SMA WB 5000 User Manual

Windy Boy 5000
Windy Boy 6000
Inverter for Wind Energy Power Plants

Operating Instructions Version 1.0 WB50_60-11:FE4105

TBE-WB50-60

SMA Technologie AG Revision Histroy

Revision History

Document number Changes Author

WB50_60-11:FE4105 First issue Welzel

Operating Instructions WB50_60-11:FE4105 Page 3

SMA Technologie AG

Page 4 WB50_60-11:FE4105 Operating Instructions

SMA Technologie AG Explanation of Symbols used in this Document

Explanation of Symbols used in this Document

This symbol indicates information that is essential for a trouble-free
and safe operation of the product. Please read these sections care­fully in order to avoid any damages of the equipment and for op­timal personal protection.

This symbol indicates information that is required for the optimal operation of
the product. Read these sections carefully in order to ensure an optimal ope­ration of the product and all its features.

This symbol indicates an example.

Operating Instructions WB50_60-11:FE4105 Page 5

Legal Restrictions SMA Technologie AG

Liability exclusion

The information contained in this documentation are the property of SMA Technologie AG. No part of this
documentation may be published without written permission from SMA Technologie AG. A reproduction for
internal purposes for the evaluation of the product or an appropriate application is permitted and does not
require authorization.

All information are based on our "General Terms and Conditions of Delivery of SMA Technologie AG”.
The content of this documentation is reviewed continuously and adjusted, if necessary. SMA Technologie
AG provides this documentation without exclusion of deviations and without warranty of completeness. You
will find the current version on the Internet at www.SMA.de or can obtain it via the usual sales channels.
Warranty or liability claims for all kinds are excluded in case of damages due to:

• Inappropriate use of the product

• Operation of the product in an improper environment

• Operation of the product without considering the relevant safety regulations

• Non-fulfillment of the warnings or safety instructions described in the documentation for the product

• Operation of the product under faulty conditions concerning security and protection

• Arbitrary changing of the product or the provided software

• Failure of the product due to interference of connected or contiguous devices out of legal limit values

• Disasters and force majeure

Software Licensing

The use of the provided software by SMA Technologie AG is subject to the following conditions:
The software may be reproduced for internal purposes and installed on any number of computers. Provided
source codes can be changed and adjusted on the company’s own authority according to the internal
purpose. Driver may be ported to other operating systems as well. No part of the source codes may be
published without written permission of SMA Technologie AG. Sublicensing of the software is not
acceptable.

Liability limitation: SMA Technologie AG disclaims liability for any direct or indirect consequential damages
arising from the use of the software produced by SMA Technologie AG. The same applies for the provision
and/or non-provision of support.

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

Trademarks

All brand and product names used herein are trademarks or registered trademarks of their respective
holders, although they may not be specifically designated as such.

SMA Technologie AG
Hannoversche Strasse 1-5
34266 Niestetal
Germany
Tel. [phone] – 0
Fax [phone] – 100

www.SMA.de

E-Mail: [e-mail]

© 2005 SMA Technologie AG. All rights reserved.

Page 6 WB50_60-11:FE4105 Operating Instructions

SMA Technologie AG Table of Contents

Table of Contents

1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3 Unit description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3.1 Appropriate usage of the Windy Boy 5000 / 6000. . . . . . . . .13

3.2 Device construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

3.3 Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

3.3.1 Normal operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

3.3.2 Critical, faulty operation . . . . . . . . . . . . . . . . . . . . . . . . .18

3.3.3 Non-critical, faulty operation . . . . . . . . . . . . . . . . . . . . . .18

3.3.4 Description of the operational status . . . . . . . . . . . . . . . .19

3.4 Messages in the optional display . . . . . . . . . . . . . . . . . . . . . .25

4 Setting the display language . . . . . . . . . . . . . . . . . . 29

5 Maintenance and care. . . . . . . . . . . . . . . . . . . . . . . 31

6 Turbine operation . . . . . . . . . . . . . . . . . . . . . . . . . . 33

6.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

6.2 Characteristic curve function. . . . . . . . . . . . . . . . . . . . . . . . . .33

6.3 Characteristic curve operation in "Turbine" operating mode . . .36

6.4 General setting example . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

7 Maintenance and care. . . . . . . . . . . . . . . . . . . . . . . 39

8 Expansions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

8.1 Sunny Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

8.2 Sunny Data via Powerline . . . . . . . . . . . . . . . . . . . . . . . . . . .42

8.3 Sunny Data over RS232 . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

8.4 Sunny Data over RS485 . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

8.5 Sunny Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

8.6 Sunny Data Control over Sunny Beam . . . . . . . . . . . . . . . . . .44

8.7 Sunny Boy Control Light. . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

8.8 Sunny Boy Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

8.9 Sunny Boy Control Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

8.10 Sunny Data Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

8.11 Sunny WebBox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

8.12 Sunny Portal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

8.13 Sunny TV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

9 Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

9.1 Windy Boy 5000. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

9.1.1 DC connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

9.1.2 Grid connection data . . . . . . . . . . . . . . . . . . . . . . . . . . .50

9.1.3 General data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

9.2 Windy Boy 6000. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

Operating Instructions WB50_60-11:FE4105 Page 7

Table of Contents SMA Technologie AG

9.2.1 DC connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

9.2.2 Grid connection data . . . . . . . . . . . . . . . . . . . . . . . . . . .53

9.2.3 General data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

10 General information. . . . . . . . . . . . . . . . . . . . . . . . . 55

10.1 Measurement channels and messages. . . . . . . . . . . . . . . . . . .55

10.1.1 Status messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

10.1.2 Windy Boy 5000 / 6000 Operating parameters . . . . . . .57

10.2 Fault messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

10.3 Declaration of conformity (CE) . . . . . . . . . . . . . . . . . . . . . . .63

10.4 Import certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64

11 Stand-alone systems. . . . . . . . . . . . . . . . . . . . . . . . . 65

12 Contact. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Page 8 WB50_60-11:FE4105 Operating Instructions

SMA Technology AG Introduction

1 Introduction

The installation of the Windy Boy 5000 / 6000 may only be done
by qualified technicians. The installer must be approved by the
utility company. Please read the installation guide carefully before
you begin with the installation. The installation of utility interactive
power sources must be compliant with all applicable regulations of
the utility company and with all applicable regulations and
standards.

The Windy Boy inverters make it possible to operate small wind turbines as grid­connected systems. Grid-connected means that the energy generated by the wind
turbine can be fed directly into an existing house power grid, a stand-alone power
system, or the mains supply.

To this end, the Windy Boy converts the direct current (DC) from permanent-magnet
wind turbines, which vary with speed, into grid-compatible alternating current (AC).
The Windy Boy requires the constant presence of mains supply voltage!

The Windy Boy 5000 / 6000 complies with all 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. This also encompasses the regulations of the German
Professional Association for Precision Engineering and Electro technology relating to
"Automatic switching of electrical power units" (SMA grid guard) and/or DIN VDE

0126. In addition to this, the Windy Boy 5000 / 6000 conforms to the
electromagnetic tolerance regulations and the low-voltage regulations of the relevant
combined European norms, as confirmed in the CE conformity declaration (10.3
"Declaration of conformity (CE)” (page 63)).

The documentation provided here covers all such topics that are of interest when
operating Windy Boy 5000 / 6000 inverters. In addition to explanations of the
operational methods of the device and detailed technical data, advice as to data
capture and analysis is also provided.

Information relating to the installation and commission of the Windy Boy 5000 /
6000 should be taken from the installation instructions delivered with the device. The
Windy Boy 5000 / 6000 inverter has a special operational mode for wind turbines
which allows performance adjustment to the characteristic curve of the generator. In
this way you will obtain maximum yields from your wind turbine.

A wide input voltage range, high efficiency and a freely configurable output
characteristic curve with the highest level of reliability are only some of the properties
that are useful for your grid-connected system, or in a stand-alone system when
combined with the Sunny Island.

Operating instructions WB50_60-11:FE4105 Page 9

Introduction SMA Technology AG

The Windy Boy 5000 / 6000 is compatible with all SMA communications products
(RS232, RS485, Powerline, Wireless, Display), providing numerous possibilities for
diagnosis, data visualization and remote maintenance of your small wind turbine
system.

For stand-alone systems, that use the Sunny Island: Please configure your
Windy Boy 5000 / 6000 according to the specifications in the Sunny Island
manual.

Configuration of the V/I properties of the Windy Boy 5000 / 6000 with respect
to your wind turbine: the parameters U

WindMax must be configured to guarantee optimum operation of your

U

DC

Start, UDCWindStart and

PV

Windy Boy 5000 / 6000 with your wind turbine. The configuration process is
described in chapter 6 "Turbine operation” (page 33).

Apart from the parameter settings, the Windy Boy 5000 / 6000 is identical to the
Sunny Mini Central photovoltaic inverter and can therefore also be used as a PV
inverter. Please download the Sunny Mini Central manual from www.SMA.de, and
if you are planning to use the Windy Boy 5000 / 6000 in a photovoltaic system
please contact us on the SMA hotline.

Page 10 WB50_60-11:FE4105 Operating instructions

SMA Technology AG Safety information

2 Safety information

Opening of the device, and any

•electrical installation,

Windy

Boy

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The temperature of individual parts of the case of the Windy Boy
5000 / 6000 - in particular the temperature of the heatsink - can
reach 60 °C in normal operation. Touching could result in burns!

The Windy Boy 5000 / 6000 contains an independent mains disconnection
device, the "SMA grid guard". It ensures that the Windy Boy 5000 / 6000
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 0126 (4.99), which forms a part of these
regulations.

•repair or

•modification

of the Windy Boy 5000 / 6000 may only be
performed by qualified electrical personnel.
Even when no external voltage is present,
the device can still contain high voltages and
the danger of electrical shock.

Operating instructions WB50_60-11:FE4105 Page 11

Safety information SMA Technology AG

Page 12 WB50_60-11:FE4105 Operating instructions

SMA Technology AG Unit description

3 Unit description

3.1 Appropriate usage of the Windy Boy 5000 / 6000

The Windy Boy 5000 / 6000 is designed for the conversion of DC voltage from a
wind turbine (permanent magnet generator) into AC voltage for feeding into the
public mains supply. The technical data are described in more detail in chapter 9
"Technical data” (page 49).

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Overvoltage Protection

Control unit

Control unit

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Windy

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Upv

903W

3

30V

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Wind Generator

Converter

Rectifier

Windy Boy

Public Mains Grid

Many wind turbine manufacturers offer an extra over-voltage protection module.
These components prevent the destruction of the downstream Windy Boy in the case
of overvoltage.

Overvoltage can occur under the following conditions:

• High turbine rotation speeds under strong wind conditions

• An increase in turbine rotation speed caused by load-shedding when the Windy
Boy is disconnected from the mains supply e.g. in the case of mains interference
or power outage.

The overvoltage protection system has the following tasks:

• When a pre-defined voltage is reached, the Windy Boy is disconnected from the
generator and a short-circuit slows the generator and/or brings it to a standstill.

• Some devices reduce the turbine rotation speed, and thus the generator output
voltage, by switching in a resistor assembly (Dumpload). The electrical energy
generated by the turbine is then converted to heat.

Operating instructions WB50_60-11:FE4105 Page 13

Unit description SMA Technology AG

In grid-connected systems, we recommend the use of one of the electronic protection
mechanisms described here. Please note that overvoltage on the Windy Boy can lead
to destruction of the device. In addition to this, you lose the right to all warranty
claims - even if the maximum input voltage of the Windy Boy is only exceeded for a
short time.

The electronic protection systems described here are preferable to mechanical
solutions (pitch control, "turning out of the wind") in every case.

Any other use of the Windy Boy 5000 / 6000 leads to loss of the right to all warranty
claims.

In case of overvoltage, immediately disconnect the DC input of the
Windy Boy 5000 / 6000! The presence of excessive input voltage
can lead to irreparable damage!

When the Windy Boy 5000 / 6000 receives an excessive DC input voltage, it
automatically disconnects from the mains supply and no longer feeds power
into the grid. When the Windy Boy 5000 / 6000 is in operation, you must
always first disconnect the AC voltage (mains supply) and only then should you
disconnect the DC voltage from the Windy Boy 5000 / 6000!

Page 14 WB50_60-11:FE4105 Operating instructions

SMA Technology AG Unit description

3.2 Device construction

An attractive, functional design is one of the major design objectives of the entire
Windy Boy 5000 / 6000 product range. In its basic configuration, the Windy Boy
5000 / 6000 has the proven status display consisting of three LEDs. An extra display
can be provided already installed or can be retrofitted.

As long as it is installed and commissioned according to the technical specifications,
the Windy Boy 5000 / 6000 can be operated without any further modification or
configuration. The device parameters can however be modified, if required.

+

Windy Boy 5000 / 6000 Enclosure IP54 (outside installation possible)

DC - input with 4 x 2 DC connectors

+

+

+

Characte-

ristic
wind

curve

Overvoltage

protection:

Thermally
monitored

varistors

Bridge

Optional

display

(IP65)

Optional

communi-

cations

interface:

RS232
RS485

Powerline

Transformer

OptiCool

SMA

Grid Guard

R

An extra communications interface is required for ideal adaptation
of the Windy Boy 5000 / 6000 to suit the particular wind turbine
being used, and this can also be used for reporting operation data.
For further details, please refer to chapter 8 "Expansions”
(page 41).

L

N

AC - output with terminals

PE

Operating instructions WB50_60-11:FE4105 Page 15

Unit description SMA Technology AG

All DC connections and connections for the mains supply, as well as any optional
communications connections are to be found on the underside of the Windy Boy
5000 / 6000. Each of the + and - DC connections are internally connected in parallel
within the Windy Boy 5000 / 6000.

Plug connector
for DC+

Plug connector
for DC-

Cable opening for the
mains supply connection

Opening for optional communication via
RS232, RS485 or radio (PG16)

Page 16 WB50_60-11:FE4105 Operating instructions

SMA Technology AG Unit description

3.3 Operating modes

The operational status is displayed using three light-emitting diodes (LEDs) in the
cover of the Windy Boy 5000 / 6000. To allow the device to signal its operational
status via the integrated LEDs, the Windy Boy 5000 / 6000 must be connected to the
DC side of the system. There must be enough wind energy present, so that the Windy
Boy 5000 / 6000 has adequate DC voltage.

Windy

Boy

Pac 903W
Upv 330V

Netzwechselrichter für Windenergieanlagen
Grid tied inverter for wind turbines

Especially in the first year of operation, the operator of the system should
check this display under different wind speeds.

A complete description of the possible displays can be found in chapter 3.3.4
"Description of the operational status” (page 19). These can be split into three
categories:

3.3.1 Normal operation

As long as the green control LED is on, or blinking, the Windy Boy 5000 / 6000 is
operating normally. The simultaneous illumination of all three LEDs is also an
indication of normal operation ("Initialization"). All other displays are a sign of
abnormal operation.

Operating instructions WB50_60-11:FE4105 Page 17

Unit description SMA Technology AG

3.3.2 Critical, faulty operation

A comprehensive safety concept limits the number of critical conditions that can occur
to a single situation:

Input voltage exceeds the permitted value

This is indicated by the following blink-code on the yellow LED:

The yellow LED
illuminates 4 times

LED on

LED off

3s 1s1s 1s 1s

5s

The message is repeated 3 times
and then begins again.

The yellow fault LED illuminates for 5 seconds when the fault occurs, and then begins
displaying the blink code of: 3 seconds off and then 4 times briefly on. This code is
displayed three times in succession. If the fault is still present, the fault display starts
again from the beginning.

The presence of excessive input voltage can lead to irreparable
damage! Immediately disconnect the DC input of the Windy Boy
5000 / 6000.

12

34

When the Windy Boy 5000 / 6000 receives an excessive DC input voltage, it
automatically disconnects from the mains supply and no longer feeds power
into the grid. When the Windy Boy 5000 / 6000 is in operation, you must
always first disconnect the AC voltage (mains supply) and only then should you
disconnect the DC voltage from the Windy Boy 5000 / 6000!

3.3.3 Non-critical, faulty operation

All other fault codes indicate some form of faulty operation, which are not usually
dangerous to people or equipment, but which should nevertheless be investigated
and corrected.

Despite all precautions, it is possible that other faults may occur that cannot be
displayed (e.g. failure of the status display). In order to recognize such faults, the
operator of the system should use the explanations in chapter 3.3.4 "Description of
the operational status” (page 19) to check the plausibility of the displayed status.
Further detailed diagnoses are possible using the communications options detailed in
chapter 8 "Expansions” (page 41).

Page 18 WB50_60-11:FE4105 Operating instructions

SMA Technology AG Unit description

3.3.4 Description of the operational status

No (or low) input voltage

The Windy Boy 5000 / 6000 is in
Standby mode. This situation occurs

All LEDs are off.

Initialization

All LEDs are on.

Working mode

Green LED is on.

when the input performance at the
Windy Boy 5000 / 6000 is too low for
feeding the mains supply (DC input
voltage < approx. 80 V) and for
satisfying the on-board power
requirements.

The on-board computer of the Windy
Boy 5000 / 6000 is presently in the
initialization process. The DC input
voltage of the Windy Boy 5000 / 6000
lies between approx. 80 V and approx.
120 V. The power is adequate for the on­board power requirements but
insufficient for mains supply feed-in or for
data transmission.

The Windy Boy 5000 / 6000 has
successfully passed the measurement
electronics and SMA grid guard self-tests
and has begun feed-in operation.

The Windy Boy 5000 / 6000 is working
normally and is feeding electricity into
the mains supply. It is converting the DC
voltage from the wind turbine according
to the V/I characteristic curve defined by

Start, UDCWindStart and

U

PV

WindMax (chapter 5 “Turbine

U

DC

operation" on page 33).

Operating instructions WB50_60-11:FE4105 Page 19

Unit description SMA Technology AG

Stop

The Windy Boy 5000 / 6000 is in Stop
mode. Among other functions, the

1s

Green LED blinks 3
times per second.

measurement electronics are calibrated
and then finally, the device switches to
"Waiting" mode.

The "Stop" mode can also be manually
set by the system operator via the Sunny
Boy Control or the Sunny Data PC
program. In this case, the Windy Boy
5000 / 6000 remains in "Stop" mode
until a new operating mode ("MPP
mode", "Turbine mode") has been set.

Maintenance, grid monitoring

The Windy Boy 5000 / 6000 checks if

1s

The green LED blinks
once per second.

the initial conditions necessary for
feeding the mains supply are satisfied
(e.g. start voltage) and then begins
monitoring the mains supply.

Derating

The temperature monitoring of the

1s

The green LED turns
off briefly once per

Page 20 WB50_60-11:FE4105 Operating instructions

Windy Boy 5000 / 6000 has reduced
the output performance to prevent the
device from overheating. If this occurs
often, then this is an indication of
inadequate heat dissipation.

To avoid unnecessary reductions in
yield, in this case it should be checked if
the Windy Boy 5000 / 6000 can be
mounted in a better position with better
ventilation.

SMA Technology AG Unit description

Insulation fault

The green LED blinks
once per second.

The red LED is
continuously on.

Consult trained electrical personnel to correct the fault using the
"Installation manual".

The Windy Boy 5000 / 6000 indicates a
ground fault by illuminating the red LED.

Defective varistor

The green LED is
continuously on.

The red LED is
continuously on.

At least one of the two thermally
monitored varistors on the DC input side
of the device has become highly resistive
and thus no longer functions correctly.

Consult trained electrical personnel to correct the fault using the
"Installation manual".

Constant operational limiting

This message is displayed if a fault
develops in the grid monitoring and/or
the independent disconnection device

The yellow LED is
continuously on.

Operating instructions WB50_60-11:FE4105 Page 21

(SMA grid guard). The Windy Boy 5000
/ 6000 has detected a fault in the SMA
grid guard during an internal test and
has disabled the mains supply feed-in.

This usually indicates a fault that cannot
be corrected on site. Please consult the
manufacturer (chapter 12 "Contact”
(page 67)) and discuss further action to
solve the problem with them.