SMA Sunny Boy 2000 Technical Description
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SMA Sunny Boy 2000 Technical Description

SMA Sunny Boy 2000 Technical Description

The transformerless string inverter for photovoltaic plants
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Sunny Boy 2000
Technical Description
Version 1.2
Sunny Boy 2000
The Transformerless String Inverter
for Photovoltaic Plants
SB2000-11:EE0101

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Summary of Contents for SMA Sunny Boy 2000

  • Page 1 Sunny Boy 2000 Technical Description Version 1.2 Sunny Boy 2000 The Transformerless String Inverter for Photovoltaic Plants SB2000-11:EE0101...
  • Page 2 Sunny Boy 2000 Technical Description - 2 - SB2000-11:EE SMA Regelsysteme GmbH...
  • Page 3 Sunny Boy 2000 Technical Description Explanation of Symbols used in this Document To enable optimal usage of this manual and safe operation of the device during in- stallation, operation and maintenance routines, please note the following description of symbols: This indicates a feature that is important either for optimal and comfort- able usage or optimal operation of the system.

  • Page 4: Table Of Contents

    Introduction......................6 System Description .................... 7 String Technology ..................8 Diagnosis and Communication ..............10 Technical Design of the Sunny Boy 2000 ..........11 Installation ......................16 What must be done in case of transport damages? ........ 16 Mounting ....................17 Electric Connection ..................
  • Page 5 Sunny Boy 2000 Technical Description Important Safety Notice: The Sunny Boy String Inverter may only be opened by qualified per- sonnel for both installation and maintenance. The device can still be charged with very high hazardous voltages even when disconnected.

  • Page 6: Introduction

    European harmonized standards as certified in the CE declaration (see appendix). In the following you will find the technical description of the Sunny Boy 2000. Don’t worry about its size, it is not necessary to read everything. This technical description is both installer’s guide and user manual, so it is used as reference for the commis-...

  • Page 7: System Description

    Sunny Boy 2000 Technical Description 2 System Description Reducing the emission of carbon dioxide and reducing other environmental emis- sions resulting from energy conversion is becoming more and more important. Re- newable energy sources can make an important contribution to solve this problem.

  • Page 8: String Technology

    DC cabling on the DC side is not necessary anymore. No additional planning is required. SMA is the European market leader for inverters in photovoltaic applications with over 53 MW of installed inverter power in over 38,000 single units in a power range from 700 W up to 500 kW (figures from 12/2000).
  • Page 9 Sunny Boy 2000 Technical Description The most various system designs can be modularly created with the Sunny Boy products. • Sunny Boy 700: The small model for little PV-plants and simple extension possibilities (3 input voltage and power ranges) •...

  • Page 10: Diagnosis And Communication

    Sunny Boy or on the LCD of the Sunny Boy Control or shown on the screen of a PC running the according SMA software. Two programs Sunny Data and Sunny Data Control are based on a comfortable Windows GUI and allow the user to process or print out the data with other programs such as MS Excel.

  • Page 11: Technical Design Of The Sunny Boy 2000

    Technical Description 2.3 Technical Design of the Sunny Boy 2000 The main feature of the Sunny Boy 2000 is the simple and absolutely sturdy design with outstanding reliability and high efficiency. The PV-plant’s DC voltage is con- verted to a DC circuit with a high frequency step-up converter (16 kHz). From this intermediate circuit the grid feeding is done directly with an IGBT bridge.
  • Page 12 The sequential control system is extended by the possibility to communicate with the corresponding SMA tools Sunny Data or Sunny Data Control for data analysis. This feature makes the Sunny Boy a universal system either used as standalone device or as part of a large PV-plant with centralized operation monitoring and evaluation.
  • Page 13 Sunny Boy 2000 Technical Description Automatic Grid Disconnection Device (MSD) This chapter covers the safe disconnection of the inverters in case of a grid discon- nection from the electricity company. That means that in the case that the electricity company disconnects part of its grid e.g. in order to conduct maintenance work on the grid sufficient safety for maintenance personnel must be guaranteed.
  • Page 14 Sunny Boy 2000 Technical Description Criteria for disconnecting the Sunny Boy from the grid: Mains impedance The inverter does not start feeding to the mains if a maximum impedance value = 1.25 Ω). is exceeded (Z ≥ 0.5 If the mains impedance changes by a certain value in a certain time (Z Ω) or if it exceeds a maximum value (Z...
  • Page 15 Sunny Boy 2000 Technical Description The grid impedance is measured by every Sunny Boy just at the place where it is con- nected to the mains. The measured grid impedance consists of the impedance of the public grid and the mains impedance in the house (from the house connection to the Sunny Boy).

  • Page 16: Installation

    SMA or your local supplier can help you in this matter. In any case a declaration of transport damage must be made within 6 days upon receipt of the product and must be stated in writing directly to the forwarding agent.

  • Page 17: Mounting

    If moisture is enclosed in the case it will eventually con- dense within the device which could damage the electric components and lead to failure of the inverter. SMA cannot provide warranty for damages resulting directly or indirectly from faulty installation.
  • Page 18 Sunny Boy 2000 Technical Description Please note the following points in any case: • The mounting ground must be firm. • The ambient temperature must lie between -25 °C and +60 °C. • Take into account mains impedance at the feeding point, see para- graph “Autonomous Grid Disconnection Device (MSD)”...
  • Page 19 The Sunny Boy is prepared for mounting at PV- panels with the MultiContact plug connector system. For PV-panels where this plug system is not used SMA offers an adapter set (SMA material no. SWR1500-MC). Sunny Boy 2000 Cable gland PG 16 with corresponding lock nut 2 pc.
  • Page 20 Drilling Template Sunny Boy 2000 Distance between top holes 217.50 mm position of top holes total width of Sunny Boy 2000: 434.50 mm Fig. 3.2: Drilling Template Preparing the Mounting The Sunny Boy is mounted on its back with three metal straps on a firm sur- face.
  • Page 21 Sunny Boy 2000 Technical Description Fig. 3.3: Mounting to wall, side view Metal straps for mounting: The top straps take the load, the bottom is screwed down in order to prevent tilting off the wall. Securing the Sunny Boy against lifting up:...

  • Page 22: Electric Connection

    Sunny Boy 2000 Technical Description 3.3 Electric Connection The electric connection of the Sunny Boy can be done once the device is correctly mounted in its position. The PV-modules are connected to the inverter with safe to touch snap cable connec- tors accessible from outside.
  • Page 23 • The mains terminals (in the lower middle to right section) • The mains fuse (in the lower middle to right section) thermally monitored PV-panel connectors mains connectors mains fuse varistors (12.5 A, slow blow) Fig. 3.4: Connectors in the Sunny Boy 2000 - 23 - SB2000-11:EE SMA Regelsysteme GmbH...

  • Page 24: Mains Connection

    Sunny Boy 2000 Technical Description 3.3.1 Mains Connection The Sunny Boy must be connected to the mains with three cables (L, N, PE). We recommend a 16 A fuse with ‘B’ characteristics for the circuit the Sunny Boy is connected to. No consumers are allowed on this circuit or else must be fused separately.
  • Page 25 Sunny Boy 2000 Technical Description Please note that a cable of: 20m length/1.5 mm² cross section already has a resistance of ca. 0.48 Ω! 35m length/ 2.5 mm² cross section already has a resistance of ca. 0.50 Ω! The Sunny Boy is equipped with two PG16 sized openings on the bottom of the in- verter for cable insertion.

  • Page 26: Connection Of The Pv-Panels

    Sunny Boy 2000 Technical Description 3.3.2 Connection of the PV-panels The PV-panel’s DC voltage is connected to the inverter with safe to touch snap con- nectors in order to provide maximum protection. The inverter is equipped with con- ®2 nectors especially designed for PV-plants from Multi-Contact Make sure the „+“...
  • Page 27 After you have checked the PV-panel is isolated from earth you can establish the electrical connection to the Sunny Boy. Remove the seal from the plug connectors at each cable end of the PV-panel and firmly insert them into the Sunny Boy 2000. As ®...
  • Page 28 A highly dangerous voltage is on between the plus and minus poles of the PV-panel and PE also during grid feeding by the (transformerless) Sunny Boy 2000. - 28 - SB2000-11:EE...
  • Page 29 Sunny Boy 2000 Technical Description Always provide a sufficient connection of metal parts of the PV-panel (metal frames, aluminum foil from the modules themselves, con- struction holding the panels etc.) to the ground to allow that voltages are discharged during operation.

  • Page 30: Commissioning

    Sunny Boy have been closed with the seals included in delivery. First switching on The Sunny Boy 2000 can be put into operation as soon as it has been connected electrically and the grounding of the PV-panel’s metal frame has been checked.

  • Page 31: Operation And Failure Indication Leds

    Sunny Boy 2000 Technical Description 5 Operation and Failure Indication LEDs The inverter normally operates automatically, without user interaction and without any maintenance. The inverter automatically turns itself off when a grid feeding is not possible (e.g. at night). The Sunny Boy automatically starts grid feeding the next day once the solar radiation is high enough.
  • Page 32 Earth Fault Photovoltaik-Stringwechselrichter Störung Photovoltaic string inverter Failure Fig. 5.1: Partial front view of Sunny Boy 2000 Description for the following text: LED off LED blinks once per second LED blinks fast (ca. three times per second) LED is constantly on...
  • Page 33 Sunny Boy 2000 Technical Description LED-indicator Operating Condition Description green: standby (night) input voltage < 60 V red: yellow: green: initialization input voltage 60 V … 120 V red: yellow: green: stop changing operating condition or manually initiated condition red:...
  • Page 34 Sunny Boy 2000 Technical Description Operation Indicator Standby (night) All LEDs are off. The Sunny Boy is in so called ‘Stand by’ mode. The input voltage is too low < approx. 60 V) to supply the inverter control system with enough power.
  • Page 35 Sunny Boy 2000 Technical Description Stop Green LED blinking (approx. three times per second) Red LED off Yellow LED off The inverter has stopped operation, among other things the measurement electron- ics is calibrated. Subsequent condition is ‘Waiting’. ‘Stop’ condition can also be initiated by the user with the Sunny Boy Control or the PC program Sunny Data.
  • Page 36 Sunny Boy 2000 Technical Description Operation Green LED on Red LED off Yellow LED off The Sunny Boy has successfully completed self-testing its measurement electronics and MSD and starts feeding to the local electricity grid. • ‘MPP’ mode (default setting): The Sunny Boy independently acquires the MPP voltage of the PV-panel which is internally defined as PV setpoint voltage.
  • Page 37 Sunny Boy 2000 Technical Description Earth Fault Indicator Isolation failure, defective varistor Red LED on The inverter indicates an earth failure with the red LED. This condition can occur to- gether with other conditions indicated by the LEDs. The ‘Earth Fault’ indication can be based on two different conditions: Either the PV-...
  • Page 38 Sunny Boy 2000 Technical Description • Failure of the thermally monitored varistors on DC-side On the DC input side the Sunny Boy is equipped with thermally monitored varis- tors (plus and minus pole to protective earth each). They are installed in order to prevent the inverter from being destroyed by atmospheric surge voltages (thunderstorm etc.
  • Page 39 The red LED is off. At least one of the thermally monitored varistors is defective. We recom- mend to replace both varistors by original SMA spare parts. The thermally monitored varistors are only available from the manu- facturer because they are designed especially for the Sunny Boy in- verter systems.
  • Page 40 Sunny Boy 2000 Technical Description • Re-connect the PV-panel to the inverter. • If the red LED is still on the inverter is damaged and has to be repaired by the manufacturer. If the LED is off the insulation of the inverter or the connection cabling is defec- tive.
  • Page 41 Sunny Boy 2000 Technical Description Failure Indicator Consistent Failure Yellow LED on The yellow failure LED is permanently on. This is a failure of the grid monitoring or the autonomous disconnection device MSD. In an internal test the inverter has detected a failure in the disconnection facilities and has suppressed grid feeding.
  • Page 42 Sunny Boy 2000 Technical Description Blinking code 2: Grid Failure The yellow failure indication LED is activated for 5 seconds, is out for 3 seconds and then blinks twice. The code is sent three times. If the failure persists the indication blinking code is repeated.
  • Page 43 Sunny Boy 2000 Technical Description Blinking Code 3: Grid impedance too high The yellow failure LED is activated for 5 seconds, remains dark for 3 seconds and then blinks three times. The code is sent three times. If the failure persists the indication begins once again.
  • Page 44 Sunny Boy 2000 Technical Description Blinking code 4: Input voltage (PV-panel) too high The yellow failure indication LED is activated for 5 seconds, out for 3 seconds and then blinks four times. The code is sent three times. If the failure persists the indication is repeated.
  • Page 45 Sunny Boy 2000 Technical Description Blinking code 5: Device failure The yellow failure indication LED is activated for 5 seconds, out for 3 seconds and then blinks five times. The code is sent three times. If the failure persists the indication is repeated.
  • Page 46 Sunny Boy 2000 Technical Description Blinking code 6: Discharge Current too high The yellow failure indication LED is activated for 5 seconds, out for 3 seconds and then blinks six times. The code is sent three times. If the failure persists the indication is repeated.
  • Page 47 Sunny Boy 2000 Technical Description Blinking code 7: Drastic Differential Current change The yellow failure indication LED is activated for 5 seconds, out for 3 seconds and then blinks seven times. The code is sent three times. If the failure persists the indication is repeated.

  • Page 48: Plant Monitoring And Diagnosis

    The phase coupling device is available from SMA and must be installed by qualified personnel. It will make com- munication within the entire in-house network possible.
  • Page 49 Sunny Boy RS232, modem Powerline Sunny Boy Control Fig. 6.1: Example of data transmission via Powerline A detailed description of this data transmission called “Technical Description of Pow- erline Communication” is available from SMA. - 49 - SB2000-11:EE SMA Regelsysteme GmbH...
  • Page 50 Sunny Boy 2000 Technical Description What do you need for Powerline communication? • The Sunny Boy must be suitable for Powerline communication (order no.: SWRxxxx-NE:1x0). I.e.: • The Powerline piggy back modem is installed (see Fig. 6.6). • The last digit of the system control software version is a two (VX.x2).

  • Page 51: Data Transmission With A Separate Data Cable

    Sunny Boy 2000 Technical Description 6.2 Data Transmission with a Separate Data Cable Data transmission via Powerline is a reliable and affordable solution. In electrical grids which are strongly influenced by high-frequency disturbance such as those in industrial sites data transmission via Powerline may not be possible. Communication between the Sunny Boys and the Sunny Boy Control or the PC can then be done with a separate data cable.
  • Page 52 Sunny Boy 2000 Technical Description What do you need for RS232 communication? • a special RS232 piggy back module for the Sunny Boy • the last digit of the system control software version is a two (VX.x2). • the visualization software Sunny Data is installed on the PC •...
  • Page 53 Sunny Boy 2000 Technical Description 232 PB - G3 Piggy-Back socket Jumpers light blue resistors (not mounted) (removed) Shield connect shield to case Shield PC with DB9 plug in COM1 .. COM4 PC with DB25 plug in COM1 .. COM4 Fig.
  • Page 54 Sunny Boy 2000 Technical Description RS485 communication In grids loaded with high interference several Sunny Boys can be connected to a PC or the Sunny Boy Control via RS485 and a separate data cable. Data cables of up to 1200 m are permissible.
  • Page 55 Sunny Boy 2000 Technical Description Sunny Boy Control with DB25 plug-in (Socket “Sunny Boy 485”) COM1 or COM2 RS485 / RS232 interface converter SUB-D 9 pin to SUB-D 25 pin No. 39-0020 Sunny Boy Control: plug-in DB9 PC with interface converter: socket DB9...
  • Page 56 Sunny Boy 2000 Technical Description Installation of the RS485 cable Work on the inverter may only be carried out if the device has been disconnected and discharged! (See also chapter 3: ’Installation’) • Connect pin 7 and pin 9 on the end of the cable that is connected to the interface converter.

  • Page 57: Upgrading Or Modification Of The Sunny Boy Interface

    Faulty upgrading can lead to damage at the device and danger to people by electric voltage. Therefore the device may only be upgraded by qualified personnel or the SMA service. - 57 -...
  • Page 58 Sunny Boy 2000 Technical Description Only work on the Sunny Boy when it is disconnected from the grid and sufficiently discharged! Follow ESD protection countermeasures when modifying the Sunny Boy: Electronic components are sensitive to electrostatic discharge. To protect them you have to be on the same electric potential.
  • Page 59 Resistors for piggy back module Powerline Communication Fig. 6.6: Sunny Boy 2000 sequential control board Remove any piggy back that might be installed on the system control board. Only for installation of an RS232 or RS485 board: § Remove the light blue resistors that might be installed on the system control board by cutting them out with a wire cutter.
  • Page 60 Sunny Boy 2000 Technical Description Connect the green-yellow PE cable to the lid and close the Sunny Boy with the lid. Tighten all four screws. Reconnect the PV-panel. Connect the inverter to the grid. If enough PV-power is supplied the inverter automatically starts feeding to the grid.

  • Page 61: Graphic User Interface Under Windows

    Sunny Boy 2000 Technical Description 6.3 Graphic User Interface under Windows Sunny Data Sunny Data is used in order to establish a communication between a PC and your Sunny Boys and process and evaluate data from these. It provides a graphic user interface with all positive features known under Windows.
  • Page 62 PV-plant. Additional features are remote diagnosis via modem and fax mes- sages. For global visualization of PV plant data SMA offers the Sunny Data Control PC soft- ware under Windows. E.g. the power output of the entire large-scale PV-plant can be shown in a matrix.

  • Page 63: Measuring Channels And Messages Of The Sunny Boy

    Sunny Boy 2000 Technical Description 6.4 Measuring Channels and Messages of the Sunny Boy If your PC is equipped with communication (see chapter 2.2: ‘Diagnosis and Com- munication’), it supports a number of measuring channels and messages from the Sunny Boy inverters and transmits them to the output unit for diagnosis.
  • Page 64 Sunny Boy 2000 Technical Description MPP-Such PV setpoint voltage is determined and set Sunny Boy is in MPP mode U-Konst. Sunny Boy is in constant voltage mode Stoer. failure Error messages Bfr-Srr communication between microcontrollers is failing EEPROM EEPROM cannot be read or written in...

  • Page 65: Measurement Precision

    Sunny Boy 2000 Technical Description 6.5 Measurement Precision Any kind of measurement is inaccurate to a certain degree. Measurements taken by the Sunny Boy are required for its operational control and the control unit of current to be fed to the grid. The reproducibility of measurement values complies with these requirements.

  • Page 66: Troubleshooting

    Sunny Boy 2000 Technical Description 7 Troubleshooting Our quality management strategy includes a constant quality improvement of our products. We always are concerned to avoid all failures and malfunctions of our products. The product you purchased was shipped in impeccable condition after successfully passing numerous tests concerning the operation behavior, the disconnection de- vices and a long term heavy duty tests.
  • Page 67 Use the original box the Sunny Boy was delivered in if the inverter has to be returned to the manufacturer in order to protect it against damage during transport. SMA can- not provide warranty for damages resulting directly or indirectly from inappropriate transport packaging.

  • Page 68: Warranty Regulations And Liability

    The warranty period is 24 months from the date the end user purchases the device. It ends at the latest 30 months after the date the device left the SMA production site and includes all defects caused by material or manufacturing faults.
  • Page 69 Sunny Boy 2000 Technical Description Exclusion of Liability Excluded are any guaranty claims and liabilities for direct or consequential damages due to − transportation damages, − faulty installation or commissioning, − manipulation, alterations or repairing attempts, − inappropriate use or operation, −...

  • Page 70: Technical Data

    Sunny Boy 2000 Technical Description 9 Technical Data Input Values (PV-panel) When determining how many PV-modules are connected in series the operator has to make sure that the output voltage of the PV-panel is within the permissible input voltage range of the inverter even in case of extreme outside temperatures.
  • Page 71 Sunny Boy 2000 Technical Description Surge voltage protection thermally monitored varistors Pole interchange protection yes, by short-circuit diode Personnel safety Isolation monitoring and all-pole sensitive fault current monitoring system ≥ 30 mA > 2 MΩ; I ∆ Output Values (mains connection)
  • Page 72 Sunny Boy 2000 Technical Description Efficiency η Max. efficiency > 96 % Ambient conditions Ambient temperature (permissible): -25°C … + 60°C Rel. air humidity 0 … 100%, class 3K6 Mechanical values Protection class I (basic insulation + PE connection) Protection classification EN 60529:...
  • Page 73 Sunny Boy 2000 Technical Description Input Current of the Sunny Boy 2000 10.0 Vpv [V] Maximum output power of the Sunny Boy 2000 2000 1500 1000 Vpv [V] Fig. 9.1: Output Power P and Input Current I depending on Input Voltage U...
  • Page 74 Sunny Boy 2000 efficiency for different input voltages 100.0% 95.0% 90.0% Upv = 400 V 85.0% Upv = 300 V Upv = 200 V 80.0% 90% 100% 110% Pac/Pnom Fig. 9.2: Sunny Boy 2000 efficiency curve - 74 - SB2000-11:EE SMA Regelsysteme GmbH...
  • Page 75 Sunny Boy 2000 Technical Description Parameter List Sunny Boy 2000 All parameters are transmitted to Sunny Data or Sunny Boy Control when configuring the Sunny Boy 2000. The following table lists the parameters which can be displayed and changed: Name Unit...

  • Page 76: Appendices

    Sunny Boy 2000 Technical Description 10 Appendices Appendix 1: Certificates for the Sunny Boy 2000 • SMA Declaration of Conformity • Clean Report of Findings by the employee association - 76 - SB2000-11:EE SMA Regelsysteme GmbH...
  • Page 77 Sunny Boy 2000 Technical Description - 77 - SB2000-11:EE SMA Regelsysteme GmbH...
  • Page 78 Sunny Boy 2000 Technical Description - 78 - SB2000-11:EE SMA Regelsysteme GmbH...
  • Page 79 This is especially useful if you want to send the Sunny Boy Service files with recorded data of your PV-plant. If you want to know more about SMA Regelsysteme GmbH and its products visit us on our homepage. This literature can be ordered at a low price covering our expenses. All documents are also available on the Internet free of charge.

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