SMA SUNNY ISLAND 4.4M Use and care manual

SI44M-80H-12-SG-en-12 | Version 1.2ENGLISH
Replacement of Various Components
SUNNYISLAND 4.4M / 6.0H / 8.0H

Legal Provisions SMA Solar Technology AG
Replacement of Various ComponentsSI44M-80H-12-SG-en-122
Legal Provisions
The information contained in these documents is the property of SMA Solar Technology AG. No part of this document
may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, be it electronic,
mechanical, photographic, magnetic or otherwise, without the prior written permission of SMA Solar Technology AG.
Internal reproduction used solely for the purpose of product evaluation or other proper use is allowed and does not
require prior approval.
SMA Solar Technology AG makes no representations or warranties, 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 representations or warranties are
expressly disclaimed. Neither SMA Solar Technology AG 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 product improvements and field usage experience may
cause SMA Solar Technology AG to make changes to these specifications without advance notice, or per contract
provisions in those cases where a supply agreement requires advance notice. SMA Solar Technology AG 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 Warranty
You can download the current warranty conditions from the Internet at www.SMA-Solar.com.
Trademarks
All trademarks are recognized, even if not explicitly identified as such. Missing designations do not mean that a
product or brand is not a registered trademark.
SMA Solar Technology AG
Sonnenallee 1
34266 Niestetal
Germany
Tel. [phone]
Fax [phone]
www.SMA.de
Email: [email protected]
Status: 11/8/2018
Copyright © 2018 SMA Solar Technology AG. All rights reserved.

Table of Contents
SMA Solar Technology AG
Replacement of Various Components 3SI44M-80H-12-SG-en-12
Table of Contents
1 Information on this Document..................................................................................................... 4
1.1 Validity ............................................................................................................................................................. 4
1.2 Target Group ................................................................................................................................................... 4
1.3 Content and Structure of this Document......................................................................................................... 4
1.4 Levels of warning messages............................................................................................................................ 4
1.5 Symbols in the Document................................................................................................................................ 5
1.6 Typographies in the document ....................................................................................................................... 5
1.7 Additional Information..................................................................................................................................... 5
2 Safety ............................................................................................................................................ 6
2.1 Intended Use.................................................................................................................................................... 6
2.2 IMPORTANT SAFETY INSTRUCTIONS......................................................................................................... 6
3 Component Overview ................................................................................................................. 9
4 Replaceable Components and Order Numbers........................................................................ 10
5 Additionally Required Materials and Equipment...................................................................... 12
6 Disconnecting the Inverter from Voltage Sources ..................................................................... 13
7 Component Replacement ............................................................................................................ 14
7.1 Replacement of the assembly SI-AST ............................................................................................................. 14
7.1.1 Overview of the assembly connections .......................................................................................................... 14
7.1.2 Removing the SI-AST........................................................................................................................................ 15
7.1.3 Installing the SI-AST.......................................................................................................................................... 16
7.2 Replacement of the assembly SI-BFSLAN ...................................................................................................... 21
7.2.1 Removing the SI-BFSLAN................................................................................................................................. 21
7.2.2 Installing the SI-BFSLAN................................................................................................................................... 22
7.3 Replacement of the assembly SI-LED.............................................................................................................. 25
7.3.1 Removing the SI-LED ........................................................................................................................................ 25
7.3.2 Installing the SI-LED.......................................................................................................................................... 25
8 Performing the VAC Test.............................................................................................................. 27
9 Recommissioning the Inverter ..................................................................................................... 28
10 Packing and Returning the Defective Assembly / Disposing of the Defective Assembly ...... 29
11 Contact .......................................................................................................................................... 30

1 Information on this Document SMA Solar Technology AG
Replacement of Various ComponentsSI44M-80H-12-SG-en-124
1 Information on this Document
1.1 Validity
This document is valid for:
• SI4.4M-12 (SunnyIsland 4.4M)
• SI6.0H-12 (SunnyIsland 6.0H)
• SI8.0H-12 (SunnyIsland 8.0H)
1.2 Target Group
The tasks described in this document must only be performed by qualified persons. Qualified persons must have the
following skills:
• Training and approval must be made by SMA Solar Technology AG or subsidiary companies of SMA Solar
Technology AG to carry out the activities described in this document
• Knowledge of how to safely disconnect SMA inverters
• Knowledge of how an inverter works and is operated
• Knowledge of how batteries work and are operated
• Training in how to deal with the dangers and risks associated with installing, repairing and using electrical
devices, batteries and installations
• Training in the installation and commissioning of electrical devices and installations
• Knowledge of all applicable laws, standards and directives
• Knowledge of and compliance with this document and all safety information
• Knowledge of and compliance with the documents of the battery manufacturer with all safety information
1.3 Content and Structure of this Document
This document describes how to replace components.
Illustrations in this document are reduced to the essential information and may deviate from the real product.
1.4 Levels of warning messages
The following levels of warning messages may occur when handling the product.
DANGER
Indicates a hazardous situation which, if not avoided, will result in death or serious injury.
WARNING
Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
NOTICE
Indicates a situation which, if not avoided, can result in property damage.

1 Information on this Document
SMA Solar Technology AG
Replacement of Various Components 5SI44M-80H-12-SG-en-12
1.5 Symbols in the Document
Symbol Explanation
Information that is important for a specific topic or goal, but is not safety-relevant
☐
Indicates a requirement for meeting a specific goal
☑
Desired result
✖
A problem that might occur
Example
1.6 Typographies in the document
Typography Use Example
bold • Messages
• Terminals
• Elements on a user interface
• Elements to be selected
• Elements to be entered
• Connect the insulated conductors
to the terminals X703:1 to
X703:6.
• Enter 10 in the field Minutes.
>• Connects several elements to be
selected • Select Settings > Date.
[Button]
[Key]
• Button or key to be selected or pressed • Select [Enter].
1.7 Additional Information
For more information, please go to www.SMA-Solar.com.
Title and information content Type of information
Mounting, installation, commissioning, operation, configuration, troubleshooting
and decommissioning Operating manual

2 Safety SMA Solar Technology AG
Replacement of Various ComponentsSI44M-80H-12-SG-en-126
2 Safety
2.1 Intended Use
Use the retrofit kits only in accordance with the information provided in this documentation and with the locally
applicable laws, regulations, standards and directives. Any other application may cause personal injury or property
damage.
Unauthorized or improper use will void guarantee and warranty claims and in most cases terminate the operating
license. SMA Solar Technology AG shall not be held liable for any damage caused by such use.
If the replacement and all activities stated in this document are carried out by persons who are not qualified within the
meaning of this documentation, this will void the guarantee and warranty claims and in most cases terminate the
operating permit. SMA Solar Technology AG shall not be held liable for any damage caused directly or indirectly due
to such changes by unauthorized persons.
The provided documentation is an integral part of this product. You must read and observe the documentation.
This document does not replace and is not intended to replace any local, state, provincial, federal or national laws,
regulations or codes applicable to the installation, electrical safety and use of the product. SMA Solar Technology AG
assumes no responsibility for the compliance or non-compliance with such laws or codes in connection with the
installation of the product.
2.2 IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS
This section contains safety information that must be observed at all times when working on or with the product.
The product has been designed and tested in accordance with international safety requirements. As with all electrical
or electronical devices, there are residual risks despite careful construction. To prevent personal injury and property
damage and to ensure long-term operation of the product, read this section carefully and observe all safety
information at all times.
DANGER
Danger to life due to electric shock when live components or cables are touched
High voltages are present in the conductive components or cables of the product. Touching live parts and cables
results in death or lethal injuries due to electric shock.
• Do not touch non-insulated parts or cables.
• Disconnect the product from voltage sources and make sure it cannot be reconnected before working on the
device.
• After disconnection, wait 15 minutes until the capacitors have discharged.
• Observe all safety information on components associated with the product.
• Wear suitable personal protective equipment for all work on the product.

2 Safety
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DANGER
Danger to life due to electric shock when operating a damaged product
Operating a damaged product can lead to hazardous situations since high voltages can be present on accessible
product parts. Touching live parts and cables results in death or lethal injuries due to electric shock.
• Only operate the product when it is in a flawless technical condition and safe to operate.
• Check the product regularly for visible damage.
• Make sure that all external safety equipment is freely accessible at all times.
• Make sure that all safety equipment is in good working order.
• Wear suitable personal protective equipment for all work on the product.
WARNING
Risk of crushing injuries due to moving PV array parts
A generator can be started automatically by the SunnyIsland. Moving parts in the PV array can crush or sever
body parts.
• Operate the generator only with the specified safety equipment.
• Carry out all work on the generator in accordance with the manufacturer's specifications.
CAUTION
Risk of burns due to short-circuit currents on the disconnected inverter
The capacitors in the DC input area of the inverter store energy. After the battery is isolated from the inverter,
battery voltage is still temporarily present at the DC terminal. A short circuit at the DC terminal of the inverter can
lead to burns and may damage the inverter.
• Wait 15minutes before performing any work at the DC terminal or on the DC cables. This allows the
capacitors to discharge.
CAUTION
Risk of burns due to hot components
Some components of the inverter can become very hot during operation. Touching these components can cause
burns. Heat build-up can cause burns.
• During operation, do not touch any parts other than the enclosure lid of the inverter.
• After opening the inverter, wait until the component parts have cooled down.
NOTICE
Damage to the product due to sand, dust and moisture ingress
Sand, dust and moisture penetration can damage the product and impair its functionality.
• Only open the product if the humidity is within the thresholds and the environment is free of sand and dust.
• Do not open the product during a dust storm or precipitation.

2 Safety SMA Solar Technology AG
Replacement of Various ComponentsSI44M-80H-12-SG-en-128
NOTICE
Damage to the inverter due to electrostatic discharge
Touching electronic components can cause damage to or destroy the inverter through electrostatic discharge.
• Ground yourself before touching any component.
NOTICE
Damage to the enclosure seal in subfreezing conditions
If you open the product when temperatures are below freezing, the enclosure seals can be damaged. Moisture can
penetrate the product and damage it.
• Only open the product if the ambient temperature is not below -5°C.
• If a layer of ice has formed on the enclosure seal when temperatures are below freezing, remove it prior to
opening the product (e.g. by melting the ice with warm air). Observe the applicable safety regulations.
NOTICE
Damage due to cleaning agents
The use of cleaning agents may cause damage to the product and its components.
• Clean the product and all its components only with a cloth moistened with clear water.
Grounding conductor test prior to recommissioning
Prior to recommissioning SMA inverters after the installation of SMA components or power assemblies which
cannot be replaced intuitively, ensure that the grounding conductor in the inverter is correctly connected. The
function of the grounding conductor must be ensured and all locally applicable laws, standards and directives
must be observed.
Observe superordinate standards
The repair work on devices and the consideration and application of other standards which correspond to a
superordinate standard is the responsibility of the qualified person performing the work. Unauthorized alterations
will void guarantee and warranty claims and in most cases terminate the operating license. SMA Solar
Technology AG shall not be held liable for any damage caused by such changes.

3 Component Overview
SMA Solar Technology AG
Replacement of Various Components 9SI44M-80H-12-SG-en-12
3 Component Overview
A
C
B
Figure 1: Overview of the assemblies in the inverter
Position Designation
A SI-LED
B SI-BFSLAN
C SI-AST

4 Replaceable Components and Order Numbers SMA Solar Technology AG
Replacement of Various ComponentsSI44M-80H-12-SG-en-1210
4 Replaceable Components and Order Numbers
Assembly SI-AST
SIAST50-48PS
(Material description: SP-SIAST50-48PS
Material number: SP-SIAST50-48PS)
for SI4.4M-12, comprising:
Designation Quantity
Assembly SIAST50-48PS 1
Screw and washer assembly M4x15 with
pan head 9
Screw and washer assembly M6x20 with
cylindrical head 4
Spacer bolt M4x15 3
Spring washers M8 2
SIAST50-48PG
(Material description: SP-SIAST50-48PG
Material number: SP-SIAST50-48PG
for SI6.0H-12 / SI8.0H-12, consisting:
Designation Quantity
Assembly SIAST50-48PG 1
Screw and washer assembly M4x15 with
pan head 9
Screw and washer assembly M6x20 with
cylindrical head 4
Spacer bolt M4x15 3
Spring washers M8 2

4 Replaceable Components and Order Numbers
SMA Solar Technology AG
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Assembly SI-BFSLAN
SIBFSLAN
(Material description: SP-SIBFSLAN
Material number: SP-SIBFSLAN)
for SI4.4M-12 / SI6.0H-12 / SI8.0H-12, consisting:
Designation Quantity
Assembly SIBFSLAN 1
Printed circuit board retaining clip 4
Label with identification key (PIC), registra-
tion ID (RID) and device-specific WLAN pass-
word (WPA2-PSK)
1
Assembly SI-LED
SILED
(Material description: SP-SILED
Material number: SP-SILED)
for SI4.4M-12 / SI6.0H-12 / SI8.0H-12, consisting:
Designation Quantity
Assembly SILED 1
Printed circuit board retaining clips 4
Pan head screw M4x8 4

5 Additionally Required Materials and Equipment SMA Solar Technology AG
Replacement of Various ComponentsSI44M-80H-12-SG-en-1212
5 Additionally Required Materials and Equipment
Material:
Material Quantity Explanation
Ethanol cleaning agent (e.g. Isopropanol) – For cleaning the contact surfaces during SI-AST in-
stallation
Equipment:
Equipment Quantity Explanation
Adjustable torque wrench (measurement
range: 0.8Nm to 8.0Nm) 1 to n For the installation of SI-AST and SI-BFSLAN
Screwdriver bit for torque wrench TX20 1 For the installation of SI-AST and SI-BFSLAN
Screwdriver bit for torque wrench TX30 1 For the installation of SI-AST
Screwdriver bit for torque wrench (hex socket
AF5) 1 For the installation of SI-AST
Screwdriver bit for torque wrench (hex socket
AF7) 1 For the installation of SI-AST
Screwdriver TX20 1 For the removal of SI-AST and SI-BFSLAN
Screwdriver TX30 1 For the removal of SI-AST
Allen key AF5 1 For the removal of SI-AST
Wrench AF7 1 For the removal of SI-AST
Multimeter 1 For voltage measurement during disconnection and
VAC test
Pliers 1 For the removal of SI-BFSLAN and SI-LED
Diagonal cutting pliers for electronics 1 For the installation of SI-BFSLAN and SI-LED
End device (e.g. laptop) 1 For connecting to the user interface of the inverter
after recommissioning

6 Disconnecting the Inverter from Voltage Sources
SMA Solar Technology AG
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6 Disconnecting the Inverter from Voltage Sources
NOTICE
The replacment of SI-BFSLAN assembly in a slave is possible as of firmware version 1.02.11.R.
If an older firmware version than 1.02.11.R is installed in the master of a SunnyIsland system, the system cannot be
started properly anymore after replacing the SI-BFSLAN in a slave. The new SI-BFSLAN are damaged when
restarting the system. The damage of the SI-BFSLAN leads to a permanent system failure.
• Check whether at least the firmware version 1.02.11.R is installed in the master of the SunnyIsland.
• If an older firmware version is installed, update the firmware at the master of the SunnyIsland system (see
inverter operating manual).
1. Stop the system (see the inverter operating manual).
2. Switch off all SunnyIsland inverters (see the inverter operating manual).
3. Disconnect the circuit breakers and the load-break switches in the sub-distributions and secure against
reconnection.
4. Open the load-break switch in the DC cable and secure against reconnection.
5. Wait 15minutes. This enables electric discharge of the capacitors in the inverter.
6. NOTICE
Destruction of the SunnyIsland inverter due to electrostatic discharge (ESD)
By touching electronic components within the SunnyIsland, you can damage or destroy the SunnyIsland.
• Ground yourself before touching any component.
7. Unscrew all six screws of the enclosure lid using an Allen key (AF5) and remove the enclosure lid.
8. Ensure that the DC terminal is disconnected from all voltage sources (for an overview of the connection area see
the inverter operating manual).
9. Ensure that the terminals AC1Loads/SunnyBoys and AC2Gen/Grid are disconnected from all voltage
sources (for an overview of the connection area see the inverter operating manual).
10. Ensure that the terminal ExtVtg is disconnected from all voltage sources (for an overview of the connection area
see the inverter operating manual).
11. Ensure that the terminals Relay1 and Relay2 are disconnected from all voltage sources (for an overview of the
connection area see the inverter operating manual).
12. Ground and short-circuit the AC power cables outside the SunnyIsland.
13. Cover or isolate any adjacent live components.

7 Component Replacement SMA Solar Technology AG
Replacement of Various ComponentsSI44M-80H-12-SG-en-1214
7 Component Replacement
7.1 Replacement of the assembly SI-AST
7.1.1 Overview of the assembly connections
A
F
BD
G
H
I
C
I
E
B
JJ
Figure 2: Overview of the assembly connections (example)
Position Designation
A Internal power cables
B Internal control and measuring cables
C Center busbars
D Ribbon cable at the upper edge of the assembly (left)
E Ribbon cable at the upper edge of the assembly (right), connection cable of the assembly SI-LED
F DC connection cable
G Fan cable
H External data cable
I External control and measuring cables
J AC connection cable

7 Component Replacement
SMA Solar Technology AG
Replacement of Various Components 15SI44M-80H-12-SG-en-12
7.1.2 Removing the SI-AST
1. Disconnect the inverter from all voltage sources (see Section6, page13).
2. Label the terminal used on each connected cable. Use marking tape and a waterproof marker to do this.
3. CAUTION
Danger of crushing when locking levers snap shut
The locking levers of the terminal blocks close by snapping down fast and hard.
• Do not grip the entire terminal block.
• Do not place your fingers under the locking levers.
4. Remove the AC connection cable and internal power cable (see Section7.1.1 "Overview of the assembly
connections", page14). For this, push the safety levers of the terminal blocks right up to the stop.
5. Remove the DC connection cables. To do so, unscrew the pan-head screws (Allen key AF5) and store them
safely.
6. Dispose the conical spring washers after the DC connection cables have been removed.
7. Remove the external communication cable.
8. Remove both ribbon cables on the upper edge of the assembly. Release and remove the ribbon cable plugs.
9. Release and disconnect the plug of the fan cable. Mark the position of the plug for the later connection.
10. Release and disconnect the plugs of the internal control and measuring cables.
11. Disconnect the terminal blocks of the external control and measuring cables.
12. Remove the assembly SI-BFSLAN. In doing so, observe the handling areas of the assembly (see Section7.2.2,
page22):
• Unfasten the fastening screw of the assembly (TX20).
• Carefully remove the assembly by pulling it towards you. Press together both locking tabs with pliers on each
printed circuit board retaining clip (see Section7.2.1, page21).
13. Remove the carrier plate including the assembly SI-LED. Unscrew
all fastening screws of the carrier plate (TX20).
14. Remove the center busbars. Unscrew all fastening screws of the
busbars (TX30).

7 Component Replacement SMA Solar Technology AG
Replacement of Various ComponentsSI44M-80H-12-SG-en-1216
15. Remove the protective cover. Unscrew all fastening screws of the
protective cover (TX20).
16. Only unscrew the spacer bolts at the marked positions (Allen Key
AF7).
17. Unscrew all fastening screws of the SI-AST (TX20) and dispose of
the mounting screws.
18. Carefully remove the assembly by pulling it towards you.
7.1.3 Installing the SI-AST
There are assemblies on this assembly with a safety extra-low voltage circuit (SELV circuit). To ensure the safety of the
circuits, an optical inspection must be carried out before installation.

7 Component Replacement
SMA Solar Technology AG
Replacement of Various Components 17SI44M-80H-12-SG-en-12
A
A
A
A
A
Figure 3: Handling areas of the SI-AST
Position Designation
A Area of the assembly that can be touched without consequence.
Area that can be used as a holding point during mounting.
The remaining areas may not be touched. The assembly can be damaged through touching.
Additionally required equipment
☐ Ethanol cleaning agent (e.g. Isopropanol)
Procedure:
1. Check the new assembly for visible dirt prior to installation. If dust or other deposits cover the assembly, the safety
of the SELV circuits is no longer guaranteed.
2. If the safety of the SELV circuits is no longer guaranteed, do not use the assembly and contact the service
department (see Section11, page30).
3. Align the SI-AST and insert in the inverter.

7 Component Replacement SMA Solar Technology AG
Replacement of Various ComponentsSI44M-80H-12-SG-en-1218
4. Tighten the provided screw and washer assemblies M4x15 at all
anchoring points (TX20, torque: 2Nm).
5. Tighten the spacer bolts of the DC protective cover at the three
marked positions (Allen key AF7, torque: 2Nm).
6. Position the protective cover above the spacer bolts and tighten
the four fastening screws (TX20, torque: 1.1Nm).

7 Component Replacement
SMA Solar Technology AG
Replacement of Various Components 19SI44M-80H-12-SG-en-12
7. Clean the contact surfaces of the center busbars using a clean
cloth and ethanol cleaning agent and do not touch the contact
surfaces after cleaning.
8. Position the center busbars above the contact surfaces, insert the
provided screw and washer assemblies M6x20 and tighten in the
specified sequence (TX30, torque: 6Nm).
1
24
3
9. Install the assembly SI-BFSLAN. In doing so, observe the handling areas of the assembly (see Section7.2.2,
page22):
• Ensure that all printed circuit board retaining clips are in place and intact (see Section7.2.2, page22).
• Align the assembly and insert it into the inverter. When doing so, ensure that the printed circuit board
retaining clips snap into place correctly.
• Tighten the fastening screw (TX20, torque: 2Nm).
10. Connect the internal control and measuring cables (see Section7.1.1 "Overview of the assembly connections",
page14).
11. Connect the external control and measuring cables.
12. Connect the external communication cables.
13. Connect the fan cable. Observe that the plug is positioned as noted during removal.
14. CAUTION
Danger of crushing when locking levers snap shut
The locking levers of the terminal blocks close by snapping down fast and hard.
• Do not grip the entire terminal block.
• Do not place your fingers under the locking levers.
15. Connect the AC connection cables and internal power cables. For this purpose, insert the AC cables into the
respective terminals right up to the stop and move the lever downward.
16. Connect the left ribbon cable to the upper edge of the assembly.

7 Component Replacement SMA Solar Technology AG
Replacement of Various ComponentsSI44M-80H-12-SG-en-1220
17. Position the carrier plate including the SI-LED assembly above the
spacer bolts and tighten the fastening screws (TX20, torque:
2Nm).
18. Fasten the connection cable of the assembly SI-LED on the
assembly SI-AST.
19. Clean the contact surfaces of the terminals DC+ and DC- using a clean cloth and ethanol cleaning agent and do
not touch the contact surfaces after cleaning.
20. NOTICE
Damage to the SunnyIsland due to reverse polarity
If the DC cables are swapped, high currents will flow after the load-break switch has closed and these can
damage the SunnyIsland.
• Observe the marking of poles on the protective cover when connecting the DC cables.
21. Fasten the DC cables with hexagon socket screws. Use the provided conical spring washers for this and be sure
to adhere to the following screw assembly: screw head | conical spring washer | fender washer | terminal lug |
DC connection.
22. Tighten the hexagon socket screws used to attach the DC cables (AF5, torque: 12Nm).
23. Carry out the necessary tests according to the locally applicable laws, standards and directives for the correct
recommissioning after power assembly replacement. Take the requirements for component replacements into
account (see Section2.2 "IMPORTANT SAFETY INSTRUCTIONS", page6).
24. Ensure that the grounding conductor in the inverter is correctly connected and functions properly.
25. Close the inverter (for information on sealing and closing see inverter operating manual).
26. Switch on the SunnyIsland (see the inverter operating manual).
27. Establish a connection to the user interface of the inverter (see the inverter operating manual).
28. Log in as installer and follow the instructions on the user interface (for information on the basic configuration of
the installation assistant see inverter operating manual).