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Technical Description - SMA Solar Technology AG

1. Commissioning The Sunny Boy works with high voltages externally and internally which can cause considerable harm to people Only a qualified elec trician may work on the device especially open it While upgrading the Sunny Boy interface the operator can get into touch both with electronic components and components carrying lethal voltage 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 SB2000 11 EE 57 SMA Regelsysteme GmbH 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 Discharge the electrostatic charge by touching the grounded case before touching an electronic component otherwise you run a great risk of destroying your electronics Work on the inverter always has to be done in the order described 1 Disconnect the inverter from the grid 2 Disconnect the inverter from all poles of the PV panel Wait for approximately 30 minutes until internal voltages have discharged Open the device only after the above steps have been taken SB2000 11 EE u 58 SMA Regelsysteme GmbH Sunny Boy 2000 Technical Descripti
2. SB2000 11 EE 25 SMA Regelsysteme GmbH 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 nectors especially designed for PV plants from Multi Contact Make sure the and poles of the PV panel are correctly con nected to the respective MultiContact plug connectors at the bottom of the Sunny Boy Depending on the type of PV panels you must distinguish between connecting one single or two parallel strings In order to be able to connect two strings there are two connectors for plus and minus pole each The connectors are switched parallel in side the inverter N Seal the unused connectors if you are using only one string In order to provide maximum safety during initial installation it is necessary to have the plus and minus pole from the PV panels clearly separated from the PE protective earth MC is a registered trademark of Multi Contact SB2000 11 EE 26 SMA Regelsysteme GmbH Sunny Boy 2000 Technical Description Before connecting the PV panel to the Sunny Boy check the installation is isolated from earth by e Determining the DC voltage between protective earth PE and the plus and minus poles of the PV panel If you measure stable voltages there is a ground fault in the PV panel or its cab
3. Sunny Boy 2000 Technical Description Contents 1 giigele ici lo re tt Te ee eh eer Ea 6 2 System Description msn nennen 7 2 1 String Technel 9Ya 2u 222er 8 2 2 Diagnosis and Communication a neigen 10 2 3 Technical Design of the Sunny Boy 2000 2244444sosnnnnnn nennen 11 3 IST AA ON a ET a rear 16 3 1 What must be done in case of transport damages neenn 16 3 2 MOUNINO rer a a aE oa r aE aa ara EEE 17 3 3 Electric Connection use eedeeeninieiaeinieehneeieeeee 22 3 3 1 Mains Connection uuuusssssssesnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nn 24 3 3 2 Connection of the PV panels cccccceceeeeeessseeeeeeeeeeeeeeeeessseeeeeeeeeees 26 41 COMMISSIONING n ae eect cecti ethene E A a a A EA AS 30 5 Operation and Failure Indication LEDS ssssssssssenneneesseerrerrnenrnsssrrrrrrnnnreeeeee 31 6 Plant Monitoring and Diagnosis uusunnnsssnennnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nn 48 6 1 Data Transmission via Powerline 24400044444444nnnnnnnnnnnnnnnnnnnnnnnnn 48 6 2 Data Transmission with a Separate Data Cable uuunnnn nennen 51 6 2 1 Upgrading or modification of the Sunny Boy interface 57 6 3 Graphic User Interface under Windows cceeeeeeeeeeeeeeeeeeeeteeeeeeees 61 6 4 Measuring Channels and Messages of the Sunny Boy 2 22222000 63 6 5 MeasuremenkPrecisioneussaneiiken
4. amp Yellow LED off Technical Description 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 In MPP mode the maximum power point P is set by changing the required PV voltage at the PV panel Constant Voltage mode The voltage from the PV modules can be manually set to a fixed value U Konst defined by the operator via the Sunny Boy Control or with Sunny Data software In the constant voltage mode the Sunny Boy uses an externally de fined PV setpoint voltage as a default value for its internal control SB2000 11 EE u 36 SMA Regelsysteme GmbH Sunny Boy 2000 Technical Description Earth Fault Indicator Isolation failure defective varistor Operation O Earth Fault Red LED on Failure 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 panel connection has an isolation failure or at least one of the two thermally moni tored varistors on the DC side are defective and therefore do not let any current pass The possible failures and methods to find out how
5. 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 In order to guarantee this safety the employee association for precision mechanics and electric engineering developed a safety concept that became part of the VDEW guidelines in August 1994 The Sunny Boy String Inverter is absolutely restricted to supplementary grid feeding operation i e the grid feeding must stop in case the local electricity supply is cut off The Sunny Boy is equipped with a certified automatic disconnection device for the safe disconnection when the external grid is down in order to avoid islanding This disconnection device is officially certified by the employee associations The device is a Selbsttatige Freischaltung f r Eigenerzeugungsanlagen einer Nennleistung lt 4 6 kVA mit einphasiger Paralleleinspeisung ber Wechselrichter in das Netz der ffentlichen Versorgung i e Automatic Disconnection Facility for Photovoltaic Plants with a Rated Output lt 4 6 kVA and a Single Phase Parallel Feed by Means of an Inverter into the Public Low Voltage Mains For maximum safety it is important that the automatic disconnection device consists of two independent units for mains monitoring each equipped with a disconnecting de vice and connected in series Each of these devices permanently supervises the pa rameters of the connected grid by checking the voltage
6. 200 V 80 0 0 10 20 30 40 50 60 70 80 90 100 110 Pac Pnom Fig 9 2 Sunny Boy 2000 efficiency curve SB2000 11 EE u 74 SMA Regelsysteme GmbH 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 No Name Unit Validrange Default Value Changeable by pt From ftom Installer 500 450 installer 29 300 261 Installer Table 9 1 Sunny Boy 2000 Parameter List We reserve the right to perform technical changes for improvement of the device SB2000 11 EE z 75 SMA Regelsysteme GmbH Sunny Boy 2000 Technical Description 10 Appendices Appendix 1 Certificates for the Sunny Boy 2000 e SMA Declaration of Conformity e Clean Report of Findings by the employee association SB2000 11 EE 76 SMA Regelsysteme GmbH MI SMA Regelsysteme GmbH Hannoversche Stra e 1 5 D 34266 Niestetal SMA Regelsysteme GmbH Hannoversche Stra e 1 5 D 34266 Niestetal Telefon 05 61 95 22 0 Telefax 05 61 95 22 100 Ihr Zeichen Unser Zeichen Bearbeiter Telefon Durchwahl Datum 05 61 95 22 03 05 99 Declaration of Conformity for the PV inverter SWR 2000 Sunny Boy We declare that the PV inverter SWR 2000 complies with the VDE regulations for parallel grid feeding es pecially the Richtlinie f r den Parallel
7. at the beginning of the cable that is connected to the Sunny Boy Control or the PC One is soldered from pin 3 to pin 6 the other is soldered from pin 5 to pin 8 e _ For the RS485 connection we recommend an LIYCY 2 x 0 25 mm twisted pair cable with a maximum length of 1200 m 4000 ft It consists of four data lines two of which are combined respectively to form altogether two twisted pairs sur rounded by a single common shield which must be connected to protective earth PE on both ends e If necessary an adapter for the RS232 plug from the interface converter to the PC 9 pin plug to 25 pin socket SB2000 11 EE 56 SMA Regelsysteme GmbH Sunny Boy 2000 Technical Description 9 pin to 25 pin adapter pee f _ps25_ __deseripion _ 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 6 2 1 Upgrading or modification of the Sunny Boy interface The Sunny Boy is prepared for data transmission By simply plugging on a piggy back module it supports the RS232 or RS485 interfaces or 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 and 4
8. cables L N PE SS 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 The inverter autonomously monitors ground fault currents of the PV panel PV modules cabling and inverter and disconnects the plant from the mains if the dis charge current changes drastically by gt 30 mA The inverter distinguishes between real ground fault currents and normal capacitive discharges Conventional AC sensitive RCBs with a sensitivity of 30 mA could result in false alarms due to the normal capacitive discharges resulting in disconnection The installation of an additional RCB in the mains connection cable is therefore not advisable If the user wishes to install an additional RCB anyway this must have at least a sen sitivity of 100 mA Note that accessible components of the PV system metal frames aluminum foil shielding of the PV panels mounting racks etc must be grounded in order to provide a safe discharge from the system during operation A sufficiently thick cable should be used to prevent an increase of the grid imped ance internal resistance of the grid resulting from the connection between the Sunny Boy and the in house distribution network Z lt 0 5 Q is recommended More about this in paragraph Autonomous grid disconnection device MSD in chapter 2 3 page 13 i The imped
9. electric power household devices lights etc In case that not enough energy is produced the additionally nec essary energy is obtained from the grid A potential surplus of energy is fed into the local grid and is therefore available for other consumers This way every single kilo watt hour is used and the electricity companies power plants are relieved In the most simple case a grid connected solar energy plant therefore consists of two com ponents the PV panel and the inverter SB2000 11 EE u 7 u SMA Regelsysteme GmbH Sunny Boy 2000 Technical Description 2 1 String Technology The experience with several thousand grid connected PV systems in Europe with an output range from one to several hundred kilowatts has shown us that the costs for connecting and monitoring the PV system add up to almost 50 of the cost of the entire system The reduction of these costs especially the costs for the cabling on the DC side and the subsequent distribution on the AC side along with a drastic simplification of PV system design were the reasons for developing the string technology from SMA The String Inverter connects a small number of serially connected PV panels strings with the local electricity grid Even large PV systems can be created with this method the large PV system then consists of several strings each with a single inverter The electricity is then collected on the AC side therefore the expensive and work intensive DC cabli
10. frequency and impedance The redundant design and an automatic self test before each connection to the mains guarantee its reliable function While former disconnection devices for islanding detection only checked the voltage of the connected three phase mains the new concept uses above all the mains imped ance alterations in the one wire mains feeding phase as a measured value for dis connection In addition voltage and frequency in the one wire mains are also checked SB2000 11 EE 1 3 SMA Regelsysteme GmbH Sunny Boy 2000 Technical Description Criteria for disconnecting the Sunny Boy from the grid e Mains impedance The inverter does not start feeding to the mains if a maximum impedance value is exceeded Z 1 25 Q If the mains impedance changes by a certain value in a certain time Z 2 0 5 Q or if it exceeds a maximum value Z 2 1 75 Q during grid feeding the in verter will be disconnected from the mains within 5 s e Mains voltage Incase the mains voltage exceeds or falls below a range of 15 10 of the nominal mains voltage V the Sunny Boy is disconnected from the mains within 0 28 e Mains frequency If the frequency exceeds a range of 0 2 Hz of nominal mains frequency f with a mains voltage of 30 15 of nominal mains voltage this must additionally cause a mains disconnection within 0 2 s e Insulation The quality of insulation in the entire system is guaranteed by two independ
11. grid current from PV panel discharge current of PV plant inverter and PV panel total energy fed to the grid total operation hours number of times the inverter starts feeding to the grid Sunny Boy serial number current status failure description for status failure manual system stop offset calibration of the electronics waiting starting conditions not fulfilled yet U lt U start checking grid grid impedance electronics are connecting to grid 63 SMA Regelsysteme GmbH Sunny Boy 2000 MPP Such MPP U Konst Stoer Error messages Bfr Srr EEPROM Fac Bfr Fac Srr DI dl Srr dl Mess dZac Bfr dZac Srr Imax K1 Schliess K1 Trenn K2 Trenn NUW UAC NUW dl NUW FAC NUW Mess NUW REL NUW ZAC Offset Rechner Riso Uac Bfr Uac Srr UpvMax Uzwk Zac Bfr Zac Srr Watchdog SB2000 11 EE Technical Description PV setpoint voltage is determined and set Sunny Boy is in MPP mode Sunny Boy is in constant voltage mode failure communication between microcontrollers is failing EEPROM cannot be read or written in BFR frequency measurement value out of tolerable range SSR frequency measurement value out of tolerable range BFR sudden change of differential current value out of tolerable range 30 mA s SRR sudden change of differential current leap value out of tolerable range 30 mA s Acquisition of differential or fault current defective BFR sudden change of impedance value
12. humid ity within its case SS If the Sunny Boy is placed outside air humidity during installation should not be extremely high e g in case of fog pay special attention that it does not rain 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 A suitable position must be found for the inverter s while the PV plant is designed It is important to take the following criteria into account Criteria for device mounting Due to the high protection class IP65 the installation is possible indoors as well as outdoors e If possible do not expose the inverter to direct moisture despite IP65 e Keep the DC cabling from the solar generator to the inverter as short as possible e _ Avoid installation in the living area because a slight noise emission is possible e Avoid mounting on resonant parts e g thin wooden panels plaster panels etc e Provide accessibility for installation work and later servicing Installation in eye height allows easy reading of the operating indicators LEDs SB2000 11 EE 1 7 SMA Regelsysteme GmbH Sunny Boy 2000 Technical Description Please note the following points in any case A e The mounting ground must be firm e SB2000 11 EE The ambient temperature must lie bet
13. local electricity company Please read this chapter carefully before installation Pay attention to all safety requirements the connection regulations imposed by the local electricity company and the VDE regulations 3 1 What must be done in case of transport damages The inverters are thoroughly checked before they are shipped Even though they are delivered in a sturdy packaging which can be recycled the inverters can be dam aged in transit Please inspect your inverter thoroughly after it is delivered If any damages can be detected on the packaging that could make you conclude the contents is damaged or if you detect that the inverter is damaged please immediately notify the forwarding company 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 If it is necessary to return the inverter to the manufacturer please use the packaging the inverter was sent in if it is still functional Only then can transport damages be avoided as far as possible SMA cannot provide warranty for damages resulting directly or indirectly from unsuitable transport packaging SB2000 11 EE 1 6 SMA Regelsysteme GmbH Sunny Boy 2000 Technical Description 3 2 Mounting Placement of the Sunny Boy The Sunny Boy is a highly integrated electronic device therefore sensitive to
14. mounted Resistors under the piggy back module must off be removed resale x i Ne a ise Oy do Connect shield i we ER oD 8 l e ee ou OEE ae 2 Lee TO eran we _ N Second Sunny Boy Jumpers MOSR25 SP not mounted Resistors under the piggy back module must cee be removed o age oO SSC oom RN gt ae 1 of se sei IO se eel bce ze tO Connect shield o ne ae oO BERT ae o E to case g BL ee O a a Last Sunny Boy MOSR25 SP Connect shield to case Resistors under the piggy back module must be removed Fig 6 5 System control board Sunny Boy with RS485 cabling SB2000 11 EE 55 SMA Regelsysteme GmbH 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 e _ Connect pin 7 and pin 9 on the end of the cable that is connected to the interface converter e 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 e _ The transmission cable is terminated on the last Sunny Boy on the cable There a termination resistor is connected by mounting a jumper no 1 jumper directly above the terminal strip e Two resistors of 680 Ohm each must be integrated into the DB9 connection
15. protection Pole interchange protection Personnel safety Output Values mains connection Nominal output power Maximum output power Output voltage range Output frequency range Total harmonic distortion of output current Phase shifting factor related to fundamental Grid monitoring All pole disconnection grid side Short circuit proof Surge voltage protection Insulation test voltage 50 Hz Surge voltage test 1 2 50 us External interfaces Data transmission via Powerline Data transmission via data cable Internal Power Consumption In operation In standby e g at night SB2000 11 EE thermally monitored varistors yes by short circuit diode Isolation monitoring and all pole sensitive fault current monitoring system Rigo gt 2 MQ lay 230 mA 1800 W AC 2000 W AC R 180 260 V AC A 48 52 Hz Kac lt 4 for Ki AC lt 2 Pac gt 0 5 Pisce p 0 V orig U AZ u Riso Alay MSD Mains monitoring with allocated Switching Devices acc DIN VDE 0126 VDEW Independent disconnection device MSD double current controlled IIl 1 35 kV 1 5 s piece type test 4 kV serial interface 6 kV optional optional electrically separated RS232 RS485 lt 7 W lt 0 1W 71 SMA Regelsysteme GmbH Sunny Boy 2000 Efficiency Max efficiency N max Ambient conditions Ambient temperature permissible Rel air humidity Mechanical values Protection class Pro
16. 5S 5 3s is is 1s 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 The inverter has detected a failure based on non permissible grid impedance values Criteria for grid impedance during connection and feeding are described in detail in paragraph Autonomous Grid Disconnection Device on page 13 Should the inverter switch off very often during grid monitoring the grid impedance might be too high The impedance can be checked with the Sunny Boy Control or Sunny Data If the impedance exceeds Z 2 1 25 Q the Sunny Boy may not conduct grid feeding This failure can normally be avoided by increasing the thickness of the AC cabling SB2000 11 EE 43 SMA Regelsysteme GmbH Sunny Boy 2000 Technical Description Blinking code 4 Input voltage PV panel too high Operation amp amp Q amp amp amp Earth Faut Q amp Failure gt amp D D D D gt 55 3s 1s is 1s 1s 5 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 Input voltage is too high The PV panel is generating a voltage higher than the per missible 500 V Disconnect the PV panel from the Sunny Boy immediately Too high input voltage ca
17. 6 of 25 C Other temperatures must be evaluated with respect to the inaccu racy resulting from these different temperatures Range Resolution Max fail Display Measurement 8 25 C input voltage U V 0 561 V 0 55 V grid voltage Une V 190 300 V i l R 1 0 3 V 1 1V mA 12 mA 2 aoi nd Mac bad Table 6 2 Measurement accuracy of the Sunny Boy SB2000 11 EE u 65 SMA Regelsysteme GmbH 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 We recommend to conduct the following steps in case your PV plant nonetheless does not operate correctly e _ 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 e Check the Status and Failure messages in one of the monitoring systems described in chapter 6 Plant Monitoring and Diagnosis if present e Contact the Sunny Boy service if the system malfunction persists The address is listed in the appendix In order to let your PV plant
18. 6 1 pc Washer M5 plastic for fixing to lid Drilling template 1 pc Plug for mains connection 1 pc Seal for Multi Contact plug 1 pc Seal for Multi Contact socket 1 pc Table 3 1 Packing list for mounting and installation SB2000 11 EE 1 9 SMA Regelsysteme GmbH Sunny Boy 2000 Technical Description Drilling Template Sunny Boy 2000 Distance between top holes position of top ah total width of Sunny Boy 2000 434 50 mm Total hight of Sunny Boy 2000 295 50 mm E E e 2 o a N 7 2 S 2 Ei 2 gt 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 Three 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 For outside mounting use stainless steel material screws washers etc The Sunny Boy is mounted to the wall by three metal straps on the back of the de vice see Fig 3 2 SB2000 11 EE 20 SMA Regelsysteme GmbH 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 After the Sunny Boy has bee
19. Netz der ffentlichen Versorgung Die elektrische Sicherheit o g Erzeugnisse entspricht den zum Zeitpunkt der Ausstellung dieser Bescheinigung geltenden Bestimmungen Diese Unbedenklichkeitsbescheinigung gilt befristet bis 31 12 2001 V hy Ji Sy H C spare N ter r Pr f und Zertifizierungsstelle Sh 4 Mianya 27 Havsadresse Gostav Heinemann Urer 130 50948 K te Tei 02 211 37 73 0 Sunny Boy 2000 Technical Description Appendix 2 Information on SMA Additional SMA literature for products in the Sunny Boy family e Technical Description of PV inverter Sunny Boy 700 850 Sunny Boy 1100 and Sunny Boy 2500 e User Manual for PC program Sunny Data e User Manual for PC program Sunny Data Control e User Manual for monitoring unit Sunny Boy Control e Technical Description SWR COM e Sunny Boy INFO periodical issues with up to date topics covering the Sunny Boy e SMA CD products technical documentation drivers e Technical Description Powerline Communication Sunny Boy on the Internet http www SMA de For all users of SMA photovoltaic system components we have established a forum Sunny Box under http www sma de There you will find e Latest information on the Sunny Boys e The latest version of Sunny Data for download e The Sunny Boy service supports you in all matters related to your PV plant e You can leave messages for SMA This is especially useful if you want to send the Sunny Boy
20. 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 SB2000 11 EE 79 z SMA Regelsysteme GmbH
21. Sunny Boy 2000 Technical Description Version 1 2 Sunny Boy 2000 The Transformerless String Inverter for Photovoltaic Plants SB2000 11 EE0101 Sunny Boy 2000 Technical Description Alteration Review Document Version Comments Number and Alteration SB2000 Review 11 EE0101 1 2 New document based on translation of German Laschinski version SB2000 11 ED2000 changes of input translated current drilling template modified by Kreter A Alterations due to faulty documents or improvement of the documentation B Alterations maintaining full or upward compatibility C Alterations limiting or excluding compatibility SB2000 11 EE 2 SMA Regelsysteme GmbH 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 Example Useful C routines for this purpose are on the support disk This indicates a fact or feature very important for the safety of the user and or can cause a serious hardware defect if not appropriately applied Example Disconnect the mains plug before opening the case This indicates an example za 7 SB2000 11 EE 3 SMA Regelsysteme GmbH
22. alled Technical Description of Pow erline Communication is available from SMA SB2000 11 EE gt 49 SMA Regelsysteme GmbH Sunny Boy 2000 Technical Description What do you need for Powerline communication e The Sunny Boy must be suitable for Powerline communication order no SWRxxxx NE 1x0 l e e The Powerline piggy back modem is installed see Fig 6 6 e The last digit of the system control software version is a two VX x2 e The blue resistors under the piggy back have to be installed for Powerline communication see Fig 6 6 page 59 e For communication with the PC e A socket modem SWR COM is available e Some PCs are equipped with a 25 pole DSUB plug connector e g COM2 in terface Then an RS232 adapter 25 pin plug to 9 pin socket is necessary order no 36 5010 e The visualization software Sunny Data must be installed How to install Powerline Communication e Powerline Communication with a PC The RS232 connector from the SWR COM is plugged into a free COM port of the PC COM1 COM4 If necessary use the interface adapter DB9 DB25 The SWR COM is plugged into the electricity socket For details on the visuali zation software Sunny Data please see the Sunny Data manual e 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 or Sunny Data Control for Sunny Boy Control plea
23. ance value results from the mains impedance at the house ur Ban A a gt connection point plus all resistance values of additional cables and con hela nection points SB2000 11 EE 24 SMA Regelsysteme GmbH Sunny Boy 2000 Technical Description Please note that a cable of 20m length 1 5 mm cross section already has a resistance of ca 0 48 Q 35m length 2 5 mm cross section already has a resistance of ca 0 50 Q The Sunny Boy is equipped with two PG16 sized openings on the bottom of the in verter for cable insertion In most cases only one cable opening is needed for Power line Before inserting the Powerline into the device check whether it is disconnected from the mains e Insert the according PG fastening into the case and secure it with a bolt from inside e _ Strip the insulation off the end of the cable and insert it into the inverter e _ The inverter is delivered with a plug connect this inside the inverter according to the plug documentation e Check that the plug is connected correctly and that it cannot be removed Insert the plug into the appropriate opening and secure it with the two screws e Tighten the PG16 cable sealing e _ Close the remaining reserve opening with a PG seal e _ Close the inverter and tighten the 4 screws Don t forget to attach the PE grounding cable green yellow to the tab connector on the lid Check the correct position of the front panel and the LEDs
24. ation Sunny Data Control The PC program for visualization of data from your Sunny Boy Control SB2000 11 EE 2 9 SMA Regelsysteme GmbH Sunny Boy 2000 Technical Description 2 2 Diagnosis and Communication The modular PV system technology leads to a spread out distribution of the Sunny Boy String Inverters A simple and fast function monitoring of the status and measured val ues for each single Sunny Boy can be achieved with only a few system components The data collected is either displayed on the optional Sunny Display integrated in the front panel of the 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 The signal transmission between the PC and the single inverters is normally done via Powerline communication see chapter 6 1 Data Transmission via Powerline The Sunny Boy String Inverters support the following monitoring concepts developed by SMA e PC with Sunny Data for Windows for small and medium size PV plants e Sunny Boy Control as stand alone controller for any PV plant size e PC with Sunny Data Control for Windows together with a Sunny Boy Control Communication based on one of the above concepts supports the following func tions e Continuous acquisition of operatio
25. betrieb von Photovoltaik Eigenerzeugungsanlagen mit dem Nieder spannungsnetz Regulation for the parallel operation of photovoltaic electricity facilities with the low volt age electricity supply grid ofthe VDEW The SWR 2000 complies with the latest regulations concerning the redundant grid monitoring with allocated switching devices English MSD i e Mains monitoring with allocated switching devices German ENS i e Einrichtung zur Netz berwachung mit jeweils zugeh rigen Schaltorgan as issued by the council for elec tronics the central organization for accident avoidance and industrial medicine of the main organization of the employee associations mainly the employee association of the precision mechanics and electric engi neering and issued on the 7 of July 1994 together with the organization of German electricity producers VDEW The SWR 2000 complies with the according regulations of the European Community especially with those concerning EMC EMI in accordance with 89 336 EWG and the low voltage regulation in accordance with 73 23 EWG The inverter is marked with a CE sign The following regulations are furthermore complied with DIN EN 50081 Part 1 with EN 60555 Part EN 55014 EN 55011 Group 1 Class B and the DIN EN 50082 Part 1 DIN EN 50178 04 98 VDE 0160 DIN EN 60146 Part 1 1 03 94 VDE0558 Part 11 E DIN VDE 0126 10 97 ra ES Systeme GmbH Ly _ G Cramer A Gesch ftsf hrer Amtsgericht Kassel Com
26. d has suppressed grid feeding Please see chapter 7 Troubleshooting for further proceedings SB2000 11 EE 41 SMA Regelsysteme GmbH Sunny Boy 2000 Technical Description Blinking code 2 Grid Failure Operation amp Q amp Earth Fault X Q amp Failure gt amp O 5S 6 3s is 1s i 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 The Sunny Boy is indicating a grid failure which has one of the following reasons Low grid voltage lt V see Table 9 1 AC min High grid voltage gt V see Table 9 1 AC max Low grid frequency lt f see Table 9 1 AC min High grid frequency gt f see Table 9 1 AC max Check the electric grid supply check the function of other electric consumers and check the fuse of the mains connector to the inverter If you do not detect any failure have the mains connection to the in verter checked by a qualified electrician This person should check the correct connection and the internal fuse see Fig 3 4 on page 23 N Disconnect the inverter before opening the device SB2000 11 EE 42 SMA Regelsysteme GmbH Sunny Boy 2000 Technical Description Blinking Code 3 Grid impedance too high Operation amp QROQQ Earth Fault D IIQ Failure gt 9 9 9 a
27. e thermally monitored varistors are only available from the manu facturer because they are designed especially for the Sunny Boy in verter systems B The red LED is still on The following must be done disconnect all poles of the PV panel from the inverter N Wait at least 30 minutes until all internal voltages have discharged Remove the short circuits from 2 to 3 in the two connector blocks X2 and X3 Short circuit the connector 2 in connector block X2 to connector 2 in connector block X3 SB2000 11 EE 39 SMA Regelsysteme GmbH Sunny Boy 2000 Technical Description Re connect the PV panel to the inverter e lf 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 The failure must be detected with appropriate measurements and then re moved see chapter 3 3 2 Connection of the PV panels Disconnect the inverter from the PV panel Seal the connectors with the caps SB2000 11 EE 40 SMA Regelsysteme GmbH Sunny Boy 2000 Technical Description Failure Indicator Consistent Failure Operation amp Earth Fault X 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 an
28. ea 65 MMOUBDIGSNOOUNG ns 66 8 Warranty Regulations and Liability ccccccceeeeeeeeeeeeeceeeeeeeeeeeeeeeseeeeeeeeeees 68 O Technical Dalaran 70 10 2Appendices ae 76 SB2000 11 EE 4 SMA Regelsysteme GmbH Sunny Boy 2000 Technical Description SB2000 11 EE 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 For optimal safety closely follow all steps as described in chapter 3 Installation 2 5 SMA Regelsysteme GmbH Sunny Boy 2000 Technical Description 1 Introduction Thank you very much for purchasing a Sunny Boy String Inverter By purchasing a Sunny Boy String Inverter you have decided to use one of the most advanced devices for modular PV system technology The Sunny Boy inverters are the first systems that utilize the String Technology developed by SMA and con vince with their outstanding qualities concerning efficiency and reliability The Sunny Boys comply with all regulations from the VDEW Association of German Electricity Producers for supplementary grid feeding to the low voltage electricity grid of the utility This includes the regulations of the employee association Berufsgenossenschaft f r Feinmechanik und Elektrotechnik concerning the Inde pendent Disconnection Device known as MSD Mains monitor
29. ed varistors if necessary Determining the Failure The red LED indicates one of the above mentioned failures A short descrip tion on how to distinguish between these and conduct the appropriate coun termeasures is given in the following This description is very concise please stick to the relevant regulations in chapters 3 3 Electric Connection and 4 Commissioning e Disconnect the inverter from the grid mains fuse e Disconnect the inverter from all poles of the PV panel snap cable connec tors N Wait for at least 30 minutes for the internal voltages to discharge e Open the inverter e Remove the two internal thermally monitored varistors Fig 5 2 with an appropriate screwdriver e Short circuit the connectors 2 and 3 in the connector blocks X2 and X3 see Fig 5 2 SB2000 11 EE u 38 SMA Regelsysteme GmbH Sunny Boy 2000 Technical Description e Reconnect the PV panel do not connect the mains voltage e lf the red LED is off see A if the LED is on see B a oe 2 2 x In N thermally monitored PV panel varistors connectors Fig 5 2 Thermally monitored varistors A 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 iS Th
30. ent monitoring activities The inverter will only start feeding to the grid if its resistance to ground insula tion resistance exceeds 2 MQ During operation the fault current to earth is continuously monitored If this cur rent exceeds 95 mA or if the value increases or decreases by more than 30 mA the Sunny Boy is disconnected from the grid within 0 2 s The new concept of the Sunny Boy provides maximum safety Nevertheless the instal lation expenses of a solar plant are drastically reduced because now a one phase con nection of the inverter with MSD is sufficient SB2000 11 EE 1 4 SMA Regelsysteme GmbH 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 A drastic grid impedance increase caused by the connection to the Sunny Boy must therefore be avoided We recommend to pay attention to an impedance increase due to the dis tance between house connection and Sunny Boy further information is given in chapter 3 3 1 Mains Connection The VDEW regulations demand a device test which the inverter manufacturer must have performed by a qualified certification organization Furthermore the manufacturer has to check the function of the mains disconnection device of e
31. er Windows E g the power output of the entire large scale PV plant can be shown in a matrix For the numerous possibilities of establishing a monitoring concept with Sunny Boy Control please see the Sunny Boy Control manual Device field te Aekt ki Information on single device T Derre Singin el le Gees Humber Than Dranse Tipe Gert Faid Painge 151 Good a Roa Leila ee T Short information Fig 6 8 Sunny Data Control graphic user interface SB2000 11 EE gt 62 z SMA Regelsysteme GmbH 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 The following abbreviations are used BFR SRR BetriebsfUhrungsrechner Sequential Control System Stromregelungsrechner Current Control System Measuring Channels Upv Ist Upv Soll lac Ist Uac Fac Pac Zac Rerd Start Ipv dl E Total h Total Netz Ein Seriennummer Status Fehler Status Messages Stop 1 Offset Warten Netzueb Zuschalt SB2000 11 EE PV input voltage PV desired voltage of the internal Upv control current to the grid grid voltage grid frequency power fed to grid grid impedance isolation resistance of PV plant before connected to the
32. feeding the grid The specific causes for this and how to avoid them are described in paragraph Failure Indicator starting on page 42 SB2000 11 EE 31 SMA Regelsysteme GmbH Sunny Boy 2000 Technical Description KM T Betrieb O peration Erdschlu SW R 2000 Earth Fault Photovoltaik Stringwechselrichter St rung 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 not relevant L KI SB2000 11 EE 32 SMA Regelsysteme GmbH Sunny Boy 2000 Technical Description standby night input voltage lt 60 V initialization input voltage 60 V 120 V changing operating condition or manually initiated condition waiting starting conditions are being checked checking grid feeding grid normal operation MPP or constant voltage mode isolation failure earth fault of the PV panels or failure of surge voltage protection failure internal or external failure exact description O depending on blink code Table 5 1 Operation indication overview SB2000 11 EE 33 SMA Regelsysteme GmbH Sunny Boy 2000 Technical Description Operation Indicator Standby night Operation amp Earth Fault amp All LEDs are off Failure Q The Sunny Boy is in so called Stand by mode The input voltage is too low V
33. he grid connection via Powerline This requires a minimum of installation see Fig 6 1 Example of data transmission via Powerline The Sunny Boy must be equipped with a Powerline modem for data transmission The PC must be equipped with the socket modem SWR COM This is already integrated in the Sunny Boy Control the specific controller for PV plants The PC or the Sunny Boy Control can be positioned anywhere within the in house network as they acquire data directly from the AC circuit For trouble free operation the Sunny Boys and the PC socket modem or the Sunny Boy Control must be connected to the same phase of the in house network If the communicating partners are connected to different phases the communication must be established with a so called phase coupling device 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 SB2000 11 EE 48 SMA Regelsysteme GmbH Sunny Boy 2000 Technical Description Sunny Boy Sunny Boy Sunny Boy Powerline Sunny Boy Control Sunny Boy Sunny Boy Sunny Boy eoee b o Powerline SWR COM PC Sunny Boy Sunny Boy Sunny Boy oo RS232 modem gt P li owerline Sunny Boy Control Fig 6 1 Example of data transmission via Powerline A detailed description of this data transmission c
34. he inverter 4 Switch on fuse of the phase If at any time the inverter has to be dismantled please note that the device must be disconnected in the opposite order Always keep in mind to wait for at least 30 minutes before opening the inverter after disconnecting it The PV panel may never be disconnected from the Sunny Boy pull ing out the plug connectors while under load i e during the inverter feeds to the grid Always disconnect the mains before 22 SMA Regelsysteme GmbH Sunny Boy 2000 Technical Description Preparing the connection The front panel of the inverter must be removed in order to attach the output wiring this is done by removing the four screws M5 accessible from the front The front panel is grounded with a tab and receptacle connector care fully remove the green yellow cable in order to remove the front panel You can now see the position of relevant modules and clamps in the open case in front of you You will find e The plug connectors for PV panel connection e The mains terminals in the lower middle to right section e The mains fuse in the lower middle to right section thermally monitored PV panel connectors mains fuse mains connectors varistors 12 5 A slow blow Fig 3 4 Connectors in the Sunny Boy 2000 SB2000 11 EE gt 23 SMA Regelsysteme GmbH Sunny Boy 2000 Technical Description 3 3 1 Mains Connection The Sunny Boy must be connected to the mains with three
35. ing device with allo cated Switching Devices and the regulations of DIN VDE 0126 Furthermore the Sunny Boy complies with the EMC and low voltage regulations and the according 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 installers guide and user manual so it is used as reference for the commis sioning and as guideline on how to use all functions of the inverter optimally and how you can extend your existing PV plant Sunny Boy is a registered Trademark of SMA Regelsysteme GmbH SB2000 11 EE 6 u SMA Regelsysteme GmbH 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 The direct conversion of solar radiation to electric energy photovoltaics will play a substantial role in this essential matter Supplementary grid feeding includes the conversion of the DC voltage from the PV panel to grid conform AC voltage with so called inverters and the subsequent con nection to the mains in the house distribution Here the solar energy system provides all consumers with
36. ling You can assess where the failure is located from the ratio of the different voltages measured It is essential to solve this failure before continuing the installation e Acquiring the electric resistance between protective earth PE and the plus and minus poles of the PV panel A low resistance lt 2 MQ shows there is a high resistance ground fault of the PV panel It is essential to repair this failure before continuing the installation 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 soon as the PV panel has been connected to the Sunny Boy with the MC plug con nectors the internal PV panel voltage is on SB2000 11 EE 27 SMA Regelsysteme GmbH Sunny Boy 2000 Technical Description Safety notice The resistance of the plus and minus pole and PE is measured each time before the inverter starts feeding to the grid If the resistance is below 2 MQ the inverter does not begin feeding the grid and the red warning LED goes on see chapter 5 Operation and Failure Indication LEDs When the PV panel is first connected to the Sunny Boy an electric potential to protective earth arises on the plus and minus lines equaling the PV panel voltage string voltage The monitoring of the isolation results in a minor electric con
37. lt approx 60 V to supply the inverter control system with enough power Initialization Operation Earth Fault All LEDs are on Failure e The Sunny Boy control system is initializing The string voltage to the inverter is between approx 60 and 120 V The supply is sufficient for the system control and not quite sufficient for feeding to the grid Data transmission is not possible yet SB2000 11 EE 34 SMA Regelsysteme GmbH Sunny Boy 2000 Technical Description Stop Operation 69 Green LED blinking approx three times per second Earth Faut Red LED off Failure Q 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 In this case the Sunny Boy inverter remains in this condi tion until set to MPP Operation or Constant Voltage Operation Waiting Grid Monitoring Operation 9 Green LED blinking once a second Earth Faut X Red LED off Failure Q Yellow LED off The inverter is checking the grid concerning its suitability for feeding electricity start ing voltage starting time and begins to monitor the grid SB2000 11 EE u 35 SMA Regelsysteme GmbH Sunny Boy 2000 Operation Operation Green LED on Earth Faut Red LED off Failure
38. merzbank Kassel Deutsche Bank Kassel Kasseler Sparkasse Landeskreditkasse Kasse Dipl Ing G nther Cromer HRB 3972 BLZ 520 400 21 BLZ 520 700 12 BLZ 520 503 53 BLZ 520 500 00 Dipl Ing Peter Drews Kto 264 201 500 Kto 041 8004 Kto 132 994 Kto 40 622 04 005 Dipl Ing Reiner Wettlaufer UST ID DE 113085 954 SWIFT COBA DE FF520 BG Federf hrung Berufsgenossenschaft der Feinmechanik und Elektrotechnik Fachausschu Elektrotechnik der Zentralstelle f r Unfallverh tung und Arbeitsmedizin des Hauptverbandes der gewerblichen Berufsgenossenschaften Fachavsschu Elektrotechnik Postfach 5105 80 5094 K ln SMA Regeisysteme GmbH Hannoversche Stra e 1 5 34266 Niestetal Ihre Zeichen Nachricht vom Unser Zeichen Bite stets angeben Bearbeiter 0221 3778 Datum UB 010 17 FA Bie san 10 05 1999 Unbedenklichkeitsbescheinigung Erzeugnis String Wechselrichter Typ SWR 1500 SWR 2000 Bestimmungsgem e Verwendung Parallelbetrieb von Photovoltaikanlagen am EVU Niederspannungsnetz Pr fgrundlagen DIN EN 50178 04 98 Ausr stung von Starkstromanlagen mit elektronischen VDE 0160 Betriebsmitteln DIN VDE 0558 Teil 1 Halbleiter Stromrichter Allgemeine und besondere 7 87 Bestimmungen f r netzgef hrte Stromrichter E DIN VDE 0126 Selbstt tige Freischaltstelle f r Photovoltaikanlagen einer 10 97 Nennleistung lt 4 6 kVA und einhpasiger Paralleleinspeisung ber Wechselrichter in das
39. n are excluded insofar as not otherwise com pelling stated by law SB2000 11 EE 69 SMA Regelsysteme GmbH 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 In Central Europe one should expect module temperatures between 10 C and 70 C e LU 10 C lt max input voltage The open circuit voltage of the connected string has to be within the specified input voltage range even in case of very low outside temperatures 10 C e Usp 70 C gt min input voltage The MPP voltage of the connected string must not exceed the specified input voltage range even in case of very high outside temperatures The inverter tolerates currents higher than the specified input volt N 3 age as long as the input voltage is within the specified range Input voltage Vov 125 500 V DC Max input current loy 10 A DC Max input power Pa 2100 W DC Recommended max PV panel power 2600 Wp Voltage ripple U lt 10 All pole disconnection on DC input side MultiContact snap connectors MultiContact is a registered trademark of company Multi Contact SB2000 11 EE z 70 SMA Regelsysteme GmbH Sunny Boy 2000 Technical Description Surge voltage
40. n hanged into the top screws fasten the bottom screw to secure against lifting up Mounting to the 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 looking out e Hang the inverter into the two top screws e _ Fasten the bottom screw in order to prevent lifting up e _ Check the mounting of the inverter SB2000 11 EE 21 SMA Regelsysteme GmbH 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 On the other hand the mains connection is located inside the string inverter It is a three cable connection L N PE for cables with a cross section of up to 4 mm At the bottom of the case there are two openings suitable for PG16 fastening clamps to insert the cable SB2000 11 EE The electric connection of the Sunny Boy and the connection to the input and output cabling must be done in the order described here Following this order the installer will make sure not to open contacts under load and exclude high voltages during the installation 1 Connect mains 2 Close inverter case 3 Connect PV panels remove seals from the cable ends and plug in the cables to t
41. n cause a non repairable damage Have the circuits of your PV panel checked Please see chapter 9 Technical Data for the permissible PV input voltage SB2000 11 EE 44 SMA Regelsysteme GmbH Sunny Boy 2000 Technical Description Blinking code 5 Device failure Operation amp QROQQ Earth Fault X 9 amp amp W amp Failure gt amp 3 9 9 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 The device is in a condition that makes it impossible to return to normal operation The device is most likely defective N The inverter has to be checked by a qualified technician SB2000 11 EE 45 SMA Regelsysteme GmbH Sunny Boy 2000 Technical Description Blinking code 6 Discharge Current too high Operation amp amp amp amp amp amp amp amp Earth Fault Q 9888988 Failure gt 9 0 0 0 0 0 5S 5 3s 1s 18 1s 1s 18 Is 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 The discharge current between the inverter and the PV panel exceeds 95 mA The inverter stops feeding to the grid immediately after the current goes beyond the above mentioned threshold and restarts normal operation afte
42. n data of all connected Sunny Boys e Supervision of operating states and failure indication e Spot value transmission from one or several selected Sunny Boys e Identification of failures in the single strings e When using a PC graphical representation of the data from single Sunny Boys or comparison of the data of several ones e Modification of operation parameters to optimize the entire plant SB2000 11 EE 1 0 SMA Regelsysteme GmbH 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 mains bridge relay mains relay 195 253 V 50 Hz 125 V 500 V 0 10 A filter surge voltage protection surge voltage protection current control system K a z 00 00 PE MSD 1 MSD 2 E Fig 2 1 Block Circuit Diagram of Sunny Boy 2000 The string inverters nominal power is dimensioned for the serial connection of a maximum of 20 modules with 36 to 40 cells each It is possible to connect two separate strings parallel to the Sunny Boy depending on the PV module type used The management of feeding current with a one chip micro controller guarantees an absolutel
43. nection be tween the plus minus and PE The high resistance of the monitoring cir cuit results in the fact that normally no danger arouses from this circuit even though certain voltage meters show a voltage between the case of the inverter and the plus and minus pole 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 SB2000 11 EE 28 SMA Regelsysteme GmbH Sunny Boy 2000 Technical Description gt a gt SB2000 11 EE 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 The PV panel may never be disconnected from the Sunny Boy pull ing out the plug connectors while under load i e during the inverter feeds to the grid Always disconnect the mains first The plug connectors can be damaged by an electric arc occurring when separating the PV panel while feeding to the grid In this case both parts of the relevant plug connector have to be exchanged Caution The input capacitors are still loaded even after disconnect ing the PV panel from the inverter Therefore the inverter still can have high voltages for approx 30 minutes even after disconnecting the AC and DC side The DC voltage can be up to 500 V It is essen tial f
44. ng 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 The Sunny Boy is the result of a dedicated development resulting from the substantial experience with utility interac tive inverters for photovoltaics SB2000 11 EE u 8 a SMA Regelsysteme GmbH Sunny Boy 2000 Technical Description The most various system designs can be modularly created with the Sunny Boy products e Sunny Boy 700 The small model for little PV plants and simple extension possibilities 3 input voltage and power ranges Sunny Boy 850 The output optimized inverter for PV plants with 1 kWp e Sunny Boy 1100E The inverter for PV plants in a power range of 1 5 kWp with extended input voltage range Sunny Boy 2000 The transformerless String Inverter with extended input voltage range and ex cellent efficiency ideal for large PV plants Sunny Boy 2500 The most powerful string inverter with electric separation ideal for large scale plants e Sunny Display The optional integrated LCD display for direct data acquisition Sunny Data The PC program for communication with your Sunny Boy inverters e Sunny Boy Control The intelligent terminal for your PV plant for data acquisition and evalu
45. on Program memory PROM sequential control SMA SWRT BFR A au At amp P 6 2 at N Em OB C a fd co cS Slot for Resistors for piggy back module Powerline Communication Fig 6 6 Sunny Boy 2000 sequential control board e 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 Only for installation of a board for Powerline Communication Please make sure that the light blue resistors are plugged onto the system control board If not bridges corresponding to 0 Q resistors have to be installed in there e Plug the desired piggy back module onto the required slot When plugging on the piggy back please make sure no socket of the piggy back plug in contacts re mains open SB2000 11 EE 59 SMA Regelsysteme GmbH Sunny Boy 2000 Technical Description e Connect the green yellow PE cable to the lid and close the Sunny Boy with the lid Tighten all four screws e Reconnect the PV panel e Connect the inverter to the grid If enough PV po
46. one chip microcomputers and fully complies with all grid feeding regulations of the VDEW and the employee associations MSD with evaluation of the grid impedance and GFCl The Sunny Boy therefore can be connected to the grid at any point of the house grid resulting in most simple installation The relevant guidelines regulations and standards must of course be kept to The Sunny Boy is equipped with a stainless steel enclosure which is dustproof and water proof protection class IP65 This protection class allows mounting at nearly any place with ambient temperatures of 25 C to 60 C Even with small PV plants personnel protection is a priority The Sunny Boy is equipped with an all pole sensitive RCB residual current breaker for 30 mA with a so called shifting base This RCB and the insulation monitoring make sure any insu lation failure is detected immediately and the plant is switched off Due to the shifting base real grounding failures can be distinguished from normal ground discharge cur rents of the PV panel Of course the relevant standards e g for electromagnetic compatibility EMC and safety technology are also complied with SB2000 11 EE 1 2 SMA Regelsysteme GmbH 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
47. onnected 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 Sunny Boy Sunny Boy Sunny Boy Control RS485 ci ee Sunny Boy Sunny Boy Sunny Boy interface oo A sae gt lt ae FF PC Fig 6 4 Schematic layout of RS485 data transmission with several Sunny Boys What do you need for RS485 communication e aspecial RS485 piggy back module has been installed in all Sunny Boys e the last digit of the system control software version is a two VX x2 e the light blue resistors on the system control board are removed e if connected to a PC e The interface converter RSU485 ordering no 39 0020 is available e Sunny Data visualization software is installed on the PC e Some PCs have a 25 pin COM port However the cable suports a 9 pin COM port In this case a small adapter ordering no 39 5010 is necessary SB2000 11 EE 54 SMA Regelsysteme GmbH Sunny Boy 2000 Technical Description PC Sunny Boy Control with DB25 plug in Socket Sunny Boy 485 COM1 or COM2 Fein or 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 6800 Im Njo Io First Sunny Boy _ Jumpers MOSR25 SP not
48. operate again as soon as possible it is essential to pro vide the following information SB2000 11 EE u 66 SMA Regelsysteme GmbH Sunny Boy 2000 Technical Description e Information concerning the Sunny Boy e type of Sunny Boy e serial number of the inverter e short failure description Number of the blink code see chapter 5 Operation and Failure Indication LEDs If Sunny Boy Control or a PC with Sunny Data is present Which status and failure are indicated Can you reproduce the failure If so how can you reproduce it Does the failure occur sporadically Has this failure always occurred What were the ambient conditions when the failure occurred e Information concerning the PV modules e type of modules supplier e number of modules per string number of strings e output power e open circuit voltage 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 SB2000 11 EE a 67 SMA Regelsysteme GmbH Sunny Boy 2000 Technical Description 8 Warranty Regulations and Liability You have purchased a product which was thoroughly checked before delivery Should your device nonetheless be defective or show a malfunction during the warranty period please contact your distributor
49. or installer Warranty 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 The warranty period for guaranty repairs or substitution deliveries ends 12 months after delivery but runs at least until the expiration of the original warranty period for the item delivered Evidence SMA will only render guaranty services if the objected device is sent back to SMA to gether with a copy of the invoice the distributor made out to the consumer The type plate at the device must be completely legible In case of non fulfillment SMA reserves the right to refuse guaranty services Conditions It is in SMA s discretion whether the device will be repaired in its works without invoic ing material and work cost or a replacement device will be delivered The objected device is to be sent back to SMA free of charge in the original packaging or in a transport packaging of equal quality If the warranty applies transport costs will be for SMA s account The customer has to grant SMA the necessary time and opportunity to repair the de fects SB2000 11 EE u 68 SMA Regelsysteme GmbH Sunny Boy 2000 Technical Description Exclusion of Liability Excluded are any guaranty claims and liabilities for direct or consequential damages due to transpor
50. or qualified personnel to wait approx 30 minutes after discon necting the device before opening it in order to let the harmful volt ages discharge 29 SMA Regelsysteme GmbH Sunny Boy 2000 Technical Description 4 Commissioning Do not put anything on top of the inverter case during operation The heat sink on top of the Sunny Boy can have temperatures above 80 C Danger of burning Make sure that all remaining openings for cable insertion at the bottom of the 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 e Connect the inverter to the grid by switching on the fuse of the phase the inverter is connected to The Sunny Boy will begin operation as soon as the input voltage is sufficient How much power the Sunny Boy feeds to the grid depends on the amount of PV power supplied by the PV panel When designing the Sunny Boy SMA kept the internal consumption as low as possi ble The Sunny Boy requires a maximum of 7 W out of the PV power supplied by the PV panel Please note that despite an extremely low radiation the PV panel is under load due to the inverter s internal consumption The real open circuit voltage is only produced with higher solar radiation when the internal consumption is negligible compared to the power s
51. out of tolerable range SSR sudden change of impedance value out of tolerable range internal overcurrent Relay K1 does not close correctly Relay K1 does not separate correctly Relay K2 does not separate correctly different values between BFR and SRR for grid voltage different values between BFR and SRR for differential current different values between BFR and SRR for grid frequency different values between BFR and SRR for dl Fac Uac or Zac Relay test failed different values between BFR and SRR for grid impedance Offset check for grid voltage measurement failed BFR or SSR controller failure isolation resistance out of tolerable range BFR grid voltage measurement value out of tolerable range SSR grid voltage measurement value out of tolerable range PV input voltage above the tolerable maximum value Internal voltage out of tolerable range BFR grid impedance measurement value out of tolerable range SSR grid impedance measurement value out of tolerable range Watchdog for operation control triggered 64 SMA Regelsysteme GmbH 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 A maximum measurement error is conceived for an ambient tempera ture
52. r a short while The discharge voltage depends on the PV panel s capacity to the grounding as well as on the kind of mounting and type of modules A temporary variation is therefore normal Have the system checked by an electrician if this failure occurs very often SB2000 11 EE 46 SMA Regelsysteme GmbH Sunny Boy 2000 Technical Description Blinking code 7 Drastic Differential Current change Operation amp amp Q amp amp amp Earth Fault X 9 amp amp W Failure gt amp 9 9 09 Bs 3s 1s 18 18 18 18 18 is 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 The Sunny Boy s monitoring systems have detected a differential current and imme diately disconnected the device from the grid The integrated all pole sensitive differ ential current control monitors the discharge current between the AC output of the inverter and the PV panel This additional safety feature is triggered by drastic changes of the differential current of lay 2 30 mA and disconnects the inverter from the grid within 0 2 seconds SB2000 11 EE 47 SMA Regelsysteme GmbH Sunny Boy 2000 Technical Description 6 Plant 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 t
53. se refer to the according manuals SB2000 11 EE 50 SMA Regelsysteme GmbH 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 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 Single Sunny Boy RS 232 Sey nmp Electricity Grid PC Fig 6 2 Data transmission with a separate data cable to one single Sunny Boy IF RS232 communication with one Sunny Boy is only a reasonable solution with direct connection to the PC If a Sunny Boy Control is used instead of the PC an RS485 connection is necessary even for communication with only one Sunny Boy see section RS485 communication for details SB2000 11 EE 51 SMA Regelsysteme GmbH Sunny Boy 2000 Technical Description What do you need for RS232 communication e a special RS232 piggy back module for the Sunny Boy e the last digit of the system control software version is a two VX x2 e the visualization software Sunny Data is in
54. stalled on the PC e the light blue resistors Fig 6 3 on the system control board are removed e Some PCs are equipped with a 25 pin DSUB plug connector In this case an RS232 adapter 25 pin plug to 9 pin socket adapter is necessary or der no 36 5010 Installation of the RS232 cable Work on the inverter may only be carried out if the device has been disconnected and discharged See also chapter 3 Installation e Connect RS232 connection cable LIYCY 0 25 mm minimum three cable with common shield and a maximum length of 15 m You can see the connector layout in Fig 6 2 1 The shielding should be connected to protective earth PE on both ends at the Sunny Boy and the PC case SB2000 11 EE 52 SMA Regelsysteme GmbH Sunny Boy 2000 Technical Description figgy Back socket Jumpers not mounted connect shield to case 2015 cy O OB GC O Ja Q CCA AOAC AKA AMA DB25 socket Fig 6 3 System control board Sunny Boy with RS232 cabling SB2000 11 EE light blue resistors removed PCwith DB9 a_ COM4 PC Zn PC with DB25 BEE COM CoM4 PC 53 SMA Regelsysteme GmbH Sunny Boy 2000 Technical Description RS485 communication In grids loaded with high interference several Sunny Boys can be c
55. tation damages faulty installation or commissioning manipulation alterations or repairing attempts inappropriate use or operation insufficient air supply to the device non respect of relevant safety regulations VDE etc or force majeure lightning surge voltage storm fire We cannot guarantee the proper function of data transmission via mains lead power line modem in case it is carried out in electric grids with high harmonic distortion or high frequency line distortions e g in industrial power supply grids or in the neighborhood of irregular consumers unshielded mo tors switching power supplies converters etc Furthermore the simulta neous operation of babyphones may lead to short time data transmission disturbances or interruptions In case of disturbed data transmission via mains lead we alternatively offer communication via separate data line as an option RS232 or RS485 see chapter 6 We do not guarantee that the software is completely free of faults In case of a fault an instruction how to avoid the effects of the fault is also considered as sufficient repair Only the customer is responsible for the correct selection orderly use supervision and the consequences of the use of software We reserve the right to make alterations for improvement of the device Further or other claims for direct or indirect damages especially including claims for damages from positive contract violatio
56. tection classification EN 60529 Size width x height x back to front Weight Certification EMC Grid interference Grid monitoring Low voltage regulation SB2000 11 EE 72 Technical Description gt 96 25 C 60 C 0 100 class 3K6 basic insulation PE connection IP65 _ dust proof jet proof ca 434 x 295 x 214 mm ca 24 kg DIN EN 50081 part 1 EN 55014 EN 60555 part 2 EN 55011 group 1 class B DIN EN 50082 part 1 DIN EN 61000 3 2 independent disconnection device MSD according to VDEW EN DIN VDE 0126 10 97 DIN EN 50178 4 98 VDE 0160 DIN EN 60146 part 1 1 3 94 VDE 0558 part 11 SMA Regelsysteme GmbH Sunny Boy 2000 Technical Description Input Current of the Sunny Boy 2000 10 0 8 0 6 0 Ipv A 4 0 2 0 0 0 100 200 300 400 500 600 Vpv V Maximum output power of the Sunny Boy 2000 2000 1500 Pac W 1000 500 100 200 300 400 500 600 Vpv V Fig 9 1 Output Power P and Input Current depending on Input Voltage U SB2000 11 EE z 73 SMA Regelsysteme GmbH Sunny Boy 2000 Technical Description Sunny Boy 2000 efficiency for different input voltages 100 0 95 0 oO a o I 90 0 A Upv 400 V 85 0 Upv 300 V Upv
57. to distinguish the reasons for the failure are described in the following e Isolation failure An isolation failure has occurred at the PV panel or its cabling The plus or mi nus pole of the PV panel or one of its modules has a connection lt 2 MQ to the grounding earth PE N Any isolation failure must always be removed by qualified personnel only A low resistance connection between the plus or minus pole and the grounding can lead to highly dangerous electric shocks even if only one pole is touched Since the user himself normally is connected with the grounding he is highly in danger when touching any pole SB2000 11 EE 37 SMA Regelsysteme GmbH 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 invoked electric fields If the thermally monitored varistors have triggered for several times a thermally monitored varistor is the serial cir cuit of a varistor and a thermal fuse they can get defective by not letting any current pass anymore and therefore not providing the intended safety This condition is indicated with the Earth fault LED It is highly recommended to have qualified personnel exchange the thermally monitor
58. upplied by the PV panel The inverter s operating condition is indicated with the 3 LEDs on the front a de tailed description will be given in chapter 5 Operation and Failure Indication LEDs SB2000 11 EE z 30 SMA Regelsysteme GmbH 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 The inverter switches to idle mode if the radiation and the resulting electric input energy are too low Each time the Sunny Boy starts up it runs a number of self test and safety proce dures which the user does not notice The user can obtain the inverters operating status from the three LEDs integrated in the lid See Table 5 1 Operation indication overview The green LED Operation describes the current operation of the inverter see para graph Operation Indicator starting on page 35 The red LED warns the user that an Earth Fault has occurred A description of this situation and what has to be done in that case is given in paragraph Earth Fault In dicator starting on page 38 The yellow LED Failure indicates an internal or external failure that keeps the in verter from
59. very single unit before delivery For the owner of the PV plant this means e The time consuming disconnection device testing by the electricity company and the installer is not necessary e The previously required periodic tests are not necessary Important arguments for the omission of repeated tests are the redundant design and the recurring self test of the disconnection device During every new mains connection the correct function of the mains monitoring is checked in order to guarantee that the according switching devices transistor bridge relay are working and able to discon nect the load circuit In case of a negative test result the complete self test will be re peated If the negative result occurs again the disconnection device has to be checked by qualified personnel In this case the operation will be blocked and indicated to the user by the LEDs This operating state will be recorded and cannot be overridden with simple switching operations from the outside signals via the serial interface resetting the internal computers switching the device off and on etc This ensures that only qualified personnel can unlock the device for grid feeding after testing the disconnec tion device has failed SB2000 11 EE T 1 5 SMA Regelsysteme GmbH Sunny Boy 2000 Technical Description 3 Installation The installation of the Sunny Boy String Inverter must be conducted by qualified personnel The installer must be approved by the
60. ween 25 C and 60 C e Take into account mains impedance at the feeding point see para graph Autonomous Grid Disconnection Device MSD p 13 et seq and chapter 3 3 1 Mains Connection e Do not expose the string inverter to direct sunlight if necessary in stall a shading roof A minimum distance of 200 mm must be clear above the inverter for ventilation i e no cupboards ceiling etc Free air circulation around the case must not be obstructed e If you are installing the Sunny Boy in a cabinet etc air circulation must be sufficient for heat dissipation provide external ventilation e The heat sink can reach a temperature of more than 80 C Mount the inverter in a correct position See below CAUTION Mount the inverter Never upright or tilted to mount tilted the back to the front Fig 3 1 Recommended outside mounting of the inverter side view 1 8 SMA Regelsysteme GmbH Sunny Boy 2000 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 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 Blank screwed joint PG 1
61. wer is supplied the inverter automatically starts feeding to the grid SB2000 11 EE u 60 z SMA Regelsysteme GmbH 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 The available measurement channels of the Sunny Boy see chapter 6 4 Measuring Channels and Messages of the Sunny Boy can be displayed online The data can be displayed manually or automatically and is stored in files on any available storage medium Special functions allow the installer to modify the operating parameters of the Sunny Boy in order to improve system performance Please see the Sunny Data manual for further information on Sunny Data SS eo E E E Fig 6 7 Sunny Data user interface SB2000 11 EE 61 SMA Regelsysteme GmbH Sunny Boy 2000 Technical Description 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 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 und
62. y sine formed curve with extremely low harmonic distortion The SCS pro vides fully automatic functioning of the system as well as the MPP tracking MPP detection of the voltage point with maximum power Maximum Power Point Unnec essary losses resulting from stand by operation and during operation are avoided The heat sink of the Sunny Boy disposes of the inevitable power loss resulting from switching the power semiconductors It is large enough to enable the Sunny Boy to SB2000 11 EE 1 1 SMA Regelsysteme GmbH Sunny Boy 2000 Technical Description continuously feed nominal power to the grid even in case of high ambient tempera ture e g when the Sunny Boy is installed directly under the roof The Sunny Boy 2000 which can feed peak power of 2000 watts to the grid has an integrated heat sink temperature monitoring When the maximum temperature is exceeded e g due to high ambient temperature or insufficient heat dissipation the Sunny Boy reduces the input current so that it is not overheated and still feeds maximum possible power to the grid 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 The grid is simultaneously monitored by two independent

Technical Description - SMA Solar Technology AG

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