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Sunny Boy 700 Technical Description

String inverter for photovoltaic plants
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Sunny Boy 700
Technical Description
Issue 1.0
String Inverter for Photovoltaic Plants
SB700-11:EE0502

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  • Page 1 Sunny Boy 700 Technical Description Issue 1.0 String Inverter for Photovoltaic Plants SB700-11:EE0502...
  • Page 2 Sunny Boy 700 Technical Description Alteration Review Document Issue Comments Author Number and Alteration SB700 Review -11:EE0502 Translation from German Issue 1.0 Simon A: Changes due to faulty documents or improvement of the documentation B: Changes maintaining full or upward compatibility...
  • Page 3 Sunny Boy 700 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 comfortable usage or optimal operation of the system.

  • Page 4: Table Of Contents

    System Monitoring and Diagnosis ..............49 Data Transmission via Powerline..............49 Data Transmission with a Separate Data Cable ........51 Upgrading or modification of the Sunny Boy interface ......59 Graphic User Interface under Windows ............62 Measuring Channels and Messages of the Sunny Boy ......64 Measurement Precision ................67...
  • Page 5 Sunny Boy 700 Technical Description Important Safety Notice: The Sunny Boy String Inverter may only be opened by qualified per- sonnel for both maintenance and modification. The device can still be charged with very high hazardous voltages even when disconnected.

  • Page 6: Introduction

    Sunny Boy complies with the according harmonised standards and the low voltage regulations as certified in the CE declaration (see appendix). In the following you will find the technical description of the Sunny Boy 700. 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 700 Technical Description 2 System Description The need to reduce the CO emission and other pollutants resulting from energy con- ² versions is becoming more and more apparent. Renewable energy sources can make an important contribution to solve this problem. The direct conversion of solar radiation to electric energy (photovoltaics) will play a substantial role in this essential matter world-wide.

  • Page 8: String Technology

    To reduce these costs, especially the costs for the cabling on the DC side and the subsequent distribution on the AC side, and drastically simplify the de- sign of PV-systems the string-technology was developed by SMA. The Sunny Boy finally enabled this new, considerably simpler and better affordable String Technol- ogy to be the standard system design for PV-plants.
  • Page 9 100 MW of installed inverter power in over 60,000 single units with powers from 700 W up to 500 kW (11/01). The Sunny Boy is the result of a dedicated develop- ment resulting from the substantial experience with utility interactive inverters for photovoltaics.

  • Page 10: Diagnosis And Communication

    Sunny Boy can be achieved with only a few system components. The data collected is either displayed on the LCD of the Sunny Boy Control or is shown on the screen of a PC running the according SMA software. Two programs “Sunny Data“...

  • Page 11: Technical Design Of The Sunny Boy 700

    Fig. 2.2: Block circuit diagram of the Sunny Boy 700 The PV input voltage range of the Sunny Boy 700 is designed for up to 10 standard PV modules. It can be configured with three different voltage ranges so that even small PV panel power can be optimally utilized (see chapter 3.3.2).
  • Page 12 Sunny Boy 700 Technical Description trol. The Sunny Boy therefore is not only a simple standalone device as it can be part of one big PV-plant that has one central control and monitoring facility. Two independent one-chip computers monitor the grid. This fully complies with the according regulations of the VDEW and the employee associations.
  • Page 13 (German Employee Association of Precision Mechanics and Electronics Engi- neering). The Sunny Boy string inverter is designed only for utility interactive operation. To en- sure safe shut-down in case of grid disconnection etc. and to avoid an “islanding condition” the inverter is equipped with an independent disconnection device that has been certified by the “Berufsgenossenschaft für Feinmechanik und Elektrotechnik“.
  • Page 14 Conditions that cause the Sunny Boy to be disconnected from the grid: • Grid Impedance − The Sunny Boy does not start to feed to the grid if the grid impedance Z is higher than 1.25 Ω. − The Sunny Boy is disconnected from the grid within 5 seconds once the ≥...
  • Page 15 Sunny Boy 700 Technical Description The value of the grid impedance measured at the Sunny Boy is the total of the im- pedance of the public grid and the cabling impedance in the house (from house dis- tribution to the Sunny Boy). Excessive increase of grid impedance through the con- nection cable to the inverter therefore has to be avoided.

  • Page 16: Installation

    Sunny Boy 700 Technical Description 3 Installation The installation of the Sunny Boy string inverter must be done by qualified personnel that is approved by the local electricity company. Make sure that all instructions in this chapter are followed. Follow all safety regulations and regulations of the local electricity company.

  • Page 17: Placement Of The Sunny Boy

    Sunny Boy 700 Technical Description 3.2 Placement of the Sunny Boy The Sunny Boy is a complicated electronic device and is therefore sensitive to humidity within the case. If the Sunny Boy is placed outside, the humidity during the installation should be as low as possible - pay special attention that it does not rain.
  • Page 18 The free air circulation around the case must not be obstructed to ensure sufficient cooling. • If you install the Sunny Boy in a cabinet or closet etc., the air circula- tion must be sufficient for heat dissipation - provide external ventila- tion.
  • Page 19 Sunny Boy 700 Technical Description Packing list for mounting and installation The following components provide for safe and simple installation of the Sunny Boy and are included in the packing list: Sunny Boy 700 Drilling template in appendix 1 pc.
  • Page 20 Technical Description Preparing the Mounting The Sunny Boy is mounted on its back with 3 metal straps on a firm surface. 3 screws and the corresponding dowels are necessary. The screws and dowels are not included and have to have a sufficient size. We recommend 6 mm screws and 8 mm dowels.
  • Page 21 Sunny Boy 700 Technical Description Mounting to wall • Mark the holes with the drilling template. • Drill the holes (and put in the dowels), put in the screws of both top holes and screw them in until ca. 4 mm are sticking out.

  • Page 22: Electric Connection

    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 grid and the input from the PV-modules are connected to the inverter in the bot- tom of the case.

  • Page 23: Connection To The Electricity Grid

    Technical Description 3.3.1 Connection to the Electricity Grid The Sunny Boy must be connected to the grid with three cables - one phase, one neutral and one protective earth (PE). We recommend a 16 A automatic circuit breaker. No consumers are allowed on this circuit or they have to be fused separately.
  • Page 24 For cables that require the PG16 gland: Tighten the bolt of the PG16 gland. • The AC connector socket is now ready to use. • Seal the AC connector socket in case you do not insert it into the Sunny Boy. SB700-11:EE SMA Regelsysteme GmbH...

  • Page 25: Connection Of The Pv-Panels

    Technical Description • The AC connector socket can be inserted into the Sunny Boy in case the Sunny Boy is already mounted in the correct position. Remove the transparent seal from the AC connector on the Sunny Boy, insert the AC connector plug and tighten the seal.
  • Page 26 10 modules with 36 to 40 cells each. This results in an input voltage of 125 V to 250 V DC. The Sunny Boy 700 can be specially configured in order to be able to process volt- ages from PV-generators with less than 10 modules (with 36 to 40 cells each). PV- module strings with 8 or only 6 modules are possible, which produce a voltage of 100 V to 200 V DC or 75 V to 150 V DC.
  • Page 27 Sunny Boy 700 Technical Description Fig. 3.5: Position of adapter block and jumpers 1. release internal clamp 2. insert cable in connector with screwdriver and rem ove screwdriver Fig. 3.6: How to fix cable in adapter block SB700-11:EE SMA Regelsysteme GmbH...
  • Page 28 Sunny Boy 700 Technical Description Sunny Boy 700 - Configuration of the input voltage PV-voltage Adapter connector block Jumpers connector 125 V -250 V DC both Jumpers stay (default) connector remove this Jumper open 100 V - 200 V leave this Jumper...
  • Page 29 Sunny Boy 700 Technical Description Connection to the PV-modules In order to simplify safe mounting and servicing the Sunny Boy is connected to the PV-modules with safe to touch snap cable connectors type Multi-Contact which were especially designed for PV applications.

  • Page 30: Commissioning

    Check that no tools, wires or similar equipment are placed on the case of the Sunny Boy 700 during operation. On top of the device you can find the heat sink of the Sunny Boy with po- tential temperatures of over 80 °C. Danger of burning.
  • Page 31 The internal consumption is negligible for the voltage measurement with higher solar radiation. The operating state of the Sunny Boy will be indicated with three LEDs integrated into the lid. The meaning of the LEDs will be explained in chapter 5, “Operation and Failure Indication LEDs”.

  • Page 32: Operation And Failure Indication Leds

    The inverter goes to standby mode if the radiation and the result- ing electric input energy is too low and is therefore always ready for operation. Each time the Sunny Boy starts up it runs a number of self tests and safety proce- dures.
  • Page 33 Sunny Boy 700 Technical Description Fig. 5.1: Front view of part of the Sunny Boy Description of the symbols used in the following section: LED off LED blinks once per second LED blinks fast (ca. three times per second) LED is constantly on...
  • Page 34 MSD red: yellow: Table 5.1: Sunny Boy operation indication overview SB700-11:EE SMA Regelsysteme GmbH...
  • Page 35 Operation Indicator Standby (night) All LEDs are off. The Sunny Boy is in “standby (night)“ mode. The input voltage is too low < approx. 60 V) to supply the Sunny Boy control system with enough power. Initialization All LEDs are on.
  • Page 36 The inverter has stopped operation, among other things the measurement electron- ics is calibrated. Subsequent condition is “Waiting“. “Stop“ condition can be initiated by the user with the Sunny Boy Control or the pro- gram Sunny Data. The Sunny Boy remains in this condition until set to “MPP- Operation“...
  • Page 37 Konst”) can be manually defined by the operator and transmitted to the Sunny Boy via the Sunny Boy Control or with the Sunny Data software. In the constant voltage mode the Sunny Boy uses a strictly defined PV voltage setpoint.
  • Page 38 Insulation failure, defective varistor Red LED on The Sunny Boy indicates an earth failure with the red LED. This condition can occur together with other indications. The indication of “Earth Fault“ can result from two different reasons: Either the PV-...
  • Page 39 • Failure of the thermally monitored varistors On its 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 (electric fields from thunderstorms etc.).
  • Page 40 Re-connect the PV-panels and the grid to the Sunny Boy. If the red LED is still on, the Sunny Boy is damaged and must be repaired by the manufacturer. If the red LED is off the isolation of the Sunny Boy or the connection cabling is defec- tive. •...
  • Page 41 The yellow failure LED is permanently on. This is a failure of the grid monitoring or the autonomous disconnection device MSD. The Sunny Boy has detected a failure in the autonomous disconnection facilities and has suppressed the grid feeding. Further proceedings are described in chapter 7.
  • Page 42 The code is sent three times. If the failure consists the indication blinking code is repeated. The Sunny Boy is indicating a failure which has one of the following reasons (see also Table 9.1 on page 79.
  • Page 43 The criteria for the grid impedance are described in the section “MSD“. A too high grid impedance can be the reason in case this failure occurs very often, forcing the inverter to switch off. The impedance can be checked with the Sunny Boy ≥ 1,25 Ω the Sunny Boy may Control or Sunny Data.
  • Page 44 Too high input voltages can cause a non-repairable damage. Have the circuits of your PV-panels checked by your electrician. The permissible PV input voltage of the Sunny Boy is listed in the technical data in chapter 9. SB700-11:EE SMA Regelsysteme GmbH...
  • Page 45 The code is sent three times. If the failure consists the indication is repeated. The Sunny Boy is in a condition that makes it impossible to return to normal opera- tion and is most likely defect.

  • Page 46: Opening And Closing Of The Sunny Boy

    When working on the Sunny Boy follow the instructions below: 1. Separate the Sunny Boy from the grid by opening the circuit breaker. 2. Separate all poles of the Sunny Boy from the PV-panel by pulling the MC plug connectors.
  • Page 47 On the inside of the lid there is a tab connector contact with a green- yellow grounding cable (PE connection). Carefully separate this cable. You now have the opened Sunny Boy in front of you and can see the position of components and clamps relevant for you. You will find: •...
  • Page 48 When screwing the inner screws make sure that the thread in the Sunny Boy case is not damaged by tilted screws. Under certain conditions the protection class IP65 cannot be guaranteed any more. When mounting the Sunny Boy outside moisture can get into the device and damage the electronics.

  • Page 49: System Monitoring And Diagnosis

    6 System Monitoring and Diagnosis 6.1 Data Transmission via Powerline Signal transmission between the Sunny Boy and the Sunny Boy Control or the PC is done with the grid connection via Powerline. This requires a minimum of installation (see below). The Sunny Boy must be equipped with a Powerline modem for data transmission.
  • Page 50 • Powerline Communication with a Sunny Boy Control Plug the 230V power cable of the Sunny Boy Control into the electricity socket. For operation of the Sunny Boy Control and the usage of Sunny Data Control for Sunny Boy Control refer to the according manuals.

  • Page 51: Data Transmission With A Separate Data Cable

    RS232 communication If only one Sunny Boy has to be connected to the PC the easiest way is direct cou- pling via an RS232 port. A maximum of 15 m is permissible between the PC and the Sunny Boy.
  • Page 52 15 m. You can see the connector lay- out in Fig. 6.3. The shielding should be connected to protective earth (PE) on both ends at the Sunny Boy and the PC case. SB700-11:EE...
  • Page 53 (not mounted) (removed) Shield connect shield to case Shield PC with DB9 plug in COM1 .. COM4 PC with DB25 plug in COM1 .. COM4 Fig. 6.3: System control board Sunny Boy with RS232 cabling SB700-11:EE SMA Regelsysteme GmbH...
  • Page 54 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. Sunny Boy...
  • Page 55 Sunny Boy 700 Technical Description What do you need for RS485 communication: • A special RS485 Piggy-Back module and appropriate cable glands for all Sunny Boys • The light blue resistors (Fig. 6.6) on the system control board are removed.
  • Page 56 Up to 50 Sunny Boys last Sunny Boy Jumper 1 mounted MOSR15-SP connect shield to case (PE) Resistors under the Piggy- Back module must be removed Fig. 6.6: System control board Sunny Boy with RS485 cabling SB700-11:EE SMA Regelsysteme GmbH...
  • Page 57 Connect pin 7 and pin 9 on the end of the cable that is connected to the interface converter. • If you are using a PC instead of a Sunny Boy Control, switch the interface con- verter RS485/RS232 (ordering no. 39-0020) to “DTE“. •...
  • Page 58 Sunny Boy 700 Technical Description 9-pin to 25-pin adapter DB25 Description DCD (Data Carrier Detect) RX (Receive Data) TX (Transmit Data) DTR (Data Terminal Ready) GND (Signal Ground) DSR (Data Set Ready) RTS (Request To Send) CTS (Clear To Send) RI (Ring Indicator) Table 6.1: Pin designation of the DB9/DB25 adapter...

  • Page 59: Upgrading Or Modification Of The Sunny Boy Interface

    RS232 or RS485 interfaces for the Powerline protocol. In order to install a new interface in the Sunny Boy a corresponding piggy back mod- ule has to be installed on the system control board. Please follow all relevant instruc- tions in chapters 3.3, “Electric Connection”, 4, “Commissioning”, 5.1, “Opening and...
  • Page 60 Connect the cables for RS232 (see Fig. 6.3) or RS485 (see Fig. 6.6). No cabling is necessary for Powerline communication. Data cables are lead outside through the free opening at the bottom of the Sunny Boy. Please insert the PG16 screws into this opening and fasten them.
  • Page 61 Sunny Boy 700 Technical Description • Lead the communication cable through the contact unit of the PG cable gland. • Connect the terminal cables to the terminal strip of the system control board and check whether they are firmly fastened.

  • Page 62: Graphic User Interface Under Windows

    Special functions allow the installer to modify the operating parameters of the Sunny Boy in order to improve system per- formance. Please see the Sunny Data manual for further information on Sunny Data.
  • Page 63 Sunny Data Control Large PV-plants with numerous Sunny Boys are supervised and monitored with a Sunny Boy Control. The Sunny Boy Control handles central measurement data ac- quisition and diagnosis for up to 50 Sunny Boys and assists the commissioning of the PV-plant.

  • Page 64: Measuring Channels And Messages Of The Sunny Boy

    6.5 Measuring Channels and Messages of the Sunny Boy If your PC is equipped with communication (see chapter 2.2), it supports a number of measuring channels and messages from the Sunny Boy inverters and transmits them to the output unit for diagnosis.
  • Page 65 Zuschalt electronics are connecting to grid MPP-Such PV voltage is determined and set Sunny Boy is in MPP mode U-Konst. Sunny Boy is in constant voltage mode Derating Reduction of current fed to the grid Stoer. failure Error messages F-Bfr-Srr...
  • Page 66 Sunny Boy 700 Technical Description F-UpvMax PV input voltage above the tolerable maximum value F-Zac-Bfr BFR-grid impedance measurement - value out of tolerable range F-Zac-Srr SSR-grid impedance measurement - value out of tolerable range F-Watchdog Watchdog for operation control triggered...

  • Page 67: Measurement Precision

    Any kind of measurement always depends on the accuracy. The 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 is conceived for there requirements.

  • Page 68: Troubleshooting

    We recommend to conduct the following steps in case your PV-plant does not oper- ate correctly: • Check the blink code on the lid of the Sunny Boy and compare the code with the blink codes listed in chapter 5. Follow the countermeasures listed there, if necessary contact the installer.
  • Page 69 Supplier, type of modules − Number of modules in string − Output power − Open circuit voltage Use the original box the Sunny Boy was delivered in if the Sunny Boy has to be sent to the manufacturer. SB700-11:EE SMA Regelsysteme GmbH...

  • Page 70: Warranty Regulations And Liability

    Sunny Boy 700 Technical Description 8 Warranty Regulations and Liability If your inverter shows a defect or a malfunction during the warranty period please contact your distributor or installer. Warranty The warranty period is 24 months from the date of purchasing the device by the end user.
  • Page 71 Sunny Boy 700 Technical Description Exclusion of Liability Excluded are any warranty claims and liability for direct or consequential damages due • transportation damages, • improper installation or commissioning, • improper alterations, modification or repairing attempts, • inappropriate use or operation, •...

  • Page 72: Technical Data

    You can enter these data into our EXCEL file “GenAu” and check whether the maximum admissible input voltage of the Sunny Boy is not exceeded in any possible operating state. You will find this tool in the Internet for download at: http://www.sma.de/ftp/energietechnik/sunnyboy/GenAu/GenAu.exe.
  • Page 73 PV panel power to the low-voltage electricity grid. The inverter stays at the lower input voltage limit and cannot follow the MPP of the PV panel any more. Therefore the Sunny Boy has got a flexible MPP voltage range.
  • Page 74 Sunny Boy 700 Technical Description Depending on grid voltage the following minimum MPP voltages result from the three possible input voltage ranges of the Sunny Boy 700: 125-250 V 100-200 V 75-150 V 700 W P 600 W P 460 W P...
  • Page 75 Sunny Boy 700 Technical Description Fig. 9.2: Input current as a function of input voltage of the Sunny Boy The inverter is not damaged if the input current supplied by the connected PV panel exceeds the maximum that can be used. How- ever the input voltage has to be within the admissible input voltage range.
  • Page 76 Sunny Boy 700 Technical Description Output values (grid) Nominal power: 460, 600, 700 W ACnom Peak power: 460, 600, 700 W Acmax Harmonic distortion of output current: < 3 % (at K < 2 %, P > 0.5 P Ugrid...
  • Page 77 Sunny Boy 700 Technical Description 100 % 100 % Fig. 9.3: Sunny Boy 700 efficiency P acnom Fig. 9.4: Output current and output voltage of the Sunny Boy SB700-11:EE SMA Regelsysteme GmbH...
  • Page 78 Sunny Boy 700 Technical Description Power consumption Power consumption during operation: < 4 W Power consumption during stand-by: < 0.1 W Certifications: EMC: DIN EN 50081, part 1 (EN 55014, EN 55011 section 1, class B) DIN EN 50082, part 1...
  • Page 79 Sunny Boy 700 Technical Description Parameter List Sunny Boy 700 All parameters are transmitted to Sunny Data or to the Sunny Boy Control when the Sunny Boy 700 is configured. The following table shows the available parameters: Name Unit Range Default (for PV-input voltage) Chang.

  • Page 80: Appendix

    Sunny Boy 700 Technical Description 10 Appendix Certificates for the Sunny Boy 700 • SMA Declaration of Conformity for the Sunny Boy 700 • Clean Report of Findings for MSD in the Sunny Boy 700 SB700-11:EE SMA Regelsysteme GmbH...
  • Page 81 Sunny Boy 700 Technical Description SB700-11:EE SMA Regelsysteme GmbH...
  • Page 82 Sunny Boy 700 Technical Description SB700-11:EE SMA Regelsysteme GmbH...
  • Page 83 SMA CD (products, technical documentation, driver) • Manual “Improved Powerline Communication with the Sunny Boy Family” This literature can be ordered from SMA for a small fee - most of this although is available free of charge for download from WWW.SMA.DE .
  • Page 84 • You can leave messages for SMA. This is especially useful if you want to send data recorded from your PV-plant to the Sunny Boy service. Those who want to know more about SMA Regelsysteme GmbH and its products are very welcome to visit us on our homepage.
  • Page 85 Sunny Boy 700 Technical Description • Address: SMA Regelsysteme GmbH Hannoversche Straße 1-5 D-34266 Niestetal • Telephone: 0561/9522-0 (operator) 0561/9522-499 (Sunny Boy Service) • Fax: 0561/9522-100 (main fax) 0561/9522-4699 (Sunny Boy Service) • eMail: info@sma.de Internet: http://www.sma.de Appendix: drilling template...

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