SMA SUNNY BOY 4000-US User manual

Sunny Boy 3000US
Sunny Boy 4000US
Installation Guide Version 1.2 SB3000US-4000US-11-SE1607
TBUS-SB30_40US

ii SMA America SB3000US-4000US-11-SE1607

SB3000US-4000US-11-SE1607 SMA America iii
Copyright © 2007 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 February 2007 GAS 1st Edition
1.1 March 2007 Welzel 2nd Edition
1.2 April2007 Welzel 3rd Edition

iv SMA America SB3000US-4000US-11-SE1607
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS
This manual contains important instructions for the Sunny Boy SB 3000US / Sunny
Boy SB 4000US 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.

SB3000US-4000US-11-SE1607 SMA America v
Warnings
WARNING: A Warning describes a hazard to equip-
ment 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 con-
nected to the SMA equipment or personal 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.
General Warnings
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 handle cover 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.

vi SMA America SB3000US-4000US-11-SE1607
Before connecting the Sunny Boy to the electrical utility
grid, contact the local utility company. This connection
must be made only by qualified personnel.
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 iii (to send E-
mail, see the Contact section of the SMA America Web site).

SB3000US-4000US-11-SE1607 SMA America vii
Contents
Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii
Safety and Hazard Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iv
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
Other Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
General Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vi
1 Introduction
Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Installation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
2 Unpacking and Inspection
Scope of Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
3 Mounting
Choosing a Mounting Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Dimensions and Recommended Clearances . . . . . . . . . . . . . . . . . . . 3-4
Mounting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Mounting the SMA DC-Disconnect (if applicable) . . . . . . . . 3-10
Mounting the Sunny Boy . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
4 AC Voltage Configuration
Opening the Sunny Boy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Locating Internal Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Automatic Grid Voltage Detection . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Utility Configuration Jumpers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
5 Wiring the Sunny Boy
Sequence of Connecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Wiring without SMA DC-Disconnect. . . . . . . . . . . . . . . . . . . 5-2
Wiring with SMA DC-Disconnect . . . . . . . . . . . . . . . . . . . . . 5-3
Bottom view and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Opening the Sunny Boy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Opening the SMA DC-Disconnect (if applicable) . . . . . . . . . . . . . . . . 5-5
Wiring the AC Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
AC Connection Requirements . . . . . . . . . . . . . . . . . . . . . . . 5-7

viii SMA America SB3000US-4000US-11-SE1607
AC Wiring Without SMA DC-Disconnect . . . . . . . . . . . . . . 5-10
AC Wiring With SMA DC-Disconnect . . . . . . . . . . . . . . . . 5-12
Wiring the DC Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
DC Connection Requirements . . . . . . . . . . . . . . . . . . . . . . 5-15
DC Input Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Connecting the DC Wires . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
DC Wiring Without SMA DC-Disconnect . . . . . . . . . . . . . . 5-19
DC Wiring With SMA DC-Disconnect . . . . . . . . . . . . . . . . 5-21
Communication Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
RS-485 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
Closing the Sunny Boy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Closing the SMA DC-Disconnect (if applicable) . . . . . . . . . . . . . . . . 5-28
6 Commissioning
7 Displays and Messages
LED Operation Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
LED Fault Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Status Messages on the LCD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
LCD Language Selection . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Communication Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Measuring Channels and Parameters . . . . . . . . . . . . . . . . . . . . . . . 7-17
Measuring Channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Operating Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Sunny Boy Operating Parameters . . . . . . . . . . . . . . . . . . . . . . 7-19
8 Troubleshooting
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
9 Maintenance
Cleaning the Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Testing the Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Cleaning the Handle Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Exchanging the Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Exchanging the GFDI Fuse within the Sunny Boy. . . . . . . . . . 9-4
Exchanging the PV String Fuses within the SMA DC-Disconnect 9-5

SB3000US-4000US-11-SE1607 SMA America ix
10 Technical Specifications
FCC Compliance Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Sunny Boy Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
Trip Limits / Trip Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
Torque Values and Wire Sizes. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6

x SMA America SB3000US-4000US-11-SE1607

Introduction
SB3000US-4000US-11-SE1607 SMA America 1-1
Section 1:
Introduction
This installation guide provides all the information needed to install, commission and
operate a Sunny Boy SB 3000US / SB 4000US 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 rec-
ommended that only qualified personnel install and
operate this equipment.

Introduction Product Overview
1-2 SMA America SB3000US-4000US-11-SE1607
Product Overview
The Sunny Boy is a DC to AC grid-tied utility interactive inverter for use with
photovoltaic (PV). The SB 3000US is additionally UL listed for the use with fuel cell,
wind turbine and other sources of DC power.
In general, the Sunny Boy 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 Sunny Boy Installed in a Utility Interactive PV System
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.
PV Array
Sunny Boy
Utility Grid
Meter

Introduction Product Overview
SB3000US-4000US-11-SE1607 SMA America 1-3
Safety
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 insure 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 U.S. regulatory
agencies 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 NEC 690.9
Interconnection Code Compliance
The Sunny Boy has been tested and certified by UL 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 1547 Standard for Interconnecting Distributed
Resources with Electric Power Systems. The Sunny Boy is also UL listed under
UL1741 for use in Canada.

Introduction Product Overview
1-4 SMA America SB3000US-4000US-11-SE1607
UL1741 is the standard applied by Underwriters Laboratories
to the Sunny Boy 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 Sunny Boy to the utility
grid.
FCC Compliance
The Sunny Boy 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 Sunny Boy. As a result, the Sunny Boy 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 with simplified fan replacement
• Auto line voltage detection and configuration
• Advanced communication options
• Compatible with all SMA inverter and communication products
• High efficiency
• Simple installation
• Powder coated diecast enclosure
Operating Temperature
The Sunny Boy 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 Sunny Boy will continue to operate well
beyond 45°C and derates as needed to maintain a safe internal component
temperature.

Introduction Installation Overview
SB3000US-4000US-11-SE1607 SMA America 1-5
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 Sunny Boy 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 Sunny Boy inverter.
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: Wiring the Sunny Boy
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 6: 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 7: Displays and Messages
This section provides troubleshooting tips and procedures for resolving problems
that may occur during installation and operation.

Introduction Installation Overview
1-6 SMA America SB3000US-4000US-11-SE1607

Unpacking and Inspection
SB3000US-4000US-11-SE1607 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 weighs 88 lb. (40 kg). To
avoid injury, be sure to use proper lifting techniques
and secure the help of someone to assist in the unpack-
ing and installation 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

Unpacking and Inspection Scope of Delivery
2-2 SMA America SB3000US-4000US-11-SE1607
Scope of Delivery
Sunny Boy:
Aone Sunny Boy
Bone M6 x 16 screw for closing the Sunny Boy cover (spare)
Cone M6 washer for closing the Sunny Boy cover (spare)
Dtwo M6 x 10 screws for fastening the Sunny Boy to the wall-mounting
bracket
Etwo M6 washers for fastening the Sunny Boy to the wall-mounting bracket
Fone wall-mounting bracket
Gtwo jumpers in spare (1 x fan test and 1 x grid configuration)
Htwo handle covers (left and right)
SMA DC-Disconnect (if applicable):
Ione DC-Disconnect
Jone screw for the switch handle of the DC-Disconnect (spare)
Kone allen key for fastening the switch
Lthree M6 x 10 screws (2 x for fastening the DC-Disconnect to the wall-
mounting bracket and 1 x for closing the DC-Disconnect cover)
Mthree M6 washers (2 x for fastening the DC-Disconnect to the wall-mounting
bracket and 1 x for closing the DC-Disconnect cover)
A
F
H
H
I
J
L
M
K
DE
G
BC

Mounting
SB3000US-4000US-11-SE1607 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 Sunny Boy inverter.
WARNING: The Sunny Boy weighs 88 lb. (40 kg). To
avoid injury, be sure to use proper lifting techniques
and secure the help of someone to assist in the unpack-
ing and installation of the inverter.
Note: Occasionally, the rating label on the Sunny Boy 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.

Mounting Choosing a Mounting Location
3-2 SMA America SB3000US-4000US-11-SE1607
Choosing a Mounting Location
Consider the following guidelines, cautions, and warnings when choosing a
mounting location for the Sunny Boy:
• Do not install the Sunny Boy in direct sunlight. External heating from exposure to the sun
may cause excessive internal heating. This can result in reduced output power to protect
the internal components from damage.
• Install the Sunny Boy in a location that maintains an ambient air temperature that is less
than 45°C. To maintain a safe internal component temperature, the Sunny Boy may re-
duce 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 Sunny Boy 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
Sunny Boy 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 Sunny Boy 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.
• 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
Note: These inverter types are intended for operation in an
environment having a maximum ambient temperature of 45
°C.
Vertica
l
(best)
Tilted Back
(Acceptable)
Ti
l
te
d
Forwar
d
(Unaccaptable)