Istapower 48V 2000 Hybrid Wind Solar Controller User Manual

Istapower 48V 2000 Hybrid Wind Solar Controller

Product information

Specifications:

• Product Name: Istapower Hybrid Wind and Solar Controller
• Compatible with: Three-phase wind turbine with permanent magnets and 12/24/48V battery bank
• Solar Panel Compatibility: Maximum 600W
• Controller Type: Hybrid (Wind and Solar)
• Controller Design: Electronic components without electromechanical components (relays)
• Housing Material: High mechanical strength metal
• Heat Dissipation: Efficient convection cooling

Introduction:

• The Istapower controller enables the direct connection of a three-phase wind generator with permanent magnets and a 12/24/48V  battery bank, providing a complete solution for battery charging using wind power. Additionally, it has an input for a solar cell panel (maximum 600W) to create a hybrid system that utilizes both solar and wind energy. This hybrid system is beneficial as it allows the utilization of solar energy on days with little wind and vice versa.

• The controller circuit is designed with electronic components,  eliminating the use of electromechanical components (relays). This design choice ensures a long service life and significantly increases the reliability of the installation. The entire set is packaged in a high mechanical strength metal housing, which efficiently dissipates the generated heat, preventing overheating.

Connection:

The controller offers the following connections:

• Wind generator (three-phase turbine with permanent magnets)
• Battery bank (12/24/48V)
• Solar cell panel (maximum 600W)

It is important to note that a braked wind turbine may continue to rotate at a low speed due to dynamic friction. In case of strong winds (above 35 km/h), there might be a temporary interruption in the wind, allowing the turbine to slow down. Once at a low speed, the turbine will remain in this state until the manual braking is  disabled, even if the wind returns to levels above 45 km/h.

Surgery:

The mechanical assembly of the controller should always be  vertical, with the connectors for the battery connection, wind turbine, and solar panel in the lower position. This ensures efficient cooling through convection.
To start the operation, connect the battery bank to the controller using a 6 mm2 copper wire (preferably as short as possible, less than 3 meters between the controller and battery bank). Once connected, two LEDs (red and yellow) will indicate system startup. Shortly after, the yellow LED should activate, indicating that the controller has measured the voltage of the battery bank and initialized its internal constants correctly.
Pay attention to the polarity when connecting the battery. If it  is reversed, no damage will occur to the system, but the controller will remain de- energized.

LED indications:

1. Yellow LED: Constantly lit to indicate that the battery is connected.
2. Red (Red) LED: Lights up only when the brake is activated, waits for 3 seconds, and then turns off.

Warning:

The wires of the wind generator can generate very high voltages  when the propeller is moving, posing an electrical shock hazard. Always make sure to short circuit the terminals or mechanically stop the turbine before handling it.
If the installation includes a solar panel, connect it to the controller. The system is now connected and ready to operate. Press the manual brake button to release the brake if the turbine was mechanically immobilized.

FAQ (Frequently Asked Questions)

• What is the maximum power rating for the solar cell panel?
  The Istapower controller can handle a maximum power rating of 600W for the solar cell panel.

• Can the wind turbine continue to rotate when the brake is applied?
  Yes, as the braking is based on dynamic friction, a braked wind turbine might continue to rotate at a low speed. However, in case of strong winds above 35 km/h, a temporary interruption in the wind can allow the turbine to slow down further.

• How should I connect the battery bank to the controller?
  When connecting the battery bank to the controller, ensure that the wiring has a diameter of 6 mm2 copper and is as short as  possible (preferably less than 3 meters between the controller and  battery bank). Pay attention to the polarity of the battery to avoid any connection issues.

• What should I do if the wind turbine is mechanically immobilized?
  If the wind turbine is mechanically immobilized, you can press the manual brake button on the controller to release the brake.

Istapower Charge Controller

Introduction

• The function of the charge controller is to monitor the battery voltage, and once it reaches full charge, disconnect energy sources (wind turbine and / or solar panel), to avoid overloading the battery bank.
• Furthermore, at risk to the turbine (excessive rotation), the controller actuates the braking automatically. Also, in case of risk to the controller, such as over temperature, load interruption occurs and braking of the turbine. Other protections are also present, such as input voltage limits.
• The Istapower controller allows direct connection of wind generator (three-phase turbine with permanent magnets,) and 12/24/48V battery bank, to generate a complete solution to battery charge with power wind. It also has input for solar cell panel (600W maximum), to use solar and wind energy (hybrid system). The hybrid system as an interesting combination, since often days of little wind exhibit good insulation, and vice versa.
• All the controller circuit is designed with electronic components without the use of electromechanical components (relays). This contributes to a long service life and substantially increases the reliability of the installation.
• The whole set is packaged in a metal housing of high mechanical strength which removes the heat generated efficiently, avoiding overheating.

Connection

The controller has the following connections:

• The main connector has seven contacts: three contacts for the three phases of the wind turbine (PHASE A, B, C), a contact to the positive terminal of the battery (BATTERY+), a contact to the negative terminal of the battery (BATTERY-), a contact to the negative terminal of the solar panel (SOLAR-), and a contact to the positive terminal of the solar panel (SOLAR+).

• Internally there is a 40A fuse protect the circuit in the event of a short circuit. Normally, this fuse should not burn because there is protection against reverse polarity, both the battery and solar panel.

• Two LED lights (yellow and red) indicate the operation of the controller. They are located to the left of the main connector
  (front view), as shown in the drawing.

• As the braking is based on dynamic friction, that is, the energy generated by the turbine itself, will not necessarily completely stopping. A braked wind turbine could continue to rotate but with a low speed. In case of strong winds (above 35 km / h) may occur that the turbine falls your speed when there is a wind temporary interruption, allowing your downswing. Once at low speed, the turbine will remain so until manual braking is off, even if the wind returns to levels above 45 km / h.

Operation

• The mechanical assembly of the controller must always be vertical, with connectors for battery connection, wind turbine, and solar panel in the lower position. This ensures efficient cooling by convection.
• Connect the battery bank to the controller. The wiring to the battery bank must have 6 mm2 of copper in diameter and preferably as short as possible (less than 3 meters between the controller and battery bank). After a moment, the two LEDs (red and yellow), indicate system startup. Soon after, the yellow LED should be activated, indicating that the controller measured the voltage of the battery bank, and initialized its internal constants properly
• When connecting pay attention to the polarity battery. If reversed there will be no damage to the system, but the controller will remain de-energized.
• Once the controller, place the three wind turbine wires shorted together to force the turbine stop. Beware of terminals open turbine, since this situation can arise high voltages if the propeller is moving. Wait about 30 seconds to perform the complete cycle of braking, then remove the short circuit between the turbine wires and connect to the corresponding terminals (phases A, B, C).
• The order of the wires is irrelevant. Do not do this operation if there is strong wind, because the little time with open wires may be sufficient to speed the propeller and generate high voltages at its terminals. In this case, first stop mechanically the propeller spinning before handling the wires of the wind generator.

Warning : the wires of the wind generator open can generate very high voltages if the propeller is moving, with electrical shock hazard. Always should do short-circuit the terminals or stop mechanically the turbine before handling it.

If the installation has solar panel connect it to the controller. The system is connected and ready to operate. Press the manual brake button to release the brake. If the turbine was mechanically immobilized can be released.
When reach full charge voltage, the red LED is turned on and the charge of the battery bank is interrupted.

Characteristics

• Input for wind generator 800/100/2000W.
• Input for solar panel 600W.
• Operation in 12/24/48V.
• Reverse polarity protection on the battery.
• Short-circuit protection (internal fuse 40A).
• Reverse polarity protection on the solar panel.
• Reverse Current protection at night in the solar panel.
• Disconnection and brake of the turbine by overspeeding.
• Turbine brake soft, avoiding mechanical shock.
• Turbine brake operates without even energy.
• Manual brake Switch
• Status display via two LED lights.

Technical specifications

6

v

| 6V
Voltage for battery charge start| 12,5V| 24,5V| 48,8V
Voltage for battery charge end| 14,8 V| 28,5V| 58,5,5 V
Minimum voltage to detect battery| 6,0V| 17,5 V| 17,5 V
Maximum input voltage| 60,0 V| 60,0 V| 80,0 V
Wiring recommendedfor battery bank| 6 mm2| 6 mm2| 4mm2
Maximum distance for battery bank| 3 m| 3 m| 3 m
Maximum current to charge| 40A| 40A| 35A
Maximum speed turbine| 2500 rpm| 1500 RPM| 1200RPM
Maximum power inwind turbine| 800W| 1000 W| 2000 W
Maximum power insolar input| 300W| 600W| 600W
Recommended minimum battery| 12V / 100Ah| 24V /100A| 4 x 12v 100A
Internal fuse| 50A| 50A| 40A

see your controller voltage on the label attached to the door

Information about the Display

1. Out-battery charging program
2. 48.7V Current battery voltage
3. 0.00% Percentage linked to the wind turbine brake; this percentage is not linked to the battery charge but to the wind turbine brake based on the Voltage coming from the wind turbine
4. The display is factory-locked and it is not possible to change the brake voltage parameters
5. the display will flash when the turbine is braked, just press the central button once and it will stop flashing

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