SMA SUNNY BOY 2500 User manual

Sunny Boy 2500
String Inverter Sunny Boy 2500
Installation Guide Version 1.2 SB2500-11:SE2006
IME-SB2500

SMA Technologie AG Explanation of Symbols used in this Document
Installation Guide SB2500-11:SE2006 Page 3
Explanation of Symbols used in this document
This symbol indicates information that is essential for a trouble-free
and safe operation of the product. Please read these sections care-
fully in order to avoid any damages of the equipment and for op-
timal personal protection.
This symbol indicates information that is required for the optimal operation of
the product. Read these sections carefully in order to ensure an optimal ope-
ration of the product and all its features.
This symbol indicates an example.

Legal Restrictions SMA Technologie AG
Page 4 SB2500-11:SE2006 Installation Guide
Liability exclusion
All information are based on our "General Terms and Conditions of Delivery of SMA Technologie AG”.
The content of this documentation is reviewed continuously and adjusted, if necessary. SMA Technologie
AG provides this documentation without exclusion of deviations and without warranty of completeness. You
will find the current version on the Internet at www.SMA.de or can obtain it via the usual sales channels.
Warranty or liability claims for all kinds are excluded in case of damages due to:
• Inappropriate use of the product
• Operation of the product in an improper environment
• Operation of the product without considering the relevant safety regulations
• Non-fulfillment of the warnings or safety instructions described in the documentation for the product
• Operation of the product under faulty conditions concerning security and protection
• Arbitrary changing of the product or the provided software
• Failure of the product due to interference of connected or contiguous devices out of legal limit values
• Disasters and force majeure
Software Licensing
The use of the provided software by SMA Technologie AG is subject to the following conditions:
The software may be reproduced for internal purposes and installed on any number of computers. Provided
source codes can be changed and adjusted on the company’s own authority according to the internal
purpose. Driver may be ported to other operating systems as well. No part of the source codes may be
published without written permission of SMA Technologie AG. Sublicensing of the software is not
acceptable.
Liability limitation: SMA Technologie AG disclaims liability for any direct or indirect consequential damages
arising from the use of the software produced by SMA Technologie AG. The same applies for the provision
and/or non-provision of support.
Provided software not produced by SMA Technologie AG is subject to the respective licensing and liability
agreements of the manufacturer.
Trademarks
All brand and product names used herein are trademarks or registered trademarks of their respective
holders, although they may not be specifically designated as such.
SMA Technologie AG
Hannoversche Strasse 1-5
34266 Niestetal
Germany
Tel. [phone] – 0
Fax [phone] – 100
www.SMA.de
E-Mail: [e-mail]
© 2005 SMA Technologie AG. All rights reserved.

SMA Technologie AG Table of Contents
Installation Guide SB2500-11:SE2006 Page 5
Table of Contents
1 Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.1 Unit description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
3.2 External dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
4 Installation requirements . . . . . . . . . . . . . . . . . . . . . 13
4.1 Installation site requirements . . . . . . . . . . . . . . . . . . . . . . . . .13
4.2 PV generator requirements. . . . . . . . . . . . . . . . . . . . . . . . . . .15
4.3 Low voltage grid 230 V (AC). . . . . . . . . . . . . . . . . . . . . . . . .15
5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.1 Mounting the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
5.2 Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
5.3 Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
6 Opening and closing the Sunny Boy . . . . . . . . . . . . 29
6.1 Opening the Sunny Boy . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
6.2 Closing the Sunny Boy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
7 Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.1 PV generator connection data . . . . . . . . . . . . . . . . . . . . . . . .31
7.2 Grid connection data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
7.3 Device description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
7.4 Sunny Boy 2500 Operating parameters . . . . . . . . . . . . . . . . .33
8 Replacing the varistors. . . . . . . . . . . . . . . . . . . . . . . 35
9 Rating for a line circuit breaker. . . . . . . . . . . . . . . . . 39
10 Contact. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Table of Contents SMA Technologie AG
Page 6 SB2500-11:SE2006 Installation Guide

SMA Technologie AG Foreword
Installation Guide SB2500-11:SE2006 Page 7
1 Foreword
This installation manual is intended solely for qualified electricians. Its aim is to help
install and set up SMA Sunny Boy 2500 inverters quickly and correctly.
For detailed information on troubleshooting and on how to use the Sunny Boy 2500,
including information about the different communication options, please see the
operating instructions.
The „Sunny Design“ tool will help to dimension and check the size of your strings with
respect to the inverter you intend to use. Further information about „Sunny Design“
is available at www.SMA.de.
If your Sunny Boy is equipped with a communication interface, you will find detailed
instructions for installation in the description of the communication interfaces (Piggy-
Backs), which has been delivered with the device.
If you require further information, please call the Sunny Boy hotline on the following
number:
[phone] - 499
The installation of the Sunny Boy may only be done by qualified
technicians. The installer must be approved by the utility company.
Please read the installation guide carefully before you begin with
the installation. The installation of utility interactive power sources
must be compliant with all applicable regulations of the utility
company and with all applicable regulations and standards.
The Sunny Boy 2500 is equipped with the SMA grid guard. This is a type of
independent disconnection device. It ensures that the Sunny Boy 2500
complies with the VDEW (Verband der Elektrizitätswirtschaft – German
Electricity Industry Association) regulations for the connection and parallel
operation of electrical power units to the low-voltage grid of the electricity
supply company and with DIN VDE 0126 (4.99) which forms a part of these
regulations.

Foreword SMA Technologie AG
Page 8 SB2500-11:SE2006 Installation Guide

SMA Technologie AG Safety information
Installation Guide SB2500-11:SE2006 Page 9
2 Safety information
Check your plant configuration and the
string sizing with „Sunny Design“
(available at www.SMA.de) or with the
Sunny Boy Hotline before you start with
the installation. Exceeding the
specifications with the input voltage will
destroy the Sunny Boy. Overvoltage on
the DC side can even cause dangerous
explosions of the Sunny Boys input
capacitors and explosions of the
electrolytes coming from the exploded
capacitors.
Work on the Sunny Boy with the lid removed must be carried out
by a qualified electrician. Hazardous and even lethal voltages can
be encountered within the enclosure. Before working on the Sunny
Boy with the lid removed, the AC and DC voltages MUST be
disconnected from the Sunny Boy and it must be sure that all
capacitors are discharged.
The Sunny Boy must be disconnected from the mains and
precautions must be taken to prevent the grid being reconnected.
In addition, the connections to the PV generator must be
disconnected.
After isolating the AC and DC voltage you must wait approx. 30
minutes for the capacitors in the Sunny Boy to discharge. Only then
is it safe to open the unit by removing the lid. You must also make
sure that no voltage is present in the device.
The electronics inside your Sunny Boy 2500 is vulnerable in terms
of electrostatic discharge. Be sure to be connected to ground (e.g.
the enclosure of the Sunny Boy) before handling anything within
the enclosure of the Sunny Boy.
Betrieb
Operation
Erdschluss
EarthFault
Störung
Failure
Photovoltaik-Stringwechselrichter
Photovoltaicstring inverter

Safety information SMA Technologie AG
Page 10 SB2500-11:SE2006 Installation Guide

SMA Technologie AG Overview
Installation Guide SB2500-11:SE2006 Page 11
3 Overview
3.1 Unit description
The following diagram gives a schematic overview of the various components and
connection points inside the Sunny Boy 2500 with the lid removed:
PE
L
N
Varistors
page 35
Socket for communication
(RS232, RS485, NLM Piggy-
Back, Radio)
PE (protective
earth) connecting
cable for lid
Slot for
display unit
Operating status
LEDs
Communications
connector
Connection plug
(AC) page 21
PV input plug
(DC) page 26

Overview SMA Technologie AG
Page 12 SB2500-11:SE2006 Installation Guide
3.2 External dimensions
214 mm
295 mm
434 mm

SMA Technologie AG Installation requirements
Installation Guide SB2500-11:SE2006 Page 13
4 Installation requirements
Please check that all of the conditions listed below are met before installing and
setting up the Sunny Boy.
4.1 Installation site requirements
The Sunny Boy 2500 weighs 30 kg. Please take this weight into
account when choosing the installation site and method of
installation.
The Sunny Boy 2500 should be installed in a place where it is not
exposed to direct sunlight. An increased ambient temperature can
reduce the yield of the PV system.
The Sunny Boy is designed to be mounted on a vertical wall. For an optimum energy
yield and the most convenient operation, vertical installation at eye-level is
preferable. In case it is absolutely necessary to tilt the Sunny Boy to the back the
maximum angle is 45 °. If installing the unit outdoors, make sure that it is not slanted
forwards.
It is not recommended to install the Sunny Boy lying on the back side with the lid
facing upwards.
The ambient temperature must not be outside the range of -
25 °C to +60 °C.
30 kg
min. 45°
Mount the Sunny Boy in a vertical position
or with a slight angle to the back.
Do not mount the Sunny Boy with an
angle to the front or on the back.

Installation requirements SMA Technologie AG
Page 14 SB2500-11:SE2006 Installation Guide
When choosing the installation site, be sure to note the
following:
When choosing the installation site, ensure there is enough space for heat to
dissipate. Under normal conditions, the following guidelines should be applied for
the space to be kept clear around the Sunny Boy 2500:
In domestic installations, the unit should not be
mounted on plasterboard walls or similar as otherwise
audible vibrations are likely to result.
We recommend securing the unit to a solid surface.
The Sunny Boy 2500 will emit a slight noise during
operation. This noise can be annoying when the Sunny
Boy is installed within a living area.
Unintentionally pulling out the DC plug connector under load can
damage the plug and result in bodily injury or death! Install the
Sunny Boy in such a way that it is not possible (e.g. for children) to
unplug the DC plug connector unintentionally.
Individual components in the Sunny Boy can reach a temperature
of more than 60 °C.
Do not install the Sunny Boy on flammable construction materials,
in areas where highly inflammable materials are stored or in
potentially explosive environments!
Minimum clearance
Sides 20 cm
Top 20 cm
Underneath 20 cm
In front 5 cm
20 cm 20 cm
20
cm
20
cm
5
cm

SMA Technologie AG Installation requirements
Installation Guide SB2500-11:SE2006 Page 15
4.2 PV generator requirements
The Sunny Boy 2500 is designed to be connected to up to two strings (PV modules
wired in series) having a homogenous structure (modules of the same type, identical
orientation and tilt).
The „Sunny Design“ tool will help to dimension and check the size of your string with
respect to the inverter you intend to use. Information about the „Sunny Design“ tool
is available at www.SMA.de.
The unit has four DC plug connectors (two for each string) for connecting the PV
generators. The connecting cables from the PV generators must also be fitted with this
type of plug connector. A pre-assembled set for connecting the free cable ends from
a string is available as an optional accessory. The SMA order codes for the various
connectors are as follows:
• Multi-contact 3 mm: "SWR-MC"
• Multi-contact 4 mm: "MC-SET"
• Tyco: "TYCO-SET"
4.3 Low voltage grid 230 V (AC)
The Sunny Boy must have a three-conductor connection to the mains (live (L), neutral
(N), protective earth (PE)).
The grid connection terminals on the AC connection
socket included in the accessories kit can take wires
with a cross-section of up to 2.5 mm². The accessories
kit also contains a PG13.5 AC connection socket for
connecting cables with a diameter between 9 mm and
13.5 mm, while the PG16 connection socket is used for
cables with a diameter up to a maximum of 17 mm. For detailed instructions, see
sections "Connecting the AC output with PG13.5" (page 22) and "Connecting the
AC plug with PG16" (page 24).
Limit values for DC input
Max. voltage 600 V (DC)
Max. input current 12 A (DC)
We recommend using a 16 A line circuit
breaker to protect the power circuit. No
loads should be connected to this power
circuit.
max. 2,5 mm²9 …17 mm
Cable
diameter Wire cross-
section

Installation requirements SMA Technologie AG
Page 16 SB2500-11:SE2006 Installation Guide
Rating for a line circuit breaker in a photovoltaic electrical
power unit operated in parallel with the low-voltage grid
Various factors should be taken into account when selecting line circuit breakers.
These include, for example:
• The type of cable used (conductor material and insulation)
• Ambient temperatures affect the cables (higher temperatures result in a reduced
maximum current load)
• Method of routing the cable (reduces the ampacity of the conductor)
• Bundling cables together (reduces the ampacity of the conductor)
• Loop impedance [Z] (in the event of a body contact this limits the current that can
flow and therefore determines the response behaviour of the circuit breaker)
• Adequate space between the line circuit breakers in order to avoid overheating
(in case of overheating, the line circuit breaker could trigger earlier).
• Selectivity
• Protection class of the connected load (VDE 0100, part 410), Protection against
electric shock and / or the international standard IEC 60364-4-41:1992
The following standards1should be followed in all cases:
• DIN VDE 0298-4 („Types of cable installation and conducting
capacity“)
• DIN VDE 0100; part 430 („Protection measures for protection of cables
and conductors in terms of overcurrent“) and
/ or the international standard IEC
364-4-43:1977 and IEC 364-4-473:1977
• DIN VDE 0100; part 410 (Protection against electric shock“) and / or
the international standard IEC 60364-4-
41:1992
Please have a look at chapter 9 "Rating for a line circuit breaker" (page 39).
1. The standards mentioned above are to be only used as a guideline for your
installation. They apply for installations in Germany. Please note that other
standards will apply for different countries throughout the world.

SMA Technologie AG Installation requirements
Installation Guide SB2500-11:SE2006 Page 17
The system impedance at the installation site of the Sunny Boy 2500 must be less than
1 Ohms for the islanding detection and the fuses to work porperly. In addition, we
recommend dimensioning the conductor cross-section so that line losses do not
exceed 1% at the nominal power. Line losses depending on the cable length and
cross-section are shown in the graph below.The compitation is based on copper
cables with several wires (phase and neutral).
Cable losses of the Sunny Boy 2500
The maximum cable lengths for the different cable cross-sections are as follows:
Conductor cross-section 1.5 mm² 2.5 mm²
Max. length 10 m 15 m
0.0%
0.2%
0.4%
0.6%
0.8%
1.0%
1.2%
1.4%
Length
0 m 10 m 15 m 20 m 25 m 30 m 35 m 40 m 45 m 50 m
5 m
Losses
1.5 mm²
2.5 mm²
Do not use cable specification with losses above 1.0 %

Installation requirements SMA Technologie AG
Page 18 SB2500-11:SE2006 Installation Guide
The Sunny Boy 2500 is designed for operation on 230 V grids and works at grid
voltages of 198 V to 260 V at 49.8 Hz to 50.2 Hz. All settings shown below are
based on the German standard DIN VDE 0126. You are also able to use other
settings.
The Sunny Boy 2500 is equipped with an automatic 50 Hz / 60 Hz utility frequency
detection. It can therefore be connected to a 50 Hz or 60 Hz utility without any
further configuration changes. Pay attention to the local utility regulations in any
case.
Limit values for AC output
Voltage range 198 V ... 260 V
Frequency range 49.8 Hz ... 50.2 Hz
Voltage range
(without "MSD" independent
disconnection device)
180 V ... 260 V
Frequency range
(without "MSD" independent
disconnection device)
45.5 Hz ... 54.5 Hz

SMA Technologie AG Installation
Installation Guide SB2500-11:SE2006 Page 19
5 Installation
5.1 Mounting the unit
To make the job easier, we recommend you use the
supplied wall bracket to mount the Sunny Boy 2500.
For vertical installation on solid concrete or block walls,
for example, you can fit the bracket using 8 mm x 50
mm hexagon bolts to DIN 571 standard, stainless steel
type, and with wall plugs type SX8.
When selecting the mounting materials, be sure to take
into account the weight of the Sunny Boy 2500
(30 kg).
1. Fit the wall bracket (1). To mark the positions to
drill the holes, you can use the wall bracket as a
drilling template.
2. Now hook the Sunny Boy 2500 onto the wall
bracket (2) at its upper mounting plate so that it
cannot be moved sideways.
3. Fix the Sunny Boy 2500 onto its bracket by
screwing the supplied M6x10 bolt into the central
threaded hole at the bottom of the bracket (3).
4. Make sure the Sunny Boy 2500 is positioned
securely on the bracket.
Betrieb
Operation
Erdschluss
EarthFault
Störung
Failure
Photovoltaik-Stringwechselrichter
Photovoltaicstringinverter
2
3
1

Installation SMA Technologie AG
Page 20 SB2500-11:SE2006 Installation Guide
5.2 Electrical installation
The complete wiring for a Sunny Boy 2500 is shown schematically in the following
diagram:
Check the correct polarity before you connect the PV-strings!