SMA Sunny Boy 3800U User manual

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Installation Guide
SB3800U-12:SE2006 SMA America i
Copyright © 2005 SMA America, Inc. 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, Inc.
SMA America 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 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 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.
SMA America, Incorporated
12438 Loma Rica Drive
Grass Valley, California 95945
Tel [phone]
Fax [phone]
www.sma-america.com
Revision History
Rev. No. Date By Version
1.0 May 04, 2005 YS 1st Edition
2.0 June, 2005 JP 1st US Edition
2.1 August, 2005 JP 2nd US Edition
2.2 November, 2005 JP 3rd US Edition
2.3 February, 2006 JP 4th US Edition
2.4 May, 2006 JP 5th US Edition

Installation Guide
ii SMA America SB3800U-12:SE2006
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS
This manual contains important instructions for the Sunny Boy 3800U 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.
Safety and Hazard Symbols
This symbol is used to call attention to important information that
you must have when installing and/or operating the Sunny Boy.
Failure to read and follow instructions marked with this symbol
could result in injury or death and/or damage to the equipment.
This symbol appears beside instructions and warnings that deal
with dangerous voltages that can injure or kill people who come
in contact with them.
This symbol appears beside terminations that are connected to
earth-ground.

Installation Guide
SB3800U-12:SE2006 SMA America iii
Warnings
WARNING: 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 dam-
age to or destruction of part or all of the SMA equipment and/
or other equipment connected to the SMA equipment or per-
sonal injury.
Warnings and Cautions may also be accompanied by one or more of the safety and
hazard symbols described above to indicate the type of hazard described therein.
Other Symbols
In addition to the safety and hazard symbols described on the previous pages, the
following symbol is also used in this Installation Guide:
This symbol accompanies notes that call attention to supplementary
information that you should know and use to ensure optimal operation
of the system.
All electrical installations must be done in accordance with
the local and National Electrical Code ANSI/NFPA 70.
The Sunny Boy contains no user-serviceable parts except
for the fan on the bottom of the enclosure and the filter
behind the fan as well as the exhaust fin on the left hand
side of the unit. For all other 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, the
PV array, and in this Installation Guide.
Before connecting the Sunny Boy 3800U to the electrical
utility grid, contact the local utility company. This
connection must be made only by qualified personnel.

Installation Guide
iv SMA America SB3800U-12:SE2006
PV arrays produce electrical energy when exposed to light
and thus can create an electrical shock hazard. Wiring of
the PV-arrays should only be performed by qualified
personnel.
Warranty
All Sunny Boy inverters sold in the USA have a five-year warranty, as indicated on the
warranty card included in the Sunny Boy shipping container. For warranty coverage, or
if you have questions about the Sunny Boy warranty, contact SMA America at the
address, telephone number or Web site listed on page i (to send E-mail, see the Contact
section of the SMA America Web site).

SB3800U-12:SE2006 SMA America v
Contents
Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
Safety and Hazard Symbols . . . . . . . . . . . . . . . . . . . . . . . . . ii
Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Other Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
1 Introduction
Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Installation Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
2 Unpacking and Inspection
3 Mounting
Choosing a Mounting Location . . . . . . . . . . . . . . . . . . . . . . 3-1
Dimensions and Recommended Clearances . . . . . . . . . . . . . 3-3
Mounting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
4 AC Voltage Configuration
Opening the Sunny Boy 3800U . . . . . . . . . . . . . . . . . . 4-1
Locating Internal Components . . . . . . . . . . . . . . . . . . . . 4-2
5 Wiring the Sunny Boy 3800U
Wiring the AC Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
AC Connection Requirements . . . . . . . . . . . . . . . . . . . . 5-3
Connecting the AC Wires . . . . . . . . . . . . . . . . . . . . . . . 5-5
Wiring the DC Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
DC Connection Requirements . . . . . . . . . . . . . . . . . . . . 5-7
Connecting the DC Wires . . . . . . . . . . . . . . . . . . . . . . . 5-9
Connecting Communication Cables . . . . . . . . . . . . . . . . . . 5-12
RS-232 Communication . . . . . . . . . . . . . . . . . . . . . . . 5-12
RS-485 Communication . . . . . . . . . . . . . . . . . . . . . . . 5-15
Replacing the Cover. . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
6 Commissioning
7 Displays and Messages
LED Fault Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Status Messages on the LCD . . . . . . . . . . . . . . . . . . . . 7-11

vi SMA America SB3800U-12:SE2006
Communication Options. . . . . . . . . . . . . . . . . . . . . . . 7-14
8 Troubleshooting
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
9 Maintenance
Cleaning the Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Cleaning the Exhaust Vent . . . . . . . . . . . . . . . . . . . . . . 9-2
Testing the Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
10 Technical Specifications
FCC Compliance Information . . . . . . . . . . . . . . . . . . . 10-1
Sunny Boy SB3800U Wiring Diagram. . . . . . . . . . . . . 10-2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2

SB3800U-12:SE2006 SMA America 1-1
Section 1:
Introduction
This installation guide provides all the information needed to install, commission and
operate a Sunny Boy 3800U (SB3800U) grid-tied photovoltaic (PV) inverter.
Note: To help avoid problems during the installation,
familiarize yourself with the installation process by reading
the entire Installation Guide before starting the installation.
WARNING: Lethal voltages are present at various points
in a PV system. For safety reasons, it is recommended that
only qualified personnel install and operate this equip-
ment.
Product Overview
The SB3800U is a DC to AC grid-tied utility interactive inverter for use with photovoltaic
(PV), fuel cell, wind turbine and other sources of DC power.
In general, the SB3800U takes power from a DC source (PV modules) and converts it to
AC power for the utility grid. This power is delivered first to local loads (household
appliances, lights, motor loads, etc.), with any excess power fed to the utility. The power
consumed by the local loads reduces the power needed from the utility. Excess power
may actually “spin the utility meter backwards” depending on the type of meter in your
system. This power may also be recorded as power credits by the utility company
depending on the interconnection agreement. An example of basic system components
is shown in Figure 1-1.
Figure 1-1 SB3800U Installed in a Utility Interactive PV System
Störung
Failure
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Operation
Erdschluss
EarthFault
PVArray
Sunny Boy 3800U
Utility Grid
Meter

1-2 SMA America SB3800U-12:SE2006
Note: Policies vary from one utility company to another. Consult
with a representative of the local utility company before
designing and installing a PV system.
Safety
Anti-Islanding Protection
Islanding is a condition that can occur if the utility grid is disconnected while the
SB3800U is operating and the remaining load is resonant at 60 Hz and matches the
output of the SB3800U perfectly. This condition is highly unlikely and had never been
witnessed outside of a controlled laboratory. Nevertheless, the SB3800U incorporates
an advanced active islanding protection algorithm to insure that the system will not
export power into a balanced 60 Hz resonant load while the utility is disconnected. The
SB3800U periodically injects both leading and lagging reactive current into the utility
grid. This method has been proven by U.S. regulatory agencies to effectively destabilize
and disconnect from a balanced island condition.
PV Ground Fault Detection and Interruption
The SB3800U is equipped with a ground fault detection device. If a ground fault current
greater than 1 Amp is detected, the SB3800U 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 NEC 690.9
Interconnection Code Compliance
The SB3800U has been tested and certified by ETL to meet the requirements of UL1741
Static Inverters and Charge Controllers for use in Photovoltaic Power Systems as well
as IEEE-929-2000 Recommended Practice for Utility Interface of Photovoltaic Systems
and IEEE 519 Standard Practices and Requirements for Harmonic Control in Electrical
Power Systems. The SB3800U is also ETL listed under UL1741 for use in Canada.

SB3800U-12:SE2006 SMA America 1-3
UL1741 is the standard applied by ETL to the Sunny Boy 3800U
to certify that it meets the requirements of the NEC 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.
Note: Contact the local utility and/or the authority having
jurisdiction prior to connecting the SB3800U to the utility grid.
FCC Compliance
The SB3800U has been tested and certified by a nationally recognized testing
laboratory and conforms to all FCC Part 15 B EMI/EMC emissions regulations.
Feature Overview
Over twenty years of inverter manufacturing experience has gone into the design of the
SB3800U. As a result, the SB3800U represents state-of-the-art technology, high
reliability and overall ease of use - all the qualities you’ve come to expect from SMA,
the industry leader in inverter technology. Some of the features included are:
•LCD
• Temperature regulated fan cooling - simple replacement
• Auto line voltage detection and configuration
• Advanced communication options available
• Compatible with all SMA inverter and communication products
• High efficiency
• Simple installation
• Powder coated diecast enclosure
Operating Temperature
The SB3800U has been designed to maintain full power output with ambient
temperatures as high as 45°C. Fan cooling allows this level of output power to be
achieved even in enclosed spaces. The SB3800U will continue to operate well beyond
45°C and derates as needed to maintain a safe internal component temperature.

1-4 SMA America SB3800U-12:SE2006
Installation Overview
This section provides a high-level overview of the installation process so you have an
idea what to expect as you proceed through the rest of the Installation Guide.
The installation process is broken down into the following tasks:
Section 2: Unpacking and Inspection
This section provides instructions and information for unpacking the SB3800U and
inspecting it for shipping damage.
Section 3: 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 SB3800U inverter.
Section 4: Input 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: Wiring the Sunny Boy 3800U
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 SB3800U to a PV array, household electrical circuits
and the utility grid. Procedures are also included for connecting optional data-
communication cables.
Section 6: Commissioning
Commissioning involves applying DC input power to the SB3800U, observing the LED
and LCD indicators on the front cover, and resolving any problems that occur.
Section 7: Displays and Messages
This section provides troubleshooting tips and procedures for resolving problems that
may occur during installation and operation.

SB3800U-12:SE2006 SMA America 2-1
Section 2:
Unpacking and Inspection
All Sunny Boy inverters are thoroughly tested and inspected before they are packed and
shipped. Although they are shipped in sturdy, recyclable packaging; damage can still
occur during shipping. It is important to carefully inspect the shipping container prior to
beginning the installation. If any external damage to the packaging makes you suspect
the inverter itself could be damaged, or if you find that the inverter is damaged after
unpacking it, report the damage immediately to your SMA dealer and to the shipping
company that delivered the Sunny Boy. If it becomes necessary to return the Sunny Boy,
use the original packaging in which it was delivered.
WARNING: The Sunny Boy 3800U weighs 85 lb. (38 kg). To
avoid injury, be sure to use proper lifting techniques and se-
cure the help of someone to assist in the unpacking and instal-
lation of the inverter.
If you need assistance with a damaged Sunny Boy, contact your SMA dealer or SMA
America. Contact information for SMA America is provided below.
SMA America, Incorporated
12438 Loma Rica Drive
Grass Valley, California 95945
Tel [phone]
Fax [phone]
www.sma-america.com

2-2 SMA America SB3800U-12:SE2006

SB3800U-12:SE2006 SMA America 3-1
Section 3:
Mounting
This section provides 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 a SB3800U inverter.
WARNING: The SB3800U weighs 85 lb. (38 kg). To avoid in-
jury, be sure to use proper lifting techniques and secure the
help of someone to assist in the unpacking and installation of
the inverter.
Note: Occasionally, the rating label on the SB3800U will need
to be referred to. For this reason, it is required that the inverter
be mounted so that the rating label on the side of the inverter be
visible.
Choosing a Mounting Location
Consider the following guidelines, cautions, and warnings when choosing a mounting
location for the SB3800U:
•Do not install the SB3800U in direct sunlight. External heating from exposure to the
sun may cause excessive internal heating. This can result in derated output power to
protect the internal components from damage.
• Install the SB3800U in a location that maintains an ambient air temperature that is
less than 45°C. To maintain a safe internal component temperature, the SB3800U
may reduce its power output if the ambient air temperature exceeds 45°C. (The
cooler the air temperature, the longer the life expectancy of any power electronics
device.)
• The SB3800U is constructed in a rugged powder coated aluminium enclosure
designed for outdoor installations. However, care should always be taken to
minimize exposure to the elements. It is best to minimize exposure to rain, snow and
ice, etc. Do not install the SB3800U in a location exposed to sources of direct water
spray such as sprinklers or downspouts.
• The inverter should be installed in a location that is inaccessible to children.
• The SB3800U may emit a slight vibrating noise when operating. This vibration is
normal and has no effect on performance, but it may be noticeable if the inverter is
mounted on a wall in a living area, on the outside of a wall that is near a living area,
or on certain types of materials, such as thin wood panelling or sheet metal.

3-2 SMA America SB3800U-12:SE2006
• If the inverter is installed outside, it should be mounted vertically or tilted back. (See
Figure 3-1).
Figure 3-1 Sunny Boy Mounting Positions
CAUTION: The SB3800U weighs 85 lb. (38 kg.). Ensure
that the mounting surface is strong enough to hold the
weight of the SB3800U. Do not mount the Sunny Boy on
plasterboard (sheet-rock) or thin wood panelling.
CAUTION: All electrical conduits and any communication
cables must be positioned and/or sealed so that no water
can enter the inverter enclosure through these conduits and
cables.
CAUTION: Do not install the SB3800U during periods of
precipitation or high humidity (>95%). Moisture trapped
within the enclosure may cause corrosion and damage to
the electronic components.
CAUTION: If you are installing the Sunny Boy in a cabinet,
closet, or other relatively small enclosed area, you must pro-
vide sufficient air circulation to dissipate the heat generated
by the inverter.
WARNING: To prevent electrical shock or other injury,
check for existing electrical or plumbing installations in the
walls before drilling mounting holes for the Sunny Boy.
CAUTION: Outdoor installations must use raintight or wet
location hubs that meet the requirements of the Standard for
Fittings for Cable and Conduit, UL514B.
Vertical
(Best option)
Tilted Back
(Acceptable)
Tilted Forward
(Unacceptable)

SB3800U-12:SE2006 SMA America 3-3
Dimensions and Recommended Clearances
The outer dimensions of the SB3800U are shown in Figure 3-2. The SB3800U must be
mounted so that there is at least eight inches of clearance around it.
Figure 3-2 Outer Dimensions of the SB3800U
CAUTION: You must ensure that there is sufficient clearance for
the flow of the air around the SB3800U! In a normal operating
environment with good ventilation, eight inches of clearance is
adequate.
Note: The National Electrical Code may require significantly
larger working clearances (see NEC Section 110.26).
Störung
Failure
Betrieb
Operation
Erdschluss
Earth Fault
236 mm
(9.3 in)
351 mm
(13.83 in)
452 mm
(17.80 in)

3-4 SMA America SB3800U-12:SE2006
Figure 3-3 Dimensions of the Wall Mounting Bracket
434,60 mm (17,12 in)
250 mm (9,85 in)
75 mm (2,95 in)
349,3 mm (13,76 in)
178,9 mm (7,05 in)
104 mm (4,09 in)

SB3800U-12:SE2006 SMA America 3-5
Mounting Procedure
The SB3800U is shipped with a removable mounting plate. This plate is also the wall-
mounting bracket suitable for use on most material (see Figure 3-4). The plate has three
holes for mounting to wooden stud wall panels. Make sure that the wall you choose to
mount the Sunny Boy on is sturdy enough to support the weight (38 kg/85 lb.) and that
the wall is plumb. The bracket may also be mounted on stone, brick or solid walls. Be
sure to use the appropriate type of mounting hardware for the wall material and ensure
that the hardware is no smaller than 1/4” diameter.
Figure 3-4 SB3800U with removable mounting plate
Störung
Failure
Betrieb
Operation
Erdschluss
EarthFault
Störung
Failure
Betrieb
Operation
Erdschluss
EarthFault
Stone wall mounting Wood wall mounting

3-6 SMA America SB3800U-12:SE2006
Figure 3-5 Mounting the SB3800U
Use the following procedure to mount the SB3800U:
1. Locate the mounting plate included in the shipping container with the SB3800U.
2. The holes in the mounting plate are sealed with plastic plugs. Remove the plastic
plugs for only the holes used.
3. Position the mounting plate against the wall where you intend to mount the
SB3800U. (Try to mount the SB3800U so that the display is approximately at eye-
level.) Place a level on the top edge of the mounting plate, and adjust the position of
the mounting plate until it is level. The bottom of the mounting plate will be equal to
the approximate location of the bottom of the inverter.
4. Using the mounting plate as a template, mark the wall through three holes in the
mounting plate. (See Figure 3-4)
CAUTION: Ensure that there are studs in the wall at the places where
you intend to drill the mounting-holes. DO NOT use molly or toggle bolts
to mount the SB3800U to sheet rock or panelling.
5. Set the mounting plate aside temporarily, and drill holes at the marks on the wall.
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