Mastervolt Windmaster 500 User Manual

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Page 1

USER’S MANUAL

Windmaster 500

Grid connected wind inverter

This product must be protected externally against over voltages that may occur in no-

load and / or extreme wind conditions. Exceeding the specified maximum input

voltage must be avoided under any circumstances. Most turbine manufacturers

supply a protection circuit to protect power converters from these conditions. Failure

to do so may cause serious damage to the inverter and will void product warranty.

MASTERVOLT Snijdersbergweg 93, 1105 AN Amsterdam The Netherlands Tel.: +31-20-342 21 00 Fax: +31-20-697 10 06

www.mastervolt.com

v 1.0 December 2006

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WINDMASTER 500

LED indicator

Ventilation opening

Tab to release the mounting lock

MultiContact plug positive (+) MultiContact plug negative (–)

Communication port

Ventilation openings

Mains cord

Page 3

INSTALLATION

• Mark the position of the two mounting spots A and B by using the mounting bracket

• If necessary, drill mounting holes at spots A and B

• Fix the mounting bracket to the wall

• Read instructions on page 5 -8 prior to installation.

• Place the Windmaster 500 over the mounting bracket and then move it downwards until it is locked by the mounting bracket

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INSTALLATION

• Check whether the Windmaster 500 is mounted in a secure way.

• After starting up, the LED-indicator starts blinking yellow.

• If wind power is too low, the indicator will extinguish

• Connect the string cabling to the Windmaster 500. If wind power is sufficient, the

LED indicator will illuminate red.

–

• Connect mains cord to the AC-wiring. Then switch on the grid. If wind power is sufficient, the LED-indicator starts blinking red: the Windmaster 500 is starting up. This may last a few seconds

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ENGLISH USERS MANUAL WINDMASTER 500

Product description and application

Congratulations for choosing the Mastervolt Windmaster 500. The Windmaster 500 is a inverter for grid connection of small wind turbines. The design is based on the successful Soladin 600 Solar inverter. Windmaster 500 is an “OEM” product and is sold as a part of a system through selected system vendor. The product is to be installed only with selected wind turbines. A system is evaluation by Mastervolt is part of the qualification process.

Unpacking

The delivery consists of the following parts:

• The Windmaster 500 with mounting bracket

• This user’s manual

• MultiContact “Pigtail” adapters (2x)

• Windmaster 500 PC-Link

After unpacking, check the Windmaster 500 for possible damage. Do not use the Windmaster 500 if it is damaged. If in doubt, contact your system vendor.

Safety

• Contact an installer if the wind system does not comply with the above mentioned stipulations. Due to possible high voltages installation and modification may only be carried out by a qualified electrician who is familiar applicable regulations and standards.

• Install the Windmaster 500 according to the instructions stated in this manual.

• Be sure that the Windmaster 500 is disconnected from the grid during installation. This can be done by removing the fuse of the corresponding branch circuit at the AC distribution board

• Connections and safety features must be executed according to the locally applicable regulations

• The Windmaster 500 must be used in accordance with the specifications as stated on page 10

• Never open the housing as high voltages may be present inside!

Max Input Voltage 150V Max Input Current 8A Nom Input Power 550Wdc Max Short Circuit 12A

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USERS MANUAL WINDMASTER 500 ENGLISH

Choosing the location to install

Obey the following stipulations during installation:

• The Windmaster 500 is suited for indoor use only.

• Ambient temperature: -20 ... 50°C; (power derating above 40°C), Humidity: 0-90% non condensing

• Choose a optimal location to avoid long DC and / or AC wiring to minimize loses.

• Do not install the Windmaster 500 in environments with heavy dust development or humidity.

• If the Windmaster 500 is installed in the immediate vicinity of living areas, take into account that it produces a slight noise level when operating.

• Mount the Windmaster 500 vertically on a solid, non-resonating, wall.

• Mount the Windmaster 500 in such a way that obstruction of the airflow through the ventilation openings is prevented

• No objects must be located within a distance of 20 cm around the Windmaster 500.

• Multiple Windmaster 500 may be mounted next to each other, not above each other. Minimum spacing: 20 cm.

Things you need to install the Windmaster 500

Make sure you have all the parts you need to install the Windmaster 500:

• The Windmaster 500

• Two screws (with plugs) to mount the

Windmaster 500. Maximum diameter: 4.5 mm. Use mounting materials which are suitable to carry the weight of the Windmaster 500.

• Tools to fix the screws / bolts with plugs into the wall (screwdriver, drilling machine, a set of drills, a pencil)

Directions for installation

The Windmaster 500 is equipped with a so called “anti-islanding safety device”. It ensures immediate switch off in case of grid failure. European countries maintain different regulations with regard to antiislanding devices and the supply of energy back to the utility grid in general.

In some countries one single Windmaster 500 may be connected to an existing electricity branch circuit which is fused with 16 Amp. In other countries different restrictions apply. Please acquaint yourself with the local regulations on this issue!

The Windmaster 500 is sold as a part of a system. Your system vendor will provide the Windmaster 500 with the appropriate settings for the local electrical grid. Never connect the Windmaster 500 to a utility grid which is not suitable for use with the apparatus!

During installation you can check by means of the LED-indicator whether the installation is done properly. This check can only be carried out when sufficient wind power is present.

Although the Windmaster 500 is protected against wrong polarity, the positive (+) and negative (–) of the wind turbine connections should not be exchanged.

Install the product according to the instructions stated on page 3 and 4.

Monitoring

The Windmaster 500 has a communication port that can be connected to the COM-port (RS232) of a PC or laptop. Use the provided “Mastervolt PC–link” interface and cable to set up a connection.

Part number Description 130391030 PC-link Soladin/Windmaster,

incl. communication cable, 2m

NOTE: Communication is only possible when sufficient wind power is present.

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ENGLISH USERS MANUAL WINDMASTER 500

LED indicator

The operation mode of the Windmaster 500 is displayed by means of a LED indicator at the front side of the housing. In normal operation it flashes yellow: the faster the LED blinks yellow, the more power is converted.

If the energy of the wind turbine is insufficient, the Windmaster 500 switches off automatically. When switched off, the LED indicator is off

Failures

As long as the indication LED isn’t illuminated red, no failure is detected: the Windmaster 500 is operating normally. If an error occurs, it is detected by the apparatus itself: the LED indicator turns red. Consult the vendor, if you cannot solve the problem by means of the table below.

NOTE: during low wind trubine voltage detected by the Windmaster 500, indicated by a red blinking LED indicator. This is a normal situation

Indication of the LED Meaning What to do?

LED is off

Insufficient wind power

Nothing. The Windmaster 500 operates normally, but power coming from the wind turbine is insufficient

LED is off

No power from the wind turbine

Consult an installer if the LED indicator is off while wind power is sufficient. The wiring between the wind turbine and the Windmaster 500 might be defective. Check for loose connections or incorrect polarity.

• • • • • Yellow blinking

Normal operation Nothing. The Windmaster 500 operates normally. The faster the LED

blinks yellow, the more power is converted.

▬ ▬ ▬ Slow blinking long red pulses

Reclosure time Nothing. After the Windmaster 500 was (re)connected to the AC grid,

it checks the quality of the AC grid before it starts operating normally.

This may take up to 5 minutes. ▬ ▬ ▬ ▬ ▬ ▬ Fast blinking long red pulses

Restart time lag Nothing. A system check is carried out during startup. This may take

up to 5 seconds before the Windmaster 500 starts operating

normally. ▬▬▬▬▬▬▬▬ Uninterrupted red

No grid voltage Plug the AC-plug of the Windmaster 500 into the wall socket; check

the fuse in the meter cupboard.

• • • • • Red blinking 1 time

Turbine voltage too low

Nothing; normal condition during low wind conditions.

Consult an installer if the problem remains while a strong wind

conditions exists.

Error in the Wind turbine system. Is the wind turbine qualified for use

in accordance with Windmaster 500?

• • • • • • • • Red blinking 2 times

Turbine voltage too high

Consult an installer. Error in the installation. Is the wind turbine

qualified for use in accordance with Windmaster 500?

• • • • • • • • • Red blinking 3 times

AC grid voltage too high

Check the grid connection.

• • • • • • • • Red blinking 4 times

AC grid voltage too low

Check the grid connection.

• • • • • • • • • • Red blinking 5 times

Grid frequency too high or too low

Check the grid connection.

• • • • • • Red blinking 6 times

Internal temperature too high

Air flow of the Windmaster 500 may not be obstructed. If the problem

remains, switch off the Windmaster 500 by removing the fuse from

the meter cupboard and consult your system vendor.

• • • • • • • Red blinking 7 times

NTC error Consult your system vendor for repair of a defective safety device in

the Windmaster 500.

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USERS MANUAL WINDMASTER 500 ENGLISH

Operation

After installation the Windmaster 500 will switch on automatically if wind power is sufficient. The Windmaster 500 operates automatically: there is no need for user adjustment or control. The Windmaster 500 has no ON/OFF switch; If necessary remove the fuse from the AC distribution board to switch it off. Do not disconnect the MultiContact plugs during operation of the Windmaster 500! No specific maintenance is required. If necessary, use a soft clean cloth to clean the Windmaster 500. Never use any liquids, acids and/or scourers.

Decommissioning

First remove the Fuse from the AC distribution board before you disconnect the MultiContact plugs. Now the Windmaster 500 can be demounted in a safe way:

1. Push on the lower tab of the mounting bracket to release the mounting lock.

2. Lift the Windmaster 500 upwards for approximately 1 cm.

3. Move the Windmaster 500 straight from the wall

Warranty and Support

The inverter is supplied with a 2-year standard product warranty. Other warranty agreements between system vendor and Mastervolt may apply. First line service and support is performed by the system vendor. Defects caused by DC or AC over voltage, out-of-specification short circuit current, direct or induced lightning and surges as well as cost of travel, installation and energy loss are excluded from product warranty.

Liability

Mastervolt cannot be held liable for:

• Possible errors in this included manual and the consequences of these.

• Use that is inconsistent with the purpose of the product.

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ENGLISH USERS MANUAL WINDMASTER 500

Power Curve

The Windmaster 500 converts DC power from a wind turbine to the AC grid based. This conversion is based upon a linear curve with a start voltage and a maximum operating voltage (see figure 1). These parameters may be adjusted and optimized by the system vendor for use with a particular wind turbine. When DC voltage reaches the threshold voltage to start up the Windmaster, the inverter starts a 5 seconds countdown before delivering energy to the AC grid.

Figure 1

Example installation diagram

See figure 2. This drawing is not specific for any wind turbine or installation. It is provided as a basic reference, showing necessary major components and installation sequence. Please contact your system vendor for detailed installation drawings, specific for you wind turbine.

DC interface

The DC interface is for protection of the Windmaster 500, and should provide the following.

• Surge protection (if applicable)

• Over voltage protection, max. 150VDC (*)

• Disconnection switch (if applicable)

(*) Mechanical either electrical OVP may be integrated in the wind turbine

Grounding

The Windmaster 500 is a class II device with galvanic isolation between DC and AC. The inverter doesn’t need to be grounded. Grounding of the Wind turbine however is recommended.

Paralleling

Multiple Windmasters 500 can be operated in parallel to increase output power. The DC-side of each Windmaster 500 must be protected by a 10A (slow blow) fuse (refer to fig. 2).

Figure 2

10 20 30 40 50 60 70 80 90 100 110 120130140150

100

150

200

250

300

350

400

450

500

550

Udc [V]

Pdc [W]

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SPECIFICATIONS

Model Windmaster 500

Part number: 140000500 Manufacturer: Mastervolt, Amsterdam, the Netherlands Operating temperature: -20°C to 50°C (full power up to 40°C) Storage temperature: -20°C to 70°C Relative humidity: Max. 95%, non condensing (electronics have anti-moisture coating) Protection degree: IP23 (for indoor use) Safety class: Class II Double insulated

Galvanic isolation Class II HF transformer Dimensions (H x W x D): 365 x 143 x 75 mm Weight: Approx. 2 kg.

Enclosure: UL 5V fire retardant ABS/PC Mounting Wall mounting bracket included

Input (DC)

Nominal power: 550WDC Operating voltage range: 35-150 VDC Full power voltage range: 65-125 VDC Max current: 8A Max short current: 12A Start-up power: 1W Connectors: MultiContact 4mm type connectors ; adapters are included

Paralleling

Multiple units can be operated in parallel to increase output power The DC-input of each unit must be protected by a 10A DC (slow blow) fuse

Output

Voltage: 230V (185V-264V) Nominal power: 525W Nominal current: 2,25A Fuse: 3,15A -T Frequency: 50 Hz (48-52 Hz) Cos phi: 0,99 Stand-by power: < 0,05Wac Maximum efficiency: 93% Mains cord: 1,8 meter of AC wire

Safety Functions

Anti-Islanding Voltage- and frequency window; frequency shift G83 compliant Over temperature Power derating at > 40 °C; switch off at internal over temperature Polarity Protected against inverse polarity Surges Protected against AC and DC surges caused by indirect lightning strike

User Interface

Front indicator Dual color (yellow/red) Normal operation Yellow blinking (faster blinking = higher power) Fault indication Red flashing (6 different codes) Communication PC-Link adapter and cable for RS-232 communication included. PC software

downloadable from www.mastervolt.com

National grid connection regulations

Approvals: G83 (GB); NTA 8493 (Netherlands) Country compatibility Standard suitable for all 230V / 50 HZ countries. Country specific settings

programmable. External ENS may be required for some countries (contact your local distribution network operator for local grid connection) requirements)

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DIMENSIONS

65 245

350

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CE DECLARATION OF CONFIRMITY

Manufacturer: Mastervolt

Address: Snijdersbergweg 93 1105 AN Amsterdam The Netherlands

Herewith declares that:

Product: Windmaster 500

Is CE-marked and complies with the following standards:

EMC directive 89/336/EEC Environment: residential, commercial and light industrial

Emission

Emission - class B: EN 55022: 1998 harmonic current emission: EN 61000-3-2: 2000

Immunity

Generic immunity standard: EN 61000-6-2: 2001 Electrostatic discharge (ESD): EN 61000-4-2: 1995 Radiated EMC: EN 61000-4-3: 1996 Electrical fast transients (EFT) : EN 61000-4-4: 1995 Surge transient : EN 61000-4-5: 1995 Conducted RF disturbances : EN 61000-4-6: 1996 Voltage dips and short interrupts : EN 61000-4-11: 1994 Digital radio telephones : ENV 50204: 1995

Safety

Low Voltage directive : LV 73/23 EEC Electrical safety : EN 60950 : 2003

Amsterdam,

R.J. ter Heide, General Manager MASTERVOLT