Document Outline

• Table of Contents
• 1 Introduction
• 2 Safety Instructions
  • The Sunny Boy is equipped with high voltage capacitors that can contain lethal voltages even when...
• 3 Overview
  • 3.1 Device Description
    • Fig. 3.1: Inside view of the Sunny Boy 2800i
  • 3.2 External Dimensions
    • Abb. 3.2: Size of the Sunny Boy 2800i
• 4 Requirements for the Installation
  • 4.1 Requirements: Mounting Place
    • Pay attention to the required minimum clearance for the Sunny Boy 2800i
      • Table 4.1: Minimum clearance
    • Mounting the Sunny Boy on a thin surface may emit a slight noise!
  • 4.2 Requirements: PV-Modules
  • 4.3 Requirements: Grid 230 V~ (AC)
    • The Sunny Boy has to be connected to grid with three wires!
    • No additional consumers may be connected between the Sunny Boy and the fuse!
      • Fig. 4.1: Losses in AC cable
    • Limits for AC output
      • Table 4.2: Limits for AC output of the Sunny Boy 2800i
• 5 Installation
  • 5.1 Mounting
    • 1. Mount the bracket. To mark the positions for drill holes you can also use the bracket as a dri...
    • 2. Hang the upper fixing straps on the Sunny Boy 2800i into the bracket (2) so that it cannot be ...
    • 3. Secure the Sunny Boy 2800i against lifting off by screwing the M6x10 screw (included in delive...
    • 4. Ensure that the Sunny Boy 2800i has been tightly fastened.
  • 5.2 Electrical Installation
    • 1. Disconnect the grid (switch off the circuit breaker), secure it against accidental reactivatio...
    • Before opening the Sunny Boy check whether the AC output is safely isolated from supply!
      • 2. The AC connector is a round socket that is suitable to take different cable diameters. A PG13....
      • 3. Strip the insulation off the ends of the cable and connect the cable to the AC socket as shown...
      • 4. Push the rubber ring into the fastening case.
      • 5. Put the cable through the PG13.5 or 16 cable seal. Put the cable through the fastening case wi...
      • 6. Connect the wires of the AC cable as follows:
      • 7. Make sure that all wires are firmly connected.
      • 8. Push the socket tube firmly onto the socket.
      • 9. For cables that require the PG16 gland: Tighten the bolt of the PB16 gland.
      • 10. The AC connector socket is now ready to use.
      • 11. Seal the AC connector socket in case you do not insert it into the Sunny Boy.
      • 12. The AC connector socket can be inserted into the Sunny Boy in case the Sunny Boy is already m...
      • 1. Check the PV generator connections on their correct polarity and compliance with the maximum s...
      • 2. Measure the DC voltages between each Multi-Contact plug connector of a string and ground poten...
      • 3. If the voltages you measured is constant and more than a few volts, a ground fault has occured...
      • 4. Repeat steps 2 and 3 for each string.
      • 5. Connect the trouble-free PV strings to the Sunny Boy. Make sure to connect them to the correct...
    • When connecting the plus and minus poles of a string make sure to choose the correct connection!
  • 5.3 Activation
    • 1. Switch the circuit breaker on.
    • 2. Check whether the LEDs indicate trouble-free operation of the Sunny Boy 2800i based on the fol...
      • Table 5.1: LED blinking codes
• 6 Opening and closing the Sunny Boy
  • 6.1 Opening the Sunny Boy
    • 1. Switch off the AC connection.
    • 2. Disconnect the PV generator from the Sunny Boy 2800i, by pulling off all the connectors.
    • 3. Wait 5 minutes! (This is necessary to let the internal capacitors discharge.)
    • 4. Unscrew the lid from the enclosure of the Sunny Boy 2800i. The screws are on the underside of ...
    • 5. Pull down the lid carefully (approx. 4 cm)
    • Make sure that you pull off the green- yellow PE cable from the inside of the Sunny Boy when you ...
      • 6. and carefully move the lid forward. Then pull the PE cable off the inside of the lid.
  • 6.2 Closing the Sunny Boy
    • 1. Connect the PE conductor to the lid. Then attach the lid to the enclosure of the Sunny Boy 280...
    • 2. Connect the PV generator. Make sure to connect each plug to the correct terminal.
    • 3. Switch on the circuit breaker. This activates the Sunny Boy 2800i.
    • 4. Check whether the LEDs of the Sunny Boy 2800i indicate trouble-free operation.
• 7 Communication
  • 7.1 Powerline Communication
  • 7.2 RS232 Communication
    • Abb. 7.1: Sunny Boy connected to a PC via RS232
  • 7.3 RS485 Communication
    • 1. Use the gland fitting with one hole.
    • 2. Now attach one of the two plug connectors delivered to the data cable. Connect the wires of on...
    • 3. Connect one (or both) wires of the second twisted pair to terminal 5 on the communication slot...
    • 4. If no other inverters have to be connected, continue with point 8.
    • 5. Now connect the next inverter. Use the contact units with two holes.
    • 6. Connect the wires of a cable to the terminals on the communication slot with the same allocati...
    • 7. Repeat points 5 and 6 for each Sunny Boy to be connected.
    • 8. To be able to connect them to a Sunny Boy Control or a PC with an interface converter later, l...
      • Fig. 7.2: One or several Sunny Boys connected with an RS485 cable to a PC with interface converter.
• 8 Exchanging varistors
  • 1. Disconnect the grid (switch off the circuit breaker), secure it against accidental reactivatio...
  • Ensure that the AC voltage is off before you open the Sunny Boy!
    • 2. Disconnect the Multi-Contact plug connectors of all strings. Make sure that their allocation t...
  • Disconnect the PV strings!
    • 3. Measure voltages between one Multi-Contact plug connector of each string and the ground potent...
  • Measure voltages between Multi-Contact plug connectors and the ground potential.
    • 4. If the voltages measured are constant and their total is approximately equal to the open-circu...
    • 5. Repeat points 3 and 4 for each string. If you have found a ground fault it is probably unneces...
    • 6. Unscrew the lid of the Sunny Boy 2800i and remove it. Disconnect the PE plug inside the lid. T...
    • 7. Test all varistors for an electric connection between terminals 2 and 3. If there is no electr...
    • 8. Replace the defective varistor by a new one as shown in the figure on the left. Ensure correct...
    • 9. Reconnect the PE plug to the lid and close the Sunny Boy 2800i again.
    • 10. Connect the faultless strings of the PV panel. Ensure correct allocation to strings.
    • 11. Switch on the circuit breaker.
    • 12. Check whether the LEDs of the Sunny Boy 2800i show trouble-free operation.
• 9 Contact