Honeywell DCCC6500 Quick Start Manual

DC CHARGE CONTROLLER

for Honeywell Wind Turbine Model WT6500

Quick Start:
DC CHARGE CONTROLLER

Model #DCCC6500
48VDC

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.

2

Safety Instructions

Important Safety Instructions

1. This Quick Start contains important instructions for the Honeywell Wind Turbine
installation and maintenance. Please save it.

2. Read the entire Quick Start prior to installation and follow all warnings and
cautions included in the Quick Start 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 very calm, nearly no wind, day for the installation.

5. Follow the installation procedures contained within this Quick Start and all safety
codes. Follow your National Electric Code and your local building zoning codes.

Quick Start

6. Only WindTronics Authorized Installers or other licensed contractors should move
and lift the Honeywell Wind Turbine. The turbine should only be moved using
standard hoists and hydraulic lifts such as a crane or bucket truck.

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 DCCC junction box at the turbine

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

9. The installation directions include recommendations of a variety of options. These

must be approved and certied by your local Professional Engineer (PE). The

installer must acquire all the necessary permits from the local authorities prior to
installation.

The Honeywell Wind Turbine is manufactured by WindTronics. Please contact
WindTronics at:

621 Sprucewood Avenue
Windsor, Ontario N9C 0B3
Canada

Tel: [phone]

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 1.0 - 28Sep11

Quick Start 3

Site Survey

Refer to the Site Survey Guide.

Evaluation and Installation List

Permits

Permit#_________________________ Date_____________
Permit#_________________________ Date_____________
Permit#_________________________ Date_____________
Permit#_________________________ Date_____________

Site evaluation

Distance from turbine to DC Charge Controller (max 200 ft (60m))__________

Height to center of turbine______________________________
Draw all obstructions on site map

Draw site map (view from above - use space on page 5 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 7-8)

Flat roof: QUADPOD Mount and Ballast (refer to page 9)
Pitched roof: QUADPOD Mount and ROOFBOX Mount (refer to page 10)

Accessories (Supplied by Installer)

Quick Start: DC Charge Controller for Honeywell Wind Turbine WT6500 - Rev 1.0 - 28Sep11

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

grade ooded

Battery enclosure

(1) 30 Amp fuse (refer to page 14)
(1) 15 Amp fused disconnect (refer to page 14)
(1) Battery switch (refer to page 14)

4

Connection:

Quick Start

(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

Unpacking (Refer to instructions in package)

DC Charge Controller: Serial #___________________
Quick Start Manual

Turbine crate:

Turbine: Serial #____________________

(2) Deectors and mounting hardware

DCCC junction box with dump load
Anemometer
Owner’s Manual
QA Inspection Sheet
Unpacking instructions

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.

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

Connect – Refer to pages 13-14 for wiring diagrams

Commissioning – Refer to page 15

Status LED’s Operation Legend – Refer to page 16

Quick Start: DC Charge Controller for Honeywell Wind Turbine WT6500 - Rev 1.0 - 28Sep11

Quick Start 5

Quick Start: DC Charge Controller for Honeywell Wind Turbine WT6500 - Rev 1.0 - 28Sep11

T

BB

DCCC

N



LEGEND

Turbine

Tree

Battery Box

DC Charge Controller

Prevailing Wind



Compass

6

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.

Quick Start

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 warranty.

Whichever mounting option is chosen should be approved by a local Professional Engineer (PE). All of
the options listed have been rated by our Professional Engineer and certied for WindTronics. Please
refer to the following designs and their included specications.

Quick Start: DC Charge Controller for Honeywell Wind Turbine WT6500 - Rev 1.0 - 28Sep11