SMA Sunny Island 4500 Manual

Bi-directional Battery Inverter SI4500
for Stand-alone Applications
Sunny Island 4500
Installation & Operating Instructions

BWRI45-13:EE0304
Bi-directional Battery Inverter SI4500
for Stand-alone Applications
Version 3.1
Installation & Operating Instructions
Sunny Island

Sunny Island 4500 Installation & Operating Instructions
BWRI45-13-EE0304 - 2 - SMA Regelsysteme GmbH
Alteration Review
Document
number
BWRI45
Issue and type
of alteration 1)
Comments Author
-13:EE5103 3.0 A,C Compilation and enhancement of SI3300
documentation for SI4500
Sabban
-13:EE0304 3.1 A Minor changes of layout Salisbury
1) A: Changes due to faulty documents or improvement of the documentation
B: Changes maintaining full or upward compatibility
C: Changes limiting or excluding compatibility

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Explanation of Symbols used in this Document
To enable optimal usage of this manual and safe operation of the device during in-
stallation, operation and maintenance routines, please note the following description
of symbols:
This indicates a feature that is important either for optimal and comfortable
usage or optimal operation of the system.
Example: “To keep string voltage low we recommend the following proce-
dure.”
This indicates a fact or feature which is very important for the safety of the
user and / or which can cause a serious defect if not applied appropriately.
Example: ”Disconnect the mains plug before opening the case!“
This indicates an example.

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Contents
1Introduction........................................................................................................ 10
1.1 About these instructions............................................................................ 12
1.2 What to do in case of transport damages? ............................................... 12
1.3 General Safety Instructions....................................................................... 13
2Device Description............................................................................................. 14
2.1 Operating Modes....................................................................................... 15
2.1.1 Grid-Forming Operation (RUN_U)........................................................ 16
2.1.2 Grid-Tied Operation (RUN_I)................................................................ 18
2.1.3 Droop-mode operation (RUN_U, RUN_UEXT) .................................... 19
2.1.4 Overload Behavior................................................................................ 21
2.2 Battery Management................................................................................. 23
2.2.1 Charging Methods ................................................................................ 24
2.2.2 Battery States ....................................................................................... 26
2.2.3 Low Battery Load Mode........................................................................ 29
2.2.4 Failure of Individual Cells ..................................................................... 30
3Installation ......................................................................................................... 31
3.1 Mounting Accessories Included in Delivery............................................... 31
3.2 Placement of the Sunny Island ................................................................. 33
3.3 Electric Connection ................................................................................... 38
3.3.1 Preparing the Connection..................................................................... 38
3.3.2 Cable Connections ............................................................................... 40
3.4 Examples for Connection .......................................................................... 43
3.4.1 Connection to Ground .......................................................................... 43
3.4.2 Connection of the battery ..................................................................... 45
3.4.3 Connection of Battery Temperature Sensor ......................................... 47

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3.4.4 Connection to AC Voltage .................................................................... 48
3.4.5 Connection measure Generator / Mains Current and Voltage ............. 49
3.4.6 Connection of a Generator ................................................................... 51
3.4.7 Connection to an External Utility .......................................................... 53
3.4.8 Connection to Generator and Utility ..................................................... 56
3.4.9 Connection of a Battery Room Fan and Electrolyte Pump ................... 58
3.4.10 Connection of a Dump Load ............................................................. 60
3.4.11 Connection to “ecopower-Mini-BHKW” ............................................. 61
3.4.12 Connection to “ecopower-Mini-BHKW” and utility............................. 62
3.5 Finalization of Electrical Wiring ................................................................. 63
3.6 Interfaces for Communication ................................................................... 64
3.6.1 Assignment of COM1 Interface (Three-Phase Operation) ................... 65
3.6.2 Assignment of COM2 Interface ............................................................ 66
3.7 Connection with Sunny Boy and Sunny Boy Control ................................ 67
3.7.1 Simple Connection at COM2 Interface ................................................. 67
3.7.2 Multiple Connection at COM2 Interface................................................ 69
3.7.3 Simple Connection to PC ..................................................................... 71
3.7.4 Alternative Communication at COM1 Interface .................................... 72
3.7.5 Assignment of COM3 Interface ............................................................ 73
3.8 Communication in a Three-Phase Island Grid .......................................... 74
4Operating Instructions ....................................................................................... 75
4.1 Display and Operating Elements............................................................... 75
4.1.1 Key Assignment.................................................................................... 76
4.1.2 Contrast in Display ............................................................................... 77
4.1.3 Return to Status Display....................................................................... 77
4.1.4 Edit Mode ............................................................................................. 78
4.2 Menu Structure.......................................................................................... 78

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5First Commissioning of the Sunny Island .......................................................... 81
6Configuration ..................................................................................................... 84
6.1 First Configuration..................................................................................... 85
6.1.1 “Master” or Single Sunny Island (“New Sys MASTER”) ....................... 85
6.1.2 “Slave” Sunny Island (“New Sys SLAVE”)............................................ 92
6.2 Configuration after Battery Exchange (“New Battery“).............................. 95
6.3 Configuration after Restart (“Restart”)....................................................... 98
7Operation (OPERAT)......................................................................................... 99
7.1 Menu “START” (2-1), Operation of the Sunny Island.............................. 100
7.2 Menu “GENSET” (2-2), Operation of Generator ..................................... 101
7.3 Menu “FUNCT“ (2+3), Special Functions................................................ 104
7.4 Menu „BHKW“ (2+5), ecopower support................................................. 105
8Settings (SETUP) ............................................................................................ 107
8.1 Menu “SETTIM“ (3-1), Setting the System Clock.................................... 108
8.2 Menu “PASSWD“ (3-2), Entry of Password ............................................ 109
8.3 Menu “PARSYS“ (3+3), Parameters System .......................................... 110
8.4 Menu “PARGRD“ (3+4), Parameters Grid .............................................. 112
8.5 Menu “PARBAT“ (3+5), Parameters Battery........................................... 114
8.6 Menu “PARGEN“ (3+6), Parameters Generator ..................................... 117
8.7 Menu “PARREL“ (3+7), Parameters Relays ........................................... 121
8.8 Menu “PARSB“ (3+8), Parameters Sunny Boy ....................................... 128
8.9 Menu “PARALL“ (3+9), all Parameters ................................................... 130
9Operating Data (DATA) ................................................................................... 131
9.1 Menu „DATAV“ (1-0), Overview of Measured Values ............................. 133
9.2 Menu “DATSYS“ (1-1), System Data ...................................................... 134
9.3 Menu “DATALL“ (1-2), Overall Plant Data .............................................. 134
9.4 Menu “DATBAT“ (1+3), Battery Data ...................................................... 136

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9.5 Menu “DATGRD“ (1+4), Grid Data.......................................................... 138
10 Diagnosis (DIAG)............................................................................................. 140
10.1 Menu “ACKN“ (4-1), Error Confirmation.................................................. 142
10.2 Menu “HISTOR“ (4-2), Overall Protocol .................................................. 142
10.3 Menu “ERRHIS“ (4-3), Error Protocol ..................................................... 143
10.4 Menu “EVTHIS“ (4-4), State Protocol...................................................... 143
11 Island Grids – Examples.................................................................................. 144
11.1 Photovoltaically powered Island Grid ...................................................... 145
11.2 Photovoltaically powered Island Grid with Generator ............................. 150
11.3 Mains Backup System with Photovoltaics............................................... 154
11.4 Mains Backup System with Generator and PV ....................................... 157
11.5 Integrating CHP-Units ............................................................................. 161
11.6 Multiple Sunny Island Systems (w/ Data interchange)............................ 165
11.6.1 Single-Phase System...................................................................... 165
11.6.2 Three-Phase System ...................................................................... 169
11.7 Multiple Sunny Island Systems (w/o Data interchange).......................... 172
11.7.1 Single-Phase System...................................................................... 173
11.7.2 Three-Phase System ...................................................................... 173
11.7.3 Mixed Single/Three-Phase Systems............................................... 174
12 Terminal Diagrams for Generator Options ...................................................... 175
12.1 Stationary Generators ............................................................................. 175
12.2 Temporarily connected Generators......................................................... 179
12.3 “ecopower Mini-BHKW”, CHP-units ........................................................ 181
13 Technical Data................................................................................................. 182
14 Servicing and Maintenance ............................................................................. 185
15 Warranty and Liability Regulations .................................................................. 188
16 Parameters (Overview).................................................................................... 190

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17 Measured Values Displayed (Overview) ......................................................... 211
18 Error and Status Signals.................................................................................. 217
18.1 Error Signals ........................................................................................... 217
18.2 Status Signals (“Events“) ........................................................................ 219
19 Declaration of Conformity ................................................................................ 222
20 Contact ............................................................................................................ 223
21 List of Figures .................................................................................................. 224
22 List of Tables ................................................................................................... 228

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Important Safety Notice:
The Sunny Island inverter may only be opened, installed and ser-
viced by qualified personnel. The device can still be charged with
very high hazardous voltages even when disconnected. Please
closely follow all steps as described in this document when working
on the inverter. All safety instructions and all appropriate technical
and local regulations must be followed.

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1 Introduction
By purchasing a Sunny Island you have decided to use one of the most advanced
modular battery inverters.
The Sunny Island works as
• a high-quality sine wave AC source for 230 V, 50 or 60 Hz island grids with
sophisticated overload behavior
• a high-class battery charger that assures a maximum lifetime of the con-
nected lead storage battery by using highly sophisticated charging algorithms
and providing external signals in order to activate electrolyte pumps and even
battery room fans
• a controller providing a high level energy management, including loadman-
agement and interaction with power sources like generators or photovoltaic in-
verters
• a universal generator management system, with capability to start, pre-
heat, cool down etc. combustion engines and even to control dedicated CHPs
(Combined Heat and Power units)
• a modularly expandable unit that can be combined with other Sunny Islands
for higher power demands or for three-phase systems
Furthermore it provides a large number of valuable features like system data monitor-
ing, time dependent switching operations etc. and complies with the according Euro-
pean standards on EMC as certified in the CE declaration (see Chapter 19).

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In the following you will find the installation and operating instructions of the Sunny
Island1battery inverter. Don’t worry about the size of the document, it is not neces-
sary to read everything at once. However, the general safety instructions described in
Chapter 1.3 have to be observed at any rate.
This is both installer’s guide and user manual, so it is used as reference for the com-
missioning and as guideline on how to use all functions of the inverter optimally.
1Sunny, Sunny Family, Sunny Island and Sunny Boy are registered trademarks of SMA Regelsysteme
GmbH, Germany.
All other trademarks used in this documentation are the property of their respective owners and are
used herein for identification purposes only.

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1.1 About these instructions
This document contains important information for the installation and commissioning of
the Sunny Island as well as its safe operation. Please read these instructions carefully
before starting the inverter. The inverter must be installed and commissioned by quali-
fied personnel. Work must be carried out according to the local installation and safety
regulations. Please also refer to our warranty and liability terms at the end of this docu-
ment. This version of Installation and Operating Instructions considers the features for
the Sunny Island SI4500 with firmware BFR 2.00 / DSP 2.00, and higher.
1.2 What to do in case of transport damages?
Our products are thoroughly checked before they are shipped. Even though they are
delivered in sturdy packaging (which can be recycled) the inverters can be damaged
in transit which is usually the forwarder’s fault.
Please inspect your inverter thoroughly after it has been delivered. If any damages
can be detected on the packaging that could make you conclude the contents is
damaged or if you detect any damage please immediately notify the forwarding com-
pany.
SMA or your local supplier can help you in this matter. In any case a declaration of
transport damage must be made within six days upon receipt of the product and must
be stated in writing directly to the forwarding agent.

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1.3 General Safety Instructions
The Sunny Island is only suitable for installation in closed rooms.
Therefore do not expose it to humidity, rain or direct sunlight.
The inverter is designed for use in places up to 2000 m (6561 ft)
above sea-level.
Make sure there is sufficient air circulation in the battery room. Bat-
teries can develop an explosive atmospheres in normal operation.
Use specialized tools when mounting and wiring the storage battery
(risk of short circuit).
As a precaution against injuries wear suitable clothes for handling
heavy and bulky devices when mounting and removing the Sunny
Island (such as working gloves and safety shoes).
The device may only be opened, installed and serviced by a qualified
electrician. Even when disconnected there can be high touch volt-
ages within the device. Please see our detailed description of how to
handle the Sunny Island and closely follow all instructions!
Under certain circumstances the Sunny Island may start up autono-
mously! Keep this in mind when working on the island grid and al-
ways switch off the AC fuses of all Sunny Islands in the island grid!

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2 Device Description
As the central component of a modular power supply system the Sunny Island will
not only convert the energy to supply various kinds of electrical consumers or to
charge its batteries but also allow to connect the SMA Sunny Boy®String Inverters for
supplementary grid feeding. Furthermore, small wind energy converters or generator
sets and even Combined Heat and Power units (CHPs) are also supported.
To fulfill its tasks the Sunny Island can work in different operating modes. A short
overview is given in Chapter 2.1.
An outstanding feature of the Sunny Island is its capability to take care of the con-
nected lead storage battery. Highly sophisticated charging algorithms assure a
maximum lifetime of the battery. A quick abstract of the battery management is given
in Chapter 2.2.
Although the first commissioning of stand alone systems using the Sunny Island can
be kept very simple, it is just as well possible to fine-tune the system by a vast num-
ber of parameters (see Chapter 16) giving the users complete satisfaction.
Moreover, using this system-compatible battery inverter lets the planner / installer
reduce planning, execution and system costs for PV island supply considerably.

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2.1 Operating Modes
The Sunny Island can be modularly combined with other power sources and must
then operate in different operating modes. Depending on the system’s structure, the
Sunny Island can be configured to toggle automatically between these operating
modes. This chapter covers both basic grid configurations and the resulting require-
ments for the Sunny Island and the other components in the island grid.
Control of voltage and frequency in the island grid
Operation of the Sunny Island is based on the following operating modes:
• Grid forming (RUN_U), the Sunny Island keeps the voltage and the frequency of
the grid at a constant level.
• Grid-tied (RUN_I), the Sunny Island complies with the voltage and frequency
that is defined by an additional component of the island grid that itself forms the
grid.
• Droop-mode (special kind of RUN_U), the Sunny Island varies its battery cur-
rent depending on the grid’s frequency, and the grid’s voltage depending on its
current reactive power. It also tries to affect the grid’s frequency according to its
battery state. In case of being synchronized to a generator, the status
“RUN_UEXT” is shown in the display.

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2.1.1 Grid-Forming Operation (RUN_U)
In grid-forming mode the Sunny Island keeps the grid voltage at a constant sine-wave
voltage and constant frequency. The voltage and frequency is defined in the
“PARGRD“ 3+4 menu. The Sunny Island then has to provide the necessary active
and reactive power that is required for the control of the grid. All other components in
the grid then have to operate as grid-controlled power generators or consumers.
Consumers
230 V 50 Hz/60 Hz
Fig. 2.1: Sunny Island as grid-forming element
This operating mode requires that there are no further components within the grid
that control the frequency or the voltage. Parallel operation with the public utility or an
independent synchronous generator is not possible in this mode.
In this mode the Sunny Island can only charge the batteries whenever the compo-
nents within the grid (Sunny Boy inverters, synchronous generators) generate more
power than required. In case that these components generate less power than con-
sumed within the grid the Sunny Island supplies power to the grid by discharging the
batteries.

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The state of charge of the batteries can therefore only be manipulated by controlling
the power generating components and the consumers within the grid.
Due to the battery management, the Sunny Island can perform a full charge of high
quality even in this operating mode. This might take several days, if necessary (for
example if there are only photovoltaic feeders).

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2.1.2 Grid-Tied Operation (RUN_I)
In grid-tied operation the Sunny Island follows the voltage and frequency defined by
an external power source. This can be an independent synchronous generator or the
public utility. In this case, the Sunny Island does not control the grid voltage and grid
frequency but controls the current it draws from the grid to charge the battery in a
defined and most suitable manner.
Sunny Island
Control of battery
current and
battery voltage
Control of
frequency
and voltage
Sunny Boy
PV Modules
Consumers
Generator as
grid forming element
SG
230 V 50 Hz/60 Hz
Fig. 2.2: Sunny Island with external grid-former