SMA SWR 1800U - V1.0 Setup guide

SB1800U-11:NE0402
Grid Tied String Inverter for Photovoltaic Systems
Issue 1.0
Installation and Operator’s Manual
Sunny Boy
SWR 1800U

Sunny Boy 1800U Installation and Operator’s Manual
SB2500U-11:NE - 2- SMA Regelsysteme GmbH
Alteration Review
Document
Number
SB1800U
Issue
and Alteration
Review 1)
Comments Author
-11:NE0402 1.0 A First issue Homburg
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
Name Date Signature
Approved Bremicker

Sunny Boy 1800U Installation and Operator’s Manual
SB2500U-11:NE - 3- SMA Regelsysteme GmbH
IMPORTANT SAFETY INSTRUCTIONS
This manual contains important instructions that shall be followed during installa-
tion and maintenance of the Sunny Boy.
To reduce the risk of electrical shock, and to ensure the safe installation and op-
eration of the Sunny Boy, the following safety symbols have been placed through-
out this technical description to indicate dangerous conditions and important
safety instructions.
WARNING: This indicates a fact or feature very important for the safety of
the user and / or which can cause a serious hardware defect if not applied
appropriately.
Use extreme caution when performing this task.
NOTE: This indicates a feature that is important either for optimal and
comfortable usage or optimal operation of the system.
Follow instructions closely.
EXAMPLE: This indicates an example.
SAVE THESE INSTRUCTIONS

Sunny Boy 1800U Installation and Operator’s Manual
SB2500U-11:NE - 4- SMA Regelsysteme GmbH
IMPORTANT SAFETY INSTRUCTIONS
• All electrical installations shall be done in accordance with the local and na-
tional electrical codes ANSI/NFPA 70.
• The Sunny Boy contains no user serviceable parts. Please return the unit to
an SMA authorized Service Center (see page 56) for maintenance.
• Before installing or using the Sunny Boy, please read all instructions and cau-
tionary markings in the technical description and on the Sunny Boy and the
PV-array.
• Connecting the Sunny Boy to the electrical utility grid must only be done after
receiving prior approval from the utility company and performed only by
qualified personnel.
• Completely cover the surface of all PV-arrays with opaque (dark) material be-
fore wiring them. PV arrays produce electrical energy when exposed to light
and could create a hazardous condition.
• On top of the device you can find the heat sink of the Sunny Boy with poten-
tial temperatures of over 175°F (80 °C). To reduce the risk of burns, do not
touch.
SAVE THESE INSTRUCTIONS

Sunny Boy 1800U Installation and Operator’s Manual
SB2500U-11:NE - 5- SMA Regelsysteme GmbH
Table of Contents
1Introduction............................................................................................................... 6
2Installation................................................................................................................. 7
2.1 What Must Be Done in Case of Transport Damages?...................................... 7
2.2 Placement of the Sunny Boy ............................................................................ 8
2.3 Electric Connection ........................................................................................ 12
2.3.1 Preparation of the electric connection........................................................ 14
2.3.2 Connection to Electrical Utility Grid............................................................ 16
3Commissioning ....................................................................................................... 20
4Operation and Failure Indication LEDs ................................................................... 24
4.1 Operation Indicator......................................................................................... 27
4.2 Ground Fault Indicator.................................................................................... 30
4.3 Failure Indication ............................................................................................ 31
4.4 Opening and closing of the Sunny Boy .......................................................... 36
4.5 Upgrading or modification of the Sunny Boy interface.................................... 39
4.6 Measuring Channels and Messages .............................................................. 41
4.7 Measurement Precision.................................................................................. 43
5Troubleshooting ...................................................................................................... 44
6Warranty Regulations and Liability ......................................................................... 46
7Technical Data........................................................................................................ 48
7.1.1 Minimum MPP-voltage of the PV panel ..................................................... 49
8Appendix................................................................................................................. 56

Sunny Boy 1800U Installation and Operator’s Manual
SB2500U-11:NE - 6- SMA Regelsysteme GmbH
1 Introduction
The SMA Sunny Boy is a string inverter for grid tied operation. With this manual the
Sunny Boy can be installed and operated in a safe way. This installer’s guide is used as
reference for the commissioning and as guideline on how to use all functions of the in-
verter optimally and how you can extend your existing PV-plant.
Supplementary grid feeding includes the conversion of the DC voltage from the PV-panel
to grid compatible AC voltage with so-called ”inverters“ and the subsequent connection to
the electricity grid in the house distribution.
Here the electricity from the PV-modules provides all consumers with electric power
(household devices, lights etc.). In case that not enough power is produced the addition-
ally necessary power is obtained from the grid. In case that there is a surplus of power,
this surplus is fed into the local grid and is therefore available for other consumers. This
way every single kilowatt-hour is utilized and the electricity company’s power systems are
relieved. In the most simple case a PV-plant therefore consists of two basic components:
the PV-panel and the inverter.
Fig. 1.1: Grid-tied string inverter application
For a more detailed technical description of the Sunny Boy and its functionality please
read “Sunny Boy 1800U Technical Description”.

Sunny Boy 1800U Installation and Operator’s Manual
SB2500U-11:NE - 7- SMA Regelsysteme GmbH
2 Installation
WARNING: Before installing the Sunny Boy, read all instructions and
cautionary markings in the technical description and on the Sunny
Boy and the photovoltaic array.
WARNING: All electrical installations shall be done in accordance
with all local electrical codes and the National Electrical Code (NEC),
ANSI/NFPA 70.
WARNING: Connecting the Sunny Boy to the electrical utility grid
must only be done after receiving prior approval from the utility
company and performed only by qualified personnel.
2.1 What Must Be Done in Case of Transport Damages?
The Sunny Boy inverters are thoroughly checked before they are shipped. Even though
they are delivered in a sturdy packaging (which can be recycled) the inverters can be
damaged which is the forwarding company’s fault in most cases.
Please inspect your inverter thoroughly after it is delivered. If any damages can be de-
tected on the packaging that could lead to the conclusion that the contents is damaged or
if you detect that the inverter is damaged please immediately notify the forwarding com-
pany.
SMA or your local supplier can help you in this matter. In any case the declaration of
transport damage must be made within 6 days upon receipt of the product and must be
stated in writing directly to the forwarding agent. If it is necessary to return the inverter to
the manufacturer please use the packaging the inverter was sent in.

Sunny Boy 1800U Installation and Operator’s Manual
SB2500U-11:NE - 8- SMA Regelsysteme GmbH
2.2 Placement of the Sunny Boy
The Sunny Boy is a sophisticated electronic device and is therefore sensitive to humidity
within the case.
NOTE: If the Sunny Boy is placed outside, the humidity during the installa-
tion should be as low as possible - pay special attention that it does not
rain. If moisture is enclosed in the case it will eventually condense within
the device which could damage the electronics.
A suitable position must be found for the inverter while the PV-plant is designed. In the
following you will find a summary of the most important criteria.
Criteria for device mounting:
• Due to the high protection class (NEMA 4X) of the enclosure the installation is pos-
sible indoors as well as outdoors.
• If possible, do not expose the inverter to rain despite NEMA 4X.
• Keep the DC cabling from the solar panel to the inverter as short as possible.
• Avoid installation in the living area because a slight noise emission is possible.
• Avoid mounting on resonant parts (e.g. thin wooden panels, plaster panels, etc.).
The Sunny Boy tends to slightly vibrate when under load.
• Provide accessibility for installation and later service.
• Installation in eye-height allows to easily read the operating LEDs or the Sunny Dis-
play.

Sunny Boy 1800U Installation and Operator’s Manual
SB2500U-11:NE - 9- SMA Regelsysteme GmbH
CAUTION: Please note the following points in any case:
• The mounting background must be firm.
• The ambient temperature must be between –13°F and +140°F.
• The National Electrical Code (NEC) requires that the inverter be
connected to a dedicated circuit and no other outlets or device may
be connected to this circuit. See NEC Section 690-64(b)(1). The
NEC also impose limitations on the size of the inverter and the man-
ner in with it is connected to the utility grid. See NEC Section 690-
64(b)(2).
• Do not expose the string inverter to direct sunlight (if necessary in-
stall a shading roof).
• A minimum distance of 8 inch (200 mm) must be clear above the in-
verter for ventilation, i.e. no cupboards, ceiling, etc.
• Free air circulation around the case must not be obstructed.
• If you are installing the Sunny Boy in a cabinet or closet etc., the air
circulation must be sufficient for heat dissipation - provide external
ventilation.
• The heat sink can reach a temperature of more than 175 oF.
• Check existing electrical installations or plumbing prior to drilling
holes into the wall.
• Provide a correct position of the inverter - see below:
mount straight or tilted to the back never mount tilted to front
Fig. 2.1: How to mount the Sunny Boy

Sunny Boy 1800U Installation and Operator’s Manual
SB2500U-11:NE - 10 - SMA Regelsysteme GmbH
The Sunny Boy inverter is mounted on the back side with the three metal straps.
Fig. 2.2: Picture of drilling template - original template in appendix

Sunny Boy 1800U Installation and Operator’s Manual
SB2500U-11:NE - 11 - SMA Regelsysteme GmbH
Preparing the Mounting
The Sunny Boy is mounted on its back side with the 3 metal straps. For that 3 screws
and 3 according dowels (wall anchors) are necessary. The screws and dowels are not
included. We recommend 6 mm screws and 8 mm dowels.
NOTE: For outside mounting use stainless steel screws. Use a plas-
tic washer in order to avoid scratching the paint.
Fig. 2.3: Side view of the mounting to wall
Metal straps for mounting: The top straps take the load, the bottom is screwed down
in order to prevent the tilting off the wall.
Mounting to wall
• Mark the holes with the drilling template.
• Drill the holes (and put in the wall anchors), put in the screws of both top holes and
screw them in until ca. 4 mm are sticking out.
• Hang the inverter into the two top screws.
• Fasten the bottom screw. This will prevent lifting of the inverter case.
• Check the mounting of the inverter.

Sunny Boy 1800U Installation and Operator’s Manual
SB2500U-11:NE - 12 - SMA Regelsysteme GmbH
2.3 Electric Connection
The electric connection of the Sunny Boy can be done once the device is correctly
mounted in its position.
Fig. 2.4: Simplified electrical wiring diagram of the PV-system
Fig. 2.5: Bottom view of the Sunny Boy
DC Connection AC Connection
GFDI-Fuse
Communication
Connection

Sunny Boy 1800U Installation and Operator’s Manual
SB2500U-11:NE - 13 - SMA Regelsysteme GmbH
WARNING: All electrical installations shall be done in accordance
with all local electrical codes and the National Electrical Code (NEC),
ANSI/NFPA 70. Use no. 14 AWG, minimum 90°C (194°F), copper wire
for all connections with the Sunny Boy. Voltage drop and other con-
siderations may dictate that larger wire sizes be used.
The AC-grid and the input from the DC disconnect enclosure are connected to the in-
verter inside the case. Cables with wire sizes up to 10 AWG (5.26 mm2) are accepted by
the AC- and DC-terminals on the printed circuit board.
WARNING: The connection of the Sunny Boy to the DC voltage from
the PV string and the AC voltage of the utility must be done in the
order described here. This ensures that the disconnecting of con-
tacts as well as hazardous voltages during the installation are
avoided.
• Connect the Sunny Boy to the electricity grid
• Connect the PV strings to the DC disconnect enclosure
• Connect the DC disconnect enclosure to the Sunny Boy
• Connect the utility by switching all breakers ON
To disconnect the Sunny Boy from the system, first turn all breakers and switches OFF.
Then disconnect the various conductors in the reverse order listed above.

Sunny Boy 1800U Installation and Operator’s Manual
SB2500U-11:NE - 14 - SMA Regelsysteme GmbH
2.3.1 Preparation of the electric connection
Remove all screws (1-4, size M5 (see Fig. 2.6)) and take off the lid. When removing
these screws, be sure to save the special lock washers and reinstall them to properly
ground the front panel.
Fig. 2.6:Front view of the Sunny Boy 1800U
You now have the opened Sunny Boy in front of you (see Fig. 2.7) and can see the posi-
tion of components and clamps relevant for you. You will find:
• The internal grid fuse
WARNING: A defective grid fuse has to be replaced only with a UR
fuse of 20AMP / 250V AC in order for continued protection against
risk of fire.
• The control system board with the socket for the Piggy Back board for the com-
munication
• Terminal for the AC-connection
• Terminals for the DC-connection
1
2
3
4

Sunny Boy 1800U Installation and Operator’s Manual
SB2500U-11:NE - 15 - SMA Regelsysteme GmbH
Fig. 2.7: Interior of the Sunny Boy 1800U
DC-Connection
Place for Piggy Back
Resistors
Grid Fuse
AC-Connection

Sunny Boy 1800U Installation and Operator’s Manual
SB2500U-11:NE - 16 - SMA Regelsysteme GmbH
2.3.2 Connection to Electrical Utility Grid
The Sunny Boy must be connected to the grid with 3 cables
- with L1 and N and one equipment-grounding conductor (Protective earth (PE)).
WARNING: Make sure the main 120 V breaker in the main utility
breaker box is switched OFF before you connect the AC terminal
block.
The grid impedance value at the connection point should be as low as possible to avoid
an increase of the AC-voltage to non-permissible values while the Sunny Boy feeds to
the grid. This also results in a higher system efficiency.
EXAMPLE: The impedance is the sum of the electricity grid impedance at
house distribution and all impedance values of cables and clamping
points.
NB: Impedance values are
- ca. 0.44 Ωfor a 70 feet (16.4 m) cable with a cross section of AWG 14
- ca. 0.40 Ωfor a 100 feet (33 m) cable with a cross section of AWG 12
- ca. 0.43 Ωfor a 175 feet (57 m) cable with a cross section of AWG 10
The total impedance of the grid plus the interconnecting ac cables should be less than
1.25 Ohm.

Sunny Boy 1800U Installation and Operator’s Manual
SB2500U-11:NE - 17 - SMA Regelsysteme GmbH
Fig. 2.8: AC connection socket
• Connect the main 120 V AC-breaker box to the Sunny Boy by a 1/2“ conduit.
• Insert the conduit fitting in the very right opening of the Sunny Boy. Fasten the fit-
ting on the inside of the Sunny Boy with the nut.
• Pull the wires through the conduit into the interior of the Sunny Boy.
• Connect the wire L1 to the terminal labeled L in the Sunny Boy (see Fig. 2.8).
• Connect the wire N to the terminal labeled N in the Sunny Boy.
• Connect the equipment-grounding conductor to the terminal labeled PE in the
Sunny Boy.
• Torque wires with torque of 35 in-lb.
• Ensure all connections are correctly wired and properly torqued.
L1
N
Ground
AC conduit and wiring

Sunny Boy 1800U Installation and Operator’s Manual
SB2500U-11:NE - 18 - SMA Regelsysteme GmbH
Connection of the PV-panels to the DC disconnect enclosure
WARNING: Completely cover the surface of all PV-arrays with opaque
(dark) material before wiring them. PV-arrays produce electrical energy
when exposed to light and could create a hazardous condition.
Depending on the type of PV-module used it is possible to connect one single string or
several parallel strings. Therefore there are three connections for both the + and the –
pole. Within the device these connections are connected in parallel each.
WARNING: Before connecting the connectors of the PV-panel to the
DC disconnect enclosure check the correct polarity and admissible
PV-panel voltage between the + and the – cable connectors of the
PV-panel.
The PV-panel open circuit voltage must be below or at most equal to
400 V DC (VPV ≤400 V DC) under all conditions. Please read chapter
7.1.1

Sunny Boy 1800U Installation and Operator’s Manual
SB2500U-11:NE - 19 - SMA Regelsysteme GmbH
Connection of the Sunny Boy to the DC disconnect enclosure
• Install the DC conduit from the DC disconnect enclosure to the Sunny Boy.
• Insert the conduit fitting in the very left opening of the Sunny Boy. Fasten the fitting
on the inside of the Sunny Boy with the nut. Do the same at the DC disconnect
enclosure .
• Ensure all circuit breakers in the DC disconnect enclosure are in the OFF-
position.
• Route the wires from the DC disconnect enclosure through the conduit and into
the Sunny Boy.
• Connect the positive (+) wire to the terminal block labeled with (+), see Fig. 2.9.
• Connect the negative(-) wire to the terminal block labeled with (-), see Fig. 2.9.
• Torque wires with torque of 35 in-lb .
• Ensure all connections are correctly wired and properly torqued.
Fig. 2.9: DC connection socket
DC- conduit and wiring
Positive plug Negative plug

Sunny Boy 1800U Installation and Operator’s Manual
SB2500U-11:NE - 20 - SMA Regelsysteme GmbH
3 Commissioning
Safety Notice
NOTE: Make sure that nothing is on top of the heat sink of the Sunny
Boy when it is running.
WARNING: The heat sink can get very hot - i.e. over 175 °F (80 °C).
NOTE: Make sure that all fittings are sealed and all openings on the bot-
tom are closed with the seals.
• When putting the lid on make sure the seal in the inner side of the lid is placed
correctly. When screwing the inner screws make sure that the thread in the Sunny
Boy case is not damaged by tilted screws. Under certain conditions the enclosure
type NEMA 4X cannot be guaranteed any more. When mounting the Sunny Boy
outside moisture can get into the device and damage the electronics.
WARNING: Make sure that the lid is closed before applying power to
the Sunny Boy.
• Ensure that all AC and DC wiring is correct.