SMA SUNNY BOY 3.0-US User manual

ENGLISH Service Manual ESPAÑOL Instrucciones de servicio técnico
FRANÇAIS Manuel de service
SB3.0-1SP-US-40 / SB3.8-1SP-US-40 / SB5.0-1SP-US-40 /
SB6.0-1SP-US-40 / SB7.0-1SP-US-40 / SB7.7-1SP-US-40
Replacing the Power Unit
SBxx-1SP-US-40-AT-PU-SG-xx-13 | Version 1.3

Table of Contents
Service ManualSBxx-1SP-US-40-AT-PU-SG-xx-132
Table of Contents
1 Information on this Document................................................. 3
1.1 Validity........................................................................................................................ 3
1.2 Target Group.............................................................................................................. 3
1.3 Content and Structure of this Document ................................................................... 3
1.4 Symbols in the Document .......................................................................................... 3
2 IMPORTANT SAFETY INSTRUCTIONS.................................... 3
3 Overview of the Enclosure Parts ............................................ 8
4 Disassembling the Defective Power Unit ............................... 8
5 Mounting the New Power Unit............................................... 11
6 Packaging the Defective Power Unit for Pick-Up .................. 13
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1 Information on this Document
Service Manual SBxx-1SP-US-40-AT-PU-SG-xx-13 3
1 Information on this Document
1.1 Validity
This document is valid for:
• SB3.0-1SP-US-40 (Sunny Boy 3.0-US)
• SB3.8-1SP-US-40 (Sunny Boy 3.8-US)
• SB5.0-1SP-US-40 (Sunny Boy 5.0-US)
• SB6.0-1SP-US-40 (Sunny Boy 6.0-US)
• SB7.0-1SP-US-40 (Sunny Boy 7.0-US)
• SB7.7-1SP-US-40 (Sunny Boy 7.7-US)
1.2 Target Group
The tasks described in this document must only be performed by qualified persons. Qualified
persons must have the following skills:
• Knowledge of how to safely disconnect SMA inverters
• Knowledge of how an inverter works and is operated
• Training in how to deal with the dangers and risks associated with installing, repairing and
using electrical devices and installations
• Training in the installation and commissioning of electrical devices and installations
• Knowledge of all applicable laws, standards and directives
• Knowledge of and compliance with this document and all safety information
1.3 Content and Structure of this Document
This document describes how to replace components.
Illustrations in this document are reduced to the essential information and may deviate from the real
product.
1.4 Symbols in the Document
Icon Explanation
Information that is important for a specific topic or goal, but is not safety-rele-
vant
☐
Indicates a requirement for meeting a specific goal
☑
Desired result
Example
2 IMPORTANT SAFETY INSTRUCTIONS
Keep the manual for future reference.
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2 IMPORTANT SAFETY INSTRUCTIONS
Service ManualSBxx-1SP-US-40-AT-PU-SG-xx-134
This section contains safety information that must be observed at all times when working.
The product has been designed and tested in accordance with international safety requirements. As
with all electrical or electronical devices, there are residual risks despite careful construction. To
prevent personal injury and property damage and to ensure long-term operation of the product,
read this section carefully and observe all safety information at all times.
DANGER
Danger to life due to electric shock when live components or DC conductors
are touched
When exposed to light, the PV modules generate high DC voltage which is present in the DC
conductors. Touching live DC conductors results in death or lethal injuries due to electric shock.
• Disconnect the product from voltage sources and ensure it cannot be reconnected before
working on the device.
• Do not touch non-insulated parts or cables.
• Do not remove the terminal block with the connected DC conductors from the slot under
load.
• Wear suitable personal protective equipment for all work on the product.
DANGER
Danger to life due to electric shock when touching live system components in
case of a ground fault
If a ground fault occurs, parts of the system may still be live. Touching live parts and cables
results in death or lethal injuries due to electric shock.
• Disconnect the product from voltage sources and ensure it cannot be reconnected before
working on the device.
• Only touch the cables of the PV modules on their insulation.
• Do not touch any parts of the substructure or frame of the PV array.
• Do not connect PV strings with ground faults to the inverter.
• Ensure that no voltage is present and wait 5 minutes before touching any parts of the PV
system or the product.
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2 IMPORTANT SAFETY INSTRUCTIONS
Service Manual SBxx-1SP-US-40-AT-PU-SG-xx-13 5
DANGER
Danger to life due to electric shock in case of overvoltages and if surge
protection is missing
Overvoltages (e.g. in the event of a flash of lightning) can be further conducted into the building
and to other connected devices in the same network via the network cables or other data cables
if there is no surge protection. Touching live parts and cables results in death or lethal injuries due
to electric shock.
• Ensure that all devices in the same network are integrated in the existing overvoltage
protection.
• When laying the network cable outdoors, ensure that there is suitable surge protection at
the network cable transition from the product outdoors to the network inside the building.
• The Ethernet interface of the product is classified as "TNV-1" and offers protection against
overvoltages of up to 1.5kV.
WARNING
Danger to life due to fire and explosion
In rare cases, an explosive gas mixture can be generated inside the product under fault
conditions. In this state, switching operations can cause a fire inside the product or explosion.
Death or lethal injuries due to hot or flying debris can result.
• Disconnect the AC circuit breaker, or keep it disconnected in case it has already tripped,
and secure it against reconnection.
WARNING
Risk of injury due to toxic substances, gases and dusts.
In rare cases, damages to electronic components can result in the formation of toxic substances,
gases or dusts inside the product. Touching toxic substances and inhaling toxic gases and dusts
can cause skin irritation, burns or poisoning, trouble breathing and nausea.
WARNING
Danger to life due to electric shock from destruction of the measuring device
due to overvoltage
Overvoltage can damage a measuring device and result in voltage being present in the
enclosure of the measuring device. Touching the live enclosure of the measuring device results in
death or lethal injuries due to electric shock.
• Only use measuring devices with a DC input voltage range of 600V or higher.
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2 IMPORTANT SAFETY INSTRUCTIONS
Service ManualSBxx-1SP-US-40-AT-PU-SG-xx-136
CAUTION
Risk of burns from hot surfaces
The surface of the inverter can get very hot. Touching the surface can result in burns.
• Mount the inverter in such a way that it cannot be touched inadvertently.
• Do not touch hot surfaces.
• Wait 30 minutes for the surface to cool sufficiently.
• Observe the safety messages on the inverter.
CAUTION
Risk of injury due to weight of product
Injuries may result if the product is lifted incorrectly or dropped while being transported or
mounted.
• Transport and lift the product carefully. Take the weight of the product into account.
• Wear suitable personal protective equipment for all work on the product.
NOTICE
Damage to the enclosure seal in subfreezing conditions
If you open the product or disconnect the PowerUnit and ConnectionUnit when temperatures
are below freezing, the enclosure seals can be damaged. Moisture can penetrate the product
and damage it.
• If a layer of ice has formed on the enclosure seal when temperatures are below freezing,
remove it prior to opening the product (e.g. by melting the ice with warm air).
• Do not disassemble the PowerUnit and ConnectionUnit unless the ambient temperature is
at least 0°C (32°F) and conditions are frost-free.
• Do not disassemble the PowerUnit unless the ambient temperature is at least 0°C (32°F)
and conditions are frost-free.
NOTICE
Damage to the product due to sand, dust and moisture ingress
Sand, dust and moisture penetration can damage the product and impair its functionality.
• Only open the product if the humidity is within the thresholds and the environment is free of
sand and dust.
• Do not open the product during a dust storm or precipitation.
• Close tightly all enclosure openings.
• Only use listed rain-tight or liquid-tight conduit fittings to attach the conduits to the product.
• Only disassemble the PowerUnit if a new PowerUnit is already available.
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2 IMPORTANT SAFETY INSTRUCTIONS
Service Manual SBxx-1SP-US-40-AT-PU-SG-xx-13 7
NOTICE
Damage to the inverter due to electrostatic discharge
Touching electronic components can cause damage to or destroy the inverter through
electrostatic discharge.
• Ground yourself before touching any component.
NOTICE
Damage to the product due to cleaning agents
The use of cleaning agents may cause damage to the product and its components.
• Clean the product and all its components only with a cloth moistened with clear water.
Electrical installations (for North America)
All installations must conform with the laws, regulations, codes and standards applicable in the
jurisdiction of installation (e.g. National Electrical Code® ANSI/NFPA 70 or Canadian
Electrical Code® CSA-C22.1.).
• Before connecting the product to the utility grid, contact your local grid operator. The
electrical connection of the product must be carried out by qualified persons only.
• Ensure that the cables or conductors used for electrical connection are not damaged.
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3 Overview of the Enclosure Parts
Service ManualSBxx-1SP-US-40-AT-PU-SG-xx-138
3 Overview of the Enclosure Parts
Figure 1 : Overview of the enclosure parts
Position Designation
A Power Unit
B Connection Unit
4 Disassembling the Defective Power Unit
Prior to disassembling the defective Power Unit, all connections between the Power Unit and the
Connection Unit must be severed. Only then can the Power Unit be removed from the Connection
Unit. All cables connected to the communication assembly can remain plugged in and do not need
to be removed to disassemble the PowerUnit.
CAUTION
Risk of injury due to weight of product
Injuries may result if the product is lifted incorrectly or dropped while being transported or
mounted.
• Transport and lift the product carefully. Take the weight of the product into account.
• Wear suitable personal protective equipment for all work on the product.
Procedure:
1. Disconnect the inverter from voltage sources (see inverter manual).
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4 Disassembling the Defective Power Unit
Service Manual SBxx-1SP-US-40-AT-PU-SG-xx-13 9
2. Remove the terminal block with the connected DC
conductors from slot DC-in. Loosen the screws using
a flat-blade screwdriver (blade width: 4mm
(5⁄32in)) and pull the terminal block out of the slot.
While doing so, only touch the terminal block on the
black enclosure.
COM
DC-in
2
A+ B+ C+ A− B C− −
1
A+ B+ C+ A− B− C−
3. Remove the terminal block with the connected AC
conductors from slot AC-out. Loosen the screws
using a flat-blade screwdriver (blade width: 4mm
(5⁄32in)) and pull the terminal block out of the slot.
AC-out SPS
L1 L2
N
2
1
4. If there is a switch and an outlet for secure power
supply operation connected, remove the terminal
block with the connected cable from the SPS slot. To
do this, unscrew the screws using a flat-blade
screwdriver (blade width: 3.5mm (9/64in)) and
pull the terminal block out of the slot.
AC-out SPS
2
L N
1
5. Pull the ribbon cable connecting the communication
assembly to the PowerUnit out of the
communication assembly.
COM SPS
AC-out
D-IN SPS
A B
M1
X1 X2 M2
ANT.
FCC ID: SVF-KP20
IC: 9440A-KP20
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4 Disassembling the Defective Power Unit
Service ManualSBxx-1SP-US-40-AT-PU-SG-xx-1310
6. If the inverter is fitted with a padlock for theft
protection, open the padlock and remove it.
7. Unscrew the screw M5x60 that fastens the inverter
to the wall mounting bracket (TX25).
8. Remove the 2 screws on the right and left side of the
PowerUnit (TX25) and retain together with the
washers for later use.
9. Lift to remove the Power Unit out of the wall
mounting bracket, thus separating the Power Unit
from the Connection Unit.
TOP
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