SMA SB 4200TL User Manual

SUNNY BOY 4200TL HC / SB 5000TL HC
PV Inverter

Installation Guide Version 1.1 SBTLHCMS-IEN080411

IME-SB42-50-TLHC

SMA Technologie AG Table of Contents

Table of Contents

1 Explanation of the Symbols Used . . . . . . . . . . . . 5

2 Foreword. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2. 1 Target Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2. 2 Appropriate Usage. . . . . . . . . . . . . . . . . . . . . . . . . 8

2. 3 Validity of the Documentation . . . . . . . . . . . . . . . . . 8

3 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . 9

4 overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

4. 1 Unit Description . . . . . . . . . . . . . . . . . . . . . . . . . . 11

4. 2 External dimensions . . . . . . . . . . . . . . . . . . . . . . . 12

5 Installation Requirements. . . . . . . . . . . . . . . . . . 13

5. 1 Installation Site Requirements . . . . . . . . . . . . . . . . . 13

5. 2 PV Generator Requirements . . . . . . . . . . . . . . . . . . 15

5. 3 Low-voltage Grid (AC) . . . . . . . . . . . . . . . . . . . . . 16

5.3. 1 Line Losses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

6. 1 Mounting the Unit. . . . . . . . . . . . . . . . . . . . . . . . . 21

6. 2 Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . 22

6.2. 1 Connecting the AC Output . . . . . . . . . . . . . . . . . . . . . . . . . . .24

6.2. 2 PV String (DC) Connection . . . . . . . . . . . . . . . . . . . . . . . . . . .26

6. 3 Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

7 Opening and Closing the Sunny Boy . . . . . . . . 31

7. 1 Opening the Sunny Boy . . . . . . . . . . . . . . . . . . . . 31

7. 2 Closing the Sunny Boy . . . . . . . . . . . . . . . . . . . . . 32

8 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . 33

8. 1 PV generator connection data . . . . . . . . . . . . . . . . 33

8. 2 Grid connection data . . . . . . . . . . . . . . . . . . . . . . 34

Installation Guide SBTLHCMS-IEN080411 Page 3

Table of Contents SMA Technologie AG

8. 3 General Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

8. 4 Operating parameters . . . . . . . . . . . . . . . . . . . . . 38

8.4. 1 Explanation of the Operating Parameters . . . . . . . . . . . . . . . . .38

8.4. 2 Parameter settings for Germany . . . . . . . . . . . . . . . . . . . . . . . .41

8.4. 3 Country-specific Parameter Settings . . . . . . . . . . . . . . . . . . . . .43

8.4. 4 Non-modifiable Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . .43

9 Inspection of the Electronic Solar Switch . . . . . . 45

10 Replacing the Varistors . . . . . . . . . . . . . . . . . . . 47

11 Rating for a Line Circuit Breaker . . . . . . . . . . . . 51

12 The Communications Interface . . . . . . . . . . . . . . 53

12. 1 Connection RS232, RS485, Radio Piggy-Back. . . . . 54

12.1. 1 Jumper Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

12. 2 Powerline Connection . . . . . . . . . . . . . . . . . . . . . . 56

13 Contact. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Page 4 SBTLHCMS-IEN080411 Installation Guide

SMA Technologie AG Explanation of the Symbols Used

1 Explanation of the Symbols Used

To ensure optimum use of this document, note the following explanation of the symbols
used.

This symbol indicates an example.

This symbol indicates a notice which, if ignored, will make the procedure or oper­ation more difficult.

This symbol indicates a fact which, if not observed, could result in damage
to components or represent a danger to persons. Read these passages es­pecially carefully.

Installation Guide SBTLHCMS-IEN080411 Page5

Explanation of the Symbols Used SMA Technologie AG

Page 6 SBTLHCMS-IEN080411 Installation Guide

SMA Technologie AG Foreword

2 Foreword

The Sunny Boy inverters are equipped with the "SMA grid guard". This is a type
of automatic disconnection device. It ensures that the Sunny Boy complies with the
VDEW (Verband der Elektrizitätswirtschaft – German Electricity Industry Associa­tion) regulations for the connection and parallel operation of electrical power units
to the low-voltage grid of the electricity supply company and with DIN VDE 0126­1-1, which forms a part of these regulations.

For detailed information on troubleshooting and on how to use the Sunny Boy and the
various communications options, please see the operating instructions.

"Sunny Design" helps you design the system and check string size taking the relevant
inverter into consideration. Further information on Sunny Design is available at

www.SMA.de.

If you require further information, please call the SMA Service Line on the following
number:

(0561) 95 22 - 499

2. 1 Target Group

Notice!
The Sunny Boy may only be installed by qualified personnel. The installer

must be approved by the local energy supplier. Read this "installation
guide" carefully. All prescribed safety regulations, the technical connec­tion requirements of the local energy supplier and all applicable provi­sions must be adhered to.

This installation manual is intended solely for qualified personnel. Its aim is to help install
and set up SMA inverters type “SB 4200TL HC Multi-String“ or “Sunny Boy SB 5000TL
HC Multi-String“ quickly and correctly.

Installation Guide SBTLHCMS-IEN080411 Page7

Foreword SMA Technologie AG

2. 2 Appropriate Usage

The Sunny Boy is designed for operation in grid-connected PV systems. Any other use
of the leads to loss of the right to all warranty claims and may lead to a fault in the
device. This includes, among other things, the operation at voltage sources without any
current limit. When in doubt, contact SMA.

Plant Design

The Sunny Boy may only be operated with PV-generators (Modules and according ca­bles) with protection class II.

It is mandatory to ensure that all components will operate within the specified operating
range. The free design tool "Sunny Design" (www.SMA.de/SunnyDesign) will help you
with this.

The manufacturer of the modules should have approved the modules for operation with
this Sunny Boy. It is furthermore advisable to implement all measures for maintaining the
module performance (see also Application Note 2 "Module Technology" in the down­load area of www.SMA.de).

2. 3 Validity of the Documentation

The Sunny Boy SB 4200TL HC Multi-String and Sunny Boy SB 5000TL HC Multi-String
are identical except for the technical data. The devices are referred to as Sunny Boy in
case the information applies for both models. The full device name is used in case of
device specific information.

Page 8 SBTLHCMS-IEN080411 Installation Guide

SMA Technologie AG Safety Instructions

3 Safety Instructions

Caution! Overvoltage!
Check the system design using the "Sunny Design" design tool

(www.SMA.de) or by calling the SMA Service Line. Overvoltage damages
the Sunny Boy and results in the exclusion of all warranty claims!

Warning! High voltages!
Work on the Sunny Boy with the cover removed must be carried out by a

qualified electrician. High voltages are present in the device. Before work­ing on the Sunny Boy with the cover removed, the AC and DC voltages
must be disconnected from the Sunny Boy and the capacitors must be dis­charged.

The Sunny Boy must be disconnected from the mains grid and precautions
must be taken to prevent the grid being inadvertently reconnected. In ad­dition, the connections to the PV generator must be disconnected.

After isolating the AC and DC voltage, you must wait approx. 30 minutes
for the capacitors in the Sunny Boy to discharge. Only then is it safe to
open the unit by removing the cover. You must also make sure that no
voltage is present in the device.

Caution! Electrostatic charge!
When working on the Sunny Boy and handling the components, remem-

ber to observe all ESD safety regulations. Electronic components are vul­nerable in terms of electrostatic charge. Discharge any electrostatic
charge by touching the grounded enclosure before handling any electron­ic component.

Notice! Entry of water and dirt!
Once the handle of the Electronic Solar Switch has been pulled out, the

Sunny Boy provides protection degree IP21. The Sunny Boy is then no
longer protected against water and contamination with dirt!

Grounding the PV generator

Pay attention to local regulations for the grounding of the modules and the PV­generator. SMA reccomends to electrically bond the module frames, the racks
and all metal surfaces and ground these in order to have optimal protection of the
system and personnel.

Installation Guide SBTLHCMS-IEN080411 Page9

Safety Instructions SMA Technologie AG

Page 10 SBTLHCMS-IEN080411 Installation Guide

SMA Technologie AG overview

4 overview

4. 1 Unit Description

The following diagram gives a schematic overview of the various components and con­nection points inside the Sunny Boy with the cover removed:

Varistors, section 10

Socket for communication (RS232, RS485,
NLM Piggy-Back, Radio), section 12

Sunny Display

Operating status
LEDs

Jumper slot for com­munication

Communications
connector

Connection terminals
(AC), section 6.2. 1

Flat connection for grounding the cable shield
for RS232 and RS485 communications

PV input plug (DC),
section 6.2. 2

Socket for the DC disconnection unit
Electronic Solar Switch

Installation Guide SBTLHCMS-IEN080411 Page11

Socket for PLC power module (required for
mains grid communications)

overview SMA Technologie AG

4. 2 External dimensions

225 mm

470 mm

490 mm

Page 12 SBTLHCMS-IEN080411 Installation Guide

SMA Technologie AG Installation Requirements

5 Installation Requirements

Please check that all of the conditions listed below are met before installing and setting
up the Sunny Boy.

5. 1 Installation Site Requirements

The Sunny Boy weighs more than 31 kg. Please take this weight into
account when choosing the installation site and method of installa­tion.

The ambient temperature must not be outside the -25 °C to
+60 °C range.

The Sunny Boy is designed for outdoor installation and should be
installed in a place where it is not exposed to direct sunlight. An in-

31 kg

solutely necessary, however, the Sunny Boy can be installed tilted back at a maximum
angle of 45°. For an optimum energy yield and the most convenient operation, vertical
installation at eye-level is preferable. If installing the unit outdoors, make sure that it is
not slanting forward.

A horizontal installation of devices in outside locations is not permissible.

creased ambient temperature can reduce the yield of the PV system.
The Sunny Boy is designed to be mounted on a vertical wall. If ab-

Install the inverter vertically or tilt-

ing backward.

Installation Guide SBTLHCMS-IEN080411 Page13

Never install the inverter horizon-

tally or so that it tilts forward.

Installation Requirements SMA Technologie AG

When choosing the installation site, be sure to note the following:

Caution: high voltage!
Unintentionally pulling out the DC plug connector under load can damage

the plug and result in bodily injury or death! Install the Sunny Boy in such
a way that it is not possible (e.g. for children) to unplug the DC plug con­nector unintentionally.

Caution: risk of burns!
The temperature of individual parts of the enclosure - in particular the tem-

perature of the heatsink and the components within the Sunny Boy - can
reach more than 60 °C. Touching could result in burns!

Warning!
Do not install the Sunny Boy

• on flammable construction materials,

• in areas where highly flammable materials are stored,

• in potentially explosive areas!

When choosing the installation location, ensure there is enough space for heat to dissi­pate! Under normal conditions, the following guidelines should be followed to provide
enough clearance around the inverter.

Minimum Clearance

Sides 20 cm

Top 20 cm

Underneath 50 cm

Front 5 cm

In domestic installations, the unit should not be mounted
on plasterboard walls or similar as otherwise audible vi­brations are likely to result.

We recommend securing the unit to a solid surface.
The Sunny Boy makes noises when in use which can, in

the domestic setting, be seen as a nuisance.

Page 14 SBTLHCMS-IEN080411 Installation Guide

SMA Technologie AG Installation Requirements

5. 2 PV Generator Requirements

The Sunny Boys have two input areas "String A" and "String B", each equipped with a
separate MPP-tracker. The input area "String A" can be used for the connection of up
to two strings (modules connected in series) with identical properties (modules with iden­tical orientation, identical type, slant and number). The input area "String B" can be
used for a single string, while this string can be different from the strings connected to
"String A".

“Sunny Design“ helps you design the system and check string size taking the relevant
inverter into consideration. Further information on "Sunny Design" is available at

www.SMA.de.

The unit has six DC plug connectors (four for String A and two for String B) for connect­ing the PV generators. The connecting cables from the PV generators must also be fitted
with this type of plug connector. The SMA order codes for the various connectors are
as follows:

• Multi-contact 3 mm: "SWR-MC"

• Multi-contact 4 mm: "MC-SET"

• Tyco: "TYCO-SET"

Limit values for DC input Input Values

„String A“

Input Values

„String B“

Max. voltage 750 V (DC) 750 V (DC)

Max. input current 11 A (DC) 11 A (DC)

Notice!
Parallel connection of the "String A" and "String B" is not permitted!

Installation Guide SBTLHCMS-IEN080411 Page15

Installation Requirements SMA Technologie AG

5. 3 Low-voltage Grid (AC)

Caution!
The feed-in connection is fused by a 25 A

circuit breaker type B. No further devices
must be connected to the secured cable.

The relevant technical regulations and the special instructions of the local grid operator
must be followed.

The connection terminals of the Sunny Boy are suit­able for wire cross-sections of up to 10 mm². The ex­ternal diameter of the cable must be between 9 mm
and 17 mm. The connection is made with three wires
(L, N, PE).

Page 16 SBTLHCMS-IEN080411 Installation Guide

SMA Technologie AG Installation Requirements

Rating for a Line Circuit Breaker in a Photovoltaic Electrical Power Unit
Operated in Grid-parallel Mode

Various factors should be taken into account when selecting line circuit breakers. These
include, for example:

• The type of cable used (conductor material and insulation)

• Ambient temperatures affect the cables (higher temperatures result in a reduced
maximum current load)

• Method of routing the cable (reduces the ampacity of the conductor)

• Bundling cables together (reduces the ampacity of the conductor)

• Loop impedance [Z] (in the event of a body contact this limits the current that can
flow and therefore determines the response behavior of the circuit breaker)

• Sufficient distance between the circuit breakers so as to avoid undue heating (heat
can trigger the circuit breakers early).

•Selectivity

• Protection class of the connected load (VDE 0100, part 410, protection against
electric shock)

The following standards should be followed in all cases:

• DIN VDE 0298-4 (Cable routing and current-carrying capacity)

• DIN VDE 0100; part 430 (Protective measures "Protection of cable and

cords against overcurrent")

• DIN VDE 0100; part 410 (Protective measures "Protection against electric

shock")

For examples for the rating of a line circuit breaker, please refer to section 11 "Rating
for a Line Circuit Breaker" (Page 51)

A 30 mA RCD or FI circuit breaker must not be installed.

The Sunny Boy is equipped with an integrated universal current sensitive leakage-cur­rent monitoring unit. The Sunny Boy can automatically differ between real fault currents
and "normal" capacitive leakage currents.

Installation Guide SBTLHCMS-IEN080411 Page17

Installation Requirements SMA Technologie AG

The Sunny Boy does not generate any extraordinary leakage currents in normal oper­ation. In some operating states (e.g. during self-test of the protection units) discharge
currents can occur which would trip a standard 30 mA RCD or ground fault circuit in­terrupter.

In case an RCD or ground fault circuit interrupter is imperative, you must use a
circuit breaker with a sensitivity of 100 mA or more.

5.3. 1 Line Losses

AC cable system impedance should not exceed 1 ohm. This is necessary, amongst other
things, for the correct operation of impedance observation. In addition, we recommend
dimensioning the conductor cross-section so that line losses do not exceed 1 % at the
nominal power. Line losses depending on the cable length and cross-section are shown
in the graph below. Multi-wire cables with copper forward and return conductors are
used.

Sunny Boy SB 4200TL HC Multi-String

Do not use cables where the losses will exceed 1.0 %

Line Losses

Cable length

The maximum cable lengths for the different cable cross-sections are as follows:

Cable cross-section 6.0 mm² 8.0 mm² 10.0 mm²

Max. length 22 m30 m37 m

Page 18 SBTLHCMS-IEN080411 Installation Guide

SMA Technologie AG Installation Requirements

Sunny Boy SB 5000TL HC Multi-String

Do not use cables where the losses will exceed 1.0 %

Line Losses

Cable length

The maximum cable lengths for the different cable cross-sections are as follows:

Cable cross-section 6.0 mm² 8.0 mm² 10.0 mm²

Max. length 19 m26 m32 m

Installation Guide SBTLHCMS-IEN080411 Page19

Installation Requirements SMA Technologie AG

The Sunny Boy is designed for operation on 220 - 240 V grids at a grid frequency of
50 Hz. When connecting an inverter to the public grid, follow the connection require­ments of the local grid operator.

Limit values for AC output

Voltage range

198 V ... 260 V

a)

(in the area of application of DIN VDE 0126-1-1)

Frequency range

47.55 Hz ... 50.2Hz

(in the area of application of DIN VDE 0126-1-1)

Voltage range

180V ... 260 V

(extended operating range)

Frequency range

45.5 Hz ... 52.5Hz

(extended operating range)

a) The Sunny Boy can temporarily feed power into the grid with a maximum output

voltage of 260 V. However, DIN VDE 0126-1-1 stipulates that the 10-minute
average must not exceed a voltage of 253 V. That means, if the grid voltage is
continuously 254 V (e.g.), the inverter disconnects itself from the grid. In this
case, contact the local grid operator for assistance.

DIN VDE 0126-1-1 only applies in Germany. See section 8.4. 3 "Country-spe­cific Parameter Settings" (Page 43) for all other preset country values of your
inverter.

Page 20 SBTLHCMS-IEN080411 Installation Guide

SMA Technologie AG Installation

6 Installation

6. 1 Mounting the Unit

To make the job easier, we recommend you use the
supplied wall bracket to mount the Sunny Boy. For
vertical installation on solid concrete or block walls,
for example, you can fit the bracket using 8 mm x 50
mm hexagon bolts to DIN 571 standard, stainless
steel type, and with wall plugs type SX10.

When selecting the mounting materials, be sure to
take into account the weight of the Sunny Boy (31
kg).

If you do not wish to use the wall bracket provided as a template, then use the dimen­sions specified in the drawing below. The installation of the inverter using the wall brack­et is described on the following page.

Installation Guide SBTLHCMS-IEN080411 Page21

Installation SMA Technologie AG

1. Mount the wall bracket (1). To mark the posi­tions to drill the holes, you can use the wall
bracket as a drilling template.

2. Now hook the Sunny Boy onto the wall bracket
(2) at its upper mounting plate so that it cannot
be moved sideways.

3. Fix the Sunny Boy onto its bracket by screwing
the supplied M6x10 bolt into the central thread­ed hole at the bottom of the bracket (3).

4. Make sure that the Sunny Boy is positioned se­curely on the bracket.

6. 2 Electrical Installation

Notice!
Make sure to check the polarity of the strings before connecting them!

The complete wiring for a Sunny Boy is shown schematically in the following diagram:

Opening for

optional com-

AC connection, max. 10 mm²

munication

String A

Page 22 SBTLHCMS-IEN080411 Installation Guide

String B

SMA Technologie AG Installation

View from below

Socket for the

Electronic Solar Switch

Plug and socket connector
for connection of the solar

modules

AC plug for

mains connection

Opening for optional

communication via

RS232, RS485 or radio

(PG16)

Installation Guide SBTLHCMS-IEN080411 Page23

Installation SMA Technologie AG

6.2. 1 Connecting the AC Output

To connect the AC cable, proceed as follows:

1. Check the grid voltage. The Sunny Boys were prepared for the DIN VDE 0126-­1-1 in two steps. In the first step the inverter disconnects from the grid when the
grid voltage exceeds 253 V.

In the second step the Sunny Boy can feed into the public grid at a maximum out­put voltage of 260 V for brief periods. However, DIN VDE 0126-1-1 stipulates
that the 10-minute average must not exceed a voltage of 253 V. That means, if
the grid voltage is constantly 254 V (e.g.), the inverter disconnects itself from the
grid. In this case, contact the local grid operator for assistance.

DIN VDE 0126-1-1 only applies in Germany. See section 8.4. 3 "Country-specific
Parameter Settings" (Page 43) for all other preset country values of your inverter.

2. Isolate the grid connection (switch the line circuit
breaker to its "off" position), make sure it cannot
be switched back on, and test to make sure no
voltage is present.

3. Remove the screws that secure the case of the
Sunny Boy and carefully remove the cover. Re­move the PE connection from the cover.

Off!

4. Connect the main cables as shown in the figure.
Use the supplied cable feed-through.

"L" and "N" must not be swapped.

N

Page 24 SBTLHCMS-IEN080411 Installation Guide

L

SMA Technologie AG Installation

5. Connect the earth wire (PE) of the mains cable to
the upper screw terminal with the earth sign.

PE

6. Reconnect the PE connection on the cover. Fix the housing cover of the and tighten
the four screws evenly.

Notice!
A normal operation of your Sunny Boy requires, among other things, con-

necting the PE conductor to the equipotential bonding of the building.
Please check the prescribed PE connection from the Sunny Boy enclosure
to protective earth when commissioning the device!

Notice!
Do not switch the line circuit breaker on yet! The Sunny Boy may only be

connected to the AC grid once the PV strings are connected and the device
is securely closed.

Installation Guide SBTLHCMS-IEN080411 Page25

Installation SMA Technologie AG

6.2. 2 PV String (DC) Connection

To connect up the DC input, follow these steps:

1. Remove the Electronic Solar Switch.

2. Make sure the PV generator connectors have the
right polarity and do not exceed the maximum
string voltage of 750 V (DC). See also section 5.
2 "PV Generator Requirements" (Page 15).

Warning!
Dangerous high voltages may be present. Danger of death!

3. Taking one DC plug connector at a time, mea­sure the direct current voltage between one DC
plug connector of a string and earth potential.

4. If the measured voltages are constant and if their
total is roughly the same as the open circuit volt­age of the string, then there is a ground fault in
this string. Its approximate location can be de­duced from the relationships between the voltag­es.

Notice!
Do not connect strings to the Sunny Boy that contain a ground fault until

you have fixed the earth fault in the PV generator!

Page 26 SBTLHCMS-IEN080411 Installation Guide

SMA Technologie AG Installation

5. Repeat points 2 and 3 for each string.

6. Connect up the faultless PV generator strings to
the inverter. Ensure the assignment of the strings
is correct.

7. Close the unnecessary DC input sockets with the
caps included in the delivery.

8. Attach the handle of the Electronic Solar Switch.

Notice!
The Electronic Solar Switch can become damaged if it has not been at-

tached properly.
Firmly insert the handle all the way into the socket in the Sunny Boy and

check that it is firmly inserted. Never tighten the screws of the socket inside
the Sunny Boy in order to avoid that the socket locks in place.

Installation Guide SBTLHCMS-IEN080411 Page27

Installation SMA Technologie AG

6. 3 Startup

You can start up the Sunny Boy when

• the enclosure's cover is securely screwed shut,

• the AC (mains) cable is connected correctly,

• the DC cables (PV strings) are fully connected and the unused DC plug connectors
on the bottom of the enclosure are closed using the protective caps.

How to Start up the Inverter

1. First of all, switch the line circuit breaker to the
"on" position.

2. Now look at the LED display and consult the ta­ble on the following page to check whether the
Sunny Boy is in a fault-free and expedient oper­ating mode. Once the inverter is in a fault-free
operating status, commissioning is successfully
completed.

On

Notice!
If the bottom yellow LED flashes four times at intervals of one second, the

grid voltage and the PV generator must be disconnected from the Sunny
Boy immediately! There is a risk of damage to the inverter resulting from
excessive DC input voltage.

Check the string voltages again to make sure they are within the limits stated in section

5. 2 "PV Generator Requirements" (Page 15). If the string voltages are too high, the PV

generator's planner/installer should be called upon for assistance.
If despite checking the string voltages the LED signal occurs again when the PV gener-

ator is connected to the SUnny Boy, disconnect the PV generator from the Sunny Boy
again and contact SMA Technologie AG (see section 13 "Contact" (Page 61)).

Page 28 SBTLHCMS-IEN080411 Installation Guide

SMA Technologie AG Installation

Green Red Yellow Status

Illuminates continu-

ously

Is not illuminated Is not illuminated OK (working mode)

Illuminates continu-

ously

Is not illuminated Disturbance

Illuminates continu-

OK (initialization)

ously

Flashes quickly

(3 x per second)

Is not illuminated Is not illuminated OK (stop)

Illuminates continu-

Is not illuminated Disturbance

ously

Flashes slowly (1x

per second)

Briefly goes out

(approx. 1 x per

second)

Is not illuminated Is not illuminated OK (waiting, grid

monitoring)

Illuminates continu-

Is not illuminated Disturbance

ously

Is not illuminated Is not illuminated OK (derating)

Is not illuminated Is not illuminated Is not illuminated OK (night shut-

down)

Illuminating/flashing Disturbance

Illuminates continu-

ously

Is not illuminated Disturbance

Illuminating/flashing Disturbance

For a detailed description of the fault messages and their causes, see the operating in­structions.

Installation Guide SBTLHCMS-IEN080411 Page29

Installation SMA Technologie AG

Page 30 SBTLHCMS-IEN080411 Installation Guide

SMA Technologie AG Opening and Closing the Sunny Boy

7 Opening and Closing the Sunny Boy

Notice!
If you need to open the device for whatever reason, please pay attention

to section 3 "Safety Instructions" (Page 9).

7. 1 Opening the Sunny Boy

Notice!
Follow the sequence below under all circumstances.

1. Switch the line circuit breaker to the "off" position.

2. Remove the Electronic Solar Switch.

3. Immediately remove the DC cables from the Sunny Boy in order to completely dis­connect the PV-generator from the Sunny Boy.

4. Wait 30 minutes!

5. Remove the four screws from the enclosure cover and pull the cover forward
smoothly. Remove the PE connection from the cover. Loosen the locking on the PE
connectors on the cover when you remove them.

Installation Guide SBTLHCMS-IEN080411 Page31

Opening and Closing the Sunny Boy SMA Technologie AG

7. 2 Closing the Sunny Boy

Caution!
Follow the sequence below under all circumstances.

1. Reconnect the earth wire (PE) to the housing cover. Now secure the housing cover
to the Sunny Boy by tightening the four screws evenly. The screws must be tight­ened with approximately 4 Nm torque in order to guarantee the sealing of the en­closure.

2. Connect the PV generator. Ensure the assignment of the strings is correct.

3. Check the Electronic Solar Switch for wear as described in chapter 9 "Inspection
of the Electronic Solar Switch" (Page 45).

4. Firmly insert the handle into the socket of the Electronic Solar Switch’s in the bottom
of the Sunny Boy.

Notice!
The Electronic Solar Switch can become damaged if it has not been at-

tached properly.
Firmly insert the handle all the way into the socket in the Sunny Boy and

check that it is firmly inserted. Never tighten the screws of the socket inside
the Sunny Boy in order to avoid that the socket locks in place.

5. Switch the line circuit breaker to the "on" position.

6. Now check whether the LED display indicates that the Sunny Boy is functioning cor­rectly.

Page 32 SBTLHCMS-IEN080411 Installation Guide

SMA Technologie AG Technical Data

8 Technical Data

8. 1 PV generator connection data

Description Short

descrip­tion

Max. input voltage U

Input voltage, MPP range U

Max. input current I

DC, max

PV

PV max

SB 4200TL HC SB 5000TL HC

750 V

a)

125V ... 750 V

11 A for each input area "String A" and

Setting

"String B"

Max. input power P

Voltage ripple U

DC

pp

4400 W 5300 W

< 10 % of the input voltage

Operating consumption < 10 W (standby)

a) Ensure that the maximum input open-circuit voltage occurring at a cell temper-

ature of -10 °C does not exceed the specified maximum input voltage.

Installation Guide SBTLHCMS-IEN080411 Page33

Technical Data SMA Technologie AG

8. 2 Grid connection data

Description Short

descrip­tion

Nominal output power P

Max. output power P

Nominal output current I

Harmonic distortion of output cur­rent (at K
P

ACnom

< 2 %, PAC > 0.5

Ugrid

)

Operating range, grid voltage U

Operating range, grid frequency f

ACnom

ACmax

ACnom

K

IAC

AC

AC

SB 4200TL HC SB 5000TL HC

4000 W 4600 W

4200 W 5000 W

17.5A 20 A

< 3 %

180 - 260 V AC
Germany: 198 - 260 V AC

45.5 - 52.5 Hz

Setting

b)

Germany: 47.55 - 50.2 Hz

Phase shift angle (based on the cur-

cos phi 1 (at nominal power output)

rent's fundamental frequency)

Overvoltage category III

Test voltage (50 Hz) 1.65 kV (1 s routine testing / 5 s type

testing)

Test surge voltage 4 kV (1.2/50 ms)

(serial interface: 6 kV)

Internal consumption in night mode 0.25 W

b) The Sunny Boy can temporarily feed power into the grid with a maximum output

voltage of 260 V. However, DIN VDE 0126-1-1 stipulates that the 10-minute
average must not exceed a voltage of 253 V. That means, if the grid voltage is
continuously 254 V (e.g.), the inverter disconnects itself from the grid. In this
case, contact the local grid operator for assistance.

DIN VDE 0126-1-1 only applies in Germany. See section 8.4. 3 "Country-spe­cific Parameter Settings" (Page 43) for all other preset country values of your
inverter.

Page 34 SBTLHCMS-IEN080411 Installation Guide

SMA Technologie AG Technical Data

8. 3 General Data

For a detailed description of the devices, see the operating instructions.

General data

Protection rating per EN 60529 IP65

Dimensions (w x h x d) 470 mm x 490 mm x 225 mm

(approx.)

Weight approx. 31 kg

Protective function DC side

All-pole isolator on the DC input side DC plug connector (ESS optional)

Overvoltage protection Thermally monitored varistors

Personal protection Ground fault monitoring

(Riso > 1 MOhm)

Reverse polarity protection Via short circuit diode

Protective function AC side

Short-circuit proofing Grid-side via current regulation

All-pole isolation on grid side Independent disconnection device

(SMA grid guard), double imple­mentation

External interfaces

Data transmission over mains power line optional

Data transmission over separate data cable Optional, RS232 / RS485, electri-

cally separated

Wireless data transmission optional

Installation Guide SBTLHCMS-IEN080411 Page35

Technical Data SMA Technologie AG

Efficiency Sunny Boy SB 4200TL HC Multi-String

Efficiency

Max. efficiency ηmax 96.1 %

European efficiency ηeuro 95.5 %

The efficiency of the Sunny Boy SB 4200TL HC depends greatly on the input voltage
of the connected PV strings. The higher the input voltage, the higher the efficiency.

Sunny Boy SB 4200TL HC

Overall efficiency [%]

Output power [kW]

Page 36 SBTLHCMS-IEN080411 Installation Guide

SMA Technologie AG Technical Data

Efficiency Sunny Boy SB 5000TL HC Multi-String

Efficiency

Max. efficiency ηmax 96.2 %

European efficiency ηeuro 95.6 %

The efficiency of the Sunny Boy SB 5000TL HC depends greatly on the input voltage
of the connected PV strings. The higher the input voltage, the higher the efficiency.

Sunny Boy SB 5000TL HC

Overall efficiency [%]

Output power [kW]

Installation Guide SBTLHCMS-IEN080411 Page37

Technical Data SMA Technologie AG

8. 4 Operating parameters

Warning!
Unauthorized changes to the operating parameters may result in:

• injury or accidents as a result of changing the internal safety routines
in the Sunny Boy,

• voiding the Sunny Boy's operating approval certificate,

• voiding the Sunny Boy's guarantee.

Never change the parameters of your Sunny Boy without express autho­rization and instructions.

8.4. 1 Explanation of the Operating Parameters

Name Explanation

ACVtgRPro Surge voltage protection (only relevant for Germany).

In Germany, Sunny Boys can feed into the public grid with up to
260 V AC. However, DIN VDE 10-0126-1 stipulates that the av­erage AC voltage over 1 minutes must not exceed 253 V. If the
average over 10 minutes exceeds the threshold value of 253 V,
the inverter disconnects itself from the grid. Once the average
over 10 minutes returns to a value of less than 253 V, the inverter
returns to "Working" mode. If surge voltage protection is not re­quired in the relevant grid area (outside Germany), it can be de­activated by means of presetting the LDVtgC parameter. In this
event, only the fast cut-off via the Uac-Max parameter inter­venes.

AntiIsland-Ampl Amplification of the AntiIsland process (alternative AntiIslanding

process, which is deactivated for Germany).

AntiIsland-Freq Repetition rate of the AntiIsland process (alternative AntiIsland-

ing process, which is deactivated for Germany).

Betriebsart Operating mode of the Sunny Boy:

MPP: Maximum Power Point
UKonst: constant voltage mode

(desired voltage is defined in "Usoll-Konst")
IKonst: Operating mode for test purposes
Stopp: disconnection from grid, no operation

Page 38 SBTLHCMS-IEN080411 Installation Guide

SMA Technologie AG Technical Data

Name Explanation

Default Used for setting the country-specific information.

GER/VDE0126-1-1: Country-specific parameter settings for Ger­many in accordance with DIN VDE 0126-1-1

GB: Country-specific parameter settings for Great Britain
IT: Country-specific parameter settings for Italy
Other: Here, parameter settings can be defined for countries for

which no predefined setting exists.
Trimmed: If country-specific parameters have been changed,

"trimmed" is shown in the display.

dFac-Max Maximum "mains frequency change" before the mains monitor-

ing system disconnects the device from the mains supply.

dZac-Max Maximum "grid impedance change" before the grid monitoring

system disconnects the device from the grid.

E_Total Total energy yield for the inverter. This change may be neces-

sary when you exchange the Sunny Boy and want to use the
data from the old device.

Fac-delta- Maximum frequency, above (Fac-delta+) and below (Fac-delta-)

Fac-delta+

the mains frequency, before the mains monitoring system discon­nects the device from the mains supply.

Fac-Tavg Averaging time of grid frequency gaging

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

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

FirmwareSRR Firmware version of the current control unit (SRR)

h_Total Total hours of operation for the inverter. This change may be

necessary when you exchange the Sunny Boy and want to use
the data from the old device.

Hardware-DC-BFS Hardware version of the DC operation control unit (DC-BFR)

Inst.-Code Parameters for self contained power system recognition can only

be changed after entering the SMA grid guard password.

Installation Guide SBTLHCMS-IEN080411 Page39

Technical Data SMA Technologie AG

Name Explanation

LDVtgC Compensation for the voltage drop in the cabling.

With this parameter, the voltage drop between the inverter and
the grid connection point is taken into account. The average volt­age over 10 minutes at the inverter connection must not exceed
the sum of ACVtgRPro plus LDVtgC. The parameter LDVtgC is
preset to 0 V for Germany. In grid areas in which the additional
surge voltage protection (see parameter ACVtgRPro) is not re­quired, the parameter LDVtgC is preset to 50 V. Thus, the surge
voltage protection is deactivated for these grid areas (253 V +
50 V = 303 V) and only the fast cut-off via the Uac-Max param­eter intervenes.

Ni-Test Impulse setting for impedance monitoring. This parameter takes

effect when the Sunny Boy is deactivated (disconnected on the
AC side) or put to "Stopp" mode.

Plimit Upper limit for AC output power

Ripple-Ctl-Frq The Ripple-Ctl-Frq, Ripple-Ctl-Lev, Ripple-Ctl-Rcvr parameters are

Ripple-Ctl-Lev

Ripple-Ctl-Rcvr

intended to handle ripple control signals from the SMA inverters.
These parameters are not available for all inverters. These pa­rameters may only be changed after prior agreement with SMA
Technologie AG.

Riso-Min Lower limit of the allowable insulation resistance

SMA-Grid-Guard SMA grid guard version number

SMA-SN Serial number of the Sunny Boy

Speicherfunkt. Default Parameter: Returns all parameter values to the factory

setting.
Reset Betriebsdaten: Returns all user level parameter values to
the factory setting.
Reset Fehler: Resets a permanent fault.

Storage Permanent: Modified parameters are stored in the EEPROM and

can be used even when the Sunny Boy has been restarted.
Volatil: Prevents the parameters being stored in the EEPROM, the

parameters are only stored until the next restart.

T-Start The period the Sunny Boy waits after all switch-on conditions

have been satisfied.

Uac-Min Lower (Uac-Min) and upper (Uac-Max) limits of the allowable

Uac-Max

AC voltage (self contained power system recognition), before
the grid monitoring system disconnects the device from the grid.

Page 40 SBTLHCMS-IEN080411 Installation Guide

SMA Technologie AG Technical Data

Name Explanation

Uac-Tavg Averaging time of grid frequency gaging

Uzwk-Start The DC voltage required before the Sunny Boy begins feeding

power into the mains supply.

Usoll-Konst A PV desired voltage for constant operational voltage. These pa-

Usoll-Konst B

rameters are only important when the "Betriebsart" parameter is
set to U-konst.

8.4. 2 Parameter settings for Germany

Grayed out parameters are only displayed in installer mode. The table below contains
the parameters that are applicable in Germany. The Sunny Boys were prepared for the
DIN VDE 0126-1-1 in two steps. The table specifies the settings that are respectively
valid.

Name Short

Value range Factory setting

descr.

ACVtgRPro V 230 ... 300 253

AntiIsland-Ampl * grd 0 ... 10 0

AntiIsland-Freq * mHz 0 ... 2000 500

Betriebsart MPP, IKonst, UKonst,

MPP

Stopp,

Default * GER/VDE0126-1-1,

GER/VDE0126-1-1
IT/DK5950, Other,
trimmed

dFac-MAX * Hz/s 0.1 ... 4.0 4.0

dZac-MAX * mOhm 350 ... 20000 600

E_Total kWh 0 ... 200000 0

Fac-delta- * Hz 0.1 ... 4.5 2.45

Fac-delta+ * Hz 0.1 ... 4.5 0.19

h_Total h 0 ... 200000 0

Inst.-Code

LDVtgC V 0 ... 50 0

Ni-Test * 0 / 1 1

Ripple-Ctl-Frq Hz 110 ... 1605 1605

Ripple-Ctl-Lev % 0.5 ... 8.00 8

Installation Guide SBTLHCMS-IEN080411 Page41

Technical Data SMA Technologie AG

Name Short

Value range Factory setting

descr.

Ripple-Ctl-Rcvr enable, disable, auto auto

Riso-Min kOhm 1500 ... 30000 1500

Speicherfunkt. Default Parameter, Reset

none
Betriebsdaten, Reset Fe­hler

T-Start * s 2 ... 300 2

Uac-Min * V 160 ... 230 198

Uac-Max * V 230 ... 300 260

Usoll-Konst A V 0 ... 750 290

Usoll-Konst B V 0 ... 750 290

Parameters designated with * are safety-related grid monitoring parameters. To
change the SMA grid guard parameters, you must enter your personal SMA grid
guard password (Inst.-Code). Please call the SMA Service Line to obtain your per­sonal SMA grid guard password.

Page 42 SBTLHCMS-IEN080411 Installation Guide

SMA Technologie AG Technical Data

8.4. 3 Country-specific Parameter Settings

The parameters listed below represent country-specific settings and are only displayed
in installer mode. All other parameters are international and can be viewed in the table
in section 8.4. 2.

Name Short

descr.

Default GER/VDE0126-1-1 IT GB

dFac-Max Hz/s 4.0 0.20 0.25

dZac-Max mOhm 600 350 350

Fac-delta- Hz 2.45 0.29 0.5

Fac-delta+ Hz 0.19 0.29 0.5

Ni-Test 1 0 0

T-Start s 2 2 180

Uac-Min V 198 198 209

Uac-Max V 260 260 261

Country settings

Germany Italy Great Britain

8.4. 4 Non-modifiable Parameters

The following parameters are displayed in the parameter list but cannot be changed:

Name Short

descr.

Fac-Tavg ms 160 160

Firmware-DC-BFR

Hardware-DC­BFR

Plimit W 4200 5100

SMA-SN

Software-BFR

Software-SRR

Uac-Tavg ms 80 80

SB 4200TL HC SB 5000TL HC

Factory setting

Installation Guide SBTLHCMS-IEN080411 Page43

Technical Data SMA Technologie AG

Page 44 SBTLHCMS-IEN080411 Installation Guide

SMA Technologie AG Inspection of the Electronic Solar Switch

9 Inspection of the Electronic Solar Switch

Check the Electronic Solar Switch for wear before plugging it in.
Check if the metal tongues inside the plug show brown discolorations.

Metal tongues

The Electronic Solar Switch can no longer safely disconnect the DC side if one of the
metal tongues is completely worn out (see figure below). The Electronic Solar Switch
must then be exchanged.

Metal tongues

Replacements for damaged Electronic Solar Switch handles are available from SMA.

Installation Guide SBTLHCMS-IEN080411 Page45

Inspection of the Electronic Solar Switch SMA Technologie AG

Page 46 SBTLHCMS-IEN080411 Installation Guide

SMA Technologie AG Replacing the Varistors

10 Replacing the Varistors

The Sunny Boy is a complex high-technology device. As a result, the possibilities for fix­ing faults on site are limited to just a few items. Do not attempt to carry out repairs other
than those described here. Use the SMA Technologie AG 24-hour exchange service
and repair service instead.

If the red LED on the status display glows continuously during operation, you should first
of all make sure that there is no ground fault in the PV generator. Only skip points 3 to
5 if the green LED is permanently lit at the same time.

1. Disconnect the Sunny Boy from the low-voltage
grid (switch the line circuit breaker to its "off" po­sition). Make sure the grid cannot be inadvert­ently reconnected and test to make sure no
voltage is present at the AC output.

2. Remove the Electronic Solar Switch.

Off!

3. Immediately remove the DC cables from the Sun­ny Boy in order to completely disconnect the PV­generator from the Sunny Boy.

Make sure you note the order of the individual
inverter inputs so you can put them back in the
right place later!

4. Taking one DC plug connector at a time, mea­sure the voltages between one DC plug connec­tor of a string and earth potential. Pay attention
to the safety instructions!

Warning!
Dangerous high voltages may be present. Danger of death!

Installation Guide SBTLHCMS-IEN080411 Page47

Replacing the Varistors SMA Technologie AG

5. If the measured voltages are constant and if their total is roughly the same as the
open-circuit voltage of the string, then there is an ground fault in this string. Its ap­proximate location can be deduced from the relationships between the voltages.

6. Repeat points 3 and 4 for each string.
If you found a ground fault, it is probably not necessary to replace the varistors.

Instead, make sure the ground fault is fixed. Generally the PV generator's installa­tion engineer should be hired for this job. In this case continue as described under
point 10, but without reconnecting the faulty string. Instead of reconnecting the
string, protect its DC plug against accidental touch contact (e.g. by fitting the pro­tective caps or using sufficient high-voltage insulating tape).

If you did not find any ground fault in the PV generators, it is likely that one of the
thermally monitored varistors has lost its protective function. These components are
wearing parts. Their functioning diminishes with age or following repeated re­sponses as a result of overvoltages. You can now check these varistors in the fol­lowing way, paying attention to the safety instructions in section :3 "Safety
Instructions" (Page 9)

7. Remove the screws that secure the cover and remove the cover from the Sunny
Boy. Disconnect the PE connection from the cover. Make sure that no voltage is
present.

8. Using a continuity tester, check all the varistors to see if there is a conducting con­nection between connectors 2 and 3. If there is no connection, then that varistor
is not working. The positions of the varistors in the Sunny Boy can be seen in the
diagram in section 4. 1 "Unit Description" (Page 11).

9. Replace the varistor concerned with a new one
as shown in the drawing to the right. Ensure the
varistor is installed the right way round! If you do
not receive a special tool for operating the termi­nal clamps with your replacement varistors, con-

Insert the spe-

cial tool to open

the terminal.

tact SMA. As an alternative, the terminal
contacts can be operated using a suitable screw­driver. Since the failure of one varistor is gener­ally due to factors that affect all varistors in a

Remove
the varistor

similar way (temperature, age, inductive over­voltages), it is highly recommended that you re­place all three varistors, not just the one that is
obviously defective. The varistors are specially
manufactured for use in the of the Sunny Boy SB
4200TL HC Multi-String and SB 5000TL HC
Multi-String and are not commercially available.
They must be ordered directly from SMA Tech-

The pole with the small loop

(crimp) must be fitted to ter­minal 1 when replacing the

varistor.

nologie AG (SMA order code: „MSWR-TV6“).

Page 48 SBTLHCMS-IEN080411 Installation Guide

SMA Technologie AG Replacing the Varistors

10. If no replacement varistors are available on site,
the Sunny Boy can temporarily run without them.
To do this, remove the varistors you identified as
being faulty and in their place, bridge the termi­nals 2 and 3 with a length of wire.

Notice!
The input modified in this way is no longer protected against overvoltag-

es! Replacement varistors should be obtained as soon as possible. In sys­tems with a high risk of overvoltages, the Sunny Boy should not be
operated without varistors.

11. Reconnect the PE connection to the cover and close the Sunny Boy.

12. Connect up the faultless PV generator strings to
the inverter. Ensure the assignment of the strings
is correct.

13. Close the unnecessary DC input sockets with the
caps included in the delivery.

14. Attach the handle of the Electronic Solar Switch.

Notice!
The Electronic Solar Switch can become damaged if it has not been at-

tached properly.
Firmly insert the handle all the way into the socket in the Sunny Boy and

check that it is firmly inserted. Never tighten the screws of the socket inside
the Sunny Boy in order to avoid that the socket locks in place.

Installation Guide SBTLHCMS-IEN080411 Page49

Replacing the Varistors SMA Technologie AG

15. Switch the line circuit breaker to the "on" posi­tion.

On

16. Now check whether the LED display indicates
that the Sunny Boy is functioning correctly.

If no ground fault and no defective varistor were found, there is probably a fault in the
Sunny Boy. In this case, contact the SMA Service Line to discuss what to do next.

Page 50 SBTLHCMS-IEN080411 Installation Guide

SMA Technologie AG Rating for a Line Circuit Breaker

11 Rating for a Line Circuit Breaker

Example for the thermal rating for a line circuit breaker in a photovoltaic electrical
power unit operated in grid-parallel mode.

A PV system with 9 inverters type Sunny Boy SB 4200TL HC Multi-String or Sunny
Boy SB 5000TL HC Multi-String is assumed, with 3 inverters per phase.

Required technical information for the inverters used

• Maximum output current = 19 A (Sunny Boy SB 4200TL HC Multi-String)

22 A (Sunny Boy SB 5000TL HC Multi-String)

• Maximum permissible fuse protection for the inverter = 25 A

The choice of cable together with the way it is routed, ambient temperatures and other
underlying conditions limit the maximum fuse protection for the cable.

• In our example we assume that the chosen cable (6 mm²) is ideally routed and
can take a nominal current of 32.2 A.

Selecting a line circuit breaker:

• The maximum possible nominal current for the cable used and the maximum pos­sible fuse protection for the inverter now limit the maximum possible nominal cur­rent for the line circuit breaker.

• In our example, 25 A is possible.

However, the thermal suitability of the line circuit breaker still needs to be checked.

Installation Guide SBTLHCMS-IEN080411 Page51

Rating for a Line Circuit Breaker SMA Technologie AG

When selecting line circuit breakers, a number of load factors need to be taken into
account. These can be found in the respective data sheets.

Example for the thermal selection of a 25 A line circuit breaker with B sensitivity
with no gap between the circuit breakers:

For example, one manufacturer's circuit breaker may be designed for an ambient tem­perature of 50 °C.

Load factors according to data sheet specifications:

• Reduction through permanent load >1h = 0.9

• Reduction when 9 circuit breakers are arranged side-by-side without gaps = 0.77

b

a

• Increase in nominal current as a result of ambient temperatures of 40 °C in the
circuit breaker panel = 1.07

c

Result:
The nominal load current for the line circuit breaker is calculated as:
Ibn = 25 A x 0.9 x 0.77 x 1.07 = 18.5 A

Summary:

The selected line circuit breaker cannot be used in our example case since the maximum
current-carrying capacity for fault-free operation is lower than the maximum output cur­rent of the inverter used. It will trip under rated operating conditions!

In this case one solution would be to ensure there is an 8 mm gap between the circuit
breakers. This would mean that the reduction factor is 0.77 instead of 0.98. As a result,
the maximum current-carrying capacity would be 23.6 A.

In addition to the thermal rating of the circuit breakers, the boundary conditions as laid
out in section "Rating for a Line Circuit Breaker in a Photovoltaic Electrical Power Unit
Operated in Grid-parallel Mode" (Page 17) and the applicable DIN VDE standards
also need to be taken into account, of course. The main ones that apply here are:

• DIN VDE 0100, part 410

• DIN VDE 0100, part 430

• DIN VDE 0298, part 4

In special applications the relevant standards must be followed.

a. Permanent loads longer than 1 hour are possible in photovoltaics.
b. When only one circuit breaker is used, this factor = 1
c. Due to the fact that the circuit breakers are rated for 50 °C.

Page 52 SBTLHCMS-IEN080411 Installation Guide

SMA Technologie AG The Communications Interface

12 The Communications Interface

Installation or replacement of the communications interface is only to be
carried out by a qualified electrician.

The communications interface is used to communicate with SMA communication devic­es (e.g. Sunny Boy Control, Sunny WebBox) or a PC with appropriate software (e.g.
Sunny Data). Depending on the selected communications interface, up to 2500 invert­ers can be interconnected. Detailed information on this topic can be found in the com­munication device manual, the software, or on the Internet at www.SMA.de.

Depending on the type of interface, there are two different ways to install the commu­nications interfaces:

• RS232, RS485, Radio Piggy-Back
(see section 12. 1 "Connection RS232, RS485, Radio Piggy-Back" (Page 54))

•Powerline
(see section 12. 2 "Powerline Connection" (Page 56))

The detailed wiring diagram for the individual communications interfaces can be found
in the communication device manual. This wiring diagram includes the following infor­mation:

• Details on the required cable type

• Which of the inverter's connections are used

• Whether jumpers need to be mounted, and if so, which jumpers

• Whether the PE needs to be connected to the cable shield

The next pages will describe the following:

• The enclosure feed-throughs for the communications interface

• The permitted cable route in the Sunny Boy

• The location of the PE connector

• The location of the screw terminals for connection of communication wires

• The location of the jumper slots

• The location of the interface port

• The location of the interface port for the PLC power module and the powerline mo­dem

Installation Guide SBTLHCMS-IEN080411 Page53

The Communications Interface SMA Technologie AG

12. 1 Connection RS232, RS485, Radio Piggy-Back

This section describes the installation of the Piggy-Backs for the different Sunny Boy com­munication systems. RS232 Piggy-Back (SMA-Order No: 232PB-MS-NR), RS485 Pig­gy-Back (SMA-Order No:: 485PB-MS-NR), Funk Piggy-Back (SMA-Order No:
BEAMPB-NR).

When opening the Sunny Boy, follow all the safety instructions as de­scribed in section 3.

Electrostatic discharges are an acute danger to the Sunny Boy and to the commu­nications interface. Ground yourself by touching PE before removing the commu­nications interface from the packaging, and before touching any components
within the Sunny Boy.

Read the communication device manual before beginning installation work. Fur­ther wiring details can be found there.

1. Open the inverter as described in section 7. 1.

2. Guide the PG screw fitting over the communication cable.

3. Thread the cable through one of the cable feed-throughs (A) on the Sunny Boy.
Use one or two cable feed-throughs, depending on the type of cable. Use the right­hand housing feed-through for the Radio Piggy-Back.

4. Screw the PG screw fitting onto the Sunny Boy.

5. Sheathe the cable inside the Sunny Boy using the silicon tube provided. The sili­cone tube is imperative for safety reasons. The interface is not to be operated with­out this silicone tube (with the exception of the Radio Piggy-Back).

6. Lay the cable in area (B) as shown in the figure to the right.

7. Ground the cable shield at the PE connector (C) if the connection diagram of the
communication device indicates this as necessary.

8. Connect the communication wires to the screw terminal strip (D) as described in
the terminal connection diagram of the communication device. Take note of the
conductors' color coding. The devices can be damaged in case the cables are not
connected correctly.

- Pin 2 Color:

- Pin 3 Color:

- Pin 5 Color:

- Pin 7 Color:

Page 54 SBTLHCMS-IEN080411 Installation Guide

SMA Technologie AG The Communications Interface

9. Connect the jumpers (E) if the connection diagram of the communication device
indicates this as necessary. The table shown to the right provides an overview of
the jumper functions.

10. Plug the communications interface to the left of the board (F).

11. Close the Sunny Boy as described in section 7. 2.

F

D

E

A Enclosure feed-throughs in the base of the Sunny Boy

B Cable route (gray surface)

C PE connector

D Screw terminals for connection of the communication wires

EJumper slots

FInterface port

12.1. 1 Jumper Functions

Jumper A Jumper B Jumper C

RS232 - - -

RS485 termination bias 1 bias 2

Radio Piggy-Back - - -

A

CB

A detailed description of the jumper functions can be found in the communication de­vice manual.

Installation Guide SBTLHCMS-IEN080411 Page55

The Communications Interface SMA Technologie AG

F

12. 2 Powerline Connection

This chapter describes the installation of the "Powerline Kit" (SMA order number:
NLMPB-MS-NR) for the mains grid communication in a Sunny Boy.

When opening the Sunny Boy, follow all the safety instructions as de­scribed in section 3.

Electrostatic discharges are an acute danger to the Sunny Boy and to the commu­nications interface. Ground yourself by touching PE before removing the commu­nications interface from the packaging, and before touching any components
within the Sunny Boy.

Read the communication device manual before beginning installation work. Fur­ther wiring details can be found there.

Two component groups must be installed in the Sunny Boy in order to make the mains
grid communication possible. These component groups and a support for the power
module are included in the "Powerline Kit" (SMA order number: NLMPB-MS-NR):

PLC power module Powerline modem

(NLM Piggy-Back)

The Sunny Boy can only be operated with a
powerline modem (NLM Piggy-Back) with ver­sion identifier "F" or higher. When installing the

MOSR05-NLM

339363 26584

Support for the

PLC power module

F

other (older) Piggy-Backs, mains grid connec­tion is not possible. Please use therefore the
powerline modem (NLM Piggy-Back) which is
included in the "Powerline Kit".

Page 56 SBTLHCMS-IEN080411 Installation Guide

SMA Technologie AG The Communications Interface

1. Open the inverter as described in section 7. 1.

2. Press the lockings at the sides of the plug connector and remove them as displayed
in the figure below.

Installation Guide SBTLHCMS-IEN080411 Page57

The Communications Interface SMA Technologie AG

3. Plug the NLM Piggy-Back into the board (F). Do not mount any jumpers.

4. Place the included support (G) of the PLC power module in the socket as seen in
the figure (the rightmost). It must snap into place.

5. Then place the PLC power module (H) in the socket as seen in the figure. The PLC
power module must snap into place.

6. Place the plug connector in the free socket of the PLC power module.

7. Close the Sunny Boy as described in section 7. 2.

F

G

H

FInterface port

G Support

H PLC power module

Page 58 SBTLHCMS-IEN080411 Installation Guide

SMA Technologie AG The Communications Interface

Note on the Different PLC Power Module Variants

Different variants of the PLC power module may be
delivered. The modules only differ in the location of
the sockets for the plug connectors, which may be ei­ther horizontally or vertically arranged (see figure).

Installation Guide SBTLHCMS-IEN080411 Page59

The Communications Interface SMA Technologie AG

Page 60 SBTLHCMS-IEN080411 Installation Guide

SMA Technologie AG Contact

13 Contact

If you have any questions or technical problems concerning the Sunny Boy, contact the
SMA Service Line. Have the following information available when you contact SMA:

• Inverter type

• Type and number of modules connected

• Communication

• Serial number of the Sunny Boy

• Blink code or display of the Sunny Boy

Address:
SMA Technologie AG
Hannoversche Strasse 1 - 5
34266 Niestetal
Germany
Tel.:[phone] - 499
Fax:[phone] - 4699
[e-mail]
www.SMA.de

Installation Guide SBTLHCMS-IEN080411 Page61

Legal Restrictions SMA Technologie AG

The information contained in this document is the property of SMA Technologie AG. Publishing its content,
either partially or in full, requires the written permision of SMA Technologie AG. Any internal company copying
of the document for the purposes of evaluating the product or its correct implementation is allowed and does
not require permission.

Exclusion of liability

The general terms and conditions of delivery of SMA Technologie AG shall apply.
The content of these documents is continually checked and amended, where necessary. However,

discrepancies cannot be excluded. No guarantee is made for the completeness of these documents. The latest
version is available on the Internet at www.SMA.de or from the usual sales channels.

Guarantee or liability claims for damages of any kind are exlcuded if they are caused by one or more of the
following:

• Improper or inappropriate use of the product

• Operating the product in an unintended environment

• Operating the product whilst ignoring relevant, statutory safety regulations in the deployment location

• Ignoring safety warnings and instructions contained in all documents relevant to the product

• Operating the product under incorrect safety or protection conditions

• Altering the product or supplied software without authority

• The product malfunctions due to operating attached or neighboring devices beyond statutory limit values

• In case of unforeseen calamity or force majeure

Software licensing

The use of supplied software produced by SMA Technologie AG is subject to the following conditions:
This software may be copied for internal company purposes and may be installed on any number of

computers. Supplied source codes may be changed or adapted for internal company purposes on your own
responsibility. Drivers may also be transferred to other operating systems. Source codes may only be published
with the written permission of SMA Technologie AG. Sub-licensing of software is not permissible.

Limitation of liability: SMA Technologie AG rejects any liability for direct or indirect damages arising from the
use of software developed by SMA Technologie AG. This also applies to the provision or non-provision of
support activities.

Supplied software not developed by SMA Technologie AG is subject to the respective licensing and liability
agreements of the manufacturer.

Trademarks

All trademarks are recognized even if these are not marked separately. Missing designations do not mean that
a product or brand is not a registered trademark.

SMA Technologie AG
Hannoversche Straße 1-5
34266 Niestetal
Germany
Tel. [phone]
Fax [phone]
www.SMA.de
E-mail: [e-mail]
© 2005 SMA Technologie AG. All rights reserved.

Page 62 SBTLHCMS-IEN080411 Installation Guide

www.SMA.de

Sales
Solar Technology

SMA Technologie AG
Hannoversche Strasse 1–5
34266 Niestetal, Germany
Tel. : [phone]
Fax: [phone]
E-Mail: [e-mail]
Freecall: +800 SUNNYBOY

Freecall: [phone]

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