Wait 5 minutes until the residual voltage has been drained and the fans are no longer turning Cleaning the Fan Guard 3 Remove the ventilation grids Pr...

Page 81: ...t slowly and carefully downward 7 Unlock and remove the plug The cables of the fans are long enough to disconnect the plug in the inside of the Sunny Boy 8 Remove the fan 9 Clean the fan with a soft b...

Page 82: ...e to be mounted is stated on the inside of the handle covers links left and rechts right 10 3 Checking the DC Disconnect It is recommended though not compulsory to Check the DC disconnect regularly Ac...

Page 83: ...or checking the fans is included in the scope of supply of the Sunny Boy Setting the Parameter 1 Ask for the installer password from SMA Service Line See Contact on page 103 2 Set the Fan Test paramet...

Page 84: ...9 3 Insert the jumper supplied into the slot on the sequential control system board shown below 4 Close the Sunny Boy as described in section 6 8 Closing the Sunny Boy page 56 5 Check the air flow of...

Page 85: ...the Sunny Boy as described in section 6 3 Opening the Sunny Boy page 39 2 Replace the fuse A For the correct position of the fuse observe section DC Input Grounding on page 48 3 Completely insert the...

Page 86: ...ual voltage has been drained 3 Open the DC disconnect as described in section 6 4 Opening the DC Disconnect page 40 4 Replace the fuse 1 2 3 or 4 5 Close the DC disconnect as described in section 6 9...

Page 87: ...ding this up to the nearest standard size for fuses DC Disconnect Requirements National Electrical Code 690 15 18 enables the use of fuse holders as a suitable medium for disconnecting PV arrays for m...

Page 88: ...utes for the components to cool down 3 Open the DC disconnect as described in Section 6 4 Opening the DC Disconnect page 40 Only the following inverter types are equipped with DC varistors SB 5000US 1...

Page 89: ...use extractors Insert the four fuse extractors without the string fuses into the fuse holders B of the DC disconnect 6 Ensure that no voltage is present at the DC varistors If no voltage is present re...

Page 90: ...DC disconnect Remove the four fuse extractors without string fuses from the fuse holders B of the DC disconnect Equip the four fuse extractors with functional string fuses Insert the four fuse extrac...

Page 91: ...voltage range at 208 V nominal value 183 V 229 V AC operating voltage range at 240 V nominal value 211 V 264 V AC operating voltage range at 277 V nominal value 244 V 305 V AC operating frequency ran...

Page 92: ...C 95 5 CEC weighted efficiency at 277 V AC 95 5 Ambient temperature range SB 5000US 13 F 113 F 25 C 45 C Ambient temperature range SB 5000US 12 40 F 113 F 40 C 45 C Width x height x depth 183 8 in x 2...

Page 93: ...range at 208 V nominal value 183 V 229 V AC operating voltage range at 240 V nominal value 211 V 264 V AC operating voltage range at 277 V nominal value 244 V 305 V AC operating frequency range 59 3 H...

Page 94: ...C 95 5 CEC weighted efficiency at 277 V AC 96 0 Ambient temperature range SB 6000US 13 F 113 F 25 C 45 C Ambient temperature range SB 6000US 12 40 F 113 F 40 C 45 C Width x height x depth 183 8 in x 2...

Page 95: ...e range at 208 V nominal value 183 V 229 V AC operating voltage range at 240 V nominal value 211 V 264 V AC operating voltage range at 277 V nominal value 244 V 305 V AC operating frequency range 59 3...

Page 96: ...C 96 0 CEC weighted efficiency at 277 V AC 96 0 Ambient temperature range SB 7000US 13 F 113 F 25 C 45 C Ambient temperature range SB 7000US 12 40 F 113 F 40 C 45 C Width x height x depth 183 8 in x 2...

Page 97: ...pple 10 AC operating voltage range at 240 V nominal value 211 V 264 V AC operating voltage range at 277 V nominal value 244 V 305 V AC operating frequency range 59 3 Hz 60 5 Hz AC frequency nominal va...

Page 98: ...ficiency at 240 V AC 96 0 CEC weighted efficiency at 277 V AC 96 0 Ambient temperature range SB 8000US 13 F 113 F 25 C 45 C Ambient temperature range SB 8000US 12 40 F 113 F 40 C 45 C Width x height x...

Page 99: ...to change without notice Maximum DC input current 30 A Maximum DC short circuit current 36 A Maximum system voltage 600 V Maximum nominal size for string fuses 20 A Maximum AC operating current 34 A D...

Page 100: ...standard max 0 1602 s 57 0 Hz 56 95 Hz 57 05 Hz max 0 1602 s Nominal Voltage Trip Limit Trip Voltages Conductor Neutral Conductor Trip Voltages Conductor Conductor Trip Times 208 V 50 88 110 120 57 6...

Page 101: ...used in the configuration of the AC voltage Phoenix 15 in lb 1 7 Nm AC DC terminal blocks DC disconnect 15 in lb 1 7 Nm 10 6 AWG Combined terminal block DC disconnect Spring terminal 10 6 AWG Groundi...

Page 102: ...is no guarantee that interference will not occur in a particular installation If this equipment does cause harmful interference to radio or television reception which can be determined by turning the...

Page 103: ...mmunication Interference or warning messages from Sunny Boy Sunny Boy display message SMA Solar Technology America LLC 6020 West Oaks Blvd Ste 300 Rocklin CA 95765 Tel 1 916 625 0870 Tel 1 877 MY SMA...

Page 104: ...SMA America LLC Installation Manual SB50US 80US IA en 36 104 4 NFSJDB 1SPEVDUJPO XXX 4 NFSJDB DPN...

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