Honeywell DCCC6500 User 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 a WindTronics Authorized

Installer, please download the application from our website www.windtronics.com.

Quick Start:

DC CHARGE CONTROLLER

Model #DCCC6500

48 VDC

DC CHARGE CONTROLLER

for Honeywell Wind Turbine Model WT6500

Quick Start: DC Charge Controller for Honeywell Wind Turbine WT6500 - Rev 2.0 - 29Nov11

2 Quick Start

Safety Instructions

PLEASE READ THIS QUICK START GUIDE AND THE ENTIRE MANUAL PRIOR TO INSTALLATION. INSTALLATION

OF THIS WIND TURBINE CAN ONLY BE PERFORMED BY A WINDTRONICS AUTHORIZED INSTALLER OR OTHER

LICENSED CONTRACTOR.

Safety Icons

The following symbols identify dangers associated with the installation, use or ownership of

the Honeywell Wind Turbine. When you see the symbols be aware of the protocol 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 property

damage.

IMPORTANT: PLEASE TAKE NOTE

PROFESSIONAL INSTALLATION: REQUIRED

TIP: HELPFUL INFORMATION TO EASE THE INSTALLATION

Important Safety Instructions

1. This Quick Start Guide contains important instructions for the Honeywell Wind Turbine

installation and maintenance. Please save it.

2. Read the entire Quick Start Guide prior to installation and follow all warnings and cautions

included in the Quick Start Guide and/or attached to the Honeywell Wind Turbine.

3. Improper installation, adjustment, alteration, service maintenance or use can cause re,

electrical shock or other conditions which may cause death, personal injury or property

damage.

4. Choose a calm day with very little wind for the installation.

5. Follow the installation procedures contained within this Quick Start Guide and all safety

codes. Follow your National Electric Code (NEC) and your local building and zoning codes.

6. The Honeywell Wind Turbine can only be moved and lifted by WindTronics Authorized

Installers or other licensed contractors using standard hoists and hydraulic lifts such as a

crane and bucket truck.

Quick Start: DC Charge Controller for Honeywell Wind Turbine WT6500 - Rev 2.0 - 29Nov11

Quick Start 3

7. Appropriate protective personal equipment such as hard hat, work gloves, safety glasses

and closed-toe work shoes should be worn when installing the Honeywell Wind Turbine.

8. Only WindTronics Authorized Installers or other licensed contractors can perform the

following installation and maintenance functions on this Honeywell Wind Turbine:

• Open and work on the DC Charge Controller

• Open and work on the DC Charge Controller (DCCC) junction box at the turbine

• Apply any torque to any of the turbine’s fasteners

9. The installation directions include a variety of options. These must be approved and

certied by your local Professional Engineer (PE) and the installer must acquire all the

necessary permits from the local authorities prior to installation.

The Honeywell Wind Turbine is manufactured by WindTronics, Inc. Please contact

WindTronics, Inc. at:

621 Sprucewood Avenue

Windsor, Ontario N9C 0B3

Canada

Tel: 877-946-3898

Manufacturer reserves the right, without notice or liability, to change design and specications

at any time.

Quick Start: DC Charge Controller for Honeywell Wind Turbine WT6500 - Rev 2.0 - 29Nov11

4 Quick Start

Site Survey

Refer to the Site Survey Guide.

Evaluation and Installation List

Permits

Permit#_________________________ Date_____________

Site Evaluation

Distance from Turbine to DC Charge Controller (max 200 ft. (60 m))______

Height to center of turbine______________________________

Draw all obstructions on site map

Draw Site Map (View from above - use space on page 6 for your drawing)

Prevailing wind direction

Location of:

Obstacles

Turbine

DC Charge Controller

Battery Enclosure (max 6 ft. (1.8 m) from DC Charge Controller)

Mounting Hardware (Choose one or have your local PE design a custom mount -

see Honeywell Wind Turbine WT6500 Owner’s Manual for more details)

Pole: Height____________ Material_______________ with Pole Top Mount (refer

to pages 8- 9)

Flat roof: Ballast Mount (refer to page 10)

Pitched roof: ROOFBOX with Extended QUADPOD Mount (refer to page 11)

Accessories (Supplied by Installer)

(4) Batteries: 12 V, 100 Ah, deep cycle batteries - Type may be AGM or marine-

grade ooded

Battery enclosure

(1) 30 Amp fuse (refer to page 15)

(1) 15 Amp fused disconnect (refer to page 15)

(1) Battery switch (refer to page 15)

Quick Start: DC Charge Controller for Honeywell Wind Turbine WT6500 - Rev 2.0 - 29Nov11

Quick Start 5

Connection:

(2) ¾” Conduit

(1) 1” Conduit

Battery terminal lugs

CAT5E or CAT6 stranded cable

(1) #4 THWN - 2 red

(4) #4 THWN - 2 black

(1) #4 THWN - 2 green

(1) #6 THWN - 2 green

(3) #10 THWN - 2 black

(1) #10 THWN - 2 red

Unpack (Refer to instructions in package)

DC Charge Controller: Serial #___________________

Quick Start: DC Charge Controller

On/Off Switch Box: Serial #___________________

Turbine crate:

Unpacking Instructions

Turbine: Serial #____________________

(2) Deectors and mounting hardware

DCCC Junction box with dump load

Owner’s Manual: Wind Turbine

QA Inspection Sheet

Warranty Registration Card

Mount and Level Turbine – Refer to lift point on page 12

Connect – Refer to pages 14-15 for wiring diagrams

Commissioning – Refer to page 16

Status LED’s Operation Legend – Refer to page 17

Note:

• A run of conduit shall contain not more than four quarter bends

or a combination of bends totaling 360 degrees between pull

points. Tubing shall not be threaded, and ttings shall be listed

for use with EMT and shall be securely fastened to the tubing.

Quick Start: DC Charge Controller for Honeywell Wind Turbine WT6500 - Rev 2.0 - 29Nov11

6 Quick Start

LEGEND



Turbine

Tree

Battery Box

DC Charge Controller

Prevailing Wind

Compass



DCCC

Quick Start: DC Charge Controller for Honeywell Wind Turbine WT6500 - Rev 2.0 - 29Nov11

Quick Start 7

Mounting Options

PERSONAL INJURY AND PROPERTY DAMAGE HAZARD

Do not install the Honeywell Wind Turbine in a location

that is accessible to children or pets. Failure to follow this

warning may result in death, personal injury or property

damage.

PERSONAL INJURY AND PROPERTY DAMAGE HAZARD

The Honeywell Wind Turbine must be mounted by

WindTronics Authorized Installers or other licensed

contractors only, with the use of all appropriate hardware.

Failure to follow this warning may result in death, personal

injury or property damage.

Failure to follow proper installation practices for any of the

mounting options could result in death, serious injury and/or

property damage.

When mounting on or over a combustible surface, a foot

plate of at least 1.43 mm galvanized or 1.6 mm uncoated

steel extended at least 150 mm beyond the equipment on all

sides must be installed.

Power shall be disconnected from the equipment before the

DCCC junction box enclosure is opened and the enclosure

shall be closed before the power is restored. Failure to do so

may result in death, serious injury and/or property damage.

If any maintenance is to be done on the turbine, the turbine

must be put in STOP mode, the turbine switch on the DCCC

junction box must be in the “Turbine OFF” position and the

wheel must be tie-wrapped to prevent turning. Failure to

do so may result in death, serious injury and/or property

damage.

Use of WindTronics’ products for other than their intended

purpose may void the warranty.

Whichever mounting option design is chosen, it must be approved by a local PE. All of the

options listed have been rated and approved by our PE and certied for WindTronics, Inc.

Please refer to the following designs and their included specications.

Quick Start: DC Charge Controller for Honeywell Wind Turbine WT6500 - Rev 2.0 - 29Nov11

8 Quick Start

Figure 1: Pole Mount

Pole Mount

Step 1:

• Position Leg Weldment

#WTM001 to bottom of

#WTM002 Coupler Weldment.

• Bolt together using fastener #’s:

70210, 70714, 71021, 71071 as

shown.

• Repeat pattern in three additional

locations.

Step 2:

• Position Mounting Bracket

#WTM003 to top of #WTM002

Coupler Weldment.

• Bolt together using fastener #’s:

70210, 70714, 71021, 71071 as

shown.

Note:

Be sure both pole and pole cou-

pler are installed level. Failure to

install them level will impact turbine

performance and may impact

warranty coverage.

Be sure the inner surface of the

Mounting Leg Weldment is ush

against the pole prior to bolting the

fasteners. Choose the bolt hole in

the base of the Pole Mount Turbine

Coupler Weldment that aligns with the

slot in the Mounting Leg Weldment.

Pole Top Mount Assembly #WTMASSY001

Item No. Part No. Description Qty

1 WTM001 Mounting Leg Weldment 4

2 WTM002 Pole Mount Turbine Coupler Weldment 1

3 WTM003 Pole Mount Junction Box Mounting Bracket 1

5 Fastenal #70210 Hex Cap Screw, 1/2-13 x 1.75” lg Full Thread 18-8 S/S 9

6 Fastenal #71071 Flat Washer - 1/2”, Medium Split, 18-8 Stainless Steel 9

7 Fastenal #71021 Flat Washer - 1/2”, Small O.D., 18-8 Stainless Steel 9

8 Fastenal #70714 Hex Nut - 1/2-13 - 18-8 Stainless Steel 9

Quick Start: DC Charge Controller for Honeywell Wind Turbine WT6500 - Rev 2.0 - 29Nov11

Quick Start 9

Instructions for Pole Top Mount Assembly

Step 1:

• Position Leg Weldment

#WTM001 to bottom of

#WTM002 Coupler Weldment.

• Bolt together using fastener #’s:

70210, 70714, 71021, 71071 as

shown.

• Repeat pattern in three additional

locations.

Step 2:

• Position Mounting Bracket

#WTM003 to top of #WTM002

Coupler Weldment.

• Bolt together using fastener #’s:

70210, 70714, 71021, 71071 as

shown.

Note:

Be sure both pole and pole cou-

pler are installed level. Failure to

install them level will impact turbine

performance and may impact

warranty coverage.

Be sure the inner surface of the

Mounting Leg Weldment is ush

against the pole prior to bolting the

fasteners. Choose the bolt hole in

the base of the Pole Mount Turbine

Coupler Weldment that aligns with the

slot in the Mounting Leg Weldment.

Figure 2: Pole Top Mount

Pole Top Mount Assembly #WTMASSY001

Item No. Part No. Description Qty

1 WTM001 Mounting Leg Weldment 4

2 WTM002 Pole Mount Turbine Coupler Weldment 1

3 WTM003 Pole Mount Junction Box Mounting Bracket 1

5 Fastenal #70210 Hex Cap Screw, 1/2-13 x 1.75” lg Full Thread 18-8 S/S 9

6 Fastenal #71071 Flat Washer - 1/2”, Medium Split, 18-8 Stainless Steel 9

7 Fastenal #71021 Flat Washer - 1/2”, Small O.D., 18-8 Stainless Steel 9

8 Fastenal #70714 Hex Nut - 1/2-13 - 18-8 Stainless Steel 9

Quick Start: DC Charge Controller for Honeywell Wind Turbine WT6500 - Rev 2.0 - 29Nov11

10 Quick Start

Figure 3: Ballast Mount

Ballast Mount

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