SMARTFORMER FOR SUNNY ISLAND
Contents
1. Sunny Island PY inverter Figure 16 Smartformer system overview Position Description Explanation TI Autotransformer See Section 4 2 Autotransformer page 17 QI Overload protection See Section 4 6 Overload Protection page 20 Q2 Load shedding contactor See Section 4 4 Load Shedding Contactor page 18 Q3 Bypass switch See Section 4 3 Bypass Switch page 18 F2 2 pole miniature When the bypass switch is set to ON F2 and F3 ngg circuit breaker protect the loads F4 2 pole miniature F4 and F5 protect the PV inverters me SH circuit breaker Fo 2 pole miniature When the bypass switch is set to II ON F6 protects the circuit breaker loads and the generator When the bypass switch is set to ON F6 protects the AC 2 output of the Sunny Island SEZ When the bypass switch is set to I ON FZ protects the loads and the generator ATS Automatic Transfer Automatic transfer switch not included in scope of delivery Switch Installation Manual SI_TDBOX IA eng IlUS122211 35 6 Electrical Connection SMA America LLC 6 3 Selecting Cables Cable requirements o O o O Conductor material copper Conductor structure solid wire coarse stranded wire or fine stranded wire The cable must be approved for 167 F 75 C Maximum wire size 4 AWG Minimum wire sizes Components for connection Minimum wire size Loads 6 AWG PV p2. Max Load current xxA RMS ENCLOSURE NEMA Type 1 IP20 For more details see the Operator s Manual US LISTED Interconnection System Equipment LISTED UL 1741 36AN This device complies with Part 15 of the FCC Rules Operation is subject to the following two conditions 1 this device may not cause harmful interface and 2 this device must accept any interface received induding interference that may cause undesired operation Figure 7 Layout of the type label Position Description Explanation A Model Device type B Serial No Serial number of the Smartformer C Date of manufacture D Device specific characteristics Installation Manual SI_TDBOX IA eng IUS12221 1 21 5 Mounting SMA America LLC 5 Mounting 5 1 Selecting the Mounting Location A WARNING Danger to life due to fire or explosion Despite careful construction electrical devices can cause fires Do not mount the Smartformer on flammable construction materials e Do not mount the Smartformer near highly flammable materials Do not mount the Smartformer in potentially explosive atmospheres Danger to life due to electric shock Penetrating moisture may result in voltage being applied to parts of the mounting location e Do not mount the Smartformer outdoors NOTICE Destruction of the Smartformer due to direct solar irradiation Direct solar irradiation can damage the pa
3. 10 Electrical Connection esssssseeseessessesso 31 Safety during Electrical Connection 0 00000 31 Overview of the Connection Area 00 00 eevee 32 View from BELOW n T ee sect r A T edie Ae 32 View trom Aboye s prenie yros teea aad de e a Bate 32 Interior Mie wiy tia eise i E e LUN et A a EA A E TAA 33 System Overview oo visa te a Tra ea Ea a E e E 35 Selecting Cables te tend a Mae Say N 36 Inserting the Cables 53 hie nannaa 37 Connecting Insulated Conductors to Spring Clamp Terminals 39 Connecting loads 655 veser aea aE E EE at awes 40 Connecting the PV Plant o n nannaa Al Connecting the Generator or Power Distribution Grid A2 Connecting the Sunny Island o oa dw dwdendaa ee denned 43 Connecting the Load Shedding Contactor 44 C mimissi hihg sessa n i a i awe oe Rees 46 Setting the Operating Mode via the Bypass Switch 50 Mounting and Disassembling the Contact Hazard Protection Gover 4 suxtee coeur nek se enn bens pee ners 51 Disassembling the Contact Hazard Protection Cover 52 Mounting the Contact Hazard Protection Cover 53 Disconnecting the Smartformer from the Power Supply i i f0 6de ee eens bn by Odes Deedes 55 Cleaning i 0k rca salience dvbewensGbeiqees deer wees 57 SI_TDBOX 1A eng 1US122211 Installation Manual SMA America LLC 12 12 1 12 2 13 13 1 13 2 13 3 13 4 14 15 16 Troubleshooting tii ccdeswiad cice wen ei
4. 2 Remove coarse dirt contamination from the outside of the enclosure with a soft brush or similar tool 3 NOTICE Damage to Smartformer due to moisture penetration Moisture penetration can cause short circuits and damage to the Smartformer e Use a moist cloth to remove dust from the outside of the enclosure Do not use solvents abrasives or other corrosive substances Cleaning the ventilation slots e If the ventilation slots of the Smartformer are dusty clean them with a soft brush hand brush or similar tool Installation Manual SI_TDBOX 1A eng 1US122211 57 12 Troubleshooting SMA America LLC 12 Troubleshooting 12 1 Activating Overload Protection The overload protection of the Smartformer was tripped Activate the overload protection using the following procedure 1 Switch the overload protection to O 2 Switch the overload protection to 1 M The overload protection stays set to 1 and the connected loads are supplied with voltage x What if the overload protection jumps back to a position between O and 12 Possible cause of fault The temperature in the autotransformer is still too high e Wait at least 10 minutes Switch the overload protection to 0 Switch the overload protection to 1 Possible cause of fault Too many loads are connected via Load L2 e Switch off individual loads e Connect more loads via Load L1 58 SI_TDBOX IA eng IUS122211 Installation Manual SMA America LLC 12 Trou
5. Accessories for Sunny Island SMARTFORMER FOR SUNNY ISLAND Installation Manual c CO E2 E Vg Co oC CoC Co oC Cc CO Cc S E SI_TDBOX IA eng IUS122211 IMEN SITDBOX US Version 1 1 C SMA America LLC Legal Restrictions Copyright 2012 SMA America LLC All rights reserved No part of this document may be reproduced stored in a retrieval system or transmitted in any form or by any means electronic mechanical photographic magnetic or otherwise without the prior written permission of SMA America LLC SMA America LLC doesn t make representations express or implied with respect to this documentation or any of the equipment and or software it may describe including with no limitation any implied warranties of utility merchantability or fitness for any particular purpose All such warranties are expressly disclaimed Neither SMA America LLC nor its distributors or dealers shall be liable for any indirect incidental or consequential damage under any circumstances The exclusion of implied warranties may not apply in all cases under some statutes and thus the above exclusion may not apply Specifications are subject to change without notice Every attempt has been made to make this document complete accurate and up to date Readers are cautioned however that SMA America LLC reserves the right to make changes without notice and shall not be responsible for any damage including indirect inciden
6. e Only operate the generator with safety equipment provided by the manufacturer e Install maintain and operate the generator according to the manufacturer s specifications A CAUTION Risk of injury due to hot components Components inside the Smartformer may become hot during operation This may result in burns to the body e Always use a contact hazard protection cover when operating the Smartformer e Allow the Smartformer to cool down before removing the contact hazard protection cover NOTICE Property damage due to moisture and dust intrusion The Smartformer corresponds to the NEMA 1 degree of protection when it is closed and is only suitable for indoor installation The intrusion of dust and moisture into the interior can damage the Smartformer e Protect the Smartformer against moisture and dust e After working on the Smartformer mount the contact hazard protection cover and close the Smartformer e While the Smartformer is open protect it against dust and water 14 SI_TDBOX IA eng IUS122211 Installation Manual SMA America LLC 3 Scope of Delivery 3 Scope of Delivery Check the delivery for completeness and any externally visible damage Contact your specialty retailer if the delivery is incomplete or you find any damage B C D 9 Oa Oa Cjo a 2 2 2 2 2 a 2 2 cS JEE 2 S z Z gt E P lt lt 2 F G Figure 2 Components inclu
7. 7000 US 8000 US Sunny Boy 2000HF US 2500HF US 3000HF US 25 A Yes see Section 12 2 Sunny Boy 3000 US 3800 US 4000 US 25 A Yes see Section 12 2 Sunny Boy 5000 US 6000 US 50 A No In stand alone grids 50 A No The FA and F5 miniature circuit breakers of the Smartformer are preinstalled with 50 A on delivery 1 Make sure that each PV inverter is protected in the Smartformer or in the AC sub distribution of the PV plant according to its rated current see the PV inverter installation manual 2 Connect the PE conductor to a vacant spring clamp terminal of a Grounding connecting terminal plate see Section 6 5 3 Connect the N conductor to a vacant spring clamp terminal of a Neutral N connecting terminal plate see Section 6 5 4 Shorten insulated conductors L1 and L2 and strip the insulation by in 10 mm Installation Manual SI_LTDBOX lA eng IUS122211 41 6 Electrical Connection SMA America LLC 5 Connect the L1 conductor to the lower screw terminal Sunny Boy L1 of the miniature circuit breaker F4 and tighten screw torque 25 in lbs 2 8 Nm Use a torque wrench with a PZ 2 attachment or another suitable cross head screwdriver attachment 6 Connect the L2 conductor to the lower screw terminal Sunny Boy L2 of the miniature circuit breaker F5 and tighten screw torque 25 in lbs 2 8 Nm Use a torque wrench with a PZ 2 attachment or another suitable cross head screwd
8. Smartformer can crush or break bones if it falls Hang the Smartformer onto the screws and carefully slide it into the guides of the anchorage brackets When doing so note that the weight of the Smartformer is 132 Ibs 60 kg and make sure that the Smartformer does not tilt or slip out of place during mounting ANNL 6 Tighten the screws in the wall firmly Use a torque wrench with a suitable attachment and adhere to the maximum torque specified for the screws used 30 SI_TDBOX A eng IUS122211 Installation Manual SMA America LLC 6 Electrical Connection 6 Electrical Connection 6 1 Safety during Electrical Connection A DANGER Danger to life due to electric shock High voltages that can result in electric shocks are present in the live components of the Smartformer e Disconnect the Smartformer from the power supply before performing any work on the Smartformer see Section 10 e Always use a contact hazard protection cover when operating the Smartformer Work on the Smartformer may only be performed by a skilled worker Do not touch live components of the Smartformer or other components of the Sunny Island system A WARNING Risk of lethal electric shock due to faulty grounding There may be only 1 conducting connection between N and PE in the entire Sunny Island system Any further connections disturb the fault current detection and can lead to electric shock e Establish 1 conne
9. Smartformer using the two door handles Disassemble the contact hazard protection cover see Section 9 1 Select the conduit that matches the external diameter of the chosen cable see Section 6 2 1 or Section 6 2 2 Take the National Electrical Code ANSI NFPA 70 and all locally applicable standards and regulations into consideration Select the flange plate for inserting the cable To introduce the cable from below into the Smartformer select the lower flange plate To introduce the cable from above into the Smartformer select the upper flange plate Select the knockout that matches the conduit see Section 6 2 1 and Section 6 2 2 Open the selected knockout using a hammer and screwdriver Tip Open all knockouts for the upper or lower flange plate before reinserting the flange plates NOTICE Destruction of the thread if flange plate is mounted multiple times When they are being screwed in the PZ 2 screws cut a thread into the Smartformer enclosure Screwing them in more than once destroys this thread This means that the flange plates are no long screwed tight e Make sure that all required knockouts have been opened before the flange plate is mounted e The flange plates must not be screwed to the enclosure more than once Installation Manual SI_TDBOX 1A eng IUS122211 37 6 Electrical Connection SMA America LLC 8 38 Insert the flange plates into the Smartformer e Hold the lower flange plate against
10. a PV array switch off the PV array and ensure that it cannot be reconnected see the PV array manual 6 If there is a power distribution grid switch off the power supply from the power distribution grid and ensure that it cannot be reconnected Follow the instructions from the local grid operator 7 Disconnect the PV inverter from the power supply see PV inverter manual Installation Manual SI_TDBOX IA eng IUS122211 55 10 Disconnecting the Smartformer from the Power Supply SMA America LLC 56 WARNING Risk of lethal electric shock due to unnoticed start of the Sunny Island The Sunny Island can start on its own from standby e Disconnect the Sunny Island from the power supply see technical description of the Sunny Island Ensure that the Sunny Island system with the Smartformer cannot be reconnected Ascertain that the Sunny Island system and the Smartformer are dead Ground and short circuit the Sunny Island system at the connection of the generator or the power distribution grid Cover or shield any adjacent live components SI_TDBOX IA eng IUS122211 Installation Manual SMA America LLC 11 Cleaning 11 Cleaning Cleaning the enclosure 1 Check the Smartformer enclosure for externally visible damage If the Smartformer enclosure exhibits externally visible damage perform the following measures e Take the Smartformer out of service see Section 13 Decommissioning page 62 e Contact the SMA Service Line
11. a splitphase generator connect conductors L1 and L2 of the generator Strip the insulation of insulated conductors L1 and L2 by 3 in 10 mm e Connect the L1 conductor to the lower screw terminal Grid or Generator L L1 of miniature circuitbreaker F6 and tighten screw torque 25 in lbs 2 8 Nm Use a torque wrench with a PZ 2 attachment or another suitable cross head screwdriver attachment e Connect the L2 conductor to the lower screw terminal Grid or Generator L2 of the miniature circuit breaker F7 and tighten screw torque 25 in lbs 2 8 Nm Use a torque wrench with a PZ 2 attachment or another suitable cross head screwdriver attachment 6 9 Connecting the Sunny Island l Connect each of the PE conductors to a vacant spring clamp terminal of a Grounding connecting terminal plate see Section 6 5 Connect each of the N conductors to a vacant spring clamp terminal of a Neutral N connecting terminal plate see Section 6 5 Connect the L conductor of the AC 1 terminal of the Sunny Island to the lower spring clamp terminal of the Sunny Island AC1 L connecting terminal plate see Section 6 5 Connect the L conductor of the AC 2 terminal of the Sunny Island to the lower spring clamp terminal of the Sunny Island AC2 L connecting terminal plate see Section 6 5 Installation Manual SI_TDBOX 1A eng IUS122211 43 6 Electrical Connection SMA America LLC 6 10 Connecting the Load Shedding Contactor Ca
12. contact hazard protection cover in a straight movement Do not touch any components or terminals in doing so oooooooooooo0000 fN 3 Lower the right hand side of the contact hazard protection cover towards the back M Contact hazard protection cover is in place in the Smartformer j 0000000000000000 fi Installation Manual SI_TDBOX A eng IUS122211 53 9 Mounting and Disassembling the Contact Hazard Protection Cover SMA America LLC 4 Align the contact hazard protection cover with the 6 spacers The mounting openings of the contact hazard protection cover must be positioned directly above the inner threads of the spacers 5 Tighten the 6 fastening screws of the contact hazard protection cover torque 45 in lbs 5 Nm Use a torque wrench with an attachment for hexagon socket screws 3 4 in 5 mm 6 Mount the split lock washer terminal lug and contact washer onto the screw and tighten torque 45 in lbs 5 Nm Use a torque wrench with an attachment for hexagon socket screws Ys in 5 mm 54 SI_TDBOX IA eng IUS12221 1 Installation Manual SMA America LLC 10 Disconnecting the Smartformer from the Power Supply 10 Disconnecting the Smartformer from the Power Supply 1 Switch off the loads 2 Set the bypass switch to O OFF 3 Set the overload protection to 0 4 Move the switch of miniature circuit breakers F1 to FZ to the lower position 5 If there is
13. function of the load shedding contactor Installation Manual SI_TDBOX 1A eng IUS122211 49 8 Setting the Operating Mode via the Bypass Switch SMA America LLC 8 50 Setting the Operating Mode via the Bypass Switch To have the connected loads supplied by the Sunny Island set the bypass switch to ON To have the connected loads supplied only by the generator or power distribution grid set the bypass switch to II ON To switch off the supply of the loads set the bypass switch to O OFF SI_TDBOX A eng IUS122211 Installation Manual SMA America LLC 9 Mounting and Disassembling the Contact Hazard Protection Cover 9 Mounting and Disassembling the Contact Hazard Protection Cover A DANGER Danger to life due to electric shock e Disconnect the Smartformer from the power supply before performing any work on the Smartformer see Section 10 e Always use a contact hazard protection cover when operating the Smartformer Work on the Smartformer may only be performed by a skilled worker Do not touch live components of the Smartformer or other components of the Sunny Island system High voltages that can result in electric shocks are present in the live components of the Smartformer A CAUTION Risk of burns due to hot components Components inside the Smartformer may become hot during operation e Always use a contact hazard protection cover when operating the Smartformer e Allow the Smartformer to c
14. input power at 104 F 40 C 10 kw AC input power at 122 F 50 C 9 1 kw AC current at rated grid input power 48 A AC current at 104 F 40 C 41 6A AC current at 122 F 50 C 37 9 A Connection type Spring clamp terminal screw terminal Maximum wire size 4 AWG Minimum wire size 6 AWG Torque for screw terminal 25 indbs 2 8 Nm Fuse type Miniature circuit breaker Miniature circuit breakers used in Smartformer Eg and pz Installation Manual SI_TDBOX IA eng IlUS122211 67 14 Technical Data PV plant connection SMA America LLC Nominal AC voltage 240 V Rated power 9 6 kw AC power at 104 F 40 C 8 3 kw AC power at 122 F 50 C 7 6 kW Maximum AC power for parallel grid operation to power 6 kw distribution grid AC current at rated power 40 A AC current at 104 F 40 C 34 6 A AC current at 122 F 50 C 31 6 A Connection type Spring clamp terminal screw terminal Maximum wire size 4 AWG Minimum wire size at 25 A 10 AWG Minimum wire size at 50 A 6 AWG Torque for screw terminal 25 indbs 2 8 Nm Fuse type Miniature circuit breaker Miniature circuit breakers used in Smartformer F4 and F5 Nominal current of miniature circuitbreakers F4 and F5 Load connection General data Nominal AC voltage 120 V 240V Rated grid voltage between L1 and N 120V AC v
15. see Section 6 6 Start the generator or connect the power distribution grid Move the switches of miniature circuitbreakers FO and F7 to the upper position Check whether the generator or the power distribution grid is supplying the loads with voltage If the loads are not being supplied with voltage check the connection of the generator or the power distribution grid to the Smartformer see Section 6 8 Set the bypass switch to ON The Sunny Island synchronizes with the generator or the power distribution grid and takes over supply of the loads SILTDBOX lA eng IUS122211 Installation Manual SMA America LLC 7 Commissioning 16 Move the switch of miniature circuit breaker F 1 to the upper position 17 If the load shedding contactor is connected set the parameter 241 02 Rly2Op on the Sunny Island to Off see technical description of the Sunny Island This triggers the load shedding contactor of the Smartformer 18 Check whether the load shedding contactor interrupts the supply of the loads If the load shedding contactor does not interrupt the supply of the loads check the connection of the load shedding contactor to the Sunny Island see Section 6 10 Connecting the Load Shedding Contactor page 44 19 If the load shedding contactor is connected set the parameter 241 02 Rly2Op on the Sunny Island to AutoLodExt see technical description of the Sunny Island This is used to set the desired
16. spring clamp distribution for the loads the PV plant terminals the Sunny Island and the generator or the power distribution grid F Connecting terminal blocks Black For connecting L of the AC 2 terminal of Sunny Island AC2 L with Sunny Island spring clamp terminals G Connecting terminal blocks Black For connecting L of the AC 1 terminal of Sunny Island AC1 L with Sunny Island spring clamp terminals H 2 pole miniature circuit breaker Black red For connecting L or L1 and L2 of the F and F7 with screw generator or for connecting L1 and L2 of terminals the power distribution grid Grid or Generator L L1 Grid or Generator L2 2 pole miniature circuit breaker Black red For connecting L1 and L2 of the PV plant FA and F5 with screw terminals Sunny Boy L1 Sunny Boy L2 K 2 pole miniature circuit breaker See Section 4 5 A and MEW L 1 pole miniature circuit breaker See Section 4 5 E W M Bypass switch See Section 4 3 N Overload protection See Section 4 6 O Contact hazard protection Contact hazard protection cover with cover 6 anchorage points The contact hazard protection cover is shown as semi transparent 34 SI_TDBOX IA eng IlUS122211 Installation Manual SMA America LLC 6 2 4 System Overview Power distribution grid Generator 6 Electrical Connection SMARTFORMER j AC sub distribution L AC2
17. the Smartformer enclosure and tighten the 14 PZ 2 screws torque 25 in lbs 2 8 Nm Use a torque wrench with a PZ 2 attachment or another suitable cross head screwdriver attachment e Hold the upper flange plate against the Smartformer enclosure and tighten the 14 PZ 2 screws torque 25 in lbs 2 8 Nm Use a torque wrench with a PZ 2 attachment or another suitable cross head screwdriver attachment Install the cable conduit between the Smartformer and the components being connected Attach the conduit on the inside of the Smartformer with a counter nut TIA If a metal cable conduit is used ground the cable conduit according to the locally applicable standards and regulations Tip You can use a vacant terminal of the Grounding connecting terminal plate to ground the conduit Insert the cable of the components being connected through the cable conduit into the Smartformer If the cable is being introduced into the Smartformer from above attach the cable with a cable tie to one of the cable clamps Use a cable length that reaches to the specified terminal Make sure that all opened knockouts are closed again SI_TDBOX A eng IUS122211 Installation Manual SMA America LLC 6 Electrical Connection 6 5 Connecting Insulated Conductors to Spring Clamp Terminals Some of the terminals of the Smartformer are executed as spring clamp terminals Always use the following procedure when connecting an insulated conducto
18. 489 Miniature circuitbreaker F6 60 A K UL 489 2 pole Miniature circuitbreaker F7 60 A K UL 489 AC 1 terminal of Sunny Island Number of devices 1 Sunny Island Nominal AC voltage 120 V Rated power 7 2 kW AC power at 104 F 40 C 6 7 kw AC power at 122 F 50 C 6 0 kw AC current at rated power 60 A AC current at 104 F 40 C 55 7A AC current at 122 F 50 C 49 6 A Number of phases 1 phase Connection type Spring clamp terminal Wire size 4 AWG Valid for Sunny Island 4548 US 6048 US and for Sunny Island 5048 US with labeling Smartformer compatible on the original packaging 66 SILTDBOX lA eng IUS122211 Installation Manual SMA America LLC AC 2 terminal of Sunny Island 14 Technical Data Number of devices 1 Sunny Island Nominal AC voltage 120 V Rated power 5 8 kW AC power at 104 F 40 C 5 0 kw AC power at 122 F 50 C 4 5 kW AC current at rated power 48 A AC current at 104 F 40 C 41 6A AC current at 122 F 50 C 37 9 A Number of phases 1 phase Connection type Spring clamp terminal Maximum wire size 4 AWG Minimum wire size 6 AWG Fuse type Miniature circuit breaker Miniature circuit breaker used in Smartformer FO Connection to power distribution grid generator Nominal AC voltage 120 V 240 V Rated grid input power 11 5 kw AC
19. ble requirements O Conductor material copper O Minimum wire size 18 AWG O Maximum wire size 14 AWG O The cable must be approved for 167 F 75 C O The cable must be approved for AC 120 V Selecting a wire size e Choose the dimension of the wire size according to the maximum electrical current strength which occurs at the terminals of the Smartformer maximum electrical current strength AC 3 A Overview e Q lt N Z O e Q x lt N Figure 17 Connecting the load shedding contactor to the Sunny Island Required tools O Screwdriver maximum blade width 2 5 mm 1 Insert 2 insulated conductors into the Sunny Island and route to the terminal of the multi function relay 2 see technical description of the Sunny Island 2 Connect both insulated conductors to the 3 pin terminal supplied with the Sunny Island Use the contacts C and NC and label the insulated conductors accordingly Tighten the terminals torque 5 in lbs 7 in lbs 0 56 Nm 0 79 Nm Insert the terminal into the Relay 2 connection in the Sunny Island Introduce both insulated conductors into the Smartformer see Section 6 4 oak amp Shorten both insulated conductors and strip the insulation by 3 in 10 mm 44 SI_TDBOX IA eng IlUS12221 1 Installation Manual SMA America LLC 6 Electrical Connection 7 Connect the NC conductor to the lower spring clamp terminal of the Relay2 NC connecting terminal plate Note t
20. bleshooting 12 2 Replacing Miniature Circuit Breakers F4 and F5 A DANGER Danger to life due to electric shock High voltages that can result in electric shocks are present in the live components of the Smartformer e Disconnect the Smartformer from the power supply before performing any work on the Smartformer see Section 10 e Always use a contact hazard protection cover when operating the Smartformer e Work on the Smartformer may only be performed by a skilled worker Do not touch live components of the Smartformer or other components of the Sunny Island system 1 Release the upper screw terminals of miniature circuit breakers F4 and F5 and remove the conductors Use a PZ 2 screwdriver or a suitable cross head screwdriver 2 Release the lower screw terminals of miniature circuit breakers F4 and F5 and remove the conductors Use a PZ 2 screwdriver or a suitable cross head screwdriver Installation Manual SI_TDBOX 1A eng IUS122211 59 12 Troubleshooting SMA America LLC 3 Use a screwdriver to release the locking lever of each miniature circuitbreaker and lift the miniature circuit breaker off the top hat rail 4 Ensure that the fuse rating of the new miniature circuitbreaker matches the maximum feed current of the PV plant of 25 A or 50 A 5 Ensure that the miniature circuitbreaker is certified according to the specified UL standard and adheres to the specified tripping charac
21. ct or install components that are not explicitly recommended or distributed by SMA 2 2 Qualification of Skilled Workers The tasks described in this document are intended for skilled workers only Skilled workers must have the following skills e Knowledge about the functional principle and operation of off grid systems and backup systems e Knowledge of how to deal with the dangers and risks associated with installing and using electrical devices e Knowledge of the installation and commissioning of electrical devices e Knowledge of all applicable standards and guidelines e Knowledge of and adherence to this document and all safety precautions Installation Manual SI_TDBOX IA eng 1US122211 13 2 Safety SMA America LLC 2 3 Safety Precautions A DANGER Danger to life due to electric shock High voltages that can result in electric shocks are present in the live components of the Smartformer e Disconnect the Smartformer from the power supply before performing any work on the Smartformer see Section 10 e Always use a contact hazard protection cover when operating the Smartformer Work on the Smartformer may only be performed by a skilled worker Do not touch live components of the Smartformer or other components of the Sunny Island system A WARNING Risk of injury due to moving parts A generator can be started automatically by the Sunny Island Moving parts in the generator can crush or sever body parts
22. ction between N and PE in the AC main distribution unit Observe the National Electrical Code ANSI NFPA 70 and all local standards and regulations that may apply e Make sure that there are no other connections between N and PE in the entire Sunny Island system NOTICE Destruction of the Smartformer due to cables coming loose The insulated conductors can become detached from the terminals due to their heavy weight thereby damaging or destroying the Smartformer e Use cable conduits to insert the cables into the Smartformer e Use the cable clamps within the Smartformer to clamp the cables Installation Manual SI_TDBOX 1A eng 1US122211 31 6 Electrical Connection SMA America LLC 6 2 Overview of the Connection Area 6 2 1 View from Below QO O PRORA Figure 13 Flange plate with knockouts on the bottom of the Smartformer Position Description Suitable conduit for connection diameter A Knockouts YA in 19 mm B Knockouts 1 in 25 mm C Knockouts 1 yy in 32 mm 6 2 2 View from Above oO O Q O O O Ce Cc a oe o o o o J Figure 14 Flange plate with knockouts on the upper side of the Smartformer Position Description Suitable conduit for connection diameter A Knockouts 3 in 19 mm B Knockouts 1 in 25 mm C Knockouts 1 v in 32 mm 32 SI_TDBOX IA eng IlUS12221 1 Installation Manual SMA America LLC 6 2 3 Interi
23. ded in delivery Position Quantity Description A 1 Smartformer B Anchorage bracket sealing ring and hexagon head screw M6x8 C Hexagon socket screw M8x12 D 28 Phillips screw PZ 2 E 1 2 pole miniature circuit breaker 25 A F 1 Upper flange plate G 1 Lower flange plate H 1 Installation manual technical description Information about the circuitry of the Smartformer in the Sunny Island can be found in the technical description Installation Manual SI_TDBOX IA eng IUS12221 1 15 4 Product Description SMA America LLC 4 Product Description 4 1 Smartformer for Sunny Island The Smartformer for Sunny Island is a pre wired AC distribution board with an autotransformer bypass switch load shedding contactor overload protection and miniature circuit breakers E 2 o 2 BE l c 2 2 2 A Lo 2 i L g E D 2 A 2 o 2 2 2 9 o B Figure 3 Structure of the Smartformer Position Description A Door handles B Flange plate C Ventilation slots D Type label E Rear wall of enclosure with 8 drill holes The Smartformer is the AC distribution board in a Sunny Island system with 1 Sunny Island The Smartformer provides the terminals for all components in the Sunny Island system The Smartformer expands the scope of functions of the Sunny Island with the autotransformer bypass switch load shedding contactor overload protection and miniature circuit breakers 16 SI_TDBOX IA en
24. e The product can become hot during operation Do not touch the product during operation Observe the operating instructions Read the documentation of the product before working on it Follow all safety precautions and instructions as described in the documentation UL1741 is the standard applied by Underwriters Laboratories to the product to certify that it meets the requirements of the National Electrical Code Installation Manual SI_TDBOX lA eng IUS122211 5 General Warnings SMA America LLC General Warnings WARNING General Warnings All electrical installations must be done in accordance with the local and National Electrical Code ANSI NFPA 70 or the Canadian Electrical Code CSA C22 1 This document does not and is not intended to replace any local state provincial federal or national laws regulation or codes applicable to the installation and use of the product including without limitation applicable electrical safety codes All installations must conform with the laws regulations codes and standards applicable in the jurisdiction of installation SMA assumes no responsibility for the compliance or noncompliance with such laws or codes in connection with the installation of the product The product contains no user serviceable parts For all repair and maintenance always return the unit to an authorized SMA Service Center Before installing or using the product read all of the instruct
25. ee Section 6 5 Connect the N conductor to a vacant spring clamp terminal of a Neutral N connecting terminal plate see Section 6 5 Connect the L1 conductor to the lower spring clamp terminal of the Load L1 connecting terminal plate see Section 6 5 Connect the L2 conductor to the lower spring clamp terminal of the Load L2 connecting terminal plate see Section 6 5 SI_TDBOX A eng IUS122211 Installation Manual SMA America LLC 6 7 Connecting the PV Plant 6 Electrical Connection A WARNING the PV inverters individually locally applicable standards and regulations Danger to life due to fire in incorrectly connected PV inverter An excessive current load can overheat the AC connection of the PV inverter and cause a cable fire e Protect the AC output of each PV inverter according to the maximum permissible AC electrical current strength see the PV inverter installation manual e If 1 PV inverter is connected to the Sunny Island system protect the PV inverter with miniature circuit breakers F4 and F5 of the Smartformer e If several PV inverters are connected to the Sunny Island system install the AC sub distribution for the PV plant according to the locally applicable standards and regulations and protect e When selecting the wire size consult the PV inverter installation manual and adhere to the PV inverter Rated current Replace the miniature circuit breaker Sunny Boy
26. ence by one or more of the following measures e Reorient or relocate the receiving antenna e Increase the separation between the equipment and the receiver e Connect the equipment into an outlet on a circuit different from that to which the receiver is connected e Consult the dealer or an experienced radio TV technician for help The user is cautioned that changes or modifications not expressly approved by SMA America LLC could void the user s authority to operate this equipment 70 SI_TDBOX IA eng IUS122211 Installation Manual SMA America LLC 16 Contact 16 Contact If you encounter technical problems with our products contact the SMA Service Line We require the following information in order to provide you with the necessary assistance e Serial number of the Smartformer Sunny Island type serial number and firmware version e PV inverter serial number and type e Wind energy inverter serial number and type e Type and rated capacity of the connected battery If a generator is connected Type Power Maximum current e Type and power consumption of the connected loads SMA Solar Technology America LLC 6020 West Oaks Blvd Ste 300 Rocklin CA 95765 Tel 1 916 625 0870 Tel 1 877 MY SMA TECH Tel 1 877 697 6283 Toll free available for USA Canada and Puerto Rico Fax 1 916 625 0871 Service SMA America com www SMA America com Installation Manual SI_TDBOX A eng 1US122211 71 SMA Solar Technolo
27. g IlUS12221 1 Installation Manual SMA America LLC 4 Product Description Symbols on the Smartformer Description Explanation Spring clamp terminals Some of the terminals of the Smartformer are executed as spring clamp terminals Always connect a conductor fo a spring clamp terminal as described in this document see Section 6 5 Connecting Insulated Conductors to Spring Clamp Terminals page 39 4 2 Autotransformer The autotransformer enables the following functions in a Sunny Island e Integration of PV inverters with an AC output voltage of 240 V Supply of AC loads with 120 V or 240 V The autotransformer converts the input voltage according to the load requirements operating in the step up and step down operating modes e Step up The Sunny Island makes an AC input voltage of 120 V available The autotransformer converts this AC input voltage into an AC output voltage of 240 V The loads use one AC output with 120 V or both AC outputs with 240 V A different load on the two 120 V outputs is compensated by the Smartformer through power transmission e Step down The PV inverter makes an AC input voltage of 240 V available The autotransformer converts this AC input voltage into an AC output voltage 120 V The Sunny Island uses this voltage to load the battery Unlike in other transformers the input circuit and the output circuit of the autotransformer are not galvanically isolated Installation Manua
28. gh the overload protection is tripped with a predefined time delay The time delay prevents tripping of the overload protection during brief switch on current peaks Lal Figure 6 Overview of the overload protection Position Description Explanation A Switch position 1 The overload protection is in its normal operating state Current is flowing through the primary side and the secondary side of the autotransformer B Switch position O The overload protection has been tripped The current flow is interrupted on the secondary side of the transformer 20 SI_TDBOX A eng IUS122211 Installation Manual SMA America LLC 4 Product Description 4 7 Type Label The type label provides a unique identification of the Smartformer The type label is on the righthand side of the enclosure SMA Solar Technology AG www SMA America de ay SMARTFORMER Sunny Island Transformer and Distribution Box A Made in Germany by SMA Solar Technology AG B Model Serial No SI TD BOX 10 xxxxxxxxxx Operating voltage range Voc xx xxx 10 15 Operating freqency Hz 60 Max PV current xxA RMS D Max Grid Gen current xxA RMS Max SI current AC1 xxA RMS Max SI current AC2 xxA RMS
29. gy SMA America LLC www SMA America com
30. hat there is 1 possible procedure for a conductor with a bootlace ferrule and 1 possible procedure for a conductor made of coarse stranded wire or solid wire To connect a conductor with a bootlace ferrule a conductor made of coarse stranded wire or solid wire or a conductor made of fine stranded wire push a screwdriver into the terminal contact of the spring clamp terminal and insert the conductor into the terminal up to the limit position To connect a conductor with a bootlace ferrule or a conductor made of coarse stranded wire or solid wire push the conductor into the terminal up to the limit position 8 Connect the C conductor to the lower spring clamp terminal of the Relay2 C connecting terminal plate Proceed as described in step 7 Installation Manual SI_TDBOX IA eng IUS122211 45 7 Commissioning SMA America LLC 7 Commissioning Requirements o ommog0g0g0g0oi0g0g0 No 46 The Smartformer must be mounted properly All conduits must be correctly installed and attached All lines must be connected correctly The contact hazard protection cover must be mounted All knockouts in the flange plates must be closed The bypass switch must be set to O OFF The overload protection must be set to O The switches of the miniature circuit breakers F 1 to FZ must be in the lower position The generator must be switched off There must be no connection to the power distr
31. iae indies Activating Overload Protection 000000e Replacing Miniature Circuit Breakers F4 and F5 Decommissioning eeeececcerecccsceece Disassembling the Smartformer 000 eee eee Storing the Smartformer 5 56508 ukotnosecnreeree teeta aa Mabie ah Packaging ne Smarnonneirs pan wass paaees 3 a8 teats se Disposing of the Smiattornet cc11e1ese eects taut Technical Dates ssccouvewstecsvestccoveseredeess ay Compliance Information cceeeeee eens Contact sseedsrag S30 doe apache ase SS SE a tae ea Installation Manual SI_TDBOX A eng 1US122211 Table of Contents Table of Contents SMA America LLC 10 SI_TDBOX IA eng IUS122211 Installation Manual SMA America LLC 1 Information on this Document 1 Information on this Document Validity This document applies to device type SI TD BOX hardware version 1 0 and higher Target Group This document is for skilled workers Only qualified personnel are allowed to perform the tasks set forth in this document see Section 2 2 Qualification of Skilled Workers page 13 Typography Typography Usage Example light e Terminals Connect the L conductor of the AC 1 Spring clamp terminals terminal of the Sunny Island to the lower spring clamp terminal in Screw terminals r connecting terminal plate Sunny Island AC1 L bold e Switch settings that you e To have the connected loads supplied should selec
32. ibution grid Start the Sunny Island see technical description of the Sunny Island Start the PV inverters see the PV inverter installation manual The PV inverters check the grid conditions Set the PV inverters to stand alone operation see the PV inverter installation manual Set the overload protection to 1 SILTDBOX lA eng IUS122211 Installation Manual SMA America LLC 7 Commissioning 5 Move the switches of miniature circuit breakers F4 and F5 to the upper position 6 Check whether the PV plant feeds into the Sunny Island system If the PV plant does not feed into the Sunny Island system check the installation of the Smartformer e Check the connection of the Sunny Island to the Smartformer see Section 6 9 e Check the connection of the PV plant to the Smartformer see Section 6 7 7 Set the bypass switch to ON 8 Move the switches of miniature circuitbreakers F2 and F3 to the upper position 9 Check whether the loads are being supplied with voltage If the loads are not being supplied with voltage check the connection of the loads to the Smartformer see Section 6 6 Installation Manual SI_TDBOX lA eng IUS122211 47 7 Commissioning SMA America LLC 10 Set the bypass switch to IT ON 12 13 48 Check whether the bypass switch interrupts the supply to the loads If the loads continue to be supplied with voltage check the connection of the loads to the Smartformer
33. intwork on the Smartformer enclosure and lead to enclosure corrosion e Ensure that the Smartformer is not exposed to direct solar irradiation Requirements for the mounting location O A firm surface must be available for mounting such as a masonry wall studs or posts In living areas make sure that the surface is not made of plasterboard or similar The Smartformer makes noises when in use which can be regarded as a nuisance O The mounting location must be suitable for the weight and dimensions of the Smartformer see Section 14 Technical Data page 64 O The mounting location is clear and has safe access at all times without any additional aids being necessary such as scaffolding or lifting platforms Non fulfillment of these criteria may restrict servicing O The ambient conditions are met see Section 14 Technical Data page 64 This ensures optimal operation of the Smartformer L The mounting location must not be exposed to direct solar irradiation 22 SI_TDBOX IA eng IUS122211 Installation Manual SMA America LLC 5 Mounting Observe minimum clearances Ya 43 3 4 in ln 48 3 4 in 1110 mm 1 235 mm H E H r H i i Le 39 1 2 in JI 3 1 000 mm E C E S x rr Figure 8 Minimum clearances NOTICE Destruction of the Smartformer due to insufficient heat dissipation The Smartformer can overheat if there is insufficient heat dissipation Freq
34. ions cautions and warnings in this manual Before connecting the product to the electrical utility grid contact the local utility company This connection must be made only by qualified personnel Wiring of the product must be made by qualified personnel only 6 SI_TDBOX IA eng IUS12221 1 Installation Manual SMA America LLC Table of Contents 1 2 2 1 2 2 2 3 3 4 4 1 4 2 4 3 4 4 4 5 4 6 4 7 5 5 1 5 2 5 3 5 4 Scope of Delivery essssnessessssssseesees Product Description cece eee cece cece Smartformer tor Sunny Islanatescen teas bh ke bea Rhee Autotransformer ontario eae ded eden wetankes Bypass SWI h s aucara ap atarauacayl steer e dau de i ite it Load Shedding Contactor n idan gad as eadnd ceyewnne Miniature CircuitBreaker 00002 c cece eee Overload Protection 403s tewr eee eh AIAG ee oS TYPE ADE neidr dendendera are nen acids hada tte ceded MOUNTING sted ease cote oe Reese dee ieee ees E es Selecting the Mounting Location 0 0000s Mounting the Anchorage Brackets on the Enclosure Rear Wallis sii snagged nnd naan ai Reel ey Mounting the Smartformer on a Masonry Wall Mounting the Smartformer on a Wooden Wall Installation Manual SI_TDBOX A eng 1US122211 Table of Contents Table of Contents SMA America LLC 6 1 6 2 6 2 1 6 2 2 6 2 3 6 2 4 6 3 6 4 6 5 6 6 6 7 6 8 6 9 6 10 9 1 9 2
35. ipment or in personal injury Symbol Description A DANGER DANGER indicates a hazardous situation which if not avoided will result in death or serious injury A WARNING WARNING indicates a hazardous situation which if not avoided could result in death or serious injury A CAUTION CAUTION indicates a hazardous situation which if not avoided could result in minor or moderate injury NOTICE NOTICE is used to address practices not related to personal injury A SI_TDBOX IA eng IUS12221 1 Installation Manual SMA America LLC Important Safety Instructions Other Symbols in this document In addition to the safety and hazard symbols described on the previous pages the following symbols are also used in this manual Symbol iJ Description Indicates information that is important for a specific topic or objective but is not safety relevant Indicates a requirement for meeting a specific goal Desired result O M x A problem that could occur Markings on this product The following symbols are used as product markings with the following meanings Symbol Description Warning regarding dangerous voltage The product works with high voltages All work on the product must only be performed as described in the documentation of the product Risk of Fire Improper installation of the product may cause a fire Beware of hot surfac
36. ition of anchorage brackets Installation Manual 24 SILTDBOX lA eng IUS122211 5 Mounting SMA America LLC Ho e o jos c fle Sg aa N jo o of 25 1 2 in 645 mm Figure 11 Dimensions with outer drill holes and horizontal position of anchorage brackets When mounting the Smartformer on a wooden wall ensure that the distance between the middle of one stud and the middle of the next stud equals the horizontal distance between the drill holes Observe permitted mounting position TEIT X X X X X Figure 12 Permitted mounting position and prohibited mounting position 100D0DDDDD Ly Ly Y e Mount the Smartformer in the permitted mounting position e Position the upper enclosure side horizontally Tip Use a spirit level SI_TDBOX lA eng IUS122211 Installation Manual 25 5 Mounting SMA America LLC 5 2 Mounting the Anchorage Brackets on the Enclosure Rear Wall A CAUTION Risk of injury due to falling Smartformer Due to its heavy weight the Smartformer can crush or break bones if it falls e When mounting take into account the weight of the Smartformer which is 132 Ibs 60 kg e Make sure that the Smartformer does not tilt or move out of position during mounting 1 Place the Smartformer on a firm substructure and open the enclosure door using the door handles WMVUIOTOVOTULWH 2 Disassemble the contact hazard protecti
37. l SI_TDBOX IA eng IUS12221 1 17 4 Product Description SMA America LLC 4 3 Bypass Switch The bypass switch is a manual automatic transfer switch that makes it possible to directly supply the loads through the generator or power distribution grid By directly supplying the loads through the generator or power distribution grid the Smartformer bypasses the terminals of the PV plant and Sunny Island In this way the Smartformer simplifies maintenance work and repairs Lal bJ Figure 4 Overview of the bypass switch Position Description Explanation A Switch position ON The Sunny Island supplies the loads and in doing so integrates the generator or power distribution grid along with the PV plant B Switch position O OFF The loads are not supplied with voltage C Switch position Il ON Generators or power distribution grids supply the loads directly 4 4 Load Shedding Contactor The load shedding contactor is an automatic switch off device used to protect the battery from deep discharge When a predefined charge status limit of the battery is reached the Sunny Island triggers the load shedding contactor The load shedding contactor disconnects the loads from the Sun
38. lant with miniature circuit breaker 25 A 10 AWG PV plant with miniature circuit breaker 50 A 6 AWG Generator or power distribution grid 6 AWG Sunny Island AC 1 terminal 4 AWG Sunny Island AC 2 terminal 6 AWG Valid for Sunny Island 4548 US 6048 US and for Sunny Island 5048 US with labeling Smartformer compatible on the original packaging Make sure that the general cable requirements are adhered to Make sure that minimum and maximum wire sizes are adhered to If you connect a Sunny Island 5048 US without labeling Smartformer compatible on the original packaging observe the following procedure 36 Select a wire size of 6 AWG for the AC 1 connection cable of the Sunny Island Fuse the AC 1 connection cable of the Sunny Island outside of the Smartformer Use a 60 A miniature circuitbreaker for example In order to avoid excessive tripping of the 60 A miniature circuit breaker limit the rated power of the loads to 5 8 kW SI_TDBOX IA eng 1US122211 Installation Manual SMA America LLC 6 Electrical Connection 6 4 Inserting the Cables Insert each cable into the Smartformer according to the following procedure A CAUTION Risk of injury due to cable fire Hot fluids that arise during a cable fire can emerge from the open knockouts in the bottom flange plate Make sure that all knockouts that have be opened for introducing cables are in use Close unused knockouts with a suitable material Open the
39. nsformer can transfer from one line conductor to the other line conductor 64 SI_LTDBOX lA eng IUS122211 Installation Manual SMA America LLC 14 Technical Data Efficiency curve SI TD BOX Efficency 0 0 0 2 0 4 0 6 0 8 1 0 Output power Rated power Figure 18 Efficiency curve of Smartformer Ambient conditions Ambient temperature 25 C 4 250 C 13 F 122 F Maximum value for relative humidity non 100 condensing Protection class NEMA 1 Enclosure degree of protection IP20 Contact hazard protection cover degree of IP10 protection Overvoltage category 3 EMC environment FCC Part 15 Installation Manual SI_TDBOX A eng IUS122211 65 14 Technical Data Possible conduits for connection SMA America LLC Top with diameter 3 4 in 19 mm 2 Top with diameter 1 in 25 mm 2 Top with diameter 11 4 in 32 mm 2 Bottom with diameter yi in 19 mm 5 Top with diameter 1 in 25 mm 3 Bottom with diameter 1 A in 32 mm 3 Miniature circuit breakers in use Designation in Smartformer Nominal Tripping Certification Version AC current characteristics Miniature circuitbreaker F1 3A Z UL 489 1 pole Miniature circuitbreaker F2 40 A K UL 489 2 pole Miniature circuitbreaker F3 40 A K UL 489 Miniature circuitbreaker F4 25 A 50 A Z UL 489 2 pole Miniature circuitbreaker F5 25 A 50 A Z UL
40. ny Island system By doing so the Sunny Island prevents deep battery discharge 18 SI_TDBOX IA eng IlUS12221 1 Installation Manual SMA America LLC 4 Product Description 4 5 Miniature Circuit Breaker The miniature circuit breakers protect the connected conductors against destruction due to overheating Each of the miniature circuitbreakers can be manually activated or can be tripped automatically To be able to trip automatically each miniature circuitbreaker monitors the electric current in the connected conductors When the current becomes too high the miniature circuitbreaker interrupts the flow of current and thus prevents overheating of the conductors L bJ Figure 5 Overview of the miniature circuit breakers Position Description Explanation A Upper switch position The miniature circuit breaker is closed B Lower switch position The miniature circuit breaker is open Installation Manual SI_TDBOX 1A eng IUS122211 19 A Product Description SMA America LLC 4 6 Overload Protection The overload protection protects the autotransformer against damage from overheating or a short circuit The overload protection identifies overheating or a short circuit by monitoring the currents in the autotransformer If currents become too hi
41. oltage range between L1 and N 102V 132V Rated grid voltage between L2 and N 120V AC voltage range between L2 and N 102V 132V Rated grid voltage between L1 and L2 240 V AC voltage range between L1 and L2 204 V 264 V Nominal frequency 60 Hz Frequency range 55 Hz 65 Hz Connection type Spring clamp terminal Maximum wire size 4 AWG Minimum wire size 6 AWG Fuse type Miniature circuit breaker 68 SI_TDBOX IA eng IlUS122211 Installation Manua SMA America LLC Load connection If bypass switch is set to ON 14 Technical Data fusing Rated power 7 2 kW Rated power between L1 and L2 6 7 kw Rated power between L1 and N 3 8 kw Rated power between L2 and N 3 4 kw AC current to L1 at rated power 32A AC current to L2 at rated power 28 A AC power between L1 and L2 at 104 F 40 C 6 6 kw AC power between L1 and N at 104 F 40 C 3 3 kw AC power between L2 and N at 104 F 40 C 3 3 kw AC current to L1 at 104 F 40 C 27 7 A AC current to L2 at 104 F 40 C 27 7 A AC power between L1 and L2 at 122 F 50 C 5 8 kW AC power between L1 and N at 122 F 50 C 3 0 kw AC power between L2 and N at 122 F 50 C 2 9 kW AC current to L1 at 122 F 50 C 25 3 A AC current to L2 at 122 F 50 C 24 3 A Miniature circuitbreakers used in the Smartformer for F2 and F3 fusing Load connection If bypa
42. on cover see Section 9 1 2 position anchorage brackets on the upper drill holes in the enclosure rear wall When doing so keep the anchorage brackets in the chosen position and align the metal bars of the anchorage bracket with the enclosure door 4 Screw on both anchorage brackets Insert the hexagon socket screw with the sealing ring through the drill hole from the inside and into the thread of the anchorage bracket 26 SI_TDBOX A eng 1US122211 Installation Manual SMA America LLC 5 Mounting e Tighten the hexagon socket screw torque 88 in lbs 10 Nm Use a torque wrench with an attachment for hexagon socket screws 3 4 in 5 mm 5 Turn the Smartformer by 180 6 2 position anchorage brackets on the upper drill holes in the enclosure rear wall When doing so keep the anchorage brackets in the chosen position and align the metal bars of the anchorage bracket with the enclosure door 7 Screw on both anchorage brackets Insert the hexagon socket screw with the sealing ring through the drill hole from the inside and into the thread of the anchorage bracket e Tighten the hexagon socket screw torque 88 in lbs 10 Nm Use a torque wrench with an attachment for hexagon socket screws 3 4 in 5 mm Installation Manual SI_TDBOX IA eng IUS122211 27 5 Mounting SMA America LLC 5 3 Mounting the Smartformer on a Masonry Wall Additional required mounting material not included in the sco
43. ool down before removing the contact hazard protection cover Installation Manual SI_TDBOX 1A eng 1US122211 51 9 Mounting and Disassembling the Contact Hazard Protection Cover SMA America LLC 9 1 Disassembling the Contact Hazard Protection Cover 1 Disconnect the Smartformer from the power supply see Section 10 2 Ensure that the Smartformer has cooled down Release the fastening screw of the grounding cable Keep the fastening screw split lock washer and contact washer safe 4 Release 6 fastening screws of the contact hazard protection cover 5 Pull the right side of the contact hazard protection cover forwards and with the cover at an angle remove the contact hazard protection cover in a straight movement forwards out of the Smartformer Do not touch any components or terminals in doing so S SS Ss Ss SS SS SS 6 Secure the terminal lug of the grounding cable with adhesive tape to the bottom right of the Smartformer enclosure wall 52 SI_TDBOX A eng IUS122211 Installation Manual SMA America LLC 9 Mounting and Disassembling the Contact Hazard Protection Cover 9 2 Mounting the Contact Hazard Protection Cover 1 Ensure that the Smartformer is disconnected from the power supply see Section 10 2 Position the left side of the contact hazard protection cover against the right hand side of the Smartformer and with the cover at an angle to the left push back the
44. or View 6 Electrical Connection mte e ore e od jele Jag g 3 B kE Commr Uouooo SS Ss amp SS SSeS Se SS terminals N MLK 1 H F E D C B Figure 15 Electrical connection area of the Smartformer Position Description Color Explanation A Cable clamps For clamping the cables when cables are inserted via the upper flange plate B Connecting terminal blocks Black For connecting the Sunny Island to the Relay2 C Relay2 NC with load shedding contactor in the spring clamp terminals Smartformer C Connecting terminal blocks Yellow For connecting PE of the AC Grounding with spring clamp green sub distribution for the loads the PV plant the Sunny Island and the generator or the power distribution grid and for grounding the protection against contact nstallation Manual SI_TDBOX lA eng IUS122211 33 6 Electrical Connection SMA America LLC Position Description Color Explanation D Connecting terminal Black red For connecting L1 and L2 of the AC blocks Load L1 Load L2 sub distribution for the loads with spring clamp terminals E Connecting terminal blocks Gray For connecting N of the AC sub Neutral N with
45. out of place a a ff during mounting jP NUNN N iy J Tighten the screws in the wall firmly Use a torque wrench with a suitable attachment and adhere to the maximum torque specified for the screws used 5 4 Mounting the Smartformer on a Wooden Wall Additional required mounting material not included in the scope of delivery O 4 screws that are suitable for the mounting substructure and the weight of the Smartformer minimum diameter ae in 8 mm minimum length 1 1 in 40 mm Requirements o O O The mounting location must be defined The 4 anchorage brackets must be mounted on the enclosure rear wall The 4 anchorage brackets must be positioned so that each drill hole can be drilled into a stud Mark the positions of the 4 drill holes on the wall Adhere to the dimensions of the Smartformer with the mounted anchorage brackets see Section 5 1 Selecting the Mounting Location page 22 Ensure that there are no electric lines or other supply lines in the wall behind the marked positions Drill the holes The diameter of each drill hole must be approx 1 mm smaller than the diameter of the screws used Screw the screws into the wall Allow the screw heads to protrude at least 9 5 in 10 mm from the wall Installation Manual SI_TDBOX 1A eng IUS122211 29 5 Mounting SMA America LLC 5 M CAUTION Risk of injury due to falling Smartformer Due to its heavy weight the
46. owing Sunny Island inverters e Sunny Island 4548 US 6048 US Sunny Island 5048 US with labeling Smartformer compatible on the original packaging Sunny Island 5048 US inverters without labeling Smartformer compatible on the original packaging require an additional fuse outside of the Smartformer for Sunny Island see Section 6 3 Selecting Cables page 36 The Smartformer may be used with the following PV inverters by SMA Sunny Boy 2000HF US 2500HF US 3000HF US Sunny Boy 3000 US 3800 US 4000 US Sunny Boy 5000 US 6000 US e In off grid systems Sunny Boy 7000 US 8000 US A generator or the power distribution grid may be connected to the Smartformer The generator or the power distribution grid may supply the Sunny Island system with 120 V on 1 line conductor or with 240 V on 2 line conductors A generator and the power distribution grid may only be connected to the Smartformer at the same time if used with an external automatic transfer switch General terms of use Only use the Smartformer in accordance with the information provided in the enclosed documentation Any other use can result in personal injury or property damage The enclosed documentation is an integral part of this product e Read and adhere to the documentation e Keep the documentation in a convenient place for future reference Do not operate the Smartformer if it has technical defects For safety reasons it is forbidden to modify the produ
47. pe of delivery O 4 screws that are suitable for the mounting substructure and the weight of the Smartformer minimum diameter Fe in 8 mm minimum length 1 17 in 40 mm O 4 screw anchors that are suitable for the mounting substructure and the size of the screws Requirements O The mounting location must be defined O The 4 anchorage brackets must be mounted on the enclosure rear wall 1 Mark the positions of the 4 drill holes on the wall Adhere to the dimensions of the Smartformer with the mounted anchorage brackets see Section 5 1 Selecting the Mounting Location page 22 2 Ensure that there are no electric lines or other supply lines in the wall behind the marked positions 3 Drill the holes Ensure that the diameter of each drill hole matches the diameter of the screw anchor 4 Insert 4 screw anchors into the drill holes 5 Screw the screws into the wall Allow the screw heads to protrude at least 3 5 in 10 mm from the wall 28 SI_TDBOX A eng 1US122211 Installation Manual SMA America LLC 5 Mounting 6 Te A CAUTION Risk of injury due to falling Smartformer Due to its heavy weight the Smartformer can crush or break bones if it falls Hang the Smartformer onto the screws and carefully slide it into the guides of the anchorage brackets When doing so note that the weight of the Smartformer is 132 Ibs 60 kg and make sure that the sss Smartformer does not tilt or slip
48. r to a spring clamp terminal A different procedure applies for connecting the insulated conductors on the load shedding contactor see Section 6 10 Connecting the Load Shedding Contactor page 44 Required tools O Screwdriver maximum blade width 5 5 mm 1 Insert the cable see Section 6 4 2 Remove the coating Shorten insulated conductors by at least 3 in 10 mm This removes any damaged or corroded conductor material Strip the insulation of the insulated conductors by 3 4 in 19 mm 5 Route the insulated conductors to the connecting terminal plate provided Connect the conductors to the spring clamp terminals Note that there is 1 possible procedure for a conductor with a bootlace ferrule and 1 possible procedure for a conductor made of coarse stranded wire or solid wire To connect a conductor with a bootlace ferrule a conductor made of coarse stranded wire or solid wire or a conductor made of fine stranded wire push a screwdriver into the terminal contact of the spring clamp terminal and insert the conductor into the terminal up to the limit position e To connect a conductor with a bootlace ferrule or a conductor made of coarse stranded wire or solid wire push the conductor into the terminal up to the limit position Installation Manual SI_TDBOX A eng IUS122211 39 6 Electrical Connection SMA America LLC 6 6 Connecting Loads There are two ways to connect load
49. rature is always between 13 F 25 C and 140 F 60 C Store the Smartformer in closed packaging 13 3 Packaging the Smartformer e Package the Smartformer and the 4 anchorage brackets Use the original packaging for this or packaging suitable for the weight and dimensions of the Smartformer see Section 14 Technical Data page 64 13 4 Disposing of the Smartformer e Dispose of the Smartformer in accordance with the locally applicable disposal regulations for electronic waste or e Send the Smartformer to SMA at your own expense see Section 16 Contact page 71 When doing so label the packaging with the information FOR DISPOSAL Installation Manual SI_TDBOX 1A eng 1US122211 63 14 Technical Data 14 Technical Data General data SMA America LLC Number of phases 1 phase split phase Nominal power of the transformer 3 4 kVA AC power of the transformer for 30 minutes 4 4 kVA AC power of the transformer for 1 minute 8 8 kVA Typical self consumption in no load operation 19 W Maximum self consumption in no load operation 23 3 W Maximum efficiency 99 0 CEC efficiency 98 8 Certification UL Permissible grounding systems TN Width x height x depth 24 in x 24 in x 9 4 in 610 mm x 610 mm x 235 mm Weight 1321 lbs 60 kg Width x height x depth of packaging 27 4 in x 27 in x 12 in 690 mm x 700 mm x 320 mm Power that the tra
50. reak bones if it falls e When disassembling take into account the weight of the Smartformer which is 132 Ibs 60 kg e Make sure that the Smartformer does not tilt or move out of position during disassembly Disconnect the Smartformer from the power supply see Section 10 Wait for at least 1 hour until the Smartformer has cooled down Open the enclosure door using the door handles Disassemble the contact hazard protection cover see Section 9 1 ors ae Release insulated conductors from all spring camp SA terminals of the Smartformer Insert a screwdriver into the terminal contact of the spring clamp terminal and pull the insulated conductor out of the spring clamp terminal 62 SI_TDBOX A eng IUS122211 Installation Manual SMA America LLC 13 Decommissioning 6 Release insulated conductors from the screw terminals of the miniature circuit breakers F4 now F6 and sy aoe 7 Remove all connection cables from the Smartformer 8 Loosen 4 screws in the wall 9 Take the Smartformer off the wall and set it down 10 Unscrew 4 screws from the wall 11 Release screws of the 4 anchorage brackets on the Smartformer and remove anchorage brackets 12 Mount the contact hazard protection cover see Section 9 2 13 Close the enclosure door using the door handles 13 2 Storing the Smartformer Store the Smartformer in a dry place where the ambient tempe
51. river attachment 6 8 Connecting the Generator or Power Distribution Grid When connecting to the power distribution grid proceed as described below for the generator 1 Connect the PE conductor to a vacant spring clamp terminal of a Grounding connecting terminal plate see Section 6 5 2 Connect the N conductor to a vacant spring clamp terminal of a Neutral N connecting terminal plate see Section 6 5 3 To connect a single phase generator connect conductor L of the generator Strip the insulation of insulated conductor L by in 10 mm e Connect the L conductor to the lower screw terminal Grid or Generator L L1 of the miniature circuitbreaker F6 and tighten screw torque 25 in lbs 2 8 Nm Use a torque wrench with a PZ 2 attachment or another suitable cross head screwdriver attachment 42 SI_TDBOX IA eng IlUS12221 1 Installation Manual SMA America LLC 6 Electrical Connection 4 5 NOTICE Destruction of the generator due to uneven power reduction If the connected loads are supplied by the Sunny Island the Smartformer only transfers the power provided by the split phase generator via L1 This uneven power reduction may destroy the generator Make sure that the splitphase generator being used is approved for uneven power reduction see manufacturer s documentation for the generator or e Connect 1 phase generator or e Also install 1 Smartformer or an autotransformer To connect
52. s AC main distribution unit In a backup system some of the loads can be connected to the AC main distribution unit The generator or the power distribution grid directly supplies all loads connected to the AC main distribution unit These loads are not integrated into the Sunny Island system AC sub distribution In a stand alone grid all loads are connected to the AC sub distribution behind the Smartformer The Smartformer and the Sunny Island supply the loads connected to the AC sub distribution behind the Smartformer This section describes the connection of the AC sub distribution for the loads to the Smartformer i Connecting loads to the AC sub distribution 40 The power requirement of the loads should be designed in accordance with the nominal power of the Sunny Island e To minimize the transmission losses connect frequently used loads or loads with a high power consumption to the Load L1 terminal block via the AC sub distribution The requirement of the loads should not exceed a nominal current of 32 A at Load L1 e Ifthe Sunny Island with power distribution grid or generator is the only power supply all loads connected to terminal block Load L2 are supplied via the autotransformer which is Fused with 32 A e The continual requirement of the loads should not exceed a nominal current of 28 A at Load L2 Connect the PE conductor to a vacant spring clamp terminal of a Grounding connecting terminal plate s
53. ss switch is set to I ON Rated power 11 5 kw AC power at 104 F 40 C 10 kw AC power at 122 F 50 C 9 1 kW AC current at rated power 2x48A AC current at 104 F 40 C 2x41 6A AC current at 122 F 50 C 2x 37 9A Miniature circuitbreakers used in the Smartformer for FO and F7 Installation Manual SI_LTDBOX lA eng IUS122211 69 15 Compliance Information SMA America LLC 15 Compliance Information FCC Compliance This device complies with Part 15 of the FCC Rules Operation is subject to the following conditions 1 This device may not cause harmful interference and 2 This device must accept any interference received including interference that may cause undesired operation NOTE This equipment has been tested and found to comply with the limits for a Class A amp B digital device pursuant to Part 15 of the FCC Rules These limits are designed to provide reasonable protection against harmful interference in a residential installation This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instructions may cause harmful interference to radio communications However there is no guarantee that interference will not occur in a particular installation If this equipment does cause harmful interference to radio or television reception which can be determined by turning the equipment off and on the user is encouraged to try to correct the interfer
54. t by the Sunny Island set the bypass switch to I ON Nomenclature The following nomenclature is used in this document Complete designation Designation in this document SMA Solar Technology America LLC SMA Smartformer for Sunny Island Smartformer or product Sunny Boy PV inverter Abbreviations Abbreviation Designation Explanation AC Alternating Current DC Direct Current PE Protective Earth PV Photovoltaics Installation Manual SI_TDBOX IA eng IUS12221 1 11 2 Safety SMA America LLC 2 Safety 2 1 Intended Use Sunny Island Loads PV inverter S PV array Sa SMARTFORMER G a enerator ME y Battery Figure 1 Principle of a simple Sunny Island system with Smartformer The Smartformer for Sunny Island is a pre wired AC distribution board with an autotransformer bypass switch load shedding contactor overload protection and miniature circuit breakers Mounting requirements The Smartformer is only suitable for indoor use Do not mount the Smartformer outdoors Do not mount the Smartformer on flammable construction materials Do not mount the Smartformer near highly flammable materials Do not mount the Smartformer in potentially explosive atmospheres 12 SI_TDBOX A eng 1US122211 Installation Manual SMA America LLC 2 Safety Electrical connection requirements The Smartformer must only be used with the foll
55. tal or consequential damage caused by reliance on the material presented including but not limited to omissions typographical errors arithmetical errors or listing errors in the content material All trademarks are recognized even if these are not marked separately Missing designations do not mean that a product or brand is not a registered trademark SMA America LLC 3801 N Havana Street Denver CO 80239 U S A Installation Manual SI_TDBOX A eng 1US122211 3 Important Safety Instructions SMA America LLC IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS This manual contains important instructions for the following product Smartformer for Sunny Island This manual must be followed during installation and maintenance The product is designed and tested according to international safety requirements but as with all electrical and electronic equipment certain precautions must be observed when installing and or operating the product To reduce the risk of personal injury and to ensure the safe installation and operation of the product you must carefully read and follow all instructions cautions and warnings in this manual Warnings in this document A warning describes a hazard to equipment or personnel It calls attention to a procedure or practice which if not correctly performed or adhered to could result in damage to or destruction of part or all of the SMA equipment and or other equipment connected to the SMA equ
56. teristic see Section 14 Technical Data page 64 6 Position the new miniature circuit breaker at the top edge of the top hat rail and press against the lower edge of the top hat rail until the locking lever engages 7 Insert the upper conductor into the upper screw terminal and tighten screws torque 25 in lbs 2 8 Nm Use a torque wrench with a PZ 2 attachment or another suitable crosshead screwdriver attachment 60 SI_LTDBOX IA eng IUS122211 Installation Manual SMA America LLC 8 Insert the lower conductor into the lower screw terminal and tighten screws torque 25 in lbs 2 8 Nm Use a torque wrench with a PZ 2 attachment or another suitable cross head screwdriver attachment Installation Manual 12 Troubleshooting SI_TDBOX lA eng IUS122211 61 13 Decommissioning SMA America LLC 13 Decommissioning 13 1 Disassembling the Smartformer A DANGER Danger to life due to electric shock High voltages that can result in electric shocks are present in the conductive components of the Smartformer e Disconnect the Smartformer from the power supply before performing any work on the Smartformer see Section 10 Work on the Smartformer may only be performed by a skilled worker Do not touch live components of the Smartformer or other components of the Sunny Island system A CAUTION Risk of injury due to falling Smartformer Due to its heavy weight the Smartformer can crush or b
57. uent overheating can destroy the Smartformer in the long term e Maintain the minimum clearance to walls and adjacent devices or objects As a result sufficient heat dissipation is ensured e Ifthe Smartformer is installed together with other electrical devices in areas with high ambient temperatures increase the distances between the Smartformer and the other electrical devices and provide a sufficient fresh air supply This prevents the Smartformer from drawing in the exhaust air from adjacent devices e Make sure that there is a distance of at least 39 in 1 000 mm between the door of the Smartformer and any obstacle in front of it This makes it easier to open the door of the Smartformer Installation Manual SI_TDBOX IA eng IUS12221 1 23 SMA America LLC 5 Mounting Selecting the positions of the anchorage brackets on the enclosure rear wall Before mounting the anchorage brackets select 1 of the following 3 options for positioning the anchorage brackets This determines the position of the 4 drill holes Le Cu lol E E So QS o oO 1 L 223 64 in 560 mm Figure 9 Dimensions with outer drill holes and vertical position of anchorage brackets Q loj E Sis ahs e 9 1 15 63 64 in a 406 mm Figure 10 Dimensions with inner drill holes and vertical pos
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