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Installation Guide
Copyright © 2005 SMA America, Inc. All rights reserved.
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
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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.
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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.
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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 page i (to send E-mail, see the Contact section of the SMA America Web site).
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Contents
Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i Safety and Hazard Symbols . . . . . . . . . . . . . . . . . . . . . . . . . ii Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii Other Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
1Introduction
Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Installation Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
2Unpacking and Inspection
3Mounting
Choosing a Mounting Location . . . . . . . . . . . . . . . . . . . . . . 3-1
Dimensions and Recommended Clearances . . . . . . . . . . . . . 3-3
Mounting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
4AC Voltage Configuration
Opening the Sunny Boy 3800U . . . . . . . . . . . . . . . . . . 4-1
Locating Internal Components . . . . . . . . . . . . . . . . . . . . 4-2
5Wiring 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
6Commissioning
7Displays and Messages
LED Fault Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 Status Messages on the LCD . . . . . . . . . . . . . . . . . . . . 7-11
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Communication Options. . . . . . . . . . . . . . . . . . . . . . . 7-14
8Troubleshooting
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
9Maintenance
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
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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
PV Array
Sunny Boy 3800U
Utility Grid
Figure 1-1 SB3800U Installed in a Utility Interactive PV System
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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.
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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.
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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 step- by-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
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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.
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•If the inverter is installed outside, it should be mounted vertically or tilted back. (See Figure 3-1).
Vertical |
Tilted Back |
Tilted Forward |
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(Best option) |
(Acceptable) |
(Unacceptable) |
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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.
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.
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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)
452 mm
(17.80 in)
Betrieb
Operation
Erdschluss
Earth Fault
Störung
Failure
351 mm
(13.83 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).
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434,60 mm (17,12 in)
250 mm (9,85 in)
349,3 mm (13,76 in) |
(4,09 in) 75 mm (2,95 in) |
178,9 mm (7,05 in) |
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104 mm |
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Figure 3-3 Dimensions of the Wall Mounting Bracket
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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 Figure 3-4). The plate has three 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.
Stone wall mounting |
Wood wall mounting |
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Figure 3-4 SB3800U with removable mounting plate
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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.
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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.)
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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.
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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 |
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Sockets for optional |
communication |
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communication Piggy-Back |
(RS-232 or RS-485) |
Firmware EEPROM |
(RS-232, RS-485, powerline or radio) |
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Display |
Status LEDs
+ |
+ |
- |
- |
L1 |
L2 |
N |
Ground |
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Terminal (PE) |
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GFDI |
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DC+ |
DC– |
Output AC Line |
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Ground |
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Fuse Holder |
Terminals (PE) for |
Terminal |
Terminal |
Terminals |
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Communication |
(input from |
(input from |
(N, L1 and L2) |
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PV array) |
PV array) |
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Figure 4-1 SB3800U Internal Components
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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)
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4HESE CONFIGURATIONS AREECOMPATIBLETWITH THE 3UNNYY"OYY 5
$ELTA 3TINGER
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$ELTA 79%
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$ELTA
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3PLIT 0HASE
.EUTRAL
$ELTA
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$ELTA |
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$/ ./4453% |
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4HESE CONFIGURATIONS |
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AREE./44COMPATIBLETWITH THE |
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3UNNYY"OYY 5 |
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Figure 4-3 Common Utility Voltage Configurations
$ELTA 79% $/ ./4453%
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Remember, when connecting the SB3800U to the utility, the phase relationship is not important, but the voltage must be compatible.
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