User Manual
Contents
1. balance mark on the front face of the blade Be sure to fit the blades the correct way round The concave surface serial number and balance mark all face forward away from the tail The rotation is clockwise viewed at the front of the turbine Each blade socket has two boltholes Fit the bolts with the Nylock nuts forward such that they will be covered by the nose cone a Support the generator 050 such that the blades can be fitted to the blade plate 060 b Fit two blade bolts 062 through the blade plate such that they face forward Now fit the first blade 067 on to the bolts followed by the blade clamp ring 061 Fit the two blade washers 065 and Nylock nut 066 on to the bolts Tighten the nuts just enough to hold the blade in position c Repeat b for the other five blades such that all the blades are sandwiched between the blade hub and hub plate IMPORTANT Measure the distance between each blade tip Adjust each blade by moving it slightly until all the distances between the six blade tips are equal The rotor is now exactly balanced d Now tighten all the blade bolts Refer to Section 3 3 for torque settings IMPORTANT Check the distances between the six blade tips once again to ensure that they are still equal after bolt tightening e Check the assembly for correctness Check the blades are fitted correctly the bolts are all tightened and that the rotor spins freely and evenly on the generat2. cables Commercial lightning arrestors are available at electrical stores and can be fitted at the bottom of the structure or pole or at the 10 kestrel wind turbines Eveready Urveersified Producta Pty Ltd a ui regulator input provo Qf SOUTH AFRICAN N 5 3 Wire and Cable Sizes The copper wire sizes given in the tables are calculated for 3 power loss in wire resistance This is usually acceptable in low voltage installations A larger wire size will increase the delivered power but usually a compromise is reached as larger cables cost more It is recommended that the wire sizes given be taken as a minimum value Measure the distance from the top of your structure i e the e150 to the regulator Select the wire size for that distance from the table The double run of ve and ve is already accounted for The power cable should be run down the inside of the pole or structure and then buried in a suitable underground conduit at least 500mm below the ground surface Wire Size for 12V e150 60A maximum current Wire Size for 24V e150 32A maximum current 20m 66 30m 96 16sq mm 5 35sq mm 2 50sq mm 0 70 sq mm 00 95 sq mm 0000 Wire Size for 48V e150 19A maximum current Wire Size for 200V e150 4A maximum current 20m 66 40m 130 60m 200 80m 260 100m 330 0 5sq mm 20 0 8sq mm 18 1 5sq mm 16 1 5sq mm 16 2 0sq mm 14 in i Everaocy Uivers feed Producta Pt
3. rotor and check for damaged blades Rebalance the rotor if possible or fit a new blade set Q_ The e150 is vibrating or noisy A Check all fasteners on the unit in particular the blade assembly Vibration or noise can only be caused by the imbalance of damaged blades Check for bearing wear on older machines Q Can the e150 be left running and disconnected A Theoretically yes but high voltages may be produced Always short the output wires when the el 50 is disconnected from the regulator Q What should be done in storm conditions A Never approach the e150 during strong wind conditions The e150 has been tested up to winds of 160km h and is designed to survive such conditions It is acceptable to lower the turbine for predicted extreme weather conditions simply for peace of mind z EVEREADY 3 Eveready Diversified Products Pty Ltd DEA provo Qf SOUTH AFRICAN N 9 MAINTENANCE 9 1 BINANNUAL CHECKLIST The e150 is designed for continuous operation on 100 duty cycle and requires no regular part replacement It is recommended that preventative maintenance checks be carried out every six months and after the occurrence of extreme weather NEVER APPROACH A ROTATING TURBINE a Inspect the tower or pole including all bolts fasteners ground anchors and guy wires b Inspect the blades for any damage Check the blade fixing bolts c Inspect the e150 securing bolts d Check the tail assembly and fixing bolts for da
4. voltage 48Vdc 250Vdc Maximum voltage 24Vdc 150Vdc Maximum voltage 12Vdc 70Vdc Output power form Two wire DC Rotor swept area 1 77 sqm No of blades 6 Tower top mass 40kg Lateral Thrust at 12ms 27mph and 40ms 90mph 200N and 2100N Speed Control Rotor turbulence Protection IP55 EVERE Eveready Diversified Producta Pry Ltd te ea Mi 7 2 DECLARATION OF CONFORMITY Declaration of Conformity Eveready Diversified Products Pty Ltd T A Kestrel Wind Turbines m South Africa declare under our sole responsibilty that the product of gt f J Wind Turbine To which thos declaration relates 1s m cordorruty with the following standards IEC 60038 Rotating Electncal Machines IEC 0204 safety of Machinery IEC 6003 IEC Standard Voltages IEC 60529 Degrees of Protection of Enclosures IEC 61000 Electromagnetic Compatibility and follows the provisions m the directives TEC 61 400 2 small wand Turbines Date 3 December 2006 Place Fort Elizabeth South Africa a A Autho Signature Maun PAP es uthonsmg signature Saro P ais James Carpy l Techracal Director Eestrel Wind Turbines Pi Box al9l Horth End Port Elizabeth AU 56 Republic of South Africa Evermacdy Uversified Products Pty Ltd a ui provo Qf SOUTH AFRICAN N 8 TROUBLE SHOOTING REST ASSURED THAT THE KESTREL WILL BE SERIOUSLY DAMAGED FROM POLARITY REVERSAL OVERCHARGING OF THE BATTERY CAN OCCUR WITH NO FITTED CHARGE CONTROLLER IT
5. ATERIAL M S 8 UFF TAPPED M8 UN 60 PCD AL ae 845 PCD 60 B76 Four bolts are supplied for mounting of the e150 unit however eight holes have been provided to allow interchange ability between all Kestrel units Secure the assembled e150 unit by using holes 1 3 5 and 7 as shown along side and the M8 Hi Tensile bolts with spring washers 4 2 Roof Mounting Roof mounting is possible but the turbine performance may suffer as a result of wind shift and turbulence Roof mounting structures are beyond the scope of this document and must comply with the relevant structural standards that are in force 4 3 Towers Towers are required to conform to relevant standards and must be designed to withstand the 9 loading regime of the wind turbine Full details are included with any Kestrel to lied wind turbines Everendy Uversified Products Pty Ltd i ui provo Qf SOUTH AFRICAN N 5 WIRING AND CABLE SIZES 5 1 Turbine Wiring The e150 wind turbine produces dc power and therefore has two double insulated output wires tails The RED wire is POSITIVE and the BLACK wire is NEGATIVE Observe the Polarity at all times Only connect VE RED cables to VE RED terminals and VE BLACK cables to VE BLACK terminals Otherwise equipment damage may result and any warranty will be invalidated The following suggestions are made as a guideline If you are in doubt consult an electrician The ou
6. BLU kestrel wind turbines RR n sn Registration Number 2006 005438 07 VAT Registration Number 4870231406 Tel 27 0 41 401 2500 Website www kestrelwind co za User Manual Revision 1 2 03 08 Revision 1 1 10 07 Revision 1 0 05 07 provo Qf SOUTH AFRICAN N CONTENTS PAGE 1 Safety Considerations 1 1 Mechanical Safety 3 1 2 Electrical Safety 3 1 3 Installation Hazards 3 1 4 Operational Safety 3 2 Wind Turbine Overview 2 1 Turbine Description 4 2 2 Identification and Markings 4 2 3 Applications and uses 5 2 4 Charge Controllers and Inverters 5 2 5 Grid Tied Applications 5 2 6 Voltage Limiter 5 3 Unpacking and Turbine Assembly 3 1 Components Supplied 6 3 2 Tools Required 6 3 3 Technical Requirements for Assembly 6 3 4 Unpacking 7 3 5 Generator Assembly 7 3 6 Tail Assembly 7 3 7 Blade Assembly 8 4 Site Considerations and Mountings 4 1 Mounting Flange Detail 9 4 2 Roof Mounting 9 4 3 Towers 9 5 Wiring and Cable Sizing 5 1 Turbine Wiring 10 5 2 Lightning Protection 10 5 3 Wire and Cable Sizes 11 6 Battery Considerations 6 1 Lead Acid Batteries 12 6 2 Sealed Gel Batteries 12 6 3 Ni Cad Batteries 12 6 4 Temperature Compensation 12 7 Technical Details 7 1 Technical Specification 13 7 2 Declaration of Conformity 14 8 Trouble shooting 15 9 Maintenance 16 10 Warranty Conditions 18 11 Customer Feedback 21 kestrel wind turbines Everenoy Uversified Praducta Pty Ltd i e
7. IS UNWISE TO DISCONTINUE CHARGING BY DISCONNECTING THE e150 FROM THE BATTERY THE TURBINE THEN HAS NO LOAD WHATSOEVER AND CAN REACH VERY HIGH ROTATIONAL SPEEDS Uncontrolled output voltage can reach LETHAL values IF THE el 50 IS DISCONNECTED FOR ANY REASON SHORT THE GENERATOR OUTPUT WIRES THIS WILL LOAD THE GENERATOR AND MINIMISE ROTATION DO NOT ALLOW THE e150 TO OPERATE WITH DAMAGED BLADES OR TAIL DAMAGE TO THE BLADES WILL CAUSE VIBRATION THAT CAN INCREASE TO DESTRUCTIVE LEVELS DO NOT ALLOW THE e150 TO OPERATE WITH ANY SIGN OF UNBALANCE ANY REPETITIVE SWINGING OF THE TAIL INDICATES THAT THE MACHINE IS UNBALANCED Q There is wind but the e150 does not rotate or only rotates very slowly A The e150 output is shorted There is an electrical short elsewhere in the system The blades are fitted the wrong way round The e150 is restricted from swinging 360 degrees into the wind The charge controller is defective Other connected equipment is defective Disconnect the e150 from the equipment and check that the blades rotate easily There is a short within the turbine generator In very light wind the e150 may well not rotate This is quite normal as there is no useful power in such a light wind and bearing life is greatly extended On older machines check the generator bearings Q The e150 is rocking from one side to the other at low speed but appears to run smoothly at higher speeds A The blade rotor assembly is unbalanced Remove the
8. Inverter Applications The 200Vdc version of the e150 is suitable for connection to an approved Grid Tie Inverter Grid Tied installation is subject to local electrical codes of practice and is usually carried out by qualified personnel Prior approval from the local utility company must be obtained before connection to the mains 2 3 3 Voltage Limiter Grid tied applications require a Voltage Limiter to be connected between the e150 200Vdc version and the Grid Tie Inverter Certain operating modes of the inverter allow the Kestrel output voltage to rise beyond the limit of the inverter The Kestrel Voltage Limiter will restrict the rise in voltage as the inverter performs various functions Refer to the manual provided with the Kestrel Voltage Limiter EVEREAIN kestrel wind turbines Eveready Diversified Producta Pty Ltd See provo Of SOUTH AFRICAN N 3 UNPACKING AND TURBINE ASSEMBLY 3 1 Components Supplied The following components are supplied Propeller hub assembly Shaft drive key Propeller blade set Generator assembly Tail boom Tail Nacelle cover Nosecone O OUOU HOU L Assembly grease 3 2 Tools Required The following hand tools are required for turbine assembly and installation 10mm metric ring spanner or socket wrench two required _ 13mm Metric ring spanner or socket wrench _ Small size electrical screwdriver Medium size electrical screwdriver 10mm Allen key _ Wire
9. PROUDLY A SOUTH AFRICAN N Kestrel Wind Turbines makes every effort to give accurate information in this manual and is in no way liable for any error or omission The user of this manual assumes full responsibility and risk We appeal to your common sense to read and apply the safety notes Consult professional engineers and take advice if you are unsure 1 SAFETY FIRST Although Kestrel s wind turbines are designed with your safety in mind accidents can easily occur and there are always inherent dangers associated with any type of machine Consult installation professionals if you lack experience or confidence 1 1 Mechanical Safety Use good handling methods and take precautions to avoid physical injury during installation and maintenance repair procedures The rotating blades of any wind turbine are a main hazard The e150 blades are extremely tough and will cause serious injury to the body Never install the e 1 50 such that any person or animal could come into accidental contact with any part of the machine Never approach the machine if the blades are rotating 1 2 Electrical Safety The e150 output voltage can become dangerous and even lethal when running on open circuit Maintain a healthy respect for this wind turbine Always short the output wires together when the e150 is disconnected Do not work on the system when the turbine is running or when lightning is possible Disconnecting a running e150 may cause a spark and the presenc
10. any damage to Turbines caused by winds exceeding 160 kilometres per hour or any other factors beyond the control of Eveready Di The Customer may purchase an extended warranty from Eveready in respect of Turbines subject to 18 Event esita wind turbines Everendy Urversified Products Pty Ltd See Eveready s standard conditions provo Qf SOUTH AFRICAN N CONTACT KESTREL WIND TURBINES SOOTAETAITIM VED TUNERS ig i Kestrel Wind Turbines Eveready Diversified Products Pty Ltd Eveready Road Struandale North End Port Elizabeth South Africa Tel 27 0 41 401 2500 Email kestrelwind eveready co za Registration Number 2006 005438 07 VAT Registration Number 4870231406 Web www kestrelwind co za P O Box 3191 North End Port Elizabeth 6056 Eastern Cape Republic of South Africa Everenty Uversified Producta Pty Ltd rrovorr Of SOUTH AFRICAN N NOTES Eveready Diversified Products Pty Ltd rrovor SOUTH AFRICAN 10 CUSTOMER FEEDBACK Em kestrel wind turbines ge cod Customer enquiry and feedback sheet Customer Name Postal Address Turbine Number Phone Number E Mail Address Fax Number Complete the form and submit to Kestrel Wind Turbines Your feedback and queries are valuable to US Indicate your enquiry or feedback in the space provided below Date Replied Signature Comments Eveready Diversified Producta Pty Ltd
11. e due to continuous development Kestrel Wind Turbines reserves the right to make design changes improvements or additions to its products without obligation to install such changes or improvements in existing products WARRANTY AGREEMENT Kestrel s wind turbines are manufactured to the highest standards in accordance with Kestrel Wind Turbines standard and quality specifications and warrants that the wind turbine is in good working order upon delivery and for a period of 24 months Warranty terms and conditions are outlined below l Eveready warrants that Turbines will on delivery be free of defects in design material and workmanship and will be fit for their intended purpose for a period of two years calculated from the date of installation subject to proper installation maintenance and use in accordance with the User Manual 2 This warranty is further subject to the Customer returning the defective Turbine at its cost to the premises of Eveready within the warranty period and furnishing full details in writing of the alleged defect di Eveready s obligations under this warranty shall be limited to the repair or replacement of defective Turbines at its cost or to a refund to the Customer of the original cost thereof as Eveready may determine in its discretion Eveready shall not be responsible for any damages suffered by the Customer pursuant to any defects covered by this warranty A This warranty shall not apply to
12. e of explosive hydrogen from battery charging is always a possibility Adequate ventilation must be provided for battery installations The wire size used for connections must be correct for the powers supplied The smaller the wire diameter the higher the wire losses and therefore the heat generated in the wire Use correct wire sizes throughout the installation The amount of energy stored in a battery is considerable and fire can result from shorts Fit a suitable fuse or circuit breaker in the battery cable In general respect the system and use common sense Consult a qualified electrician if you are unsure 1 3 Installation Hazards All installation work should be completed at ground level wherever possible Be very aware of the blades during installation Contact with the blades will only injure you not the blades The installations of poles or towers pose their own dangers Always work carefully and have an assistant wherever possible Short the generator output wires Red and Black throughout any installation procedure Consult a civil engineer or reputable builder if you are not sure about installing structures Always re check the work as you progress Slack bolts poor workmanship and loose electrical connections must be avoided 1 4 Operational Safety The turbine blades are dangerous Respect a rotating turbine Always shut the turbine down before approaching This may be achieved by shorting the generator output Preventative mainte
13. machine and check for transfer brush wear Treat any corrosion Every 5 years Every 3 years and touch up paint Dismount the machine and replace all bearings generator and yaw shaft 12 monthly intervals Every 8 10 years Every 4 5 years Maintenance Tips The generator produces a slight humming sound This is quite normal Any other grinding clicking or scraping noises are abnormal and must be investigated Good rotor balance is very important for long and reliable operation The wind turbine must not be allowed to continue in operation if any unbalance is observed The most common symptom of imbalance is observed when the turbine swings slightly from side to side as it speeds up The swinging action will be worse at a particular rotor speed and may well disappear at higher speeds The rotor blades can suffer chips and erosion mainly on their leading edge Small chips can be repaired with glass fibre filling compound All cracks must be carefully examined Surface cracks can be repaired but any structural cracks must render the blade inoperative If there is any doubt the blade set must be replaced for safety All blade damage can allow water to enter This will cause the blade set to become unbalanced which will cause other mechanical failures and shortened bearing life wind turbines Eveready Divergifiod Producta Pty Ltd provo Qf SOUTH AFRICAN N 9 3 OTHER DETAILS PRODUCT CHANGES Specifications may chang
14. mage Replace if required e Wash the blades with clean soap and water f Check the blades for any wear or erosion g Check all electrical connections for tightness and corrosion EM cesfie wind turbines Eveready Uversified Products Pty Ltd a a provo Of SOUTH AFRICAN N The e150 is designed to operate with minimum maintenance The frequency of visual inspections and integrity checks depends on the wind class of the installation site Wind Power Class definition for wind power density and average wind speed at a hub height of 10m is given below In general higher class wind sites require more frequent installation checks Wind Power Class Wind Power Density Wind Speed Wind Speed W sq m m s mph Imperial Up to 100 Up to 4 4 Up to 9 8 100 150 4 4 5 1 9 8 11 4 150 200 5 1 5 6 11 4 12 5 200 250 5 6 6 0 12 5 13 4 250 300 6 0 6 4 13 4 14 3 300 400 6 4 7 0 LE i ee ey Above 400 Above 7 0 Above 15 7 The following schedule is designed to avoid machine failure Component life will be reduced on sites that exhibit high turbulence Wind Power Class 2 3 4 5 6 7 First post installation visual check All sites 1 month after installation After extreme After extreme Visual Inspection listen for abnormal noise weather and every 3 weather and and vibrations months every 2 months Close inspection check for any loose bolts Six monthly blade damage Touch up paint intervals Dismount the
15. nance is always the best Checks are best carried out in calm weather conditions Avoid any maintenance or 3 inspection during windy weather __ RIU kestrel wind turbines Eveready Uversified Producta Pty Ltd See provoi Op SOUTH AFRICAN N 2 WIND TURBINE OVERVIEW 2 1 Turbine Description The e150 is a unique wind turbine that incorporates superior technology The heart of the machine comprises of a single axial flux permanent magnet brushless alternator The alternator contains no less than 48 poles and 26 magnets The polyphase high frequency output is internally rectified to give a dc output with extremely low ripple content The generated power is transferred to the output cables via heavy duty bronze slip rings and twin copper composite electrical brushes The prime mover on the e150 is a 1 5m 5 diameter six blade wind rotor fitted with quiet running high efficiency blades The blade hub is fixed The e150 relies on rotor turbulence and interference to achieve speed control The tail vane assembly is static and simply aligns the machine with the prevailing wind The standard finish consists of the application of an etching marine primer and an intermediate protective coat followed by polyurethane two pack finishing coats 2 2 Identification and Markings The turbine generator body carries a stamped unique serial number and a rating plate Both the stamped serial number and rating plate are visible on the bott
16. om yaw shaft housing If this e150 does not carry this stamp it does not carry a Kestrel warranty and may not be authentic wind turbines N O LLleeMS SC re Eveready Diversified Products Pty Ltd MADE IN T A Kestrel Wind Turbines SOUTH AFRICA BY P O Box 3191 Struandale North End Port Elizabeth 5056 RSA Kestrel Eveready Diversified Products Pty Ltd See provo Qf SOUTH AFRICAN N 2 3 Applications and Uses The e150 is suitable for electrical power generation on various installations that include battery charging water delivery and grid tie applications Each application requires specific additional electrical equipment Consult the manuals supplied with this equipment 2 3 1 Charge Controllers and Inverters Any wind turbine produces uncontrolled power that varies with incident wind speed The open circuit generator voltage is directly proportional to generator speed rpm Some form of regulator must control this raw power A battery charging regulator is often referred to as a charge controller A charge controller is required for the Kestrel to charge a battery Kestrel can supply a standard or charge controller for the e150 A suitable load resistor is available from Kestrel An Inverter can be connected to the battery and is used to convert the battery dc power to ac power An inverter therefore allows the use of standard electrical equipment that works on ac voltage 2 3 2 Grid Tied
17. or f Now slide the nose cone over the blade hub and fit the three retaining screws Eveready Divergifiod Products Pty Ltd rovor Qf SOUTH AFRICAN N 4 SITE CONSIDERATIONS AND MOUNTING The Turbine is supplied with a weld on mounting flange for adaptation There are infinite variations on sites and the information and suggestions may be adapted to suit local conditions Wind speed increases with height above the ground An installation site should be chosen which is free of obstructions like buildings trees mounds and hills A pure airflow is paramount for good performance Naturally some compromise can be reached but there should be a clear entry for the prevailing wind direction of the location The absolute minimum height of the structure should be 6m when placed clear of obstructions The general rule is that the e150 should be 8m 25 higher than any obstruction within a 150m 500 radius of the tower Otherwise mount the e150 as high as possible All obstructions add to possible turbulence which will cause undue stress on the unit and reduced performance Wind speed increases with height above the ground The power in the wind is a cubic function of wind speed Doubling the wind speed increases the power by eight times 4 1 Flange Mounting Detail The e150 is mounted using four M8 Hi Tensile Stainless bolts and spring washers fitted through the bottom flange on the weather cocking swivel assembly TOP FLANGE M
18. ries Sealed gel batteries are more expensive but offer clean and safer operation as no acid can be spilled Since they are sealed they must never be boosted and the charging voltage is important Charging voltage is typically 14 0 28 0Vdc Consult your battery supplier 6 3 Ni Cad Batteries This type of battery is traditionally used where large currents must be delivered and where deep cycling is required They are however relatively expensive Consult your battery supplier for details 6 4 Temperature Compensation Much has been documented on this subject and there are certain merits Generally lower and higher ambient temperatures allow higher and lower charging voltages respectively Batteries should be sited in a cool area and temperature compensation is only useful in extreme 12 temperature variations kestrel wind turbines Eveready Orversified Products Pty LEd a ui rovor Qf SOUTH AFRICAN N 7 TECHNICAL DETAILS 7 1 TECHNICAL SPECIFICATIONS Maximum Power 650W Rated power at 11m s 200Vdc 500W Rated power at 11m s 48Vdc 450W Rated power at 11m s 24Vdc 410W Rated power at 11m s 12Vdc 350W Annual energy capture 200Vdc 747kWh Annual energy capture 48Vdc 672kWh Annual energy capture 24Vdc 635kWh Annual energy capture 12Vdc 580kWh For average wind speed of 5ms and 12m tower at sea level Rated sound level lt 30dB Cut in wind speed 2 8m s Cut out wind speed N A Maximum voltage 200Vdc 1000Vdc Maximum
19. strippers for electrical connections _ Tape measure to adjust the blades 3 3 Technical Requirements for Assembly TORQUE TORQUE DESCRIPTION BOLT TYPE Metric Imperial NOSE CONE SCREWS M5 x 15 S S 5Nm 3 7 ft Ib FRONT BOLT S S ALLEN CAP M10 x 35 45Nm 33 2 ft lb BLADE BOLT M8 x 40 S S WITH M8 NYLOCK NUT 35Nm 25 8 ft lb TAIL BOOM M BOLTS S S 15Nm 11 1 ft lb M8 NYLOCKS 25Nm 18 4 ft lb NACELLE SCREWS M5 x 15 S S 3Nm 2 2 frib TAIL BOLTS M6 x 35 S S WITH M6 NYLOCK NUT 10Nm 7 4 ft lb MOUNTING BOLTS M8 x 25 8 8 HI TENSIL PLATED 35Nm 25 8 ft lb kesirel wind turbines Eveready Diversified Products Pty Ltd ea e rovor YI SOUTH AFRICAN N 3 4 Unpacking Open the packaging container and check for any transit damage The parts contained are listed in section 3 1 and on the included packing slip Lay out the parts and identify them with the assembly drawing provided DOSI AASI GENERATOR Asse I osme TAN ____ O smes mabe ves E POSGLGS BLADE NUT CT osmsa TAR BOLT vesti 6 e eee Te O50755 TAIL RODA ASSEMBLY O I omas ran sn wT 3 05006 BLADE BOLT 3 5 Generator Assembly The alternator 050 is factory assembled The blade plate 060 the hub 063 and the hub bolts 064 are factory assembled The shaft drive key 059 is factory fitted to the generator shaft with a cable tie Remove cable tie smear waterproof grease over the shaft and insert a little inside the front of the genera
20. tor where the shaft projects out Offer the blade hub assembly to the shaft after removing the Allen Cap 068 and slide it on Secure with Locktite and tighten refer to section 3 3 3 6 Tail Assembly Offer the tail boom 055 to the rear of the generator and align the three inner fixing holes with the inner studs Fasten the boom to the rear of the generator with the three Nylock nuts 56 Now fit the four outer M bolts 57 into the generator rear and tighten all fastenings Slide the nacelle 073 up the boom and fasten so that it is covering the generator Fasten the tail to the boom with the four stainless bolts 052 and four stainless flat washers 054 with the four stainless Nylock nuts 053 provided Do not over tighten such that the tail boom is crushed or distorted Check once again that all bolts are fitted and tightened to torque settings section 3 3 wind turbines Evermacdy Uversified Products Pty Ltd e ee provo Of SOUTH AFRICAN N 3 7 Blade Assembly e150 IMPORTANT The wheels of a car are balanced to allow smooth operation In the same way the propeller rotor must be assembled such that it is balanced Rotor imbalance will cause vibration unstable operation of the turbine and eventual damage Please follow the steps given below to assemble a balanced rotor Refer to the assembly drawing and fit all six blades on to the hub as shown Each blade carries a serial number at the blade root and a
21. tput wires must be extended as required for the installation Good wire connections are absolutely essential to avoid poor power delivery and high temperatures at the connection All electrical systems lose energy because cables have a resistance The mounting structure must be directly earthed for lightning The power cable is usually brought down the inside of the mounting structure to give some protection Supply cables should never be spanned or suspended from the turbine structure and should be buried at least one half metre deep in a suitable plastic or steel conduit 5 2 Lightning protection Proper grounding is essential to protect the system from induced voltages and static Local requirements for electrical installations must be satisfied Ensure that the generator is electrically connected to the mounting structure and that the structure is earthed This is usually done by burying a 2 to 3m 6 10 length of water pipe Steel or copper horizontally 800mm 2 5 below the ground surface A good connection is made between the middle of the pipe and the structure An improved method is to bury a cross of pipe which requires an X shape to be excavated The connection is made in the centre of the cross The negative battery connection should also be grounded using a ground point close to the battery First consult the Charge Controller Manual to avoid earth loops The wire size for grounding should be the same size as the power
22. y Led i nn rovor Qf SOUTH AFRICAN N 6 BATTERY AND CONSIDERATIONS Batteries are available in many shapes sizes and chemistry Battery dealers will be pleased to assist The most common ones are reviewed below In general only Deep cycle batteries and cells should be used and automotive or vehicle batteries will have a short life as they are not designed for cyclic charging and discharging A cell is a single unit of 2V and a battery consists of a number of cells joined in series The usual installation consists of 12V batteries arranged in series or parallel or both Batteries should not be exposed to temperature extremes and good ventilation is required as batteries can emit hydrogen while being charged The stored energy in a battery is given in Ampere Hours Ah or Watt hours Wh The capacity is often based on a 10 hour discharge rate A 100Ah battery will therefore supply a current of 5A for 20hrs or 10A for 10hrs or 20A of current for 5Shrs It will not however supply 100A of current for Ihr There is much literature available on this subject It is recommended that the e150 should be charging at least 200Ah of battery capacity for a 12V system 6 1 Lead Acid Batteries These are the most popular choice of battery type and can be vented flooded Water may be added or semi sealed or low maintenance Water cannot be added Charging voltage is typically 13 8 14 0 27 6 28 0Vdc for these batteries 6 2 Sealed Gel Batte
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