Manual_Montana_V2.2 - Fortis Wind Energy
Contents
1. gt gt TIT Rear side of the wind turbine generator Manual Montana Page 31 of 48 FORTIS WIND ENERGY 5 I L 11 0 Detail chain and spring between tail and support frame 11 1 Terminal box at back side of generator Serial number of Wind turbine and production year Manual Montana Page 32 of 48 FORTIS WIND ENERGY REATINS ALL TURBINE 12 Gin pole and winch Wiring of 18 m guyed tower with Gine pole and Winch Fortis Montana guyed tower with gin pole ready for erection Manual Montana Page 33 of 48 FORTIS Guyed tower picture Fortis Montana at 18 m guyed tower with 3 x 4 guy wires Manual Montana Page 34 of 48 FORTIS WIND ENERGY 13 Drawings Guyed Tower My Fy Guyed Tower Montana with 12 15 meter height Manual Montana Page 35 of 48 FORTIS WIND ENERGY 13 1 Drawings Guyed Tower Guyed Tower Montana with 24 meter height Manual Montana Page 36 of 48 FORTIS WIND ENERGY 5 1 L 14 Part numbers of Montana Manual Montana Page 37 of 48 FORTIS WIND ENERGY 14 1 Part number list Part Name Material Colour Number 1 3 Rotorblades glass fibre reinforced epoxy White 2 Generator RST37 galvanized cast iron Blue RAL 5010 3 Gondel RST37 galvanized Grey 4 Mast Adapter RST37 galvanized Grey 5 Tail lower section RST37 galvanized Grey 6 Tail Vane AR2. Appendix 13 3 2 Foundations As there is such a wide variety of masts possible we only describe here the foundations for the standard guyed steel tubular mast according to the standard FORTIS design There are three ways to make a proper foundation for the mast and guy wires 1 The first type of foundation is for very soft and unstable ground for this type concrete blocks of a certain weight have to be used Drawings for this type of foundation are provided in appendix 7 6 7 7 2 The second type of foundation is for rocky ground this type requires the use of rock bolt s for the tower and the guy wires Make sure that the rocks are heavy enough FORTIS can provide and specify the rock bolts on request The size and weight of the rocks must be about the same as the concrete blocks described in the foundation drawings 3 The third type of foundation is for medium soft but stable ground for the guy wires earth screw anchors are used and for the mast a small concrete block will be sufficient The earth screw anchors can be specified and provided by FORTIS The concrete block is the same as in appendix 7 6 7 7 ora standard block for roads can be used in the size of 2 x2 x 0 12 cm The base plate can be fit with chemical bolts 3 3 Installation preparations Before the mast is placed in a horizontal position bolted to the base plate make sure the mast will be lifted towards the main wind direction Lift and support the top of the mas
3. display 1 USB Interface Manual Montana Page 40 of 48 FORTIS WIND ENERGY Note For detail description of the GFI 5K Inverter see Manuals Installers Manual GB Version 2 4 716004 Dump load DL 35K DL 57K User manual Version 2 0 716005 MultiTool Manual Version 1 5 716006 17 Electrical scheme for grid connected Electric schema wind turbine Fortis Montana to single phase network Dump Load Box 3 phase generator Montana J Inverter connected to the public Grid 1 phase 230VAC N PE GFI 5K Rectifier inverter i Il Disconnect Switch Fuse25A tt lia Earth LNPE Brake switch at the basement of the tower Manual Montana Page 41 of 48 FORTIS WIND ENERGY 18 Electrical scheme for stand alone and battery charging 3 phase generator Montana Plug and socket at the basement ofthe tower Dumpload4x 1850Watt 56V Parallel connected PAAAAEESAEAAEEEES BAABAEAEEEESEAEEESASA Fortis Montana 48V battery charging system IN_48V_100A D DF Rectifier with voltage controller amp battery charger PWM an cable 3x 16mm2 Wires min 16 mm2 DC AC AC Load 2 230V 50Hz Victron Inverter Input 48V Size3000Watt Fuse and switch box Battery bank48DC Min 800 Ah Manual Montana Page 42 of 48 FORTIS WIND ENERGY 19 Trouble shooting list Problem Possible Cause s Diagnosis Remedy Fault lights or m
4. individual guy wire and then connect it to the mast and to its foundation The only guy wire that cannot be connected is the one directly opposite the direction in which the mast is pointing This guy wire should be connected when the mast is in the upright position All guy wires are connected to the mast with a bow shackle to the foundation with a rigging screw and twin cable clamps Both cable clamps must be fully tightened before lifting the mast Manual Montana Page 12 of 48 FORTIS WIND ENERGY 4 Electric Installations 4 1 Transmission lines 4 2 Voltage control dumpload 4 3 Grid connection 4 4 Batteries 4 1 Transmission lines The FORTIS MONTANA 5kW generator is a 3 phase generator and 3 electric wires are needed to connect the generator with the rectifier bridge which is inside the voltage control box The maximum rectified current is 150 ADC and peak voltage is 600 VDC The working temperature of the components is 40 C to 50 C The electric wires have to be flexible and should not consist of a single solid copper core Furthermore the isolation wrapping of the wires should be UV resistant PVC isolation cannot stand UV light Prevent the damaging of the electric wires by sharp edges Any damage to the electric wires will lead to short circuiting and the rotor will stop rotating or even worse the rectifier bridge might be destroyed because of too many amperes Never let the wires hang with their full weight on t
5. of the local rules of save work If you use a gin pole for erection read first the special instructions in the manual Do you have insurance public liability insurance product warranty and liability professional indemnity erection all risks Manual Montana Page 45 of 48 e FORTIS WIND ENERGY BRAKE SWITCH The brake switch is not an emergency brake Use the brake switch only for service The brake switch will stop the turbine automatically when the voltage reach S5OOVDC Release the brake when the rotor gets to zero rpm Do not try to stop the turbine during high winds The wind turbine will protect himself Any interruption in this leads to damages and dangerous situations Do not interfere the system in any case Please contact your local dealer VV VV Vv Manual Montana Page 46 of 48 FORTIS WIND ENERGY 21 Declaration of Conformity Declaration of Conformity According to type II A without external approval Declaration of approval according to appendix II A of the machine guideline Manufacturer Fortis Wind Energy Address Botanicuslaan 14 9751 AC Haren The Netherlands Herewith declare under our sole responsibility that the products Passaat 1 4 kW Montana 5 kW Aliz 10kW to which this declaration is regarded confirms to the Construction products 89 106 EEG the low voltage electricity 73 23 EEG the EMC 89 336 EEG and the machinery 98 37 EEG IEC 61400 2 Design require
6. power coming from the turbine Do not be disappointed when the wind turbine does not start up in winds slightly above 3 m sec as it sometimes needs a short running in period When lifted the wind turbine with generator short circuit the wind turbine will start to rotate very slowly if there is sufficient wind less than 10 rpm A final check can be made when the turbine is producing some power check the voltage over a period of several hours If all the connections are made correctly the voltage will increase slightly although the difference may be minimal To replace a controller first set the short circuit switch on STOP Prepare 3 copper wires without isolation and at one site connected with each other Unplug the plug and socket at the tower base and put the 3 copper wires around the 3 pins of the plug You can use also a second socket which is short circuit internal and plug this one in the plug If this has been made properly the turbine is short circuit and runs only very slow Disconnect the wires from the wind turbine and other wires but as final the wires of the dumpload If you assemble the controller again take first the dumpload wires to be connected Manual Montana Page 21 of 48 7 Appendix 7 1 Torque specifications FORTIS WIND ENERGY Specification bolt nut Description Torque N m M14 60 Mast top and mast flanges 50 Nm M12 nut Tail hinge pin 50 Nm M12 40 Tail hinge pin 50 N
7. the mast of an FORTIS MONTANA 5kW wind turbine The maximum wind speed for erection of the mast and wind turbine must not exceed 12 m sec Only an FORTIS specialist who is present during installation and erection can decide to proceed during higher wind speeds Snowfall during installation is not necessarily a problem provided the snow is not sticking to the blades in large amounts Snow or ice can cause rotor unbalance and thus damage the bearings of the generator Manual Montana Page 17 of 48 FORTIS WIND ENERGY 6 3 The installation erection procedure The simplest way to erect an FORTIS mast is to use a gin pole It is also the method most often used owing to the fact that it is usable under a wide range of circumstances The length of the gin pole must be somewhere between 1 2 and 1 3 of the length of the mast and a set of guy wires are required to prevent the mast from toppling to one side If only one set of guy wires is used connect this one guy wire to the top section of the gin pole When several sets of guy wires at different levels are used a guy wire of every set must be connected to the top section of the gin pole The last attachment point of the gin pole is used for the cable of the winch or cable jack The gin pole is now held in place by at least four cables If it is possible to climb the mast when itis in a vertical position we advise you to fix a rope to one of the blades to prevent the turbine from rotating Ev
8. 00 Watt Output 11m s 3400 Watt Rotor Diameter 5m Hub height mast 18m Rotor with fixed pitch Type Upwind rotor with fixed pitch Direction of rotation Clockwise Number of blades 3 Swept Area 19 63m Length of blades 2 35m Profile E 387 Manufacturer Fortis Wind BV Fiberglass reinforced epoxy variable max450 rpm Rotor axis angle 10 Blade material Rated speed Cone angle 0 Generator and hub Pitch control fixed pitch Hub Rigid Permanent Magnet FORTIS Synchron machine Generator Grid feeding 1 x 230V by inverter Break systems Ecliptic safety system by inclined hinged vane 90 setting of tail short circuit of generator Passive Aligned by Tail Vane Various types of towers designed for different sites Weight tower head 200 kg Manual Montana Page 25 of 48 FORTIS WIND ENERGY 7 5 Maintenance checklist In principle FORTIS wind turbines do not require any maintenance at all On the other hand it would be unwise not to check the wind turbine occasionally FORTIS advises that you should check the wind turbine at least ones a year Note The following points should be checked Check noises the noise level should not have increased and should sound normal Check nuts and bolts as far as possible They might have worked themselves loose Check the electrical wires that are hanging through the inside of the mast the tension must not be too high this can occu
9. 2 1 External Brake Resistor Battery charging Single Phase Montana 48V 230V 50Hz Dump load 4x 1850W 56V 1x 5 kW 33 Ohm Connection Parallel Cable type EMC Shielded Length Max 2 m Inverter type IN_48V_100A GFI 5K WARNING The brake switch short circuit the generator and will bring the rotor stop rotating up to wind speeds of 8 9 m sec Never let the brake switch on for more than ten minutes if the rotor does not stop because of high wind speeds The generator can be overheated and destroyed 4 3 Grid connection Grid connection is one of many options with an FORTIS system In a grid connected FORTIS MONTANA 5kW system the voltage controller IN 400V_15A can be used in combination with an active brake switch and a grid link inverter Aeocon or SMA The voltage controller is needed to protect the inverter against peak voltages when the load is disconnected At present we use a one housing solution by a GFI 5K grid tie inverter 4 4 Batteries Batteries need to be kept in a place with sufficient ventilation and no risk of freezing Charged batteries can stand temperatures of up to minus 20 C but uncharged batteries cannot withstand frost at all Place the batteries underneath the voltage control in the same room if possible as this minimizes energy loss in the wires A battery is normally 12 V so you need two batteries connected in series for 24 VDC or 4 for 48V or 10 for 120VDC Connect the minus t
10. FORTIS WIND ENERGY FORTIS Wind Energy Montana Wind Turbine Instruction Manual Manual Montana Page 1 of 48 FORTIS WIND ENERGY No part of this document may be reproduced or transmitted in any form or by any means electronic or mechanical including photocopying and recording for any purpose without the express written permission of FORTIS WIND ENERGY FORTIS WIND ENERGY reserves the right to make changes to any and all parts of the documentation at any time without obligation to notify any person or entity of such changes Copyright 2013 FORTIS all rights reserved Fortis Wind BV 9751 AC Haren The Netherlands Manual Montana Page 2 of 48 FORTIS WIND ENERGY Table of Contents Index Page 1 Introduction 6 2 Assembling Power head 7 2 1 Frame generator 7 2 2 Rotor blades Hub 7 2 3 Tail 8 2 4 High Wind speed Protection 8 2 5 Mast top 8 2 6 Nose cone 8 3 Instructions Mast 9 3 1 Producing a Mast yourself 9 3 2 Foundations 10 3 3 Installation preparations 10 4 Electric Installations 13 4 1 Transmission lines 13 4 2 Voltage control dumpload 13 4 3 Grid connection 14 4 4 Batteries 14 5 Final assembly system electronics 15 6 Erecting the turbine in the upright position 17 6 1 Safety first 17 6 2 Conditions during installation 17 Manual Montana Page 3 of 48 e FORTIS WIND ENERGY 6 3 The installation erection procedure 18 6 4 Guy wire tensioning 18 6 4 1 Determining the proper freque
11. PA Al RST37 Grey White 7 Rotor Hub RST37 galvanized Blue RAL5010 8 Nose cone Glass Fibre Polyester Blue RAL 5010 9 Rotor Bolts and Nuts M12 Stainless Steel A2 10 Generator Bolts and Nuts M12 Stainless Steel A2 11 Tail Vane shaft Stainless Steel AISI 304 12 TailVane Bearing Synthetic Material 13 Azimuth Bearing Synthetic Material 14 Tail Vane part RST37 galvanized Grey 15 Tail Vane connector RST37 galvanized Grey 16 Tail Vane part RST37 galvanized Grey 17 Tail Vane connector RST37 galvanized Grey 18 Tail Vane upper section RST37 galvanized Grey 19 Your Company logo Option Option Manual Montana Page 38 of 48 FORTIS WIND ENERGY REAT IN SMALL TURBINE 15 Brake Switch 5000 12 Type 5000 12 Valid for serial numbers 0361207xxx BRAKE SWITCH FEATURES The full automatic Brake Switch is designed for the Montana 5 kW RED STOP button for a 2step automatically safe shutdown of the wind turbine Overvoltage protection for the load Feed in Converter GFI 5K Micro Controller Unit MCU handles the braking procedure by overvoltage or RED STOP button Build in brake resistor to reduce RPM of wind turbine for safe park position generator is mechanically short circuited Note Detail Information see Manual Brake Switch 5000 12 V3 0 Manual Montana Page 39 of 48 16 Feed in Inverter GFI 5K 3 2 Technical data GFI 5K GENERAL Description Operating temperature Storage temperatur
12. cable between generator and controller between phases The rotor is mounted in the wrong way Observe if flat side is to the wind Drop the tower and reverse the blades Brake is on Check brake switch Turn brake off Failed bearings All other causes ruled out Drop tower and replace generator unit Failed generator slip ring Measure resistance between phases from bottom of tower Short circuit or variations of resistance means electrical failure Drop tower and replace generator unit or slip ring Turbine turns too fast and is more noisy than usual Cable from generator to controller is disconnected and wind turbine runs without load Check wires for continuity and loose connections Reconnect controller apply stop switch or insert emergency stop connector in mast Controller failure Open controller and check for signs of damage Replace controller Clanking noise from tower top Tail furling Use binoculars to see if its the chain clanking Normal operation Mechanical failure Visual inspection Replace worn part Manual Montana Page 44 of 48 FORTIS WIND ENERGY 20 Safety and control procedures A a a WARNING What s dangerous Spinning Rotor High tension on electric wires Falling from tower Crane drops tower wind turbine Gin pole winch fault during erection of guyed tower For safety and control instruc
13. connect the wires from the generator to the controller when the wind turbine is in operation The open circuit voltage can be 10x the nominal voltage This voltage can destroy the electronics Manual Montana Page 16 of 48 FORTIS WIND ENERGY 6 Erecting the turbine in the upright position 6 1 Safety first 6 2 Conditions during installation 6 3 The installation 6 4 Guy wire tensioning 6 5 Start up procedure 6 1 Safety first Safety becomes very important when you consider the amount of serious damage and injuries that can be caused if a wind turbine topples over Firstly therefore make sure that all the nuts and bolts of the wind turbine are tightened securely We advise you to make one person responsible for the final overall check of all the nuts and bolts Then let the same person check all the guy wires rigging screws and foundations WARNING During hoisting of the mast and wind turbine everybody who is not directly involved with the process must keep a distance of at least mast height to the base plate When a gin pole with a cable jack or cable winch is used to erect the mast and wind turbine only 2 men are necessary for the process one for the actual lifting jacking and one to check the guy wires during erection This person should make sure that the wires do not get stuck somehow or work themselves loose 6 2 Conditions during installation It is not absolutely necessary to wait for a windless day to erect
14. dings even if they are somewhat lower than the wind rotor will cause turbulent air currents to arise which seriously decrease the generator output Turbulent air has lost a large part of its original power and continually shifts from one direction to another also upwards and downwards This causes the wind turbine to vibrate to some extent All of these factors should be considered when selecting a satisfactory location for the wind turbine The higher the wind turbine is situated the better since the air currents are smoother and steadier further from the ground For a good operation the wind turbine should be mounted at least 5 metres above any obstruction within 200 metres In order to keep electrical losses caused by long transmission lines to a minimum Install the wind turbine as close to the application as possible without disturbing an unobstructed sweep from the wind The dimensions of transmission lines are described under the chapter heading Transmission lines 4 1 Manual Montana Page 9 of 48 FORTIS WIND ENERGY In most cases FORTIS advises the use of the guyed steel tubular mast as it is inexpensive easy to build easy to erect and FORTIS can provide all the required calculations These calculations can be very important when planning permission has to be obtained The drawings for a guyed steel tubular mast are provided in this manual The masts are designed according to a modular system with 6m modules guyed every 6m
15. e Relative humidity Protection degree Safety class Galvanic isolation INVERTER INPUT Nominal power Continuous power 40 C Operating voltage Nominal voltage full load Maximum voltage Rated current Maximum current Frequency range DUMP LOAD OUTPUT Nominal power Maximum power 120sec duration Maximum current GRID OUTPUT AC Voltage Nominal power Maximum power Nominal current Frequency Power factor Harmonic distortion THD DC current injection AC connector FORTIS WIND ENERGY Integrated single phase inverter 20 C to 60 C ambient full power up to 40 C ambient air temperature derating 3 C above 45 C 20 C to 60 C protected against humidity and condensing air by PCB coating IP42 class I metal housing with earth connection class II safety transformer 5 000 W 5 000 W 40 340 V AC 220 340 V AC 390 V AC 3 x 10 A rms 3 x 15 A rms 0 150 Hz 230 V AC 1 phase N PE 5 000 W 5 250 W 1x22A 50 Hz models 48 52 Hz programmable 60 Hz models 57 63 Hz programmable gt 0 99 at full power lt 3 at full power UL1741 IEEE1547 2003 IEEE 1547 1 2005 compliant galvanic grid disconnection at 1000 mA DC to VDE 0126 1 1 2006 AC glands on detachable plate in bottom of connection compartment Internal PCB fuse in inverter SYSTEM INFORMATION DIAGNOSTICS COMMUNICATION User interface Inverter external communication 10 status LED s or TFT Touch
16. eel bars can be assembled with M8 bolts according the pictures on chapter 9 0 Tail Assembly and appendix 7 1 Torque specifications The complete tail can be assembled to the frame by 2 x 2 M10 bolts There is only one way to assemble the tail parts In another way the pieces does not fit The chain which is already connected to the support frame must be connected to the tail with a D shackle Make sure the stainless steel spring is mounted between the middle of the chain and the support frame Don t forget the split pins cotter pins to secure the nuts of the D shackle 2 4 High Wind speed Protection Side Furling The High Wind speed Protection system will protect the wind turbine automatically during high wind speeds When furled the rotor will turn away from the wind direction When the rotor speed is reduced the power output of the wind turbine will be significantly reduced Side Furling is an easy method to provide high wind speed protection It is based on a basic physical relationship between aerodynamics rotor gravity the specially designed tail shape and weight balance of the Montana Side Furling is completely passive and very reliable 2 5 Mast top The mast top is fit into the support frame of MONTANA 5 kW wind turbine Do not remove the mast top from the frame Inside are Teflon coated vertical thrust bearing and radial glider bearings Further they are greased with copper grease Before you bolt it on top of the mast make
17. en when it is possible to fix one of the blades with a rope the three phases of the generator must always be connected short circuited Be very careful with short circuiting the three phases when the rotor blades are moving the voltage can easily reach dangerous levels The mast and wind turbine can now be erected 6 4 Guy wire tensioning FORTIS has developed and recommends a method for setting the pretension on guy wires for all guyed towers This simple procedure utilizes the relationship between cable tension and the rate of cable vibration to give a preload which is proportional to cable size It is based on the time required for the guy cable to complete 20 oscillations at the fundamental natural frequency The approximate desired preloads for the various cable sizes are given below EHS Cable size Preload 1 2 12mm 900 kg 7 16 675 kg 3 8 10mm 450 kg 5 16 8mm 337 5 kg 1 4 6mm 225 kg Manual Montana Page 18 of 48 FORTIS WIND ENERGY 6 4 1 Determining the proper frequency of the cable 1 Determine the length of the cable in metres from the guy bracket to the ground 2 Divide this length by 3 3 This gives the number of seconds which are required for the cable to make 20 complete cycles 4 The process is very sensitive to this time period Doubling the time required to make the 20 oscillations will result in 1 4 of the desired guy tension We recommend therefore that the ten
18. er supply FORTIS wind turbines are in operation all over the world and can withstand almost every environment imaginable Even arctic expeditions have benefited from the reliable power the FORTIS wind turbine produces FORTIS tests their systems under the worst possible weather conditions FORTIS wind turbines are installed at all over the earth Therefore the FORTIS products are designed on such a way that they can be installed and erected successfully with a minimum of tools and technical know how Also unskilled people are capable of maintaining the system with a minimum of tools and knowledge A FORTIS system is almost always composed of various components the wind turbine itself is only one component of this system We can supply controllers for battery charging and for grid connection For hybrid systems controllers are available to couple a photovoltaic solar generator or to a diesel or petrol generator together to a FORTIS Wind turbine In other words the possibilities with an FORTIS wind turbine are endless in the sense that they can be adapted to suit almost every conceivable application Sincerely Fortis Wind Energy Important security notice This Instruction Manual contains important operational guidelines and security considerations that require your attention Before installation it is essential that the user first studies this user s manual in detail and keeps in mind the safety matters that need attention During user installati
19. erminal of one battery with the plus terminal of the other battery The remaining terminals are the plus and minus of the battery group For an FORTIS Montana 24V we advise a minimum battery capacity of 1000 Ah C 10 h but a capacity of 2000 Ah is even better For lead acid batteries the charging discharging current should not exceed 20 of the capacity preferable 10 Manual Montana Page 14 of 48 FORTIS WIND ENERGY 5 Final assembly of system electronics When mounting the voltage controller IN 400V_15A Grid Connected it is very important to choose a wall or surface which is non conductive Cooling blocks are mounted on both sides of the controller to cool the rectifier bridge and the MOSFET s of the electronic part When the wind turbine is operating at full power there is a heat generated in these blocks The dumpload can get very hot Both controller and dumpload should therefore be mounted in such a way that the risk of getting scorched is minimal The wires of the dumpload must be connected to the two contacts in the middle of the contact rail The dumpload is not sensitive to plus and minus so the order of connection is not important The same applies for connecting the three phases of the generator these must be connected to the three contacts on the left of the contact rail Again the order in which they are connected is unimportant The last component to connect is the consumption circuit The consumption circuit can e
20. essages Various Various Refer to inverter manual on inverters Low output Low or turbulent wind Turbine site Create more clear space around turbine Incorrectly programmed or undersized inverters Check inverter parameters Ensure parameters are as specified Guy cables loose or tower leaning from vertical Normal cable slackening following installation Visual check Tighten to specified pre tension Heat dump on Controller is damaged Open controller and check for signs of damage Replace controller Mains failure MCB tripped Check MCB supply and mains Restore supply Incorrectly programmed or undersized inverters Check inverter parameters Ensure parameters are as specified Pole bends in high winds Normal operation Bending like an aeroplane wing is normal NA Turbine vibrates or tail shakes Natural frequency Vibrations only at a specific speed Normal operation Unbalanced blades Vibrations increase as speed increases Stop immediately Rotor blades are not running in the same plane the hub is misaligned Vibrations increase as speed increases Stop immediately Manual Montana Page 43 of 48 FORTIS WIND ENERGY Problem Possible Cause s Diagnosis Remedy The rotor blades run Short circuit in the Check cable for resistance Repair cable very slowly or fail to turn in good wind electrical
21. etwist after 6 month you can check the wires ones a year If the cables are twisted disconnect the plug and socket when the wind speed is very low Retwist the cables and plug in again It take only a few minutes WARNING Never disconnect the plug and socket at moderate or high wind speeds The open circuit voltage can reach to a very high level and results in damage of the electronics when assembling the plug and socket The lower section of the tail with spindle is assembled to the frame There is no need to change it but in case you have to replace it follow the procedure The tail uses a stainless steel pin as spindle This is fit to the frame Note in which way the spindle shaft is assembled into the frame The pin must slide into the tubular section of the tail frame where it passes through two Teflon bearings When assembling the lower tail section to the frame you put first the top of the spindle shaft into the top frame section and second the lower part Note that before you put the spindle shaft in the lower part of the frame you put the Teflon ring around the spindle The Teflon ring is the bearing surface which has to cope with the full weight of the tail In principle the tail bearings should not need any additional lubrication however applying grease extends the life of the bearings to some extent The spindle is fixed with a M12 bolt with locking rings at the bottom of the frame and a self locking nut at the top The chain which is a
22. fasteners Manual Montana Page 28 of 48 FORTIS WIND ENERGY 7 8 Voltage drop for Fortis Montana 400 V wind turbine cable cross section in mm2 2 50 4 6 10 16 cable length in meters 50 8 12 5 07 3 38 2 03 1 27 cable length in meters 100 16 23 10 15 6 76 4 06 2 54 cable length in meters 200 32 47 20 29 13 53 8 12 5 07 cable length in meters 300 48 70 30 44 20 29 12 18 7 61 cable length in meters 400 64 94 40 58 27 06 16 23 10 15 7 9 Voltage drop for Fortis Montana 48V wind turbine cable cross section in mm2 6 10 16 25 cable length in meters 50 15 5 9 3 5 8 3 7 cable length in meters 100 31 18 6 11 6 7 4 cable length in meters 200 62 37 2 23 3 14 9 cable length in meters 300 93 55 8 34 9 22 3 8 0 Voltage drop for Fortis Montana 120V wind turbine cable cross section in mm2 6 10 16 25 cable length in meters 50 6 2 3 7 2 3 1 5 cable length in meters 100 12 4 7 4 4 7 3 0 cable length in meters 200 24 8 14 9 9 3 6 0 cable length in meters 300 37 2 22 3 14 0 8 9 Allowed voltage drop 5 10 48V 2 5 5V 120V 6 12V 400V 20 40V Manual Montana Page 29 of 48 vw FORTIS 9 0 Tail Assembly Tail sections Tail frame and tail vane Tail connected to tail pivot Tail Pivot Tail connection on frame Manual Montana Page 30 of 48 FORTIS IND EN ER 10 Plug and socket in tower base
23. he cable terminals If the cable is long and heavy use steel wire inside the tower and tape the electric wires to this steel wire every 4 6 m For the wire gauge see the chapter 7 8 8 0 4 2 Voltage control dump load battery charging system The electronic voltage control prevents over charging of the batteries When the batteries reach a threshold value the current from the generator is proportionally directed to a dump load The dump load can either be a coil for water heating or for air heating The box of the voltage control unit is made according to international standard IP 44 and is not 100 weather resistant Every voltage controller is supplied with an air heating coil which functions as dump load Water heating is optional To prevent any problems with heat dissipation mount the dump load above or at some distance away from the controller It is advisable to mount the controller as close to the batteries as possible to minimize electrical losses When the controller is housed in the same room as the batteries and dump load the room must be well ventilated There are two possible voltage controller types for the FORTIS MONTANA 5kW 1 IN 400V_15A Over Voltage controller Dump load for Grid Connected 2 IN48V_100A Over Voltage controller Battery charger Dump load for Off_Grid Note Detail Information see Manual Voltage Controller 48V 100A or IN 400V_15A Manual Montana Page 13 of 48 FORTIS WIND ENERGY 4
24. ither be a battery bank an inverter for grid connection or a Pump controller for water pumping The contact rail has four terminals on the right side for the consumption circuit two plus terminals and two minus terminals Terminal connection IN 400V_15A Grid Connected Connect the metal casing to ground 2 free PE terminals are available Connect the ballast resistor to the terminals R1 R2 and its case and cable shielding to the terminal DE Connect the DC input of the grid inverter to the terminals gray blue Connect the 3 phases of the generator to the terminals L1 L2 L3 Terminal connection IN 48V_100A battery charging Connect the metal casing to ground 2 free PE terminals are available Connect the 4 ballast resistors in parallel and the cases and cable shielding to the Ballast terminals R1 gray R2 gray and PE green yellow Connect the battery to the terminals gray blue Connect the 3 phases of the generator to the terminals L1 gray L2 gray L3 gray Manual Montana Page 15 of 48 FORTIS WIND ENERGY IMPORTANT There is however a specific sequence in which all the above mentioned connections must be made This is very important as if the connections are not made in this order the generator or controller can be damaged during the insta
25. llation procedure 1 The brake switch has to be set on STOP 2 The dump load must always be the first component to be connected 3 The consumption circuit or inverters must always be the next component to be connected beware of the difference between and 4 The 3 wires of the generator are the next component to be connected 5 The batteries are the last component to be connected WARNING Be aware that step 1 and 2 are made properly before you start with step 3 and 4 If the generator has been connected first it is possible that a high voltage is generated which can damage the transistors Be also aware of static electricity on your clothes or wires because they can damage the transistors too Before the wind turbine is erected and during the process of erection the three phases of the generator should be short circuited If an IN controller and active brake switch is used this can be done by using the RED STOP button or the selector switch into position 2 short circuit Any other temporary way of short circuiting the three phases is allowed It is not necessary to disconnect the batteries as they are protected from short circuiting by the rectifier bridge In addition to this the batteries and any other consumption circuit should be properly fused FORTIS advises to fuse all other consumption circuits in accord with their specifications as required Check that all your connections are tightly and correctly connected WARNING Never
26. lready connected to the support frame must be connected to the tail with a D shackle Make sure the stainless steel spring is mounted between the middle of the chain and the support frame Don t forget the split pins cotter pins to secure the nuts of the D shackle Next to install are the rotor blades the assembly of rotor blades 3 and 2 hub plates are bolted together with the 9 x M12 bolts ss Hub plates mere Manual Montana Page 11 of 48 FORTIS WIND ENERGY The hub plates are marked with 1 2 or 3 which is corresponding with blade number One hub plate is the front which has connections for the nose cone The other hub plate can be used only in one position Don t drill the holes because the blades get only in this way in the right position and therefore are balanced Because the bolts are made of stainless steel you must be careful not to damage the threat If the threat of the bolt is damaged it is impossible to get the nut on it After the 3 blades are assembled together you can fix the complete rotor to the generator The remaining 9 holes of 15 mm corresponds with the 9 x M14 bolts on the generator There are 9 x M14 nuts with norlock washers to secure the nut of getting free Finally assemble the nose cone with 3 bolts The next stage involves the guy wires a standard FORTIS MONTANA 5kW mast according to FORTIS specifications is guyed every 6m in four directions Make a rough calculation of the length of each
27. m M12 50 Generator chassis mounting 20 Nm M 8 55 Tail boom Tail vane 20 Nm M 8 60 Tail boom 20 Nm M12 100 Rotor blades 40 Nm M14 Rotor to generator 40 Nm M6 20 Nose cone 10 Nm M24 Mast flanges 540Nm 7 2 Required tools The following tools are the minimum that required for successful installation For Free standing tower assembling Tractor or lifter to put tower sections together max weight tower section is 400kg One spanner and one socket wrench Size 36 for M24 bolts For Guyed tower assembling Max weight per tower section is 45 kg One spanner and one socket wrench Size 22 for M14 bolts Spanner and socket for M6 nuts of cable thimble guy wires Size 10 For windturbine assembling Set of spanners 10 11 13 17 19 and 22 mm Socket wrench 10 13 17 19 and22 mm Screw driver for electrical terminals Rubber hammer 2 5 kg Multimeter AC DC voltages 0 500V Ratchet Pincers Cable stripping tool and cutting tools Manual Montana Page 22 of 48 FORTIS WIND ENERGY To lift turbine with 18 tower max weight 1100kg Crane 16 m or 22m height With 16 m the crane remains below rotorblades With 22 m the crane remains above rotorblades Rope nylon 20m to remove lifting rope from crane For installing controllers and dumploads Drilling machine with drills for wood or st
28. ments for small wind turbines which has been adopted as European Standard EN 61400 2 guidelines of the EEG Instructions for installation operation and maintenance are according to the Instruction Manuals Haren 2011 08 22 Johan Kuikman CEO Fortis Wind Energy Manual Montana Page 47 of 48 FORTIS WIND ENERGY Manual Montana Page 48 of 48
29. ncy of the cable 19 6 4 2 How to oscillate the cable 19 6 4 3 Procedure of tensioning the cable 20 6 4 4 Cautions Hints and Suggestions 20 6 5 Start up procedure 21 7 Appendix 7 1 Torque specifications 23 7 2 Required tools 23 7 3 Technical data Montana 5kW 24 7 4 Power curve Montana 25 7 5 Maintenance checklist 26 7 6 Foundation blocks for guyed towers 27 7 7 Anchors and concrete specifications 28 7 8 Voltage drops Fortis Montana 400V wind turbine 29 7 9 Voltage drops Fortis Montana 48V wind turbine 29 8 0 Voltage drops Fortis Montana 120V wind turbine 29 9 0 Tail Assembly 30 10 Plug and socket in tower base 31 11 0 Detail chain and spring between tail and support frame 32 11 1 Terminal box at backside of generator 32 12 Gin pole and winch 33 13 Drawings guyed tower 35 Manual Montana Page 4 of 48 FORTIS WIND ENERGY 13 1 Drawings guyed tower 36 14 Part numbers of Montana 37 14 1 Part number list 38 15 Brake Switch 5000 12 39 16 Feed in Inverter GFI 5K 40 17 Electrical scheme for grid connected 41 18 Electrical scheme for stand alone and battery charging 42 19 Trouble shooting list 43 20 Safety and control procedures 45 21 Declaration of Conformity 47 Manual Montana Page 5 of 48 FORTIS WIND ENERGY 1 Introduction Thank you for choosing this FORTIS energy systems Your choice means proven reliability no maintenance costs only a regular check is recommended and the convenience of an independent pow
30. on and operation one must refer to this handbook s documentation If you are unfamiliar with installation as shown below DO NOT CONTINUE and let a qualified Technical Engineer proceed with correct installation Failure to comply with the guidelines and instructions will void your warranty Do not change anything of the wind turbine parts or do not paint the blades If you do so you lose the right of warrantee Any change can have effect in the behaviour of the wind turbine Manual Montana Page 6 of 48 FORTIS WIND ENERGY 2 Assembling the power head The FORTIS MONTANA 5 kW power head consists of the following parts Frame generator mast adapter Rotor blades hub Tail with tail vane 2 1 Frame generator When you first open the crate check the contents carefully starting with the generator and its support frame First make a visual check to determine any existing scratches dents or cracks Then rotate the generator by hand This must rotate smoothly lt 5 0N m If it does not check whether there is no short circuit in one of the phases out coming wires might be connected somehow Normally the generator is already attached to the support frame with a specified torque appendix 7 1 so there is no need to tighten the eight M12 bolts The power head is bolted to the crate it is transported in before you undo these bolts remove all other components inside the crate We advise to wait with unpacking the power head till i
31. one for wall plugs and screw Size from 5 up to 12 mm Mechanical crimping tool for 6 and 10 mm2 cable Screw driver for electrical terminals Multimeter AC DC voltages 0 500V Manual Montana Page 23 of 48 7 3 Technical data MONTANA 5kW FORTIS WIND ENERGY Max output 5800W Output 11m sec 3 4kW Wind speed cut in 2 5 m sec rated 17m sec survival 60 m sec Rotor blades number 3 diameter 5 0m area 19 63m airfoil E 387 tip speed ratio 7 material glass fibre reinforced epoxy Generator type brushless permanent magnet 9 pole RPM operation range 120 450 voltage from 48 to 500VDC standard other voltages on request frequency 0 70 Hz Other gearbox none braking mechanism Automatic breaking switch rotor speed control Inclined hinged vane output control voltage control with dump load rectifiers built inside controller hub type rigid yaw system tail vane rotor position upwind tower guyed steel tubular height 12 24m free standing tube mast height 12 24m Head weight 200 kg Manual Montana Page 24 of 48 7 4 Power curve Montana Rated capacity KW 6r 55 t r FORTIS WIND ENERGY 5 45 S a 20 25 30 Wind speed at hub height m s Type Fortis Montana Manufacturer Fortis Wind Energy Rated Power 58
32. r if the wires have been wound too far and there is no slip ring used Check the leading edge of the blades from the tower basement on a wind less day Small damages can be caused by small objects carried by the wind such damages will speed up the process of wear and tear and should be repaired Check if the turbine tail or tower is shaking more than usual If this shaking occur only at a specific low speed this means own frequency If it become stronger with higher wind speed stop wind turbine and contact your dealer or agent or contact Fortis direct Check the tension of the guy wires if you have a guyed tower in the first 6 months regular Manual Montana Page 26 of 48 FORTIS WIND ENERGY 7 6 Foundation blocks for guyed tower Allowable pull misalignment max 5 Dimensions block B C D and D 1000 x 600 x 1000 mm I x w x d Dimensions block A 1000 x 1000 x 600 mm I x w x d Manual Montana Page 27 of 48 FORTIS WIND ENERGY 7 7 Anchors and concrete specifications PAD A 6 BOWS 48 PAD 8B C D E 3 RINGS 6 6 BOWS 6 5 RINGS 8 1000 2 RINGS 96 notes 1 concrete requirements 2 76 m 10N 1kg cement 0 46 m 1m concrete 24000N sand 0 92 m gravel 1 38 mP 2 reinforcement steel FeB360 covered with a minimum of 40 mm concrete 3 all pads must be level and be at the same elevation 4 guy wire attachments and other fixtures are bolted to the pads using hilti type concrete
33. sion be adjusted until the time period is within 1 second of the recommended value Calculation example assume the following geometry Height of guy fixing point 12m Distance mast foundation point 6m This gives a total cable length of 13 4m Dividing by 3 gives 4 5 seconds to complete the 20 oscillations 6 4 2 How to oscillate the cable Any cable under tension will tend to oscillate at a certain natural or fundamental frequency which is dependent upon its tension weight per meter and length It is very important that the cable be moved back and forth at this frequency The cable should trace out the pattern shown below in a regular consistent way without whipping or distorting into other shapes IMPORTANT the frequency of oscillation is independent of the magnitude of oscillation The idea is then to vary the tension of the cable until the proper frequency of oscillation is observed Manual Montana Page 19 of 48 FORTIS WIND ENERGY 6 4 3 Procedure for tensioning the cable 1 2 3 4 Stand at one anchor and move the guy wire back and forth at its natural frequency Measure the number of seconds required for the cable to make 20 complete cycles Compare this time period with the recommended value If necessary adjust the tension and go back to point 1 6 4 4 Cautions hints and suggestions 1 2 3 4 5 Use your common sense If the guy wires start making noises something like a guitar
34. sure that it fits well in the support frame and can be rotated by hand in this position 2 6 Nose cone Further you will find in the packing a box with the nose cone and all the bolts and nuts for assembling Also the voltage controller with dump load is packed with the generator In some cases the dumpload is packed in the box with the rotor blades Manual Montana Page 8 of 48 FORTIS WIND ENERGY WARNING When any parts of the wind Turbine show damage that might have occurred during transportation inform your local supplier or FORTIS directly about this If you do not report such damage or the turbine is already in operation you lose the right to your warranty 3 Instructions Mast 3 1 Producing a Mast yourself 3 2 Foundations 3 3 Installation preparations 3 1 Producing a mast yourself Producing a mast for your FORTIS wind turbine is relatively simple Various constructions are possible but in most cases a steel tubular mast with guy wires is used It is also possible to use wooden poles free standing steel tubular masts or free standing lattice masts Even concrete masts are a possible option However before you start to construct your mast you have to consider where you are going to place the wind turbine and mast For a good performance it is necessary to install the wind turbine in such a way that the wind has an uninterrupted flow from all directions to the wind rotor Any obstructions such as trees hills or buil
35. t in such a way that it is possible to slide the support frame over the mast top However before you do this it is necessary to pull the wires through the mast For your FORTIS MONTANA 5kW machine 3 flexible wires of 6 or 10 mm will be sufficient in most cases Only for 48V systems 10 mm or 16 mm is required They must be pulled through the support frame first and then through the mast Now you can slide the support frame over the mast top The connecting wires must not get stuck anywhere on any part of the wind turbine Make sure the three wires can move and rotate freely inside the mast Any possible problems in this area can cause a short circuit Manual Montana Page 10 of 48 e FORTIS WIND ENERGY On top of the support frame a knot or loop in the connecting wires must act as pull relief Use three wires with the same colour to indicate the three similar phases These three wires must be connected to the three wires coming from the generator the connector block can be found in the white box that is attached to the generator The order of connection is not important since all three lines are equal at both sides At the basement of the tower the 3 wires are connected to a plug and socket This plug and socket can be used to retwist the cable in the tower In some lace the wind can change from direction regular and the turbine rotated 360 degrees When you have installed the turbine check every month the twisting If you did not r
36. they may well be too tight so stop tensioning You may be doing something incorrectly This procedure cannot be used under all wind conditions If the wind speed is above 7m sec then your readings will not be accurate owing to the additional forces on the tower caused by the wind Furling the wind turbine and stopping the rotor will reduce these additional forces and allow the use of this procedure in winds of up to 10 m sec Do not use this procedure if the cable size is different from that recommended by FORTIS For example if the cable is larger the result will be tension forces which are much greater than the recommended value On an FORTIS tilt up tubular mast with 4 anchor points the cables which are at the same height but opposite to one another will tend to develop the same pretension Both cables may require adjustment however for the tower to remain straight Do not attempt this procedure if ice is present on the cable The extra weight of the ice will give incorrect results Manual Montana Page 20 of 48 FORTIS WIND ENERGY 6 5 Start up procedure Provided the wind turbine and mast are in the final position and there is some wind more than 3 m sec the start up procedure can take place Provided the wire connections are correct If there is sufficient wind the turbine will start to rotate and power will be produced A multi meter can be used to check the system even the slightest increase in voltage indicates
37. tion please check also chapter 19 Read also section 16 of the book of Paul Gipe Wind power Renewable Energy for Home Farm and Business Published 2004 YVYVvV Y v v Choose a supervisor of the team who will be responsible for these procedures Do not fix a rope to the rotor blades and tower during erection It can damage the blades Only a rope which can mover free around the tower is possible Before erection check if the generator is on the brake or on short circuit Check all bolts and nuts of the wind turbine and tower before erection if they have the right tension During erection all persons has to be at a distance from the foundation of more than the height of the tower All electrical connections and electronics installation has to be completed before erection If possible the final connection should be the plug in the tower base Check if the earth cables are connected well Check if isolation of all cables is made well Ask crane drive for their safety and control procedures and their responsibilities Do not erect the windturbine during high winds The crane driver has always instructions at which max wind speed he can operate safely Never climb into the tower when the wind turbine is not set on the brake This will be very dangerous Never disconnect any electrical wire if the wind turbine is not set on the brake When climbing in the tower use always position belts and full body harnesses Follow always the rules Get aware
38. ts mast is ready to receive it The power head can then be moved straight from the crate on to the mast 2 2 Rotor blades hub The large cardboard box contains the rotor blades and parts of the tail frame Sometimes also the dumpload is packed with the rotorblades Unpack the rotor blades and make a visual check for any existing cracks or scratches When nothing is visible at all the blades can be mounted between the two hub plates with the 9 x M12 bolts with self locking nuts Every single blade has its unique fit to the hub and in addition to this the blades are marked with dots that correspond with dots on the hub The flat side of the blades should face the wind as is the front side of the hub WARNING Be careful with assembling the 9 x M12 bolts The bolts fits very narrow in the hols For assembling turn the bolts only into the holes Don t use a hammer or drill the holes Only in this way the rotor blades get the same position when they where balanced in the factory Be careful with any damage to the thread to the bolts because it can give problems when you fit the nuts to the bolts Stainless steel in sensitive for damaged thread Manual Montana Page 7 of 48 FORTIS WIND ENERGY 2 3 Tail The tail assembly is composed of 7 parts the tail vane the upper section and 5 steel bars The lower section is already assembled to the frame The steel bars are packed with the rotorblades The tail vane with tail upper section and st
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