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Honeywell wt6500 manual

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Table of contents for the manual

  • Page 1

    SMARTBOX ™ CONTROLLER for HONEYWELL ™ Wind T urbine Model WT6500 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@WindT ronics.com. The HONEYWELL™ trademark is used under license from Honeywell In[...]

  • Page 2

    II Safety Instructions SMARTBOX ™ Contr oller for HONEYWELL ™ W ind T urbine WT6500 Owner’ s Manual - Rev14 Safety Instructions PLEASE READ THESE INSTRUCTIONS AND THE ENTIRE MANUAL PRIOR TO INST ALLA TION. Safety Icons The following symbols identify dangers associated with the installation, use or ownership of the SMARTBOX ™ Controller . Wh[...]

  • Page 3

    III SMARTBOX ™ Contr oller for HONEYWELL ™ W ind T urbine WT6500 Owner’ s Manual - Rev14 Safety Instructions LIMIT A TIONS 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 [...]

  • Page 4

    IV Safety Instructions SMARTBOX ™ Contr oller for HONEYWELL ™ W ind T urbine WT6500 Owner’ s Manual - Rev14 The SMARTBOX ™ Controller for the HONEYWELL ™ Wind T urbine WT6500 is manufactured by WindT ronics Inc. Please contact WindT ronics Inc. at: 621 Sprucewood Avenue Windsor , Ontario N9C 0B3 877-946-3898 The Honeywell T rademark is us[...]

  • Page 5

    V SMARTBOX ™ Contr oller for HONEYWELL ™ W ind T urbine WT6500 Owner’ s Manual - Rev14 Safety Instructions[...]

  • Page 6

    VI T able of Contents SMARTBOX ™ Contr oller for HONEYWELL ™ W ind T urbine WT6500 Owner’ s Manual - Rev14 T able of Contents Safety Instructions ....................................................... II 1. Introduction The SMARTBOX ™ Controller ................................. .................. 2 Major System Components ................[...]

  • Page 7

    VII SMARTBOX ™ Contr oller for HONEYWELL ™ W ind T urbine WT6500 Owner’ s Manual - Rev14 T able of Contents 3. Commisioning Commissioning Process......................................................... 24 4. Operation Introduction............................................................................. 28 T urbine Operating States.......[...]

  • Page 8

    1 Introduction SMARTBOX ™ Contr oller for HONEYWELL ™ W ind T urbine WT6500 Owner’ s Manual - Rev14 Introduction 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 9

    2 SMARTBOX ™ Contr oller for HONEYWELL ™ W ind T urbine WT6500 Owner’ s Manual - Rev14 Introduction The SMARTBOX™ Controller The SMARTBOX ™ Controller is a proprietary WindT ronics 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 swit[...]

  • Page 10

    3 Introduction SMARTBOX ™ Contr oller for HONEYWELL ™ W ind T urbine WT6500 Owner’ s Manual - Rev14 Battery Overview Battery T ypes Batteriesareclassied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 inc[...]

  • Page 11

    4 SMARTBOX ™ Contr oller for HONEYWELL ™ W ind T urbine WT6500 Owner’ s Manual - Rev14 Introduction 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 [...]

  • Page 12

    5 Introduction SMARTBOX ™ Contr oller for HONEYWELL ™ W ind T urbine WT6500 Owner’ s Manual - Rev14 • W ater pumps can be add to the panel, but the pump must be rated at 120 V AC. • T ypically , 1500W can handle all the lighting and some appliances. • Y ou may want to mark wall plugs in the home to indicate that the plug is on [...]

  • Page 13

    6 SMARTBOX ™ Contr oller for HONEYWELL ™ W ind T urbine WT6500 Owner’ s Manual - Rev14 Introduction • Refrigerator (frost-free, 16 cubic feet) = 725 • T oaster = 800–1400 • T oaster oven = 1225 • V acuum cleaner = 1000–1440 • W ater heater (40 gallon) = 4500–5500 • W ater bed (with heater , no cover) = 120?[...]

  • Page 14

    7 SMARTBOX Installation SMARTBOX ™ Contr oller for HONEYWELL ™ W ind T urbine WT6500 Owner’ s Manual - Rev14 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 1 1 Wiring page[...]

  • Page 15

    8 SMARTBOX ™ Contr oller for HONEYWELL ™ W ind T urbine 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specicapplication.Forspecial applications,consultaqualied?[...]

  • Page 16

    9 SMARTBOX Installation SMARTBOX ™ Contr oller for HONEYWELL ™ W ind T urbine WT6500 Owner’ s Manual - Rev14 SMARTBOX™ Controller Diagram DC GFI WIND TURBINE HV POWER INPUT CHARGE CONTOL CURRENT/ VOLTAGE SENSING CURRENT/ VOLTAGE SENSING CURRENT/ VOLTAGE SENSING CURRENT/ VOLTAGE SENSING OVP AC TRANSFER SWITCH SYSTEM POWER ISOLATED LOGIC CONT[...]

  • Page 17

    10 SMARTBOX ™ Contr oller for HONEYWELL ™ W ind T urbine WT6500 Owner’ s Manual - Rev14 SMARTBOX Installation Minimum Clearance for Proper Mounting allow for at least 150 mm (6 in) clearance. 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[...]

  • Page 18

    11 SMARTBOX Installation SMARTBOX ™ Contr oller for HONEYWELL ™ W ind T urbine WT6500 Owner’ s Manual - Rev14 Grounding The SMARTBOX ™ Controller is designed to work only with the HONEYWELL ™ Wind T urbine. The turbine uses a negative-grounded electrical system. Grounding for the turbine, battery and AC circuits are provided inside the wi[...]

  • Page 19

    12 SMARTBOX ™ Contr oller for HONEYWELL ™ W ind T urbine WT6500 Owner’ s Manual - Rev14 SMARTBOX Installation TURBINE JUN CTION BOX EARTH GROUND STAKE AC IN TURBINE SM ARTBO X™ Controller 12V 12V 12V 12V 12V 12V OPT IO NAL TURBINE POLES L1 N GND AC OUTPUT TO SUB SW ITCH BOARD SINGLE PHASE 120V 15AMP L1 N GND AC INPUT FROM MAIN SW ITCH BOARD[...]

  • Page 20

    13 SMARTBOX Installation SMARTBOX ™ Contr oller for HONEYWELL ™ W ind T urbine WT6500 Owner’ s Manual - Rev14 T urbine W iring and Distances The HONEYWELL™ Wind T urbine 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[...]

  • Page 21

    14 SMARTBOX ™ Contr oller for HONEYWELL ™ W ind T urbine WT6500 Owner’ s Manual - Rev14 SMARTBOX Installation T urbine 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[...]

  • Page 22

    15 SMARTBOX Installation SMARTBOX ™ Contr oller for HONEYWELL ™ W ind T urbine WT6500 Owner’ s Manual - Rev14 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 A WG USE-2/RHW-2 or THWN-2, 90 degrees C wire for a SMARTBOX™ Controller-to-battery-enclosu[...]

  • Page 23

    16 SMARTBOX ™ Contr oller for HONEYWELL ™ W ind T urbine WT6500 Owner’ s Manual - Rev14 SMARTBOX Installation 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 batter[...]

  • Page 24

    17 SMARTBOX Installation SMARTBOX ™ Contr oller for HONEYWELL ™ W ind T urbine WT6500 Owner’ s Manual - Rev14 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 stan[...]

  • Page 25

    18 SMARTBOX ™ Contr oller for HONEYWELL ™ W ind T urbine WT6500 Owner’ s Manual - Rev14 SMARTBOX Installation 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 b[...]

  • Page 26

    19 SMARTBOX Installation SMARTBOX ™ Contr oller for HONEYWELL ™ W ind T urbine WT6500 Owner’ s Manual - Rev14 Control Wiring Control wiring can use stranded CA T5, CA T6 or equivalent wire. JUNC TION BOX TUR BINE SMARTBOX ™ Controller CAT 5E o r CAT6 GRN/WHT GRN BRN/W HT BRN BLU/WHT BLU ORG/WHT ORG GRN/W HT GRN BRN /WHT BRN BLU/W HT BLU ORG[...]

  • Page 27

    20 SMARTBOX ™ Contr oller for HONEYWELL ™ W ind T urbine WT6500 Owner’ s Manual - Rev14 SMARTBOX Installation 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[...]

  • Page 28

    21 SMARTBOX Installation SMARTBOX ™ Contr oller for HONEYWELL ™ W ind T urbine WT6500 Owner’ s Manual - Rev14 T o 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 [...]

  • Page 29

    22 SMARTBOX ™ Contr oller for HONEYWELL ™ W ind T urbine WT6500 Owner’ s Manual - Rev14 SMARTBOX Installation[...]

  • Page 30

    23 Commissioning SMARTBOX ™ Contr oller for HONEYWELL ™ W ind T urbine WT6500 Owner’ s Manual - Rev14 Commissioning Chapter 3 describes the step by step process of commissioning the SMARTBOX ™ Controller . For Information on: See: Commissioning Process page 24 3[...]

  • Page 31

    24 SMARTBOX ™ Contr oller for HONEYWELL ™ W ind T urbine WT6500 Owner’ s Manual - Rev14 Commissioning Commissioning Process EXPLOSION OR FIRE HAZARD Entering battery information incorrectly may result in explosionorre. During commissioning, the SMARTBOX™ Controller and turbine must be set up. Settings for the battery type, battery [...]

  • Page 32

    25 Commissioning SMARTBOX ™ Contr oller for HONEYWELL ™ W ind T urbine WT6500 Owner’ s Manual - Rev14 6. Select the battery Amp-hour rating for ONE battery by using the arrow keys. Press ENTERwhennished. Display Description Optimal ENTER BA TTERY AHr 100 Set the battery amp-hour rating for ONE battery Enter 140 for 100Ahr batteries 7[...]

  • Page 33

    26 SMARTBOX ™ Contr oller for HONEYWELL ™ W ind T urbine WT6500 Owner’ s Manual - Rev14 Commissioning[...]

  • Page 34

    27 Operation SMARTBOX ™ Contr oller for HONEYWELL ™ W ind T urbine WT6500 Owner’ s Manual - Rev14 Operation Chapter 4 is an overview of SMARTBOX™ Controller operation including operating states, system faults and menu structures. For Information on: See: Introduction page 28 T urbine Operating States page 28 Starting/Stopping T urbine page [...]

  • Page 35

    28 SMARTBOX ™ Contr oller for HONEYWELL ™ W ind T urbine WT6500 Owner’ s Manual - Rev14 Operation Introduction The basic operation of the turbine/ SMARTBOX ™ Controller electronic system is to optimizetheefcientutilizationoftheenergycapturedfromthewind.Lowwindenergy is stored in batteries while l[...]

  • Page 36

    29 Operation SMARTBOX ™ Contr oller for HONEYWELL ™ W ind T urbine WT6500 Owner’ s Manual - Rev14 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[...]

  • Page 37

    30 SMARTBOX ™ Contr oller for HONEYWELL ™ W ind T urbine WT6500 Owner’ s Manual - Rev14 Operation the energy consumption state (see the Fault and T roubleshooting section for complete details): Display- Display State Description TURBINE F AUL T GFI T urbine is stopped and contains a GFI fault. TURBINE F AUL T NO WIND SPEED V oltage sensed but[...]

  • Page 38

    31 Operation SMARTBOX ™ Contr oller for HONEYWELL ™ W ind T urbine WT6500 Owner’ s Manual - Rev14 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. “TU[...]

  • Page 39

    32 SMARTBOX ™ Contr oller for HONEYWELL ™ W ind T urbine WT6500 Owner’ s Manual - Rev14 Operation SMARTBOX™ Controller Front Panel BACK UP DOWN ENTER .TECHNICIAN ..BA TTERY SE TUP 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 ch[...]

  • Page 40

    33 Operation SMARTBOX ™ Contr oller for HONEYWELL ™ W ind T urbine WT6500 Owner’ s Manual - Rev14 1. This is the home screen. The SMARTBOX™ Controller will scroll the listed informationwhileinrunmodeandalsothecurrentrmwarerevision. 2. T urbine Fault Stop. Indicates if a fault has occurred. 3. This is the top[...]

  • Page 41

    34 SMARTBOX ™ Contr oller for HONEYWELL ™ W ind T urbine WT6500 Owner’ s Manual - Rev14 Operation View Data Menu .VIEW-TURBINE INPUT V=100 I=4 P=400 .VIEW-BATTERY CHARGE V=27.2 I=2 P=54.4 .VIEW-INVERTER V=27.2 I=0 P=0 .VIEW-AC OUTPUT V=120 I=0 P=0 .VIEW-ENVIRONMENT ws=5 wd=16 .VIEW-TEMPERATURE Te=30 Tc=35 Ti=0 .VIEW-WS POWER ws=10 P=400 E=34 [...]

  • Page 42

    35 Operation SMARTBOX ™ Contr oller for HONEYWELL ™ W ind T urbine WT6500 Owner’ s Manual - Rev14 Battery Setup Menu RISK OF FIRE OR EXPLOSION These settings must be followed correctly . Setting them incorrectlywillhighlyincreasetheriskofreand/orbattery explosion. Failure to follow this warning may result in d[...]

  • Page 43

    36 SMARTBOX ™ Contr oller for HONEYWELL ™ W ind T urbine WT6500 Owner’ s Manual - Rev14 Operation[...]

  • Page 44

    37 Specications SMARTBOX ™ Contr oller for HONEYWELL ™ W ind T urbine WT6500 Owner’ s Manual - Rev14 Specications 5[...]

  • Page 45

    38 SMARTBOX ™ Contr oller for HONEYWELL ™ W ind T urbine WT6500 Owner’ s Manual - Rev14 Specications Description Rating Units Input Maximum T urbine V oltage 200 V olts DC Operating input voltage range 30-170 V olts DC Maximum input current 18 Amps DC Maximum input short circuit current 20 Amps DC Inverter Operating voltage range 120V AC+/[...]

  • Page 46

    WindT ronics Honeywell International Inc. 621 Sprucewood Avenue W indsor , Ontario N9C 0B3 T ell: 877-946-3898 www .honeywell.com The Honeywell T rademark is used under license from Honeywell International Inc.and makes no representations or warranties with respect to this product.[...]