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PV Inverter SUNNY BOY 3000-US / 3800-US / 4000-US Installation Guide SB30-40US-IUS103030 | TBUS-SB30_40US | Version 3.0...
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(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 damages under any circumstances.
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 personal injury. DANGER DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.
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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 symbol is also used in this installation guide: Information This symbol accompanies notes that call attention to supplementary information that you must know and use to ensure optimal operation of the system.
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The Sunny Boy contains no user-serviceable parts except for the fans on the bottom of the enclosure and the filters behind the fans as well as the handle covers on the sides of the unit. For all repair and maintenance, always return the unit to an authorized SMA Service Center.
You will find further information on special topics in the download area at www.SMA-America.com. 1.5 Nomenclature In this document SMA America Production, LLC is referred to in the following as SMA. The syntax specified here for menus and parameters applies throughout the entire manual.
Safety SMA America, LLC 2 Safety 2.1 Appropriate usage The Sunny Boy is a DC to AC grid-tied utility interactive inverter for use with photovoltaic (PV). The Sunny Boy 3000‑US is additionally UL listed for the use with fuel cell, wind turbine and other sources of DC power.
Sunny Boy will continue to operate well beyond 113 °F and de-rates as needed to maintain a safe internal component temperature. Principle of a PV plant with a Sunny Boy Position Description PV array Sunny Boy with SMA DC Disconnect Local loads Energy meter Utility grid 2.2 Safety instructions DANGER High voltages are present in the Sunny Boy during operation.
Safety SMA America, LLC 2.3 Installation overview This section provides a brief overview of the installation process of a Sunny Boy. Section 3: Unpacking and inspection This section provides instructions and information for unpacking the Sunny Boy and inspecting it for shipping damage.
It is important to carefully inspect the shipping box and contents prior to installation. If you detect any external damage after unpacking, report the damage immediately to your SMA dealer and to the shipping company that delivered the unit. If it becomes necessary to return the Sunny Boy, use the original packing material.
Unpacking and inspection SMA America, LLC 3.1 Scope of delivery Position Number Description Sunny Boy Wall-mounting bracket Spare screw and spare washer for closing the Sunny Boy lid Screws and washers for fastening the Sunny Boy to the wall-mounting bracket Spare jumpers for fan test...
SMA America, LLC AC Voltage configuration 4 AC Voltage configuration 4.1 Opening the Sunny Boy 1. Remove the four screws and lock washers from the housing cover and pull the cover forward smoothly. 2. Place the cover, screws, and lock washers aside where they will be out of your way while you are connecting wires and cables to the Sunny Boy.
AC Voltage configuration SMA America, LLC 4.2 Locating internal components Following figure illustrates the locations of the major internal components of the Sunny Boy. Refer to this illustration to locate particular components. SB30-40US-IUS103030 Installation Guide...
SMA America, LLC AC Voltage configuration Position Description Sockets for optional communication Piggy-Back (RS485 or wireless) Display Status LED Output AC Line Terminals (N, L1 and L2) Ground Terminal (PE) PV Grounding + DC Grounding electrode conductor Output AC Line Terminals (L1, L2, N and PE)
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AC Voltage configuration SMA America, LLC Commonly used transformer types When connecting the Sunny Boy to the utility, the phase relationship is not important, but the voltage must be compatible. SB30-40US-IUS103030 Installation Guide...
SMA America, LLC AC Voltage configuration 4.4 Utility configuration jumpers The Sunny Boy comes from the factory pre-configured for utility interconnection with neutral conductor. The Sunny Boy may be reconfigured for grids without neutral by setting the jumpers on the board of the Sunny Boy.
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AC Voltage configuration SMA America, LLC 240 V Delta : 120 V stinger SB30-40US-IUS103030 Installation Guide...
SMA America, LLC Mounting 5 Mounting This section provides guidelines to help you select the best mounting location, suggestions to insure optimum performance, cautions and warnings that you should follow to avoid injury and/or equipment damage, and step-by-step instructions for mounting a Sunny Boy inverter.
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Mounting SMA America, LLC • Observe the minimum clearances to walls, other devices or objects as shown in the diagram to ensure sufficient heat dissipation. ® The National Electrical Code may require significantly larger working clearances (see ® National Electrical Code section 110.26).
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SMA America, LLC Mounting DANGER Danger to life due to fire or explosion. There is always a certain risk with electric devices that a fire can occur, even though greatest attention was paid to avoiding this during the development. Do not install the inverter •...
Mounting SMA America, LLC 5.2 Dimensions of the Sunny Boy and DC Disconnect The following figure shows the outer dimensions of the Sunny Boy and the DC Disconnect. 9 in. 18 in. (236 mm) (452 mm) 14 in. (351 mm) SB30-40US-IUS103030...
SMA America, LLC Mounting 5.3 Mounting the Sunny Boy with a wall mounting bracket The Sunny Boy is shipped with a T-shaped wall-mounting bracket that is suitable for use with most walls. The horizontal part of the bracket has 12 holes. Make sure that the wall you choose to mount the Sunny Boy on is plumb and sturdy enough to support the weight over a long period of time.
Mounting SMA America, LLC 5.3.1 Possibilities for mounting the wall mounting bracket Mounting on stone wall Attach the wall mounting bracket with a minimum of 3 screws. The position of the screws on the wall mounting bracket is as follows: • 1 screw on the upper left side.
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SMA America, LLC Mounting Mounting on a wooden wall with a stud or on a pillar Attach the wall mounting bracket with 3 screws. The position of the screws on the wall mounting bracket is as follows: • 2 screws on the upper middle.
Mounting SMA America, LLC Mounting on a wooden wall with two studs Attach the wall mounting bracket with 2 screws. The position of the screws on the wall mounting bracket is as follows: • 1 screw on the upper left side.
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SMA America, LLC Mounting 2. Place a level on the top edge of the bracket. Adjust the position until it is leveled. The bottom of the bracket will be the approximate location of the bottom of the inverter. DANGER Risk of electric shock by drilling into power cables.
SMA America, LLC 5.4 Mounting the SMA DC Disconnect Attach the SMA DC Disconnect to the two lower holes of the wall-mounting bracket, using two screws and washers provided. 1. Place the screws and the washers in the holes in the fastening tabs on the DC Disconnect. The teeth on the washers must lie against the DC Disconnect's fastening tabs.
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SMA America, LLC Mounting 3. Hook the Sunny Boy using the enclosure opening in the back plate into the wall bracket (1). 4. Inspect the Sunny Boy from both sides to ensure that it sits centered on the wall bracket (2).
Electrical connection SMA America, LLC 6 Electrical connection DANGER High voltages are present on the AC and DC cables. Death or serious injuries due to touching the voltage-conducting cables. • Always wait a minimum of 5 minutes for stored potentials in the Sunny Boy to discharge completely before opening the enclosure.
2. Wiring from the AC breaker to the SMA DC Disconnect, follow the procedure on page 38 et seq. 3. AC wiring from the SMA DC Disconnect to the Sunny Boy, follow the procedure on page 41 et seq. 4. Wiring from the PV array to the SMA DC Disconnect, follow the procedure on page 50 et seq.
7. Turn the AC breaker on. Disconnecting the Sunny Boy • First turn off all AC disconnects and turn the SMA DC Disconnect to position "0". • The AC side must always be disconnected before the DC side. • After the Sunny Boy is de-energized, disconnect the wiring in the reverse order from above.
• If not, unscrew the screw further until you can remove the knob. The screw is attached with a rubber washer in order to make the assembly easier. 3. Remove the screw and the washer from the bottom side of the SMA DC Disconnect, that fasten the cover.
Electrical connection SMA America, LLC 4. Pull off the switch handle. 5. Remove the cover of the SMA DC Disconnect by pulling it down. At the same time, carefully move it forward at its lower edge. 6.6 AC wiring All electrical installations must be done in accordance with the local electrical codes and ®...
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SMA America, LLC Electrical connection Sunny Boy 3000-US Percent voltage drop for 208 V AC and 240 V AC service Sunny Boy 3800-US/4000-US Percent voltage drop for 208 V AC (only for Sunny Boy 4000-US) and 240 V AC service...
Electrical connection SMA America, LLC 6.6.1 Without SMA DC Disconnect 1. Turn off the main breaker in the main utility breaker box. 2. Remove interior breaker panel cover. 3. If you are replacing an existing inverter, disconnect the wires for the AC line you are working with in the breaker box.
3. If you are replacing an existing inverter, disconnect the wires in the breaker box for the AC line you are working with. 4. Install a ⁄ in. conduit fitting in the SMA DC Disconnect AC wiring knockout. Fasten the conduit fitting on the inside of the SMA DC Disconnect with the appropriate locknut. 5. Install ⁄...
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10. Connect the N (AC line N) wire to the terminal labeled N in the SMA DC Disconnect. 11. Connect the wires to the terminal blocks in the SMA DC Disconnect and tighten to a torque of 15 in-lbs. (1.7 Nm).
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SMA America, LLC Electrical connection Connecting the AC cable in the Sunny Boy 13. Use a screwdriver in order to poke a hole in the groove of the grommet inside the inverter. 14. Remove the membrane. 15. Pull the cable into the Sunny Boy.
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Electrical connection SMA America, LLC 18. Connect the white wire of the SMA DC Disconnect to the L1 N terminal labeled N and the black wire to the terminal labeled L1 of the Sunny Boy. 19. Connect the red wire to the terminal labeled L2 in the Sunny Boy.
• Check both the polarity and the open-circuit voltage from the PV strings. • Configure the DC-input-voltage range correctly before connecting the DC-input wires from the PV array to the inverter. • Use the free design programs "Solar Design Tools" at www.SMA-America.com to determine the correct string configuration. Installation Guide...
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Electrical connection SMA America, LLC Simplified electrical wiring diagram of a PV system SB30-40US-IUS103030 Installation Guide...
The SMA DC disconnect is shipped with four 15 A, 600 V DC fuses (one for each string). The maximum fuse rating for the four SMA DC disconnect fuses is 20 A, 600 V DC (one for each string). See "Exchanging the PV String Fuses within the SMA DC Disconnect" on page 85 for details.
Electrical connection SMA America, LLC 6.7.2 DC input grounding Negative grounding The Sunny Boy comes from the factory configured for negative ground systems. Positive grounding Certain types of PV modules may require that the positive terminal be grounded instead of the negative terminal.
SMA America, LLC Electrical connection 6.7.3 DC wiring without SMA DC Disconnect 1. Verify that the AC breaker is OFF. 2. Verify that the DC disconnect is open in the external DC disconnect enclosure. 3. Install a ⁄ in. conduit fitting in the DC wiring knockout of the inverter. Fasten the conduit fitting on the inside of the inverter with the appropriate locknut.
⁄ in. conduit fitting in the SMA DC Disconnect’s DC wiring knockout (the knockout on the left side of the SMA DC Disconnect). Fasten the conduit fitting on the inside of the SMA DC Disconnect with the appropriate locknut. 3. Install ⁄...
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Negative DC wires GROUNDED in the SMA DC Disconnect. 4. Torque all wires in the terminal blocks inside the SMA DC Disconnect to 15 in-lb (1.7 Nm). 5. Use a screwdriver in order to poke a hole in the groove of the grommet.
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Electrical connection SMA America, LLC 7. Pull the DC wires from the DC disconnect through the conduit into the interior of the Sunny Boy. 8. Pull the wires slightly back in order to seal the grommet. 9. Connect the black wire (PV UNGROUNDED) to the terminal labeled DC+ in the Sunny Boy.
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Positive DC wires GROUNDED in the SMA DC Disconnect. 4. Torque all wires in the terminal blocks inside the SMA DC Disconnect to 15 in-lbs. (1.7 Nm). 5. Use a screwdriver in order to poke a hole in the groove of the grommet.
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Electrical connection SMA America, LLC 7. Pull the DC wires from the DC disconnect through the conduit into the interior of the Sunny Boy. 8. Pull the wires slightly back in order to seal the grommet. 9. Connect the white wire (PV GROUNDED) to the terminal labeled DC+ in the Sunny Boy.
2. Connect the negative DC wire to the terminal labeled PV Negative DC wire GROUNDED in the SMA DC Disconnect. 3. Torque all wires in the terminal blocks inside the SMA DC Disconnect to 15 in-lbs. (1.7 Nm). Installation Guide SB30-40US-IUS103030...
Positive DC wire GROUNDED in the SMA DC Disconnect. 3. Torque all wires in the terminal blocks inside the SMA DC Disconnect to 15 in-lbs. (1.7 Nm). 6.8 Communication wiring Various data-communication options are available for the Sunny Boy. These options are provided in the form of accessory Piggy-Back modules that can be installed and connected either at the time the inverter is installed or at any time thereafter.
24 AWG. Use the cable type specified in the RS485 Tech Note on www.SMA‑America.com. • RS485 cables are available from SMA America. • Conduit may be required for communication wiring, per local electrical code requirements. Connecting a RS485 cable 1.
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Electrical connection SMA America, LLC Jumper configuration for RS485 communication RS485 Piggy-Back Signal Symmetry and Communication Module Termination Jumpers Terminal Block for RS-485 Connection Jumpers B and C Installed: Installing these jumpers puts 680 Ohm symmetry resistors between pin 2 (Data+) and +5V and between pin 7 (Data − ) and Ground.
SMA America, LLC Electrical connection 6.9 Closing the Sunny Boy NOTICE Humidity can ingress, when mounting and installing the inverter. Damage to the Sunny Boy will result. • Ensure no moisture is trapped inside the enclosure when securing the lid. CAUTION...
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Electrical connection SMA America, LLC 6. Carefully insert the four screws with lock washers through the holes in the cover into the threaded holes in the case. Turn them until they are finger-tight. 7. Verify that the cover is in the correct position and that the seal is in place between the case and the cover.
Pillips pan head machine screw). 4. Install the M6x10 screw and washer on the bottom side of the SMA DC Disconnect, to fasten the cover. For proper grounding, the teeth of the washers must face towards the lid.
3. Switch the external DC disconnect to position „on“. Switch the SMA DC Disconnect to the “1“ position. If there is sufficient sunlight available, the Sunny Boy will enter the “Wait” mode at this time and the green LED will begin to blink.
SMA America, LLC Displays and messages 8 Displays and messages Each Sunny Boy inverter comes equipped with three LED status indicators. This allows the user to determine the operatin g mode of the inverter at a glance. The green LED indicates normal operation of the inverter.
Displays and messages SMA America, LLC 8.1 LED operation indicators Standby (night) The inverter is in standby mode because the input voltage is too low for operation or no DC is connected. Initialization The inverter is initializing. The power from the array is sufficient to initialize control power, but not yet powerful enough to begin normal operation.
SMA America, LLC Displays and messages Waiting The inverter has determined that there is enough voltage from the array to operate and is checking the condition of the grid prior to connecting to it. If the inverter fails to connect to the utility grid 3 times in a row, it will wait 10 minutes before the next attempt.
Displays and messages SMA America, LLC 8.2 LED fault indicators Ground fault The inverter has detected a ground fault in the PV system and has disconnected from the grid. The ground fault must be located and fixed before the inverter will resume normal operation. Refer to section 9 ”Troubleshooting”...
The Sunny Boy has detected a fault within the internal monitoring systems. When the inverter detects a fault of this kind it will no longer connect to the utility grid. To correct this, the inverter must be serviced by a qualified service technician. Contact SMA for assistance. Grid failure The yellow LED is on for 5 seconds, out for 3 seconds and then blinks twice.
3 times. If the condition remains the code will continue to be sent. The inverter has encountered an internal fault that prohibits normal operation and will most likely require servicing. If problems occur contact SMA for assistance. SB30-40US-IUS103030 Installation Guide...
SMA America, LLC Displays and messages 8.3 Status messages on the LCD display Activation of the backlight The backlight is activated by knocking twice on the lid. Additional knocks will scroll through the display messages. The backlight shuts off automatically after 2 minutes.
Displays and messages SMA America, LLC MSG #4 Accumulated energy yield of the device since installation E-total 724.4kWh and the total operating hours: h-total 512h Fault messages Each fault message is displayed for 5 seconds. After 5 seconds, the LCD will once again scroll through its normal operating screens.
SMA America, LLC Displays and messages 8.3.1 LCD display language selection The LCD Display has the ability to display information in one of four different languages. Setting the language is performed by using a pair of slide switches located along the bottom edge of the display PC board.
(page 18)) to communicate with special data acquisition devices (e.g. Sunny WebBox) or a PC with appropriate software (e.g. Sunny Data). For a complete listing of all applicable communication options refer to the SMA web page or the product catalogue.
SMA America, LLC Displays and messages 8.5.1 Measuring channels Vpv: PV input voltage Vpv Setpoint: MPPT DC voltage target Iac: Grid current Vac: Grid voltage L1 - L2 Vac L1: Grid voltage L1 - N Vac L2: Grid voltage L2 - N...
Displays and messages SMA America, LLC Derating: Reduction of the grid feeding power due to abnormal heatsink temperatures Disturbance: Grid related fault condition, self clearing Error: Inverter fault, user interaction required Warning: System warning advising further investigation 8.5.3 Sunny Boy operating parameters CAUTION The changing of operating parameters should only be performed by qualified personnel.
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SMA America, LLC Displays and messages Name Unit Range Default Password Description Level Fac-delta–* 0.2 ... 3.0 0.69 (for Installer Maximum allowable operating country setting frequency above and below 60 Hz USA/UL1741/ Default value is optimal for 2005) installations < 30 kW.
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Displays and messages SMA America, LLC Name Unit Range Default Password Description Level V-Const Setval SB 3000‑US: SB 3000‑US: Installer PV Setpoint voltage for constant 185 ... 500 voltage operation. These parameters only are important in SB 3800‑US: SB 3800‑US: case the parameter “Operating...
• If the system problem persists, contact SMA. In order to better assist you when contacting SMA, please provide the following information. This information is required for service assistance. Information regarding the Sunny Boy •...
- this failure does not effect performance. Error EEPROM p Data EEPROM defective, device is set to permanent disable due to the fact that the data loss affects important functions of the inverter. Contact SMA. Disturbance EeRestore Internal failure Disturbance...
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OFFSET Grid monitoring self-test failed. Contact SMA for assistance. Error The internal test of the Sunny Boy control system firmware failed. Contact SMA in case you observe this failure often. Disturbance Shut-Down Internal over current continuous. Contact SMA for assistance.
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Troubleshooting SMA America, LLC Error Type Error Code Description Warning XFMR_TEMP_W High transformer temperature is gone. The Sunny Boy starts working and shows the failure “XFMR_TEMP_W“. Verify that the fans are operating normally and that the intake screens are clean. Check the intake vents for debris.
SMA America, LLC Maintenance 10 Maintenance The Sunny Boy is designed to provide many years of trouble-free service. Performing regular maintenance will help ensure the long life and high efficiency of your system. 10.1 Cleaning the fans The fan intakes and handle covers should be cleaned periodically with a vacuum cleaner. Do not blow air into the fan areas.
Maintenance SMA America, LLC 10.2 Cleaning the handle covers There are handle covers on either side of the Sunny Boy. The Sunny Boy sucks air in from underneath via the fan and blows it out again on the upper left side. For optimum heat dissipation within the device, you have to clean the left handle cover.
• Once the LEDs are off, remove the cover and set the jumpers as shown below. • Turn on the inverter by turning on the AC disconnect and then the DC disconnect or switch the SMA DC Disconnect to the "1" position. • After testing the fans, remove the jumpers.
Maintenance SMA America, LLC 10.5 Exchanging the fuses 10.5.1 Exchanging the GFDI fuse within the Sunny Boy 1. Turn OFF all AC and DC switches and/or breakers. 2. Wait for at least 5 minutes. 3. Open the Sunny Boy as described in section 4.1 ”Opening the Sunny Boy” (page 17).
1. Turn OFF all AC and DC switches and/or breakers. 2. Wait for at least 5 minutes. 3. Open the SMA DC Disconnect as described in section 6.5 ”Opening the SMA DC Disconnect” (page 37). 4. Exchange the fuses having regard to the information on the next page.
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Do not remove a fuse while the inverter is under load. PV string fuses The SMA DC Disconnect is shipped with 15 A, 600 Vdc fuses in fuse holders. The maximum string fuse rating for the SMA DC Disconnect is 20 A.
• Connect the equipment into an outlet on a circuit different from that to which the receiver is connected. • Consult the dealer or an experienced radio/TV technician for help. • The user is cautioned that changes or modifications not expressly approved by SMA could void the user’s authority to operate this equipment. Installation Guide...
Sunny Boy connection to 208 V and 240 V AC utility grids. The AC disconnect switch shown below may or may not be required by the local utility grid operator. Wiring diagram without SMA DC Disconnect Wiring diagram with SMA DC Disconnect...
SMA America, LLC Technical specifications 11.3 Sunny Boy 3000-US PV generator connection Peak Power Tracking Voltage at 208 V nominal 180 V … 400 V Peak Power Tracking Voltage at 240 V nominal 200 V … 400 V Range of Input Operating Voltage 200 V … 500 V Maximum Array Input Power 3,750 W Maximum DC Power 3,250 W...
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Technical specifications SMA America, LLC Efficiency Power factor at nominal power Peak Inverter Efficiency 96.8 % CEC Weighted Efficiency at 208 V nominal 95.0 % CEC Weighted Efficiency at 240 V nominal 95.5 % Ambient conditions Ambient Temperature Range − 13 °F … +113 °F ( − 25 °C … +45 °C)
SMA America, LLC Technical specifications 11.4 Sunny Boy 3800-US PV generator connection Peak Power Tracking Voltage at 240 V nominal 250 V … 480 V Range of Input Operating Voltage 250 V … 600 V Maximum Array Input Power 5,000 W Maximum DC Power 4,250 W PV Start Voltage 285 V Maximum DC Input Current 18 A...
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Technical specifications SMA America, LLC Efficiency Power factor at nominal power Peak Inverter Efficiency 96.8 % CEC Weighted Efficiency at 240 V nominal 96.0 % Ambient conditions Ambient Temperature Range − 13 °F … +113 °F ( − 25 °C … +45 °C) Protection Devices DC reverse polarity protection Short circuit diode...
SMA America, LLC Technical specifications 11.5 Sunny Boy 4000-US PV generator connection Peak Power Tracking Voltage at 208 V nominal 220 V … 480 V Peak Power Tracking Voltage at 240 V nominal 250 V … 480 V Range of Input Operating Voltage 250 V … 600 V Maximum Array Input Power 5,000 W Maximum DC Power 4,300 W...
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Technical specifications SMA America, LLC Efficiency Power factor at nominal power Peak Inverter Efficiency 96.8 % CEC Weighted Efficiency at 208 V nominal 95.5 % CEC Weighted Efficiency at 240 V nominal 96.0 % Ambient conditions Ambient Temperature Range − 13 °F … +113 °F ( − 25 °C … +45 °C)
SMA America, LLC Technical specifications 11.5.1 SMA DC Disconnect Maximum DC Input Current 36 A DC Maximum System Voltage 600 V DC Maximum String Fuse Rating 20 A DC Maximum AC Operating Current 40 A AC Dimensions W x H x D 7.87 in. x 12.20 in. x 7.48 in. (200 mm x 310 mm x 190 mm) Weight 8 lbs.
• Connect the equipment into an outlet on a circuit different from that to which the receiver is connected. • Consult the dealer or an experienced radio/TV technician for help. • The user is cautioned that changes or modifications not expressly approved by SMA America, Inc. could void the user’s authority to operate this equipment. SB30-40US-IUS103030...
SMA America, LLC Accessories 12 Accessories You will find the corresponding accessories and replacement parts for your product in the following overview. If needed, you can order these from SMA or your SMA dealer. Name Brief description SMA order number RS485 upgrade kit...
Contact SMA America, LLC 13 Contact If you have technical problems concerning our products, contact the SMA Serviceline. We require the following information in order to provide you with the necessary assistance: • Type of inverter, if applicable • Type and number of modules connected, if applicable •...