WIND TURBINE Instructions
Contents
1. optimum state When the voltage is over the set value 290V 300V the controller can unload automatic and the wind turbine yawing 30 When the voltage is below the revert point 270V 280V relieve the unload and go on to charge the batteries When the charge current is over than 35A for protect the batteries unload automatically Yawing 30 60 or 90 The change angle 1 based on the charging current When the wind speed is over 10m s yawing angle 15 30 When the wind speed is over 12m s yawing angle is 60 When the wind speed is over 15m s yawing angle is 90 When the wind speed is over 18m s yawing angle is 90 unload amp brake When the wind speed is below 3m s the system will stop When the wind speed is over 3m s the system is working The power of the wind turbine is count and totting up by the media server 6 MODBUSRTU transmission definitions The controller can send the signal by RS485 transmission mode After confirming the web station number transmit by MODSRTU consultative The definition of data transmission 1s shown in From 7 27 Form7 The definition of Data Transmission IputLie No 6 0006 jvolagexlO 8 0008 Require angle of deviation 9 000 __ D105 2104 D103 D102 ___40 0004 0 Chinese iX __ 1English En ic wiring Off grid electr MAOZ MOL MAS2. seuejeg sg J0je1euec jueuudinb3 MAZ MAL MOOG MOOZ MOOE saueyeg sauayeg T YMS h jueuudinb3 asn YMS yuawdinbg N am 29 The dateline of this manual is December 2008 Specifications are subject to change without notice for further improvement Please forgive The guarantee of turbine and controller is 2 years and the inverter is 6 months from the date of purchasing non done by man or majeure 30
3. b Controller specification Controller Principle Page 22 2 On grid electric wiring All the modes can be applied to on grid environment But it is approved by local regulations What is more on grid controller and inverter need to be purchased additionally 17 Maintenance Wind turbine may be operated under extremely harsh environment or meet various complicated weather Therefore regular examination and maintenance are needed in order to keep the system operate rightly Safeguard Steps 1 Check the cable wire if it is too loose or too tight And if it is adjust them in particular in initial stage of installation and post gale 2 Check whether or not the wire 1s damaged or loose And whether the Joints are loose and rusted or not in order to secure electrical safety 3 For the batteries keep the height of electrolyte If it is lower add it in time The specific way 1 shown in the batteries manual 4 Before storm it is better to lay down the tower for escaping from unpredictable loss Notice do the inspection every three months Maintenance 1 When maintaining the wind turbines check them as the following procedures a examine whether the transmission cable 18 connected or not b Measure the resistance of the slip ring and the crust it must be no less than 0 5K c Measure the three phase of wind turbine 1s connected or not d Measure the resistance of the wind turbine cable the standard value as shown i
4. have no sensor is 000 Integral adjust modulus 100 a Proportion adjust modulus 15 The above are the number of factory reset Don t amend it in normal Adjust it at random will lead to the controller chaos the number to show is forbid to avoid the wind turbine and controller malfunction 2 1 In the aid mode can press 2 and to refer to related things 1 Power in time 2 Accumulated electrical energy 3 Rotated speed 4 The temperature of controller and host 5 The communications quality of the main board 6 The communications quality of the wind speed panel 7 The communications of the wind direction panel 8 The communication quality of the host direction panel the communications quality of the main board wind speed wind direction and the host direction If the number is large the communications must have mistake The theory number is 000 3 Display screen show Batteries voltage charge current yawing angle unbitten angle machine needed yawing angle wind speed in time rotate speed in time powerintime batteries opposition or exception hand mode unbitten exception positive and opposite direction of over pressure unload and so on 4 Sensor connects The three lines of the host displacement sensor can through the plug 25 connect to three core interface in breadboard of the dogvane The wind direction and the transmission line of the host R485 can connect to the parallel connection socket RS
5. step dig the pits The size and the depth of the pits are seen in Form 2 2 Pouring concrete C25 Put four anchor bolts in the center base Pay attention to the base hole the base will be fixed with bolts in the prior pouring cement seat as shown in Figure 2 Fig 2 Layout of the Base 3 Located the ring shaped anchor to the base at an angle of about 60 80 check the distance between the hook ring of every anchor and the base center and anchored around the basic level as shown in Figure 3 Fig 3 Layout of the Anchor Step4 Install the tower and wind turbine 1 Installation of tower Fixing the base 1 4 Fixing the guy cable of the tower 5 Connecting the turnbuckle in the end of the guy cable Fig 4 Tower Fixing 2 Installation of complete set of wind turbines 3 Connecting the tower Holding up the tower and adjusting to verticality 6 Holding up the tower keeping it vertical Then lay down the tower to installing the hidung 1 Open case inspection check all of the parts with the packing list If have something wrong please contact with our company or the dealer Installation of wind turbines is shown in the following Figure 5 and Figure 6 but these figures may not in correspond to the outer structure of the real products tail vane pin role nose cone Fig5 2Kw amp below 2Kw blade anemoscope Ls T pressure plate dogvane spacer and nut
6. the slip ring location screw change the slip ring Electric brush slip E ring installation as shown in Fi gure 15 Fig 15 Installation for Slip Ring 19 FAQS Why does not my electro equipment work after connected to inverter Check the dump energy If the energy is not enough the system will not operate normally if the energy is enough please check the connecting wire between batteries and inverter is cor rect Why can not the batteries be charged Check whether the rotor 1s rolling or not the turbine has no output at too high or too low wind speed If the rotor is normal connect the turbine s wire from batteries and controller in right way If the is normal please check the batteries are break or not If the voltage is zero check the wire of turbine Why does the rotor can t roll at a normal wind speed If the output wire of turbine is short the rotor will not roll Check the turbine s wire after disconnected from batteries At the same time check carefully whether the rotor 1s installed in a right way How to lay down the turbine For 3KW amp above 3KW 1 Firstly stop the turbine Set control hand and auto to hand and then hold on the reverse or turn to make the turbine turn a 90 angle with wind direction 2 After the blades stop rolling shortcut three line of turbine 3 Press the reverse or turn key to make the turbine s end face to the direction of putting down Ensure the
7. 485 of wind direction Put the transport signal line RS485 of anemoscope to conne ct with the quadripuntal plug the connect way plug 5V plug plug plug ground through the cable to the either faucet 8 9 or 10 of main controller Dogvane and anemoscope are shown in Figure 20 dogvane anemoscope Fig 20 Dogvane and Anemoscope 5 Working principle of controller When connecting the wind turbine to the controller please do as the following shown in Figure 21 Wind turbine Input Line 22 2 2 7 Fig21 Connection of Wind turbine Batteries Yawing motor and Controller 26 1 Connect anode and cathode to the interface 1 2 of the controllers Connect the three transmission line of the wind turbine to the interface 3 4 5 of the controller Connect the yawing motor to the interface for yawing motor Connect sensor RS485 to the interface 8 9 or 10 of main board Check it before working When the motor is running the control panel must be in the state of auto startup When the wind speed is over 3m s the host can be facing the wind automatically If in the hand the host can not facing the wind automatically can press the key 2 and 1 Show the batteries voltage charge current wind speed in time yaw angle host direction host temperature rotate speed in time and so on 2 The controllers running in set order the wind turbines batteries and electric equipments can be running
8. V input plug D 12 V plug OV and plug 3 empty 2 Connect current transducer board plug A plug plug 3 and plug 4 common port 3 Connect speed sensor plug D 5 plug sign and plug ground 4 Batteries voltage input plug l batteries plug batteries 5 Connect temperature sensor DS18B20 6 MODBUSRTU transmission interface plug D 5V plug plug3 B plug ground 7 Connect display control panel plug 5V plug A plug 3 plug 9 ground 8 9 10 wind speed wind direction and host sensor 11 Reserve 12 Brake signal interface 13 Unload fan interface 14 Rectifier heat output fan interface 15 Unload relay interface 16 opposite direction yawing relay interface 17 Positive direction yawing relay interface 23 Controller manual Controller is the bridge of batteries electrical equipment and wind turbine Not only protect wind turbine to run safely but also protect the batteries against overcharge and overdischarge It s one of the most important parts of wind generating system 1 Key assignment explanation as shown in Figure 18 19 Display screen 5 4 3 L1 d OO Fig 18 Block diagram Fig 19 Real Diagram 1 Key 6 and 5 function as cut over interface 2 Key 4 and 3 function as Chinese and English transform 3 Key 2 and 1 function as adjustment Press 2 at the hand mode the yawing motor clockwise minitrim Press 2 long time the adjustment continued Press the yawing moto
9. WIND TURBINE Instructions amp Parameter List 2 Installation Specification of Guyed Tower 3 Installation Specification of Tapered Tower 11 e Configuration Specification of Batteries 16 e Electric Wiring 17 eMaintenance 18 eZLFD II Wind Turbine Controller Principle 22 e Controller Manual 24 0000zd3 6000103 Tei 0 00010 00cd3 oeda PHM Jo 1sjeurereq x PPO up WLIO ur se 13j2urered pue apour 24 xz 0 MODE Woy sangin pura sa npoud Aueduroo mo 1517 12j12u IPeq apop Uu I 201121077 Prey s u peadg pur AID as 5 ru paads pura dan irfig Installation Specification of Guyed Tower Erection sequence of Guyed Tower Step 1 Choose the installation site The wind turbine should be erected as high as possible and far away from the obstructions so as to get greater speed At the same time the soil of the installation site needs to be considered It 15 necessary to avoid choosing the soft sanded or rugged site or the place vulnerable to the effects of climate change When selecting the locations you should also consi
10. der the distance between the motor of the wind turbine and the batteries The shorter the distance is the shorter the transferring lines will be used And thus the less the energy 15 used in the process of transferring If there must be a longer distance try to use thicker standard cable Step 2 Layout of Tower Base amp Anchor The relative position of tower base and anchor Reference Figure 1 Rear Center base Front base e base Sid Fig1 Layout of Concrete Base The size of tower base and anchor as shown in Form 2 Form2 Layout of Tower Base and Anchor Size of centre base m Size of side base m long wide deep 6 sww so owes 05056 wen w wu wem For 2Kw amp below 2Kw Pay attention to the following when laying out the base and anchor 1 Connecting line of two side anchors should be in parallel with the connection of two pinholes on the tail edge 2 The height of the anchor should be consistent with the height of the tower base Therefore the pulling force between the fixed cable wires can be balanced for the sake of easy adjustment Otherwis e too tight or too loose fastening pull will lead to the curvature or even breakdown of tower while erecting the tower Step3 Pouring base the anchor base and installation of the tower base Diagrammatic sketch of installing the base and the anchor are shown in Figure 2 and 3 1 In accordance with the last
11. e between the blades screw down the bolts is sequence as shown in Figure 8 300w has three bolts screw them down one by one 200w 500w Tkw 2 Fig8 Layout of Blade 8 Fit on the nose cone by the M6 screw and lock it 9 Install the tail rod see in Figure 8 and tail vane on the host by the M16 screw nut and lock it 10 Install the charge controller in the safe place and connect them Please do as the specifications shows Step 5 Preparations before erecting the tower For 2Kw amp below 2Kw wind turbines 1 Put one end of the four cables through the cable hole in the top of the montant and lock with fixture Except the cable for the farthest anchor the other three cables need not to lock tightly Because erecting and adjusting pulling force is necessary before locking 2 Connect the last fixed wire cable to the one which 1 at least 16 meters Tie one end to the winch or tractor 3 Drill the wire cable or bracing cord through one end of the ladder 2 4 2 5 which will be served as support pole For 3Kw and above 3Kw wind turbines 1 Fix the fixed cable wire on the tower The cable wire both right and left sides should be directly connected to side anchor through turnbuckle Cable wire behind should be fixed on back anchor according to the same length Make sure there is no twist among the three cable wires The front cable wire will be fixed afterwards 2 Con
12. ections of rotate speed temperature and electric current are completed in the controllers to lessen the transmission cable 3 Can reset the parameter The controllers can deliver debugging Based on the local wind regime alter the parameter at any time 4 To keep the wind turbine running smoothly use treble protection the yawing brake and unload Combining active protection with passive protection makes them more reliable 5 Can automatic cast loose ensure the cable can not intertwine and break 6 The wide voltage input switch power supply up to 1000V can guarantee controller main control panel and the yawing motor operate safely under the high voltage 7 Can telecommunications by the communications interface 485 of main computer controllers Transport 52 common data of the controllers to the upper computer by MODUBOS agreement Telecontrol the controller after install relevant software 22 Main Panel Wiring Manual Main panel wiring is shown in Figure 17 ect current nput interlace VERE tt E e i z L 2 Ar e 2 r il t n dino temperature sensor interface re E 5 z LE qn 1 T oi T MODUBOS transmission ___ _ bis e mmn iu panel interface Fig 17 Main Panel Wiring Interface 1 DC12
13. greased Install the fuse on the positive electrode of batteries The distance of conducting wire between batteries and controller should be less than 3m 4 Charge parameter of batteries 1s shown Form 5 Form 5 Parameter of Charging Batteries Bates voee V 12 fa 96 120 240 Feat ola as 30 fo 120 fiso 309 Ovevolge V as 30 60 120 fiso 500 Over charge sume volg V o 280 Undervolige 105 210 Unedegemsmewige V 2 24 48 96 120 240 16 Electric Wiring 1 Off grid Electric Wiring Off grid block diagram Page 29 To ensure the safety and easy maintenance please install the switch and fuse according to the diagram Make sure there are consisten ce among the output voltages of turbine batteries voltage and input voltage of inverter A wire connecting mistake will lead to burn down the turbine batteries and inverter Special attention to 3kw amp above 3kw a There are two cables elicited from the turbine head One 15 the cable of wind direction wind speed unbitten signal with aviation plug on cable head You need to insert it into the socket The other cable is for the output of turbine power and yawing turbine There are five lines Three of them are relative thick for turbine output The other two relative thin for yawing turbine which 1 classified as positive electrode and negative one All of these should be connected to the connecting interface at the back of controller accordingly
14. ication of taper tower Step 1 Choosing installation sites Please refer to the installation specification of guyed tower Step 1 Step 2 Concrete the base and install of tower In accordance with the drawings of the base dig the hole use the flat steel to weld or wind up every anchor by the size and then put the anchor into the hole and deposit concrete after arraying them The size of the concrete is C25 Use the vibrating spear to density the concrete The concrete volume of the tower 1s about 1 7 cubic meters 6 cubic meters and 16 cubic meters Before installing the tower pour the reinforced concrete base first as is shown in Figure 10 The base size of different model is shown in Form 4 3 20 flat steel planform side view Fig 10 Installation of Taper Tower Base 11 Form4 Installation size of Taper Tower Base mensem n efef e u 1000 1200 The specification of the bolt EE M24 M24 The layout diameter of bolt 1 Installation of tower The taper towers have 3 parts both ends of each part have flange According to the diameter size connect each part by the bolt one by one As shown the Figure 11 Fig 11 Layout of Taper Tower The Side elevation of installation as shown the Figure 12 The Parameter of installation for taper tower as sho wn in form3 12 Upper Flange Ac shown in figure 13 1 Upper Section Middle Section Bottom Section Bottom F
15. lange AS Shown in figure 13 2 Fig 12 Side elevation of installation Form3 Parameter of Installation for Taper Tower taper tower ta mE NM tower c tower s EL e Upper Heghtm 2 4 6 section parameter Thicknemm 4 6 Middle Hegh 3 4 6 section Parameter Thiessmm 5 8 8 Bottom Heghtm 3 J 4 6 section parameter 6 Weghtkg 150 310 500 Upper flange 2 mm connecting C3 mm 90 16 380 The turbine T1 mm Bottom flange fixing the base 13 1 upper flange 2 bottom flange Fig 13 Upper and Bottom Flanges Put the bottom in the ground the top a wooden stand The height of the wooden stand is about 1 1 5 meters And install the wind turbine in the top of the tower As shown in the Figure 14 Fig 14 Installation for Wind Turbine After installation the wind turbine use the crane to trice the tower and wind turbine by professional Use hanging strip instead of wire cable The hanging strip is tied to the wind turbine so as to protect the blades After hanging adjust the position Let the flange hole on the bottom aim at the anchor of the base Then put the whole anchor into the hole Mounting spacers and nuts to tightening add some butter to antisepsis 14 2 Lay down the tower Be sure to choose a calm weather to lay down the tower prepare a wooden stand in
16. n Form 6 From6 Standard Value of Three Phase Model _____ 390 5 2 Measure the three phase is isolated from the ground before laying down it 3 Prepare a wooden tripod and power dump before lay ing down the wind turbine The way of laying down is the same as installing but the sequence 1 just opposite 4 First loose a steel wire cable People can not stand opposite to the line If it s windy lay down it to the tripod in tail wind direction 5 a Tear down the tail rod and tail vane open M16 nut to unload them b Tear down the nose cone then the 9 pieces of M10 bolts to take down the blades c Tear down the M27 nut and the flange don t lose anything 6 a Use 6mm interior angle spanner to tear down the 8 pieces of M8 interior angle bolts in the front of the wind turbine Then tear down the full turn shell Don t pull it too strong in order to avoid pulling cut the line inside b Use the spanner to tear down the line of electric brush 7 If the resistance of the slip ring 1s not enough take off 1t and change a new one a First tear down the rubber cover b Use the washer on shaft pliers to tear down the washer on shaft in the bearing Then tear down the rotating shaft Don t roughening the shaft c Screw off M8 nut near the Slip Ring Snap Spring Brush Rocker waterproof and dustproof cover iaio Sith Tear down the electric brush rocker d After that tear down
17. necting the two supporting poles 3 Fix the two relative thin cable wires on the two ears of su pporting 9 pole and then drill the cable wire before the tower through the two ears and fix them after putting into the upper pulley 4 Insert the supporting pole into the tower The cable wire on the two ears should be fixed on the two side anchors and then fixed by tighter 5 First fix the lower pulley on the front anchor Fix one end of the longest thin cable wire on the pulley of supporting pole And make sure the other end drill through the lower pulley and then drill through the upper and lower pulley Finally fix it on a hoist or tractor As shown in the Figure 9 Fig9 Installation of Guyed Tower Step 6 Erecting the tower 1 Drive the winch or tractor slowly and the tower will stand up along the moving of the cord Stop at each rising 15 and check t he tensile force of wire cable on both sides Any over tight or loose wire should be regulated by putting down the tower slowly and adjusting the length of wire cable 2 Go on pulling the bracing cord until the tower stands up right Separate the working cord and fix it on its anchor 3 Check and adjust the strain of each fixed wire cable Over tight force may bend the tower while over loose force may cause the tower unstable and shakable The perfect force 1s neither too loose nor too tight and can be adjusted through circumrotate the bolt 10 Installation specif
18. nose cone Fig6 3Kw amp above3Kw 7 2 Choose desirable triplex cable connect one end of the cable to the line of wind turbine reliable and insulating 3 According to the local wind resources choose the height of the tower in proportion Put the cable through the tower from the top to the bottom Connect this cable to the charge controller not to use the adaptor 4 Connect the bottom flange of the wind turbine to the top flange of the tower Install the host in the top of the tower 5 Fixing the flange in the rotating shaft of the wind turbine and screw down the nut M27 in the top Ensure the flange and the rotating shaft fit 6 Install the three blades to the flange as the specification shows cover the pressure pad by nine piece of 8 screw Keep the balance of blades when installing First do not screw the bolts too tight adjust the distance between the tips of two blades after screwing all the bolts Installation of blades and flange As shown in Figure 7 ELANDE S CENTER LINE BLADE Fig7 Blade and Flange Make sure L1 L2 L3 error allowed 5mm Utilizing spanner for force moment when screwing the bolts of blades and achieving the set force moment 200w 300w 15Nm1 500w IKw 2Kw 20Nmxc1 3Kw 5Kw 1OKw 20Kw 50Nm 1 Notice if you haven t installed them as is mentioned above We will not be responsible for any possibility of breaking down the blades or flange 7 After adjusting the equal distanc
19. r anticlockwise minitrim Press 1 long time the adjustment continued Other frames will adjust other value 4 Key 8 can change the hand and the auto Press 8 long time over 3 seconds work mode can change between hand and auto At the hand mode the light above key 8 will twinkle The third line of LCD screen will show manual be careful 5 Key 9 is the shut down key At hand mode turn on hand shut down to load off Press it long time to cancel the alarm in the main board At the auto the motor can yaw 90 to face the wind automatic According to the batteries to state to control unload 6 Key 7 is the turn on key At the hand mode press it to cancel unload Open the alarm sound in the main board 7 Access to the factory reset need professional and change it after asking the password from the factory press the key 5 or 6 above 3 seconds the machine will request to enter the password key 4 15 key3isnumber2 key2isnumber3 key 41s numberl 24 1 Aid telephone 13773769552 2 Batteries nominal voltage regulate parameter 240V 3 Current modulus regulate parameter 42 4 Voltage modulus regulate parameter 98 5 Face the wind time lag as the time lag of the turbine follow the wind regulate parameter 10 6 Stop the unload time lag 10 7 Angular distance modulus 24 MODBUS ID is used for set the motor in the modbus website 000 9 For virtual sensor 001
20. race the wind direction the reason causing this 1 mostly for low wind speed Only when the wind speed is larger than 3m s staying more than 30seconds can you trace wind speed and change windw ard angle How long is the turbine s lifespan It s 15 years under normal care If you have any other questions please contact us by phone or E mail 21 ZLFD II Wind Turbine Controller Principle This series 3KW 20KW wind turbine controllers are full automaticity intelligent controllers Adopt by the microcomputer chip and many kinds of sensor include anemoscope dogvane host displacement pickup revolution transmitter and so on to protect the wind turbines and batteries It s one of the most advanced and intelligentized controllers at the present time The exterior of controller 1s shown in Figure 16 These controllers were run in the Red bay test site in Shanwei by institute of Oceanology Academia Sinica in Guangzhou one year Everything has been in accordance with the design since the last year and run normally The secretary general of CWEA Li Defu inspect to Nantong after actual motion he highly appreciate the function and the idea of these controller Main feature apt Fig 16 Exterior of Controller 1 Signal transmission is stable The signal of wind direction wind speed and accommodation cast loose adopt the communications interface 485 Use one cable to parallel connection transmission 2 The det
21. rotors are not damaged by putting down the generator with its rotors up 4 Put down the turbine in the reverse steps of installation For 2KW amp below 2KW 1 Disconnect the turbine and controller Make the three output lines be short circuit to prevent the blades from further running 2 Put down the turbine in the reverse steps of installation 20 Can I enlarge the batteries capability to lengthen the available time for electrical appliance Enlarge the capability of batteries would make the batteries on half full state and can not shorten it lifespan What if the wind turbines 3kw amp above 3kw can not trace wind direction automatically 1 Check whether the anemoscope 1 broken or not The concrete way 1 to examine whether there is wind speed indicator on controller 2 Check whether the dogvane is broken or not The concrete way 15 to unplug the plug of dogvane from controller and you will see there are three line on dogvane with marks 2 3 Measure the resistance between and by multi meter the resistance should be appropriately 1000 and then measure the resistance between and along with and The resistance figure of these two and should be equal to the resistance figure between and 02 3 If no problem exist the ahead two procedures check whether the controller board has been set on auto Otherwise it can not trace the wind direction automatically If it can not t
22. the same way that you install the tower 1 Disconnect the electrical make the wind turbine power off as 1 shown in wind turbine user manual 2 Use the hanging strip tie up the wind turbine by professional Drive the crane and make sure that the tower does not fall down after screwing off the anchor bolt 3 Screw off the anchor bolt 4 Drive the crane to trice the tower and wind turbine to separate them from the anchor 5 Lay down the tower and wind turbine slowly to the wooden stand in a slanting position Step 3 Assembly of tower and turbine Please refer to the installation specification of guyed tower Step 4 Step 4 Hoisting the tower A hoist 15 needed while installing the guyed tower which will be proceeded by professional Non working people should be far away from the site when hoisting Use the hanging strip tied the upper side of pole and hoist slowly 2 When the tower has been erected face the open hole on tower base to the cotter bolt and screw down the bolt nut 15 Configuration Specification of Batteries 1 Batteries should be placed inside the buildings which should be dry and in constant temperature After finalizing the quantity of batteries in series it is necessary to design a wooden stand to put on the batteries controller and inverter 2 Connect the batteries in series The specific way is to connect the anode of the first batteries to cathode of the second one 3 Make the joints
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