Honeywell WT6500 User's Manual
Contents
1. 1 View Data Menu VIEW TURBINE INPUT V 100 1 4 400 UP DWN VIEW BATTERY CHARGE V 27 2 1 2 P 544 UP DWN Y VIEW INVERTER V 27 2 0 0 UP DWN Y VIEW AC OUTPUT UP DWN V 120 1 0 0 UP DWN mO mO VIEW ENVIRONMENT ws 5 wd 16 A UP DWN v VIEW TEMPERATURE Te 30 Tc 35 Ti 0 A VIEW WS POWER ws 10 400 E 34 Figure 4 7 View Data Menu 1 Turbine Input This screen shows the turbine output voltage VDC current amps and power W 2 Battery charge This screen shows the voltage VDC current amps and power W being applied to the batteries 3 Inverter This screen shows the voltage VDC current amps and power W being applied to the inverter 4 AC Output This screen shows the output voltage VDC current amps and power W of the inverter 5 Environment This screen shows the current wind speed ws and wind direction wd The wind speed is in mph and wind direction is in degrees 6 Temperature This screen shows enclosure temperature Te charger temperature Tc and external temperature Ti Temperature external is reserved for future use and may display O All temperatures are in Celsius 7 WS Power This screen shows wind speed ws in MPH power P in W and total energy E in watt hours SMARTBOX Controller for HONEYWEL2. e ale 0 EN Jud BP ES mg l gt o 2 IHAVITS l gt t g gt HH L E NH8 m IHAVNH8 a ac RIO EL 9 L 1 EIC 2 Lu B 2 Q E gt Y ry Ho 2 ww Q a Q 2 5 9 In FUSE REFER TO MANUAL I on e JUNCTION BOX e x u hols DYO L 5 ad P jl 1 z LL L ma Qe LIS THM UIM z 8 E ARARE THM NUS 8 la NHO CATSE or 6 Control Wiring Chart Figure 2 12 SMARTBOX Controller for HONEYWELL Wind Turbine WT6500 Owner s Manual Rev14 SMARTBOX Installation 20 Enclosure Internal Wiring NEC CEC and UL require that no wires cross within the Junction Box Punch outs have been provided on the bottom of the Junction Box to meet this requirement Battery Setup FIRE HAZARD WARNING Batteries must be set correctly to avoid explosion or fire Failure to follow this warning may result in death personal injury or property damage Battery setup takes place during the commissioning process and can be accessed in the menu where the ins
3. 20 Connecting the SMARTBOX Controller 20 SMARTBOX Controller for HONEYWELL Wind Turbine WT6500 Owner s Manual Rev14 Table of Contents VII 3 Commisioning Commissioning FIODBSS oda cia eae 24 4 Operation DPOGNI CG SEF TO 28 Turbine Operating SIAIGS 28 Starting Stopping 4404222 28 Viewing Operating 28 Controller Energy Consumption 29 Turbine Operating 2 2 RG dw 29 System PrOLGCLIOTI RR Tn 30 System IUS EWN RA FRY A FE NY FAT FR NF 31 SMARTBOX Controller Front Panel 32 Navigation Button iie DR 32 System Menu and 112 32 Operations ee ce eere po ur dre RE RED RED UD pr red R dud 32 Technician Menuer mw 33 View Data Menu GCE dE DID d RS 34 Battery Setup 2 2 35 5 Specifications Non Grid tie SMARTBOX Electrical Specifications 38 SMARTBOX Controller for HONEYWELL Wind Turbine WT6500 Owner s Manual Rev14 1 Introduction Introduction Chapter 1 describes the SMARTBOX Controller with battery overview and selection d
4. NI UN 4 AC Load Detail and 4 2 SMARTBOX Controller Installation System EF O 8 Turbine Block tcu apto eon 8 SMARTBOX Controller 9 II 9 Minimum Clearance for Proper 10 OFO BYT Cl YG FD Y O m 11 WINN O NEW 11 VATI Ie aea 12 Turbine Wiring and 101112 13 Turbine Current Rating and 1111111 13 Turbine Over current 14 Battery sedeo DR ER 15 Battery Over current 2 16 AC Input VVIFITIQ ss oss acte eae rn xenon Dun yo Una 17 AC Output dere De pier eet 17 AC Output Over current 2 2 18 Control WIO uto Sint Input E tdeo I c IR RR 19 Enclosure Internal 20 ER a YG 20 Battery Setup Chat a nd
5. n PT cM EDEN 2 4 THWN 2 4 GND 1 CONDUIT MAX DISTANCE 6 FEET SS SS SS SS Sy Figure 2 8 Battery Circuit Diagram SMARTBOX Controller for HONEYWELL Wind Turbine WT6500 Owner s Manual Rev14 17 SMARTBOX Installation Pu _ eee AC Input Wiring The AC input current is rated at 15 amps Use standard NEC calculations and local codes for proper wiring 1 2 3 L1 N 120V X AC OUT 60Hz 15 AMP 120V N AC IN 60Hz 15 AMP CAUTI ON THIS IS A SINGLE PHASE INVERTER USE ONLY WIRING SCHEME SHOWY ABOVE ULEMENT AU PROJET al CAUTI ON 15 AMP MAXIMUM EXTERNAL BREAKER OR FUSED DISCONNECT MUST BE CONNECTED TO AC IN REFER TO INSTRUCTION MANUAL P RU DE NC E C EST UNE PHASE SIMPLE L UTILISATION d INVERTER T L GRAPHIAN MONTR CI DESSUS P RU DE NC E Un 15 MAXIMUM D AMP RE QUE LE BRISANT EXTERNE OU FAIT FUSIONNER D BRANCHE DOIT TRE RACCORD au COURANT ALTERNATIF DANS FAITES ALLUSION AU MANUEL D INSTRUCTION CAUTI ON A 15 AMP MAXIMUM EXTERNAL BREAKER OR FUSED DISCONNECT MUST BE CONNECTED TO OUT REFER TO INSTRUCTION MANUAL PRU DENCE Un 15 MAXIMUM D AMPERE QUE LE BRISANT EXTERNE OU FAIT FUSIONNER D BRANCHE DOIT TRE RACCORD au COURANT ALTE
6. Controller for HONEYWELL Wind Turbine WT6500 Owner s Manual Rev14 15 SMARTBOX Installation Battery Wiring The battery charge current is rated at 60 amps and inverter current is rated 72 amps maximum The recommended wire type is 4 AWG USE 2 RHW 2 or THWN 2 90 degrees C wire for a SMARTBOX Controller to battery enclosure distance of up to 6 3 feet The wire gauge should be increased to 2 AWG wire for a distance of 6 3 10 feet je e ih B moe EGND pP Iwo ATTERY TURBINE TROL o REFER TO MANUAL AND LOCAL CODES FOR WIRE SITES DC DC GND DC DC RB p CAUTION THIS CONTROLLER IS FOR USE H WINDTRONICS TURBINES ONLY PRECAUTIO N CE CONTR LEUR EST POUR P AT EC LES TURBINES WINDTRONICS SEULEMENT CAUTI ON A100 MAXIMUM EXTERNAL FUSE AND EXTERNAL DISCONNECT SWITCH MUST BE CONNECTED TO BATTERY REFER TO INSTRUCTION MANUAL PRECAUTIO N Un 100 MAXIMUM D AMP RE LE FUSIBLE EXTERNE ET EXTERNE D BRANCHE LE CHANGEMENT DOIT TRE RACCORD LA BATTERIE FAITES ALLUSION AU MANUEL D INSTRUCTION CAUTI ON DO NOT CONNECT BATTERY NEGATIVE TO GROUND DOING SO WILL BYPASS THE GFI CIRCUIT PRECAUTIO N NE RACCORDEZ PAS DE BATTERIE N GATIVE POUR FOND
7. NID 78 1 ax Pa E Wiring Diagram 191103009 w XOG LHVNS 3NIS3n L NOLLNNAL ANISYNL IAVLS OND ti 002 8 vie 06 9 OL LWI 13 SONVLSIC JMIM 1 371 38HIM H3TIOHLNOO OL 3NISSLL Soe S31Od ANISYNL SMARTBOX Controller for HONEYWELL Wind Turbine WT6500 Owner s Manual Rev14 13 SMARTBOX Installation pum M H 1 Turbine Wiring and Distances The HONEYWELL Wind Turbine and SMARTBOX Controller can be installed at a maximum distance of 200 feet apart The SMARTBOX Controller and battery enclosure can be installed at a maximum distance of 10 feet apart Turbine Current Rating and Wiring The turbine input is rated for 20 amps maximum Isc short circuit The rec
8. User Stop uu stopped off off Grid On The dump load is enabled as required to keep turbine voltages at an efficient level Figure 4 1 Turbine Operation States Starting Stopping Turbine 1 Toggle the DOWN key on the SmartBox front panel to MAIN MENU Display Description MAIN MENU Allows user to turn the turbine on or off STOP START TURBINE 2 Press enter Display Description TURBINE STOPPED Press UP to stop the turbine Press DOWN to start 5 DWN RUN the turbine Viewing Operating Status The operating status of the WT6500 can be viewed via the LCD screen on the SMARTBOX Controller To regulate energy consumption the SMARTBOXTM Controller has two operating states display and running The SMARTBOX Controller will also maintain one of three different turbine operating states turbine running fault stop and user stop SMARTBOX Controller for HONEYWELL Wind Turbine WT6500 Owner s Manual Rev14 29 Operation Controller Energy Consumption States Display On State The Display state is enabled by pressing any key on the SMARTBOX Controller This state will enable the LCD backlight and cause user information to scroll on the second line of the LCD screen This state is also active when accessing the menus If no buttons are pressed the SMARTBOX Controller will automatically switch back to the running state Display Off State The off state is the
9. are rated with CCA care must be used when selecting a marine battery AC Load Detail and Selection The non grid tie option requires the installation of AC sub panel This means that the user must select certain loads and move them into a separate sub panel The sub panel will always be provided with AC power from either the grid or the turbine when the batteries are charged The SmartBox controls a transfer switch internally when the conditions are ready A critical decision to be made during installation is selecting which loads to run off of the sub panel The first step is to measure the current in the sub panel The second step is to determine which loads should be moved to the sub panel The calculation is made by determining the appliances to be run off the sub panel and adding up the listed wattage on each appliance The total should be less than 1500W The SMARTBOX Controller can handle most home appliances starting current The limitation is 1750W for three minutes and 3000W for two seconds General rules to determine what should go on the sub panel In general avoid appliances in the kitchen and laundry room Putting the furnace or refrigerator on the sub panel is okay but be sure to total the time wattage required by all appliances SMARTBOX Controller for HONEYWELL Wind Turbine WT6500 Owner s Manual Rev14 Introduction E e Water pumps can be add to the panel but the pump must
10. default state if the turbine is producing energy from the wind waiting for the wind or if any button on the system controller is pressed The display backlight will be off and no information will scroll If any faults occur in this state the fault will be displayed The controller will maintain this state if the turbine input voltage is greater than 20VDC Turbine Operating States Turbine Running State When the turbine is in its running state the following will be shown on the display and is based on the energy consumption state Display Main Menu Scroll Description CHARGER BULK ABSORPTION FLOAT READY STOPPED FAULT Displays the charger operating state Charge is in bulk charge stage Battery is in absorption stage Battery charge cycle complete and ready for use Charge cycle has stopped Reference Fault Table on page 37 Figure 4 3 TURBINE STOPPED RUN NO WIND RUN WIND FAULT STOP Displays the turbine operating state Stopped State Turbine is running but no wind is present Turbine is running and wind is present Reference Fault Table on page 37 Figure 4 3 AC GRID AC TURBINE FAULT Displays the transfer switch location AC output is connected to grid AC output is connected to turbine inverter Reference Fault Table on page 37 Figure 4 3 POWER Displays the power generated by the turbine PRODUCTION Displays the total accumulated energy generated by the inverter from batteries WIND SP
11. EED Display Display Off Displays measured wind speed Description TURBINE RUNNING PRESS ANY KEY Turbine is running with no faults Back light is off with no information scroll Figure 4 22 Turbine Running States Turbine Fault Stop State The turbine will enter its Fault Stop state if any faults occur The turbine will stop operating and the user must clear the faults to restart the turbine The faults are cleared by pressing ENTER on the SMARTBOX Controller control panel The following will be shown on the SMARTBOX Controller LCD screen and is based on SMARTBOX Controller for HONEYWELL Wind Turbine WT6500 Owner s Manual Rev14 Operation 30 EEDD the energy consumption state see the Fault and Troubleshooting section for complete details Display Display State Description UA Turbine is stopped and contains GFI fault TURBINE FAULT Voltage sensed but Anemometer not sensing wind NO WIND SPEED speed TURBINE FAULT TURBINE OVER CURRENT Turbine is stopped and contains an over current fault TURBINE FAULT Turbine is stopped and contains an over temperature TURBINE OVER VOLTAGE fault TURBINE FAULT Anemometer is sensing wind speed but there is no NO TURBINE voltage sensed TURBINE FAULT LOW BATT Turbine is stopped and contains a low battery fault TURBINE FAULT Turb
12. ER L ACTION VITERA AINSI LE Figure 2 7 Battery Connection Location SMARTBOX Controller for HONEYWELL Wind Turbine WT6500 Owner s Manual Rev14 SMARTBOX Installation 16 Battery Over current Protection The NEC CEC requires the battery circuit to be protected with a device rated for 125 of the rating of the circuit The DC rated fuse or circuit breaker between the battery and the SMARTBOX Controller must have a maximum size of 75A the maximum current rating of the SMARTBOX Controller SHOCK OR FIRE HAZARD WARNING Over current protection must be installed to protect the SMARTBOX Controller from short circuits and to provide a means of disconnecting it Failure to follow this warning may result in death personal injury or property damage REVERSE POLARITY DAMAGE WARNING Before making the final DC connection or closing the DC breaker or disconnect check cable polarity at both the battery and the SMARTBOX Controller Positive must be connected to positive Negative must be connected to negative Failure to follow this warning may result in death personal injury or property damage TURBINE SMARTBOX Controller Lle Hoo je D e TURBINE CONTROL jp
13. Honeywell SMARTBOX CONTROLLER for HONEYWELL Wind Turbine Model WT6500 Owner s Manual This manual is intended for the use of a licensed contractor If you are a licensed and insured contractor who would like to become an Authorized Installer please send your request to Installer WindTronics com The HONEYWELL trademark is used under license from Honeywell International Inc Honeywell International Inc makes no representations or warranties with respect to this product or service Safety Instructions Safety Instructions PLEASE READ THESE INSTRUCTIONS AND THE ENTIRE MANUAL PRIOR TO INSTALLATION Safety Icons The following symbols identify dangers associated with the installation use or ownership of the SMARTBOX Controller When you see these symbols please be aware of the potential for personal injury or property damage WARNING indicates a hazard that could result in death WARNING personal injury or property damage CAUTION 2 indicates hazard that could result in property IMPORTANT PLEASE TAKE NOTE e PROFESSIONAL INSTALLATION REQUIRED Q TIP Helpful information to ease the installation Important Safety Instructions This manual contains important safety instructions that WARNING should be followed during the installation and maintenance of this product Be sure to read understand and save these safety instructions General Safety Instructi
14. L Wind Turbine WT6500 Owner s Manual Rev14 35 Operation Battery Setup Menu RISK OF FIRE OR EXPLOSION A WARNING These settings must be followed correctly Setting them incorrectly will highly increase the risk of fire and or battery explosion Failure to follow this warning may result in death personal injury or property damage BATTERY SETUP BATTERY SETUP gt ENTERIBACK gt Type FLOODED UP DWN Y BATTERY SETUP BATTERY SETUP jus I ENTER BACK MRS UP DWN 3 BATTERY SETUP BATTERY SETUP UP DWN mud lt _ gt UP DWN Y BATTERY SETUP BATTERY SETUP RECHARGE VOLTAGE lt gt Voltage 23 0 UP DWN 5 BATTERY SETUP BATTERY SETUP a RE COMMISSION ENTER ENO UP HOLD CLEAR Figure 4 8 Battery Setup Menu 1 Battery Type Use the up and down keys to select the type of batteries you have Choose from FLOODED GEL and AMG Press Enter to save Back to cancel 2 Ahr Use the up and down keys to select the Amp Hours of your batteries Press Enter to save Back to cancel 3 Banks Use the up and down keys to select the number of battery banks you have Press Enter to save Back to cancel 4 Recharge Voltage The recharge voltage is the battery voltage at which point the inverter will shut off The charge system will leave the float state and return
15. OX Controller Figure 2 1 Turbine Block Diagram SMARTBOX Controller for HONEYWELL Wind Turbine WT6500 Owner s Manual Rev14 9 SMARTBOX Installation SMARTBOX Controller Diagram CHARGER DSPCONTROL __ _ INVERTER IO BOARD _ CURRENT CURRENT CURRENT CURRENT VOLTAGE VOLTAGE VOLTAGE VOLTAGE SENSING SENSING SENSING SENSING SYSTEM DC GFI ISOLATED 9 LOGIC O CONTROL Y E DN E 777 EQUIPMENT GROUND WIND TURBINE 24V TURBINE RS485 AC OUT AC GRID i HV POWER BATTERY LOGIC i CONTROL FROM TURBINE Figure 2 2 SMARTBOX Controller Diagram Mounting The SMARTBOX Controller must be mounted vertically and installed indoors in dry protected location away from flammable material sources of high temperature moisture and vibration The location must also be sheltered from direct sunlight rain snow and wind blown debris It is best to mount the SMARTBOX Controller near near the building s electrical panel egress This will typically result in the SMARTBOX Controller being mounted on or near an external wall where the battery enclosure can then be located outdoors RISK OF FIRE OR EXPLOSION WARNING To reduce the risk of fire or explosion do not install the SMARTBOX Controller sealed compartments containgin batteries or in locations that r
16. RNATIF DANS FAITES ALLUSION AU MANUEL D INSTRUCTION Figure 2 9 Input Current Wiring Diagram AC Output Wiring The AC output current is rated at 15 amps Use standard NEC calculations and local codes for proper wiring 1 2 3 L1 N 120V AL AC OUT 120V N AC IN 60Hz 15 AMP 60Hz 15 AMP CAUTI ON THIS IS A SINGLENPHASE INVERTER USE ONLY WIRING SCHEME SHOWN ABOVE P RU DENCE C EST UNE PHASE SIMPLE L UTILISATION d INVERTER T L GRJPHIANT SEULEMENT AU PROJET MONTR CI DESSUS CAUTION A 15 AMP MAXIMUM EXTERI REFER TO INSTRUCTION MANUAL BREAKER OR FUSED DISG AINECT MUST BE CONNECTED TO AC IN P RU DE NCE Un 15 MAXIMUM D AMP RE QUE LE BRISANT EXTERNE OU FAIT FUSIONNER D BRANCHE DOIT RACCORD au COURANT ALTERNATIF DANS FAITES ALLUSION AU MANUEL D INSTRUCTION CAUTI ON A15 AMP MAXIMUM EXTERNAL BREAKER OR FUSED DISCONNECT MUST BE CONNECTED TO AC OUT REFER TO INSTRUCTION MANUAL PRUDENCE un 15 maximum DAMP RE QUE LE BRISANT EXTERNE OU FAIT FUSIONNER D BRANCHE DOIT ETRE RACCORD au COURANT ALTERNATIF DANS FAITES ALLUSION AU MANUEL D INSTRUCTION Figure 2 10 AC Output Current Rating Diagram SMARTBOX Controller for HONEYWELL Wind Turbine WT6500 Owner s Manual Rev14 SMARTBOX Installation 18 AC Output Over current Pro
17. ation 14 Turbine Over current Protection The NEC requires the turbine circuit to be protected with a device rated for 125 of the rating of the circuit The DC rated fuse or circuit breaker between the turbine and the SMARTBOX Controller must have a maximum size of 15 the maximum current rating of the SMARTBOX Controller SHOCK HAZARD OR FIRE HAZARD Over current protection must be installed to protect the SMARTBOX Controller from short circuits and to provide a means of disconnecting it Failure to follow this warning may result in death personal injury or property damage A WARNING REVERSE POLARITY DAMAGE WARNING Before making the final DC connection or closing the DC breaker or disconnect check cable polarity at both the battery and the SMARTBOX Controller Positive must be connected to positive Negative must be connected to negative Failure to follow this warning may result in death personal injury or property damage TURBINE POLES pn TURBINE TO CONTROLLER WIRE SIZE CHART 10 6 GND 150 ED 3 4 8 4 GND 200 1 2 10 THWN 2 6 GND SEE TURBINE TO CONTROLLER SIZE MAX DISTANCE 3 FEET CHART ON SHEET 1 Figure 2 6 Turbine Circuit Diagram SMARTBOX
18. be rated at 120 VAC e Typically 1500W can handle all the lighting and some appliances e You may want to mark wall plugs in the home to indicate that the plug is on wind turbine power instead of grid power The following are lists of various recommended and non recommended appliances and their typical power reguirements Recommended Appliances Appliance Wattage Notes Clock radio 10 Electric blanket 60 100 Single Double Fans Ceiling 65 175 Window 55 250 Energy Star Furnace NOAC 100 750 200 for a 2500 sq ft home Lights 10 150 Add total wattage of each lights on panel Personal computer CPU awake asleep 120 30 Monitor awake asleep 150 30 Laptop 50 Radio stereo 70 400 Televisions 65 170 VCR DVD 17 25 Water pump 250 1100 Figure 1 1 Recommended Appliances NOT Recommended Air conditioner 1000 3000 e Coffee maker 900 1200 Clothes washer 350 500 e Clothes dryer 1800 5000 e Dishwasher 1200 2400 using the drying feature greatly increases energy consumption e Dehumidifier 785 e dryer 1200 1875 Heater portable 750 1500 e Clothes iron 1000 1800 e Microwave oven 750 1100 SMARTBOX Controller for HONEYWELL Wind Turbine WT6500 Owner s Manual 14 Introduction 6 Refrigerator frost free 16 cubic feet 725 Toaster 800 1400 Toaster oven 1225 Vacuum cleaner 1000 1440 Wa
19. ctrical system Grounding for the turbine battery and AC circuits are provided inside the wiring compartment Each ground connection can accommodate up to 6 AWG wire size GFI A fuse rated at 5A 250V accessible from the bottom of the wiring compartment grounds the negative conductor of the turbine and provides turbine ground fault protection Only a Littelfuse 0312 500HXP or equivalent fuse should be used as a Grounding replacement WARNING A WARNING A WARNING Wiring SHOCK HAZARD DO NOT connect the battery negative to ground NEC requirements specify that the battery negative ground must be done only through the 1A fuse Bonding the battery negative to ground will disable the turbine s ground fault protection and will result in improper operation The battery compartment should be grounded if made of metal Failure to follow this warning may result in death personal injury or property damage SHOCK HAZARD AND FIRE HAZARD Fuses must only be replaced by qualified service personnel such as a certified electrician or technician For continued protection again risk of fire replace only with the same type and rating of fuse Failure to follow this warning may result in death personal injury or property damage SHOCK HAZARD Disconnect wind and battery circuits before removing the grounding connections or before removing or installing the fuse Wait at least 5 minutes for the internal circuitry to discharge before servicing t
20. d with removable caps or a so called maintenance free type All gelled batteries are sealed and a few are valve regulated which means that a tiny valve keeps a slight positive pressure Nearly all AGM batteries are sealed valve regulated commonly referred to as Valve Regulated Lead Acid or VRLA Most valve regulated types are under some pressure 1 to 4 psi at sea level Starting sometimes called SLI for starting lighting ignition batteries are commonly used to start and run engines Engine starters need a very large starting current for a very short time Starting batteries have a large number of thin plates for maximum surface area The plates are composed of a lead sponge similar in appearance to a very fine foam sponge This creates a very large surface area but if deep cycled this sponge will guickly be consumed and fall to the bottom of the cells Automotive batteries will generally fail after 30 150 deep cycles if deep cycled while they may last for thousands of cycles with normal starting use 2 5 discharge Most marine batteries are usually actually a hybrid and fall between the starting and deep cycle batteries while a few Rolls Surrette and Concorde for example are true deep cycle In a hybrid type the plates may be composed of lead sponge but the material is coarser and heavier than that used in starting batteries It is often hard to tell what you are getting in a marine battery b
21. dspeed but no voltage from wind turbine Turbine Voltage 5 VDC and WindSpeed gt 10 MPH for 1 minute LOW BATTERY Battery too low Battery Voltage 15 VDC for 1 minute HIGH BATTERY Battery too high Battery Voltage 32 VDC OVER TEMP Enclosure or Heat Sink over temp Enclosure gt 65 or Heat Sink gt 140 C CHARGE OVER CURRENT Current to batteries over limit Charge current gt 66 Amps INVERTER NO OUTPUT Inverter is on but not outputting A C Inverter AC output 100 VAC for 1 minute INVERTER OVER CUR RENT Inverter is over current limit Figure 4 4 Non Grid Tie SmartBox Specifications Inverter AC Current 14 5 Amps for 3 minutes SMARTBOX Controller for HONEYWELL Wind Turbine WT6500 Owner s Manual Rev14 Operation 32 SMARTBOX Controller Front Panel TECHNICIAN BATTERY SETUP t BACK UP DOWN ENTER Honeywell Figure 4 4 SMARTBOX Controller Front Panel Navigation Buttons 1 BACK button The back button will bring you back to the previous menu level and CANCEL any changes made 2 UP button The up button will scroll through the current menu selections or make a configuration change depending on the current menu level 3 DOWN button The down button will scroll through the current menu selections or make a configuration change depending on the current menu level 4 ENTER button The enter button w
22. e control wiring diagram on page 19 Figure 2 12 7 Run battery wiring Reference the battery wiring diagram on page 15 Figure 2 7 Run AC wiring Reference AC wiring diagrams on pages 17 18 Figure 2 9 2 10 2 11 9 Follow commissioning for start up procedure Page 24 o REVERSE POLARITY DAMAGE A WARNING Before making the final DC connection or closing the DC breaker or disconnect check cable polarity at both the battery and the SmartBox Positive must be connected to positive Negative must be connected to negative Failure to follow this warning may result in death personal injury or property damage SMARTBOX Controller for HONEYWELL Wind Turbine WT6500 Owner s Manual 14 SMARTBOX Installation 22 AXXK9 VVVVVvvw T SMARTBOX Controller for HONEYWELL Wind Turbine WT6500 Owner s Manual Rev14 23 Commissioning Commissioning Chapter 3 describes the step by step process of commissioning the SMARTBOX Controller For Information on See Commissioning Process page 24 SMARTBOX Controller for HONEYWELL Wind Turbine WT6500 Owner s Manual Rev14 Commissioning 24 Commissioning Process EXPLOSION OR FIRE HAZARD WARNING Entering battery information incorrectly may result in explosion or fire During commissioning the SMARTBOX Controller and turbine must be set up Settings
23. equire ignition protected equipment Failure to follow this warning may result in death personal injury or property damage SMARTBOX Controller for HONEYWELL Wind Turbine WT6500 Owner s Manual Rev14 SMARTBOX Installation 10 Minimum Clearance for Proper Mounting allow for at least 150 mm 6 in clearance 1 c e poga lt lt allow for at least allow for at least allow for at least 300 mm 12 in 300 mm 12 in 508 mm 20 in clearance clearance clearance allow for at least 150 mm 6 in clearance Figure 2 3 Minimum Clearance for Proper Mounting EQUIPMENT DAMAGE CAUTION Never install the SMARTBOX Controller where it is exposed to salt water spray Exposure to salt water will void the warranty and may cause a shock hazard A EXPLOSION CORROSION DAMAGE A WARNING To reduce the risk of corrosion from hydrogen sulfide gas vented by batteries do not install the SMARTBOX Controller in sealed compartments containing batteries Failure to follow this warning may result in death personal injury or property damage SMARTBOX Controller for HONEYWELL Wind Turbine WT6500 Owner s Manual Rev14 11 SMARTBOX Installation The SMARTBOX Controller is designed to work only with the HONEYWELL Wind Turbine The turbine uses a negative grounded ele
24. esume working after the wind speed drops to 35mph or lower SMARTBOX Controller for HONEYWELL Wind Turbine WT6500 Owner s Manual Rev14 31 Operation W F F F System Faults The SMARTBOX Controller constantly monitors the status of the turbine Any time the turbine senses a fault the dynamic brake will stop the turbine and the SMARTBOX Controller will stop producing energy from the turbine TURBINE FAULT will be displayed on the LCD screen along with the fault detected The user must clear any faults in order to restart the turbine If a fault occurs follow these steps to clear it 1 View the faults listed and correct the fault 2 Press ENTER on the front panel If the fault is fixed the controller will go to stop state If the system finds any other faults the next fault will be displayed 3 When all faults are clear go to start stop turbine in the menu and restart the turbine Non Grid Tie SmartBox Fault Specifications Fault Description State Required for Fault GFI GFI Ground Fault NO WINDSPEED Voltage from Turbine but no data from anemometer Turbine Voltage gt 40 VDC and Wind Speed 1 MPH for 1 minute TURBINE OVER CUR RENT Turbine over current Current from turbine 18 Amps TURBINE OVER VOLTAGE Turbine over voltage Voltage from turbine gt 190 VDC NO TURBINE Anemometer reporting win
25. etails For Information On See The SMARTBOX Controller page 2 Battery Overview page 3 Battery Selection page 4 AC Load Detail and Selection page 4 SMARTBOX Controller for HONEYWELL Wind Turbine WT6500 Owner s Manual Rev14 Introduction 2 _ The SMARTBOX Controller The SMARTBOX Controller is a proprietary WindTronics control system that consists of a charge controller and a non grid tie 1 5 kW inverter Included within the charge controller is an automatic AC transfer switch that will automatically switch between your AC grid and power generated via the turbine The DC output from the turbine is fed into the Junction Box located beneath the turbine assembly The J Box serves three purposes provide wiring interconnections for the installation provide an output over voltage protection of 170 VDC and provide a diversion or dump load that can dynamically brake and stop the turbine either upon request from the SMARTBOX Controller or if a failure occurs in the system Beyond the J Box all connections are fed into the SMARTBOX Controller The SMARTBOX Controller consists of four main elements an I O interface that provides wiring interconnect for installation a charge controller to charge a bank of batteries a non grid tie 1 5 kW inverter to back convert
26. for the battery type battery banks and battery capacity must be set up in the SMARTBOX Controller and the turbine s components will need to be tested This testing can be done with the control panel and LCD screen on the front of the system controller Ensure you have this system information prior to commissioning The commissioning process will reference menu displays The following is the proper procedure to commission the turbine Do not proceed with commissioning until all disconnects are in the off position and the turbine is mechanically locked The turbine dynamic brake will remain enabled up until the turbine disconnect step The following is the proper procedure to commission the HONEYWELL Wind Turbine Do not proceed with commissioning until ALL DISCONNECTS are in the OFF position and the turbine blades rotate freely 1 all connections for polarity 2 Apply battery power to the unit with the disconnect or selector switch inside the battery enclosure 3 The LCD display will light up and prompt a display Display Description WINDTRONICS RX XX The Smart Box will display this for FIRST POWER UP 5 seconds and then move to the reguired setup information 4 The system will automatically walk you through the commissioning process All steps must be completed before the turbine will operate If problems are found during this process the battery disconnect can be turned off at any time to restart the pr
27. he unit Failure to follow this warning may result in death personal injury or property damage PROFESSIONAL INSTALLATION REQUIRED Installations must meet all local electrical codes Installations for the equipment should only be performed by a qualified electrician or an Authorized Installer A WARNING SHOCK HAZARD Disconnect turbine and battery circuits before wiring Turn off all power before wiring Failure to follow this warning may result in death personal injury or property damage SMARTBOX Controller for HONEYWELL Wind Turbine WT6500 Owner s Manual Rev14 12 SMARTBOX Installation WNOLLdO D amp T D 1133 5 NO LYYHD 1334 JINVLSIC XVW 3715 3371031402 01 ANISYNL 335 dWVSI InaNOD 3SVHd 315NIS ASWHd TIONIS GND 9 2 NMHL 018 Z auvoa HOLIMS WOU HOLIMS 80501 Rn nn nf lt r g ALUINGNOD wt o _ _ im 5 D ue db mel 2 cod leat lta a NS YI Oe O OK O O IO a ca NW i ES gt lt za 1 aecc 22282 28 BS 8 z 2 AREE 88 E S 2 53715 afin S30b2 avv ni di adau
28. ied by 333 hours or 6 67 Ah The accepted amp hour rating time period for batteries used in wind electric and backup power systems and for nearly all deep cycle batteries is the 20 hour rate This means that a battery is discharged down to 10 5 volts over a 20 hour period while the total actual amp hours it supplies is measured Sometimes ratings at the 6 hour rate and 100 hour rate are also given for comparison and for different applications The 6 hour rate is often used for industrial batteries as that is a typical daily duty cycle The 100 hour rate is sometimes used for determining battery capacity for long term backup amp hour requirements Battery Selection Battery selection is one of the most important steps in the installation process Not selecting the correct batteries will result in short battery life constant charge and discharge cycles and overheating of batteries which could result in serious damage to equipment battery explosions or fire The charge controller will prevent over charging although this must be set up correctly DO NOT use standard automotive starting batteries While automotive batteries may last for thousands of cycles in normal starting use 2 596 discharge they will generally fail after 30 150 cycles if used in a deep cycle application as with the HONEYWELL Wind Turbine which will discharge batteries down to 5096 Any battery rated in CCA or CA should not be used Since some marine batteries
29. ill enter the currently selected menu choice It will also commit and save any configuration changes if applicable 5 Line 1 In this example line one shows you your current menu level in this case the TECHNICIAN menu the one dot tells us that we are one menu level deep from the home screen 6 Line 2 The second line shows us that if we hit ENTER we will enter the BATTERY SETUP menu the two dots indicate that we will be two menu levels deep from the home screen if we enter the BATTERY SETUP menu System Menu and Navigation Operations Menu i 2 FN DEFAULT DISPLAY WHEN RUNNING DISPLAY SLEEPING a TURBINE RUNNING Turbine Status a T a TURBINE STOPPED UONE PRESS ANY KEY Production Wind Speed TURBINE FAULT 15 SEC TIMEOUT UP DOWN Y P MAIN MENU TECHNICIAN TECHNICIAN C ENTER BACK MENU UP DOWN UP DOWN 3 v 4 22 d MAIN MENU STOP START TURBINE STOP STARTTURBINE UP STOP DWN START Figure 4 5 System Menu SMARTBOX Controller for HONEYWELL Wind Turbine WT6500 Owner s Manual Rev14 33 Operation 1 This is the home screen The SMARTBOX Controller will scroll the listed information while in run mode and also the current firmware revision 2 Turbine Fault Stop Indicates if a fault has occurred 3 This is the top menu level From here you can g
30. ine is stopped and contains high battery fault TURBINE FAULT Turbine is stopped and contains an over temperature OVER TEMP fault TURBINE FAULT CHARGE OVER CURRENT TURBINE FAULT INVERTER NO OUTPUT TURBINE FAULT INVERTER OVER See Figure 4 4 CURRENT Turbine is stopped and contains an over current fault See Figure 4 4 Figure 4 3 Turbine Fault Stop States Turbine User Stop State The turbine will enter its User Stop state if the user engages the manual stop command in the technician s menu accessible via the SMARTBOX Controller When the SMARTBOX Controller is in user mode the turbine is immediately stopped While in user stop mode no A C will be produced so the inverter is shut off and the transfer switch is switched back to the grid The SMARTBOX Controller must be placed in run mode before a charge cycle can start again Display Stopped State Description TURBINE STOPPED Turbine is stopped with no faults Back light is off with PRESS ANY KEY no information scroll System Protection e Cool Down The turbine will shut off and begin cool down if the charger reaches or exceeds a temperature of 125 c or and the enclosure reaches or exceeds a temperature of 60 c The turbine will resume working after the charger temperature drops below 70 c and or the enclosure temperature drops below 45 c e Over Wind Speed The turbine will turn off when wind speed reaches 42mph or higher It will r
31. nd batteries Always wear eye protection such as safety glasses when working with batteries Remove all jewelry before working with batteries e Never work alone Have someone assist you with the installation or be close enough to come to your aid when working with batteries Always use proper lifting techniques when handling batteries Always use identical types of batteries e Never install old or untested batteries Check each battery s date code or label to ensure age and type e Batteries should be installed in a well vented area to prevent the possible buildup of explosive gasses If the batteries are installed inside an enclosure vent its highest point to the outdoors When installing batteries allow at least 1 inch of air space between batteries to promote cooling and ventilation NEVER smoke in the vicinity of a battery or generator Always connect the batteries first then connect the cables to the inverter or controller This will greatly reduce the chance of spark in the vicinity of the batteries e Use insulated tools when working with batteries When connecting batteries always verify proper voltage and polarity Do not short circuit battery cables Fire or explosion can occur ln the event of exposure to battery electrolyte wash the area with soap and water If acid enters the eyes flood them with running cold water for at least 15 minutes and get immediate medical attention e Always recycle old ba
32. nd menu structures For Information on See Introduction page 28 Turbine Operating States page 28 Starting Stopping Turbine page 28 Viewing Operating Status page 28 System Protection page 30 System Faults page 31 SMARTBOX Controller Front page 32 Panel SMARTBOX Controller for HONEYWELL Wind Turbine WT6500 Owner s Manual Rev14 Operation 28 EE FF P P P Introduction The basic operation of the turbine SMARTBOX Controller electronic system is to optimize the efficient utilization of the energy captured from the wind Low wind energy is stored in batteries while loads are connected automatically to the grid High wind energy is efficiently and rapidly transferred to the load via the bulk storage capacity of the batteries If the batteries are fully charged and no AC demand is present the SMARTBOX Controller will send the turbine s energy to a dump load and wait for an AC demand Turbine Operating States The turbine goes through a series of different states The chart lists and describes each possible operating state Transfer Dump State Description Charger Inverter Switch Load Bulk Charge Bulk charging the on off Grid On batteries F Absorption charging F Absorption Charge ihe batteries Off Grid On Float Charge Float charging ine On On Turbine On batteries Fault Stop Turbine fault exists Off Off Grid On
33. ng the turbine Turn on the turbine disconnect 10 If the wind is not causing the turbine wheel to spin gently spin the wheel by hand to determine if the system Smart Box is detecting a voltage level Display Description TURBINE INPUT OK Shows if a turbine voltage was found 11 Step 12 is for testing the AC grid connection Turn on the AC disconnect from the grid input 12 Check the LCD screen and make sure the AC voltage is OK Press ENTER to continue Display Description Checks the AC voltage Press ENTER AC Grid 120V OK to skip this step if this is a non grid tie connection 13 Step 14 is for testing the AC load connection Turn on the AC disconnect to the load Turn on all items on the sub panel load to make sure that the turbine inverter can handle the load 14 The system commission process is now complete Press ENTER to start the turbine If required this process can be restarted via the technician s menu Display Description COMMISSION COMPLETE Press ENTER to start the turbine SMARTBOX Controller for HONEYWELL Wind Turbine WT6500 Owner s Manual Rev14 Commissioning 26 e ww SMARTBOX Controller for HONEYWELL Wind Turbine WT6500 Owner s Manual Rev14 27 Operation EDE N Uu N I dcCc Oe OI o 7 Operation Chapter 4 is an overview of SMARTBOX Controller operation including operating states system faults a
34. o to the TECHNICIAN MENU or the START STOP TURBINE MENU Pressing enter to make a selection 4 The Start Stop Turbine Menu Pressing UP will place the SMARTBOX Controller in user stop mode In this mode the turbine will not spin and no A C will be produced Pressing DOWN will start the turbine This will start a battery charge cycle Technician Menu TECHNICIAN FORCE CHARGE gt FORCE CHARGE ENTEIVBACIS gt UP START UP DWN TECHNICIAN START CHARGE FORCE AC ENTERIBAGK M UP START UP DWN 3 TECHNICIAN CLEAR PRODUCTION UP DWN CLEAR PRODUCTION ENTER BACK gt UP HOLD CLEAR A UP DWN 4 M UP DWN 5 i TECHNICIAN Figure 4 6 Technician Menu 1 Force Charge This forces the turbine into the bulk charge state to begin charging the batteries 2 Force AC This turns on the inverter and switches the transfer switch to turbine AC It also switches the turbine mode into float charge 3 Clear production This clears the Watt Hour productions values in the turbine both turbine and AC productions values 4 View Data Selecting view data moves a menu level down to the view data menu 5 Battery Setup Selecting battery setup moves a menu level down to the battery setup menu SMARTBOX Controller for HONEYWELL Wind Turbine WT6500 Owner s Manual Rev14 Operation 34 6 9 9 9 9
35. ocess All of the settings will be saved but you must start over and go through all the steps until commissioning is complete 5 For optimal performance it is important to enter optimal battery information steps 5 7 We highly recommend using two 12V deep cycle flooded marine 100Ahr batteries For this selection please enter the following optimal settings for best performance At the first prompt screen select the battery type by using the arrow keys Press ENTER when finished Display Description Optimal ENTER BATTERY TYPE Set the battery type Flooded FLOODED SMARTBOX Controller for HONEYWELL Wind Turbine WT6500 Owner s Manual Rev14 25 Commissioning E 6 Select the battery Amp hour rating for ONE battery by using the arrow keys Press ENTER when finished Display Description Optimal ENTER BATTERY AHr 100 Set the battery amp hour rating Enter 140 for 100Ahr for ONE battery batteries 7 Select the number of battery banks in parallel by using the arrow keys Press ENTER when finished Display Description Optimal ENTER BATTERY BANKS 1 Set the number of battery banks 2 12V batteries Enter 3 for one bank of 8 Atthis point the batteries are all set up Now you will proceed to setting up the turbine and checking its components for operation Turbine setup requires two people one located at the turbine and one located at the system Smart Box 9 Step 10 is for testi
36. ommended wire type is 10 AWG USE 2 RHW 2 or THWN 2 90 degrees C wire for a turbine to Smart Box distance of up to 150 feet The wire gauge should be increased to 8 AWG for a distance of 150 200 feet Due to the outside location of the turbine a 70 degree C ambient temperature correction is recommended z TURBINE TURBINE OL TO MANUAL AND LOCAL BODES FOR WIRE SIZE 24VDC BATTERY TURBINE INPUT AUTION THIS CONTROLLERJ6 FOR USE WITH WINDTRONICS TURBINES ONLY PR ECAUTIO N CE EST POUR L UTILISATION AVEC LES TURBINES WINDTRONICS SEULEMENT AU Of OT AMP MAXIMUM EXTERNAL FUSE AND EXTERNAL DISCONNECT SWITCH MUST BE CONNECTED BATTERY REFER TO INSTRUCTION MANUAL P RECAUTIO N Un 100 MAXIMUM D AMP RE LE FUSIBLE EXTERNE ET EXTERNE D BRANCHE LE CHANGEMENT DOIT ETRE RACCORDE LA BATTERIE FAITES ALLUSION AU MANUEL D INSTRUCTION CAUTION DO NOT CONNECT BATTERY NEGATIVE TO GROUND DOING SO WILL BYPASS THE GFI CIRCUIT P RECAUTIO N NE RACCORDEZ DE BATTERIE N GATIVE POUR FONDER L ACTION VITERAAINSI LE CIRCUIT GFI Figure 2 5 Turbine Connection Location SMARTBOX Controller for HONEYWELL Wind Turbine WT6500 Owner s Manual Rev14 SMARTBOX Install
37. ons e All electrical work must be done in accordance with all applicable local national and or international electrical codes Before installing or using this device read all instructions and cautionary markings located in or on this guide the unit the batteries turbine and any other equipment used e This product is designed for indoor mounting only Do not expose this unit to rain snow or liquids of any type Toreduce the chance of short circuits use insulated tools when installing or working with the unit or any DC source such as PV hydro wind or batteries Remove all jewelry when installing or working with the unit or any DC source This will greatly reduce the chance of accidental exposure to live circuits The unit contains more than one live circuit batteries and turbine Power may be present at more than one source e This product contains no user serviceable parts SMARTBOX Controller for HONEYWELL Wind Turbine WT6500 Owner s Manual Rev14 Safety Instructions LIMITATIONS ON USE WARNING The SMARTBOX Controller is not intended for use in connection with life support systems or other medical equipment or devices Battery Safety Information A battery can produce the following hazards to personal WARNING no 9 e electrical shock from high short circuit current fire or explosion from vented gasses Observe proper precautions when working with or arou
38. property damage SMARTBOX Controller for HONEYWELL Wind Turbine WT6500 Owner s Manual Rev14 21 SMARTBOX Installation To connect the SMARTBOX Controller 1 Mount SMARTBOX Controller to the wall per instructions on pages 9 10 Figure 2 3 2 Place battery enclosure in a dry well ventilated indoor space 3 Install and level turbine See the HONEYWELL WindTurbine Owner s Manual SHOCK HAZARD WARNING Always lock the blades before working with the turbine Unlocked blades can produce voltages on the DC output Failure to follow this warning may result in death personal injury or property damage 4 Attach the electrical conduit Follow local electrical codes for compliance WARRANTY VOID WARNING WARNING DO NOT drill holes for conduit in SMARTBOX Controller Use pre punched holes located at the bottom of the SMARTBOX Controller Drilling holes anywhere on the SMARTBOX Controller will void the warranty of the product Failure to follow this warning may also result in death personal injury or property damage FIRE AND SHOCK HAZARD WARNING The NEC code stipulates that AC DC and control wiring MUST NOT cross within any enclosure Failure to follow this warning may result in death personal injury or property damage 5 Run wiring between turbine and SMARTBOX Controller Reference the turbine wiring diagram on page 12 Figure 2 4 6 Run turbine control wiring Reference the turbin
39. taller must configure the SMARTBOX Controller based on what batteries are connected to the system The following table shows the battery options and the values that will be set up by default The installer does have the option to configure the charging manually Of the parameters listed below the installer sets up the first three Battery Type Battery Banks and Capacity Battery Setup Chart Setting Values Defaults Description Battery Type Flooded Flooded Sets the battery type and automati GEL cally set the default values below AGM based on that type Battery Banks 1 6 1 Sets the number of 24V paralleled battery banks connected Capacity 50 500 100 Ah Sets the amp hour rating of ONE battery Recharge Voltage 20 0 27 0 V 22 V Sets the voltage at which the charger transitions from absorption to bulk charge Figure 2 13 Battery Setup Chart Connecting the SMARTBOX Controller SHOCK HAZARD WARNING Whenever a turbine is not locked and turning a shock hazard exists at the output wires or exposed terminals To reduce the risk of shock during installation stop and lock the turbine before making the connections Failure to follow this warning may result in death personal injury or property damage SHOCK HAZARD WARNING Do not connect the battery negative to ground Bonding the battery negative to ground disables turbine ground fault protection Failure to follow this warning may result in death personal injury or
40. tection The NEC CEC requires the AC output circuit to be protected with a device rated for 125 of the rating of the circuit The AC rated fuse or circuit breaker between the battery and the SMARTBOX Controller must have a maximum size of 15A the maximum current rating of the SMARTBOX Controller SHOCK OR FIRE HAZARD A WARNING maximum of a 15amp over current protection must be installed to protect the SMARTBOX Controller from short circuits and to provide a means of disconnecting the SMARTBOX Controller Failure to follow this warning may result in death personal injury or property damage Turbine SMARTBOX Controller E 2 412 THWN 2 2 12 THWN 2 4 4 6 GND 4 4 6 GND 34 CONDUIT 34 CONDUIT L1 N GND 15 AMP FUSE OR BREAKER AC INPUT FROM MAIN SWITCH BOARD SINGLE PHASE 120V 15AMP EA N GND AC OUTPUT TO SUB SWITCH Figure 2 11 AC Circuit Diagram SMARTBOX Controller for HONEYWELL Wind Turbine WT6500 Owner s Manual 14 19 SMARTBOX Installation Control Wiring Control wiring can use stranded CAT5 CAT6 or equivalent wire TURBINE SMARTBOX Controller r ia
41. ter heater 40 gallon 4500 5500 Water bed with heater no cover 120 380 SMARTBOX Controller for HONEYWELL Wind Turbine WT6500 Owner s Manual Rev14 7 Installation uum SMARTBOX Controller Installation Chapter 2 provides details on installing the SMARTBOX Controller and getting it ready for operation For Information On See System Diagrams page 8 Mounting page 9 Grounding page 11 Wiring page 11 Battery Setup page 20 Connecting the SMARTBOX page 20 Controller SMARTBOX Controller for HONEYWELL Wind Turbine WT6500 Owner s Manual Rev14 SMARTBOX Installation System Diagrams TIP The instructions in this section apply to a typical installation Installation procedures may vary according to your specific application For special applications consult a qualified electrician or your WindTronics certified dealer electrical codes Installation of this equipment should only be performed by a PROFESSIONAL INSTALLATION Installation must be compliant with all local qualified electrician or by a Certified Renewable Energy System Installer Turbine Block Diagram WIND WIND SPEED WIND DIRECTION DUMP LOAD _ JUNCTION BOX _ INTERFACE PCB DIVERSION LOAD CONTROL LOGIC WIND CONTROL TURBINE HV POWER OUTPUT TO SMARTB
42. the batteries to an AC output and a transfer switch that can switch between AC grid input and the internal inverter s AC Major System Components SMARTBOX Controller Batteries and battery enclosure Parts Inspection Upon opening the shipping container review all contents to ensure the contents have not been damaged during shipping and handling Failure to properly inspect and verify damages prior to installation may result in voiding of the manufacturer warranty If any turbine components appear to be damaged please contact the WindTronics service department at the following WindTronics Inc Service Department 621 Sprucewood Windsor ON N9COB3 Canada 1 877 946 3898 SMARTBOX Controller for HONEYWELL Wind Turbine WT6500 Owner s Manual Rev14 Introduction Battery Overview Battery Types Not to be used Minimum to be used Recommended use and construction how they are built The major applications are automotive marine and deep cycle Deep cycle includes solar electric PV wind power backup power and RV boat house batteries ab Batteries are classified in two different ways by application their The major construction types are flooded or wet gel and AGM Ab sorbed Glass Mat AGM batteries are also sometimes called starved electrolyte or dry because the fiberglass mat is only 95 saturated with sulfuric acid and there is no excess liquid Flooded batteries may be standar
43. to bulk charge to restart the charger cycle 5 Re Commission To start the commissions process over hold down the up key This is necessary if the turbine has moved and needs to be reconfigured SMARTBOX Controller for HONEYWELL Wind Turbine WT6500 Owner s Manual 14 Operation 36 gt nr SMARTBOX Controller for HONEYWELL Wind Turbine WT6500 Owner s Manual Rev14 37 Specifications 2 14114A 4 1 11 1 111 LL L 1 5m AaLAALGLXAKKAKXAXA o in Specifications SMARTBOX Controller for HONEYWELL Wind Turbine WT6500 Owner s Manual Rev14 Specifications 38 EEE ve F _ _ Non Grid Tie Smart Box Electrical Specifications Description Rating Units Input Maximum Turbine Voltage 200 Volts DC Operating input voltage range 30 170 Volts DC Maximum input current 18 Amps DC Maximum input short circuit current 20 Amps DC Inverter Operating voltage range 120VAC 3 Volts AC Operating frequency range or single frequency 60Hz 0 05 Hz Nominal output voltage ac 120 Volts AC Nominal output frequency 60 Hz Maximum continuous output current 12 5 Amps AC Maximum continuous output power ac 1500 VA Ma
44. tteries Contact your local recycling center for proper disposal information NOTE TO INSTALLER This Owner s Manual should be left with the owner of the SMARTBOX Controller SMARTBOX Controller for HONEYWELL Wind Turbine WT6500 Owner s Manual Rev14 IV Safety Instructions SMARTBOX Controller for the HONEYWELL Wind Turbine WT6500 is manufactured by WindTronics Inc Please contact WindTronics Inc at 621 Sprucewood Avenue Windsor Ontario N9C 0B3 877 946 3898 The Honeywell Trademark is used under license from Honeywell International Inc Honeywell International Inc makes no representations or warranties with respect to this product SMARTBOX Controller for HONEYWELL Wind Turbine WT6500 Owner s Manual Rev14 Safety Instructions V E SS SMARTBOX Controller for HONEYWELL Wind Turbine WT6500 Owner s Manual Rev14 VI Table of Contents Table of Contents Safety 5 1 Introduction SMARTBOX Controller eene nnne 2 Major System Components 2 Parts iecit so peas Gn On O NER O 2 2 nnne ahhh nnne rrr 3 Baten NW lj 3 Amp hour Ratings raise uo yny Wu Y LL 4 DST FSG SCI
45. ut most are a hybrid type Hybrid types should not be discharged more than 5090 Since starting batteries are usually rated as either cold cranking amps or CCA or marine cranking amps or the same as cranking amps or CA any battery with the capacity shown in CA or MCA may not be a true deep cycle battery It is sometimes hard to tell as the terms marine and deep cycle are sometimes overused CA and MCA ratings are at 32 degrees F while CCA is at 0 degrees F We only recommend using TWO 12V 100Ah flooded deep cycle marine grade batteries Deep Cycle batteries are designed to be discharged down as much as 80 time after time and have much thicker plates The major difference between a true deep cycle battery and others is that the plates are SOLID Lead plates not sponge SMARTBOX Controller for HONEYWELL Wind Turbine WT6500 Owner s Manual Rev14 Introduction 4 The popular golf cart battery is generally a semi deep cycle better than any starting battery better than most marine but not as good as a true deep cycle solid lead plate such the L 16 or industrial type Amp hour Ratings All deep cycle batteries are rated in amp hours An amp hour Ah is a unit of electric charge measurement calculated by multiplying amps by hours For example if you have a device that pulls 20 amps and you use it for 20 minutes then the amp hours used would be 20 amps multipl
46. ximum output fault current ac for 3 minutes 14 5A 3 min Amps AC Maximum output overcurrent protection ac 20 Amps AC Charge Nominal output voltage dc 24 Volts DC Charger output voltage operation range dc 12 30 Volts DC Maximum continuous output current dc 60 Amps DC Maximum continuous output power dc 1500 Watts DC Maximum output current dc 60 Amps DC Maximum output fault current dc 62 Amps DC Environment 60 Hz 0 05 Normal operation temperature range 0 40 Deg C Storage temperature range 30 70 Deg C Other GFI Trip 0 5 Amps Operating Power 3 5 Watts Output Waveform Pure Sine THD gt 3 Inverter Efficiency 94 00 Changer Efficiency gt 90 Charger regulation method Three Stage bulk absorption float Manufacturer reserves the right without notice or liability to change design and specifications at any time DATA SUBJECT TO CHANGE WITHOUT NOTICE SMARTBOX Controller for HONEYWELL Wind Turbine WT6500 Owner s Manual Rev14 The Honeywell Trademark is used under license from Honeywell International Inc and makes no representations or warranties with respect to this product WindTronics Honeywell International Inc 621 Sprucewood Avenue Windsor Ontario N9C OB3 Tell 877 946 3898 www honeywell com Honeywell
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