Airforce4.1 5KW grid-tied system User`s manual
Contents
1. HOPEFUL WIND ENERGY TECHNOLOGY Airforce4 1 SKW grid tied system User s manual 2011 Edition CE HOPEFUL WIND ENERGY TECHNOLOGY Hopeful Wind Energy Technology Co Ltd Congratulations on your purchase and welcome to our family Dear Airforce 4 1 Owner Thank you for your purchase of Airforce 4 1 You have just selected the most cost effective technologically advanced renewable energy appliance available for a home or small business We congratulate you on your choice and are confident you will experience years of dependable service Before going any further please complete and return the enclosed Warranty Registration Card or register online via www hopefulenergy com The conditions of your warranty are dependent upon the proper installation of Airforce 4 1 Furthermore this will assure you of being kept up to date with the latest developments from Hopeful Wind Energy These include new options performance tips updated software to maximize output and user notices It is important to know that we do not sell or distribute your information to any third party We understand your privacy is important Please call during working hours Monday Friday 8 30 am to 5 00 pm Beijing time Our phone number is 86 756 3819866 or 3819868 or you can contact us by info hopefulenergy com Again welcome to our family and thank you for investing in the future of wind energy with Airforce 4 1 Sincerely Hopeful Wind Energy2. Hopeful Energy will repair or replace free of charge any part or parts of the Hopeful Energy Airforce 4 1 wind generator determined by Hopeful Energy to be defective in materials and or workmanship under normal authorized use consistent with product instructions for a period of five years from the date the original purchaser Customer receives the wind generator Start Date This warranty extends only to the original purchaser The Customer s sole and exclusive remedy and the entire liability of Hopeful Energy its dealers and affiliates under the warranty is at Hopeful Energy s option either i to replace the wind generator with new or reconditioned wind generator ii to correct the reported problem or iii to refund the purchase price of the wind generator Repaired or replaced products are warranted for the remainder of the original warranty period Restrictions Problems with the wind generator products can be due to improper use maintenance non Hopeful Energy additions or modifications or other problems not due to defects in Hopeful Energy s workmanship or materials No warranty will apply if the wind generator i has been altered or modified except by Hopeful Energy ii has not been installed HOPEFUL WIND ENERGY TECHNOLOGY operated repaired or maintained in accordance with instructions supplied by Hopeful Energy iii or iv has been exposed to winds exceeding 134 mph 60 m s or has been subj
3. into position as an assembly or Airforce 4 1 may be hoisted to an already erected tower These latter two options require specialized equipment and Suspension training and should only be attempted by trained professionals rubber washer A e As depicted in figure 3 insert the suspension rubber washer B to the Vibration isolator base vibration isolator base tighten the suspension rubber washer B and A Tower flange K through the vibration isolator base e Install the washer on the bolt insert the bolt through the suspension M6 Socket head screw rubber washer B suspension rubber washer A and the tower flange refer to figure 3 e Install nuts and flat gasket on bolts to secure Airforce 4 1 to the tower Earthing wire Cover of vibration e Torque the vibration isolator bolts to 5 N m in two steps First torque all isolator bolts to 3 N m then tighten all bolts to 5 N m M6 bolt e Mount the covers of vibration isolator using six M6 socket head screws Refer to figure 3 Figure 3 E Airforce4 1 5KW grid tied system user s manual HOPEFUL WIND ENERGY TECHNOLOGY Installation Blades And Nosecone Assembly Installing the Blades Hub Not on Turbine Proper installation of the blades is critical for safe operation The blade nuts and bolts are a unique grade of steel and are specially coated to prevent corrosion DO NOT substitute different nuts and bolts Spare nuts and bolts a
4. 37 Sitting Finding the Best Location for Airforce 4 1 15 Disposal of Airforce A 38 LocalReguitementi nre 15 Frequently Asked Questions iii 38 Choosing A Proper Site for Aiforce KI 16 Warranty Registration Card eee Attachment Basic Components Descriptions Hub Blade Long U bolt M10 105mm Blade root shim M10 Nut Nosecone Bolt M10 80mm Nut M30 x 12 Spring washer 31mm Woodruff key Generator Nylon sheath HOPEFUL WIND ENERGY TECHNOLOGY Quantity 1 3 6 24 E ES Ee Airforce4 1 5KW grid tied system user s manual HOPEFUL WIND ENERGY TECHNOLOGY 14 15 Item 17 13 14 18 15 16 19 17 18 19 20 AININ 21 22 E Airforce4 1 5KW grid tied system user s manual Descriptions Bolt M12 x 85mm Washer 50 12 5mm Suspension rubber washerA Suspension rubber washer B Tower flange 240 120mm Flat gasket 25 12 5mm M12 Nut Cover of vibration isolator Socket head screw M6 x 8mm M6 bolt Quantity N OO HOPEFUL lt WIND ENERGY TECHNOLOGY Introduction of The Controlle This manual is applicable for 5KW grid tied wind power generator unit and its power generation system Main functions of the controller lt adopts an embeded microprocessor as its core control unit with PWM function It possesses a dual protection function automatic braking of wind turbine over loading over loading of voltage an
5. Airforce 4 1 installation parts blades and the nosecone Hoist Airforce 4 1 and the tower to a proper height mount the tower to the ground Airforce4 1 5KW grid tied system user s manual HOPEFUL WIND ENERGY TECHNOLOGY Installation Priorto Installation Typical Airforce 4 1 Installation 24V 100Ah Battery I Controller HE W385B Au N Municipal Grid Input L 110V 220V Airforce4 1 5KW grid tied system user s manual D HOPEFUL WIND ENERGY TECHNOLOGY Installation Prior to Installation Sitting Finding the Best Location for Airforce 4 1 Local Requirement The best location to install a wind turbine is often a compromise Building codes and installation regulations may vary greatly Local building restrictions the height of surrounding structures wire depending upon country state city and local townships Be sure length and available open space may require Airforce 4 1 be to obtain all the required building permits BEFORE beginning installed in a less than optimum location installation In general Airforce 4 1 will produce more power if installed on a Additionally be sure to contact the local electrical utility company taller tower However towers are expensive so it is important Many utility companies will require an Interconnection to balance per
6. Airforce 4 1 please contact your local waste disposal authorities your household waste disposal service or the store where you purchased Airforce 4 1 Airforce 4 1 was manufactured in compliance with the Restriction of Certain Hazardous Substances in Electrical and Electronic Equipment 2002 95 EC RoHS and therefore does not contain any of the materials regulated by that standard E Airforce4 1 5KW grid tied system user s manual Warning Power to Airforce 4 1 MUST BE TURNED OFF prior to servicing Frequently Asked Questions 1 What happens if I lose power from my utility company If there is a power outage the Airforce 4 1 will shut down within one second It will resume normal operation when power is restored There are many safety requirements of a utility tied inverter We strongly suggest our users apply an inverter in accordance with these requirements 2 Does the Airforce 4 1 have lightning protection Yes the Airforce 4 1 has lightning protection The Airforce 4 1 can handle 6000 Volts as required by related regulations and standards If you live in a lightning prone area Hopeful Wind Energy recommends an additional lightning arrestor at the base of the tower 3 What should I do if I m expecting a severe storm The Airforce 4 1 is designed for very high winds but itis always a good idea to shut Airforce 4 1 down if there is going tobea severe storm to protect against any flying debris Operation And Mainten
7. Technology Co Ltd HOPEFUL WIND ENERGY TECHNOLOGY Table of Contents 1 Basic Components iii 1 Installation aa ai 17 Introduction of The Controller ze 3 Electrical Connections To Airforce 4 10 17 Main Functions of The Controller i 18 Wire SIZING vs 18 Electrical Circuit Chart of The Controller as 18 Grounding viet ries 19 Technological Specifications of The Controller 4 Requirements of Installation Controller for 5 kw 2 Technical Specifications mimina ees 5 Grid tied System 000 20 3 Gurves of Pero Mai 6 The Use of Cable Connection Handle 23 4 Important Safety Instructions 6 Installing Airforce 4 1 On A Tower 25 5 The Content of Your Airforce 4 1 Shipment er 8 Bolting Airforce 4 1 To The Tower 30 6 Airforce 4 1 Limited 5 Year Warranty 9 Blades And Nosecone Assembly i 31 WIND TURBINE WARRANTY AGREEMENT 9 Final Electrical Tests iia 34 T Installationi resse aaa 12 8 Operation And Maintenance ini 35 Priorto Installationi ariani aiar 12 Manual Operation of Airforce 4 1 35 intended US6 aa 12 Maintenance iaia 35 Rhett aide FE AIR TE 12 Service nella 36 Installation Personnel eee anale 13 Troubleshooting E 36 Sequence of Installation Aa 13 Emergency Shutdown veri ris 36 Typical Airforce 4 1 Installation i 14 Key Operating Characteristics
8. user s manual HOPEFUL WIND ENERGY TECHNOLOGY Installation Wire Sizing all electrical connections are completed with copper core cables wires Measure the distance from the electrical utility panel and Airforce 4 1 include the tower height Refer to the table below and based on the measured distance and system voltage select the appropriate wire size Wire Size Table Wire Size 4 AWG 25mm 6 AWG 16mm 8 AWG 10mm 10 AWG 6mm 12 AWG 4mm 14 AWG 2 5mm Maximum Distance 670m 450m 270m 165m 105m 65m IMPORTANT Size of cables connecting the automatic electromagnetic braking system should be the same as of the three main cables from the generator so as to minimize the resistance in the circuit of brake control Airforce4 1 5KW grid tied system user s manual Installation Grounding All electrical systems must be grounded in accordance with local and national standards Grounding provides protection from electrical shock voltage surges and static charge build up W Note The instructions in this section are provided as reference local electrical codes and standards have precedence over these instructions Please complete the grounding following the requirements depicted in the accompanying figure Note When processing the grounding make sure the grounding holes on the vibration isolator base and tower flange are aligned pr
9. 0 45 1500 370 W x260 H x184 D 10 7 HE W385B Controller for 5 kw grid tied system Model Max output power Rated wind speed Max wind speed Survival wind speed Start up wind speed Cut in wind speed Rated rotational speed Max rotational speed No of blades Rotor diameter Blade length Blade material Generator Braking system Type Yaw Total weight Warranty Controller Grid tided inverter Tower Technical Specifications Airforce 4 1 5 KW grid tied system 5 KW 12 M S 27 MPH 25 M S 56 MPH 60 M S 134 MPH 1 8 M S 4 MPH 3 M S 7 MPH 500 RPM 550 RPM 3 4 1M 2 02M FRP 3 Phases PM Generator Electromagnetic braking system control Downwind rotor passive 120 KG 5 years Protection controller for generator 120 240Vac 50 60Hz optional 12 M optional Woodruff key Generator HOPEFUL lt WIND ENERGY TECHNOLOGY Blade root shim Long U bolt M10 105mm Spring washer 31mm Nut M30x12 Nosecone Bolt M10 80mm 0 0 Nylon sheath Airforce4 1 5KW grid tied system user s manual 5 HOPEFUL WIND ENERGY TECHNOLOGY Curves of Performance Curves of Performance 5 kw grid tied system 6400 6000 5600 5200 4800 4400 4000 3600 3200 2800 Power w 2400 2000 1600 1200 800 400 O m s 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 mph 0 5 9 13 18 22 27 31 36 40 4
10. 5 49 53 58 62 Wind Speed D Airforce4 1 5KW grid tied system user s manual Important Safety Instructions Read these instructions in their entirety before installing or operating recommends Airforce 4 1 be installed by trained professional Professional installation Hopeful Wind Energy strongly d s 1 2 3 4 5 6 7 8 SAVE THESE INSTRUCTIONS This manual contains important instructions for Airforce 4 1 that must be followed during installation and maintenance Read understand and respect all warnings Do not install Airforce 4 1 around standing water Do not install Airforce 4 1 on a windy day The allowed wind speed should be less than 2 m s 4mph Install Airforce 4 1 in accordance with local related electric code and local building codes If required by local authorities always obtain a building permit before construction A minimum of 2 adults are required to safely lift or move Airforce 4 1 Use proper equipment such as hydraulic hoists to lift Airforce 4 1 Always wear appropriate protective personal equipment such as closed toe work shoes hard hat work gloves and safety glasses when working on or installing Airforce 4 1 If unusual noise or abnormal operation is observed from Airforce 4 1 turn off the machine and contact authorized service personnel Important Safety Instructions 10 Shut Airforce 4 1 OFF if ice accumulates on blades to avoid possible inju
11. EFUL WIND ENERGY TECHNOLOGY Installation Regardless of the tower design and height you select there are two critical areas that must be considered when selecting the tower These are the stub tower height and blade clearance refer to figure 2 lt Warning Working on towers is dangerous and should be left to professionals with proper safety equipment and training IMPORTANT Hopeful s Warranty is only extended to installations that are made on a properly engineered tower Hopeful reserves the right to deny any warranty claim in which an improperly designed tower is used gt 44 5cm Figure 2 Airforce4 1 5KW grid tied system user s manual 29 HOPEFUL WIND ENERGY TECHNOLOGY Installation Bolting Airforce 4 1 To The Tower Warning Do not attempt to hoist a tower and Airforce 4 1 into position using a sling attached to Airforce 4 1 Airforce 4 1 CANNOT support the hanging weight of a tower tower Before Airforce 4 1 is bolted to the tower complete the electrical connections as described in the ELECTRICAL CONNECTIONS section of this manual The following section provides directions for bolting Airforce 4 1 to the k Bolting Airforce 4 1 to the tower is most easily accomplished at ground level as in the case with a tilt up tower Alternately Airforce 4 1 may be bolted to the tower on the ground and the tower with Airforce 4 1 hoisted
12. ERCHANTABILITY AND NON INFRINGEMENT NO OTHER WARRANTY EXPRESSED OR IMPLIED WETHER OR NOT SIMILAR IN NATURE TO ANY OTHER WARRANTY PROVIDED HEREIN SHALL EXIST WITH RESPECT TO THE PRODUCT SOLD UNDER THE PROVISIONS OF THESE TERMS AND CONDITIONS HOPEFUL ENERGY EXPRESSLY DISCLAIMS ALL LIABILITY FOR BODILY INJURIES OR DEATH THAT MAY OCCUR DIRECTLY OR INDIRECTLY BY UES OF THE PRODUCT BY ANY PERSON ALL OTHER WARRANTIES ARE EXPRESSLY WAIVED BY THE CUSTOMER HOPEFUL WIND ENERGY TECHNOLOGY Airforce 4 1 Limited 5 Year Warranty WIND TURBINE WARRANTY AGREEMENT Limitation of Lliability UNDER NO CIRCUMSTANCES WILL HOPEFUL ENERGY ORITS AFFILIATES OR DEALERS BE LIABLE OR RESPONSIBLE FORANY LOSS OF USE INTERRUPTION OF ANY BUSINESS LOST PROFITS LOST DATA OR INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES OF ANY KIND REGARDLESS OF THE FORM OF ACTION WETHER IN CONTRACT TORT INCLUDING NEGLIGENCE STRICT LIABILITY OR OTHERWISE RESULTING FROM THE DEFECT REPAIR REPLACEMENT SHIPMENT OR OTHERWISE EVEN IF HOPEFUL ENERGY ORITS AFFILIATES OR DEALERS HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGE Neither Hopeful Energy nor its affiliates or dealers will be held liable or responsible for any damage or loss to any items or products connected to powered by or otherwise attached to the Hardware The total cumulative liability to Customer from all causes of action and all theories of liability will be limited to and will not exceed the
13. Hopeful Wind Energy recommends Airforce 4 1 be shut down on an annual basis and an inspection of the blades performed The inspection may be accomplished using binoculars or by close visual inspection Inspect for cracks and chips particularly along the edges of the blades Any damage is cause for replacing the blades If in doubt contact our service center In the event you must gain access to Airforce 4 1 use the opportunity to perform the following inspections e Check tightness of blade bolts with torque wrench All blade bolts should be torqued to 85 N m e Clean the rotor blades with a mild soap and water Remove as much of the dead bug matter as possible from the blades e Look for any problems with the blades such as cracks or damage to the edges of the rotor blade e Inspect the face nacelle and the rest of the Airforce 4 1 and note any potential damage or problem Airforce4 1 5KW grid tied system user s manual HOPEFUL WIND ENERGY TECHNOLOGY Operation And Maintenance Service The internal components of Airforce 4 1 should only be serviced by qualified technicians specifically trained to perform the service Under no circumstances should untrained technicians attempt to perform service or repairs unless under the direct guidance of a trained technician Service operations that were performed during the installation of Airforce 4 1 for example bolting on the blades or bolting Airforce 4 1 to the tower may b
14. W grid tied system user s manual 25 HOPEFUL WIND ENERGY TECHNOLOGY Installation Tower Installation Main Steps D Important When bolting the tower to the ground make sure that the tower is secured uprightly which is one of the crucial factors affecting the performance of Airforce 4 1 The bolts are not only used to secure the tower but also helpful for adjusting the tower s verticality Eg Airforce4 1 5KW grid tied system user s manual D HOPEFUL WIND ENERGY TECHNOLOGY Installation Tower Installation Main Steps Airforce4 1 5KW grid tied system user s manual HOPEFUL WIND ENERGY TECHNOLOGY Installation Tower Installation Connecting Three Main Parts Together For the main part of the tower it s composed with three tubes 3m 4 5m 4 5m check the figure marked at the bottom of each section inside the tube if the figures are the same in these three sections that means they belong to the same tower and should be connected together in the same tower When these three sections are lined up together mind the Arrow Marks at the conjunction ends of each section align these two arrows between every two tubes so that the verticality of the tower can be achieved see figures below AU fg S EJ Airforce4 1 5KW grid tied system user s manual HOP
15. ance Frequently Asked Questions 4 How do shut down Airforce 4 1 To turn off Airforce 4 1 all you need to do is to press down the red button on the controller s main panel This will cause NO damage to the unit 5 Can I leave Airforce 4 1 unattended Yes the Airforce 4 1 is designed to operate without any user input Ifthere is any fault it will shut down on its own 6 Whatdo I do ifAirforce 4 1 is facing upwind even though there is a strong wind If the Airforce 4 1 is not tracking correctly you should check to see if the tower is level 7 When should I contact an authorized service technician a If there is any unusual vibration coming from Airforce 4 1 b If you hear any noise that sounds like mechanical interference c If the Airforce 4 1 is connected to the utility power i e all breakers and disconnects are turned on the wind is blowing but the Airforce 4 1 is not turning very fast HOPEFUL WIND ENERGY TECHNOLOGY 8 Can I mount Airforce 4 1 to my roof Roof and building mount is not recommended Because of the size and weight of the wind generator Airforce 4 1 needs to be mounted on a PE certified tower to ensure the quietest and safest system Roof mounting will invalidate the warranty 9 What should I do if ice forms on Airforce 4 1 blades To avoid the possibility of injury from ice breaking loose from the blades and injuring anyone Airforce 4 1 should be turned OFF if ice accumulates on th
16. ausing it to remain shut down It is important to set the elevation for the turbine to operate correctly If itis not set the turbine may experience premature shut downs If a wind gust exceeds 25 m s 56mph then the Airforce 4 1 will shut down for 36 hours However in order to raise the efficience of the whole generation system when the wind speed returns to normal the user can restart Airforce 4 1 by processing a manual reset firstly disconnect the electrical source and battery unit then resume the connection to normal Or press down the red button and turn counter clockwise to release this automatic shut down Cc Warning Though the manual reset is easy to carry out the user should ask professionals to finish it in case there are risks of electrical shock Airforce4 1 5KW grid tied system user s manual e HOPEFUL WIND ENERGY TECHNOLOGY Operation And Maintenance Disposal of Airforce 4 1 This symbol shown onAirforce 4 1 or its packaging indicates it may not be treated as household waste Dispose of Airforce 4 1 properly by handing the entire turbine assembly over to the applicable collection point for recycling of electrical equipment By ensuring Airforce 4 1 is disposed of correctly you will help prevent harm to the environment which may be caused by inappropriate disposal of this product The recycling of materials will help conserve natural resources For more detailed information about recycling of
17. d current and emergency stop Protection against over charging of battery Protection against reverse connection of battery Protection against electrical shock and voltage surges Electrical circuit chart of the controller Rectifier Charging Electromagnetic Stable Power supply Transformer bridge control Battery braking control for braking system Municipal grid input gt Ae i AC Wind power generator circuit input Voltage meter Switch of automatic Switch of manual s Current mster emergency brake emergency brake Airforce4 1 5KW grid tied system user s manual E HOPEFUL WIND ENERGY TECHNOLOGY Introduction of The Controller Main technological specifications of the controller refer to table 1 Table 1 Item Max output alternating current voltage V Max output current A Max output power of the generator KW The capacity of battery The protection voltage of over charging V The recovery voltage of over charging V Time of automatic braking resuming Electrical source output of electromagnetic braking Voltage of exterior working electrical source The protection grade of controller s crust Applied temperature C Operating height above sea level M The external size of controller MM The total weight of controller KG D Airforce4 1 5KW grid tied system user s manual Spec 438 8 6 24V 100Ah 28 8 26 36 hours 150W 24V 220V 110V Ip20
18. e blades O TIP Anything else you want to ask please log on our website www hopefulenergy com we ll answer your questions within 3 business days Airforce4 1 5KW grid tied system user s manual JUS9UWINI SUI Siy paseyoind an noA Jaye SAep og UIUJIM pe163s1681 LON S JInpoJ y J pioA SE pa eas aq IM AJUBJEMIYL ZILON yonpoijd ay paseyoind 8A no sae SsAep og UIY IM S18 ESp e90 sx 10 ABsauy njadoH 0 yOeq zu s aq pinoys jeuro eu pue Aoeinooe pue APubazui SJ ul pie uoles Boy AJUBEM SIU a a dwoo asea q asn jo asodind uoqeoljioeds Jsj18Au Mloede9 Alejjeg JUBISH JOMOL apo wajsAs ino Jnoqy 8U0Ud J8 eeg A uno9 Je eag At Je eag ssaJppy Je esq 8WEN Je eeg Ja eag sno Mogy uoqa duoojo8 e TTT aseydind Jo ajeq suoyd TT 8p09 EISOd dIZ Ayjunog 89UlAOJd 8 B S AUD sselppy eueujsej 7 BU Isi pewg UOIIEWJOJU INOX Jagwnu jelias JOnNpold pie uoljessiBay AzuesieMm ADOTONHD311 ADUANA ANIM YA 4InN43d0H HOPEFUL WIND ENERGY TECHNOLOGY CO LTD Address Building C No 18 7th Keji Road National Hi tech zone Jinding Zhuhai China 519085 Tel 86 756 3819866 3819868 Fax 86 756 3882362 E mail info hopefulenergy com Website www hopefulenergy com
19. e performed as necessary by the user operator Troubleshooting Check the connections as close to Airforce 4 1 as possible Depending on the installation this may be at the utility panel or at a disconnect switch The connections may also be checked at terminals of the cable connection handle see page 24 in this manual however this will require removing Airforce 4 1 from the tower E Airforce4 1 5KW grid tied system user s manual Measure this voltage and additional troubleshooting information may be accessed without the need to remove the turbine Contact your local dealer or Hopeful Service Meanwhile check the operation condition of the controller and the information on the display screen Process the troubleshooting following the inspection requirements on page 21 in this manual Emergency Shutdown Manual emergency shutdown When aserious fault occurred to Airforce 4 1 press down the red button on the controller s main panel to shutdown Airforce 4 1 for necessary repair Automatic emergency shutdown If Airforce 4 1 s internal microprocessor determines a serious internal fault has occurred it will execute an Emergency Stop an E Stop An E Stop will only take place if the fault is severe and requires servicing Airforce 4 1 s internal components Refer to the Key Operating Characteristics Operation And Maintenance section of this manual for a complete description of the Airforce 4 1 s various shut down
20. e voltage from the wind generator is 380 V PI 1 01A The line current from the wind generator is 1 01 A BV 24 54V The voltage of battery is 24 54 V 1000W The wind generator s power output is 1000 W Airforce4 1 5KW grid tied system user s manual HOPEFUL WIND ENERGY TECHNOLOGY Installation Requirements of Installation Controller for 5 kw Grid tied System Matters needing attention during installation and operation Before connecting the controller make sure all the equipments such as the wind generator unit the inverter battery unit lightning protection device and cables are properly selected configured and installed e Check the grounding insulation resistance in all equipments it should be in accordance to the technological requirements of wind power generation system e The controller is an electrical device with high voltages unauthorized professionals are not allowed to open the cover of the chassis in case that electrical shock and damages are caused Furthermore this device must be appropriately grounded with the grounding resistance not higher than 40 e This device must be firmly placed on a position which is away from hand s reach and make sure that there is a surrounding environment of ventilation and no substance of flammability e When this device is under installation disassembly or inspection make sure to push up the manual brake on the controller s side panel to ay be wel S E Airf
21. ear and require more frequent e Do not install blades other than those supplied with Airforce 4 1 inspections Use only genuine replacement blades supplied by us Unintendeg Use Do not attempt to use a power source other than the wind to Utilizing Airforce 4 1 for other than its intended purposes or with power Airforce 4 1 for example connecting pulleys or as inappropriate equipment or modifying Airforce 4 1 is not authorized by us water powered turbine and will void the warranty and may result in serious or even fatal injury Observe the following precautions S IMPORTANT Precautions listed here cannot address all the possible misuses of Airforce 4 1 therefore contact us if there is any doubt or question regarding the installation or use of Airforce 4 1 IM Airforce4 1 5KW grid tied system user s manual Installation Prior to Installation Installation Personnel D HOPEFUL WIND ENERGY TECHNOLOGY Hopeful Wind Energy recommends professional installation of Airforce 4 1 While Airforce 4 1 is not difficult to install and many homeowners have successfully installed their own Airforce 4 1 knowledge of local zoning and building code requirements construction techniques as well as residential electrical systems is required for a safe installation Sequence of Installation Complete the piney ies installation of hub Install Airforce 4 1 to the tower Preparation of all connections to
22. ected to abnormal physical thermal or electrical stress misuse negligence or accident If Hopeful Energy s repair facility determines that the problem with the wind generator is not due to a defect in Hopeful Energy s workmanship or materials then the party requesting warranty service will be responsible for the costs of all necessary repairs and expenses incurred by Hopeful Energy Warranty Claims amp Return Procedures In order to be eligible for service under this warranty the Customer MUST return the Warranty Registration Card or log on www hopefulenergy com to complete the warranty registration within 30 days of purchasing the wind generator Additionally the Customer must submit a service request for the wind generator covered by this warranty within the warranty period by contacting Hopeful Energy in writing or via telephone and obtaining a Return Authorization RA number This RA must be obtained before returning any product under this warranty Airforce4 1 5KW grid tied system user s manual D HOPEFUL WIND ENERGY TECHNOLOGY Airforce 4 1 Limited 5 Year Warranty WIND TURBINE WARRANTY AGREEMENT Notification must include a description of the alleged defect the manner in which the wind generator was used the serial number and the original purchase date in addition to the name address and telephone number of the party requesting warranty service Within 3 business days of the date of notification Hopef
23. ents MUST be followed strictly Every piece of nut MUST be fixed to every U bolt Woodruff key Spring washer Nosecone M10 Bolt Nylon sheath Figure 5 Airforce4 1 5KW grid tied system user s manual HOPEFUL WIND ENERGY TECHNOLOGY Installation Final Electrical Tests At this point Airforce 4 1 should be bolted to the tower and all the ancillary equipment blades nosecone cover of vibration isolator controller and a special A C inverter equipped by user attached Prior to tilting the tower into position the following final electrical tests should be performed e Push up the manual brake on the controller s side panelto WYW wyw attempt to rotate the blades there should be noticeable resistance although the leverage provided by the blade will make it possible to rotate the blades e Pull down the manual brake to and attempt to rotate the blades after approximately 5 minutes There should be noticeably less resistance required to rotate the blades e With the manual brake switched to I _ verify that Airforce 4 1 returns to a braked condition Do not attempt to put Airforce 4 1 into service until these tests passed If tests passed tower may be tilted into position and placed into service EI Airforce4 1 5KW grid tied system user s manual Operation And Maintenance Manual Operation of Airforce 4 1 When there is an abnormal over speed happens to Airforce 4 1 unde
24. formance tower height to installed cost in order Agreement prior to installation Some utilities may also require to achieve the lowest cost of energy and the quickest payback installation of aseparate power metre for Airforce 4 1 Prevailing wind Airforce4 1 5KW grid tied system user s manual IG AP HOPEFUL WIND ENERGY TECHNOLOGY Installation Prior to Installation Choosing AProper Site for Airforce 4 1 gt ck cb NO e73 ATE 4 IG Airforce4 1 5KW grid tied system user s manual HOPEFUL WIND ENERGY TECHNOLOGY Installation Introduction The following sections of this manual assume a tower and foundation appropriate for use with a Airforce 4 1 are in place and ready for Airforce 4 1 to be installed Electrical Connections To Airforce 4 1 1 Airforce 4 1 is designed for easy installation Please complete the electrical connections to Airforce 4 1according to the figure depicted below Connection terminals of controller HE W385B I 000000000000 wl we w3 v1 vVe V3 B B BR1JBR2 L N Municipal Grid Input 110V 220V LE On grid devices AC Output to the Grid 24V 100Ah Battery Airforce4 1 5KW grid tied system
25. h extreme caution Ne J Airforce4 1 5KW grid tied system user s manual HOPEFUL WIND ENERGY TECHNOLOGY The Content of Your Airforce 4 1 Shipment When you ve received the shipment of Airforce 4 1 please check all parts should be included as followed Item Descriptions Part No Quantity Item Descriptions Part No Quantity 1 Hub A05 1 13 Bolt M12 x 85mm B24 8 2 Blade A06 3 14 Washer50 12 5mm B32 8 3 Long U bolt M10 105mm A10 6 15 Suspension rubber washer A B22 8 4 Blade root shim A07 3 16 Suspension rubber washer B B23 8 5 M10 Nut A12 24 7 Tower flange 240 0120mm B21 1 6 Nosecone A02 1 18 Flat gasket 25 12 5mm B25 8 7 Bolt M10 80mm A01 1 19 M12 Nut B26 8 8 Nut M30x12 A03 1 20 Cover of vibration isolator B29 3 9 Spring washer 31mm A04 1 ZI Socket head screw M6 x 8mm B30 6 10 Woodruff key A13 1 22 M6 bolt B28 2 11 Generator A33 1 23 Controller HE W385B B33 1 12 Nylon sheath B15 1 24 Cable connection handle B31 1 25 Earthing wire10 AWG 6 mm 100mm B27 1 O TIP Every part equipped to Airforce 4 1 has its own part number If there is any fault found on these parts during the installation or operation you can contact Hopeful Energy or your local dealers by tracking these part numbers for timely repair or replacement D Airforce4 1 5KW grid tied system user s manual Airforce 4 1 Limited 5 Year Warranty WIND TURBINE WARRANTY AGREEMENT Hardware Warranty Hopeful Wind Energy Technology Co Ltd
26. ments on live electrical systems Airforce4 1 5KW grid tied system user s manual E HOPEFUL WIND ENERGY TECHNOLOGY Installation The Installation of The Cable Connection Handle Cables connected by user 5 connected to BR2 xs ge 3 connected to W3 3 Bi 4 connected to BR1 1 connected to W1 2 connected to W2 50cm Cables connected by manufacturer wijwejw3 vi ve v3 B B BRIBRe L N 2 e Connection terminals of controller HE W385B Figure 1 24 Airforce4 1 5KW grid tied system user s manual Installation Installing Airforce 4 1 On A Tower There are several types of towers that can be used with Airforce 4 1 Itis essential that Airforce 4 1 is installed ona properly engineered tower One of the leading causes of wind generator failure is use ona poorly designed tower Construction of tower refer to the figure beside d120mm thickness10mm seamless steel pipe 4 5m 4 5m 4 1m p 160mm 12 icosahedral thickness 5mm material Q235 b500mm 12 icosahedral O HOPEFUL WIND ENERGY TECHNOLOGY 540 450mm thickness 8mm steel rim b14mm screw threaded steel p 50mm copper tube for lightning protection Airforce4 1 5K
27. modes including Emergency Stops Resetting an Emergency Stop requires special equipment and can only be accomplished by a trained technician If you suspect your Airforce 4 1 has executed an Emergency Stop contact Airforce 4 1 Technical Support Warning There is risk of electric shock from both AC and DC voltages within Airforce 4 1 Do not attempt to open the controller box to access the internal components AC source should always be disconnected the turbine restrained from yawing and blades secured from rotating prior to servicing or serious or fatal injury may occur Key Operating Characteristics The Airforce 4 1 operates by converting the kinetic energy of the wind into rotational motion that turns an alternator and ultimately produces usable electric power In actuality this is a great oversimplification of Airforce 4 1 s operation since it must very precisely match the frequency and voltage of the special A C inverter equipped by user in order to power your home and its appliances Airforce 4 1 will begin producing power in a wind of approximately 3 m s 7mph At that speed the blades will rotate at approximately HOPEFUL WIND ENERGY TECHNOLOGY 120 rpm As the wind speed increases the blade speed will also increase If a condition occurs that causes the rotational speed to exceed 550 rpm Airforce 4 1 will shut down for approximately 36 hours after which it will resume normal operation unless a fault is detected c
28. operly or the grounding and the installation of suspension rubber washers would be affected HOPEFUL WIND ENERGY TECHNOLOGY Grounding hole i E gt Grounding hole ee Jy k M6 bolt n Pi gt W S KS gt SS A 6 Sg Se U Airforce4 1 5KW grid tied system user s manual I HOPEFUL WIND ENERGY TECHNOLOGY Installation Requirements of Installation Controller for 5 kw Grid tied System Installation of components According to its protection grade the controller should be Table 2 Section table of external connective cables installed in an indoor environment with dryness and a Model Spec of municipal Spec ofbatter ventilation and beside the controller there should not be any grid input pec y substance of flammability g HE W385B dla i e The controller should be installed vertically and hanged firmly RA e Before the cable connection push up the manual brakeon the controller s side panel to wyw wyw in case electric shock accidents will occur from the operation of wind w1 we w3 Vv1 Ve V3 B B BR1 BR2 L N generator during the connection e Follow the signs below the connection terminals connect the W1 W2 W3 Wind generator input phase sequence optional cables of related equipments properly The section of cable V1 V2 V3 Wind generator output phase sequence optional B Positive pole of batte
29. orce4 1 5KW grid tied system user s manual HOPEFUL WIND ENERGY TECHNOLOGY Installation The Use of Cable Connection Handle For the safety and convenience of cable connection Airforce 4 1 is specially equipped with a safety cable connection handle refer to figure 1 on page 24 Connect cables long enough to Airforce 4 1 then finish the connection between the cable connection handle and cables from Airforce 4 1 corresponding to the serial numbers of connection terminals in the cable connection handle refer to figure 1 on page 24 Position Airforce 4 1 to the top of the tower and bolt it to the tower While selecting proper wire sizes for cables that can be connected directly to Airforce 4 1 please refer to Wire Sizing Section on page 18 ofthis manual for instructions With controller connected to the circuit process the basic test of braking by applying the manual brake on the controller s side panel e Do not push up the manual brake on the controller s side panel to wyw LL wait approximately 5 minutes and attempt to rotate main blade shaft blade should be noticeably easier to turn than with the manual brake switched to niw nw e Push the manualbrake to E E and verify that Airforce 4 1 has returned to its braked mode If Airforce 4 1 fails this test check connections and repeat test test MUST be passed before proceeding Caution Electrical Shock Hazard use extreme care when making electrical measure
30. purchase price of the product paid by Customer This Warranty gives the Customer specific legal rights and the Customer may also have other legal rights that vary from state to state or province to province Airforce4 1 5KW grid tied system user s manual DI HOPEFUL WIND ENERGY TECHNOLOGY Installation Prior to Installation Intended Use Airforce 4 1 is a wind powered electricity generator It is designed to 9 Observe all related electrical code requirements including supplement the electrical power provided by the local electrical utility tower grounding requirements electrical disconnect company in residential applications by connecting to the main AC utility switches wires size and type panel via a user equipped special AC inverter Airforce 4 1 may also be e Do not use unauthorized fasteners Use fasteners supplied utilized to provide power with battery based residential electrical systems with Airforce 4 1 Contact your dealer for authorized or utility grid connected systems with battery backup A typical Airforce 4 1 replacement fasteners installation is depicted in the figure on page 14 of this manual Airforce 4 1 e Observe fastener torque requirements is designed to operate at sites with average wind speeds no less than 5 e Do not attempt to modify Airforce 4 1 in any fashion m s 11mph The installation of Airforce 4 1 at sites with higher average internally or externally wind speeds will accelerate component w
31. r a strong wind but the discharging and braking system cannot be started in time press down the red button of emergency shutdown on the controller s main panel After the wind speed has returned to normal press down the red button and turn counter clockwise to its former position then Airforce 4 1 will resume normal operation If there is still abnormality call the professionals for an inspection Maintenance After 25 years of service the blades MUST be replaced even if there is not apparent damage The blades should be replaced asa set Do not attempt to replace individual blades All blade mounting hardware bolts blade root shims nuts should be replaced at the same time Do NOT attempt to reuse the blade fasteners There are no periodic service requirements other than replacing the blades after 25 years All bearings and rotating components were designed for a 25 year life This corresponds to a site with an average wind speed of 5 m s 11mph Although there are no routine service or maintenance requirements Airforce 4 1 owners should be observant of any unusual sounds HOPEFUL WIND ENERGY TECHNOLOGY e vibrations or erratic behavior If unusual behavior is noticed the best course of action is usually to shut down the turbine and contact the dealer or service center One area ofAirforce 4 1 that may experience damage is the blades for example from flying debris during a high wind storm For this reason
32. re provided with Airforce 4 1 Carefully follow these instructions to obtain secure bolted joints and maximum corrosion protection particularly in corrosive marine environments Start the assembly by positioning a blade between the hub blade root shim and the U bolt Let the 0 tick mark on the blade root parallel to the plane A WIND ENERGY TECHNOLOGY Note During the adjustment of the blade s installation angle always make sure that the UP arrow mark oriented upward refer to the figure beside Blade root Important The applied installation angle of the blade may affect directly the performance of the whole power generation system Airforce4 1 5KW grid tied system user s manual HOPEFUL WIND ENERGY TECHNOLOGY Installation Blades And Nosecone Assembly Install the bolts by passing the bolt through the BLADE HUB Note must use blade root shim supplied by Hopeful Energy refer to Item 4 in figure 4 Leave the nuts loose until all blades are installed and then tighten the bolts just enough to clamp the blades between the hub blade root shim and the U bolt refer to figure 4 O TIP DO NOT substitute nuts bolts or blade root shims Contact Hopeful Energy for replacements DO NOT apply lubricants to nuts or bolt threads RECHECK bolt torque after tightening bolts E Airforce4 1 5KW grid tied system user s manual Item oak p Descriptions H
33. ry B Negative pole of battery Br1 Brake input terminal polarity optional Br2 Brake input terminal polarity optional L Municipal grid input N Municipal grid input refers to table 2 e After the correct connection pull down the manual brake to o O thenthe generator is under operation EJ Airforce4 1 5KW grid tied system user s manual HOPEFUL WIND ENERGY TECHNOLOGY Installation Requirements of Installation Controller for 5 kw Grid tied System Inspection The display screen of operation state and the operation indicator Table 3 Table of operation indicator lights lights State of lights System operation condition When the controller is working the display screen and indicator The battery is in full lights will show the operating conditions in different working status 4 capacity Constantly on Details refer to the figure below and table 3 Indicator light of the capacity of Flashing battery green PV380V PI 1 01A Off BV 24 54V 1000W The battery is notin full capacity The battery is under over discharging The wind generator is Charging indicator Flashing changing tha baite i y light green O O O On Automatic braking Battery Charging Brake Indicator light of capacity automatic braking There is an interval or the automatic braking orange BI is not started Descriptions in the display screen PV 380V The lin
34. ry resulting from ice flying off blades 11 This wind generator complies with international safety standards and therefore the design or its installation must never be compromised a Do not open the nacelle cover doing so without factory authorization will void the warranty b Apply the proper torque to all fasteners c Torque field wire connections to Airforce 4 1 to 2 3 2 5 N m Refer to Electrical Connections section of this manual electrical connections to Airforce 4 1 on page 17 d Install only on a Professional Engineer PE certified tower e Do not paint the blades 12 Use only proper grounding techniques as established by local related electric code 13 Properly complete the warranty registration card or you can log on our website www hopefulenergy com to finish its electronic format failure to complete and return the card may affect your warranty HOPEFUL WIND ENERGY TECHNOLOGY 14 Airforce 4 1 must be installed in accordance with this manual and local and national building codes Failure to comply with the manual and local codes will affect and possibly void your warranty 15 Airforce 4 1 uses high voltage and is potentially dangerous Be sure to use all safety precautions at all times C N In this manual Q IMPORTANT Please take note O TIP Helpful information to ease the installation O Professional installation highly recommended O Warning Risk of injury ordeath proceed wit
35. ub Blade Long U bolt M10 105mm Blade root shim M10 Nut Figure 4 Quantity 1 3 6 3 N N Installation Blades And Nosecone Assembly Bolt Tightening Sequence Torque the blade bolts to 85 N m in three stages e Following the Blade Bolt Tightening Sequence shown torque each bolt to 85 N m in three stages e After completing the first torque of 30 N m following the Blade Bolt Tightening Sequence and tighten each bolt to 55 N m then finally to 85 N m e The blades are now assembled to the hub and ready for installation onto the turbine rotor shaft e Coat the inside diameter of the blade hub with a multipurpose lithium grease to prevent corrosion between the hub and shaft Position the entire hub blade assembly onto the shaft and make sure that the groove on the hub is corresponding accurately to the groove on the shaft Then with its circular surface at the direction to the shaft insert and tighten the woodruff key to the groove between the hub and the shaft refer to figure 5 e Put the spring washer on the shaft tighten the shaft nut to 150 N m and secure the hub Installing the Nosecone 9 Position the Nylon sheath behind the nosecone then secure the nosecone with one M10 socket head bolt refer to figure 5 HOPEFUL lt WIND ENERGY TECHNOLOGY Important To assure safe operation all torques of the blade bolts and the shaft nut are extremely important their tightening requirem
36. ul Energy will provide the Customer with a RA number and the location to which the Customer must return the defective wind generator Any wind generator requiring warranty repair shall be transported at the expense and risk of the party requiring warranty service including but not limited to proper packaging of the product The Customer must return the entire wind generator kit within 30 days after issuance of the RA number Hopeful Energy will be under no obligation to accept any returned wind generator that does not have a valid RA number Customer s failure to return the wind generator within 30 days of its receipt of a RA number may result in cancellation of the RA All parts that Hopeful Energy replaces shall become Hopeful Energy s property on the date Hopeful Energy ships the repaired wind generator or part back to the Customer Hopeful Energy will use all reasonable efforts within five days of receipt ID Airforce4 1 5KW grid tied system user s manual of the defective wind generator to repair or replace such wind generator If a warranty claim is invalid for any reason the Customer will be charged at Hopeful Energy s current rates for services performed and will be charged for all necessary repairs and expenses incurred by Hopeful Energy Disclaimer EXCEPT FOR THE EXPRESSED WARRANT SET FORTHABOVE HOPEFUL ENERGY DISCLAIMS ALL OTHER EXPRESSED AND IMPLIED WARRANTIES INCLUDING THE IMPLIED WARRANTIES OF FITNESS FORA PARTICULAR PURPOSE M
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