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: [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 2.0 - 29Nov11
4 Quick Start
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. (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
T
BB

N
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

Quick Start: DC Charge Controller for Honeywell Wind Turbine WT6500 - Rev 2.0 - 29Nov11
Quick Start 11
Figure 4: ROOFBOX with Extended QUADPOD Mount
ROOFBOX with Extended QUADPOD Mount

Quick Start: DC Charge Controller for Honeywell Wind Turbine WT6500 - Rev 2.0 - 29Nov11
12 Quick Start
Lift Point
Only WindTronics Authorized Installers or other licensed contractors may 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. The recommended lift point is shown below in
gure 5.
Note:
To ensure proper operation of the Honeywell Wind Turbine it is critical for it to be vertically level
when mounted on either a pole or the QUADPOD Mount (or any other mount designed by the
installer).
Figure 5: Lift Point
DCCC Junction Box
Purpose:
The purpose of the DCCC junction box is to interface between the turbine and the DC Charge
Controller which includes the dump load, turbine ON/OFF switch and anemometer. The DC
Charge Controller uses the dump load to put the turbine in STOP mode when there is a fault,
a user has pressed the STOP key or when the generator voltage exceeds 165 VDC. When the
voltage decreases, the brake is released. The turbine ON/OFF switch will put the turbine in a
hard STOP mode whether or not the dump load is connected. It also disconnects the turbine
from the DC Charge Controller.

Quick Start: DC Charge Controller for Honeywell Wind Turbine WT6500 - Rev 2.0 - 29Nov11
Quick Start 13
Mounting:
The DCCC junction box comes hard-wired to the turbine. It should be mounted to ensure the
anemometer will be able to function through all seasons (i.e. will not be covered with snow
in the winter). The DCCC junction box can be mounted using two pre-drilled holes tapped for
5/16-18 bolts in the black bars on the back of the DCCC junction box. The QUADPOD Mount
and Pole Top Mount have pre-drilled holes for mounting of the DCCC junction box.
Mounting hardware is supplied by the Installer.
Figure 6: DCCC Junction Box
Wiring
ELECTRIC SHOCK HAZARD
Disconnect turbine and battery circuits before wiring. Failure
to follow the safety warning could result in serious injury
and/or death.
PROFESSIONAL INSTALLATION: REQUIRED
Installations must meet all local electrical codes. Installations for the equipment should only be
performed by WindTronics Authorized Installers or other licensed contractors.
The wiring connections between a mounted Honeywell Wind Turbine, battery box and DC
Charge Controller are relatively simple. Figure 8 (page 15) details and species the wire
gauges required in this installation. It is strongly recommended that a licensed electrician
performs all the electrical connections. All electrical systems must be grounded in accordance
to your National Electric Code and local standards.

Quick Start: DC Charge Controller for Honeywell Wind Turbine WT6500 - Rev 2.0 - 29Nov11
14 Quick Start
Illustration of Turbine System Connections
Figure 7: System Connection

Quick Start: DC Charge Controller for Honeywell Wind Turbine WT6500 - Rev 2.0 - 29Nov11
Quick Start 15
Junction Box
Figure 8: Electrical Wiring Diagram

Quick Start: DC Charge Controller for Honeywell Wind Turbine WT6500 - Rev 2.0 - 29Nov11
16 Quick Start
1. To congure the DC Charge Controller to a 48 VDC system (refer to gure 9) set
switch S1 to “On”.
2. Set switch S2 to “On”.
3. Set switch S3 to either “On” if using AGM batteries, or “Off” is using ooded batteries
(refer to gure 9).
4. Turn on the following switches in the following sequence:
• Battery switch
• DC Charge Controller ON/OFF switch
• 15 Amp fused disconnect
• DCCC junction box ON/OFF switch
5. Verify turbine LED on DC Charge Controller is green.
Commissioning
EXPLOSION OR FIRE HAZARD
Entering battery information incorrectly may result in
explosion or re.
Figure 9: Battery Conguration Switches

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Quick Start 17
BATTERY LED
1. GREEN
• Batteries are charged (when battery voltage stays at 55 V for a 48 V
battery system).
2. ONE RED BLINK
• Low battery fault – Batteries are lower than 45 V (for a 48 V battery
system).
3. TWO RED BLINKS
• High battery fault – Batteries are higher than 58 V (for a 48 V battery
system).
4. THREE RED BLINKS
• Charge over temp – Enclosure > 65°C or Heat Sink > 140°C
5. FOUR RED BLINKS
• Charge over current – Charge current > 24 Amps
GFI LED
1. RED
• Indicates GFI Fault
Status LED’s Operation Legend
TURBINE LED
1. NO LED
• Turbine is sleeping or DC Charge Controller is off
2. GREEN
• Turbine is running
3. RED
• Turbine is stopped
4. ONE RED BLINK
• No Wind Speed – Turbine Voltage > 40 VDC and Wind Speed = 0 MPH for
1 minute
5. TWO RED BLINKS
• Turbine over current – Turbine current > 9 Amps
6. THREE RED BLINKS
• No turbine fault – Turbine Voltage < 5 VDC and Wind Speed > 10
MPH for 1 minute
7. FOUR RED BLINKS
• Turbine over voltage – Turbine Voltage > 170 VDC

Quick Start: DC Charge Controller for Honeywell Wind Turbine WT6500 - Rev 2.0 - 29Nov11
18 Quick Start
Spare Parts
Part Description Part Number #/Turbine Supplier
Replacement Honeywell Turbine RWT6500 1 WindTronics
Replacement DC Charge Controller 48 VDC RDCCC6500 1 WindTronics
On/Off Switch Box WT6K230 1 WindTronics
Anemometer DI7911 1 WindTronics
Finned Dump Load Enclosure Assembly RDLASSY6500 1 WindTronics
Pole Top Mount MPT6500 1 WindTronics
QUADPOD Mount MQP6500 1 WindTronics
QUADPOD Mount - Ballast (for at roof) MQP6500B 1 WindTronics
QUADPOD Mount - Feet (for pitched roof) MQP6500F 4 WindTronics

WindTronics, Inc.
621 Sprucewood Avenue
Windsor, Ontario N9C 0B3
Canada
Tel: [phone]
www.windtronics.com WT6500-QSDCCC-Rev2.0-29Nov11
The Honeywell trademark is used under license from
Honeywell International Inc. Honeywell International Inc.
makes no representation or warranties with respect to this
product.