Page 2 - Safety Instructions; Safety Icons; SMARTBOX; Important Safety Instructions; General Safety Instructions
II Safety Instructions SMARTBOX ™ Controller for HONEYWELL ™ Wind Turbine WT6500 Owner’s Manual - Rev14 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 ownersh...
Page 3 - LIMITATIONS ON USE; Battery Safety Information
III SMARTBOX ™ Controller for HONEYWELL ™ Wind Turbine WT6500 Owner’s Manual - Rev14 Safety Instructions 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 produc...
Page 4 - The; TM Controller for the; 21 Sprucewood Avenue
IV Safety Instructions SMARTBOX ™ Controller for HONEYWELL ™ Wind Turbine WT6500 Owner’s Manual - Rev14 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 877-946-389...
Page 6 - Table of Contents; II; TM Controller; SMARTBOXTM Controller Installation; Connecting the
VI Table of Contents SMARTBOX ™ Controller for HONEYWELL ™ Wind Turbine WT6500 Owner’s Manual - Rev14 Table of Contents Safety Instructions ....................................................... II 1. Introduction The SMARTBOX ™ Controller ................................................... 2 Major...
Page 7 - Controller Energy Consumption States; Navigation Buttons
VII SMARTBOX ™ Controller for HONEYWELL ™ Wind Turbine WT6500 Owner’s Manual - Rev14 Table of Contents 3. Commisioning Commissioning Process......................................................... 24 4. Operation Introduction.............................................................................
Page 8 - Introduction
1 Introduction SMARTBOX ™ Controller for HONEYWELL ™ Wind Turbine 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 9 - The SMARTBOXTM Controller; Major System Components; Parts Inspection
2 SMARTBOX ™ Controller for HONEYWELL ™ Wind Turbine WT6500 Owner’s Manual - Rev14 Introduction 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 controlle...
Page 10 - Battery Overview; Battery Types; Not to be used
3 Introduction SMARTBOX ™ Controller for HONEYWELL ™ Wind Turbine WT6500 Owner’s Manual - Rev14 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 cycl...
Page 11 - Battery Selection; HONEYWELLTM; AC Load Detail and Selection; SMARTBOXTM
4 SMARTBOX ™ Controller for HONEYWELL ™ Wind Turbine 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 industri...
Page 12 - • Typically, 1500W can handle all the lighting and some appliances.; Recommended Appliances; NOT Recommended; • Dehumidifier = 785
5 Introduction SMARTBOX ™ Controller for HONEYWELL ™ Wind Turbine WT6500 Owner’s Manual - Rev14 • 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 ...
Page 14 - SMARTBOXTM Controller
7 SMARTBOX Installation SMARTBOX ™ Controller for HONEYWELL ™ Wind Turbine 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 p...
Page 15 - System Diagrams; PROFESSIONAL INSTALLATION:; Installation must be compliant with all local; Turbine Block Diagram
8 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...
Page 16 - SMARTBOXTM Controller Diagram; Mounting
9 SMARTBOX Installation SMARTBOX ™ Controller for HONEYWELL ™ Wind Turbine 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 S...
Page 17 - Minimum Clearance for Proper Mounting; EQUIPMENT DAMAGE
10 SMARTBOX ™ Controller for HONEYWELL ™ Wind Turbine 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 ...
Page 18 - Grounding
11 SMARTBOX Installation SMARTBOX ™ Controller for HONEYWELL ™ Wind Turbine WT6500 Owner’s Manual - Rev14 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 ...
Page 19 - Wiring Diagram
12 SMARTBOX ™ Controller for HONEYWELL ™ Wind Turbine WT6500 Owner’s Manual - Rev14 SMARTBOX Installation TURBINE JU N CTI O N B O X EART H G ROUND STAKE AC IN TU R B IN E SM A R TB O X™ Controller 12V 12V 12V 12V 12V 12V O PT IO N AL TURBINE P O LES L1 N G ND A C OUTP U T TO SUB S W ITCH BO ARD SIN...
Page 20 - Turbine Wiring and Distances; Turbine Current Rating and Wiring
13 SMARTBOX Installation SMARTBOX ™ Controller for HONEYWELL ™ Wind Turbine WT6500 Owner’s Manual - Rev14 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 ...
Page 21 - Turbine Over-current Protection; TURBINE TO CONTROLLER WIRE SIZE CHART
14 SMARTBOX ™ Controller for HONEYWELL ™ Wind Turbine WT6500 Owner’s Manual - Rev14 SMARTBOX Installation 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 t...
Page 22 - Battery Wiring; degrees C wire for a; Battery Connection Location
15 SMARTBOX Installation SMARTBOX ™ Controller for HONEYWELL ™ Wind Turbine 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 AWG USE-2/RHW-2 or THWN-2, 90 degrees C wire for a SM...
Page 23 - Battery Over-current Protection
16 SMARTBOX ™ Controller for HONEYWELL ™ Wind Turbine 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 t...
Page 24 - AC Input Wiring; AC Output Wiring; codes for proper wiring.
17 SMARTBOX Installation SMARTBOX ™ Controller for HONEYWELL ™ Wind Turbine 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 outp...
Page 25 - AC Output Over-current Protection; Turbine
18 SMARTBOX ™ Controller for HONEYWELL ™ Wind Turbine 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 betwe...
Page 26 - Control Wiring; Control wiring can use stranded CAT5, CAT6 or equivalent wire.; JUN; SM; Control Wiring Chart
19 SMARTBOX Installation SMARTBOX ™ Controller for HONEYWELL ™ Wind Turbine WT6500 Owner’s Manual - Rev14 Control Wiring Control wiring can use stranded CAT5, CAT6 or equivalent wire. JUN CTI O N BOX TU R BINE SM A R TB O X ™ Controller C A T5E or C A T6 GRN /WHT GRN BRN/ WHT BRN BLU /WHT BLU ORG/W ...
Page 27 - Enclosure Internal Wiring; Battery Setup; FIRE HAZARD; Battery Setup Chart; Connecting the SMARTBOXTM Controller; SHOCK HAZARD
20 SMARTBOX ™ Controller for HONEYWELL ™ Wind Turbine 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 Se...
Page 28 - To connect the SMARTBOXTM Controller:
21 SMARTBOX Installation SMARTBOX ™ Controller for HONEYWELL ™ Wind Turbine WT6500 Owner’s Manual - Rev14 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. In...
Page 30 - Commissioning; Chapter 3 describes the step by step process of commissioning the; Commissioning Process
23 Commissioning SMARTBOX ™ Controller for HONEYWELL ™ Wind Turbine 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 - EXPLOSION OR FIRE HAZARD; Entering battery information incorrectly may result in; with th; for best performance.
24 SMARTBOX ™ Controller for HONEYWELL ™ Wind Turbine WT6500 Owner’s Manual - Rev14 Commissioning 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. Settin...
Page 32 - ENTER when finished.; located at the turbine and one located at the system Smart Box.
25 Commissioning SMARTBOX ™ Controller for HONEYWELL ™ Wind Turbine WT6500 Owner’s Manual - Rev14 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 for ONE batter...
Page 34 - Operation
27 Operation SMARTBOX ™ Controller for HONEYWELL ™ Wind Turbine 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 Turbine Operating States pag...
Page 35 - Turbine Operating States; Viewing Operating Status
28 SMARTBOX ™ Controller for HONEYWELL ™ Wind Turbine WT6500 Owner’s Manual - Rev14 Operation 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...
Page 37 - System Protection
30 SMARTBOX ™ Controller for HONEYWELL ™ Wind Turbine WT6500 Owner’s Manual - Rev14 Operation 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...
Page 38 - System Faults; Non Grid-Tie SmartBox Fault Specifications
31 Operation SMARTBOX ™ Controller for HONEYWELL ™ Wind Turbine 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 prod...
Page 39 - SMARTBOXTM Controller Front Panel
32 SMARTBOX ™ Controller for HONEYWELL ™ Wind Turbine WT6500 Owner’s Manual - Rev14 Operation SMARTBOX™ Controller Front Panel BACK UP DOWN ENTER .TECHNICIAN ..BATTERY SETUP Figure 4.4 SMARTBOX™ Controller Front Panel Navigation Buttons 1. BACK button . The back button will bring you back to the pre...
Page 41 - View Data Menu
34 SMARTBOX ™ Controller for HONEYWELL ™ Wind Turbine 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=...
Page 42 - Battery Setup Menu
35 Operation SMARTBOX ™ Controller for HONEYWELL ™ Wind Turbine 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 fire and/or battery explosion. Failure to follow this warnin...
Page 44 - Specifications
37 Specifications SMARTBOX ™ Controller for HONEYWELL ™ Wind Turbine WT6500 Owner’s Manual - Rev14 Specifications 5
Page 45 - DATA SUBJECT TO CHANGE WITHOUT NOTICE; Non Grid-Tie Smart Box Electrical Specifications
38 SMARTBOX ™ Controller for HONEYWELL ™ Wind Turbine WT6500 Owner’s Manual - Rev14 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 Inverte...
Page 46 - WindTronics
WindTronics Honeywell International Inc.621 Sprucewood AvenueWindsor, Ontario N9C 0B3Tell: 877-946-3898www.honeywell.com The Honeywell Trademark is used under license from Honeywell International Inc.and makes no representations or warranties with respect to this product.