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 [email protected].
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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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 with batteries.
Remove all jewelry before working with batteries.
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.
Never install old or untested batteries. Check each battery’s date code or label to
ensure age and type.
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.
•
•
•
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.
In 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.
Always recycle old batteries. 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.
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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.
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Safety Instructions
V
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VI
Table of Contents
Table of Contents
II
Safety Instructions.......................................................
1. Introduction
The SMARTBOX™ Controller...................................................
Major System Components....................................................
Parts Inspection...................................................................
BatteryOverview.....................................................................
Battery Types......................................................................
Amp-hour Ratings................................................................
Battery Selection....................................................................
AC Load Detail and Selection................................................
2
2
2
3
3
4
4
4
2. SMARTBOX™ Controller Installation
System Diagrams...................................................................
Turbine Block Diagram..........................................................
SMARTBOX Controller™ Diagram..........................................
Mounting.................................................................................
Minimum Clearance for Proper Mounting..................................
Grounding...............................................................................
Wiring......................................................................................
WiringDiagram....................................................................
Turbine Wiring and Distances.................................................
Turbine Current Rating and Wiring...........................................
Turbine Over-current Protection..............................................
BatteryWiring......................................................................
Battery Over-current Protection...............................................
AC Input Wiring...................................................................
AC Output Wiring.................................................................
AC Output Over-current Protection..........................................
Control Wiring.....................................................................
Enclosure Internal Wiring.......................................................
Battery Setup..........................................................................
Battery Setup Chart..............................................................
Connecting the SMARTBOX™ Controller.............................
8
8
9
9
10
11
11
12
13
13
14
15
16
17
17
18
19
20
20
20
20
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Table of Contents
VII
3. Commisioning
Commissioning Process.........................................................
24
4. Operation
Introduction.............................................................................
Turbine Operating States.......................................................
Starting/Stopping Turbine.......................................................
Viewing Operating Status.......................................................
Controller Energy Consumption States.....................................
Turbine Operating States.......................................................
System Protection..................................................................
System Faults.........................................................................
SMARTBOX™ Controller Front Panel...................................
Navigation Buttons...............................................................
System Menu and Navigation.................................................
Operations Menu............................................................
Technician Menu............................................................
View Data Menu.............................................................
Battery Setup Menu.........................................................
28
28
28
28
29
29
30
31
32
32
32
32
33
34
35
5. Specifications
Non Grid-tie SMARTBOX™ Electrical Specifications............
38
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1
Introduction
Introduction
1
Chapter 1 describes the SMARTBOX™ Controller with battery
overview and selection details.
For Information On:
The SMARTBOX™ Controller
Battery Overview
See:
page 2
page 3
page 4
page 4
Battery Selection
AC Load Detail and Selection
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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 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 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 N9C0B3
Canada
1-877-946-3898
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3
Introduction
Battery Overview
Battery Types
Batteries are classified in two different 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 fiberglass mat is only 95% saturated
with sulfuric acid and there is no excess liquid. Flooded batteries may
be standard, 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.
Not to be used
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
quickly 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).
Minimum to be used
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, but most are a hybrid type. Hybrid types
should not be discharged more than 50%.
Since starting batteries are usually rated as either cold cranking amps (or “CCA”)
or marine cranking amps (or “MCA”), 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.
Recommended
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.
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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-hours
used would be 20 (amps) multiplied 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 (2-5% 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 50%. Any battery rated in CCA or
CA should not be used. Since some marine batteries 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 “on” time wattage required by all appliances
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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
Clock radio
Wattage
10
Notes
Electric blanket
Fans:
60 / 100
Single/Double
Ceiling
65 - 175
55 - 250
Window
Energy Star Furnace:
NO AC
100 - 750
10 - 150
200 for a 2500 sq/ft home
Lights
Add total wattage of each lights on panel
Personal computer:
CPU - awake / asleep
Monitor - awake / asleep
Laptop
120 / 30
150 / 30
50
Radio (stereo)
Televisions
70 - 400
65 - 170
17 - 25
VCR/DVD
Water pump
250 - 1100
Figure 1.1 Recommended Appliances
NOT Recommended
•
•
•
•
•
Air conditioner = 1000-3000
Coffee maker = 900–1200
Clothes washer = 350–500
Clothes dryer = 1800–5000
Dishwasher = 1200–2400 (using the drying feature greatly increases energy
consumption)
•
•
•
•
•
Dehumidifier = 785
Hair dryer = 1200–1875
Heater (portable) = 750–1500
Clothes iron = 1000–1800
Microwave oven = 750–1100
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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
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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:
System Diagrams
Mounting
See:
page 8
page 9
page 11
page 11
page 20
page 20
Grounding
Wiring
Battery Setup
Connecting the SMARTBOX™
Controller
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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 WindTronics 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 System Installer.
Turbine Block Diagram
WIND
GENERATOR
WIND
SPEED
WIND
DIRECTION
DUMP LOAD
JUNCTION BOX
INTERFACE PCB
DIVERSION
LOAD
CONTROL
OVP
LOGIC
CONTROL
WIND
TURBINE
HV POWER
OUTPUT
TO SMARTBOX™
Controller
Figure 2.1 Turbine Block Diagram
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9
SMARTBOX Installation
SMARTBOX™ Controller Diagram
CHARGER
DSP CONTROL
INVERTER
OVP
CHARGE
CONTOL
AC
TRANSFER
SWITCH
IO BOARD
CURRENT/
VOLTAGE
SENSING
CURRENT/
VOLTAGE
SENSING
CURRENT/
VOLTAGE
SENSING
CURRENT/
VOLTAGE
SENSING
SYSTEM
POWER
DC
GFI
ISOLATED
LOGIC
CONTROL
EQUIPMENT
GROUND
WIND TURBINE
HV POWER
INPUT
24V
BATTERY
BANK
TURBINE
LOGIC
CONTROL
RS485 AC OUT
AC GRID
FROM TURBINE
Figure 2.2 SMARTBOX™ Controller Diagram
Mounting
The SMARTBOX™ Controller must be mounted vertically and installed indoors in a
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
To reduce the risk of fire or explosion, do not install
the SMARTBOX™ Controller in sealed compartments
containgin batteries or in locations that require ignition-
protected equipment. Failure to follow this warning may
result in death, personal injury or property damage.
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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
300 mm (12 in)
clearance.
allow for at least
300 mm (12 in)
clearance.
allow for at least
508 mm (20 in)
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 shock hazard.
EXPLOSION/CORROSION DAMAGE
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.
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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-fault
protection. Only a Littelfuse 0312.500HXP or equivalent fuse should be used as a
replacement.
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 the unit. Failure to follow this
warning may result in death, personal injury or property
damage.
Wiring
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.
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.
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SMARTBOX Installation
12
Wiring Diagram
G R O
T H G R / W O
L U B
H T W L U B /
R N B
H T W R N B /
N R G
H T W N R / G
R G O
H T W R G O /
L U B
H T W L U B /
R N B
T H / W N R B
R N G
H T W R N G /
Figure 2.4
Wiring Diagram
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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 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.
Figure 2.5 Turbine Connection Location
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SMARTBOX Installation
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.
REVERSE POLARITY DAMAGE
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
TURBINE TO CONTROLLER WIRE SIZE CHART
TURBINE WIRE
#10 (#6 GND)
#8 (#4 GND)
MAX DISTANCE (FT)
EMT CONDUIT (INCH)
150
200
3/4
1
#4 GND
EARTH
GROUND
STAKE
TURBINE JUNCTION BOX
(2) #10 THWN-2 + #6 GND
¾” CONDUIT
MAX DISTANCE 3 FEET.
SEE TURBINE TO CONTROLLER SIZE
CHART ON SHEET 1
Figure 2.6 Turbine Circuit Diagram
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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.
Figure 2.7 Battery Connection Location
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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
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
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
(2) #4 THWN-2 + #4 GND
1” CONDUIT
MAX DISTANCE 6 FEET.
12V
12V
12V
12V
12V
12V
OPTIONAL
Figure 2.8 Battery Circuit Diagram
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SMARTBOX Installation
AC Input Wiring
The AC input current is rated at 15 amps. Use standard NEC calculations and local
codes for proper wiring.
Figure 2.9 AC 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.
Figure 2.10 AC Output Current Rating Diagram
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SMARTBOX Installation
18
AC Output Over-current Protection
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 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
AC IN
(2) #12 THWN-2
+ #6 GND
(2) #12 THWN-2
+ #6 GND
¾” CONDUIT
¾” CONDUIT
L1
N
GND
15 AMP FUSE OR
BREAKER
AC INPUT
FROM MAIN SWITCH
BOARD
SINGLE PHASE
120V 15AMP
L1
N
GND
AC OUTPUT
TO SUB SWITCH
Figure 2.11 AC Circuit Diagram
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SMARTBOX Installation
Control Wiring
Control wiring can use stranded CAT5, CAT6 or equivalent wire.
O R G
H T W O R G /
B L U
/ W U H B T L
N R B
H T W N R / B
G R N
/ W N H T G R
R G O
T H
R G O / W
L U B
H T W L U B /
R N B
/ W N H R B T
R N G
H T W R N G /
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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
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 installer 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
GEL
AGM
Flooded
Sets the battery type and automati-
cally set the default values below
based on that type
Battery Banks
Capacity
1-6
1
Sets the number of 24V paralleled
battery banks connected
50-500
20.0-27.0 V
100 Ah
22 V
Sets the amp-hour rating of ONE
battery
Recharge Voltage
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
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
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 property damage.
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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
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
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
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 turbine control wiring diagram on page 19;
Figure 2.12.
7. Run battery wiring. Reference the battery wiring diagram on page 15; Figure 2.7.
8. 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.
REVERSE POLARITY DAMAGE
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.
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SMARTBOX Installation
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Commissioning
Commissioning
3
Chapter 3 describes the step by step process of commissioning the
SMARTBOX™ Controller.
For Information on:
See:
Commissioning Process
page 24
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Commissioning
24
Commissioning Process
EXPLOSION OR FIRE HAZARD
Entering battery information incorrectly may result in
explosion or fire.
During commissioning, the SMARTBOX™ Controller and turbine must be set up.
Settings 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. Check 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
FIRST POWER UP
The Smart Box will display this for
5 seconds and then move to the
required 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 process. 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
Flooded
ENTER BATTERY TYPE
FLOODED
Set the battery type
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Commissioning
6. Select the battery Amp-hour rating for ONE battery by using the arrow keys. Press
ENTER when finished.
Display
Description
Set the battery amp-hour rating Enter 140 for 100Ahr
for ONE battery batteries
Optimal
ENTER BATTERY AHr 100
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 Enter 3 for one bank of
2-12V batteries
8. At this 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 testing 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
to skip this step if this is a non-grid-tie
connection.
AC Grid 120V OK??
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.
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Commissioning
26
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Operation
Operation
4
Chapter 4 is an overview of SMARTBOX™ Controller operation including
operating states, system faults and menu structures.
For Information on:
Introduction
See:
page 28
page 28
page 28
page 28
page 30
page 31
page 32
Turbine Operating States
Starting/Stopping Turbine
Viewing Operating Status
System Protection
System Faults
SMARTBOX™ Controller Front
Panel
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Operation
28
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 charging the
batteries
Bulk Charge
Absorption Charge
On
On
Off
Off
Grid
On*
Absorption charging
the batteries
Grid
On*
Float charging the
batteries
Float Charge
Fault Stop
User Stop
On
Off
Off
On
Off
Off
Turbine
Grid
On*
On
On
Turbine fault exists
Turbine stopped by
user
Grid
* 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
UP=STOP DWN=RUN
Press UP to stop the turbine. Press DOWN to start
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 SMARTBOX™
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.
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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 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
Displays the charger operating state:
Charge is in bulk charge stage
ABSORPTION
FLOAT/READY
STOPPED
FAULT
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
Displays the turbine operating state:
Stopped State
RUN NO WIND
RUN WIND
FAULT STOP
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
Displays the transfer switch location:
AC output is connected to grid
AC TURBINE
FAULT
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 SPEED
Displays measured wind speed
Display - Display Off
Description
TURBINE RUNNING
PRESS ANY KEY
Turbine is running with no faults. Back light is off
with no information scroll.
Figure 4.2 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
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Operation
30
the energy consumption state (see the Fault and Troubleshooting section for complete
details):
Display- Display State
Description
TURBINE FAULT
GFI
Turbine is stopped and contains a GFI fault.
TURBINE FAULT
NO WIND SPEED
Voltage sensed but Anemometer not sensing wind
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
NO TURBINE
Anemometer is sensing wind speed but there is no
voltage sensed.
TURBINE FAULT
LOW BATT
Turbine is stopped and contains a low battery fault.
TURBINE FAULT
HIGH BATT
Turbine is stopped and contains a high battery fault.
TURBINE FAULT
OVER TEMP
Turbine is stopped and contains an over temperature
fault.
TURBINE FAULT
CHARGE OVER CURRENT
Turbine is stopped and contains an over current fault.
See Figure 4.4
TURBINE FAULT
INVERTER NO OUTPUT
TURBINE FAULT
INVERTER OVER
CURRENT
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
PRESS ANY KEY
Turbine is stopped with no faults. Back light is off with
no information scroll.
System Protection
•
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.
•
Over Wind Speed
The turbine will turn off when wind speed reaches 42mph or higher. It will resume
working after the wind speed drops to 35mph or lower.
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Operation
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
Turbine Voltage > 40
VDC and Wind Speed <
1 MPH for 1 minute
Voltage from Turbine but
no data from anemometer
NO WINDSPEED
TURBINE OVER CUR-
RENT
Current from turbine > 18
Amps
Turbine over current
Voltage from turbine >
190 VDC
TURBINE OVER VOLTAGE Turbine over voltage
Anemometer reporting
Turbine Voltage < 5 VDC
NO TURBINE
windspeed but no voltage and WindSpeed > 10
from wind turbine.
Battery too low
Battery too high
MPH for 1 minute
Battery Voltage < 15 VDC
for 1 minute
LOW BATTERY
HIGH BATTERY
OVER TEMP
Battery Voltage > 32 VDC
Enclosure or Heat Sink
over temp
Enclosure > 65°C or Heat
Sink > 140°C
Current to batteries over
limit
Charge current > 66
Amps
CHARGE OVER CURRENT
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
Inverter AC Current >
14.5 Amps for 3 minutes
Figure 4.4 Non-Grid-Tie SmartBox Specifications
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Operation
32
SMARTBOX™ Controller Front Panel
.TECHNICIAN
..BATTERY SETUP
BACK
UP
DOWN
ENTER
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 will 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
1
2
DEFAULT DISPLAY
WHEN RUNNING
DEFAULT DISPLAY
DISPLAY SLEEPING
WINDTRONICS rx.xx
Charge Status
Turbine Status
AC Status
Turbine Power
Production
TURBINE RUNNING
PRESS ANY KEY
Or
TURBINE STOPPED
PRESS ANY KEY
Or
ANY
KEY
Wind Speed
TURBINE FAULT
15 SEC
TIMEOUT
UP/DOWN
3
3
MAIN MENU
.TECHNICIAN ?
TECHNICIAN
MENU
ENTER/BACK
UP/DOWN
UP/DOWN
4
MAIN MENU
.STOP/START TURBINE ?
.STOP/START TURBINE ?
UP=STOP DWN=START
ENTER/BACK
Figure 4.5 System Menu
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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 go 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
1
.TECHNICIAN
..FORCE CHARGE ?
..FORCE CHARGE
UP=START
ENTER/BACK
ENTER/BACK
UP/DWN
2
3
4
5
.TECHNICIAN
..FORCE AC ?
..START CHARGE
UP=START
UP/DWN
.TECHNICIAN
..CLEAR PRODUCTION ?
..CLEAR PRODUCTION
UP/HOLD=CLEAR
ENTER/BACK
ENTER/BACK
ENTER/BACK
UP/DWN
UP/DWN
.TECHNICIAN
..VIEW DATA ?
VIEW DATA
MENU
UP/DWN
.TECHNICIAN
..BATTERY SETUP ?
BATTERY SETUP
MENU
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.
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View Data Menu
1
2
3
4
5
.VIEW-TURBINE INPUT
V=100 I=4 P=400
UP/DWN
.VIEW-BATTERY CHARGE
V=27.2 I=2 P=54.4
UP/DWN
.VIEW-INVERTER
V=27.2 I=0 P=0
UP/DWN
.VIEW-AC OUTPUT
V=120 I=0 P=0
UP/DWN
UP/DWN
.VIEW-ENVIRONMENT
ws=5 wd=16
UP/DWN
6
7
.VIEW-TEMPERATURE
Te=30 Tc=35 Ti=0
UP/DWN
.VIEW-WS POWER
ws=10 P=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 0. 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.
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Operation
Battery Setup Menu
RISK OF FIRE OR EXPLOSION
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.
1
2
3
4
5
..BATTERY SETUP
...TYPE ?
..BATTERY SETUP
ENTER/BACK
Type=FLOODED
UP/DWN
..BATTERY SETUP
...AHr ?
..BATTERY SETUP
ENTER/BACK
AHr=100
UP/DWN
..BATTERY SETUP
...BANKS ?
..BATTERY SETUP
UP/DWN
ENTER/BACK
Banks=1
UP/DWN
..BATTERY SETUP
...RECHARGE VOLTAGE ?
..BATTERY SETUP
ENTER/BACK
Voltage=23.0
UP/DWN
..BATTERY SETUP
...RE-COMMISSION ?
..BATTERY SETUP
ENTER/BACK
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 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.
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Specifications
Specifications
5
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Specifications
38
Non Grid-Tie Smart Box Electrical Specifications
Description
Rating
Units
Input
Maximum Turbine Voltage
Operating input voltage range
Maximum input current
Maximum input short circuit current
200
30-170
18
Volts DC
Volts DC
Amps DC
Amps DC
20
Inverter
Operating voltage range
120VAC+/-3%
Volts AC
Hz
Operating frequency range or single frequency
Nominal output voltage (ac)
60Hz+/-0.05%
120
Volts AC
Hz
Nominal output frequency
60
Maximum continuous output current
Maximum continuous output power (ac)
Maximum output fault current (ac) for 3 minutes
Maximum output overcurrent protection (ac)
12.5
Amps AC
VA
1500
14.5A / 3 min
20
Amps AC
Amps AC
Charge
Nominal output voltage (dc)
24
Volts DC
Charger output voltage operation range (dc)
Maximum continuous output current (dc)
Maximum continuous output power (dc)
Maximum output current (dc)
12-30
60
Volts DC
Amps DC
Watts DC
Amps DC
Amps DC
1500
60
Maximum output fault current (dc)
62
Environment
60
Hz +/- 0.05%
Deg C
Normal operation temperature range
Storage temperature range
0 - 40
-30 - 70
Deg C
Other
GFI Trip
0.5
Amps
Operating Power
Output Waveform
Inverter Efficiency
Changer Efficiency
Charger regulation method
<3.5
Watts
Pure Sine
THD > 3%
94.00%
>90%
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
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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 0B3
Tell: 877-946-3898
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