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SMA Solar Technology AG

Installation Guide

SB50US-80US-IUS094030

11

1 Introduction

This installation guide provides all the information needed to install, commission and operate a Sunny
Boy (SB 5000US, SB 6000US, SB 7000US, SB 8000US) grid-tied photovoltaic (PV) inverter.

1.1 Target Group

This manual is for qualified personnel. Qualified personnel has received training and has
demonstrated skills and knowledge in the construction and operation of the device. Qualified
personnel is trained to deal with the dangers and hazards involved in installing electric devices.

To help avoid problems during the installation, familiarize yourself with the installation
process by reading the entire Installation Guide before starting the installation.

WARNING!

Lethal voltages are present at various points in a PV system. For safety reasons, it is
recommended that only qualified personnel install and operate this equipment.

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Summary of Contents for SUNNY BOY 8000-US

Page 1: ...SB50US 80US IUS094030 TBUS SB50_60_70US Version 3 0 US Solar Inverter SUNNY BOY 5000US 6000US 7000US 8000US Installation Guide...

Page 2: ......

Page 3: ...ica nor its distributors or dealers shall be liable for any indirect incidental or consequential damages under any circumstances The exclusion of implied warranties may not apply in all cases under so...

Page 4: ...ny Boy you must carefully read and follow all instructions cautions and warnings in this Installation Guide Warnings A Warning describes a hazard to equipment or personnel It calls attention to a proc...

Page 5: ...roduct works with high voltages All work on the product may only be done as described in its documentation Beware of hot surface The product can become hot during operation Avoid coming into contact w...

Page 6: ...all repair and maintenance always return the unit to an authorized SMA Service Center Before installing or using the Sunny Boy read all of the instructions cautions and warnings on the Sunny Boy the P...

Page 7: ...ring the AC Voltage 21 3 4 Utility Configuration Jumpers 24 4 Mounting 26 4 1 Choosing a Mounting Location 26 4 1 1 Selection of the Mounting Location 26 4 1 2 Ambient Conditions 27 4 1 3 Position 27...

Page 8: ...es 57 5 8 1 DC Wiring Without SMA DC Disconnect 58 5 8 2 DC Wiring With SMA DC Disconnect 60 5 8 3 DC Connection With Additional DC Distribution 65 5 9 Communication 66 5 10 Closing the Sunny Boy 66 5...

Page 9: ...2 Exchanging the PV String Fuses within the SMA DC Disconnect 94 10 Technical Specifications 96 10 1 FCC Compliance Information 96 10 2 Sunny Boy Wiring Diagrams 97 10 2 1 Without SMA DC Disconnect 9...

Page 10: ...SMA Solar Technology AG 10 SB50US 80US IUS094030 Installation Guide...

Page 11: ...d training and has demonstrated skills and knowledge in the construction and operation of the device Qualified personnel is trained to deal with the dangers and hazards involved in installing electric...

Page 12: ...ity The power consumed by the local loads reduces the power needed from the utility Excess power may actually spin the utility meter backwards depending on the type of meter in your system This power...

Page 13: ...round fault current greater than 1 Amp is detected the Sunny Boy will shut down and display the fault condition on the user interface display Once the ground fault is located and corrected the ground...

Page 14: ...D Display Temperature regulated fan cooling with simplified fan replacement Auto line voltage detection and configuration Advanced communication options Compatible with all Sunny Boy products High eff...

Page 15: ...ection includes guidelines for selecting the correct wire sizes cautions and warnings that you should follow to avoid injury and or equipment damage and step by step instructions for wiring the Sunny...

Page 16: ...inverter is damaged after unpacking it report the damage immediately to your SMA dealer and to the shipping company that delivered the Sunny Boy If it becomes necessary to return the Sunny Boy use th...

Page 17: ...g the Sunny Boy cover spare two screws and two washers for fastening the Sunny Boy to the wall mounting bracket D two jumpers in spare for the fan test and for the grid configuration E two handle cove...

Page 18: ...ful not to misplace the screws or the lock washers as all six screws and lock washers are required to ensure that the cover is grounded properly and is fully sealed to the case Handle the cover carefu...

Page 19: ...trates the locations of the major internal components of the Sunny Boy Refer to this illustration as needed to locate particular components Position Description A Sockets for optional communication Pi...

Page 20: ...nductor I Output AC Line Terminals L1 L2 N and PE J PV GROUNDED Terminal input from PV array K PV UNGROUNDED Terminal input from PV array L Combined UNGROUNDED Terminal M DC Terminal input from PV arr...

Page 21: ...jumper that is connected to the left terminal block A The Sunny Boy comes from the factory configured for connection to a 240 V system If the system is 240 V no adjustment is necessary 2 If adjustmen...

Page 22: ...id If the Sunny Boy is configured for the incorrect transformer voltage e g the inverter is configured for 240 V and then connected to a 208 V grid the Sunny Boy will display an error message The tabl...

Page 23: ...ility Voltage Configurations The figure below illustrates commonly used transformer types Remember when connecting the Sunny Boy to the utility the phase relationship is not important but the voltage...

Page 24: ...ty Voltage Configurations on page 23 The figure below shows an overview of default settings settings for grids with no neutral and fan test settings The Sunny Boy 8000US may not be connected to a 208...

Page 25: ...transformer or 240 Delta Corner grounded transformer respectively Note the order in which inverters are connected to the phases Configuration Jumper Examples for 240 V Delta 120 V Stinger Configuratio...

Page 26: ...to use proper lifting techniques and secure the help of someone to assist in the unpacking and installation of the inverter Occasionally the rating label on the Sunny Boy will need to be referred to F...

Page 27: ...ion that maintains an ambient air temperature that is less than 113 F 45 C To maintain a safe internal component temperature the Sunny Boy may power reduce if the ambient air temperature exceeds 113 F...

Page 28: ...feet of the ground Outer Dimensions of the Sunny Boy CAUTION If you are installing the Sunny Boy in a cabinet closet or other relatively small enclosed area you must provide sufficient air circulation...

Page 29: ...SMA Solar Technology AG Installation Guide SB50US 80US IUS094030 29 Dimensions of the Wall Mounting Bracket...

Page 30: ...SMA Solar Technology AG 30 SB50US 80US IUS094030 Installation Guide Dimensions for the installation of the conduits...

Page 31: ...rmost holes of the wall mounting bracket for mounting on wooden stud walls Make sure that the wall you choose to mount the Sunny Boy on is sturdy enough to support its weight 67 kg 145 lb over a long...

Page 32: ...on of the bracket until it is level The bottom of the bracket will be the approximate location of the bottom of the inverter 3 Using the wall mounting bracket as a template mark the wall through at le...

Page 33: ...w to a torque of 44 in lb 5 Nm Tip for installing The diameter of the holes you drill must match the hardware you are using to mount the Sunny Boy For example if you are mounting the Sunny Boy to a co...

Page 34: ...to the fan outputs on both sides of the Sunny Boy see 2 in Figure above The teeth of the washers should face towards the wall in order to ensure proper grounding Tighten the screws to a torque of 44...

Page 35: ...SMA Solar Technology AG Installation Guide SB50US 80US IUS094030 35 6 When the Sunny Boy has been mounted correctly it should look like one of the examples in Figure below...

Page 36: ...nnecting or operating the Sunny Boy read all of the instructions cautions and warnings on the Sunny Boy the PV array and in this Installation Guide WARNING You must connect the wires that carry the AC...

Page 37: ...S 80US IUS094030 37 DC Grounding Electrode Conductor A DC grounding electrode conductor may be required by the Authority Having Jurisdiction AHJ Use the PV Grounding and DC Grounding Electrode Conduct...

Page 38: ...breakers ON To disconnect the Sunny Boy first turn OFF all AC disconnects and then all DC disconnects The AC system should always be disconnected before the DC system After the Sunny Boy is de energiz...

Page 39: ...tion 7 Turn the AC breaker ON To disconnect the Sunny Boy first turn OFF all AC disconnects and turn the SMA DC Disconnect to the 0 position The AC system should always be disconnected before the DC s...

Page 40: ...om of the Sunny Boy near each of the terminals for the wires to enter the case see Figure below 5 3 Opening the Sunny Boy 1 Remove the six screws from the housing cover and pull the cover forward smoo...

Page 41: ...ps pan head machine screw Do not remove the screw Check if you can remove the knob of the SMA DC Disconnect If not unscrew the screw further until you can remove the knob The screw is attached with a...

Page 42: ...Use 6 AWG maximum 90 C 194 F copper wire for all AC wiring connections to the Sunny Boy Voltage drop and other considerations may dictate that larger size wires be used Use only solid or stranded wire...

Page 43: ...ogy AG Installation Guide SB50US 80US IUS094030 43 Sunny Boy 5000US Energy Losses in Various Wire Sizes and Wire Lengths Percent voltage drop for 208 V AC and 240 V AC service Percent voltage drop for...

Page 44: ...ogy AG 44 SB50US 80US IUS094030 Installation Guide Sunny Boy 6000US Energy Losses in Various Wire Sizes and Wire Lengths Percent voltage drop for 208 V AC and 240 V AC service Percent voltage drop for...

Page 45: ...ogy AG Installation Guide SB50US 80US IUS094030 45 Sunny Boy 7000US Energy Losses in Various Wire Sizes and Wire Lengths Percent voltage drop for 208 V AC and 240 V AC service Percent voltage drop for...

Page 46: ...echnology AG 46 SB50US 80US IUS094030 Installation Guide Sunny Boy 8000US Energy Losses in Various Wire Sizes and Wire Lengths Percent voltage drop for 240 V AC service Percent voltage drop for 277 V...

Page 47: ...r of the breaker box to the interior of the Sunny Boy 7 Refer to the figures on pages 48 and 49 for steps 8 through 10 8 Connect the AC equipment ground wire to the PE terminal labeled in the Sunny Bo...

Page 48: ...e sure that it is sufficiently fixed in the terminal AC Connection Terminals for 208 V not for Sunny Boy 8000US and 240 V The terminal must be opened completely before you insert the cable Grey Termin...

Page 49: ...AG Installation Guide SB50US 80US IUS094030 49 AC Connection Terminals for 277 V Position Description A L1 wire connected to L1 terminal B N wire connected to N terminal C Equipment ground wire conne...

Page 50: ...priate locknut 5 Install 3 4 inch conduit between the main breaker box and the SMA DC Disconnect s AC wiring knockout 6 Pull the AC wires through the conduit from the interior of the breaker box to th...

Page 51: ...nect The Sunny Boy 8000US may not be connected to a 208 V grid 9 For 208 240 V connect the L2 AC line 2 and N AC line N wire to the terminal labeled L2 and N in the SMA DC Disconnect The Sunny Boy 800...

Page 52: ...ommet 15 Connect the green yellow cable of the Sunny Boy to the terminal labeled 16 Connect the white wire of the SMA DC Disconnect to the terminal labeled N and the black wire to the terminal labeled...

Page 53: ...l blocks 19 Verify that all connections are correctly wired and properly torqued Pull on the cable in order to make sure that it is sufficiently fixed in the terminal For 277 V connect the red wire to...

Page 54: ...tallation Guide 5 6 Wiring the DC Input This subsection provides procedures for wiring the DC input from the PV array to the Sunny Boy The figure below shows a simplified wiring diagram of a PV system...

Page 55: ...that larger size wires be used Use only solid or stranded wire but not fine stranded wire WARNING The DC disconnect for the inverter must have a minimum rating of 600 V DC and 36 A continuous The SMA...

Page 56: ...d systems Certain types of PV modules may require that the positive terminal be grounded instead of the negative terminal To configure the Sunny Boy for positive ground move the fuse 1 and change the...

Page 57: ...o completely discharge before connecting any wires to the Sunny Boy or disconnecting any wires from the Sunny Boy Failure to do so could expose you to lethal voltages that can cause serious injury and...

Page 58: ...w Fasten the conduit fitting on the inside of the Sunny Boy with the appropriate locknut 4 Install 3 4 inch conduit between the DC disconnect enclosure and the Sunny Boy s DC wiring knockout 5 Refer t...

Page 59: ...inside the Sunny Boy to 12 Verify that all connections are correctly wired and properly torqued Make a tension test CAUTION Avoid using wire nuts to join any wires together or to make any connections...

Page 60: ...the ground wires from the PV array and the grounding electrode wire through the conduit into the interior of the SMA DC Disconnect CAUTION Avoid using wire nuts to join any wires together or to make a...

Page 61: ...that your inverter is grounded as intended please refer to section 5 7 DC Input Grounding page 56 7 Connect the positive DC wires A to the terminal labeled PV UNGROUNDED in the SMA DC Disconnect 8 Con...

Page 62: ...res from the DC disconnect through the conduit into the interior of the Sunny Boy 13 Pull the wires slightly back in order to seal the grommet 14 Connect the black wire PV UNGROUNDED to the terminal l...

Page 63: ...that your inverter is grounded as intended please refer to section 5 7 DC Input Grounding page 56 1 Connect the negative DC wires A to the terminal labeled PV UNGROUNDED in the SMA DC Disconnect 2 Co...

Page 64: ...m the DC disconnect through the conduit into the interior of the Sunny Boy 7 Pull the wires slightly back in order to seal the grommet 8 Connect the white wire PV GROUNDED to the terminal labeled DC i...

Page 65: ...tripped cable into the spring terminal 4 Return the screwdriver to its original position 5 Remove the screwdriver The spring terminal is closed and the cable is fastened DC Connection With Additional...

Page 66: ...on for a detailed wiring diagram and instructions for insertion 5 10 Closing the Sunny Boy When you have finished connecting the AC output wires the DC input wires and the communication cables re chec...

Page 67: ...over in place carefully insert the six screws with lock washers through the holes in the cover into the threaded holes in the case and turn them until they are finger tight Be careful not to cross thr...

Page 68: ...le into the cover 3 Turn the switch to the 0 position and tighten the screw on the right side of the switch with a small phillips screwdriver used screw UNC no 5 x 3 4 cross recess Pillips pan head ma...

Page 69: ...cient sunlight available the Sunny Boy will enter the Wait mode at this time and the green LED will begin to blink 4 If no AC faults are detected the Wait mode will end after 10 seconds and the green...

Page 70: ...V DC for Sunny Boy 8000US the Sunny Boy will automatically begin feeding power to the utility grid The Sunny Boy operates from the power produced by the PV array and is designed for minimal internal...

Page 71: ...indicator lights are as follows The green LED indicates normal operation of the inverter The red LED indicates the status of the GFDI fuse located inside the Sunny Boy If this LED is lit the GFDI fuse...

Page 72: ...ation Occasionally during inclement weather or low irradiation the LEDs may all turn on at once and then go off again This indicates that the inverter is trying to initialize but the power available f...

Page 73: ...ion The inverter is feeding the utility grid in either MPP Constant Voltage or Turbine mode MPP Mode The Sunny Boy adjusts the voltage and current from the PV array to obtain the greatest PV output po...

Page 74: ...e ground fault must be located and fixed before the inverter will resume normal operation Refer to Section 8 Troubleshooting page 86 for information on solving PV array ground faults The inverter will...

Page 75: ...e yellow LED is on for 5 seconds out for 3 seconds and then blinks twice The code is repeated 3 times This code sequence will repeat as long as there is a grid fault condition This code can be caused...

Page 76: ...ter has detected a DC input voltage that is too high for safe operation WARNING If opening the Sunny Boy is required do so only after disconnecting all sources of power and waiting at least 5 minutes...

Page 77: ...lt that prohibits normal operation and will most likely require servicing Contact SMA America for assistance 7 3 Status Messages on the LCD Display The Sunny Boy comes standard with the Sunny Display...

Page 78: ...power output and DC input voltage MSG 4 Accumulated energy yield of the device since installation and the total operating hours Fault Messages In case of a fault condition the LCD switches to Fault mo...

Page 79: ...will not preclude inverter operation Error For example this Error message would be displayed if the inverter detected a problem with the internal ROM An Error condition will prevent the inverter from...

Page 80: ...rformed by using a pair of slide switches located along the bottom edge of the display PC board The language choices are Spanish English French and German Use the diagram and chart below for setting t...

Page 81: ...frequency Pac Power fed to grid Vpv PE PV voltage to earth For troubleshooting PV ground faults Temperature Temperature measured at IGBT module Ipv PV current Max Temperature Max temperature measured...

Page 82: ...ult user interaction required Warning System warning advising further investigation CAUTION The changing of operating parameters should only be performed by qualified personnel Changes to factory pres...

Page 83: ...tting this parameter to 1 you can check the function of the fans This test turns the fans at maximum speed h_Total h 0 200000 0 Installer Total operating hours of the inverter Changing the value can b...

Page 84: ...esults in a trip value of 88 as listed under trip limits Vac Max 0 20 10 Installer Values are used to calculate the upper limit of allowable AC voltage Default value is optimal for installa tions 30 k...

Page 85: ...Boy Fixed Name Unit Range Default Description Plimit W fixed SB5000US 5100 SB6000US 6100 SB7000US 7100 SB8000US 8100 Upper limit of AC output power SMA SN Serial Number of the Sunny Boy Software BFR F...

Page 86: ...nual when doing so or hire a qualified professional If the system problem persists contact SMA America technical support at 916 625 0870 In order to better assist you when contacting SMA America pleas...

Page 87: ...erformance Error EEPROM p Data EEPROM defective device is set to permanent disable due to the fact that the data loss affects important functions of the inverter Contact SMA Disturbance EeRestore Inte...

Page 88: ...system firmware failed Contact SMA in case you observe this failure often Disturbance Shut Down Internal over current continuous Disturbance Vac Bfr Vac Srr The AC grid voltage is exceeding the allowa...

Page 89: ...f the grid is connected to the terminal L2 In unbalanced 208 V and 240 V grids interchanging L1 and L2 may clear this error Disturbance XFMR_TEMP_F High transformer temperature the Sunny Boy stops wor...

Page 90: ...ng attention to the safety instructions in Section 5 Wiring the Sunny Boy page 36 3 Wait for the fans to stop rotating 4 Push the 2 latches at the top of the black plastic cover to one side and remove...

Page 91: ...on the sides of the enclosure Place your fingers in the space between the top of the housing and the handle covers and gently pull the handle covers out of their bracket Insert the handle covers back...

Page 92: ...oy Control or Turn off the inverter by turning off all DC and AC disconnects and wait 5 minutes for any residual voltages to dissipate Once the LED s are off remove the cover and set the jumpers as sh...

Page 93: ...3 Open the Sunny Boy as described in section 3 1 Opening the Sunny Boy page 18 4 Exchange the fuse For correct fuse location please refer to section DC Input Grounding on page 56 5 Close the Sunny Boy...

Page 94: ...Turn OFF all AC and DC switches and or breakers 2 Wait for at least 5 minutes 3 Open the SMA DC Disconnect as described in section 5 4 Opening the SMA DC Disconnect if applicable page 41 4 Exchange th...

Page 95: ...f the PV module and then rounding up to the next standard fuse size DC Disconnect Requirements NEC 690 15 18 allows the use of fuse holders as a suitable means of disconnecting PV arrays for servicing...

Page 96: ...rdance with the instructions may cause harmful interference to radio communications However there is no guarantee that interference will not occur in a particular installation If this equipment does c...

Page 97: ...echnology AG Installation Guide SB50US 80US IUS094030 97 10 2 Sunny Boy Wiring Diagrams 10 2 1 Without SMA DC Disconnect Sunny Boy Connections for 208 and 240 V AC grids Sunny Boy Connections for 277...

Page 98: ...SMA Solar Technology AG 98 SB50US 80US IUS094030 Installation Guide 10 2 2 With SMA DC Disconnect Sunny Boy Connections for 208 and 240 V AC grids Sunny Boy Connections for 277 V AC grids...

Page 99: ...tage 250 600 V DC Maximum DC Power 5300 W 6400 W Maximum Array Input Power DC STC 6250 W 7500 W Maximum AC Continuous Output Power 5000 W 6000 W Current THD Less than 4 Output Power Factor 0 95 1 0 0...

Page 100: ...Enclosure Diecast aluminum NEMA 3R IP54 Dimensions 18 42 W x 24 14 H x 9 53 D inches 468 W x 613 H x 242 D mm Weight 147 Ibs 67 kg Compliance UL1741 UL 1998 IEEE 1547 IEEE 929 IEEE C37 90 1 IEEE C62...

Page 101: ...25 3 A 240 V 32 A 277 V 29 A Maximum DC Input Current 30 A Maximum input short circuit current 36 A Maximum utility backfeed current to PV array 50 A AC Maximum Output Fault Current 57 6 A 61 7 A 9 6...

Page 102: ...A DC Disconnect Specifications subject to change without notice Compliance UL1741 UL 1998 IEEE 1547 IEEE 929 IEEE C37 90 1 IEEE C62 41 2 test conditions 2 kV 1 kA FCC Part 15 A B Maximum DC Input Curr...

Page 103: ...fault 59 3 56 95 59 85 default 59 25 59 35 adjustable 0 16 300 default max 0 1602 57 0 56 95 57 05 max 0 1602 Nominal Voltage V Trip Limit Trip Voltages Line to Neutral V Trip Voltages Line to Line V...

Page 104: ...rminal Blocks for Unused Wires Weidm ller 11 1 2 Green AC Configuration Terminal Blocks for Unused Wires Phoenix 15 1 7 AC DC Terminal Blocks SMA DC Disconnect 15 1 7 10 6 AWG Combined Terminal Block...

Page 105: ...SMA Solar Technology AG Installation Guide SB50US 80US IUS094030 105...

Page 106: ...SMA Solar Technology AG 106 SB50US 80US IUS094030 Installation Guide...

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Page 108: ...4 NFSJDB ODPSQPSBUFE XXX TNB BNFSJDB DPN...

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