SMA Sunny Boy SB 6000US User manual

SB50US-80US-IUS094030 | TBUS-SB50_60_70US | Version 3.0 US
Solar Inverter
SUNNY BOY 5000US / 6000US / 7000US / 8000US
Installation Guide

SMA Solar Technology AG
Installation Guide SB50US-80US-IUS094030 3
Copyright © 2009 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
4031 Alvis Court
Rocklin, CA 95677
Tel. [phone]
Fax [phone]
www.SMA-America.com

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IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS
This manual contains important instructions for Models SB 5000US, SB 6000US, SB 7000US,
SB 8000US SOLAR INVERTERS, that shall 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.
Warnings
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 damage to or destruction of
part or all of the SMA equipment and/or other equipment connected to the SMA equipment or
personal injury.
DANGER!
DANGER indicates a hazardous situation which, if not avoided, will result in death or
serious injury.
WARNING!
WARNING indicates a hazardous situation which, if not avoided, could result in death or
serious injury.
CAUTION!
CAUTION indicates a hazardous situation which, if not avoided, could result in minor or
moderate injury.
NOTICE!
NOTICE indicates a situation that can result in property damage if not avoided.

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Installation Guide SB50US-80US-IUS094030 5
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:
Markings on this Product
The following symbols are used as markings on this product with the following meanings.
Information
This symbol accompanies notes that call attention to supplementary information that you
should know and use to ensure optimal operation of the system.
Warning regarding dangerous voltage
The product works with high voltages. All work on the product may only be done as
described in its documentation.
Beware of hot surface
The product can become hot during operation. Avoid coming into contact with the
product during operation.
Observe the operating instructions
Read the product’s documentation before working on it. Follow all safety precautions
and instructions as described in the documentation.
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.

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General Warnings
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 handle covers on the sides of the unit. For all 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, in this Installation Guide.
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.

SMA Solar Technology AG Table of Contents
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Table of Contents
1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1 Target Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2 Product overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.3 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.4 Installation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2 Unpacking and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . 16
2.1 Scope of Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3 AC Voltage Configuration . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.1 Opening the Sunny Boy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.2 Locating Internal Components . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.3 Configuring the AC Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.4 Utility Configuration Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4 Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.1 Choosing a Mounting Location. . . . . . . . . . . . . . . . . . . . . . . . . 26
4.1.1 Selection of the Mounting Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.1.2 Ambient Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.1.3 Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.2 Dimensions and Required Clearances . . . . . . . . . . . . . . . . . . . 28
4.3 Mounting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.3.1 Mounting the Wall-Mounting Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.3.2 Mounting the SMA DC-Disconnect (if applicable) . . . . . . . . . . . . . . . . . . . . 33
4.3.3 Mounting the Sunny Boy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5 Wiring the Sunny Boy . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.1 Sequence of Connecting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.1.1 Wiring without SMA DC-Disconnect. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.1.2 Wiring with SMA DC-Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.2 Bottom View and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . 40

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5.3 Opening the Sunny Boy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.4 Opening the SMA DC-Disconnect (if applicable). . . . . . . . . . . 41
5.5 Wiring the AC Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.5.1 AC Connection Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.5.2 AC Wiring Without SMA DC-Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.5.3 AC Wiring With SMA DC-Disconnect. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5.6 Wiring the DC Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5.6.1 DC Connection Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5.7 DC Input Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
5.8 Connecting the DC Wires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
5.8.1 DC Wiring Without SMA DC-Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5.8.2 DC Wiring With SMA DC-Disconnect. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
5.8.3 DC Connection With Additional DC Distribution . . . . . . . . . . . . . . . . . . . . . 65
5.9 Communication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
5.10 Closing the Sunny Boy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
5.11 Closing the SMA DC-Disconnect (if applicable). . . . . . . . . . . . 68
6 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
7 Displays and Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . 71
7.1 LED Operation Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
7.2 LED Fault Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
7.3 Status Messages on the LCD Display . . . . . . . . . . . . . . . . . . . . 77
7.3.1 LCD Display Language Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
7.4 Measuring Channels and Parameters. . . . . . . . . . . . . . . . . . . . 81
7.4.1 Measuring Channels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
7.4.2 Operating Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
7.4.3 Sunny Boy Operating Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
8 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
8.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
8.2 Error Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

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9 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
9.1 Cleaning the Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
9.2 Cleaning the Handle Covers . . . . . . . . . . . . . . . . . . . . . . . . . . 91
9.3 Testing the Fans. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
9.4 Exchanging the Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
9.4.1 Exchanging the GFDI Fuse within the Sunny Boy . . . . . . . . . . . . . . . . . . . . . 93
9.4.2 Exchanging the PV String Fuses within the SMA DC-Disconnect. . . . . . . . . . 94
10 Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
10.1 FCC Compliance Information . . . . . . . . . . . . . . . . . . . . . . . . . . 96
10.2 Sunny Boy Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . 97
10.2.1 Without SMA DC-Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
10.2.2 With SMA DC-Disconnect. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
10.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
10.3.1 Sunny Boy 5000US and Sunny Boy 6000US . . . . . . . . . . . . . . . . . . . . . . . 99
10.3.2 Sunny Boy 7000US and Sunny Boy 8000US . . . . . . . . . . . . . . . . . . . . . . 100
10.3.3 SMA DC-Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
10.4 Trip Limits / Trip Times. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
10.5 Torque Values and Wire Sizes . . . . . . . . . . . . . . . . . . . . . . . . 104

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1 Introduction
This installation guide provides all the information needed to install, commission and operate a Sunny
Boy (SB 5000US, SB 6000US, SB 7000US, SB 8000US) grid-tied photovoltaic (PV) inverter.
1.1 Target Group
This manual is for qualified personnel. Qualified personnel has received training and has
demonstrated skills and knowledge in the construction and operation of the device. Qualified
personnel is trained to deal with the dangers and hazards involved in installing electric devices.
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 equipment.

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1.2 Product overview
The Sunny Boy 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 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 below.
Sunny Boy Installed in a Utility Interactive PV System
Position Description
A PV array
B Sunny Boy with SMA DC-Disconnect
C Local loads
D Meter
EUtility Grid
Policies vary from one utility company to another. Consult with a representative of the local
utility company before designing and installing a PV system.

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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 ensure 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 Underwriters Laboratories 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 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 1547 Standard for Interconnecting Distributed Resources
with Electric Power Systems. The Sunny Boy is also listed under UL1741 for Canadian UL.
FCC Compliance
The Sunny Boy has been tested and shown to conform with all FCC Part 15 A & B EMI/EMC
emissions regulations.
Contact the local utility and/or the authority having jurisdiction prior to connecting the
Sunny Boy to the utility grid.

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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 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:
•LCD Display
• Temperature regulated fan cooling with simplified fan replacement
• Auto line voltage detection and configuration
• Advanced communication options
• Compatible with all Sunny Boy products
• High efficiency
•Quiet operation
• Simple installation
• Powder coated die-cast enclosure
Operating Temperature
The Sunny Boy has been designed to maintain full power output at ambient temperatures as high as
113 °F. Fan cooling allows this level of output power to be achieved even in enclosed spaces. The
Sunny Boy will continue to operate well beyond 113 °F and de-rates as needed to maintain a safe
internal component temperature.

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1.4 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: 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 4: 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 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.
Section 8: Troubleshooting
This section provides troubleshooting tips and procedures for resolving problems that may occur
during installation and operation.
Section 9: Maintenance
This section includes maintenance and cleaning of the Sunny Boy and cautions and warnings you
should follow to avoid injury and/or equipment damage.
Section 10: Technical Specifications
This section includes technical data for the Sunny Boy, connection diagrams and torque specifications
for the connection of cables and the screws of the Sunny Boy.

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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.
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
4031 Alvis Court
Rocklin, CA 95677
Tel. [phone]
Fax [phone]
www.SMA-America.com
WARNING!
The Sunny Boy weighs up to148 lb. (67 kg). To avoid injury, be sure to use proper lifting
techniques and secure the help of someone to assist in the unpacking and installation of
the inverter.

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2.1 Scope of Delivery
Sunny Boy:
SMA DC-Disconnect (if applicable):
A one Sunny Boy
B one wall-mounting bracket
C one screw and washer for closing the Sunny Boy cover (spare)
two screws and two washers for fastening the Sunny Boy to the wall-mounting bracket
D two jumpers in spare (for the fan test and for the grid configuration)
E two handle covers (left and right)
F one SMA DC-Disconnect
G one screw and one washer for closing the SMA DC-Disconnect cover two M6 x 10 screws
and two washers for fastening the SMA DC-Disconnect to the wall-mounting bracket

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3 AC Voltage Configuration
3.1 Opening the Sunny Boy
1. Remove the six screws and lock washers from the housing cover and pull the cover forward
smoothly.
2. Place the cover, screws, and lock washers aside where they will be out of your way while you
are connecting wires and cables to the Sunny Boy.
CAUTION!
Be careful not to misplace the screws or the lock washers, as all six screws and lock
washers are required to ensure that the cover is grounded properly and is fully sealed to
the case. Handle the cover carefully, as even minor damage to the cover could result in an
inadequate seal between the cover and the case, thus allowing moisture to enter the case
and damage the sensitive electronic components.
NOTICE!
Do not install the Sunny Boy during periods of precipitation or high humidity (>95%).
Moisture trapped within the enclosure may cause corrosion and damage to the electronic
components.

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3.2 Locating Internal Components
The figure below illustrates the locations of the major internal components of the Sunny Boy. Refer to
this illustration as needed to locate particular components.
Position Description
A Sockets for optional communication Piggy-Back (RS485 or wireless)
B Display
C Status LEDs
D Voltage Configuration Jumpers
E Voltage Configuration Terminal Blocks

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FGround Terminal (PE)
G Output AC Line Terminals (N, L1 and L2)
H PV Grounding + DC Grounding electrode conductor
I Output AC Line Terminals (L1, L2, N and PE)
J PV GROUNDED Terminal (input from PV array)
K PV UNGROUNDED Terminal (input from PV array)
LCombined UNGROUNDED Terminal
M DC– Terminal (input from PV array)
N DC+ Terminal (input from PV array)
O Flat connection for grounding the cable shield for communication
P Terminal for optional communication (RS485)
Position Description