OWNER`S MANUAL
Contents
1. 5 mang lt Se en E e CE e m ma I TE Y A y y me 3 P3 Auto Control y y ps y Auto Control f Shut Down Switch j MA 12 ak 3 Slow Down Switch K Slow Down Switch m a mynnar qe re Manual Control Manual Control SAT Switch Shut Down Switch Slow Down Switch f d 1 p b at 7 bt b2 E Sa al e T E Ha N Ee To Wind Turbine To Controller PE Terminal To Batteries For grounding Connect to only one 2V or 24V battery WIRING INSTRUC TIONS A This machine includes components carrying high voltage electricity that could potentially cause serious personal injury or even loss of life The controller shall only be installed by a qualified professional such as a licensed Electrician or UGE distributor The wiring of the controller shall meet the requirements of the NEC or the local electrical code A Before starting installation please make sure the input and output power both are shut down to avoid electrical shock A Do not mount the controller above the diversion load since the heat may damage the controller Connect the output of your wind turbine to LI L2 L3 terminals with 4AWG wires Make sure the wind turbine is fully shut down during wiring A Correct polarity must be observed when connecting the battery cables to the controller A Use caution when connecting the battery leads to avoid shorting them together 2 Connect BAT lines DAVVG 22. Off The diversion load will shut down Should not be in this position during normal operation 2 Manual Slow Down Switch On The wind turbine will slow down Off The Wind Charge Controller will control the braking signal automatically 3 Manual Shut Down Switch On The wind turbine will stop spinning immediately A If the wind turbine is spinning please engage the Slow Down Switch first Off he Wind Charge Controller will control the braking signal automatically 4 Advanced independent braking feature As a backup safety feature the control box can slow the wind turbine on its own CD DISPLAY Braking Status R P M of the Wind Generator Output Voltage and Current Input Voltage and Current NOTES URBAN GREEN ENERGY TECHNICAL SUPPORT If your product requires troubleshooting or warranty service contact your merchant If you are unable to contact your merchant or the merchant is unable to provide service contact UGE directly at Urban Green Energy 330 West 38th Street Suite 103 New York NY 10018 Tech Support Phone or o Email techsupport urbangreenenergy com This manual is an adaptation of the Power General WCHG 48 3000 installation manual for this product and is meant to be used as a guideline only For specific details refer to the Power General manual A certified electrician or the project electrician is responsible for verifying that the controller installation meets local elelct
3. surface with a cloth In addition please keep the wind turbine generator and battery in a good condition to ensure the whole system can function well 3 Check the operating status of the controller and diversion load box regularly Please pay attention to the warning messages and follow the instructions labeled on the charge controller 4 Contact UGE Technical Support if the controller display does not function normally See back cover for Technical Support contact information Do not try to repair the controller by yourself ZA This machine includes components carrying high voltage electricity that could potentially cause serious personal injury or even loss of life Only a qualified profes sional such as a licensed Electrician or UGE distributor should repair or replace parts A The safety brake must be applied before all maintenance procedures with the turbine Allowing the turbine to free spin without a brake can cause severe damage to the turbine and will void the warranty Keep this manual for your future reference DIVERSION LOAD OPERATION standard Operation Normal Setup Power Switch On Manual Shut Down Switch Off Manual Slow Down Switch Off 2 Manual shut down procedure Step Power Switch On Step 2 Manual Slow Down Switch 53 On Slow down first Step 3 Manual Shut Down Switch 52 On Shut down Switch Configurations Power Switch On Standard Operating Mode The diversion load Is on
4. A ES TO MAN a OR E TA N AGAIN N 1 4 4 4 4 4 4 E E A E AE LAU HE JPU EK SAT AE AS VA ET DE AT OE OE TT OF OE AT E ESF ESTE dd STA dd Sad SES Ad AAR KAS N SN SS HA MA TA AG DIL PIE TER SA NS A f EAEE ED DAS SO SON ON daan oa UA Oe OO oy N OT MA dt WOR AA OR REK AA WO OR ee A ADA GUN N OS LA A MA A Vd kV VOOR Rad A KV NX OR LA KAA 481 4 44 141 4 4 AA VN 4 4 dd OR ANAK 4 A 4 YA A MV ARS AA SS A OR A ST UIN od AA AM ETE AA AA A NAAA A IA AN poin AAA Step 2 Mount the charge controller INSTALLATION Mounting Guide Step 2 1 Step 2 2 Step 2 3 Put the controller against the Drill 6 holes and place anchors Fasten screws and secure the wall and mark the locations for into those holes controller drilling 6 holes The mounting method in is prohibited VVIRING DIAGRAM Electrical System Overview Detailed wiring diagrams are available from the UGE website or your UGE distributor TAN OS AC Disconnect Switch 1 3 See Table A a ek eel Table A 60 A Safety Brake 60 A Table A Volta Drop Table B 1 2 V 5 UGE Off Grid Controller Diversion Load 1 Wire gauge recommendations based on NEC 310 16 for THHW copper wire below 100 F A certified electrician shall verify wire gauge meets local electrical code 2 Each grounded component shall have its own gro
5. UGE 4K Off Grid Controlle OWNERS MANUAL GE URBAN GREEN ENERGY CONTENIS INTRODUCTION oom N N 5 PARTS LIST mom menanam anna NN NN NN 4 SPECIFICATIONS ni 5 SAFETY INSTRUC TONS NN 6 INSTALLATION oma nan NN NN NN 8 MOUNTING GUIDE cian 7 WIRING DIAGRAM es N ne CONTROLLER INTERFACE ee NN WIRING INSTRUCTIONS ese ee NN i SYSTEM START UP uni IS OPERATION MAINTENANCE NN 16 DIVERSION LOAD OPERATION NN 7 LCD DISPLAY neers nant ke NOT ES mnta an anna NN NN ANN NN 19 INTRODUCTION Dear UGE 4K Owner Congratulations on purchasing your Urban Green Energy UGE 4kW rated Vertical Axis Wind Turbine VAWT and Off Grid Controller and welcome to our family Enclosed in this manual is information regarding installation operation and maintenance of the controller Please read through the manual in its entirety before installing and using your turbine and controller Under certain circumstances this information may not be fully comprehensive and additional instruction or information may be required in order to successfully and safely complete the installation These installation and maintenance instructions contain important information forthe safe installation and maintenance of the UGE 4K off grid controller Designed for use with the UGE 4K VAWT the function of the controller is to take the variable 3 phase AC output from the permanent magnet generator in the wind turbine and convert it to a stable 48 V DC output to charge a batte
6. gh for cut in 8 Check the LCD display Make sure that the system displays no error messages and Is operating normally OPERATION amp MAIN TENANCE The controller includes the following safety protections to ensure safe and reliable operation of the wind turbine system a Wind Turbine Over speed Protection when the wind turbine is over speed the controller will start to dump exceeding power to external resistor s to slow down the speed If the speed is still too high the controller will trigger a short circuit brake b Input Over voltage Protection when the input voltage is too high the controller will start to dump exceeding power to resistor s to slow down the wind turbine c Output Over power Protection when the output current is too high the controller will start to dump exceeding power to resistor s to slow down the wind turbine d Battery Over charge Protection when the battery voltage is higher than the floating charge voltage the controller will start to dump exceeding power to resistor s to slow down the wind turbine In other words the controller will stop the MPPT function and enter a battery protection mode to protect the battery when the battery is full e High Voltage Protection the controller can protect itself from being damaged by certain high voltage pulse such as a lightning strike 2 The charge controller requires little maintenance if it is used properly Please periodically clean the controller
7. he controller on an angle see page 9 12 This controller is for use with the UGE 4K wind turbine only 13 Connect the wires by following the wiring instrustions on page 12 14 Follow the wire sizing guide provided in the wire connection diagram see page 13 15 It could damage the controller permanently if the controller and battery are not wired properly e g connecting the positive and negative polarities reversely 17 Ground the shell of this machine properly to avoid electrical shock 18 Check whether the battery voltage is within the normal range before starting the controller 19 Do not connect the controller to batteries that will operate in voltage outside the battery voltage range defined on the specification table page 5 20 Do not remove the warranty and or serial number labels AN AN AN AN AN A 16 Wires must be secured tightly to terminals to prevent causing a short or open circuit A A A A A 21 Keep this manual for your future reference INSTALLATION Step Check the installation location minimum 20cm 8 clear space around the machine is required for heat dissipation OS LL pe Fe aa he ME AO E A AE SR ep ee A dof rd A RO AS PL SOEN O AS OR A is i eee TE O E AE ae MA OE AR AT MT N AGE ER MS TAM Ad ON AF N MT IN AN A dd ES KS dd FEE KAK KOS OS AGE Mead KOS AS YE s 4 4 4 L AA Mk KAAS N Ae EA O V
8. i os oldse he ie Hie ON AS aa an 50Vrms 45Vrms Ro ed Int CURSE in 20A Maximum Saree En Gen y MPPT ENG ema Ga ee ee teeter gt 85 gt 90 Stang ado IT edel ee aa lt SVW dle orem Bi do EE OE EE EA 55 2Vdc V eren oe COMA A E T E e PUE PO A 5 6V HIV Bep pesto ies ie EE EE Na 46Vdc HIV Beren eo doc AA RECO EEE e o reste eieces 40Vdc 1V dd AR UA o EE 62 5A Hole KBo gp end o gig EF E na E a EE Dry Contact Can turn on a DC AC inverter A ie EE ER N LCD status indicators See SS OE AE N OE A A OS 10 Controller DIMENSION LL id do di an an an EE 400 x 325 x 130 Na es EE EE ee N 5kg lae E ME EE o OP O E OO A E N P43 Diversion Load Dimension L x W x H OE Ee N 200 x 600 x 185 NONE EE EE EE e 38kg lae EE EE UU PEE O e E IP43 SAFETY INSTRUCTIONS The charge controller shall be installed and operated in accordance with the instructions in this User Manual The following conventions are used in this guide Warnings identify conditions that could cause personal injury loss of life or serious damage to the unit or other equipment Warnings identify conditions or practices that could cause personal injury or damage to the unit A The UGE 4K OGC and supported diversion load should be installed indoors or a dry place that avoids direct sunlight rain and snow and has good ventilation Do not leave anything heavy on top of the controller A 2 Keep the controller and battery away from flammables and items that can conduc
9. in RED to the positive polarity of a battery and BAT terminal Battery lines should be shorter than 5 meters 16 0 3 Connect BAT lines IOAWG 2 in BLACK to the negative polarity of a battery and BAT terminal Adding a no fuse breaker NFB to the battery circuit is highly recommended 4 Connect the positive battery detection line I8AWG in RED to B socket and the positive polarity of a battery 5 Connect the negative battery detection line BAWG in BLACK to B socket and the negative polarity of a battery The circuit for battery detection must be independent A DO NOT share the same circuit with other wires 6 Connect the black brake signal lines to bl and b2 and the resistor brake disc and red brake signal lines a and a2 to the short circuit brake disc please see the following chart 7 Connect the discharge control lines 4AVWWG 2 in Orange from the on off switch of an AC inverter to D and D sockets SYSTEM START UP Engage the safety brake to stop the wind turbine A 2 Check the battery voltage and make sure that the battery detection lines are wired properly 3 Turn on the battery switch 4 Turn on the charge controller 5 Check whether there is LCD initializing message Make sure that the battery is operating normally 6 Put AC disconnect 1 in the On position Disengage the safety brake of the wind turbine 7 Observe whether the LCD display MPPT charging if the wind is enou
10. rical code UGE provides this manual as a guideline and is not responsible for any errors which may occur due to the use of this manual March 2012 Copyright Urban Green Energy Inc 2012
11. ry bank The controller also manages the turbine so that it performs safely and optimally The controller should only be installed by qualified personnel such as an employee of a UGE distributor or a certified electrician Yearly maintenance checks should be performed by qualified personnel The owner should retain a copy of this manual for reference and to give to future maintenance personnel This manual should be used in conjunction with turbine installation manual and the UGE Electrical Supplement These manuals can be found on the website of the tower and electronics suppliers respectively or can be provided by your UGE distributor We would like to hear from you with any questions or comments that you have Please contact us during working hours Monday Friday 9 00am to 6 00 pm US Eastern Time at Telephone 1 917 720 5685 Website www urbangreenenergy com Email techsupport urbangreenenergy com UGE URBAN GREEN ENERGY Sincerely PARIS LIST Check the Charge Controller and Parts Please check all the parts based on the following instructions when receiving the package Contact your local dealer if any part is missing xi Controller 325mm 400mm o E E S xl Diversion Load 600mm 900mm LE 85mm x3 Cable Gland E E SPECIFICATIONS Dio ao eee EE EE E o A 48V Input votese Range Nine TO line VOA aan aa said sala 50 230Vrms Chace Sar
12. t electricity A 3 Always use the controller with the supported diversion loads A 4 The diversion load cannot be covered by other items and cannot be placed within 300 mm I ft of any flammable heat sensitive and or explosive items A 5 If the controller or turbine behaves abnormally use the safety brake to stop the wind turbine and disconnect the controller from battery Do not start the controller until you have contacted UGE tech support and the observed issue is resolved A 6 When the wind speed is high the temperature of the Diversion Load will be high A 7 If the wind turbine is allowed to spin at high speeds without electrical resistance such as when the electronics are not completely and properly installed the turbine may be free spinning which can lead to extremely dangerous operation ALLOWING YOUR WIND TURBINE TO FREE SPIN WILL VOID YOUR WARRANTY Make sure that unless the turbine is fully operational it is completely stopped either through electrical or mechanical means A 8 Check the appearance of the charge controller before installation Contact your local dealer if any obvious damage is found 6 SAFETY INSTRUCTIONS A 9 The weight of this controller is around 5kg Always treat the charge controller with caution during transportation and installation A 10 Do not install the controller in gusty weather conditions II The controller should be mounted vertically against the wall Do not mount t
13. und wire and connect at acommon earth ground 3 AC disconnect switch 1 and the safety break should be nonfusible Bank 48V Battery 0000 5 E AC Disconnect Switch 2 Sub Inverter m AWG Panel Charger NIOAWG gt 120V 30A 240VAC Magnum MA448PAE SMV OI OMV Ol Disconnect Switch 3 Te l O 30A 240VAC INSTALLATION Controller Interface Battery Wind Turbine Input Output Terminals PE Terminals Communication Interface LCD Display INSTALLATION BAT Terminal PE Terminal al and a2 Terminal Connect to the positive For grounding Block STOP polarity of a battery Communicate external short circuit brake signal LI L2 and L3 Terminals N and N Terminal Connect to the Block RS 485 3 phase AC output Reserved for RS 485 of a wind turbine communication qf 13981 TT 99881 B and B Terminal Block BAT bl and b2 Terminal B connects to the positive polarity of a battery Block SLOW DOWN B connects to the negative polarity of a battery Communicate external Both of them are for detecting battery voltage slow down signal BAT Terminal D and D Terminal Block DISCHARGING Connect to the negative The controller sends the load discharging signals which polarity of a battery can turn on an AC inverter Maximum current is 8Amp INSTALLATION Diversion Load R 3 TE N
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