SMA WB 5000 Installation

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

Installation Guide Version 1.0 WB50_60-11:SE4005

IME-WB50-60

SMA Technologie AG Revision Histroy

Revision History

Document number Changes Author

WB50_60-11:SE4005 First issue Welzel

Installation Guide WB50_60-11:SE4005 Page 3

SMA Technologie AG

Page 4 WB50_60-11:SE4005 Installation Guide

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.

Installation Guide WB50_60-11:SE4005 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 c hannels.
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:SE4005 Installation Guide

SMA Technologie AG Table of Contents

Table of Contents

1 Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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

3 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3.1 Unit description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

3.2 External dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

3.3 OptiCool ventilation system . . . . . . . . . . . . . . . . . . . . . . . . . .15

4 Installation requirements . . . . . . . . . . . . . . . . . . . . . 17

4.1 Installation site requirements . . . . . . . . . . . . . . . . . . . . . . . . .17

4.2 DC input prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

4.3 Low voltage grid 230 V (AC). . . . . . . . . . . . . . . . . . . . . . . . .19

4.4 Stand-alone mains grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

5.1 Mounting the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

5.2 Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

5.3 Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

6 Opening and closing the Sunny Boy 3800 . . . . . . . . 35

6.1 Opening the Windy Boy . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

6.2 Closing the Windy Boy . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

7 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

7.1 Mains grid communication . . . . . . . . . . . . . . . . . . . . . . . . . . .37

7.2 RS232 communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

7.3 RS485 communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

8 Checking heat dissipation. . . . . . . . . . . . . . . . . . . . . 43

8.1 Cleaning the fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

8.2 Checking the fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

8.3 Cleaning the fan gills. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

9 Replacing the varistors. . . . . . . . . . . . . . . . . . . . . . . 47

10 Contact. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Installation Guide WB50_60-11:SE4005 Page 7

SMA Technologie AG

Page 8 WB50_60-11:SE4005 Installation Guide

SMA Technology AG Foreword

1 Foreword

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.

This installation guide is intended solely for qualified electricians. Its aim is to help
install and set up SMA Sunny Boy 3800 inverters quickly and correctly.

For detailed technical information and instructions on how to use the device, please
refer to the operating instructions.

The Windy Boy 5000 / 6000 is externally identical to the Sunny Mini Central inverter
for photovoltaic systems. For this reason, it can also be used as a PV inverter. Please
download the Sunny Mini Central instruction manuals from www.SMA.de and
contact the SMA hotline if you intend to use the inverter in this manner.

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

[phone] - 499

Installation Guide WB50_60-11:SE4005 Page 9

Foreword SMA Technology AG

Page 10 WB50_60-11:SE4005 Installation Guide

SMA Technology AG Safety information

2 Safety information

Work on the Sunny Boy 3800 with the
cover removed must be carried out by a
qualified electrician! Before working on
the Sunny Boy 3800 with the cover

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Pac 903W

Upv 330V

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must wait approx. 30 minutes for the capacitors in the Sunny Boy
3800 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.

The Sunny Boy 3800 is equipped with an independent mains disconnection
device, the "SMA grid guard". It ensures that the Sunny Boy 3800 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.

removed, the AC and DC voltage MUST
be disconnected from the Sunny Boy

3800.

The Sunny Boy 3800 must be
disconnected from the mains grid and
precautions must be taken to prevent the
grid being reconnected. The connection to
the DC voltage must also be removed.

After isolating the AC and DC voltage you

Installation Guide WB50_60-11:SE4005 Page 11

Safety information SMA Technology AG

Page 12 WB50_60-11:SE4005 Installation Guide

SMA Technology AG Overview

3 Overview

3.1 Unit description

The following diagram gives a schematic overview of the various components and
connection points inside the Sunny Boy 3800 with the cover removed:

Varistors
(page 47)

Socket for communication (RS232,
RS485, NLM, wireless) (page 37)

C
B
A

2357

SMC60-AST

V

40

0 V

2

Potter& Brumfield Potter& Brumfield Potter& Brumfield

Display socket
(Sunny Display)

Operating status
LEDs

Communications
connector

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

Connection

+ +

+ +

- - - -

MCMC

MC MC MC MC

VN30.15/00858

230 Vac:

MC

N

NL1

MC

L

PE

terminals (AC)
(page 19)

DC input plug
(page 19)

Installation Guide WB50_60-11:SE4005 Page 13

Overview SMA Technology AG

Netzwechselrichter für Windenergieanlagen
Grid tied inverter for wind turbines

3.2 External dimensions

250 mm

Windy

Boy

Pac 903W
Upv 330V

Netzwechselrichter für Windenergieanlagen
Grid tied inverter for wind turbines

430 mm

600 mm

Page 14 WB50_60-11:SE4005 Installation Guide

SMA Technology AG Overview

3.3 OptiCool ventilation system

The Windy Boy 5000 / 6000 is equipped with the patented OptiCool two-chamber
cooling system. At the same time, the Windy Boy's enclosure is integrated into the
temperature management and now serves not only to incorporate and protect the
internal components but also as a cool air and heat distributor.

As the central component of passive heat
abstraction, the heat sink is placed in the
enclosure, thus dividing it into two chambers.

The front chamber containing the electronic
components is especially sealed and thus
protected against infiltration by water, dust or dirt.
In addition, the heat sink, functioning as a partition
wall, provides enough space for the installation of
the heat-producing components.

The rear enclosure chamber contains the
components which develop high amounts of heat,
depending on their function, such as chokes and
transformers, which are either especially enclosed
or unsusceptible to external influences.

An active cooling unit is affixed to the underside of
the second chamber which has been specially
designed for this purpose. According to the
temperature, the power conductor and the
inductive components switch themselves on
automatically and vary the number of revolutions
as necessary for an even heat balance within the
device.

The air current provided by the fan is particularly
well channeled via a current tunnel and expels the
waste heat both from the heat sink and the other components in this area.

OptiCool makes for low component temperatures throughout the Windy Boy. This
leads to high levels of reliability and excellent overload behavior which both impact
considerably on the economic viability of the Windy Boy and, therefore, the PV
system as a whole.

Installation Guide WB50_60-11:SE4005 Page 15

Overview SMA Technology AG

Page 16 WB50_60-11:SE4005 Installation Guide

SMA Technology AG Installation requirements

4 Installation requirements

Please check that all of the conditions listed below are met before installing and
commissioning the Windy Boy 5000 / 6000.

4.1 Installation site requirements

The Windy Boy 5000 / 6000 weighs 63 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 Windy Boy 5000 / 6000 should be installed in a place where it
is not exposed to direct sunlight. An increased ambient temperature

63 kg

The Windy Boy 5000 / 6000 is designed to be mounted on a vertical wall. If
absolutely necessary, however, the Sunny Boy 3800 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.

can reduce the yield of the system.

We advise against installing the unit in a horizontal position outdoors.

min. 45°

Install the Windy Boy vertically or

tilting backward.

Installation Guide WB50_60-11:SE4005 Page 17

Never install the inverter

horizontally or so that it tilts

forward.