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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.
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II 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, personal injury or property damage. CAUTION indicates a hazard that could result in prop
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Safety Instructions III LIMITATIONS ON USE 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 safety: • electrical shock • burn from high-short-circuit current • fire or explosion from vented gasses Observe proper precautions when working with or around batteries. • Always wear eye protection, such as safety glasses, when working
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IV Safety Instructions The 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
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Safety Instructions V SMARTBOX™ Controller for HONEYWELL™ Wind Turbine WT6500 Owner’s Manual - Rev14
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VI Table of Contents Table of Contents II Safety Instructions....................................................... 1. Introduction The SMARTBOX™ Controller................................................... 2 Major System Components.................................................... 2 Parts Inspection................................................................... 2 Battery Overview..................................................................... 3 Battery Types........................
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Table of Contents VII 3. Commisioning Commissioning Process......................................................... 24 4. Operation Introduction............................................................................. 28 Turbine Operating States....................................................... 28 Starting/Stopping Turbine....................................................... 28 Viewing Operating Status....................................................... 28 Controller Energy Consum
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1 Introduction Introduction 1 Chapter 1 describes the SMARTBOX™ Controller with battery overview and selection details. 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
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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 interc
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3 Introduction Battery Overview Battery Types Batteries are classified in two dif ferent ways: by application (their 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. 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
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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-hour
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5 Introduction • Water pumps can be add to the panel, but the pump must be rated at 120 VAC. • Typically, 1500W can handle all the lighting and some appliances. • 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 requirements: Recommended Appliances Appliance Wattage Notes Clock radio 10 Electric blanket 60 / 100 Single/D
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Introduction 6 • Refrigerator (frost-free, 16 cubic feet) = 725 • Toaster = 800–1400 • Toaster oven = 1225 • Vacuum cleaner = 1000–1440 • Water heater (40 gallon) = 4500–5500 • Water bed (with heater, no cover) = 120–380 SMARTBOX™ Controller for HONEYWELL™ Wind Turbine WT6500 Owner’s Manual - Rev14
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7 SMARTBOX Installation SMARTBOX™ Controller 2 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
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SMARTBOX Installation 8 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 WindT ronics certified dealer. PROFESSIONAL INSTALLATION: Installation must be compliant with all local electrical codes. Installation of this equipment should only be performed by a qualified electrician or by a Certified Renewable Energy Syste
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9 SMARTBOX Installation SMARTBOX™ Controller Diagram CHARGER DSP CONTROL INVERTER OVP CHARGE CONTOL AC TRANSFER SWITCH IO BOARD CURRENT/ CURRENT/ CURRENT/ CURRENT/ VOLTAGE VOLTAGE VOLTAGE VOLTAGE SENSING SENSING SENSING SENSING SYSTEM POWER DC GFI ISOLATED LOGIC CONTROL EQUIPMENT GROUND WIND TURBINE 24V TURBINE RS485 AC OUT AC GRID HV POWER BATTERY LOGIC INPUT BANK CONTROL FROM TURBINE Figure 2.2 SMARTBOX™ Controller Diagram Mounting The SMARTBOX™ Controller must be mounted vertically and insta
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SMARTBOX Installation 10 Minimum Clearance for Proper Mounting allow for at least 150 mm (6 in) clearance. 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 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
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11 SMARTBOX Installation Grounding The SMARTBOX™ Controller is designed to work only with the HONEYWELL™ Wind Turbine. The turbine uses a negative-grounded electrical 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-faul
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SMARTBOX Installation 12 Wiring Diagram Figure 2.4 Wiring Diagram SMARTBOX™ Controller for HONEYWELL™ Wind Turbine WT6500 Owner’s Manual - Rev14 TURBINE POLES TURBINE TO CONTROLLER WIRE SIZE CHART TURBINE WIRE MAX DISTANCE (FT) EMT CONDUIT (INCH) #10 (#6 GND) 150 3/4 #8 (#4 GND) 200 1 #4 GND EARTH GROUND STAKE TURBINE JUNCTION BOX TURBINE SMARTBOX™ Controller AC IN CAT5E or CAT6 (2) #12 THWN-2 (2) #12 THWN-2 + #6 GND + #6 GND ¾” CONDUIT ¾” CONDUIT (2) #4 THWN-2 + #4 GND 1” CONDUIT L1 N GND M
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13 SMARTBOX Installation 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 recommended 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 1
