SMA SB 2800i Installation

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Sunny Boy 2800i
String Inverter Sunny Boy 2800i
The New Generation of PV System Technology
SB2800i-11:SE0504
Installation Guide
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Table of Contents

1 Introduction . . . . . . . . . . . . . . . . . . . 3
2 Safety Instructions. . . . . . . . . . . . . . . 5
3.1 Device Description. . . . . . . . . . . . . . . . . . 7
3.2 External Dimensions. . . . . . . . . . . . . . . . . 8
4 Requirements for the Installation . . . . 9
4.1 Requirements: Mounting Place . . . . . . . . . 9
4.2 Requirements: PV-Modules. . . . . . . . . . . 11
4.3 Requirements: Grid 230 V~ (AC) . . . . . . 12
5 Installation . . . . . . . . . . . . . . . . . . . 15
5.1 Mounting . . . . . . . . . . . . . . . . . . . . . . . 15
5.2 Electrical Installation . . . . . . . . . . . . . . . 16
5.3 Activation . . . . . . . . . . . . . . . . . . . . . . . 21
6 Opening and closing the Sunny Boy. 23
6.1 Opening the Sunny Boy . . . . . . . . . . . . . 23
6.2 Closing the Sunny Boy . . . . . . . . . . . . . . 23
7 Communication. . . . . . . . . . . . . . . . 25
7.1 Powerline Communication . . . . . . . . . . . 25
7.2 RS232 Communication . . . . . . . . . . . . . 26
7.3 RS485 Communication . . . . . . . . . . . . . 28
8 Exchanging varistors. . . . . . . . . . . . 31
9 Contact . . . . . . . . . . . . . . . . . . . . . 35
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Revision History
Document number Changes Author
SB2800i-11:SE0504 First Issue Siebert
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Installation Guide Introduction

1Introduction

This document gives short installation instructions for electricians only. It helps to swiftly and correctly install and commission an SMA inverter type „ SB 2800i“.
For detailed technical data and operating instructions please see the Operating Instructions.
The „GenAu“ tool will help to dimension and check the size of your strings with respect to the Sunny Boy you intend to use. The „GenAu“ tool is available for download at www.SMA.de.
If you have any further questions please do not hesitate to call the Sunny Boy hotline on the following number:
+49 561 9522-499
All trademarks mentioned in this Installation Guide are accepted.
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Introduction Installation Guide
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Installation Guide Safety Instructions

2Safety Instructions

Only a qualified electrician may work on the open Sunny Boy! This work is only permissible if the AC and DC power supply are safely disconnected from the Sunny Boy.
The Sunny Boy must be disconnected from the grid and secured against accidental reconnection. Connections to the PV generator must be disconnected as well.
When this has been done, always wait for approx. 5 minutes so that the capacitors in the Sunny Boy can be discharged. Only then may the lid be opened and the safe isolation from power supply be checked.
The Sunny Boy 2800i is equipped with the anti-islanding unit „SMA grid guard“. The Sunny Boy 2800i therefore complies with the VDEW guidelines for grid interactive inverters and the DIN VDE 0126 (4.99) specified in this regulation.
The Sunny Boy is equipped with high
voltage capacitors that can contain lethal
voltages even when disconnected from
supply power for some time.
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Safety Instructions Installation Guide
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Installation Guide Overview

3 Overview

3.1 Device Description

The following figure shows the different components and connection areas of an open Sunny Boy 2800i inverter.
Varistors, page 31
Communication socket (RS232, RS485, PLC), page 25
Socket for display unit (Sunny Display)
LEDs indicating
operating state
Terminal for PE
Terminals (AC) page 17
PV input plugs (DC),
page 19

Fig. 3.1: Inside view of the Sunny Boy 2800i

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Communication terminal
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Overview Installation Guide

3.2 External Dimensions

Abb. 3.2: Size of the Sunny Boy 2800i

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Installation Guide Requirements for the Installation

4 Requirements for the Installation

Please make sure to fulfill all conditions below before installing and commissioning the Sunny Boy.

4.1 Requirements: Mounting Place

The Sunny Boy 2800i has a relatively high weight of 31 kg. Please keep this in mind when selecting the place where and how to mount the Sunny Boy.
The ambient temperature should be within -25 °C and + 60 °C.
The Sunny Boy 2800i is only for inside installation. It should be mounted in a place whithout high temperatures - otherwise this may reduce the yield of the PV plant.
It can be mounted straight or to the back. To ensure optimum energy yield and easy operation it should be mounted straight and on eye level.
Important for the selection of the location:
Unintended removal of the Multi-Contact snap-cable connectors can damage the connectors and even result in serious injuries. Install the Sunny Boy in a place where an unintended removal of the Multi-Contact connectors (e. g. by children) is not possible.
Some parts of the Sunny Boy can reach temperatures over 80 °C. Keep a suitable distance to flammable materials!
Never install the Sunny Boy in areas that likely contain explosive athmospheres (battery rooms, fuel storage rooms etc.)!
31 kg
®
®
Install the Sunny Boy 2800i in a fairly dust free environment.
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Requirements for the Installation Installation Guide
Please make sure there is a sufficient space for heat dissipation! In a normal environment the following clearance should be provided for a single Sunny Boy 2800i
Minimum clearance
Lateral 20 cm
Top 20 cm
Pay attention to the required minimum
clearance for the Sunny Boy 2800i
Bottom 20 cm
Front 5 cm
Table 4.1: Minimum clearance
If you want to install several Sunny Boy 2800i side by side on the same level, pay attention to the minimum distance between them. If there is not enough space between the devices, the left Sunny Boy will reduce the yield of the PV plant because of the incomming air temperature.
Two or more Sunny Boy 2800i may not be mounted directly to each other.
The minimum space between two Sunny Boy 2800i has to be 40 cm.
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Installation Guide Requirements for the Installation
In a living area the Sunny Boy should not be mounted on plaster panels, thin wooden panels etc. in order to avoid noises.
We recommend to install the inverter on a firm and sturdy surface.
Mounting the Sunny Boy on a thin sur-
face may emit a slight noise!
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Requirements for the Installation Installation Guide

4.2 Requirements: PV-Modules

The Sunny Boy 2800i is designed for the connection of up to three strings (PV modules connected in series).
The „ GenAu“ tool will help to dimension and check the size of your strings with respect to the Sunny Boy you intend to use. The „GenAu“ tool is available for download at www.SMA.de.
The device has six Multi-Contact plug connectors (two for each string). The connecting cables of the PV panel therefore have to be equipped with such plug connectors as well.
A connection kit for connection of loose cable ends in a string can be purchased as an accessory (SMA order name: „SWR-MC“).)
Limits for DC input
Max. voltage 600 V (DC)
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Installation Guide Requirements for the Installation

4.3 Requirements: Grid 230 V~ (AC)

The relevant technical regulations as well as specific requirements defined by the local public utility have to be complied with.
The terminals of the Sunny Boy 2800i are suitable for cables with a cross-section of up to 2.5 mm². The Sunny Boy is connected with three wires (L, N, PE).
Each connection to a Sunny Boy 2800i must be equipped with a separate circuit breaker 16 A. No other consumers may be connected to the cable.
The Sunny Boy has to be connected
to grid with three wires!
No additional consumers may be
connected between the Sunny Boy
and the fuse!
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Requirements for the Installation Installation Guide
The impedance at the AC connection point of the Sunny Boy 3000 must be below 2 Ohm in order to ensure a reliable function of the anti-islanding unit. You should furthermore have a suitable cable cross-section in order to keep the losses below 1 % at nominal power. The according losses with respect to cable length and cross-section are illustrated below:
Fig. 4.1: Losses in AC cable
The Sunny Boy 2800i is designed for 230 V grids. The voltage should be within 198 V and 260 V and the frequency should be
198 V ... 260 V
49.8 Hz ... 50.2 Hz
within 49.8 Hz and 50.2 Hz.

Limits for AC Output

Limits for AC output
Voltage range 198 V ... 260 V
Frequency range 49.8 Hz ... 50.2 Hz
Voltage range (without ENS)
Frequency range (without ENS)
180 V ... 260 V
45.5 Hz ... 54.5 Hz
Table 4.2: Limits for AC output of the Sunny Boy 2800i
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Installation Guide Installation

5 Installation

5.1 Mounting

For trouble-free mounting of the Sunny Boy 2800i we recommend to use the bracket for wall installation included in delivery. You can mount it vertically in firm concrete or stone walls with e. g. stainless steel 8 mm x 50 mm hexagon screws according to DIN 571 and with dowels type SX8.
Keep the weight of the Sunny Boy 2800i (31 kg) in mind.
1. Mount the bracket. To mark the positions for drill holes you can also use the bracket as a drilling template.
2. Hang the upper fixing straps on the Sunny Boy 2800i into the bracket (2) so that it cannot be shifted sideways any more.
3. Secure the Sunny Boy 2800i against lifting off by screwing the M6x10 screw (included in delivery) into the lower middle fixing strap (3).

4. Ensure that the Sunny Boy 2800i has been tightly fastened.

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Installation Installation Guide

5.2 Electrical Installation

The following figure shows the complete cabling of a Sunny Boy 2800i:
Depending on the type of PV module used, it is reasonable to connect only one String or to use two or three parallel Strings. Thus, the module has three plus poles and three minus poles. These poles are simply connected in parallel within the inverter.
In case only one String terminal is used, please cover the four plug-in contacts not used with the seals enclosed.
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Installation Guide Installation
Connecting of AC output
Please follow the steps below:
1. Disconnect the grid (switch off the circuit breaker), secure it against accidental reactivation and ensure that it is discon­nected.
Before opening the Sunny Boy check
2. The AC connector is a round socket that is suitable to take different cable diameters. A PG13.5 and a PG16 cable seal are included with the AC connection socket. Check which size is suitable for your AC connection cable.
3. Strip the insulation off the ends of the cable and connect the cable to the AC socket as shown below.
whether the AC output is safely isola-
ted from supply!
4. Push the rubber ring into the fastening case.
5. Put the cable through the PG13.5 or 16 cable seal. Put the cable through the fastening case with the rubber ring and through the socket tube.
6. Connect the wires of the AC cable as follows:
• Protective Earth (PE) to the terminal with the „ground“ sym­bol.
• Neutral wire to the terminal marked with „1“
• Phase L to the terminal marked with „2“
• The terminal marked with „3“ is not used.
7. Make sure that all wires are firmly connected.
8. Push the socket tube firmly onto the socket.
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Installation Installation Guide
9. For cables that require the PG16 gland: Tighten the bolt of the PB16 gland.
10.The AC connector socket is now ready to use.
11.Seal the AC connector socket in case you do not insert it into the Sunny Boy.
12.The AC connector socket can be inserted into the Sunny Boy in case the Sunny Boy is already mounted in the correct posi­tion. Remove the seal from the AC connector on the Sunny Boy, insert the AC connector plug and tighten the seal.
Do not switch on the circuit breaker yet! The Sunny Boy 2800i may only be connected to the AC grid when the PV strings have been connected and the device is tightly closed.
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Installation Guide Installation
PV string (DC) connection
Connect the PV strings as follows:
1. Check the PV generator connections on their correct polarity and compliance with the maximum string voltage of 600 V DC, see chapter 4.2 "Requirements: PV-Modules" (p. 12).
The voltage from the strings is very dangerous! Be very careful and pay attention to all applicable safety regulations!
2. Measure the DC voltages between each Multi-Contact plug connector of a string and ground potential. Follow the safety instructions!
3. If the voltages you measured is constant and more than a few volts, a ground fault has occured in this string. The ratios of voltages approximately indicate where the ground fault can be found.
When you have found a ground fault in a string, only connect it to the Sunny Boy 2800i after you have removed the cause for the ground fault in the PV generator.
4. Repeat steps 2 and 3 for each string.
5. Connect the trouble-free PV strings to the Sunny Boy. Make sure to connect them to the correct terminals and with correct polarization.
When connecting the plus and minus poles of a string make sure to choose
the correct connection!
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Installation Installation Guide
If the lower yellow LED repeatedly blinks once a second for four times, immediately disconnect the grid voltage and the PV generator from the Sunny Boy 2800i. The input voltage is too high. The inverter might be damaged!
Check whether string voltages comply with limiting values stated in chapter 4.2 "Requirements: PV-Modules" (p. 12). If the values are too high, the planner / installer of the PV generator must modify the strings.
If the LED blinks again when the PV plant is reconnected to the inverter although string voltages have been checked to be ok, disconnect the PV panel again and contact SMA Regelsysteme GmbH (see chapter 9 "Contact" (p. 35)).
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Installation Guide Installation

5.3 Activation

You can activate the Sunny Boy 2800i when:
• The AC (grid) cable has been correctly connected.
• All the DC (PV) strings have been connected and all unused DC plug connectors on the underside of the inverter have been closed with the protecting caps.
• The lid has been tightly screwed on.
Proceedings for activation

1. Switch the circuit breaker on.

2. Check whether the LEDs indicate trouble-free operation of the Sunny Boy 2800i based on the following table. If this is the case commissioning has been successfully completed.
.
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Installation Installation Guide
Green Red Yellow Status
off off OK (feeding)
permanently on
blinking fast
(3 x per second)
blinking slowly
(1 x per second)
shortly turns off
(approx. 1 x per
second)
off
permanently on
off failure
permanently on OK (initialization)
off off OK (stop)
permanently on off failure
off off
OK (waiting, grid
monitoring)
permanently on off failure
off off OK (derating)
permanently on off failure
off OK (stand-by)
off
on/blinking failure
off failure
permanently on
on/blinking failure
Table 5.1: LED blinking codes
You will find a detailed description of failure messages and their causes in the „ Operating Instructions“.
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Installation Guide Opening and closing the Sunny Boy

6 Opening and closing the Sunny Boy

When the inverter has to be openend always follow the safety instructions given in chapter 2 "Safety Instructions" (p. 5).

6.1 Opening the Sunny Boy

Caution: Stick to the order specified below!

1. Switch off the AC connection.

2. Disconnect the PV generator from the Sunny Boy 2800i, by pulling off all the connectors.

3. Wait 5 minutes! (This is necessary to let the internal capaci­tors discharge.)
4. Unscrew the lid from the enclosure of the Sunny Boy 2800i. The screws are on the underside of the Sunny Boy.

5. Pull down the lid carefully (approx. 4 cm)

6. and carefully move the lid forward. Then pull the PE cable off the inside of the lid.
Make sure that you pull off the green-
yellow PE cable from the inside of the
Sunny Boy when you open it!
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Opening and closing the Sunny Boy Installation Guide

6.2 Closing the Sunny Boy

Caution: Stick to the order specified below!
1. Connect the PE conductor to the lid. Then attach the lid to the enclosure of the Sunny Boy 2800i by tightening the two screws.

2. Connect the PV generator. Make sure to connect each plug to the correct terminal.

3. Switch on the circuit breaker. This activates the Sunny Boy 2800i.

4. Check whether the LEDs of the Sunny Boy 2800i indicate trouble-free operation.

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Installation Guide Communication

7Communication

The upgrading of your Sunny Boy 2800i with communication Piggy-Backs is described in the manuals delivered with the communication Piggy-Backs.
You can see whether the Sunny Boy 2800i has already been equipped with a communication interface in the factory by checking the order name on the delivery note.
„-0xx“ without interface „-1xx“ PLC modem (Powerline Communication) „-2xx“ RS232 interface „-3xx“ RS485 interface

7.1 Powerline Communication

The following conditions must be fulfilled for Powerline Communication:
• The Sunny Boy 2800i has to be equipped with the „ PLC signal unit“ (see chapter 3.1 "Device Description" (p. 7)).
The Sunny Boy 2800i can be upgraded for powerline communication. The ordering code for the powerline upgrade kit for the Sunny Boy 2800i inverter is „ NLMPB-NR“.
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Communication Installation Guide

7.2 RS232 Communication

RS232 is a communication standard for transmission paths up to 15 m to one single Sunny Boy 2800i. The following conditions must be fulfilled for RS232 communication.
• The Sunny Boy 2800i has to be equipped with a second cable gland (included in delivery) between the PV input plugs and the cable opening for AC output on its underside.
• The Sunny Boy 2800i has to be equipped with an RS232 Pig­gy-Back. The ordering code for the RS232 is 232PB-NR
• A cable with a minimum of three wires and common shield, such as LiYCY, 0.25 mm² cross-section and a maximum 15 m length has to be used.
To provide for an RS232 interface the Sunny Boy 2800i has to be equipped with the second cable gland included in delivery. The RS232 cable enters the inverter through this gland and is connected to the communication terminal within the Sunny Boy 2800i (see chapter 3.1 "Device Description" (p. 7)). Its other end is usually connected to a serial interface of a PC. The following table specifies the pin designation for standard PC terminals.
Terminal Signal
D-SUB 9
plug (PC)
D-SUB 25
plug (PC)
Enclosure Shielding Enclosure Enclosure
2
3
RxD (Sunny Boy
output port)
TxD (Sunny Boy
input port)
23
32
5GND57
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Installation Guide Communication

Abb. 7.1: Sunny Boy connected to a PC via RS232

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Communication Installation Guide

7.3 RS485 Communication

RS485 is a communication standard for up to 50 Sunny Boy inverters with a total cable length of up to 1200 m. The following conditions must be fulfilled for RS485 communication:
• All Sunny Boys have to be equipped with the second cable gland (included in delivery) on their underside.
• All Sunny Boys have to be equipped with an RS485 Piggy-Back.
• A cable with common shield (such as LiYCY) with two twisted pair with a line impedance of 100 ohm.
• The first and the last participant of the RS485 bus have to be equipped with a termination resistor.
• The ordering code for the RS485 is 485PB-NR
At the moment the Sunny Boy Control and the Sunny Boy Control Plus can communicate with PV-plants
with up to 5 different types and all in all 50 Sunny Boy inverters in total. The Sunny Boy Control Light can communicate with 5 different Sunny Boy types and all in all 20 Sunny Boy inverters in total.
To provide for an RS485 interface the Sunny Boy 2800i has to be equipped with the second cable gland included in delivery. The delivery includes two different gland fittings (a fitting with one hole for one cable and a fitting with two holes for two cables).
Best start with the last Sunny Boy 2800i in the communication chain (i. e. the one at the end of the RS485 cable):

1. Use the gland fitting with one hole.

2. Now attach one of the two plug connectors delivered to the
data cable. Connect the wires of one twisted pair to termi­nals 2 and 7 on the communication slot (see Fig. 7.2: "One or several Sunny Boys connected with an RS485 cable to a PC with interface converter." (p. 30)). Write down which
wire is connected to which terminal!
3. Connect one (or both) wires of the second twisted pair to ter-
minal 5 on the communication slot. Write down which
wire(s) you have used!
4. If no other inverters have to be connected,
continue with point 8.
5. Now connect the next inverter. Use the contact
units with two holes.
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Installation Guide Communication
6. Connect the wires of a cable to the terminals on the commu­nication slot with the same allocation as written down for the first inverter. This applies both to the wires in the cable coming from the last inverter and in the one running to the next inverter. Proceed with special care! Finding wiring
failures can be very frustrating!

7. Repeat points 5 and 6 for each Sunny Boy to be connected.

8. To be able to connect them to a Sunny Boy Control or a PC with an interface converter later, label the wires at the end of the cable as follows.
Terminal
D-SUB 9
plug
Labeling of
wire
Your wire
labeling
Enclosure Enclosure Shielding
2 3 Data +
7 8 Data -
55GND
The connection of one or several Sunny Boy inverters to a Sunny Boy Control is described in detail in the manual of the Sunny Boy Control.
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Communication Installation Guide
Fig. 7.2: One or several Sunny Boys connected with an RS485
cable to a PC with interface converter.
SMA reccomends the usage of a I-7520 interface converter for the connection of an RS485 bus to a PC. SMA does not support any other types.
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Installation Guide Exchanging varistors

8 Exchanging varistors

The Sunny Boy 2800i is a very complex technical device. Therefore there are only a few possibilities to repair failures on site. Please do not try to make repairs other than described in this document. Make use of our 24-hour exchange service and the repair service of SMA Regelsysteme GmbH.
If the red status LED is permanently on during operation please first make sure that there is no ground fault in the PV generator.
1. Disconnect the grid (switch off the circuit breaker), secure it against accidental reactivation and ensure that it is discon­nected.

Ensure that the AC voltage is off before you open the Sunny Boy!

2. Disconnect the Multi-Contact plug connectors of all strings. Make sure that their allocation to the different inverter input ports can still be recognized!

Disconnect the PV strings!

3. Measure voltages between one Multi-Contact plug connector of each string and the ground potential. Follow all applicable safety instructions!
The voltage from the strings is very dangerous! Be very careful and pay attention to all applicable safety regulations!
Measure voltages between
Multi-Contact plug connectors and
the ground potential.
4. If the voltages measured are constant and their total is approximately equal to the open-circuit voltage of the string, there is a ground fault in this string. Its appoximate position can be deducted from the ratios of voltages.
5. Repeat points 3 and 4 for each string. If you have found a ground fault it is probably unnecessary to exchange the varistors. Make sure to remove the ground fault instead. This should normally be done by the installer of the PV panel. In this case proceed with point 10, but without reconnecting the faulty string! Protect its Multi-Contact plug connectors against touching (e. g. by protective caps or insu­lation strip with sufficient electric strength).
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Exchanging varistors Installation Guide
If you have not found any ground fault in the PV generators, probably one of the thermally monitored varistors has lost its protective function. The varistors are subject to wear and tear and their function is reduced in the course of their aging or in case of repeated strain placed on them by surge voltages. You can now check the varistors as described below while following the safety instructions given in chapter 2 "Safety Instructions" (p. 5).
6. Unscrew the lid of the Sunny Boy 2800i and remove it. Dis­connect the PE plug inside the lid. Test safe isolation from supply.
7. Test all varistors for an electric connection between terminals 2 and 3. If there is no electric connection the varistor is use­less. The position of varistors in the Sunny Boy 2800i can be seen in the figure in chapter 3.1 "Device Description" (p. 7).
8. Replace the defective varistor by a new one as shown in the figure on the left. Ensure correct orientation of the varistor! Please contact SMA if you have not received special tools to move the terminals (included in delivery of replacement varistors). However, the terminal contacts can also provisio­nally be released one by one with a suitable screwdriver. The failure of a varistor is normally due to circumstances that apply to all varistors in a similar manner (temperature, age, induced surge voltages). We therefore strongly recommend not only to exchange the defective one, but all two. These varistors are specially manufactured for use in the Sunny Boy 2800i and are not commercially available. They have to be purchased from SMA Regelsysteme GmbH direct (SMA order name:“SB-TV4“).
The input port thus modified is no longer protected against surge voltages! Equip the inverter with varistors again as soon as possible. The inverter should not be operated without varistors in plants where there is a high risk of surge voltages!

9. Reconnect the PE plug to the lid and close the Sunny Boy 2800i again.

10.Connect the faultless strings of the PV panel. Ensure correct allocation to strings.

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Installation Guide Exchanging varistors

11.Switch on the circuit breaker.

12.Check whether the LEDs of the Sunny Boy 2800i show trouble-free operation.

If you have found neither a ground fault nor a defective varistor there probably is a fault in the inverter. Please contact the SMA hotline in this case to discuss further proceedings.
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Exchanging varistors Installation Guide
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Installation Guide Contact

9Contact

If you have any questions or technical problems with the Sunny Boy 2800i our hotline will be happy to help you. Please keep the following data ready when calling SMA:
• Type of inverter used
• Connected modules
•Communication
•Serial number of device
Address: SMA Regelsysteme GmbH Hannoversche Straße 1 - 5 34266 Niestetal Germany
Tel.:+49 (561) 95 22 - 499 Fax:+49 (561) 95 22 - 4699 hotline@SMA.de www.SMA.de
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Contact Installation Guide
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SMA Regelsysteme GmbH
www.SMA.de
Hannoversche Str. 1-5 34266 Niestetal Germany Tel. +49 561 9522 -0 Fax +49 561 9522 -100 www. SMA.de
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