SMA SUNNY BOY 5000, SUNNY BOY 3600 Service Manual
ServiceManual
SUNNY BOY 3600 / 5000 SMART ENERGY
BATTERY PACK SMART ENERGY
SB36-50SE-SG-en-10 | Version 1.0
AMERICAN ENGLISH
Legal Provisions
The information contained in these documents is property of SMA Solar Technology AG. Any
publication, whether in whole or in part, requires prior written approval by SMA Solar Technology
AG. Internal reproduction used solely for the purpose of product evaluation or other proper use is
allowed and does not require prior approval.
SMA Warranty
The current warranty regulations are included with your device. You can download the version on
the Internet at www.SMA-Solar.com or obtain a printed version from the regular distribution
channels.
Trademarks
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not mean that a product or symbol is not trademarked.
The BLUETOOTH® word mark and logos are registered trademarks of Bluetooth SIG, Inc. and any
use of these marks by SMA Solar Technology AG is under license.
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Organization, Inc.
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SMA Solar Technology AG
Sonnenallee 1
34266 Niestetal
Germany
Tel. +49 561 9522-0
Fax +49 561 9522-100
www.SMA.de
E-mail: info@SMA.de
© 2004 to 2014 SMA Solar Technology AG. All rights reserved.
Legal Provisions
SMA Solar Technology AG
Service ManualSB36-50SE-SG-en-102
Table of Contents
1 Information on this Document ................................................. 4
2 Safety......................................................................................... 6
2.1 Skills of Qualified Persons .................................................................. 6
2.2 Safety Precautions............................................................................... 6
2.3 Disconnecting the Inverter from Voltage Sources ............................. 8
3 Cleaning the Inverter................................................................ 11
4 Troubleshooting ........................................................................ 12
4.1 LED Signals.......................................................................................... 12
4.2 Event Messages................................................................................... 12
4.3 Error Messages ................................................................................... 13
5 Checking the PV System for Ground Faults............................ 26
6 Checking the Function of the Varistors.................................... 29
7 Replacing the Varistors ............................................................ 31
8 Testing the Function of the Battery Pack ................................. 32
9 Recommissioning the Inverter.................................................. 33
10 Decommissioning the Inverter ................................................. 35
11 Spare Parts................................................................................ 38
12 Contact....................................................................................... 39
Table of Contents
SMA Solar Technology AG
Service Manual 3SB36-50SE-SG-en-10
1 Information on this Document
This document describes how to rectify certain errors and how to replace defective components.
This document supplements the documents that are enclosed with each product and does not
replace any locally applicable standards or directives. Read and observe all documents supplied
with the product.
Validity
This document is valid for the following device types from firmware version 2.02.17.R:
• SB 3600SE-10 (Sunny Boy 3600 Smart Energy)
• SB 5000SE-10 (Sunny Boy 5000 Smart Energy)
Target Group
This document is intended for qualified persons. Only persons with the appropriate skills are
allowed to perform the tasks described in this document (see Section2.1 "Skills of Qualified
Persons", page6).
Links to additional information can be found at www.SMA-Solar.com:
Document title Document type
SUNNY BOY 3600 / 5000 SMART ENERGY
BATTERY PACK SMART ENERGY
Operating Manual
BATTERY PACK SMART ENERGY Technical Information
Inverter Replacement in PV Systems with Com-
munication Products and Replacement of the
SMAEnergyMeter
Installation Manual
Parameter List Technical Information
Order Form for the SMAGridGuardCode Certificate
Webconnect Systems in SunnyPortal User Manual
SunnyHomeManager in SunnyPortal User Manual
Symbols
Symbol Explanation
Indicates a hazardous situation which, if not
avoided, will result in death or serious injury
Indicates a hazardous situation which, if not
avoided, can result in death or serious injury
Indicates a hazardous situation which, if not
avoided, can result in minor or moderate injury
Indicates a situation which, if not avoided, can result in property damage
1 Information on this Document
SMA Solar Technology AG
Service ManualSB36-50SE-SG-en-104
Symbol Explanation
Sections describing activities to be performed by
qualified persons only
Information that is important for a specific topic or
goal, but is not safety-relevant
Indicates a requirement for meeting a specific goal
Desired result
A problem that might occur
Nomenclature
Complete designation Designation in this document
Battery Pack Smart Energy BatteryPack
Sunny Boy 3600 / 5000 Smart Energy Inverter, product
1 Information on this Document
SMA Solar Technology AG
Service Manual 5SB36-50SE-SG-en-10
2 Safety
2.1 Skills of Qualified Persons
The tasks described in this document must only be performed by qualified persons. Qualified
persons must have the following skills:
• Knowledge of how an inverter works and is operated
• Training in how to deal with the dangers and risks associated with installing and using
electrical devices, batteries and systems
• Training in the installation and commissioning of electrical devices and systems
• Knowledge of the applicable standards and directives
• Knowledge of and compliance with this document and all safety precautions
• Knowledge of and compliance with the documents of the battery manufacturer and all safety
precautions
• Knowledge of and compliance with the regulations of the European Agreement concerning
the International Carriage of Dangerous Goods by Road (ADR) for packaging, transport and
labeling of dangerous goods
• Training in accordance with Section 1.3 ADR for packaging and transport of the Battery Pack
Smart Energy
2.2 Safety Precautions
This section contains safety precautions that must be observed at all times when working on or with
the product.
To prevent personal injury and property damage and to ensure long-term operation of the product,
read this section carefully and follow all safety precautions at all times.
Danger to life due to high voltages of the PV array
When exposed to sunlight, the PV array generates dangerous DC voltage which is present in the
DC conductors and the live components of the inverter. Touching the DC conductors or the live
components can lead to lethal electric shocks. If you disconnect the DC connectors from the
inverter under load, an electric arc may occur leading to electric shock and burns.
• Do not touch uninsulated cable ends.
• Do not touch the DC conductors.
• Do not touch any live components of the inverter.
• Have the inverter mounted, installed and commissioned by qualified persons with the
appropriate skills only.
• If an error occurs, have it rectified by qualified persons only.
• Prior to performing any work on the inverter, disconnect it from all voltage sources as
described in this document (see Section2.3, page8).
2 Safety
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Danger to life due to high voltages on the BatteryPack
Lethal voltage is present at the pin connector for the power cable. Reaching into the pin
connector for the power cable can result in lethal electric shock.
• Do not open the BatteryPack.
• Do not wipe over the Battery Pack with a damp cloth.
• Leave the protective caps on the pin connectors for the power cable and the data cable until
the inverter cables are connected to the Battery Pack.
• Only operate the BatteryPack with its protective cover. The protective cover is separately
packed.
• Prior to performing any work on the inverter or the Battery Pack, disconnect the inverter from
all voltage sources as described in this document (see Section2.3, page8).
Danger to life due to electric shock
Touching an ungrounded PV module or an array frame can cause a fatal electric shock.
• Connect and ground the PV modules, array frame and electrically conductive surfaces so
that there is continuous conduction. Observe the applicable local regulations.
Risk of chemical burns from electrolyte or toxic gases
During normal operation, no electrolyte can leak from the Battery Pack and no toxic gases can
form. Despite careful construction, if the Battery Pack is damaged or a fault occurs, it is possible
that electrolyte may be leaked or toxic gases formed.
• Store the Battery Pack in a cool and dry place.
• Do not drop the Battery Pack or damage it with sharp objects.
• Only set the Battery Pack down on its back, i.e., on the side with the mounting lugs.
• Do not open the BatteryPack.
• Only operate the Battery Pack at ambient temperatures between 0°C and +40°C.
• Do not install or operate the Battery Pack in potentially explosive atmospheres or areas of
high humidity.
• If moisture has penetrated the Battery Pack (e.g. due to a damaged enclosure), do not install
or operate the Battery Pack.
• In case of contact with electrolyte, rinse the affected areas immediately with water and
consult a doctor without delay.
2 Safety
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Service Manual 7SB36-50SE-SG-en-10
Risk of burns due to hot enclosure parts
Some parts of the enclosure can get hot during operation.
• During operation, do not touch any parts other than the enclosure lid of the inverter.
Damage to the inverter due to electrostatic discharge
Touching electronic components can cause damage to or destroy the inverter through
electrostatic discharge.
• Ground yourself before touching any component.
Damage to the display or the type label due to the use of cleaning agents
• If the inverter is dirty, clean the enclosure, the cooling fins, the enclosure lid, the type label,
the display and the LEDs using only water and a cloth.
2.3 Disconnecting the Inverter from Voltage Sources
1. Disconnect the circuit breaker and secure it against reconnection.
2. If the multi-function relay is used, switch off the load supply voltage, if necessary.
3. Turn the DC load-break switch towards OFF until it snaps into place at position O.
4. Wait until all LEDs and the display have gone out.
5.
Danger to life due to high voltages
The capacitors in the inverter take five minutes to discharge.
• Wait five minutes before opening the enclosure lid.
6.
Risk of injury from dropping the enclosure lid
After removing the last screw, the enclosure lid could fall off.
• Remove all screws of the enclosure lid using an Allen key (AF5). When removing the last
screw, support the enclosure lid with one hand. Then remove the enclosure lid by pulling
it forwards and make sure that the conical spring washers are retained.
2 Safety
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Service ManualSB36-50SE-SG-en-108
7. Grip behind the left-hand side of the protective
cover and lever it loose. Then lift the protective
cover forwards and off.
8. Hold the Battery Pack by the side handles, and
slide it to the left of the wall mounting plate up to
the stop. This deactivates the lift-off protection of
the Battery Pack and gives you more room to
pull out the cables.
9. Remove the data cable from the BatteryPack.
Press the lateral brackets in and pull the plug out
of the pin connector.
10. Remove the power cable from the BatteryPack.
Turn the mating plug to the left until it releases
and pull it out of the pin connector.
11. If the protective caps of the pin connectors for the data cable and the power cable are
available, use them to cover the corresponding pin connectors of the Battery Pack.
12. Insert the data cable and power cable into the bracket on the left-hand side of the inverter.
2 Safety
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Service Manual 9SB36-50SE-SG-en-10
13. Flip the DC contact protection up and press
firmly until it snaps into place.
14. Use a current clamp to ensure that no current is present in the DC cables.
15. Unlock and remove all DC connectors. Insert a flat-blade screwdriver or an angled
screwdriver (blade width: 3.5mm) into one of the side slots and pull the DC connectors
straight out. Do not pull on the cable.
16. Ensure that no voltage is present at the DC inputs on the inverter.
17. Ensure that no voltage is present on the
ACconnecting terminal plate between L and N
using a suitable measuring device. Insert a test
probe in each round opening of the terminal.
18. Ensure that no voltage is present on the
ACconnecting terminal plate between L and PE
using a suitable measuring device. Insert a test
probe in each round opening of the terminal.
19. If you are using the multifunction relay, ensure that no voltage is present between any of the
terminals on the multifunction relay and PE on the AC connecting terminal plate.
20.
Damage to the inverter due to electrostatic discharge
Touching electronic components can cause damage to or destroy the inverter through
electrostatic discharge.
• Ground yourself before touching any component.
2 Safety
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Service ManualSB36-50SE-SG-en-1010
3 Cleaning the Inverter
Damage to the display or the type label due to the use of cleaning agents
• If the inverter is dirty, clean the enclosure, the cooling fins, the enclosure lid, the type label,
the display and the LEDs using only water and a cloth.
• If the cooling fins on the rear of the enclosure are dirty, clean them using a soft brush.
• If the air ducts on the top of the inverter are dirty, clean them using a soft brush.
• If the protective cover of the Battery Pack is dirty, clean it with a dry cloth.
• If the Battery Pack is dirty, clean it with a dry cloth.
3 Cleaning the Inverter
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Service Manual 11SB36-50SE-SG-en-10
4 Troubleshooting
4.1 LED Signals
The LEDs indicate the operating state of the inverter.
LED Status Explanation
Green LED glowing Operation
flashing The requirements for the connection to the utility
grid have not been met.
Red LED glowing Error
The red LED indicates an error (see Section4.3
"Error Messages", page13).
Blue LED - No function
4.2 Event Messages
Display message Cause
Set parameter The parameter change is adopted.
Parameters set success-
fully
The parameter changes were successfully adopted.
Update file OK The update file found is valid.
Memory card is read USB stick (memory card) is searched for the update file and the update
file is checked.
No new update on the
memory card
On the USB stick (memory card), there is an update file that has already
been used.
Update communication The inverter is updating the communication component.
Update main CPU The inverter is updating the inverter component.
Update completed The inverter has successfully completed the update.
Condition test success-
ful
Conditions from the update file have been tested successfully.
Update transport
started
Update file is being copied.
Update transport successful
Update file was copied successfully to the inverter's internal memory.
Update BMS Battery management software (BMS) is updated.
Grid parameter un-
changed
The parameters have been locked and cannot be changed.
4 Troubleshooting
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Service ManualSB36-50SE-SG-en-1012
4.3 Error Messages
Error number Display message, cause and corrective measures
101 to 103
Grid fault
The grid voltage or grid impedance at the connection point of the inverter
is too high. The inverter has disconnected from the utility grid.
Corrective measures:
• Check whether the grid voltage at the connection point of the
inverter is permanently in the permissible range. If the grid voltage is
outside the permissible range due to local grid conditions, contact
the grid operator. The grid operator must agree with an adjustment
of the voltage at the feed-in point or with a change of the monitored
operating limits.
If the grid voltage is permanently within the permissible range and
this message is still displayed, contact the SMAServiceLine.
202 to 205
Grid fault
The utility grid has been disconnected, the AC cable is damaged or the
grid voltage at the connection point of the inverter is too low. The inverter
has disconnected from the utility grid.
Corrective measures:
• Make sure that the circuit breaker is switched on.
• Make sure that the AC cable is not damaged.
• Make sure that the AC cable is correctly connected.
• Check whether the grid voltage at the connection point of the
inverter is permanently in the permissible range.
If the grid voltage is outside the permissible range due to local grid
conditions, contact the grid operator. The grid operator must agree
with an adjustment of the voltage at the feed-in point or with a
change of the monitored operating limits.
If the grid voltage is permanently within the permissible range and
this message is still displayed, contact the SMAServiceLine.
4 Troubleshooting
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Service Manual 13SB36-50SE-SG-en-10
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