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

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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

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