SMA Sunny Boy 6000 User manual

Sunny Boy 6000U
Installation Guide
http://www.wholesalesolar.com/inverters.html
http://www.wholesalesolar.com/inverters.html

http://www.wholesalesolar.com/inverters.html
http://www.wholesalesolar.com/inverters.html

Installation Guide
SB6000U-13:SE2506 SMA America i
Copyright © 2003 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
Revision History
Rev. No. Date By Version
1.0 April 21, 2004 YS First ROW
2.0 August 9, 2004 JP First US
2.1 October 14, 2004 JP US 2.1
2.2 December 3, 2004 JP Updated
2.3 March 21, 2005 JP Pins, graphs, fusing, illustrations, language
3.0 April 29, 2005 JP Jumpers, label, re-org, doc number
3.1 July 21, 2005 JP Additional ratings added
3.2 June 2006 JP Positive ground information added
http://www.wholesalesolar.com/inverters.html
http://www.wholesalesolar.com/inverters.html

Installation Guide
ii SMA America SB6000U-13:SE2506
Tel [phone]
Fax [phone]
www.sma-america.com
http://www.wholesalesolar.com/inverters.html
http://www.wholesalesolar.com/inverters.html

Installation Guide
SB6000U-13:SE2506 SMA America iii
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS
This manual contains important instructions for the Sunny Boy 6000U 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.
http://www.wholesalesolar.com/inverters.html
http://www.wholesalesolar.com/inverters.html

Installation Guide
iv SMA America SB6000U-13:SE2506
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.
http://www.wholesalesolar.com/inverters.html
http://www.wholesalesolar.com/inverters.html

Installation Guide
SB6000U-13:SE2506 SMA America v
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 fans on the bottom of the enclosure and the filters
behind the fans as well as the exhaust fins on the sides 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 6000U 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 i (to send E-mail, see the Contact
section of the SMA America Web site).
http://www.wholesalesolar.com/inverters.html
http://www.wholesalesolar.com/inverters.html

Installation Guide
vi SMA America SB6000U-13:SE2506
http://www.wholesalesolar.com/inverters.html
http://www.wholesalesolar.com/inverters.html

SB6000U-13:SE2506 SMA America vii
Contents
Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
Safety and Hazard Symbols . . . . . . . . . . . . . . . . . . . . . . . . . iii
Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
Other Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
General Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-v
Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .v
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 Input Voltage Configuration
Opening the Sunny Boy 6000U . . . . . . . . . . . . . . . . . . 4-1
Locating Internal Components . . . . . . . . . . . . . . . . . . . . 4-1
Configuring the Input Voltage . . . . . . . . . . . . . . . . . . . . 4-3
5 Wiring the SB6000U
Wiring the AC Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
AC Connection Requirements . . . . . . . . . . . . . . . . . . . . 5-3
Connecting the AC Wires . . . . . . . . . . . . . . . . . . . . . . . 5-6
Wiring the DC Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
DC Connection Requirements . . . . . . . . . . . . . . . . . . . . 5-8
DC Input Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Connecting the DC Wires . . . . . . . . . . . . . . . . . . . . . . 5-12
Communication Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
RS-232 Communication . . . . . . . . . . . . . . . . . . . . . . . 5-14
RS-485 Communication . . . . . . . . . . . . . . . . . . . . . . . 5-17
Replacing the Cover. . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
6 Commissioning
http://www.wholesalesolar.com/inverters.html
http://www.wholesalesolar.com/inverters.html

viii SMA America SB6000U-13:SE2506
7 Displays and Messages
LED Fault Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Status Messages on the LCD Display . . . . . . . . . . . . . . 7-11
Communication Options. . . . . . . . . . . . . . . . . . . . . . . 7-14
8 Troubleshooting
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
9 Maintenance
Cleaning the Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Testing the Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Cleaning the Exhaust Fins. . . . . . . . . . . . . . . . . . . . . . . 9-3
10 Technical Specifications
FCC Compliance Information . . . . . . . . . . . . . . . . . . . 10-1
Sunny Boy SB6000U Wiring Diagrams . . . . . . . . . . . . 10-2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
http://www.wholesalesolar.com/inverters.html
http://www.wholesalesolar.com/inverters.html

Introduction Product Overview
SB6000U-13:SE2506 SMA America 1-1
Section 1:
Introduction
This installation guide provides all the information needed to install, commission and
operate a Sunny Boy 6000U (SB6000U) 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 SB6000U 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 SB6000U 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 6000U Installed in a Utility Interactive PV System
PVArray
Sunny Boy 6000U
Utility Grid
Meter
http://www.wholesalesolar.com/inverters.html
http://www.wholesalesolar.com/inverters.html

Introduction Product Overview
1-2 SMA America SB6000U-13:SE2506
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
SB6000U is operating and the remaining load is resonant at 60 Hz and matches the
output of the SB6000U perfectly. This condition is highly unlikely and had never been
witnessed outside of a controlled laboratory. Nevertheless, the SB6000U 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
SB6000U 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 SB6000U is equipped with a ground fault detection device. If a ground fault current
greater than 1 Amp is detected, the SB6000U 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 SB6000U 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 519 Standard Practices and Requirements for Harmonic Control in
Electrical Power Systems. The SB6000U is also listed under UL1741 for Canadian UL.
http://www.wholesalesolar.com/inverters.html
http://www.wholesalesolar.com/inverters.html

Introduction Product Overview
SB6000U-13:SE2506 SMA America 1-3
UL1741 is the standard applied by Underwriters Laboratories to the
SB6000U 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 6000U to the
utility grid.
FCC Compliance
The SB6000U has been tested and shown to conform with 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
SB6000U. As a result, the SB6000U represents state-of-the-art technology, high
reliability and over all ease of use - all the qualities you’ve come to expect from the
industry leader in inverter manufacturing. Some of the features included are:
•LCDDisplay
•Temperature regulated fan cooling - simple replacement
• Auto line voltage detection and configuration
• Advanced communication options available
• Compatible with all Sunny Boy and Sunny Boy Control products
• High efficiency
• Quiet operation
• Simple installation
• Stainless steel enclosure
Operating Temperature
The SB6000U has been designed to maintain full power output at ambient temperatures
as high as 45°C. Fan cooling allows this level of output power to be achieved even in
enclosed spaces. The SB6000U will continue to operate well beyond 45°C and de-rates
as needed to maintain a safe internal component temperature.
http://www.wholesalesolar.com/inverters.html
http://www.wholesalesolar.com/inverters.html

Introduction Installation Overview
1-4 SMA America SB6000U-13:SE2506
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 SB6000U 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 SB6000U 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 SB6000U
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 SB6000U 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 SB6000U, 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.
http://www.wholesalesolar.com/inverters.html
http://www.wholesalesolar.com/inverters.html

Unpacking and Inspection
SB6000U-13:SE2506 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 6000U weighs 141 lb. (63 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
http://www.wholesalesolar.com/inverters.html
http://www.wholesalesolar.com/inverters.html

Unpacking and Inspection
2-2 SMA America SB6000U-13:SE2506
http://www.wholesalesolar.com/inverters.html
http://www.wholesalesolar.com/inverters.html

Mounting Choosing a Mounting Location
SB6000U-13:SE2506 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 6000U inverter.
WARNING: The Sunny Boy 6000U weighs 141 lb. (63 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.
Note: Occasionally, the rating label on the SB6000U 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 is
visible.
Choosing a Mounting Location
Consider the following guidelines, cautions, and warnings when choosing a mounting
location for the SB6000U:
•Do not install the SB6000U 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 SB6000U in a location that maintains an ambient air temperature that is
less than 45°C. To maintain a safe internal component temperature, the SB6000U
may power derate if the ambient air temperature exceeds 45°C. (The cooler the air
temperature, the longer the life expectancy of any power electronics device.)
• The SB6000U is constructed in a rugged stainless steel 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 SB6000U 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 SB6000U emits a slight vibrating noise when operating. This vibration is normal
and has no effect on performance, but it can be objectionable 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.
http://www.wholesalesolar.com/inverters.html
http://www.wholesalesolar.com/inverters.html

Mounting Choosing a Mounting Location
3-2 SMA America SB6000U-13:SE2506
• If the inverter is installed outside, it should be mounted vertically (see Figure 3-1).
Figure 3-1 Sunny Boy Mounting Positions
CAUTION: The Sunny Boy 6000U weighs 141 lb. (63 kg.).
Ensure that the mounting surface is strong enough to hold
the weight of the SB6000U. Do not mount the Sunny Boy on
plasterboard (sheet-rock) or thin wood panelling.
CAUTION: Rain-tight or wet location hubs that comply with
the requirements in the Standard for Fittings for Cable and
Conduit, UL 514B, are to be used.
CAUTION: Do not install the SB6000U 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.
Tilted Back
(Acceptable)
Vertical
(Best)
Tilted Forward
(Unacceptable)
http://www.wholesalesolar.com/inverters.html
http://www.wholesalesolar.com/inverters.html

Mounting Dimensions and Recommended Clearances
SB6000U-13:SE2506 SMA America 3-3
Dimensions and Recommended Clearances
The outer dimensions of the Sunny Boy 6000U are shown in Figure 3-2. The Sunny Boy
must be mounted so that there is at least eight inches of clearance around the Sunny Boy
6000U.
Figure 3-2 Outer Dimensions of the Sunny Boy 6000U
CAUTION: You must ensure that there is sufficient clearance for
the flow of the air around the Sunny Boy! 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).
250 mm
(9.85 in)
600 mm
(23.64 in)
430 mm
(16.94 in)
http://www.wholesalesolar.com/inverters.html
http://www.wholesalesolar.com/inverters.html

Mounting Dimensions and Recommended Clearances
3-4 SMA America SB6000U-13:SE2506
Figure 3-3 Dimensions of the Wall Mounting Bracket
http://www.wholesalesolar.com/inverters.html
http://www.wholesalesolar.com/inverters.html