SMA SUNNY BOY 3000-US User manual

SB30-40US-IUS103030 | TBUS-SB30_40US | Version 3.0
EN
PV Inverter
SUNNY BOY 3000-US / 3800-US / 4000-US
Installation Guide

SMA America, LLC Legal Restrictions
Installation Guide SB30-40US-IUS103030 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.
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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 SB30-40US-IUS103030 Installation Guide
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS
This manual contains important instructions for Sunny Boy inverter, that must be followed during
installation and maintenance of the inverter.
The Sunny Boy 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. To reduce the risk of personal injury and to ensure the safe installation and
operation of the Sunny Boy, 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 SB30-40US-IUS103030 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
must 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 only be performed
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.
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 to certify
that it meets the requirements of the National Electrical Code® and IEEE-929-2000.
IEEE 929-2000 provides recommendations regarding the proper equipment and
functionality necessary to ensure compatible operation when power generation is
connected to the utility grid.

General Warnings SMA America, LLC
6 SB30-40US-IUS103030 Installation Guide
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 contains no user-serviceable parts except for the fans on the bottom of the
enclosure and the filters behind the fans as well as the handle covers on the sides of the
unit. For 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 in this installation guide.
Before connecting the Sunny Boy to the electrical utility grid, contact the local utility
company. This connection must be made only by qualified personnel.
Wiring of the Sunny Boy must be made by qualified personnel only.

SMA America, LLC Table of Contents
Installation Guide SB30-40US-IUS103030 7
Table of Contents
1 Notes on this manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1 Validity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2 Target group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3 Storage of the documentation . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.4 Additional information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.5 Nomenclature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.1 Appropriate usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.3 Installation overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3 Unpacking and inspection. . . . . . . . . . . . . . . . . . . . . . . . . 15
3.1 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4 AC Voltage configuration . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.1 Opening the Sunny Boy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.2 Locating internal components . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.3 Automatic grid voltage detection . . . . . . . . . . . . . . . . . . . . . . . 19
4.4 Utility configuration jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5 Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.1 Selecting a mounting location. . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.2 Dimensions of the Sunny Boy and DC Disconnect . . . . . . . . . . 26
5.3 Mounting the Sunny Boy with a wall mounting bracket . . . . . . 27
5.3.1 Possibilities for mounting the wall mounting bracket . . . . . . . . . . . . . . . . . . . 28
5.3.2 Mounting the wall mounting bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.4 Mounting the SMA DC Disconnect. . . . . . . . . . . . . . . . . . . . . . 32
5.5 Mounting the Sunny Boy onto the wall mounting bracket . . . . 32

Table of Contents SMA America, LLC
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6 Electrical connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.1 Without SMA DC Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.2 With SMA DC Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.3 Bottom view and dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6.4 Opening the Sunny Boy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6.5 Opening the SMA DC Disconnect . . . . . . . . . . . . . . . . . . . . . . 37
6.6 AC wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.6.1 Without SMA DC Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6.6.2 With SMA DC Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.7 DC wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6.7.1 DC connection requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.7.2 DC input grounding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6.7.3 DC wiring without SMA DC Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.7.4 DC wiring with SMA DC Disconnect. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6.7.5 DC connection with additional DC distribution . . . . . . . . . . . . . . . . . . . . . . . 55
6.8 Communication wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
6.8.1 RS485 communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
6.9 Closing the Sunny Boy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
6.10 Closing the SMA DC Disconnect . . . . . . . . . . . . . . . . . . . . . . . 61
7 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
8 Displays and messages . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
8.1 LED operation indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
8.2 LED fault indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
8.3 Status messages on the LCD display. . . . . . . . . . . . . . . . . . . . . 69
8.3.1 LCD display language selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
8.4 Communication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
8.5 Measuring channels and parameters . . . . . . . . . . . . . . . . . . . . 72
8.5.1 Measuring channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
8.5.2 Operating mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

SMA America, LLC Table of Contents
Installation Guide SB30-40US-IUS103030 9
8.5.3 Sunny Boy operating parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
9 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
9.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
9.2 Error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
10 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
10.1 Cleaning the fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
10.2 Cleaning the handle covers . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
10.3 Checking the DC Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . 82
10.4 Testing the fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
10.5 Exchanging the fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
10.5.1 Exchanging the GFDI fuse within the Sunny Boy . . . . . . . . . . . . . . . . . . . . . 84
10.5.2 Exchanging PV string fuses within the SMA DC Disconnect . . . . . . . . . . . . . 85
11 Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
11.1 FCC compliance information . . . . . . . . . . . . . . . . . . . . . . . . . . 87
11.2 Sunny Boy wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
11.3 Sunny Boy 3000-US. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
11.4 Sunny Boy 3800-US. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
11.5 Sunny Boy 4000-US. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
11.5.1 SMA DC Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
11.6 Trip limits/trip times. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
11.7 Torque values and wire sizes . . . . . . . . . . . . . . . . . . . . . . . . . . 96
11.8 FCC compliance information . . . . . . . . . . . . . . . . . . . . . . . . . . 96
12 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
13 Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

SMA America, LLC
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SMA America, LLC Notes on this manual
Installation Guide SB30-40US-IUS103030 11
1 Notes on this manual
1.1 Validity
This manual describes the assembly, installation, commissioning and maintenance of the following
SMA inverters:
• Sunny Boy 3000-US
• Sunny Boy 3800-US (SB 3800-US-10)
• Sunny Boy 4000-US
This manual does not cover any details concerning equipment connected to the Sunny Boy (e. g. PV
modules). Information concerning the connected equipment is available from the manufacturer of the
equipment.
1.2 Target group
This manual is for qualified personnel. Qualified personnel have received training and have
demonstrated skills and knowledge in the construction and operation of this device. Qualified
personnel are trained to deal with the dangers and hazards involved in installing electric devices.
1.3 Storage of the documentation
Keep all Sunny Boy manuals in a convenient place for future reference.
1.4 Additional information
You will find further information on special topics in the download area at www.SMA-America.com.
1.5 Nomenclature
In this document SMA America Production, LLC is referred to in the following as SMA.
The syntax specified here for menus and parameters applies throughout the entire manual.

Safety SMA America, LLC
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2 Safety
2.1 Appropriate usage
The Sunny Boy is a DC to AC grid-tied utility interactive inverter for use with photovoltaic (PV). The
Sunny Boy 3000‑US is additionally UL listed for the use with fuel cell, wind turbine and other sources
of DC power.
Anti-islanding protection
Islanding is a condition that can occur if the utility grid is disconnected while the Sunny Boy is
operating and the remaining load is resonant at 60 Hz and matches the output of the Sunny Boy
perfectly. This condition is highly unlikely and had never been witnessed outside of a controlled
laboratory. Nevertheless, the Sunny Boy incorporates an advanced active islanding protection
algorithm to ensure that the system will not export power into a balanced 60 Hz resonant load while
the utility is disconnected. The Sunny Boy periodically injects both leading and lagging reactive
current into the utility grid. This method has been proven by Underwriters Laboratories to effectively
destabilize and disconnect from a balanced island condition.
PV ground fault detection and interruption
The Sunny Boy is equipped with a ground fault detection device. If a ground 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 fault error will need to be
manually cleared and the inverter will then resume normal operation.
PV series fusing
Series fusing may be required depending on the type of PV module used in the system. See
NationalElectrical Code® 690.9
Interconnection code compliance
The Sunny Boy has been tested and listed by Underwriters Laboratories to meet the requirements of
UL1741 Static Inverters and Charge Controllers for use in Photovoltaic Power Systems and UL1998
Software in Programmable Components, as well as IEEE-929-2000 Recommended Practice for Utility
Interface of Photovoltaic Systems and IEEE 1547 Standard for Interconnecting Distributed Resources
with Electric Power Systems. The Sunny Boy is also listed under UL1741 for Canadian UL.
UL1741 is the standard applied by Underwriters Laboratories to the Sunny Boy to
certify that it meets the requirements of the National Electrical Code® and
IEEE‑929-2000. IEEE 929-2000 provides recommendations regarding the proper
equipment and functionality necessary to ensure compatible operation when
power generation is connected to the utility grid.
Contact the local utility and/or the authority having jurisdiction prior to connecting the
Sunny Boy to the utility grid.

SMA America, LLC Safety
Installation Guide SB30-40US-IUS103030 13
FCC compliance
The Sunny Boy has been tested and shown to conform with all FCC Part 15 B EMI/EMC emissions
regulations.
Operating temperature
The Sunny Boy has been designed to maintain full power output at ambient temperatures as high as
113 °F. Fan cooling allows this level of output power to be achieved even in enclosed spaces. The
Sunny Boy will continue to operate well beyond 113 °F and de-rates as needed to maintain a safe
internal component temperature.
Principle of a PV plant with a Sunny Boy
2.2 Safety instructions
Position Description
A PV array
B Sunny Boy with SMA DC Disconnect
C Local loads
D Energy meter
EUtility grid
DANGER
High voltages are present in the Sunny Boy during operation.
Death or serious injury due to electric shock.
• All work on the Sunny Boy must only be carried out by qualified personnel.
WARNING
The Sunny Boy can become hot during operation.
Risk of burns.
• Do not touch enclosure during operation.
• Only touch lid during operation.

Safety SMA America, LLC
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2.3 Installation overview
This section provides a brief overview of the installation process of a Sunny Boy.
Section 3: Unpacking and inspection
This section provides instructions and information for unpacking the Sunny Boy and inspecting it for
shipping damage.
Section 4: AC Voltage configuration
This section includes information on removing the cover, locating primary components within the
inverter and selecting the appropriate voltage configuration for the installation.
Section 5: Mounting
This section includes guidelines to help you select the best mounting location, suggestions to insure
optimum performance, cautions and warnings that you should follow to avoid injury and/or
equipment damage and step-by-step instructions for mounting the Sunny Boy inverter.
Section 6: Electrical connection
This section 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 Boy to a PV array, household electrical circuits and the utility grid. Procedures are also included
for connecting optional data-communication cables.
Section 7: Commissioning
Commissioning involves applying DC input power to the Sunny Boy, observing the LED and LCD
indicators on the front cover, and resolving any problems that occur.
Section 8: Displays and messages
This section provides troubleshooting tips and procedures for resolving problems that may occur
during installation and operation.
Section 9: Troubleshooting
This section provides troubleshooting tips and procedures for resolving problems that may occur
during installation and operation.
Section 10: Maintenance
This section includes maintenance and cleaning of the Sunny Boy and cautions and warnings you
should follow to avoid injury and/or equipment damage.
Section 11: Technical specifications
This section includes technical data for the Sunny Boy, connection diagrams and torque specifications
for the connection of cables and the screws of the Sunny Boy.

SMA America, LLC Unpacking and inspection
Installation Guide SB30-40US-IUS103030 15
3 Unpacking and inspection
All Sunny Boy inverters 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, use the
original packing material.
If you need assistance with a damaged Sunny Boy, contact your SMA dealer or SMA.
Contact information is provided in section „Contact“, page 98.
WARNING
The Sunny Boy weighs up to 88lbs. (40kg). To avoid injury, be sure to use proper lifting
techniques and secure the help of someone to assist in the unpacking and installation of
the inverter.

Unpacking and inspection SMA America, LLC
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3.1 Scope of delivery
Position Number Description
A1Sunny Boy
B 1 Wall-mounting bracket
C 1 Spare screw and spare washer for closing the Sunny Boy lid
2 Screws and washers for fastening the Sunny Boy to the wall-mounting bracket
D 2 Spare jumpers for fan test
E 2 Handle covers (left and right)
F1SMA DC Disconnect
G1Screw and washer for closing the DC Disconnect lid
2 Screws and washers for fastening the DC Disconnect to the wall-mounting
bracket

SMA America, LLC AC Voltage configuration
Installation Guide SB30-40US-IUS103030 17
4 AC Voltage configuration
4.1 Opening the Sunny Boy
1. Remove the four screws and lock washers from the
housing cover and pull the cover forward smoothly.
2. Place the cover, screws, and lock washers aside where
they will be out of your way while you are connecting
wires and cables to the Sunny Boy.
CAUTION
Be careful 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 carefully, as even minor damage to the cover could result in an
inadequate seal between the cover and the case, thus allowing moisture to enter the case
and damage the sensitive electronic components.
NOTICE
Do not install the Sunny Boy during periods of precipitation or high humidity (>95%).
Moisture trapped within the enclosure may cause corrosion and damage to the electronic
components.

AC Voltage configuration SMA America, LLC
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4.2 Locating internal components
Following figure illustrates the locations of the major internal components of the Sunny Boy. Refer to
this illustration to locate particular components.

SMA America, LLC AC Voltage configuration
Installation Guide SB30-40US-IUS103030 19
4.3 Automatic grid voltage detection
The Sunny Boy is designed to automatically detect which grid voltage it is feeding if a neutral
conductor is connected to the inverter. Depending upon the voltage and phase angle between L1-N
and L2-N, the inverter will determine if it is connected to a 208 V or 240 V.
The following table lists voltage and frequency limits for the AC connection.
Position Description
A Sockets for optional communication Piggy-Back (RS485 or wireless)
B Display
C Status LED
D Output AC Line Terminals (N, L1 and L2)
EGround Terminal (PE)
F PV Grounding + DC Grounding electrode conductor
G Output AC Line Terminals (L1, L2, N and PE)
H PV GROUNDED Terminal (input from PV array)
I PV UNGROUNDED Terminal (input from PV array)
KCombined UNGROUNDED Terminal
L DC– Terminal (input from PV array)
M DC+ Terminal (input from PV array)
N Flat connection for grounding the cable shield for communication
O Terminal for optional communication (RS485)
AC connection Range limit
208 V nominal, line to line 183 V…229 V
240 V nominal, line to line 211 V…264 V
Frequency 59.3 Hz…60.5 Hz

AC Voltage configuration SMA America, LLC
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Commonly used transformer types
.When connecting the Sunny Boy to the utility, the phase relationship is not important, but
the voltage must be compatible.