SMA SBCBTL6 User manual

SBCBTLUS-IUS094510 | IMUS-SBCBTLUS | Version 1.0
US
Sunny Boy Accessories
SUNNY BOY COMBINER BOX TLUS
SBCBTL6
Installation Guide

SMA America, LLC Legal Restrictions
Installation Guide SBCBTLUS-IUS094510 3
Copyright © 2010 SMA America,LLC. All rights reserved.
No part of this document may be reproduced, stored in a retrieval system, or transmitted, in any form
or by any means, electronic, mechanical, photographic, magnetic or otherwise, without the prior
written permission of SMA America,LLC.
SMA America,LLC makes no representations, express or implied, with respect to this documentation
or any of the equipment and/or software it may describe, including (with no limitation) any implied
warranties of utility, merchantability, or fitness for any particular purpose. All such warranties are
expressly disclaimed. Neither SMA America,LLC 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 some statutes, and thus the
above exclusion may not apply.)
Specifications are subject to change without notice. Every attempt has been made to make this
document complete, accurate and up-to-date. Readers are cautioned, however, that
SMAAmerica,LLC reserves the right to make changes without notice and shall not be responsible for
any damages, including indirect, incidental or consequential damages, caused by reliance on the
material presented, including, but not limited to, omissions, typographical errors, arithmetical errors
or listing errors in the content material.
All trademarks are recognized even if these are not marked separately. Missing designations do not
mean that a product or brand is not a registered trademark.
The Bluetooth® word mark and logos are registered trademarks owned by Bluetooth SIG, Inc. and
any use of such marks by SMA America,LLC is under license.
SMA America, LLC
3801 N. Havana Street
Denver, CO 80239 U.S.A.

Important Safety Instructions SMA America, LLC
4 SBCBTLUS-IUS094510 Installation Guide
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS
This manual contains important instructions for the Sunny Boy Combiner Box that must be followed
during installation and maintenance of the Sunny Boy Combiner Box.
The Sunny Boy Combiner Box is designed and tested according to international safety requirements,
but as with all electrical and electronic equipment, certain precautions must be observed when
installing and/or operating the Sunny Boy Combiner Box. To reduce the risk of personal injury and
to ensure the safe installation and operation of the Sunny Boy Combiner Box, you must 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 procedure or practice,
which, if not correctly performed or adhered to, could result in damage to or destruction of part or all
of the SMA equipment and/or other equipment connected to the SMA equipment or personal injury.
DANGER
DANGER indicates a hazardous situation which, if not avoided, will result in death or
serious injury.
WARNING
WARNING indicates a hazardous situation which, if not avoided, could result in death or
serious injury.
CAUTION
CAUTION indicates a hazardous situation which, if not avoided, could result in minor or
moderate injury.
NOTICE
NOTICE is used to address practices not related to personal injury.

SMA America, LLC Important Safety Instructions
Installation Guide SBCBTLUS-IUS094510 5
Other Symbols in this document
In addition to the safety and hazard symbols described on the previous pages, the following symbol
is also used in this installation guide:
Markings on this product
The following symbols are used as product markings with the following meanings.
Information
This symbol accompanies notes that call attention to supplementary information that you
should know and use to ensure optimal operation of the system.
Warning regarding dangerous voltage
The product works with high voltages. All work on the product must be done as
described in it‘s documentation.
Electric arc hazards
The product has large electrical potential differences between its conductors. Arc flashes
can occur through air when high-voltage current flows. Do not work on the product
during operation.
Beware of hot surface
The product can become hot during operation. Do not touch the product during
operation.
Earth Ground
Observe the operating instructions
Read the product’s documentation before working on it. Follow all safety precautions
and instructions as described in the documentation.
UL1741 is the standard applied by Underwriters Laboratories to the Sunny Boy
Combiner Box to certify that it meets the requirements of the National Electrical Code®.

General Warnings SMA America, LLC
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General Warnings
General Warnings
All electrical installations must be done in accordance with the local and National
Electrical Code® ANSI/NFPA 70. For installation in Canada the installations must be done
in accordance with applicable Canadian standards.
The Sunny Boy Combiner Box contains no user-serviceable parts. For all repair and
maintenance, always return the unit to an authorized SMA Service Center.
Before installing or using the Sunny Boy Combiner Box, read all of the instructions,
cautions, and warnings on the Sunny Boy Combiner Box in this installation guide.
Before connecting the Sunny Boy Combiner Box to the electrical utility grid, contact the
local utility company. This connection must be made only by qualified personnel.
Wiring of the Sunny Boy Combiner Box must be made by qualified personnel only.

SMA America, LLC Table of Contents
Installation Guide SBCBTLUS-IUS094510 7
Table of Contents
1 Notes on this manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.1 Target group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2 Validity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.3 Nomenclature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2 Security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.1 Appropriate usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3 Unpacking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.1 Unpacking and inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.2 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.3 Identifying the Sunny Boy Combiner Box . . . . . . . . . . . . . . . . . 13
4 Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.2 Selecting the mounting location . . . . . . . . . . . . . . . . . . . . . . . . 15
4.2.1 Conditions for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.2.2 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.3 Wall mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.3.1 Stone wall mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.3.2 Wood wall mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.3.3 Mounting the Sunny Boy Combiner Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5 Inserting the strings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6 Electrical connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.1 Connection area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.2 Fuse sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.3 Connecting equipment ground . . . . . . . . . . . . . . . . . . . . . . . . . 22
6.4 Connecting PV modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Table of Contents SMA America, LLC
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6.4.1 Inserting the string fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.4.2 Connecting the negative strings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.4.3 Connecting the positive strings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.5 Connecting the inverter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.5.1 Connecting DC+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.5.2 Connecting DC − . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
8 Opening and closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
8.1 Opening the Sunny Boy Combiner Box . . . . . . . . . . . . . . . . . . 27
8.2 Closing the Sunny Boy Combiner Box . . . . . . . . . . . . . . . . . . . 28
9 Replacing string fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
10 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
11 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
11.1 Cable requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
12 Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

SMA America, LLC Notes on this manual
Installation Guide SBCBTLUS-IUS094510 9
1 Notes on this manual
This manual describes the installation and commissioning of the Sunny Boy Combiner Box SBCBTL6.
Keep this manual in a convenient place for future reference
1.1 Target group
This manual is for qualified personnel only. Qualified personnel have received training and have
demonstrated skills and knowledge in the construction and operation of the device. Qualified
personnel are trained to deal with the dangers and hazards involved in installing electric devices.
1.2 Validity
This manual is valid for the Sunny Boy Combiner Box TLUS. It does not cover any details concerning
connected equipment. Information concerning the connected equipment is provided by the
manufacturer.
1.3 Nomenclature
In this document SMA America Production, LLC is referred to in the following as SMA. In this manual
the Sunny Boy Combiner Box TLUS is referred to as Sunny Boy Combiner Box.

Security SMA America, LLC
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2 Security
2.1 Appropriate usage
The Sunny Boy Combiner Box is a string combiner connecting up to 6 strings and linking them to the
inverter. All inputs must be fused in accordance with National Electrical Code® NEC 690. The
Combiner Box is designed for the use with transformerless SMA PV inverters.
Principle of a PV power system with the Sunny Boy Combiner Box
Do not use the Sunny Boy Combiner Box for purposes other than those described here. Alternative
uses, modifications to the Sunny Boy Combiner Box or the installation of components not expressly
recommended or sold by the manufacturer void the warranty claims and operation permission.
The Sunny Boy Combiner Box can only be used in ungrounded array installations.
Position Description
APV modules
B Sunny Boy Combiner Box
C Sunny Boy with DC Disconnect
D AC main circuit breaker
ELoad
F Meter
GGrid

SMA America, LLC Security
Installation Guide SBCBTLUS-IUS094510 11
2.2 Safety precautions
DANGER
Risk of electric shock due to high voltages inside the Sunny Boy Combiner Box.
Death or serious injuries will result.
• All work on the Sunny Boy Combiner Box must be carried out by qualified personnel
only.
• All work on the Sunny Boy Combiner Box must be done in accordance with this
manual only.
• Pay attention to all safety precautions.
WARNING
Risk of electric shock during operation of a damaged Sunny Boy Combiner Box.
Death or serious injuries will result.
• The Sunny Boy Combiner Box may only be used when it is technically faultless.
• Operate the Sunny Boy Combiner Box only if no damage is visibly evident.
• Inspect the Sunny Boy Combiner Box for damage on a regular basis.
• Ensure that all external safety features are freely accessible at all times, and that they
are regularly tested for correct functionality.
NOTICE
Electrostatic discharge is possible when components are touched.
Damage to components will result.
• Follow ESD protective provisions.
• Remove existing electrostatic charges by touching a grounded metal surface (e.g.
housing).

Unpacking SMA America, LLC
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3 Unpacking
3.1 Unpacking and inspection
All SMA Sunny Boy Combiner Boxes are checked before shipping and packaged in sturdy boxes.
However the sturdy boxes do not guarantee that damage will not occur during shipping and delivery.
It is important to carefully inspect the shipping box and contents prior to installation. If you detect any
external damage after unpacking, report the damage immediately to your SMA dealer and to the
shipping company that delivered the unit. If it becomes necessary to return the Sunny Boy Combiner
Box, use the original packing material.
If you need assistance with a damaged Sunny Boy Combiner Box, contact your SMA dealer or SMA.
Contact information for SMA is provided in chapter 12”Contact” (page34).
3.2 Scope of delivery
Position Number Description
A1Sunny Boy Combiner Box
B 1 Installation Guide
C12Fuse holder
The Sunny Boy Combiner is shipped without any fuses. For correct operation fuses have to
be purchased by the installer.

SMA America, LLC Unpacking
Installation Guide SBCBTLUS-IUS094510 13
3.3 Identifying the Sunny Boy Combiner Box
The Sunny Boy Combiner Box can be identified by the type label. The type label (G) is located on the
right side of the enclosure.
Position Description
A Type plate
BProduct name
C Item number
D Serial number
EDate of manufacture
F Technical data
G Position of type label

Mounting SMA America, LLC
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4 Mounting
4.1 Safety
DANGER
Danger to life due to fire or explosion.
There is always a certain risk with electric devices that a fire can occur, even though
greatest attention was paid to avoid this during the development.
• Do not install the Sunny Boy Combiner Box on flammable construction material.
• Do not install the Sunny Boy Combiner Box in areas where highly flammable material
is stored.
• Do not install the Sunny Boy Combiner Box in potentially explosive areas.
WARNING
The Sunny Boy Combiner Box becomes hot during operation.
Danger of burn injuries.
• Mount the Sunny Boy Combiner Box so that it cannot be touched accidentally.
CAUTION
Falling of the Sunny Boy Combiner Box may cause injuries.
Crushing of body parts will result.
Consider the weight of the Sunny Boy Combiner Box of approx. 81/2 lbs (3.9 kg).

SMA America, LLC Mounting
Installation Guide SBCBTLUS-IUS094510 15
4.2 Selecting the mounting location
4.2.1 Conditions for installation
• The installation method and mounting location must be suitable for the weight and dimensions
of the Sunny Boy Combiner Box (see section 11”Technical Data” (page32)).
• Mount on a solid surface.
• The mounting location must be accessible at all times.
• Never install the device with a forward tilt.
• Do not install horizontally.
• The connection area (A) must point downwards.
• Vertical installation or tilted backwards by max. 45°.
• During installation cover the PV modules with opaque material.
• The ambient temperature must be below 140°F (60°C) to ensure optimal operation.
• Do not expose the Sunny Boy Combiner Box to direct sunlight, in order to avoid excessive
heating.
• Observe the minimum clearances to walls, other
devices or objects in order to guarantee sufficient
heat dissipation.
Position Clearance
Top 12in. (300 mm)
Bottom 12in. (300 mm)
Left 12in. (300 mm)
Right 12in. (300 mm)
Front 2in. (50 mm)
If the Sunny Boy Combiner Box is installed in an outdoor environment:
Observe a minimum clearance of 36in. (900mm) to the ground.

Mounting SMA America, LLC
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4.2.2 Dimensions
Mounting holes on backside

SMA America, LLC Mounting
Installation Guide SBCBTLUS-IUS094510 17
4.3 Wall mounting
The Sunny Boy Combiner Box can be mounted on stone, brick, solid walls or wooden walls with poles.
Be sure to use appropriate type of mounting hardware for the wall material.
You may use screws of size 10, 12 or 14. The recommended length of the screws is 11⁄2 in. to 13⁄4in.
4.3.1 Stone wall mounting
Attach the Sunny Boy Combiner Box using 3 screws.
• 1 screw on the upper left side.
• 1 screw on the upper right side.
• 1 screw below.
• Use stainless screws or comparable with fender
washers.
Mount the Sunny Boy Combiner Box as described in
section 4.3.3”Mounting the Sunny Boy Combiner Box”
(page18).
4.3.2 Wood wall mounting
Attach the Sunny Boy Combiner Box to a pole using 2
screws.
• 1 screw on the upper side.
• 1 screw below.
• Use stainless steel screws or comparable and
washers.
Mount the Sunny Boy Combiner Box as described in
section 4.3.3”Mounting the Sunny Boy Combiner Box”
(page18).

Mounting SMA America, LLC
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4.3.3 Mounting the Sunny Boy Combiner Box
When mounting use the Sunny Boy Combiner Box as a template.
1. Place the Sunny Boy Combiner Box at the mounting position on the wall. Level the Sunny Boy
Combiner Box.
2. Mark the mounting position through the mounting holes.
3. Remove the Sunny Boy Combiner Box and drill the marked mounting holes.
4. Insert the wall anchors.
5. Place the Sunny Boy Combiner Box on the wall. Align the mounting holes with the drilled holes.
6. Insert the screws through the mounting holes of the Sunny Boy Combiner Box. Tighten the screws
clockwise.
7. Ensure that the Sunny Boy Combiner Box is attached firmly to the wall.
☑ The Sunny Boy Combiner Box is mounted to the wall.
DANGER
Risk of electric shock by drilling into power cables.
Death or serious injuries will result.
• Check installation location for power cables.
CAUTION
Falling of the Sunny Boy Combiner Box may cause injuries.
Crushing of body parts will result.
• Ensure that there are studs in the wall at places where you intend to drill holes.

SMA America, LLC Inserting the strings
Installation Guide SBCBTLUS-IUS094510 19
5 Inserting the strings
1. Determine the number of the required strings referring to your system calculation.
2. Open the Sunny Boy Combiner Box (see 8.1”Opening the Sunny Boy Combiner Box”
(page27)).
3. Break out the number of knockouts needed for the cable conduits. For each string cable a
seperate conduit is needed.
4. Insert the cable conduit fittings into the knockout holes.
5. Pull the cable conduits into the fittings and tighten them.
6. Draw the string cables through the cable conduits into the Sunny Boy Combiner Box.
☑ The cables are inserted into the Sunny Boy Combiner Box.
NOTICE
Infiltration of water during mounting and installation of the product.
Damage to the product will result.
• Do not open the Sunny Boy Combiner Box when it is raining or when there is very
high humidity > 95%.
• For conduit hubs, use only UL listed rainproof, or wet location hubs complying with
UL 514B for entry into the enclosure.
Position Description
ADC input
BGrounding
CDC combined output

Electrical connection SMA America, LLC
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6 Electrical connection
6.1 Connection area
Position Description
A Combined out negative
B Combined out positive
C Raceway
D Equipment grounding
E Positive string inputs
F Negative string inputs