SMA SB 3800-U User Manual

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Installation Guide

No part of this document may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photographic, magnetic or otherwise, without the prior written permission of SMA America, Inc.

SMA America makes no representations, express or implied, with respect to this documentation or any of the equipment and/or software it may describe, including (with no limitation) any implied warranties of utility, merchantability, or fitness for any particular purpose. All such warranties are expressly disclaimed. Neither SMA America nor its distributors or dealers shall be liable for any indirect, incidental, or consequential damages under any circumstances.

(The exclusion of implied warranties may not apply in all cases under some statutes, and thus the above exclusion may not apply.)

Specifications are subject to change without notice. Every attempt has been made to make this document complete, accurate and up-to-date. Readers are cautioned, however, that SMA America reserves the right to make changes without notice and shall not be responsible for any damages, including indirect, incidental or consequential damages, caused by reliance on the material presented, including, but not limited to, omissions, typographical errors, arithmetical errors or listing errors in the content material.

Revision History

Rev. No. Date By Version

1.0 May 04, 2005 YS 1st Edition

2.0 June, 2005 JP 1st US Edition

2.1 August, 2005 JP 2nd US Edition

2.2 November, 2005 JP 3rd US Edition

2.3 February, 2006 JP 4th US Edition

2.4 May, 2006 JP 5th US Edition

SMA America, Incorporated

12438 Loma Rica Drive

Grass Valley, California 95945

Tel 530.273.4895

Fax 530.274.7271

www.sma-america.com

SB3800U-12:SE2006 SMA America i

Installation Guide

IMPORTANT SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS

This manual contains important instructions for the Sunny Boy 3800U that must be followed during installation and maintenance of the inverter.

The Sunny Boy is designed and tested according to international safety requirements, but as with all electrical and electronic equipment, certain precautions must be observed when installing and/or operating the Sunny Boy. To reduce the risk of personal injury and to ensure the safe installation and operation of the Sunny Boy, you must carefully read and follow all instructions, cautions and warnings in this Installation Guide.

Safety and Hazard Symbols

This symbol is used to call attention to important information that you must have when installing and/or operating the Sunny Boy. Failure to read and follow instructions marked with this symbol could result in injury or death and/or damage to the equipment.

This symbol appears beside instructions and warnings that deal with dangerous voltages that can injure or kill people who come in contact with them.

This symbol appears beside terminations that are connected to earth-ground.

ii SMA America SB3800U-12:SE2006

Installation Guide

Warnings

WARNING: A Warning describes a hazard to equipment or personnel. It calls attention to a procedure or practice, which, if not correctly performed or adhered to, could result in damage to or destruction of part or all of the SMA equipment and/ or other equipment connected to the SMA equipment or personal injury.

Warnings and Cautions may also be accompanied by one or more of the safety and hazard symbols described above to indicate the type of hazard described therein.

Other Symbols

In addition to the safety and hazard symbols described on the previous pages, the following symbol is also used in this Installation Guide:

This symbol accompanies notes that call attention to supplementary information that you should know and use to ensure optimal operation of the system.

All electrical installations must be done in accordance with the local and National Electrical Code ANSI/NFPA 70.

The Sunny Boy contains no user-serviceable parts except for the fan on the bottom of the enclosure and the filter behind the fan as well as the exhaust fin on the left hand side of the unit. For all other repair and maintenance always return the unit to an authorized SMA Service Center.

Before installing or using the Sunny Boy, read all of the instructions, cautions, and warnings on the Sunny Boy, the PV array, and in this Installation Guide.

Before connecting the Sunny Boy 3800U to the electrical utility grid, contact the local utility company. This connection must be made only by qualified personnel.

SB3800U-12:SE2006 SMA America iii

Installation Guide

PV arrays produce electrical energy when exposed to light and thus can create an electrical shock hazard. Wiring of the PV-arrays should only be performed by qualified personnel.

Warranty

All Sunny Boy inverters sold in the USA have a five-year warranty, as indicated on the warranty card included in the Sunny Boy shipping container. For warranty coverage, or if you have questions about the Sunny Boy warranty, contact SMA America at the address, telephone number or Web site listed on section of the SMA America Web site).

page i (to send E-mail, see the Contact

iv SMA America SB3800U-12:SE2006

Contents

Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i

Safety and Hazard Symbols . . . . . . . . . . . . . . . . . . . . . . . . . ii

Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

Other Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv

1 Introduction

Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Installation Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

2 Unpacking and Inspection 3 Mounting

Choosing a Mounting Location . . . . . . . . . . . . . . . . . . . . . . 3-1

Dimensions and Recommended Clearances . . . . . . . . . . . . .3-3

Mounting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

4 AC Voltage Configuration

Opening the Sunny Boy 3800U . . . . . . . . . . . . . . . . . .4-1

Locating Internal Components . . . . . . . . . . . . . . . . . . . . 4-2

5 Wiring the Sunny Boy 3800U

Wiring the AC Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

AC Connection Requirements . . . . . . . . . . . . . . . . . . . . 5-3

Connecting the AC Wires . . . . . . . . . . . . . . . . . . . . . . . 5-5

Wiring the DC Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

DC Connection Requirements . . . . . . . . . . . . . . . . . . . . 5-7

Connecting the DC Wires . . . . . . . . . . . . . . . . . . . . . . . 5-9

Connecting Communication Cables . . . . . . . . . . . . . . . . . .5-12

RS-232 Communication . . . . . . . . . . . . . . . . . . . . . . . 5-12

RS-485 Communication . . . . . . . . . . . . . . . . . . . . . . . 5-15

Replacing the Cover. . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

6 Commissioning 7 Displays and Messages

LED Fault Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

Status Messages on the LCD . . . . . . . . . . . . . . . . . . . . 7-11

SB3800U-12:SE2006 SMA America v

Communication Options. . . . . . . . . . . . . . . . . . . . . . . 7-14

8 Troubleshooting

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

9 Maintenance

Cleaning the Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

Cleaning the Exhaust Vent . . . . . . . . . . . . . . . . . . . . . . 9-2

Testing the Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3

10 Technical Specifications

FCC Compliance Information . . . . . . . . . . . . . . . . . . . 10-1

Sunny Boy SB3800U Wiring Diagram. . . . . . . . . . . . . 10-2

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2

vi SMA America SB3800U-12:SE2006

Section 1: Introduction

This installation guide provides all the information needed to install, commission and operate a Sunny Boy 3800U (SB3800U) grid-tied photovoltaic (PV) inverter.

Note: To help avoid problems during the installation, familiarize yourself with the installation process by reading the entire Installation Guide before starting the installation.

WARNING: Lethal voltages are present at various points in a PV system. For safety reasons, it is recommended that only qualified personnel install and operate this equipment.

Product Overview

The SB3800U is a DC to AC grid-tied utility interactive inverter for use with photovoltaic (PV), fuel cell, wind turbine and other sources of DC power.

In general, the SB3800U takes power from a DC source (PV modules) and converts it to AC power for the utility grid. This power is delivered first to local loads (household appliances, lights, motor loads, etc.), with any excess power fed to the utility. The power consumed by the local loads reduces the power needed from the utility. Excess power may actually “spin the utility meter backwards” depending on the type of meter in your system. This power may also be recorded as power credits by the utility company depending on the interconnection agreement. An example of basic system components is shown in

Figure 1-1.

Meter

B e t r

i e

b O p e

E r d s

lu E

s r t

h F a

S t ö r

u n

g Fa il u

PVArray

Sunny Boy 3800U

Utility Grid

Figure 1-1 SB3800U Installed in a Utility Interactive PV System

SB3800U-12:SE2006 SMA America 1-1

Note: Policies vary from one utility company to another. Consult with a representative of the local utility company before designing and installing a PV system.

Safety

Anti-Islanding Protection

Islanding is a condition that can occur if the utility grid is disconnected while the SB3800U is operating and the remaining load is resonant at 60 Hz and matches the output of the SB3800U perfectly. This condition is highly unlikely and had never been witnessed outside of a controlled laboratory. Nevertheless, the SB3800U incorporates an advanced active islanding protection algorithm to insure that the system will not export power into a balanced 60 Hz resonant load while the utility is disconnected. The SB3800U periodically injects both leading and lagging reactive current into the utility grid. This method has been proven by U.S. regulatory agencies to effectively destabilize and disconnect from a balanced island condition.

PV Ground Fault Detection and Interruption

The SB3800U is equipped with a ground fault detection device. If a ground fault current greater than 1 Amp is detected, the SB3800U will shut down and display the fault condition on the user interface display. Once the ground fault is located and corrected, the ground fault error will need to be manually cleared and the inverter will then resume normal operation.

PV Series Fusing

Series fusing may be required depending on the type of PV module used in the system. See NEC 690.9

Interconnection Code Compliance

The SB3800U has been tested and certified by ETL to meet the requirements of UL1741 Static Inverters and Charge Controllers for use in Photovoltaic Power Systems as well

as IEEE-929-2000 Recommended Practice for Utility Interface of Photovoltaic Systems and IEEE 519 Standard Practices and Requirements for Harmonic Control in Electrical Power Systems. The SB3800U is also ETL listed under UL1741 for use in Canada.

1-2 SMA America SB3800U-12:SE2006

UL1741 is the standard applied by ETL to the Sunny Boy 3800U to certify that it meets the requirements of the NEC and IEEE-929-

2000. IEEE 929-2000 provides recommendations regarding the proper equipment and functionality necessary to ensure compatible operation when power generation is connected to the utility grid.

Note: Contact the local utility and/or the authority having jurisdiction prior to connecting the SB3800U to the utility grid.

FCC Compliance

The SB3800U has been tested and certified by a nationally recognized testing laboratory and conforms to all FCC Part 15 B EMI/EMC emissions regulations.

Feature Overview

Over twenty years of inverter manufacturing experience has gone into the design of the SB3800U. As a result, the SB3800U represents state-of-the-art technology, high reliability and overall ease of use - all the qualities you’ve come to expect from SMA, the industry leader in inverter technology. Some of the features included are:

•LCD

• Temperature regulated fan cooling - simple replacement

• Auto line voltage detection and configuration

• Advanced communication options available

• Compatible with all SMA inverter and communication products

• High efficiency

• Simple installation

• Powder coated diecast enclosure

Operating Temperature

The SB3800U has been designed to maintain full power output with ambient temperatures as high as 45°C. Fan cooling allows this level of output power to be achieved even in enclosed spaces. The SB3800U will continue to operate well beyond 45°C and derates as needed to maintain a safe internal component temperature.

SB3800U-12:SE2006 SMA America 1-3

Installation Overview

This section provides a high-level overview of the installation process so you have an idea what to expect as you proceed through the rest of the Installation Guide.

The installation process is broken down into the following tasks:

Section 2: Unpacking and Inspection

This section provides instructions and information for unpacking the SB3800U and inspecting it for shipping damage.

Section 3: Mounting

This section includes guidelines to help you select the best mounting location, suggestions to insure optimum performance, cautions and warnings that you should follow to avoid injury and/or equipment damage and step-by-step instructions for mounting the SB3800U inverter.

Section 4: Input Voltage Configuration

This section includes information on removing the cover, locating primary components within the inverter and selecting the appropriate voltage configuration for the installation.

Section 5: Wiring the Sunny Boy 3800U

This section includes guidelines for selecting the correct wire sizes, cautions and warnings that you should follow to avoid injury and/or equipment damage and stepby-step instructions for wiring the SB3800U to a PV array, household electrical circuits and the utility grid. Procedures are also included for connecting optional datacommunication cables.

Section 6: Commissioning

Commissioning involves applying DC input power to the SB3800U, observing the LED and LCD indicators on the front cover, and resolving any problems that occur.

Section 7: Displays and Messages

This section provides troubleshooting tips and procedures for resolving problems that may occur during installation and operation.

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Section 2: Unpacking and Inspection

All Sunny Boy inverters are thoroughly tested and inspected before they are packed and shipped. Although they are shipped in sturdy, recyclable packaging; damage can still occur during shipping. It is important to carefully inspect the shipping container prior to beginning the installation. If any external damage to the packaging makes you suspect the inverter itself could be damaged, or if you find that the inverter is damaged after unpacking it, report the damage immediately to your SMA dealer and to the shipping company that delivered the Sunny Boy. If it becomes necessary to return the Sunny Boy, use the original packaging in which it was delivered.

WARNING: The Sunny Boy 3800U weighs 85 lb. (38 kg). To avoid injury, be sure to use proper lifting techniques and secure the help of someone to assist in the unpacking and installation of the inverter.

If you need assistance with a damaged Sunny Boy, contact your SMA dealer or SMA America. Contact information for SMA America is provided below.

SMA America, Incorporated 12438 Loma Rica Drive Grass Valley, California 95945 Tel 530.273.4895 Fax 530.274.7271 www.sma-america.com

SB3800U-12:SE2006 SMA America 2-1

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Section 3: Mounting

This section provides guidelines to help you select the best mounting location, suggestions to insure optimum performance, cautions and warnings that you should follow to avoid injury and/or equipment damage, and step-by-step instructions for mounting a SB3800U inverter.

WARNING: The SB3800U weighs 85 lb. (38 kg). To avoid injury, be sure to use proper lifting techniques and secure the help of someone to assist in the unpacking and installation of the inverter.

Note: Occasionally, the rating label on the SB3800U will need

to be referred to. For this reason, it is required that the inverter be mounted so that the rating label on the side of the inverter be visible.

Choosing a Mounting Location

Consider the following guidelines, cautions, and warnings when choosing a mounting location for the SB3800U:

• Do not install the SB3800U in direct sunlight. External heating from exposure to the sun may cause excessive internal heating. This can result in derated output power to protect the internal components from damage.

• Install the SB3800U in a location that maintains an ambient air temperature that is less than 45°C. To maintain a safe internal component temperature, the SB3800U may reduce its power output if the ambient air temperature exceeds 45°C. (The cooler the air temperature, the longer the life expectancy of any power electronics device.)

• The SB3800U is constructed in a rugged powder coated aluminium enclosure designed for outdoor installations. However, care should always be taken to minimize exposure to the elements. It is best to minimize exposure to rain, snow and ice, etc. Do not install the SB3800U in a location exposed to sources of direct water spray such as sprinklers or downspouts.

• The inverter should be installed in a location that is inaccessible to children.

• The SB3800U may emit a slight vibrating noise when operating. This vibration is normal and has no effect on performance, but it may be noticeable if the inverter is mounted on a wall in a living area, on the outside of a wall that is near a living area, or on certain types of materials, such as thin wood panelling or sheet metal.

SB3800U-12:SE2006 SMA America 3-1

• If the inverter is installed outside, it should be mounted vertically or tilted back. (See Figure 3-1).

Vertical

(Best option)

Tilted Back

(Acceptable)

Figure 3-1 Sunny Boy Mounting Positions

CAUTION: The SB3800U weighs 85 lb. (38 kg.). Ensure that the mounting surface is strong enough to hold the weight of the SB3800U. Do not mount the Sunny Boy on plasterboard (sheet-rock) or thin wood panelling.

CAUTION: All electrical conduits and any communication cables must be positioned and/or sealed so that no water can enter the inverter enclosure through these conduits and cables.

CAUTION: Do not install the SB3800U during periods of precipitation or high humidity (>95%). Moisture trapped within the enclosure may cause corrosion and damage to the electronic components.

Tilted Forward

(Unacceptable)

CAUTION: If you are installing the Sunny Boy in a cabinet, closet, or other relatively small enclosed area, you must provide sufficient air circulation to dissipate the heat generated by the inverter.

WARNING: To prevent electrical shock or other injury, check for existing electrical or plumbing installations in the walls before drilling mounting holes for the Sunny Boy.

CAUTION: Outdoor installations must use raintight or wet location hubs that meet the requirements of the Standard for Fittings for Cable and Conduit, UL514B.

3-2 SMA America SB3800U-12:SE2006

Dimensions and Recommended Clearances

The outer dimensions of the SB3800U are shown in Figure 3-2. The SB3800U must be mounted so that there is at least eight inches of clearance around it.

236 mm

(9.3 in)

Figure 3-2 Outer Dimensions of the SB3800U

CAUTION: You must ensure that there is sufficient clearance for the flow of the air around the SB3800U! In a normal operating environment with good ventilation, eight inches of clearance is adequate.

Note: The National Electrical Code may require significantly larger working clearances (see NEC Section 110.26).

452 mm

(17.80 in)

Betrieb Operation

Erdschluss Earth Fault

Störung Failure

351 mm

(13.83 in)

SB3800U-12:SE2006 SMA America 3-3

434,60 mm (17,12 in)

250 mm (9,85 in)

75 mm (2,95 in)

349,3 mm (13,76 in)

Figure 3-3 Dimensions of the Wall Mounting Bracket

178,9 mm (7,05 in)

104 mm (4,09 in)

3-4 SMA America SB3800U-12:SE2006

Mounting Procedure

The SB3800U is shipped with a removable mounting plate. This plate is also the wallmounting bracket suitable for use on most material (see holes for mounting to wooden stud wall panels. Make sure that the wall you choose to mount the Sunny Boy on is sturdy enough to support the weight (38 kg/85 lb.) and that the wall is plumb. The bracket may also be mounted on stone, brick or solid walls. Be sure to use the appropriate type of mounting hardware for the wall material and ensure that the hardware is no smaller than 1/4” diameter.

Figure 3-4). The plate has three

Stone wall mounting

B etrie

b O pe

ration

Erdschlus Ea

B e tr

b O p

o n

E r d

l u

a u l

S t ö

g Fa i

l u r e

th Fault

Störung Failure

Figure 3-4 SB3800U with removable mounting plate

Wood wall mounting

SB3800U-12:SE2006 SMA America 3-5

Figure 3-5 Mounting the SB3800U

Use the following procedure to mount the SB3800U:

1. Locate the mounting plate included in the shipping container with the SB3800U.

2. The holes in the mounting plate are sealed with plastic plugs. Remove the plastic plugs for only the holes used.

3. Position the mounting plate against the wall where you intend to mount the SB3800U. (Try to mount the SB3800U so that the display is approximately at eyelevel.) Place a level on the top edge of the mounting plate, and adjust the position of the mounting plate until it is level. The bottom of the mounting plate will be equal to the approximate location of the bottom of the inverter.

4. Using the mounting plate as a template, mark the wall through three holes in the mounting plate. (See Figure 3-4)

CAUTION: Ensure that there are studs in the wall at the places where you intend to drill the mounting-holes. DO NOT use molly or toggle bolts to mount the SB3800U to sheet rock or panelling.

5. Set the mounting plate aside temporarily, and drill holes at the marks on the wall.

3-6 SMA America SB3800U-12:SE2006

Note: The diameter of the holes you drill must match the hardware you are using to mount the SB3800U. For example, if you are mounting the SB3800U to a concrete wall, the hole diameter should be approximately the same as the outside diameter of the concrete anchors you intend to use. If you are mounting the SB3800U on a wall that has wooden studs inside it, the hole diameter should be the correct size for the lag screws you intend to use to mount the plate. If you are installing the SB3800U outside, it is recommended that the lag screws be made of stainless steel, and the diameter of the screws closely match the diameter of the holes in the mounting plate. Make sure that the screws are long enough to penetrate the wall to a depth of 1 and 1/2 inches.

6. Insert the screws through the holes in the mounting plate and into the holes you drilled in the wall. Tighten the screws until the mounting plate is held firmly against the wall. Do not overtighten the screws.

WARNING: The SB3800U weighs 85 lb. (38 kg). To avoid injury, be sure to use proper lifting techniques and assistance in the unpacking and installation of the inverter.

7. Carefully lift the SB3800U onto the mounting bracket. There are two small slots in the top of the SB3800U. These slots sit on the pair of tabs on the top edge of the mounting plate. Mount the SB3800U so that it hangs on these tabs. (see #2 in Figure 3-5).

8. Inspect the SB3800U from both sides to ensure that the channels on the back of the SB3800U sit completely on the tabs on the top edge of the mounting bracket and that the SB3800U is centered on the bracket.

9. Insert the hex screw and lock washer (included in the accessories package) in the hole in the bottom of the SB3800U (#3 in Figure 3-5).

10.Tighten the screw to 44 inch pounds or 5 Nm. (Do not overtighten)

11.Verify that the SB3800U is securely mounted.

12.Snap the left and right exhaust fins into the SB3800U (Look for the L & R on the inside of the fins.)

SB3800U-12:SE2006 SMA America 3-7

3-8 SMA America SB3800U-12:SE2006

Section 4: AC Voltage Configuration

Opening the Sunny Boy 3800U

Remove the four screws and lock washers that attach the cover of the SB3800U. Place the cover, screws, and lock washers aside where they will be out of your way while connecting the wires and cables to the Sunny Boy.

CAUTION: Be careful not to misplace the screws or the lock washers, as all four screws and lock washers are required to ensure that the cover is grounded properly and is fully sealed to the case. Handle the cover carefully, as even minor damage to the cover could result in an inadequate seal between the cover and the case, thus allowing moisture to enter the case and damage the sensitive electronic components.

CAUTION: Do not install the SB3800U during periods of precipitation or high humidity (>95%). Moisture trapped within the enclosure may cause corrosion and damage to the electronic components.

SB3800U-12:SE2006 SMA America 4-1

Locating Internal Components

Figure 4-1 illustrates the locations of the major internal components of the SB3800U. Refer to this illustration as needed to locate particular components.

Terminal for optional communication (RS-232 or RS-485)

GFDI

Fuse Holder

Terminals (PE) for

Communication

Firmware EEPROM

Ground

(input from

PV array)

DC+

Terminal

Sockets for optional

communication Piggy-Back

(RS-232, RS-485, powerline or radio)

Display

Status LEDs

L2 N

Ground Terminal (PE)

DC–

Terminal

(input from

Output AC Line Terminals (N, L1 and L2)

PV array)

Figure 4-1 SB3800U Internal Components

4-2 SMA America SB3800U-12:SE2006

Utility Configuration Jumpers

The SB3800U comes from the factory pre-configured for utility interconnection with neutral. The SB3800U may be reconfigured for grids without neutral by setting the jumpers on the board of the SB3800U.

The utility configuration jumpers allow the SB3800U to be connected to transformers where the neutral is not present, such as the 208V and 240V Delta, shown in

Figure 4-

3. Refer to the figure below for a description of jumper settings.

Display

240 / 208 VAC (Default) (With Neutral)

208V Delta, No Neutral.

240V Delta, No Neutral.

Fan Test.

Figure 4-2 Utility Configuration Jumpers

The SB3800U may be configured for two different grid types commonly found in the U.S. The SB3800U is compatible with:

• 208 V AC output

• 240 V AC output ("split-phase" or open delta)

SB3800U-12:SE2006 SMA America 4-3

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Figure 4-3 Common Utility Voltage Configurations

Remember, when connecting the SB3800U to the utility, the phase relationship is not important, but the voltage must be compatible.

4-4 SMA America SB3800U-12:SE2006

240 Delta : 120 Stinger

Inverter 3

Jumper Settings

240 V

Jumper Settings

Inverter 2

120 V

240 V

120 V

240 V

Inverter 1

Jumper Settings

Figure 4-4 Utility Configuration Jumper Examples

The figure above illustrates the proper jumper settings when connecting to a 240 Delta : 120V Stinger type transformer. Note the order in which inverters are connected to the phases.

SB3800U-12:SE2006 SMA America 4-5

4-6 SMA America SB3800U-12:SE2006

Section 5: Wiring the Sunny Boy 3800U

This section provides step-by-step procedures and other information required for wiring the SB3800U to the PV array and the utility grid. To complete the installation in a safe and efficient manner, complete the steps in the order that they appear.

WARNING: Before connecting or operating the SB3800U, read all of the instructions, cautions, and warnings on the SB3800U, the PV array and in this Installation Guide.

WARNING: You must connect the wires that carry the AC voltage from the SB3800U to the utility grid and the wires that carry the DC voltage from the PV array to the SB3800U in the order described in the procedures in this section. Deviating from these procedures could expose you to lethal voltage that can cause serious injury.

WARNING: Always turn OFF all breakers and switches in the PV system before connecting any wires to or disconnecting any wires from the SB3800U.

WARNING: Always connect the wires to the SB3800U in the following sequence:

1. De-energize all energy sources by opening all AC and DC disconnects and/or

breakers.

2. Connect wires from the AC breaker to the AC disconnect switch.

3. Connect wires from the AC disconnect to the SB3800U.

4. Connect the PV wires to the DC disconnect.

5. Connect the DC disconnect wires to the SB3800U·

6. Turn the AC switches and/or breakers ON.

7. Turn the DC switches and/or breakers ON.

To disconnect the SB3800U, first turn OFF all AC disconnects and then all DC disconnects. The AC system should always be disconnected before the DC

SB3800U-12:SE2006 SMA America 5-1

system. After the SB3800U is de-energized, disconnect the wiring in the reverse order from above.

WARNING: Always wait a minimum of 5 minutes for stored potentials in the SB3800U to discharge completely before opening the enclosure.

WARNING: All electrical installations must be done in accordance with all local electrical codes and the National Electrical Code (NEC), ANSI/NFPA 70.

WARNING: Before connecting the SB3800U to the electrical utility grid, contact the local utility company. This connection must be made only by qualified personnel.

The internal AC and DC wiring terminals (see Figure 5-3) accept a maximum wire size of #6 AWG. Knockouts are provided on the bottom of the SB3800U near each of the terminals for the wires to enter the case (see Figure 5-6).

GFDI Fuse

1/2” Communication Cable

Gland

3/4” DC Knockout

3/4” AC Knockout

Figure 5-1 SB3800U showing wiring knockout locations

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CAUTION: The AC and DC knockouts in the SB3800U chassis are sized for 3/4-inch rigid conduit (EMT). DO NOT enlarge any of these holes, as this is may violate the listing and will void the SMA warranty.

Terminal in. lbs. nm.

AC & DC Terminal Blocks 18 2

Cover Screws 79 9

Wiring the AC Output

This subsection provides complete, step-by-step procedures for wiring the AC output from the SB3800U to the utility grid.

AC Connection Requirements

WARNING: All electrical installations must be done in accordance with all local electrical codes and with the National Electrical Code (NEC), ANSI/NFPA 70. Use #8 AWG (maximum), 90 °C (194 °F), copper wire for all AC wiring connections to the Sunny Boy 3800U. Voltage drop and other considerations may dictate that larger size wires be used.

WARNING: The National Electrical Code (NEC) states that the inverter must be connected to a dedicated circuit, and that no other outlets or devices can be connected to the same circuit. See NEC Section 690-64(b)(1). The NEC also imposes limitations on the size of the inverter and the manner in which it is connected to the utility grid. See NEC Section 690-64(b)(2).

The diagram in Figure 5-2 shows the potential losses in AC wires with respect to the cross-sectional area of the cable and the length of the cable. Use the following tables to determine the best wire size to use for your particular installation.

SB3800U-12:SE2006 SMA America 5-3

Percent voltage drop for 208 V AC and 240 V AC service

2,0%

12 AWG

1,6%

10 AWG

8 AWG

1,2%

0,8%

0,4%

6 AWG

Percent of 208 V AC and 240 V AC

0,0%

20 40 80 120 160 200 240

60 1000 140 180 220

One way distance (feet)

Figure 5-2 Energy Losses in Various Wire Sizes and Wire Lengths

The SB3800U is designed to automatically detect which grid voltage it is feeding if a neutral is connected to the inverter. Depending upon the voltage and phase angle between L1-N and L2-N, the inverter will determine if it is connected to a 208 V or 240 V grid.

Table 5-1 Voltage and Frequency Limits for the AC Connection

Table 5-1 lists the voltage and frequency limits for the AC connection.

Voltage Range for 208 V nominal, line to line 183 V - 229 V Voltage Range for 240 V nominal, line to line 211 V - 264 V

Frequency Range 59.3 Hz - 60.5 Hz

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Connecting the AC Wires

Use the following procedure to connect the AC wires to the SB3800U:

WARNING: You must connect the wires that carry the AC voltage from the SB3800U to the utility grid in the order described in this procedure. Deviating from this procedure could expose you to lethal voltages that can cause serious injury and/or death.

1. Turn OFF the main breaker in the main utility breaker panel.

2. Remove interior breaker panel cover.

3. If you are replacing an existing inverter, disconnect the wires for the AC line you

are working with in the breaker box.

4. Install a 3/4-inch conduit fitting in the SB3800U’s AC wiring knockout (the

knockout on the right side of the SB3800U, as shown in Figure 5-1). Fasten the conduit fitting on the inside of the SB3800U with the appropriate locknut.

5. Install 3/4-inch conduit between the main breaker panel and the SB3800U’s AC

wiring knockout.

6. Pull the AC wires through the conduit from the interior of the breaker panel to the

interior of the SB3800U.

Note: Refer to Figure 5-4 on page 5-7 for steps 7 through 10.

CAUTION: Avoid using wire nuts to join any wires together or to make any connections anywhere in the PV system. Wire nuts are a frequent cause of unreliable, resistive connections, and ground faults.

7. Connect the AC equipment-ground wire to the terminal labeled PE in the

SB3800U.

8. Connect the L1 (AC line 1or HOT) wire to the terminal labeled L1 in the SB3800U.

9. Connect the L2 (AC line 2) and N (AC line N) wire to the terminal labeled L2 and

N in the SB3800U.

10. Connect the wires and tighten to a torque of 18 in-lb.

11. Verify that all connections are correctly wired and properly torqued.

SB3800U-12:SE2006 SMA America 5-5

N wire connected to N terminal

L2 wire connected to L2 terminal

L1 wire connected to L1 terminal

Figure 5-3 AC Connection Terminals

Equipment ground wire connected to PE terminal

L2 N

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Wiring the DC Input

This subsection provides procedures for wiring the DC input from the PV array (via the DC disconnect enclosure) to the SB3800U. diagram of a PV system.

Figure 5-4 shows a simplified wiring

600 V DC

DC-breaker and

combiner box

Betrieb Operation

Erdschluss Earth Fault

Störung Failure

Figure 5-4 Simplified Electrical Wiring Diagram of a PV System

DC Connection Requirements

WARNING: All electrical installations must be done in accordance with all local electrical codes and with all local electrical codes and with the National Electrical Code (NEC), ANSI/NFPA 70. For installation in Canada the installations must be done in accordance with applicable Canadian standards. Use #10AWG (minimum), 90 degC, copper wire for all DC wiring connections to the Sunny Boy. Voltage drop an other considerations may dictate that larger size wires be used.

Note: Use the online SMA string size calculator at

www.sma-america.com to determine the correct string configuration (see Figure 5-5).

208 or 240 V AC 60 Hz System via Approved Disconnect

Note: Series fusing may be required depending on the type of PV module used in the system. See NEC 690.9.

SB3800U-12:SE2006 SMA America 5-7

Figure 5-5 Online String-Configuration Calculator at www.sma-america.com

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Connecting the DC Wires

WARNING: You must connect the wires that carry the DC voltage from the PV array to the Sunny Boy 3800U in the order described in the following procedure. Deviating from this procedure could expose you to lethal voltages that can cause serious injury and/or death.

WARNING: PV arrays are energized when exposed to light. Use safe working practices when working on PV arrays.

WARNING: Always turn OFF all AC and DC breakers and switches in the PV system and wait a minimum of 5 minutes for the SB3800U to completely discharge before connecting any wires to the SB3800U or disconnecting any wires from the SB3800U. Failure to do so could expose you to lethal voltages that can cause serious injury and/or death.

CAUTION: Verify the polarity and the open-circuit voltage from the PV strings before you connect the DC wires to the SB3800U. Applying an open-circuit DC-input voltage that exceeds the maximum DC-input-voltage range will cause irreversible damage to the SB3800U and void the warranty! Always verify the DC voltage before connecting the DC-input wires from the PV array to the SB3800U. (See the online SMA string size calculator at www.smaamerica.com to determine the correct string configuration as shown in Figure 5-5.)

SB3800U-12:SE2006 SMA America 5-9

Check both the polarity

and the open-circuit

voltage from the PV strings!

Use the following procedure to connect the DC wires to the Sunny Boy 3800U:

1. Verify that the AC breaker is OFF.

2. Verify that the DC disconnect is OFF.

3. Install a 3/4-inch conduit fitting in the SB3800U’s DC wiring knockout. (See Figure

5-1and Figure 5-6). Fasten the conduit fitting on the inside of the SB3800U with the appropriate locknut.

4. Install 3/4-inch conduit between the DC disconnect enclosure and the SB3800U’s

DC wiring knockout.

Note: Refer to Figure 5-6 for steps 5 through 7.

Positive DC wire connected to DC+ terminal

Negative DC wire connected to DC- terminal

Figure 5-6 DC Connection Terminals

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5. Pull the DC wires from the DC disconnect through the conduit into the interior of the

SB3800U.

6. Connect the positive DC wire to the terminal labeled DC+ in the SB3800U.

7. Connect the negative DC wire to the terminal labeled DC– in the SB3800U.

Note: The SB3800U has provisions for up to two PV strings. The positive and negative terminal blocks each have two positions, so two pairs of DC-input wires can be connected in parallel.

CAUTION: Avoid using wire nuts to join any wires together or to make any connections anywhere in the PV system. Wire nuts are a frequent cause of unreliable connections, resistive connections, and ground faults.

8. Connect the positive and negative DC wires to the appropriate terminals in the DC

disconnect enclosure.

9. Connect the DC equipment ground wire to the terminal labeled PE in the SB3800U.

10. Torque all AC and DC wires in the SB3800U to 18 in-lb.

11. Verify that all connections are correctly wired and properly torqued.

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Connecting Communication Cables

Various data-communication options are available for the SB3800U. These options are provided in the form of accessory Piggy-Back modules that can be installed and connected either at the time the inverter is installed or at any time thereafter. These modules are not included with the SB3800U. Please contact SMA America for information. Refer to the instructions included with the communication module for installation procedures.

The following subsections provide instructions for connecting the various communication cables between a SB3800U with a communication module and a personal computer (PC). The connection of a SB3800U to a Sunny Boy Control or a Sunny Beam wireless monitoring unit is shown in those respective manuals.

RS-232 Communication

RS-232 is a communication standard for bidirectional transmission of data between a Sunny Boy and a PC. Only one Sunny Boy can be connected with an RS-232 serial cable to a PC.

Requirements for RS-232 Communication:

• The SB3800U must be equipped with an RS-232 Piggy-Back communication module.

• The cable should be no longer than 15 meters (50 ft.) Use the cable type specified in the RS-232 Tech Note on www.sma-america.com.

• RS-232 cables are available from SMA America.

• Conduit may be required for communication wiring, per local electrical code requirements.

Connecting an RS-232 Cable

Use the following procedure to install an RS-232 data-communication network:

1. Run the communication cable from the location of the PC to the SB3800U.

2. Verify that the PC has a serial port and that it is activated in the BIOS and the

operating system.

3. Attach the appropriate DB-9 connector to the end of the cable near the PC. See

Table 5-2 and Figure 5-7 for the pin assignments for the serial connector. Record the wire color used for each of the pins listed in Table 5-2.

4. Route the other end of the cable into the SB3800U through the communication-

knockout on the bottom left of the SB3800U (see Figure 5-1).

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5. Referring to Table 5-2 and Figure 5-7 and your record of the wire colors used for

each pin from step 3, connect the appropriate wires to the communication terminal block in the SB3800U.

6. Connect the cable shield to the SB3800U’s case. (See Figure 5-7) Do NOT connect

the cable shield to the PC’s DB-9 connector. The shield must remain floating at the PC.

CAUTION: All AC and DC power should be off when connecting the communication wiring to the SB3800U.

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Table 5-2 RS-232 Pin Assignments

Communication Terminal

Block (SB3800U)

Case Shield Case Case

2 RxD

3 TxD

5 GND 5 7

B e tr i

b O p e r

E r d s

u E

s a

s r t h

F a u

S t ˆ r u

g F a i l u

Signal Name

(Output from

Sunny Boy)

(Input to Sunny

Boy)

3 2

9-Pin Serial-Port

25-pin Serial-Port

Connector (PC)

2 3

3 2

PC running Sunny Data

3 2

RS-232 Piggy-Back communication module

No jumper installed for RS-232 communication

Connector (PC)

Terminal block for

RS-232 communication

Ground terminal (PE)

C B A

2357

L2 N

for communication

Figure 5-7 Connecting a SB3800U to a PC with an RS-232 Cable

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RS-485 Communication

RS-485 is a communication standard for bidirectional transmission of data between one or more Sunny Boy inverters and a PC.

Note: All Sunny Boy inverters are capable of RS-485 communication. You can mix different Sunny Boy models on the RS-485 communication bus.

Requirements for RS-485 Communication:

• The Sunny Boy 3800U must be equipped with an RS-485 Piggy-Back communication module.

• The cable should be no longer than 1200 meters (4000 feet) with a common shield, and a wire size no smaller than 24 AWG. Use the cable type specified in the RS485 Tech Note on www.sma-america.com.

• RS-485 cables are available from SMA America.

• Conduit may be required for communication wiring, per local electrical code requirements.

Connecting an RS-485 Cable

Use the following procedure to install an RS-485 data-communication network:

Note: The following steps describe how to connect one or more Sunny Boy inverters to an RS-485 bus. For more information on connecting more than one inverter to an RS485 bus, please see “Technical Note: RS-485 Communication” in the Tech Updates section of our web site at www.sma-america.com

1. Connect the three wires of the RS-485 cable to terminals 2, 5, and 7 of the

communication terminal block as shown in Figure 5-8. Record the wire color used for each of the terminals. Two communication knockouts are provided for connecting multiple Sunny Boys on an RS-485 communication bus.

2. Connect the shield of the cable to the Sunny Boy 3800U’s case. (See Figure 5-8)

Do NOT connect the cable shield to the PC’s DB-9 connector. The shield must remain floating at the PC.

3. Install a jumper in position A, the bottom set of pins on the communication jumper

block, to set it for termination. (See Figure 5-8)

SB3800U-12:SE2006 SMA America 5-15

Note: The termination of the other end of the RS-485 cable will depend on what type of device you’re connecting to. For detailed information, please see the Tech Updates section of our web site at www.sma-america.com There you will find technical information on all of the Sunny Boy communication options.

Jumper Configuration for RS-485 Communication:

RS-485 Piggy-Back Communication Module

Signal Symmetry and Termination Jumpers

Terminal Block for

RS-485 Connections

Jumpers B & C Installed:

Jumper A installed:

Installing these jumpers puts 680 Ohm

symmetry resistors between pin 2 (Data+) and +5V and between pin 7 (Data-) and Ground.

Installing this jumper puts a 120 Ohm termination resistor across pin 2 (Data+) and pin 7 (Data-).

2357

L2 N

NOTE: Install jumpers B & C after the inverter is on

the RS-485 bus and only if symmetry of the signal is required. (Symmetry is already provided by the Sunny Boy Control products)

Install jumper A only, if the inverter is on one of the ends of the RS-485 bus.

Figure 5-8 Detail of RS-485 Termination and Jumper Settings

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RS-485 Pinouts

2 - A (+) (Data+)

7 - B (-) (Data-)

5 - SR (Signal Ref.)

Replacing the Cover

When you have finished connecting the AC-output wires, the DC-input wires, and the communication cables, re-check all your connections to ensure that everything is in the right place and that all connections and knockout fittings are secure and properly torqued. Check all of the knockout fittings on the bottom of the SB3800U to ensure that they provide a weather-tight seal.

WARNING: Never install the SB3800U during rain or very damp conditions. Because the SB3800U has a rain proof enclosure, you must be sure no moisture is trapped inside the enclosure when securing the lid.

CAUTION: washers that attach the cover to the case, as all four screws and lock washers are required to ensure that the cover is grounded properly and is fully sealed to the case. Handle the cover carefully, as even minor damage to the cover could result in an inadequate seal between the cover and the case, thus allowing moisture to enter the case and damage the sensitive electronic components.

Use the following procedure to replace the cover on the SB3800U:

1. Check wire routing to ensure that no wires can interfere with proper sealing of the

cover and that no pressure will be exerted on the connections when the cover is replaced.

2. Locate the four screws and lock washers you removed to take the cover off the

SB3800U. Make sure you have all four screws and lock washers, as all of this hardware is necessary to ensure proper grounding and a weather-tight seal.

3. Carefully position the cover on the front of the SB3800U so that the four holes in

the cover are aligned correctly with the four threaded holes in the case.

Note: Be sure when reinstalling the four screws that the lock washers are installed correctly. The teeth of the washers

SB3800U-12:SE2006 SMA America 5-17

Be careful not to misplace the screws or the lock

should face towards the LID.

4. While holding the cover in place, carefully insert the four screws with lock washers

through the holes in the cover into the threaded holes in the case and turn them until they are finger-tight. Be careful not to cross-thread any of the screws. Do not use power tools to start the screws.

5. Verify that the cover is in the correct position and that the seal is in place between

the case and the cover.

6. Tighten the cover screws to a torque of 79 lb-in. (9 nm.)

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Section 6: Commissioning

WARNING: Follow the steps in the commissioning procedure in the order they are presented. Deviating from these procedures could expose you to lethal voltages that can cause serious injury and/or death.

WARNING: never insert the GFDI fuse into the SB3800U without the fuse holder base. Lethal voltage may still be present and electric shock may result.

CAUTION: Follow the steps in the commissioning procedure in the order they are presented. Deviating from these procedures could cause irreversible damage to the SB3800U and void the warranty.

All Sunny Boy inverters have a sophisticated system for detecting and responding to PV array ground faults as required by NEC Section 690.5. The PV array normally operates in a grounded configuration. The array’s negative conductor is connected to the grounding system inside the inverter as a part of the UL1741 Listed ground-fault detection system. The GFDI protection is active whenever there is sufficient DC voltage to turn on the LCD in the SB3800U.

To commission the SB3800U, follow these simple instructions:

1. Connect the grid voltage to the SB3800U by switching on the main AC circuit

breaker in the main utility panel.

2. Switch the DC disconnect to the on position. If there is sufficient sunlight available,

the Sunny Boy 3800U will enter the “Wait“ mode at this time and the green LED will begin to blink.

3. If no AC faults are detected, the “Wait“ mode will end after approximately 20

seconds and the green LED will stop blinking, remain on and the SB3800U will begin to operate normally. If an AC fault was registered, the SB3800U will wait 5 minutes prior to starting.

SB3800U-12:SE2006 SMA America 6-1

Note: If there is a ground fault in the array, the „EarthCurrentMax“ error message will be displayed and the GFDI fuse may clear. If this error message is encountered, switch off the DC and AC disconnects to the SB3800U and troubleshoot the array.

Note: If there is adequate solar irradiation and the resulting PV input voltage is sufficient, the SB3800U will automatically begin feeding power to the utility grid.

Note: If the SB3800U is not operating as expected after the commissioning procedure has been completed, refer to Section 7: Displays and Messages and to Section 8 for troubleshooting assistance.

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Displays and Messages

Section 7: Displays and Messages

Each Sunny Boy inverter comes equipped with three LED status indicators. (Shown in Figure 7.1) This allows the user to determine the operating mode of the inverter at a glance. The basic definitions of the indicator lights are as follows:

The green LED indicates normal operation of the inverter.

The red LED indicates the status of the GFDI fuse, located in the holder on the underside of the inverter. If this LED is lit, the GFDI fuse has cleared or is not present.

The yellow LED indicates that there is a fault of some kind, either inside the inverter or somewhere in the PV system. The inverter will not operate until the fault has been corrected. The different error codes and possible causes are described later in this section and in Section 8: “Troubleshooting”.

The red and yellow LEDs combined indicate that the inverter has detected a ground fault. The ground fault must be located and cleared and the inverter reset manually. The inverter will not restart automatically after detecting a ground fault. The ground fault may also clear the GFDI fuse.

Note: All GFDI faults are disabled in turbine mode.

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Displays and Messages

Figure 7-1 The Sunny Boy LED Status Indicator

Betrieb Operation

Erdschluss Earth Fault

Störung Failure

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Displays and Messages

LED Operation Indicators

Standby (Night)

All LEDs are off

The inverter is in standby mode because the DC input voltage is too low for operation or no DC is connected.

Initialization

All LEDs are on

The inverter is initializing. The power from the array is sufficient to initialize control power, but not yet powerful enough to begin normal operation. Data transmission is not possible during initialization.

Occasionally, during inclement weather or low irradiation, the LEDs may all turn on at once and then go off again. This indicates that the inverter is trying to initialize but the power available from the array is not sufficient for normal operation. This is not a malfunction.

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Displays and Messages

Starting

Green LED blinks 3 times per second

The inverter has sufficient DC voltage to initialize its internal systems, but not enough to begin normal operation. Typically, the calibration lasts less than 10 seconds and then the inverter resumes normal operation. DC voltage must remain greater than the PV Start Voltage setting for the period of the T-Start parameter setting. (See Section 8) The inverter will also show this status if it has been manually set to STOP mode.

Waiting

Green LED blinks once per second

The inverter has determined that there is enough DC voltage to operate and is checking the condition of the grid prior to connecting.

Note: If the inverter fails to connect to the utility grid 3 times in a row, it will wait 10 minutes before the next attempt. In case of a grid failure, the Sunny Boy will wait 5 minutes before it tries to reconnect to the grid.

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Displays and Messages

Normal Operation

Green LED is on

The inverter is feeding the utility grid in either “MPP”, “Constant Voltage” or “Turbine” mode.

“MPP” Mode: The SB3800U adjusts the voltage and current from the PV array to obtain the greatest PV output power.

“Constant Voltage” Mode: The voltage from the PV array has been set to a fixed value. This value is set by using the Sunny Boy Control or the Sunny Data software. (The parameter name is “V-Const”) This mode is typically used for fuel cell or micro-hydro applications.

“Turbine” Mode: This mode is used for DC rectified motor sources with a dynamic power curve (typically wind turbines). The user can set the magnitude and slope of the curve to match a particular alternator.

Derating

Green LED is shortly off once per second

The SB3800U is designed to operate at full rated power up to 45°C ambient. The inverter will continue to operate beyond 45°C and will derate as required to maintain safe internal component temperatures. Unnecessary derating can also be caused by blocked fan intakes. For this reason the fan intakes should be inspected often and cleaned when necessary.

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Displays and Messages

LED Fault Indicators

Ground Fault

Red LED is on

Yellow LED is on

The inverter has detected a ground fault in the PV system and has disconnected from the grid. The ground fault must be located and fixed before the inverter will resume normal operation. The inverter will not restart automatically. Refer to Section 8: “Troubleshooting” for information on solving PV array ground faults.

Note: All GFDI faults are disabled in turbine mode.

Cleared GFDI Fuse

Red LED is on

The GFDI fuse located in the fuse holder on the bottom of the inverter has been cleared or is not present. This fuse is used to protect the PV system in the event of an array ground fault. Troubleshoot the PV array for ground faults prior to replacing this fuse.

CAUTION: For continued protection against the risk of fire, replace the GFDI fuse with fuses of the same type and rating only. The SB3800U is shipped with a Littelfuse KLKD 1 Amp, 600V AC/DC type fuse.

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Displays and Messages

Control System Fault

Yellow LED is permanently on

The yellow LED remains lit.

The SB3800U has detected a fault within the internal monitoring systems. When the inverter detects a fault of this kind it will no longer connect to the utility grid. To correct this, the inverter must be serviced by a qualified service technician. Contact SMA America for assistance.

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Displays and Messages

Grid Failure

Yellow LED blinks shortly twice

LED on

LED off

The signal is repeated 3 times and then starts from the beginning.

3s 1s

The yellow LED is on for 5 seconds, out for 3 seconds and then blinks twice. The code is repeated 3 times. This code sequence will repeat as long as there is a grid fault condition.

This code can be caused by any of the following conditions:

• Low Grid Voltage (<Vac Min)

• High Grid Voltage (>Vac Max)

• Low Grid Frequency (< fac Min)

• High Grid Frequency (>fac Max)

• Rapid change in grid frequency or voltage

Check the condition of the grid at the AC terminal blocks within the SB3800U. Also inspect the AC disconnect between the Sunny Boy and the grid.

CAUTION: Have the grid connection to the SB3800U checked only by qualified personnel.

WARNING: If opening the SB3800U is required, do so only after disconnecting all sources of power and waiting at least 5 minutes.

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Displays and Messages

High DC Input Voltage

The yellow LED is blinking 4 times in short intervals

LED an

LED aus

3s 1s1s 1s 1s

The signal is repeated 3 times and then starts from the beginning

The yellow LED is on for 5 seconds, remains off for 3 seconds and then blinks 4 times. The code is repeated 3 times. If the condition remains the code will continue to be sent.

The inverter has detected a DC input voltage that is too high for safe operation.

WARNING: Disconnect the PV array from the SB3800U immediately. High DC input voltage can permanently damage the inverter. Have the input source checked by a qualified technician.

WARNING: Always test the DC voltage at the DC disconnect switch before energizing the SB3800U.

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Displays and Messages

Inverter Fault

The yellow LED is blinking 5 times in short intervals

LED an

LED aus

3s 1s1s 1s 1s

The signal is repeated 3 times and then starts from the beginning

The yellow LED is on for 5 seconds, remains off for 3 seconds and then blinks 5 times. The code is repeated 3 times. If the condition remains the code will continue to be sent.

The inverter has encountered an internal fault that prohibits normal operation and will most likely require servicing.

Contact SMA America for assistance.

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Displays and Messages

Status Messages on the LCD

The SB3800U comes standard with the “Sunny Display“ LCD in the lid.

Betrieb Operation

Erdschluss

E-today 3.86kWH

Earth Fault

Mode MPP

Störung Failure

Figure 7-2 SB3800U LCD

Activation of the Backlight

The backlight is activated by knocking twice on the lid. Additional knocks will scroll through the display messages.

The backlight shuts off automatically after 2 minutes.

INIT Messages

The following messages are displayed during initialization of the inverter:

The installed firmware versions of the control system processor (BFR) and the current regulator processor (SRR) are displayed after 6 seconds.

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Sunny Boy 3800U

WR38UxxE

Sunny Boy Inverter Model #

BFR Version x.xx SRR Version x.xx

Firmware Version #’s

Displays and Messages

Operation Messages

The LCD continuously scrolls through all relevant operating data

. Each message (MSG) is displayed for 5 seconds, after all messages have been displayed the LCD repeats from the beginning.

MSG #1 “E-Today“ (total energy produced on this day) is displayed together with the current operating mode:

E-today 3.86kWh Mode MPP

Energy produced today

and current operating mode

MSG #2 Nominal grid voltage configuration and actual line-to-neutral voltage measurements:

MSG #3 Actual AC power output and DC input:

MSG #4 Accumulated yield of the device since installation

and the total operating hours:

Note: The screens may also be scrolled through manually by repeatedly knocking on the lid of the inverter. Each knock advances the screen to the next message.

Gridtype - 208V L1 120V L2 120V

Gridtype and phase-to-neutral

voltages

Pac 3200W Vpv 380V

AC power

and DC voltage

E-total 724.4kWh h-total 512h

Total energy yield

and total operating hours

7-12 SMA America SB3800U-12:SE2006

Displays and Messages

Fault Messages

In case of a fault condition the LCD switches to “Fault“ mode and the backlight is activated.

The upper display line indicates one of the three following failure types:

• Disturbance

For example, this Disturbance message would be displayed if the SB3800U detected a problem with the frequency of the utility grid. The message would clear automatically once the condition was corrected. Distur-

Disturbance

Fac-Bfr

Disturbance Message

bances are typically caused by a measured value exceeding a predetermined limit, the frequency of the AC grid for example. The display will show the value of the error (at:) as well as the present value for the particular parameter (present:).

at: 59.30Hz present: 59.31Hz

Disturbance Details

• Warning

For example, this Warning message would be displayed if the inverter detected a problem with the array voltage. Typically, Warning messages indicate a system condition that should be investigated. Warning conditions will

WARNING

VpvMax

Warning Message

not preclude inverter operation.

• Error

For example, this Error message would be displayed if the inverter detected a problem with the internal ROM.

Error

ROM

An Error condition will preclude the inverter from restarting until the condition is cleared.

Error Message

Note: Each fault message is displayed for 5 seconds. After 5 seconds, the LCD will once again scroll through its normal operating screens. The fault condition will be included in the series of screens until the condition is cleared.

SB3800U-12:SE2006 SMA America 7-13

Displays and Messages

Communication Options

Sunny Boy inverters are available with different communication options depending upon your needs. The SB3800U series allows for both internal and external metering options to be used simultaneously. These options may also be installed in the field by qualified personnel.

PC Applications and Monitoring

Sunny Boy operating data may be transmitted to, and stored in, a remote system or PC by one of the following methods:

• RS-232: Data from one inverter is sent via an RS-232 cable to a remote control unit or PC. Maximum length of cable is 50’ (15 m).

• RS-485: Data from up to 50 inverters is sent via RS-485 cable to a remote control unit or to a PC. Maximum length of cable is 4000’ (1200 m). An RS-485/232 converter may be necessary for communication with a PC.

• Wireless: Data from up to 4 inverters is sent to the Sunny Beam by means of an antenna installed in the SB3800U. Communication distance is dependent upon obstructions and the radio environment.

Sunny Data

This Windows based application has a user friendly graphical interface that allows you to continuously acquire and evaluate the performance data from your PV system. Each Sunny Boy inverter and the PV strings connected to them can be viewed independently for optimal performance evaluation.

Sunny Data Control

This PC application is used to communicate with the Sunny Boy Control products. It can be used to monitor multiple inverters, download historical system data and adjust system parameters. It can also send system data to the Sunny Server portal via analog modem or ethernet.

Sunny Boy Control Family

The Sunny Boy Control products provide continuous monitoring and data acquisition of your PV system. In addition to the original Sunny Boy Control, you can now choose between the economical Sunny Boy Control Light or the full featured Sunny Boy Control Plus.

For more information and assistance in choosing the right data option for your system, please visit the SMA America web site.

7-14 SMA America SB3800U-12:SE2006

Displays and Messages

Sunny Beam

The Sunny Beam is a wireless desktop system monitor. It works together with the Sunny Beam Piggy-Back option and provides wireless communication with up to four Sunny Boys in the PV plant. Its graphic display shows a bar chart of actual output power as well as daily and total-energy-yields in a single window.

For more information on SMA communications products, please refer to the individual product literature.

SB3800U-12:SE2006 SMA America 7-15

Displays and Messages

LCD Language Selection

The Liquid Crystal Display (LCD) has the ability to display information in one of four different languages. Setting the language is performed by using a pair of slide switches located along the bottom edge of the display PC board. The language choices are: Spanish, English, French and German. Use the diagram and chart below for setting the display language.

E-Total 124.4kWh h-Total 512h

AS2AB B

AS2ABB

C B A

2357

L2 N

Position of the switches for

configuration of the LCD

language

Language Switch S2 Switch S1

German B B

English B A

Switch S2

AB B

ABB

Switch S1

French A B

Spanish A A

Figure 7-3 Language Selection Switches for the LCD

7-16 SMA America SB3800U-12:SE2006

Displays and Messages

Measuring Channels

The communication options support a number of measuring channels and messages from the Sunny Boy inverters.

The following abbreviations are used:

BFR Betriebsführungsrechner (Sequential Control System)

SRR Stromregelungsrechner (Current Control System)

The BFR and SRR are redundant processor control systems for the utility protection functions.

Measuring Channels

Vpv: PV input voltage

Vpv Setpoint:MPPT DC voltage target

Iac: Grid current

Vac:Grid voltage

Fac: Grid frequency

Pac:Power fed to grid

Vpv-PE: PV-voltage to earth (For troubleshooting PV ground faults)

Ipv:PV current

E-Total: Total energy yield

h-Total: Total operation hours

h-on: h-on indicates how long sufficient DC voltage has been applied to

the Sunny Boy and the Sunny Boy has been active including the time it was not able to feed to the utility with respect to low DC voltage or operation in stop mode.

Power On: Total system start-up counter

Serial Number: Serial number of the Sunny Boy

Mode: Current operating mode

Grid Type: Type of grid the Sunny Boy is connected to

Error: Description of fault

SB3800U-12:SE2006 SMA America 7-17

Displays and Messages

Operating Mode

Stop: Manual system stop

Offset: Offset calibration of the electronics (at start-up)

Waiting: PV voltage is not high enough to start

Grid monitoring: Synchronizing to grid (at start-up)

MPP-Search: MPPT range test (at start-up)

MPP: Sunny Boy is in MPP mode (normal operation)

V-Const: Sunny Boy is in constant voltage MPP mode

Derating: Reduction of the grid feeding power due to abnormal heatsink

temperatures

Disturbance: Grid related fault condition, self clearing

Error: Inverter fault, user interaction required

Warning: System warning advising further investigation

7-18 SMA America SB3800U-12:SE2006

Displays and Messages

SB3800U Operating Parameters

CAUTION: The changing of operating parameters should only be performed by qualified personnel. Changes to factory preset parameters may adversely effect inverter operation and performance.

Table 7-1 Operating Parameters of the SB3800U

Name Unit Range Default Password

E_Total kWh 0 ... 200000 0 Total energy yield (E_Total) and

h_Total h 0 ... 200000 0

Vconst-Setval V 500 PV Setpoint voltage for constant

Vpv-Start V .8 ... 2x VAC

T-Start s 5 ... 1600 10 / 300 The time the inverter waits to

T-Stop s 1 ... 1800 2 The time that the Sunny Boy waits to

T-Stop-Fan degC

(°C)

nominal

0 ... 100 50 Fan turn-off temperature

264 V @ 240 V AC, 229 V @ 208 V AC

Level

total operating hours (h_Total) of the inverter. Changing the value can be necessary when a Sunny Boy is exchanged and you wish to match the previously acquired data.

voltage operation. These parameters only are important in case the parameter “Operating Mode“ is set to “V-const“.

Minimum DC voltage for the Sunny Boy to connect to the grid. Set using formula, for example, default value for 240 is 1.099 x 240 = 264. Formula can be adjusted from 0.8 to

2.0 x nominal V.

connect to the grid after Vpv-Start is exceeded.

This value defaults to 5 minutes after a utility fault.

disconnect from the grid when Pac falls below 10W.

Description

T-Start-Fan degC

T-Max-Fan degC

Fan-Test 1 / 0 0 By setting this parameter to “1“ you

SB3800U-12:SE2006 SMA America 7-19

(°C)

0 ... 100 60 Fan turn-on temperature at

0 ... 100 90 Temperature for maximum fan

minimum rotating speed.

rotation speed.

can check the function of the fans. This test turns the fans at maximum speed.

Displays and Messages

Name Unit Range Default Password

Operating Mode MPP-Operation

Memory Function no function

Turbine V-const Stop

Default param. Reset Op.Data Reset errors

MPPMode

no function

Level

Operating Modes of the Sunny Boy: MPP-Operation: Maximum Power Point V-const: Constant Voltage Mode (Setpoint defined in “VconstSetval“) Turbine: Operating mode for wind power plants Stop: Disconnection from utility, no operation

Default param.: Sets all parameters to default. Reset Op.Data: Sets all parameters that are visible in user level to default values. Reset errors: Resets all permanent device disable errors.

Description

The following parameters appear in parameter list but cannot be modified:

Table 7-2 Operating Parameters of the Sunny Boy 3800U (Fixed)

Name Unit Range Default Description

Plimit W 3800 Upper limit of AC output power

SMA-SN Serial Number of the Sunny Boy

Software-BFR Firmware version of the operation control unit (BFR)

Software-SRR Firmware version of the current control unit (SRR)

Hardware-BFS Hardware version of the DC converter control unit

Vac-Min % Fixed 12 Lower and upper limits of allowable AC voltage

Vac-Max % Fixed 10

Fac-delta- Hz Fixed 0.69 Maximum allowable operating frequency above

Fac-delta+ Hz Fixed 0.49

dFac-MAX Hz/s Fixed 0.5 Maximum “rate of frequency change” before anti-

Default Fixed USA/

7-20 SMA America SB3800U-12:SE2006

UL1741/ 2001

(DC-BFR)

and below 60 Hz

islanding protection engages

Used for adjusting the parameters country specific settings.

Displays and Messages

Name Unit Range Default Description

Storage Fixed permanent permanent: changed parameters are stored in

EEPROM and are still available after restarting the Sunny Boys volatile: prevents storing the parameters in EEPROM, (i.e. parameters are only saved until next startup.)

SB3800U-12:SE2006 SMA America 7-21

Displays and Messages

7-22 SMA America SB3800U-12:SE2006

Section 8: Troubleshooting

General

Our quality control program assures that each inverter is manufactured to exact specifications and is thoroughly tested before leaving the factory. If you encounter difficulty with the operation of your inverter, please follow the steps below in an effort to correct the problem.

• Check the blinking code of the LED display and compare it to the descriptions in Section 7.

• Check and record the exact "Mode" and/or "Error" messages on the LCD display or other communication system available. Take appropriate action to correct the issue.

• If necessary, check the DC and AC voltages at terminals inside the inverter. Be sure to observe all of the safety precautions listed throughout this manual when doing so, or hire a qualified professional.

• If the system problem persists, contact technical support at: 530.273.4895

In order to better assist you when contacting SMA America, please provide the following information. This information is required for service assistance.

Information Regarding the SB3800U:

• Serial number

• Model Number

• Short description of the problem

• Blinking Code (Chapter 7) or display message

• What error code is indicated on the LCD?

• AC line voltage

• DC line voltage

•Check GFDI Fuse

• Can you reproduce the failure? If yes, how?

• Has this problem occurred in the past?

• What were the operating conditions when the problem occurred?

SB3800U-12:SE2006 SMA America 8-1

Information Regarding the PV modules:

• Manufacturer name and model number of the PV module

• Output power of the module

• Open circuit voltage (Voc) of the module

• Number of modules in each string

• Number of PV strings connected to the inverter

If it becomes necessary to send the Sunny Boy back to the manufacturer for service, please ship it in the original box to avoid damage during shipping.

8-2 SMA America SB3800U-12:SE2006

Error Messages

In case of an fault, the SB3800U generates an error code according to the operating mode and the type of fault detected.

Error Type Error Code Description

Disturbance Vac-Bfr

Vac-Srr

Disturbance Fac-Bfr

Fac-Srr

Disturbance Imax Overcurrent on the AC side. This failure code is indicated if

The AC grid voltage is exceeding the available range. (“Bfr“ or “Srr“ is an internal message and is not important for the user.) Vac can also result from a disconnected grid or a dis connected AC wire. The Sunny Boy assumes that the utility grid is down and disconnects to prevent islanding.

Check the grid voltage and the grid wire connections in the Sunny Boy enclosure. If the grid voltage is out of range due to your local grid conditions contact the utility company. If the grid voltage is within the tolerable range and you still observe the failure message “Vac-Bfr“ or “Vac-Srr“ contact SMA.

The AC grid frequency is exceeding the allowable range. (“Bfr“ or “S rr“ is an int erna l function.) The Sunny Boy assumes that the utility grid is down and disconnects to prevent island ing.

Check the grid frequency and the grid wire connections in the Sunny Boy enclosure. If the grid frequency is out of range due to your local grid conditions contact the utility company. If the grid frequency is within the tolerable range and you still ob serve the failure message “Fac-Bfr“ or “Fac-Srr“, check for possible intermittent connections. For additional assistance, contact SMA.

the current to the AC grid exceeds the allowable limit. This may happen due to harmful interference on the grid. If you observe “Imax“ often, check your grid conditions. For assis tance contact SMA.

Warning VpvMax DC input voltage above the maximum allowable limit.

Error MSD-UAC

MSD-VAC MSD-FAC MSD-Idif

Error K1-Close

K1-Open K2-Open

SB3800U-12:SE2006 SMA America 8-3

Internal measurement comparison error: The internal BFS and SRR processors are measuring different values. Contact SMA for assistance.

Relay test failed. Contact SMA for assistance.

Error Type Error Code Description

Error EEPROM Transition failure during reading or writing of data EEPROM,

the data is not essential for safe operation - this failure does not effect performance.

Error EEPROM p Data EEPROM defective, device is set to permanent disable

due to the fact that the data loss affects important functions of the inverter. Contact SMA for assistance.

Error OFFSET Grid monitoring self-test failed. Contact SMA for assistance.

Error ROM The internal test of the Sunny Boy control system firmware

failed. Contact SMA for assistance.

Error Watchdog Watchdog for operation control triggered. Contact SMA for

assistance.

Error Bfr-Srr Communication between micro-controllers is failing. Contact

SMA for assistance.

Error Shut-Down Internal over current continuous. Contact SMA for assistance.

Error EarthCur-

Max-S

Error EarthCur-

Max-B

Error GFDI Fuse

Ope

The earth current between PV+ and GND has exceeded the maximum limit. Check the PV array for ground faults.

The GFDI-Fuse is open or cleared. Check the PV array for ground faults before replacing the fuse.

Error Derating The inverter is derating because of high temperature. Verify

that the fans are operating normally and that the intake screens are clean. Check the intake vents for debris. Verify that there is adequate ventilation around the inverter. This condition may be normal in periods of high ambient temper

atures (above 45°).

Error XFMR_TEMP_FHigh transformer temperature. The inverter will remain

stopped until the transformer has cooled.

Error XFMR_TEMP_WHigh transformer temperature is gone. The SB3800U starts

working and shows the failure “XFMR_TEMP_W“. Verify that the fans are operating normally and that the intake screens are clean. Check the intake vents for debris. Verify that there is adequate ventilation around the inverter. This condition may be normal in periods of high ambient temperatures (above 45°).

8-4 SMA America SB3800U-12:SE2006

Error Type Error Code Description

Error EeRestore Internal failure.

Error Grid-Time-

out Grid-Fault-S

Error VacL1-Bfr

VacL2-Bfr VacL1-Srr VacL2-Srr

The type of grid could not be detected (208/240).

Voltage is too high or too low.

SB3800U-12:SE2006 SMA America 8-5

8-6 SMA America SB3800U-12:SE2006

Section 9: Maintenance

The SB3800U is designed to provide many years of trouble-free service. Performing regular maintenance will help ensure the long life and high efficiency of your system.

Cleaning the Fans

The fan intake and exhaust fins should be cleaned periodically with a vacuum cleaner. (Do not blow air into the fan areas). For deeper cleaning, the screen and/or the fan can be removed completely.

The fan is mounted on the bottom side of the SB3800U. To clean or replace the fan please follow the steps below:

• Turn OFF the DC disconnect and the AC disconnect and wait 5 minutes for any residual voltages to dissipate.

• Carefully remove the black plastic plate and filter in front of the fan.

Plastic Plate

• The fan is fastened with three plastic tabs on the enclosure. There are two holes in front and one on the back. The tabs are inside the holes. You can loosen the tabs by pressing a screwdriver against the tabs.

• Remove the fan carefully.

• To clean the fan and filter use a soft brush or cloth. Do not use air pressure for cleaning the fan. This will damage the fan.

• When the fan is clean, reinstall it using the above steps in reverse order.

• Do not blow air through the fan or the fan screen while the fan is still mounted in the SB3800U.

SB3800U-12:SE2006 SMA America 9-1

Holes with tabs inside

Cleaning the Exhaust Vent

The vent mounted on the left side (as you face it) of the SB3800U covers the cooling fan exhaust port. To clean the vent, follow the steps below.

• Put your fingers into the opening on the top of the SB3800U next to the exhaust vent and gently remove it. (It is only snapped in.)

• Clean the filter and fins with a soft brush or cloth. Use mild soap and water if necessary.

• When the fins are clean, reinstall the vent.

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c h l u

s r t

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9-2 SMA America SB3800U-12:SE2006

Testing the Fan

You can verify the operation of the fan in two ways:

• Set the parameter “Fan Test“ to “1“ (with Sunny Data, Sunny Data Control or with the data logger Sunny Boy Control).

• Use the jumper on the control board of the Sunny Boy 3800U (see Figure 9-1).

Turn off the AC and DC breakers and wait five minutes until the LEDs got out. Open the Sunny Boy 3800U and set the jumpers as shown below for fan test. Close the SB3800U again and switch the AC and the DC breakers on. (The SB3800U will not detect the jumpers until you cycle power to the inverter.) After testing the fans, remove the jumpers.

Jumper position for verifying

the operation of the fan

Figure 9-1 Jumper Position

SB3800U-12:SE2006 SMA America 9-3

9-4 SMA America SB3800U-12:SE2006

Section 10: Technical Specifications

FCC Compliance Information

Sunny Boy Utility Interactive Inverter, Model Sunny Boy SB3800U

This device complies with Part 15 of the FCC Rules. Operation is subject to the following conditions:

(1) This device may not cause harmful interference, and

(2) this device must accept any interference received, including interference that may

cause undesired operation.

NOTE: This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses, and can radiate radio frequency energy and if not installed and used in accordance with the instructions, may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures:

• Reorient or relocate the receiving antenna.

• Increase the separation between the equipment and the receiver.

• Connect the equipment into an outlet on a circuit different from that to which the

receiver is connected.

• Consult the dealer or an experienced radio/TV technician for help.

• The user is cautioned that changes or modifications not expressly approved by

SMA America, Inc. could void the user’s authority to operate this equipment.

Contact SMA America for more information. 12438 Loma Rica Drive Grass Valley, CA 95945, USA

530.273.4895

www.sma-america.com

SB3800U-12:SE2006 SMA America 10-1

Sunny Boy SB3800U Wiring Diagram

Sunny Boy connection to 208 and 240 V AC utility grids.

SUNNY BOY 3800U

INVERTER

*The AC disconnect switch shown above may or may not be required by the local utility.

Specifications

Inverter Technology

AC Input Voltage

AC Input Frequency 59.3 - 60.5 (60 Hz)

Peak Power Tracking Voltage 400 V DC

DC MPPT Voltage Range

Sine-wave, current source, high frequency PVM

183 - 229 @ 208 V AC

211 - 264 @ 240 V AC

200 - 400 V DC @ 240 V AC

180 - 400 V DC @ 208 V AC

Maximum DC Input Voltage 500 V DC

Maximum Array Input Power

4800 Wp

(DC@STC)

Maximum AC Power Output

3800 W @ 240 V AC

3500 W @ 208 V AC

10-2 SMA America SB3800U-12:SE2006

Current THD Less than 3%

Power Factor 0.99 @ nominal power

Peak Inverter Efficiency 95.6%

Cooling Convection, speed controlled fan

PV Start Voltage (Adjustable)

264 V DC @ 240 V AC (1.099 x VAC Nom.)

229 V DC @ 208 V AC (1.099 x VAC Nom.)

Maximum AC Output Current

Maximum DC Input Current 20 A DC

DC Voltage Ripple Less than 10%

Power Consumption 0.1 W nighttime, < 7 W in operation

CO2 Conversion Factor

Ambient Temperature Rating

Up to 45°C (113°F) at full power

1.7 lb x kWh

Up to 60°C (140°F) at reduced power

Enclosure NEMA 3R

Dimensions

17.80 W x 13.83 H x 9.30 D inches

(452 W x 351H x 236 D mm.)

Weight 85 lbs. (38 kg)

Compliance

UL1741, E210376, IEEE 519, IEEE 929, FCC Part 15 A & B

Specifications subject to change without notice.

16 A AC

SB3800U-12:SE2006 SMA America 10-3

10-4 SMA America SB3800U-12:SE2006

SMA SB 3800-U User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Status LEDs

240 / 208 VAC (Default) (With Neutral)

Table 5-1 Voltage and Frequency Limits for the AC Connection

Table 5-2 RS-232 Pin Assignments

Displays and Messages

Table 7-1 Operating Parameters of the SB3800U

Table 7-2 Operating Parameters of the Sunny Boy 3800U (Fixed)