Overvoltage errors with Sunny Boy 2500's [RE-wrenches]

[jberdner at sma-america.com]

Wrenches:

Yesterday I was talking with Michael Welch and a couple of the other
Wrenches about a performance issue we have going on with the 2500.
While this has not really come up on the Wrenches list yet, I wanted to
be proactive and give you all an update. I apologize for the breach of
protocol but I felt the information is time critical and relevant.
First, and most importantly, I want to you all to know that we
understand exactly why this occurred and we recently received UL
approval for solutions that will solve the problem.   

BACKGROUND: Some of you may have seen a recent increase in the number of
over voltage shut downs when the 2500 is connected to grids with higher
grid voltages.   About 4 months ago, after some testing at Sandia, we
tried to increase the inverter’s anti-islanding sensitivity above what
is presently required by UL 1741 (IEEE 929).  We were successful but now
we are seeing nuisance tripping at higher grid voltage.  We started
seeing this about 60 days ago but only when the grid was over 252 Vac.
At first we thought it was a real issue with high grid voltage but after
a couple of weeks we realized that it was looking like an inverter
firmware/ hardware issue. Note that this issue only applies to only
those units that are running version 8.65 firmware and then only some of
the these (due to the statistical tolerance variance on one capacitor).
The key thing to look for is an LED Error code for grid failure AND the
“Vac_Srr” error message on the display or SBC. 

SOLUTION: If your customer is seeing the Vac_Srr error message then we
have two solutions:

1) Yesterday, we received the final UL thumbs up to send out a new
version 8.66 firmware (2 chips) that can be replaced by qualified
installers only, i.e. Wrenches – not “Joe Homeowner”.  Based on our
testing of returned units we think this will solve 70+ percent of the
problems in the field.  If this does fix the problem you should be able
to tell right away since the Vac_Srr error will go away and the inverter
should operate normally.

2) If the firmware update does not fix the problem (or if you don’t want
to chance it) then call us and we will send out a replacement unit ASAP
under the normal RMA process.  Please contact Jason Mills at
530.273.4848 for assistance.

Based on our measurements we believe the total number of units with this
problem should be around 300 but about half of these have already been
accounted for.  SMA Germany sent us two of their top technicians to help
us work this problem they are rechecking the values on all the suspect
capacitors to make use they are within tolerance.  They are also
retrofitting all inverters with the Version 8.66 firmware prior to
shipment from SMA America.  There may be a few of the version 8.65 units
still in the distribution chain but we are working with our distributors
and installers to find them and get them the new 8.66 firmware installed
within the next week or so.  Please note: If you have older inverters
with 8.32 firmware there is no issue at all.  The 8.32 units have a
different temperature sensor and so the 8.66 firmware is not compatible
anyway.   

If you have any questions, or if I can be of any further assistance,
please do not hesitate to contact me or off list.

Best Regards,

John Berdner

SMA America, Inc.
12438 Loma Rica Drive, Unit C
Grass Valley, CA  95945
530.273.4595 (voice)
530.274.7271 (fax) 

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