SMA SUNNY BOY 3000TL Single Tracker User manual

ServiceManual
SUNNY BOY 3000TL/ 3600TL/ 4000TL/ 5000TL/
6000TL
SB30-60TL-21-SG-en-11 | Version 1.1 AMERICAN ENGLISH

Legal Provisions
The information contained in these documents is property of SMA Solar Technology AG. Any
publication, whether in whole or in part, requires prior written approval by SMA Solar Technology
AG. Internal reproduction used solely for the purpose of product evaluation or other proper use is
allowed and does not require prior approval.
SMA Warranty
You can download the current warranty conditions from the Internet at www.SMA-Solar.com.
Trademarks
All trademarks are recognized, even if not explicitly identified as such. A lack of identification does
not mean that a product or symbol is not trademarked.
The BLUETOOTH® word mark and logos are registered trademarks of BluetoothSIG,Inc. and any
use of these marks by SMASolarTechnologyAG is under license.
Modbus® is a registered trademark of Schneider Electric and is licensed by the Modbus
Organization, Inc.
QR Code is a registered trademark of DENSO WAVE INCORPORATED.
Phillips® and Pozidriv® are registered trademarks of Phillips Screw Company.
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SMA Solar Technology AG
Sonnenallee 1
34266 Niestetal
Germany
Tel. [phone]
Fax [phone]
www.SMA.de
E-mail: [email protected]
© 2004 to 2014 SMA Solar Technology AG. All rights reserved.
Legal Provisions SMA Solar Technology AG
Service ManualSB30-60TL-21-SG-en-112

Table of Contents
1 Information on this Document ................................................. 4
1.1 Validity................................................................................................ 4
1.2 Target Group...................................................................................... 4
1.3 Symbols .............................................................................................. 4
1.4 Nomenclature..................................................................................... 5
2 Safety......................................................................................... 6
2.1 Safety Information.............................................................................. 6
2.2 Disconnecting the Inverter from Voltage Sources ............................ 7
3 Cleaning the Inverter................................................................ 9
4 Troubleshooting ........................................................................ 10
4.1 LED Signals......................................................................................... 10
4.2 Event Messages ................................................................................. 10
4.3 Error Messages .................................................................................. 11
5 Checking the PV System for Ground Faults............................ 19
6 Checking the Function of the Varistors.................................... 22
7 Replacing the Varistors ............................................................ 24
8 Recommissioning the Inverter.................................................. 25
9 Decommissioning the Inverter ................................................. 27
10 Spare Parts................................................................................ 29
11 Contact....................................................................................... 30
Table of Contents
SMA Solar Technology AG
Service Manual 3SB30-60TL-21-SG-en-11

1 Information on this Document
1.1 Validity
This document describes how to rectify certain errors and how to replace defective components.
This document supplements the documents that are enclosed with each product and does not
replace any locally applicable standards or directives. Read and observe all documents supplied
with the product.
This document is valid for the following device types:
• SB 3000TL-21 (Sunny Boy 3000TL)
• SB 3600TL-21 (Sunny Boy 3600TL)
• SB 4000TL-21 (Sunny Boy 4000TL)
• SB 5000TL-21 (Sunny Boy 5000TL)
• SB 6000TL-21 (Sunny Boy 6000TL)
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 an inverter works and is operated
• Training in how to deal with the dangers and risks associated with installing and using
electrical devices and installations
• Training in the installation and commissioning of electrical devices and installations
• Knowledge of the applicable standards and directives
• Knowledge of and compliance with this document and all safety information
1.3 Symbols
Symbol Explanation
Indicates a hazardous situation which, if not
avoided, will result in death or serious injury
Indicates a hazardous situation which, if not
avoided, can result in death or serious injury
Indicates a hazardous situation which, if not
avoided, can result in minor or moderate injury
Indicates a situation which, if not avoided, can
result in property damage
Information that is important for a specific topic
or goal, but is not safety-relevant
Indicates a requirement for meeting a specific
goal
1 Information on this Document SMA Solar Technology AG
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Symbol Explanation
Desired result
A problem that might occur
1.4 Nomenclature
Complete designation Designation in this document
Sunny Boy Inverter, product
Electronic Solar Switch ESS
SMA BLUETOOTH Wireless Technology BLUETOOTH
1 Information on this Document
SMA Solar Technology AG
Service Manual 5SB30-60TL-21-SG-en-11

2 Safety
2.1 Safety Information
This section contains safety information that must be observed at all times when working on or with
the product.
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 to life due to high voltages of the PV array
When exposed to sunlight, the PV array generates dangerous DC voltage which is present in the
DC conductors and the live components of the inverter. Touching the DC conductors or the live
components can lead to lethal electric shocks. If you disconnect the DC connectors from the
inverter under load, an electric arc may occur leading to electric shock and burns.
• Do not touch uninsulated cable ends.
• Do not touch the DC conductors.
• Do not touch any live components of the inverter.
• Have the inverter mounted, installed and commissioned only by qualified persons with the
appropriate skills.
• If an error occurs, have it rectified by qualified persons only.
• Prior to performing any work on the inverter, disconnect it from all voltage sources as
described in this document (see Section2.2 "Disconnecting the Inverter from Voltage
Sources", page7).
Danger to life due to electric shock
Touching an ungrounded PV module or array frame can cause a fatal electric shock.
• Connect and ground the PV modules, array frame and electrically conductive surfaces so
that there is continuous conduction. Observe the applicable local regulations.
Risk of burns due to hot enclosure parts
Some parts of the enclosure can get hot during operation.
• Do not touch any parts other than the lower enclosure lid of the inverter during operation.
Damage to the display or the type label due to the use of cleaning agents
• If the inverter is dirty, clean the enclosure, the enclosure lid, the type label, the display and
the LEDs with a damp cloth only.
2 Safety SMA Solar Technology AG
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2.2 Disconnecting the Inverter from Voltage Sources
Prior to performing any work on the inverter, always disconnect it from all voltage sources as
described in this section. Always adhere to the prescribed sequence.
Destruction of the measuring device due to overvoltage
• Only use measuring devices with a DC input voltage range of 1,000 V or higher.
Procedure:
1. Disconnect the circuit breaker and secure it against reconnection.
2. If an additional DC load-break switch is available, switch off the DC load-break switch and
secure against re-connection.
3. If an ESS is plugged in, remove the ESS.
4. If the multifunction relay is used, switch off any supply voltage to the load.
5. Wait until the LEDs, the display and if necessary, the load connected to the multi-function relay,
are switched off.
6. Use a current clamp to ensure that no current is present in the DC cables.
7. Remove all screws of the lower enclosure lid using an Allen key (AF3) and remove the
enclosure lid.
8. Release and remove all DC connectors. Insert a
slotted screwdriver or an angled screwdriver
(blade width 3.5mm) into one of the slide slots
and pull the DC connectors out downwards. Do
not pull on the cable.
9. Ensure that no voltage is present at the DC inputs of the inverter.
10. Use a suitable measuring device to check that no voltage is present at the AC connecting
terminal plate between L and N and L and PE. Insert the test probe (maximum diameter:
2mm) in each round opening of the terminal.
11. Flip the display up to have more space to make the measurement. Loosen the screw on the
display.
☑ The display clicks into place.
12. Ensure that no voltage is present between any terminal of the multifunction relay and PE of the
AC connecting terminal plate.
2 Safety
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13.
Damage to the inverter due to electrostatic discharge
The internal components of the inverter can be irreparably damaged by electrostatic
discharge.
• Ground yourself before touching any component.
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3 Cleaning the Inverter
Damage to the display or the type label due to the use of cleaning agents
• If the inverter is dirty, clean the enclosure, the enclosure lid, the type label, the display and
the LEDs with a damp cloth only.
• If the cooling fins on the rear of the enclosure are dirty, clean them using a soft brush.
• If the air ducts on the top of the inverter are dirty, clean them using a soft brush.
3 Cleaning the Inverter
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4 Troubleshooting
4.1 LED Signals
The LEDs indicate the operating state of the inverter.
LED Status Explanation
Green LED glowing Feed-in operation
If an event occurs during feed-in operation, an event mes-
sage will be shown on the display (for event messages see
the service manual at www.SMA-Solar.com).
flashing The conditions for feed-in operation are not yet met. As
soon as the conditions are met, the inverter will start feed-
in operation.
Red LED glowing Error
If an error occurs, the error message and the correspond-
ing event number will be shown in the display. The error
must be rectified by a qualified person (for troubleshoot-
ing, see the service manual at www.SMA-Solar.com).
Blue LED glowing BLUETOOTH communication is activated.
4.2 Event Messages
Display message Cause
Self-test The self-test is in progress.
Set parameter The parameter changes are being adopted.
Parameters set successfully The parameter changes were successfully adopted.
Update file OK The update file found is valid.
SD memory card is read The SD memory card is searched for update files and the update file
is checked.
No new update SDcard The SD memory card contains an update file that has already been
used.
Update communication The inverter is performing an update of the communication compo-
nent.
Update main CPU The inverter is updating the inverter component.
Update RS485i module The inverter is updating the corresponding component.
Update Speedwire The inverter is updating the corresponding component.
Webconnect update The inverter is updating the corresponding component.
Update Bluetooth The inverter is updating the corresponding component.
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Display message Cause
Upd. language table The inverter is updating the corresponding component.
Update completed The inverter has successfully completed the update.
Grid param. unchanged The parameters are locked and you cannot change them.
Inst. code valid The entered GridGuard code is valid. Protected parameters have
now been unlocked and you can adjust the parameters. The param-
eters will be automatically locked again after tenfeed-in hours.
4.3 Error Messages
Event number Display message, cause and corrective measures
101 to 103 Grid fault
The grid voltage or grid impedance at the connection point of the inverter is
too high. The inverter has disconnected from the utility grid.
Corrective measures:
• Check whether the grid voltage at the connection point of the inverter is
permanently in the permissible range.
If the grid voltage is outside the permissible range due to local grid
conditions, contact the grid operator. The grid operator must agree with
an adjustment of the voltage at the feed-in point or with a change of the
monitored operating limits.
If the grid voltage is permanently within the permissible range and this
message is still displayed, contact the Service (see Section11, page30
).
202 to 203, 205 Grid fault
The utility grid has been disconnected, the AC cable is damaged or the grid
voltage at the connection point of the inverter is too low. The inverter has dis-
connected from the utility grid.
Corrective measures:
• Make sure that the circuit breaker is switched on.
• Make sure that the AC cable is not damaged.
• Make sure that the AC cable is correctly connected.
• Check whether the grid voltage at the connection point of the inverter is
permanently in the permissible range.
If the grid voltage is outside the permissible range due to local grid
conditions, contact the grid operator. The grid operator must agree with
an adjustment of the voltage at the feed-in point or with a change of the
monitored operating limits.
If the grid voltage is permanently within the permissible range and this
message is still displayed, contact the Service (see Section11, page30
).
4 Troubleshooting
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Event number Display message, cause and corrective measures
301 Grid fault
The ten-minute average value of the grid voltage is no longer within the per-
missible range. The grid voltage or grid impedance at the connection point is
too high. The inverter disconnects from the utility grid to maintain power qual-
ity.
Corrective measures:
• Check whether the grid voltage at the connection point of the inverter is
permanently in the permissible range.
If the grid voltage is outside the permissible range due to local grid
conditions, contact the grid operator. The grid operator must agree with
an adjustment of the voltage at the feed-in point or with a change of the
monitored operating limits.
If the grid voltage is permanently within the permissible range and this
message is still displayed, contact the Service (see Section11, page30
).
401 Grid fault
The inverter is no longer in grid-parallel operation. The inverter has stopped
feeding into the utility grid.
Corrective measures:
• Check the grid connection for significant short-term frequency fluctuations.
501 Grid fault
The power frequency is not within the permissible range. The inverter has dis-
connected from the utility grid.
Corrective measures:
• If possible, check the power frequency and observe how often
fluctuations occur.
If fluctuations occur frequently and this message is displayed often,
contact the grid operator and request approval to change the operating
parameters of the inverter.
If the grid operator gives his approval, discuss any changes to the
operating parameters with the Service.
601 Grid fault
The inverter has detected an excessively high proportion of direct current in
the grid current.
Corrective measures:
• Check the grid connection for direct current.
• If this message is displayed frequently, contact the grid operator and
check whether the monitoring threshold on the inverter can be raised.
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Event number Display message, cause and corrective measures
701 Frq. not permitted > Check parameter
The power frequency is not within the permissible range. The inverter has dis-
connected from the utility grid.
Corrective measures:
• If possible, check the power frequency and observe how often
fluctuations occur.
If fluctuations occur frequently and this message is displayed often,
contact the grid operator and request approval to change the operating
parameters of the inverter.
If the grid operator gives his approval, discuss any changes to the
operating parameters with the Service.
801 Waiting for grid voltage > Grid failure > Check AC circuit breaker
The AC cable is not correctly connected or the country data set is not correctly
configured.
Corrective measures:
• Ensure that the AC cable is correctly connected (see the operating
manual of the inverter).
• Ensure that the country data set has been configured correctly.
• Check the fuse.
901 PE conn. missing > Check connection
The grounding conductor is not correctly connected.
Corrective measures:
• Ensure that PE is correctly connected (see operating manual of the
inverter).
1001 L/N swapped > Check connection
The connection of L and N is swapped.
Corrective measures:
• Ensure that L and N are correctly connected (see operating manual of
the inverter).
1501 Reconnection fault grid
The changed country data set or the value of a parameter you have set does
not correspond to the local requirements. The inverter cannot connect to the
utility grid.
Corrective measures:
• Ensure that the country data set has been configured correctly. Check the
setting of the rotary switches A and B or select the operating parameter
Set country standard and check the value.
4 Troubleshooting
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Event number Display message, cause and corrective measures
3301 to 3303 Unstable operation
The ten-minute average value of the grid voltage is no longer within the per-
missible range. The grid voltage or grid impedance at the connection point is
too high. The inverter disconnects from the utility grid to maintain power qual-
ity.
Corrective measures:
• Check whether the grid voltage at the connection point of the inverter is
permanently in the permissible range.
If the grid voltage is outside the permissible range due to local grid
conditions, contact the grid operator. The grid operator must agree with
an adjustment of the voltage at the feed-in point or with a change of the
monitored operating limits.
If the grid voltage is permanently within the permissible range and this
message is still displayed, contact the Service (see Section11, page30
).
3304 Gen. output too low
The DC output of the PV array is too low. The inverter cannot connect to the
utility grid.
Corrective measures:
• Wait for higher irradiation.
• If this message is displayed frequently with medium irradiation, ensure
that the PV system is correctly rated and the PV array correctly wired.
3401 to 3402 DC overvoltage > Disconnect generator
Overvoltage at the DC input. This can destroy the inverter.
This message is additionally highlighted by rapid flashing of the backlight.
Corrective measures:
• Immediately disconnect the inverter from all voltage sources (see
Section2.2, page7).
• Check whether the DC voltage is below the maximum input voltage of
the inverter. If the DC voltage is below the maximum input voltage of the
inverter, reconnect the DC connectors to the inverter.
• If the DC voltage is above the maximum input voltage of the inverter,
ensure that the PV array has been correctly rated or contact the installer
of the PV array.
• If this message is repeated frequently, contact the Service (see
Section11, page30).
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Event number Display message, cause and corrective measures
3501 Insulation failure > Check generator
The inverter has detected a ground fault in the PV array.
Corrective measures:
• Check the PV system for ground faults (see Section5, page19).
3601 High discharge curr. > Check generator
The leakage currents of the inverter and the PV array are too high. There is a
ground fault, a residual current or a malfunction.
The inverter interrupts feed-in operation immediately after exceeding a thresh-
old. When the fault is eliminated, the inverter automatically reconnects to the
utility grid.
Corrective measures:
• Check the PV system for ground faults (see Section5, page19).
3701 Resid.curr.too.high > Check generator
The inverter has detected a residual current due to temporary grounding of the
PV array.
Corrective measures:
• Check the PV system for ground faults (see Section5, page19).
3801 to 3802 DC overcurrent > Check generator
Overcurrent at the DC input. The inverter briefly interrupts feed-in operation.
Corrective measures:
• If this message is displayed frequently, ensure that the PV array has been
correctly rated and wired.
3901 to 3902 Waiting for DC start conditions > Start cond. not met
The feed-in conditions for the utility grid are not yet fulfilled.
Corrective measures:
• Wait for higher irradiation.
• If this message is displayed frequently in the morning, increase the
voltage limit for starting grid feed-in. Change the parameter Critical
voltage to start feed-in.
• If this message is displayed frequently with medium irradiation, ensure
that the PV array is correctly rated.
6001 to 6438 Self-diagnosis > Interference device
The cause must be determined by the Service.
Corrective measures:
• Contact the Service (see Section11, page30).
4 Troubleshooting
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Event number Display message, cause and corrective measures
6501 to 6502 Self-diagnosis > Overtemperature
The inverter has switched off due to excessive temperature.
Corrective measures:
• Clean the cooling fins on the rear of the enclosure and the air ducts on
the top using a soft brush.
• Ensure that the inverter has sufficient ventilation.
7008 Disturbance sensor display temperature
The cause must be determined by the Service.
Corrective measures:
• Contact the Service (see Section11, page30).
7101 SD card defective
The SD memory card is not formatted.
Corrective measures:
• Re-format the SD memory card.
• Re-save the files to the SD memory card.
7102 Parameter file not found or defective
The parameter file was not found or is defective. The update failed. The in-
verter continues feeding power into the grid.
Corrective measures:
• Copy the parameter file \PARASET into the card drive directory.
7105 Param. setting failed
It was not possible to set the parameter via the SD memory card. The inverter
continues feeding power into the grid.
Corrective measures:
• Check the parameters for valid values.
• Ensure change rights via SMAGridGuardcode.
7106 Update file defect.
Update file on the SD memory card is faulty.
Corrective measures:
• Re-format the SD memory card.
• Re-save the files to the SD memory card.
7110 No update file found
No update file has been found.
Corrective measures:
• Copy the update file in the SD memory card folder. Select the folder
\UPDATE.
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Event number Display message, cause and corrective measures
7201 to 7202 Data stor. not poss..
Internal error. The inverter continues to feed into the utility grid.
Corrective measures:
• Contact the Service (see Section11, page30).
7303 Update main CPU failed
The cause must be determined by the Service.
Corrective measures:
• Contact the Service (see Section11, page30).
7305 Update RS485I module failed
Internal error. The inverter continues to feed into the utility grid.
Corrective measures:
• Retry update.
• If this message is displayed again, contact the Service (see Section11,
page30).
7307 Update BT failed
Internal error. The inverter continues to feed into the utility grid.
Corrective measures:
• Retry update.
• If this message is displayed again, contact the Service (see Section11,
page30).
7311 Update language table failed
Internal error. The inverter continues to feed into the utility grid.
Corrective measures:
• Retry update.
• If this message is displayed again, contact the Service (see Section11,
page30).
7401 Varistor defective
At least one of the thermally monitored varistors is defective.
Corrective measures:
• Check the function of the varistors (see Section6, page22).
7508 External fan fault
The external fan is defective or blocked.
Corrective measures:
• Ensure that the fan is clean.
• Ensure that the external fan is correctly connected.
4 Troubleshooting
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Service Manual 17SB30-60TL-21-SG-en-11

Event number Display message, cause and corrective measures
8001 Derating occurred
The inverter has reduced its power output for more than ten minutes due to ex-
cessive temperature.
Corrective measures:
• Clean the cooling fins on the rear of the enclosure and the air ducts on
the top using a soft brush.
• Ensure that the inverter has sufficient ventilation.
8801 to 8803 No display
The cause must be determined by the Service.
Corrective measures:
• Contact the Service (see Section11, page30).
9002 Inst. code invalid
The SMAGridGuard code entered is incorrect. The operating parameters are
still protected and cannot be changed.
Corrective measures:
• Enter the correct SMAGridGuard code.
9003 Grid param. locked
The parameters are now locked. You cannot change the parameters.
Corrective measures:
• Unlock the parameters with the SMAGridGuard code.
9005 Changing grid param. not possible > Ensure DC supply
This error can have the following causes:
• The selected rotary switch setting for the country configuration is not
programmed.
• The parameters to be changed are protected.
• The DC voltage at the DC input is not sufficient to run the main CPU.
Corrective measures:
• Ensure that the country data set has been configured correctly.
• Enter the SMA Grid Guard code.
• Ensure that sufficient DC voltage is available (green LED is glowing or
flashing).
4 Troubleshooting SMA Solar Technology AG
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5 Checking the PV System for Ground Faults
If the inverter displays the event numbers 3501, 3601 or 3701, there could be a ground fault. The
electrical insulation from the PV system to ground is defective or insufficient.
Danger to life due to electric shock
In the event of a ground fault, high voltages can be present.
• Touch the cables of the PV array on the insulation only.
• 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.
Destruction of the measuring device due to overvoltage
• Only use measuring devices with a DC input voltage range of 1,000 V or higher.
Procedure:
In order to check the PV system for ground faults, perform the following actions in the prescribed
order. The exact procedure is described in the following sections.
• Check the PV system for ground faults by measuring the voltage.
• If the voltage measurement was not successful, check the PV system via insulation resistance
measurement for ground faults.
Test by Measuring the Voltage
Proceed as follows to check each string in the PV system for ground faults.
Procedure:
1.
Danger to life due to high voltages
• Disconnect the inverter from all voltage sources (see Section2.2, page7).
2. Measure the voltages:
• Measure the voltage between the positive terminal and the ground potential (PE).
• Measure the voltage between the negative terminal and the ground potential (PE).
• Measure the voltage between the positive and negative terminals.
If the following results are present at the same time, there is a ground fault in the PV
system:
☑ All measured voltages are stable.
☑ The sum of the two voltages to ground potential is approximately equal to the
voltage between the positive and negative terminals.
• If a ground fault is present, determine the location of the ground fault via the ratio of the
two measured voltages and eliminate the ground fault.
5 Checking the PV System for Ground Faults
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Example: Location of the ground fault
The example shows a ground fault between the second and third PV module.
3. If a definite ground fault cannot be measured and the message is still displayed, measure the
insulation resistance.
4. Reconnect the strings without ground faults to the inverter and recommission the inverter (see
Section8, page25).
Test by Measuring the Insulation Resistance
If the voltage measurement does not provide sufficient evidence of a ground fault, the insulation
resistance measurement can provide more exact results.
Figure 1: Schematic diagram of the measurement
5 Checking the PV System for Ground Faults SMA Solar Technology AG
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