SMA SI-TB-BOX-10 User Manual

US

Accessories for Sunny Island

SMARTFORMER FOR SUNNY ISLAND

Installation Manual

SI_TDBOX-IA-eng-IUS122211 | IMEN-SITDBOX-US | Version 1.1

SMA America, LLC Legal Restrictions

Copyright © 2012 SMA America,LLC. 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,LLC.

SMA America,LLC doesn’t make representations, express or implied, with respect to this
do cum ent ati on o r an y of the equip men t an d/o r so ftw are it m ay d escribe, 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,LLC nor its distributors or dealers shall
be liable for any indirect, incidental, or consequential damage 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,LLC reserves the right to make changes without notice and shall not be responsible for
any damage, including indirect, incidental or consequential damage, caused by reliance on the
material presented, including, but not limited to, omissions, typographical errors, arithmetical errors or
listing errors in the content material.

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 America, LLC

3801 N. Havana Street

Denver, CO 80239 U.S.A.

Installation Manual SI_TDBOX-IA-eng-IUS122211 3

Important Safety Instructions SMA America, LLC

IMPORTANT SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS

This manual contains important instructions for the following product:

• Smartformer for Sunny Island
This manual must be followed during installation and maintenance.
The product 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 product. To reduce the risk of personal injury and to ensure the safe installation and
operation of the product, you must carefully read and follow all instructions, cautions and warnings
in this manual.

Warnings in this document

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 in personal
injury.

Symbol Description

DANGER indicates a hazardous situation which, if not avoided, will result in
death or serious injury.

WARNING indicates a hazardous situation which, if not avoided, could result
in death or serious injury.

CAUTION indicates a hazardous situation which, if not avoided, could result
in minor or moderate injury.

NOTICE is used to address practices not related to personal injury.

4 SI_TDBOX-IA-eng-IUS122211 Installation Manual

SMA America, LLC Important Safety Instructions

Other Symbols in this document

In addition to the safety and hazard symbols described on the previous pages, the following symbols
are also used in this manual:

Symbol Description

Indicates information that is important for a specific topic or objective, but is not
safety-relevant.

☐ Indicates a requirement for meeting a specific goal.

☑ Desired result

✖A problem that could occur

Markings on this product

The following symbols are used as product markings with the following meanings.

Symbol Description

Warning regarding dangerous voltage

The product works with high voltages. All work on the product must only be
performed as described in the documentation of the product.

Risk of Fire

Improper installation of the product may cause a fire.

Beware of hot surface

The product can become hot during operation. Do not touch the product during
operation.

Observe the operating instructions

Read the documentation of the product before working on it. Follow all safety
precautions and instructions as described in the documentation.

UL1741 is the standard applied by Underwriters Laboratories to the product to
certify that it meets the requirements of the NationalElectricalCode

Installation Manual SI_TDBOX-IA-eng-IUS122211 5

®

.

General Warnings SMA America, LLC

General Warnings

General Warnings
All electri cal installations m ust be done in accordance with the local and NationalElectrical Code

ANSI/NFPA 70 or the Canadian Electrical Code® CSAC22.1. This document does not and is not
intended to replace any local, state, provincial, federal or national laws, regulation or codes
applicable to the installation and use of the product, including without limitation applicable
electrical safety codes. All installations must conform with the laws, regulations, codes and
standards applicable in the jurisdiction of installation. SMA assumes no responsibility for the
compliance or noncompliance with such laws or codes in connection with the installation of the
product.

The product contains no user-serviceable parts. For all repair and maintenance, always return the
unit to an authorized SMA Service Center.

Before installing or using the product, read all of the instructions, cautions, and warnings in this
manual.

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

Wiring of the product must be made by qualified personnel only.

®

6 SI_TDBOX-IA-eng-IUS122211 Installation Manual

SMA America, LLC Table of Contents

Table of Contents

1 Information on this Document. . . . . . . . . . . . . . . . . . . . . . 11

2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2.1 Intended Use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2.2 Qualification of Skilled Workers. . . . . . . . . . . . . . . . . . . . . . . . 13

2.3 Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3 Scope of Delivery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4 Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

4.1 Smartformer for Sunny Island . . . . . . . . . . . . . . . . . . . . . . . . . . 16

4.2 Autotransformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4.3 Bypass Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4.4 Load-Shedding Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4.5 Miniature Circuit-Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4.6 Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

4.7 Type Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

5 Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

5.1 Selecting the Mounting Location. . . . . . . . . . . . . . . . . . . . . . . . 22

5.2 Mounting the Anchorage Brackets on the

Enclosure Rear Wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

5.3 Mounting the Smartformer on a Masonry Wall . . . . . . . . . . . . 28

5.4 Mounting the Smartformer on a Wooden Wall . . . . . . . . . . . . 29

Installation Manual SI_TDBOX-IA-eng-IUS122211 7

Table of Contents SMA America, LLC

6 Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

6.1 Safety during Electrical Connection . . . . . . . . . . . . . . . . . . . . . 31

6.2 Overview of the Connection Area . . . . . . . . . . . . . . . . . . . . . . 32

6.2.1 View from Below. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

6.2.2 View from Above . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

6.2.3 Interior View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

6.2.4 System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

6.3 Selecting Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

6.4 Inserting the Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

6.5 Connecting Insulated Conductors to Spring Clamp Terminals . 39

6.6 Connecting Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

6.7 Connecting the PV Plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

6.8 Connecting the Generator or Power Distribution Grid . . . . . . . 42

6.9 Connecting the Sunny Island . . . . . . . . . . . . . . . . . . . . . . . . . . 43

6.10 Connecting the Load-Shedding Contactor . . . . . . . . . . . . . . . . 44

7 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

8 Setting the Operating Mode via the Bypass Switch . . . . 50

9 Mounting and Disassembling the Contact Hazard

Protection Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

9.1 Disassembling the Contact Hazard Protection Cover. . . . . . . . 52

9.2 Mounting the Contact Hazard Protection Cover . . . . . . . . . . . 53

10 Disconnecting the Smartformer from the

Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

11 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

8 SI_TDBOX-IA-eng-IUS122211 Installation Manual

SMA America, LLC Table of Contents

12 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

12.1 Activating Overload Protection. . . . . . . . . . . . . . . . . . . . . . . . . 58

12.2 Replacing Miniature Circuit-Breakers "F4" and "F5" . . . . . . . . . 59

13 Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

13.1 Disassembling the Smartformer. . . . . . . . . . . . . . . . . . . . . . . . . 62

13.2 Storing the Smartformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

13.3 Packaging the Smartformer. . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

13.4 Disposing of the Smartformer . . . . . . . . . . . . . . . . . . . . . . . . . . 63

14 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

15 Compliance Information . . . . . . . . . . . . . . . . . . . . . . . . . . 70

16 Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Installation Manual SI_TDBOX-IA-eng-IUS122211 9

Table of Contents SMA America, LLC

10 SI_TDBOX-IA-eng-IUS122211 Installation Manual

SMA America, LLC 1 Information on this Document

1 Information on this Document

Validity

This document applies to device type SI-TD-BOX, hardware version 1.0 and higher.

Target Group

This document is for skilled workers. Only qualified personnel are allowed to perform the tasks set
forth in this document (see Section 2.2 "Qualification of Skilled Workers", page 13).

Typography

Typography Usage Example

"light" • Terminals

• Spring clamp terminals

•Screw terminals

bold • Switch settings that you

should select

• Connect the L conductor of the AC 1
terminal of the Sunny Island to the
lower spring clamp terminal in
connecting terminal plate
"Sunny Island AC1 L".

• To have the connected loads supplied
by the Sunny Island, set the bypass
switch to ION.

Nomenclature

The following nomenclature is used in this document:

Complete designation Designation in this document

SMA Solar Technology America, LLC SMA

Smartformer for Sunny Island "Smartformer" or "product"

Sunny Boy PV inverter

Abbreviations

Abbreviation Designation Explanation

AC Alternating Current ‒

DC Direct Current ‒

PE Protective Earth ‒

PV Photovoltaics ‒

Installation Manual SI_TDBOX-IA-eng-IUS122211 11

2 Safety SMA America, LLC

SMARTFORMER

Loads

Generator

PV inverter

Battery

PV array

Power

distribution grid

Sunny Island

2Safety

2.1 Intended Use

Figure 1: Principle of a simple Sunny Island system with Smartformer

The Smartformer for Sunny Island is a pre-wired AC distribution board with an autotransformer,
bypass switch, load-shedding contactor, overload protection, and miniature circuit-breakers.

Mounting requirements:

The Smartformer is only suitable for indoor use. Do not mount the Smartformer outdoors.

• Do not mount the Smartformer on flammable construction materials.

• Do not mount the Smartformer near highly flammable materials.

• Do not mount the Smartformer in potentially explosive atmospheres.

12 SI_TDBOX-IA-eng-IUS122211 Installation Manual

SMA America, LLC 2 Safety

Electrical connection requirements:

The Smartformer must only be used with the following Sunny Island inverters:

• Sunny Island 4548‑US / 6048‑US

• Sunny Island 5048-US with labeling "Smartformer compatible" on the original packaging
Sunny Island 5048-US inverters without labeling "Smartformer compatible" on the original

packaging require an additional fuse outside of the Smartformer for Sunny Island (see
Section6.3 "Selecting Cables", page 36).

The Smartformer may be used with the following PV inverters by SMA:

• Sunny Boy 2000HF-US / 2500HF-US / 3000HF-US

• Sunny Boy 3000-US / 3800-US / 4000-US

• Sunny Boy 5000-US / 6000-US

• In off-grid systems: Sunny Boy 7000-US / 8000-US

A generator or the power distribution grid may be connected to the Smartformer. The generator or
the power distribution grid may supply the Sunny Island system with 120 V on 1 line conductor or
with 240 V on 2 line conductors. A generator and the power distribution grid may only be connected
to the Smartformer at the same time if used with an external automatic transfer switch.

General terms of use:

Only use the Smartformer in accordance with the information provided in the enclosed
documentation. Any other use can result in personal injury or property damage.

The enclosed documentation is an integral part of this product.

• Read and adhere to the documentation.

• Keep the documentation in a convenient place for future reference.

Do not operate the Smartformer if it has technical defects.
For safety reasons, it is forbidden to modify the product or install components that are not explicitly

recommended or distributed by SMA.

2.2 Qualification of Skilled Workers

The tasks described in this document are intended for skilled workers only. Skilled workers must have
the following skills:

• Knowledge about the functional principle and operation of off-grid systems and backup systems

• Knowledge of how to deal with the dangers and risks associated with installing and using
electrical devices

• Knowledge of the installation and commissioning of electrical devices

• Knowledge of all applicable standards and guidelines

• Knowledge of and adherence to this document and all safety precautions

Installation Manual SI_TDBOX-IA-eng-IUS122211 13

2 Safety SMA America, LLC

2.3 Safety Precautions

Danger to life due to electric shock

High volt ages that can result in electr ic shocks are present in t he live components of the Smartformer.

• Disconnect the Smartformer from the power supply before performing any work on the
Smartformer (see Section 10).

• Always use a contact hazard protection cover when operating the Smartformer.

• Work on the Smartformer may only be performed by a skilled worker.

• Do not touch live components of the Smartformer or other components of the Sunny Island
system.

Risk of injury due to moving parts

A generator can be started automatically by the Sunny Island. Moving parts in the generator can
crush or sever body parts.

• Only operate the generator with safety equipment provided by the manufacturer.

• Install, maintain, and operate the generator according to the manufacturer's specifications.

Risk of injury due to hot components

Components inside the Smartformer may become hot during operation. This may result in burns to
the body.

• Always use a contact hazard protection cover when operating the Smartformer.

• Allow the Smartformer to cool down before removing the contact hazard protection cover.

Property damage due to moisture and dust intrusion

The Smartformer corresponds to the NEMA 1 degree of protection when it is closed and is only
suitable for indoor installation. The intrusion of dust and moisture into the interior can damage the
Smartformer.

• Protect the Smartformer against moisture and dust.

• After working on the Smartformer, mount the contact hazard protection cover and close the
Smartformer.

• While the Smartformer is open, protect it against dust and water.

14 SI_TDBOX-IA-eng-IUS122211 Installation Manual

SMA America, LLC 3 Scope of Delivery

3Scope of Delivery

Check the delivery for completeness and any externally visible damage. Contact your specialty
retailer if the delivery is incomplete or you find any damage.

Figure 2: Components included in delivery

Position Quantity Description

A 1 Smartformer

B 4 Anchorage bracket, sealing ring, and hexagon head screw M6x8

C 4 Hexagon socket screw M8x12

D 28 Phillips screw PZ 2

E 1 2-pole miniature circuit-breaker 25 A

F 1 Upper flange plate

G1 Lower flange plate

H 1 Installation manual technical description*

* Information about the circuitry of the Smartformer in the Sunny Island can be found in the technical description.

Installation Manual SI_TDBOX-IA-eng-IUS122211 15

4 Product Description SMA America, LLC

4 Product Description

4.1 Smartformer for Sunny Island

The Smartformer for Sunny Island is a pre-wired AC distribution board with an autotransformer,
bypass switch, load-shedding contactor, overload protection, and miniature circuit-breakers.

Figure 3: Structure of the Smartformer

Position Description

A Door handles

BFlange plate

C Ventilation slots

DType label

E Rear wall of enclosure with 8 drill holes

The Smartformer is the AC distribution board in a Sunny Island system with 1 Sunny Island. The
Smartformer provides the terminals for all components in the Sunny Island system. The Smartformer
expands the scope of functions of the Sunny Island with the autotransformer, bypass switch, load­shedding contactor, overload protection, and miniature circuit-breakers.

16 SI_TDBOX-IA-eng-IUS122211 Installation Manual

SMA America, LLC 4 Product Description

Symbols on the Smartformer

Symbol Description Explanation

Spring clamp terminals Some of the terminals of the Smartformer are

executed as spring clamp terminals.
Always connect a conductor to a spring
clamp terminal as described in this document
(see Section 6.5 "Connecting Insulated
Conductors to Spring Clamp
Terminals", page 39).

4.2 Autotransformer

The autotransformer enables the following functions in a Sunny Island:

• Integration of PV inverters with an AC output voltage of 240 V

• Supply of AC loads with 120 V or 240 V

The autotransformer converts the input voltage according to the load requirements, operating in the
step-up and step-down operating modes.

•Step-up:
The Sunny Island makes an AC input voltage of 120 V available. The autotransformer converts

this AC input voltage into an AC output voltage of 240 V. The loads use one AC output with
120 V or both AC outputs with 240 V. A different load on the two 120 V outputs is
compensated by the Smartformer through power transmission.

•Step-down:
The PV inverter makes an AC input voltage of 240 V available. The autotransformer converts

this AC input voltage into an AC output voltage 120 V. The Sunny Island uses this voltage to
load the battery.

Unlike in other transformers, the input circuit and the output circuit of the autotransformer are not
galvanically isolated.

Installation Manual SI_TDBOX-IA-eng-IUS122211 17

4 Product Description SMA America, LLC

4.3 Bypass Switch

The bypass switch is a manual automatic transfer switch that makes it possible to directly supply the
loads through the generator or power distribution grid. By directly supplying the loads through the
generator or power distribution grid, the Smartformer bypasses the terminals of the PV plant and
Sunny Island. In this way, the Smartformer simplifies maintenance work and repairs.

Figure 4: Overview of the bypass switch

Position Description Explanation

A Switch position "ION" The Sunny Island supplies the loads and, in

doing so, integrates the generator or power
distribution grid, along with the PV plant.

B Switch position "O OFF" The loads are not supplied with voltage.

C Switch position "II ON" Generators or power distribution grids supply

the loads directly.

4.4 Load-Shedding Contactor

The load-shedding contactor is an automatic switch-off device used to protect the battery from deep
discharge.

When a predefined charge status limit of the battery is reached, the Sunny Island triggers the load­shedding contactor. The load-shedding contactor disconnects the loads from the Sunny Island system.
By doing so, the Sunny Island prevents deep battery discharge.

18 SI_TDBOX-IA-eng-IUS122211 Installation Manual

SMA America, LLC 4 Product Description

4.5 Miniature Circuit-Breaker

The miniature circuit-breakers protect the connected conductors against destruction due to
overheating. Each of the miniature circuit-breakers can be manually activated or can be tripped
automatically.

To be able to trip automatically, each miniature circuit-breaker monitors the electric current in the
connected conductors. When the current becomes too high, the miniature circuit-breaker interrupts the
flow of current and thus prevents overheating of the conductors.

Figure 5: Overview of the miniature circuit-breakers

Position Description Explanation

A Upper switch position The miniature circuit-breaker is closed.

B Lower switch position The miniature circuit-breaker is open.

Installation Manual SI_TDBOX-IA-eng-IUS122211 19

4 Product Description SMA America, LLC

4.6 Overload Protection

The overload protection protects the autotransformer against damage from overheating or a short
circuit. The overload protection identifies overheating or a short circuit by monitoring the currents in
the autotransformer. If currents become too high, the overload protection is tripped with a predefined
time delay. The time delay prevents tripping of the overload protection during brief switch-on current
peaks.

Figure 6: Overview of the overload protection

Position Description Explanation

A Switch position "1" The overload protection is in its normal operating state.

Current is flowing through the primary side and the secondary
side of the autotransformer.

B Switch position "0" The overload protection has been tripped. The current flow is

interrupted on the secondary side of the transformer.

20 SI_TDBOX-IA-eng-IUS122211 Installation Manual

SMA America, LLC 4 Product Description

4.7 Type Label

The type label provides a unique identification of the Smartformer. The type label is on the right-hand
side of the enclosure.

Figure 7: Layout of the type label

Position Description Explanation

AModel Device type

B Serial No. Serial number of the Smartformer

C Date of manufacture –

D Device-specific characteristics ‒

Installation Manual SI_TDBOX-IA-eng-IUS122211 21

5 Mounting SMA America, LLC

5Mounting

5.1 Selecting the Mounting Location

Danger to life due to fire or explosion

Despite careful construction, electrical devices can cause fires.

• Do not mount the Smartformer on flammable construction materials.

• Do not mount the Smartformer near highly flammable materials.

• Do not mount the Smartformer in potentially explosive atmospheres.

Danger to life due to electric shock

Penetrating moisture may result in voltage being applied to parts of the mounting location.

• Do not mount the Smartformer outdoors.

Destruction of the Smartformer due to direct solar irradiation

Direct solar irradiation can damage the paintwork on the Smartformer enclosure and lead to
enclosure corrosion.

• Ensure that the Smartformer is not exposed to direct solar irradiation.

Requirements for the mounting location:

☐ A firm surface must be available for mounting, such as a masonry wall, studs, or posts. In living

areas, make sure that the surface is no t ma de o f pl ast erb oar d or similar. The Smartformer makes
noises when in use, which can be regarded as a nuisance.

☐ The mounting location must be suitable for the weight and dimensions of the Smartformer

(see Section 14 "Technical Data", page 64).

☐ The mounting location is clear and has safe access at all times without any additional aids being

necessary (such as scaffolding or lifting platforms). Non-fulfillment of these criteria may restrict
servicing.

☐ The ambient conditions are met (see Section 14 "Technical Data", page 64). This ensures

optimal operation of the Smartformer.

☐ The mounting location must not be exposed to direct solar irradiation.

22 SI_TDBOX-IA-eng-IUS122211 Installation Manual