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Author Topic: Cooked Windy Boy WB1100  (Read 2859 times)
woodi
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« on: October 22, 2015, 09:25:22 PM »

Got asked to look at someone else's setup, an old lady over in the west of Ireland who doesn't really know what is installed, or how it works.  Anyhow, its a Windy Boy 1100LV, and a Sunny Boy feeding into a Windy Island 1100LV. About 1kw wind, 1kw solar. 24 volt system, all the batteries entirely dead, and the system has been down for 8 months. However the brake has been off the turbine, which has been feeding the WIndy Boy, despite it not being able to see a grid because the Sunny Island has shut down on the basis of low SOC. Hence (I think) a cooked Windy Boy. At least one of its capacitors look suspiciously dead -



Anyone any ideas about repairing the WB? We'll probably just put in a Morningstar or something similar to charge the batteries direct and prevent a possible repeat of the current situation. The installed kit seems overkill for the size of generation, but we have to work with whats there to get the old lady back up and running.
The Sunny Island also thinks that the SOC is 9%, despite batteries at 24.9v, and I have to try and persuade it otherwise. Suggestions gratefully received.
Cheers
Steve

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biff
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« Reply #1 on: October 22, 2015, 10:29:40 PM »

Hi Woodi,
         I think the bearings are gone on the turbine as well.
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woodi
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« Reply #2 on: October 22, 2015, 10:38:03 PM »

Amazingly it sounds ok and doesn't have much in the way of vibration. Got the system fired up with some new batts and its generating ok for now. If I can get the system up and running we'll talk to them about getting the turbine down for a proper look. DO you reckon its worth trying to get the WB repaired?
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biff
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« Reply #3 on: October 22, 2015, 10:53:15 PM »

Is it stuck on top of a telegraph pole,
          with 5 solar panels on a nearby roof,
             8 batts all dead,
                A row of ash trees growing along the front,? Grin
                                               Biff
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woodi
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« Reply #4 on: October 22, 2015, 11:16:58 PM »

Small world Smiley Yep. Thats the one. When were you out there? Judith isn't in the country, she's got someone housesitting so we got asked second hand to go take a look. Presumably you've seen the setup, what was your take on it.
« Last Edit: October 22, 2015, 11:24:36 PM by woodi » Logged

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baker
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« Reply #5 on: October 23, 2015, 04:18:57 PM »

cap looks ok
they burst and split or swall up
but a meter on the red varistors above the cap
that's what takes the rattle
baker
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woodi
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« Reply #6 on: October 23, 2015, 05:55:05 PM »

Anyone know how to hard reset a Sunny Island? The unit there is pw protected and I've a horrible feeling no one will know what it might be. Having connected new batteries, it refuses to believe that they are more than 9% SOC, despite them being fully charged. Hence it keeps shutting down. Am learning to appreciate my own Victron gear, this SMA lark is something else...
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biff
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« Reply #7 on: October 23, 2015, 06:37:22 PM »

Hi Woodi,
          A few of our members have good experiences with SMA and may be able to help, Paul, (Camilletech) knows them well.
                                                            Biff
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Ted
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« Reply #8 on: October 23, 2015, 10:27:20 PM »

Default passwords for SMA are usually 0000 or 1111.
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heatherhopper
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« Reply #9 on: October 24, 2015, 11:13:00 AM »

Which model of Sunny Island is it? How are you accessing the password input?
If it has been sitting in Battery Preservation Mode it should only require a new battery configuration set up unless you really want to reset all the system parameters.
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woodi
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« Reply #10 on: October 24, 2015, 11:30:13 AM »

Its a 2224. Looks like I can just set the installer pw based on runtime and then tell it we have new batteries, which will hopefully sort it out. I am assuming that what it is doing is battery preservation mode - it runs for about 10 mins and then shuts down, based on it thinking that SOC is 9%.
Back next thursday armed with a wind controller. That and a reconfig should get her up and running again. Also needs a shunt because of the wind controller to battery connection - the SMA one is a 200A 60mV affair, which I presume isn't proprietary, and can be any 200a 60mV shunt? The SMA one is twice the price of one out of RS comps.
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« Reply #11 on: October 24, 2015, 11:51:58 AM »

Yup - that's the password input for level 1 and new battery configuration should sort it out.
If the new wind controller is DC coupled how are you going to set up the battery charge control? The shunt (SMA version not necessary) will enable the SI to know what the total battery charge/discharge rate is (and thus SOC) but it will not, and can not, regulate it's own charge regime to allow for another controller using separate voltage only control - they could end up at odds with one another. I recall a contentious debate on this very issue recently.
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« Reply #12 on: October 24, 2015, 12:09:02 PM »

Heinz.  Ok..we'll probably have to suck it and see - the likelihood is that the SMA gear will be removed fairly soon and replaced with something simpler. For 2kw of generation, an MPPT for the solar, controller for wind and a 1kw inverter would be more than enough - they literally run a couple of lightbulbs, laptop and router off this. Whoever originally installed the SMA gear put their arm in all the way.
The Sunny Island will be confused for a while but hopefully not as confused as it is now. The SMA literature implies that as long as the shunt is installed, then all should be ok. What is the alternative? Grid tie kit only and AC coupling?
« Last Edit: October 24, 2015, 12:11:16 PM by woodi » Logged

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heatherhopper
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« Reply #13 on: October 24, 2015, 12:46:46 PM »

The Sunny Island will not adjust itself to suit another controller attempting to maintain the voltage at different levels. The shunt provides information for SOC calculation purposes only and mixed AC/DC coupling requires separate comms from the DC source for the SI to integrate the lot into it's charge regime. Without the extra comms (and I think only SMA proprietary stuff is available) a work around of some kind is needed. What the SMA documentation does and doesn't imply is, I guess, open to interpretation.
Simple (and possibly cheaper option @ 100ish) is just to fit an AC side diversion operating on frequency shift and allow the Sunny Island to control voltage this way.
Another option is to allow the frequency to drift if the wind generation raises the voltage above the Sunny Island control setting and the Sunny Boy to shutdown on frequency control. Question is - how high would the frequency go?
Agree that a simpler DC system is probably more appropriate for this situation and installers putting in this kind of set-up does no-one any favours.

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« Reply #14 on: October 24, 2015, 12:55:14 PM »

Ok. What are the implications of not having the DC generator talk to the SI? Does the SI not look at the battery voltage as part of its charging? If fitting the shunt without having the turbine and SI talk is going to be largely pointless then perhaps its not worth fitting the shunt.
Wondering how rapidly and how much out of kilter the SI SOC will go. Presumably if it isn't aware that something else is feeding the batteries, the danger is of overcharging rather than undercharging. 
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