User`s Manual - Residential Wind Turbines
Contents
1. e Wind generator power line 4 1mm Wind generator controller e 6 e e e e e e e e e e e e e e ele e e e e e HZ 11213 4 5 6 7 8 19 10 11 12 13 14 15 16 17 18 19 20 21 e o a e e o o e ele e e o e e elo o e elo e e ele Signal transmission line 12 0 3mm S controller power supply box GND bar a 13 Annex Anemometer Assembly 13 1 Please refer to the steps of dogvane assembly Pull the anemometer cable through the support firstly and then fasten anemometer to the support with a screw 13 2 Settle the anemometer support to a place near to wind generator to make sure the anemometer can detect wind speed normally It is also ok to assemble the anemometer onto a stand Make sure that the anemometer should be in similar height with wind generator This will ensure the wind speed data collected by the anemometer is correct Anemometer O Wind generator a controller S eg ae El Anemometer wire SOCOOO O G sho 10 Z Stand matched by user NOTE Anemometer connecting wire 1s 30m a ae2. Bi DC 24V hydraulic brake motor J J Relay Relay ae Direction regulating motor Inverter II Ajddns 19 Mod 2 8 Wire Connection Diagram of Yaw Shaft and Generator Nose cone Generator body a Wind generator Boy a eee ee ee output cables Wind generator temperature wires JIONPSUCI DINSSOId PW WEY 16 1 Wo Veo 19 ole Signal wire EAN jeesnas in Lightning aSset Temp psa Is eal Grade Pressure lt terminal block COG oee e o ee De eee A Dogvane SOIIM poods U01870 10 I9U9F PULM After the mechanical connection of wind generator and yaw shaft the generator body is required to connect the transmission and communication cables on the yaw shaft and then wind generator will operate normally During this process the following cables are required to be connected four wires of wind generator output cables U1 V1 U2 V2 three wind generator rotation cables three wind generator temperature cables and three dogvane cables Please connect as the following steps and the wire connection diagram 2 8 1 Connect 3 wind generator temperature wires Temp1 Temp2 Temp3 into the temperature transducer according to the signs Temp connects to the upper terminal Temp2 connects to the middle terminal and Temp3 connects to the bottom terminal 2 8 2 Connect 4 wires UI V1 U2 V2 of the two main output cables separately to terminal A B and t
3. User s Manual Applicable Model SOKW Wind Generator and Yaw Shaft CONTENT tL Product UL UG Ud Cane eerie anor hse a ec ace eaeeeiacn am eataoenaeee 1 2 Description of System F netiot secerni ree eet errr cree recor sete 2 2 1 Dogvane 2 2 Annemometer 2 3 Wind Generator Direction Regulating 2 4 Manual Tracking Function 2 5 Time Needed for Direction Regulating 2 6 Hydraulic Brake 2 7 Wind Generator Schematic Circuit 2 8 Wire Connection Diagram of Yaw Shaft and Generator 3 Cable for Transmission and Control COMMUNICATION recsssosssssuasssnsseeessnssssnseessasssenseesesanssnseeeees 5 A Bi os aH a Ree ION Para od Rol Peer een ee ee Ce ee 6 5 Power Curve of 50KW Wind Generator ike i ee eee ee deere een 7 6 SOKW Wind Generator Assembly v vsrmesuntneninnttninunnintnntinnntnetnstisnennntnnenneneinset 7 6 1 Blades Assembly 6 2 Take Out Yaw Shaft 6 3 Connection of Generator Body and Yaw shaft 6 4 Connection of Two Towers 6 5 Connection of Generator and Tower 6 6 Wire Connection of Generator and Yaw Shaft 6 7 Assembly of Lightning Rod and Dogvane 6 8 Assembly of the Bottom Yaw Shaft Protection Cover 7 Erect the Tower vvccrccscnsssssssssssssssssesssssssaensssessssssssssessssnessssaeessaneesseasesssaeesssanissssaenssaneesseaensssaenssaasa 16 g Assembly a 1 ea a A 18 O Daily Maitenanee oreo E E 19 10 Safety PRECAUTIONS aeoaea aE aaa aaraa E NEAS aa 20 Wis Troubles
4. generator system consists of the following 9 parts generator body including rotor blades yaw shaft yaw shaft power box tower wind generator PLC controller rectifier dumping controller inverter dump load energy storage components battery bank or state grid 2 1 Dogvane It receives wind signal indicates wind direction and reads the average value of the angle measured by dogvane every 120s If the angle read by dogvane is larger than 10 wind generator controller will drive DC direction regulating motor with yaw shaft to deviate to fulfill the function of facing wind automatically 2 2 Anemometer It measures wind speed If the measured wind speed is over the start up wind speed wind generator requires continuously within 30s the auto wind direction tracking system will start up and the controller will drive DC regulating direction motor to seek wind direction automatically When the blades are facing wind direction they can receive the max imum wind energy and when the blades are parallel to wind direction they can not receive any wind energy and stop running CAUTION The factory set start up wind speed value of wind generator is 1m s If wind speed is less than the required start up wind speed value the system will keep in standby mode Users can change the start up wind speed of wind generator in the User Parameter Setting window according to actual needs 2 3 Wind Generator Direction Regulating When blades
5. ator system from any unpredictable damage users can use manual track to set the blades aside or back to wind direction which can make wind generator stop working or set the blades 30 45 off wind direction In this way wind energy received by the blades will decrease and rotation speed will slow down 2 5 Time Needed for Direction Regulating 2 5 1 It takes about 13 seconds for yaw shaft with the blades to deflect 30 off wind direction 2 5 2 It takes about 38 seconds for yaw shaft with the blades to deflect 90 off wind direction 2 5 3 It takes about 150 seconds for yaw shaft with the blades to rotate a circle 360 2 6 Hydraulic Brake Under heavy wind the blades rotate too fast Users can also switch into manual mode of wind generator controller and start up the function of Hydraulic brake to make hydraulic brake calipers lock the blades which will stop the blades from rotating Or under manual mode click Manual stop wind generator will deflect 90 and stop operation then hydraulic braking will meanwhile start up and the brake calipers lock blades 2 7 Wind Generator Schematic Circuit AC220V or DC260 DC320V Anemometer sensor 4 Temperature sensor ME of wind generator N _a Temperature transmitter Generator rotation speed sensor mi C Yaw shaft deflection N angle sensor m H lt 3 Dogvane sensor Z N NM mt Pressure sensor z OQ Rectifier Stroke grade transducer lt
6. be careful during the process of connecting wires and other electronic equipments Undersized wire or a bad connection can cause over current electrical dangers and overheating in wiring systems that could cause fire or other personal dangers Thus it is important to check wire connection in daily maintainence CAUTION Don t stand near wind turbine during gale weather It is recommended that users must press the Manual stop button to make hydraulic calipers lock the blades in the case of extremely rough weather such as typhoon or hurricanes to avoid unpredictable accidents 11 Troubleshooting Check whether mistake Unbalance of the blades the blades which are not belonging to one set Blades can t rotate steadily shaking abnormally Check whether the two output cable are short circuited Change the generator Enough wind but blades 1 The two output cables do not rotate or rotate are short circuited slowly 2 Generator 1s burnt out Check whether the output Blades rotate faster G el load cables are open circuited than normal e or fuses are melted down Then reconnect the load 20 12 50KW Yaw Shaft Power Box 12 1 Structure Diagram SOK W yaw shaft power box is to receive the order of wind generator controller and supply power to two DC motors on the yaw shaft The case is made of stainless steel waterproof materials The components are listed in the below diagram 1 Door lock o o 2 24V p
7. d generators 6 2 Take Out Yaw Shaft 6 2 1 Open the packing wooden box 6 2 2 Fetch out the power cables around yaw shaft 6 2 3 Loosen 10 M12 cross screws from the bottom yaw shaft protection cover and take down the bottom cover 6 2 4 Loosen 13 M12 cross screws from the yaw shaft soleplate uplift the upper yaw shaft protection cover and take it down from yaw shaft 6 2 5 Put steel wires through the lifting hole under the yaw shaft soleplate and lift yaw shaft 6 2 6 Connect yaw shaft to the generator head with blades The detailed steps refer to the following sections the packing wooden box Upper yaw shaft protection cover Yaw shaft soleplate the bottom yaw shaft protection cover M12 cross screw Power cable 6 3 Connection of Generator Body and Yaw shaft 6 3 1 Uplift Yaw Shaft Put steel wires through the lifting hole under the yaw shaft soleplate Uplift yaw shaft with the crane hook and slowly descend it to the best position for fixing to the generator 8 Threading mouth the lifting hole the yaw shaft connection base CAUTION Pull four cables of the generator including two output cables one generator temperature cable and one generator rotation cable through yaw shaft and connect them to the flange then pull them out from the threading mouth at both sides 6 3 2 Put the brake calipers at the position between brake pad and the generator connection base and fasten it wi
8. e pole 6 7 4 Tighten lightning rod and the end of dogvane support pole with M30 1 5 round locknuts NENE o Fixed bolt Dogvane wire connector Round locknut the position of hinge slot 6 7 5 Put seal rings into seal press covers and thread them through lightning rod and the dogvane support pole Don t tighten them temporarily K 6 7 6 Strap the dogvane cable with thin iron wires and pull it from the top of support pole to the bottom Then fix the dogvane onto support pole with zero screws 6 7 7 Connect three thin dogvane wires W Direct V V at the bottom of support pole to wire connectors on the yaw shaft soleplate respectively 6 7 8 Align bolt holes on the upper yaw shaft cover with ones on the yaw shaft soleplate Use a screw driver to fix the upper yaw shaft cover onto the yaw shaft soleplate with cross screws 6 7 9 Screw the seal cover enclosed with seal ring onto the lightning rod and dogvane support pole l4 Zero screw 6 8 Assembly of the Bottom Yaw Shaft Protection Cover 6 8 1 Move slightly the bottom yaw shaft cover set around the tower to get close to the upper cover 6 8 2 Align bolt holes on the bottom cover with ones on the yaw shaft soleplate Use a screw driver to fix the bottom cover onto the yaw shaft soleplate with cross screws CAUTION The upper and bottom protection covers are made up of glass fiber reinforced plastic When installation the embedded nuts for inte
9. f grid wind turbine collocates 30 pieces 12V 400 600AH batteries CAUTION New batteries need to be charged fully by the state grid Each set of battery bank rank in series Strictly connect the battery s anode cathode to the battery terminal of rectifier dumping controller 18 __ 8 5 Emergency shut down 8 5 1 Please use the Manual mode function to switch the control model into Manual track and press the Manual stop button to drive yaw shaft to deflect 90 to let blades parallel to wind direction before typhoon or gale such as more than grade 10 coming Meanwhile hydraulic braking system will start up and the brake calipers will lock blades 8 5 2 Then put Wind Generator Stop Operation Switch at the Stop position and wind generator will stop work 8 5 3 After heavy wind please put Wind Generator Stop Operation Switch back to the Operation position and switch Manual mode into Auto mode wind generator will work normally N amma O 5 QO 5 es fas z O 5 CAUTION Wind generator stop operation switch can only be switched from Operation to Stop when blades stop rotating or rotate at a very low speed Do not slide switch when blades rotate at a high speed or it will cause a big shock to wind generator or burn the generator 9 Daily Maintenance SOKW wind generator is highly reliable and it does not need frequent maintenance However the overall system of wind turbine mus
10. hooting E T E E E E T 20 12 SOK W Voor Shatt Power Box aani 21 12 1 Structure Diagram 12 2 Instruction of Connected Switch Terminal Blocks and Wire Connection 12 3 Wire Connection Diagram of Power Box and the Whole System 13 Annex Anemometer Assembly Been to case tds ett eta ten tea eee ta eet adh eaten T 23 1 Product Structure SOK W wind generator consists of generator body and yaw shaft The generator body consists of generator blades brake pad etc Yaw shaft system has the direction regulating function and it consists of gearbox direction regulating DC motor dogvane hydraulic braking system etc The Components listed as the following drawing 2 Generator S CRE ee Brake caliper 8 Gearbox S Es Hydraulic brake assembly Braking stroke switch N DC motor wire connector C24V hydraulic braking motor raking grade probe Upper yaw shaft protection cover Seal cover Dogvane Wind generator output cable terminals 24 Lightning rod Yaw shaft angle probe Yaw shaft baseplate DC Direction regulating motor Signal wire terminal 12 Pressure gauge 24 Bottom yaw shaft protection cover l N Ia Ila a a fa a ft a O IO ON IT O To sR IO 2 Description of System Function SOK W wind generator is directly driven by rotor blades without any other speedup equipment The patented generator with high efficiency settles in front of the rotor blades which is helpful to radiate heat SOK W wind
11. iagram of the whole erection as belows Tower Erection Digram 1 Wind generator output cables Tower Erection Digram 2 16 __ Tower Erection Digram 3 a WY Tower Erection Digram 4 Nuts Spring washer Flat washer 8 Assembly precautions 8 1 When a product is to be assembled please open the cover of the gear box lubrication hole and input about 8L matching engine oil with the acutilingual bottle Oil level should get to the indicating level a Cover for lubrication hole of gear box 460 oil for the gear E A x i E AE bottle Observation lens for oil level CAUTION The 460 oil is special for gear box and it can not be used as speed reducer oil of direction regulating motor 8 2 Each set of rotor blades is made up with 3 blades which have passed the rigorous balance test and can not be exchanged between two different wind generators otherwise blades will run abnormally which will result in serious shaking Therefore please be careful to avoid mixing the blades when open the packing box 8 3 The power generated by off grid wind turbine will charge batteries after rectified Different wind turbines collocate with different numbers of batteries Please strictly follow the owner s manual to choose the right number If the battery voltage is too high or too low the generator system may work improperly or some parts of the system could burn out 8 4 SOKW of
12. ighten them 2 8 3 Connect 3 wind generator rotation speed wires G Speed V V to the Signal Wire Terminal Block 2 8 4 Put on the upper yaw shaft protection cover assemble the dogvane onto the support pole and then connect 3 dogvane wires W Direct V V separately to the Signal Wire Terminal Block under the yaw shaft baseplate Terminal Mark Connect to Ul Ul Taden V Wire connector A V output cables U2 V2 m A r x Upper Wind generator emperature 8 l p B Middle temperature wires transducer O Wire connector B Bottom G Speed Wind generator Signal wire rotation speed wires terminal block W Direct Dogvane wire terminal block Dogvane wires 3 Cable for Transmission and Control Communication There are four main cables for 50K Wwind generator extending outward from the below part of yaw shaft as shown in the following picture Two are wind generator output cables with the specification of 2 25mm for each one One is power supply cable for DC direction regulating motor and hydraulic braking motor with the specification of 4 1mm The last one is signal cable for yaw shaft and power box with the specification of 12 0 3mm 9 wires of them are for generator rotation speed signal generator temperature signal yaw shaft rotation angle signal dogvane signal hydraulic braking signal the positive and negative power wires In addition connect the external shield metal netting of signal wires
13. onnection of Generator and Yaw Shaft 6 6 1 Connect four main wires of generator output cables U1 V1 U2 V2 to wire connectors A and B at the both sides of gear box and fasten them tightly Temperature transducer a Yes Wire connector B MEN 6 6 2 Connect and fasten generator temperature signal wires to the temperature transducer which is at the side of gearbox Generator temperature signal wires Temperature transducer NOTE There are three thin wires in the generator temperature signal cable connect the one marked Temp 1 to the top terminal block on the temperature transducer the one marked Temp 2 to the middle terminal block and the one marked Temp 3 to the below terminal block 6 6 3 Connect and fasten three thin wires G Speed V V in the generator rotation cable to the signal wire connector respectively Please connect as shown in the diagram in Section 2 7 6 7 Assembly of Lightning Rod and Dogvane 6 7 1 Set the upper yaw shaft protection cover on the yaw shaft soleplate and don t fix it 6 7 2 Insert lightning rod and the end of dogvane support pole from the corresponding holes of the upper yaw shaft protection cover into the corresponding taper hole of yaw shaft soleplate 6 7 3 The hinge slot at the end of dogvane support pole is corresponding to the position of fixed screw on the taper hole of soleplate Tighten the screw and press it into the hinge slot to fix the dogvan
14. other outside hexagonal bolts through the yaw shaft connection base and fix them onto the generator connection base and the brake calipers 10 __ 6 4 Connection of Two Towers 6 4 1 With the help of a crane and canvas belt put two towers on the ground in line and try to align screw holes 6 4 2 Connect two towers with outside hexagonal bolts flat washers and spring washers and fasten nuts 6 4 3 Prop up the top of the tower witha 1 6m height support and then wipe out the crane See the below picture Canvas belt ss 6 5 Connection of Generator and Tower 6 5 1 Place the bottom yaw shaft protection cover from the top of tower and then do the following steps 6 5 2 Pull steel wires through the lifting hole under the yaw shaft soleplate and uplift yaw shaft well connected with generator 6 5 3 Pull the cables under yaw shaft with iron wires from the top of tower to the thread holes 6 5 4 Uplift yaw shaft and move it near to the flange at the top of tower Align one bolt hole and fix it with outside hexagonal bolts flat washers and spring washers 6 5 5 Align other screw holes separately with outside hexagonal bolts flat washers and spring washers 6 5 6 Fasten nuts and yaw shaft will be fixed onto the tower __ 6 5 7 After settlement please remove the wires then assemble and fix nose cone with M16 12 stainless steel bolts Stainless z steel bolts Nose cone 6 6 Wire C
15. ower supply 0 0 Feesrserssrs 3 Rectifier bridge 4 Relay rolotefoletet slate slate 5 Connected switch DIDI PIPIDIDIDI DIDI 6 Connecting terminal DIDI DIDIDIGICIP IPP 7 Connection lid 12 2 Instruction of connected switch terminal blocks and wire connection lela ljelelelelelelelololelelelelelelelelele m V V 1 2 3145 6 7 11718119120 21 V 4V V V Eass i E e AAA A AAAA Ole L N AC Input Terminal Cable aoe L Connect to PLC controller power output L Connect to PLC controller power output N Connect to anode of DC direction regulating motor Output cables power line Y101 Connect to anode of hydraulic braking motor Y102 Connect to cathode of hydraulic braking motor Protective grounding a zs 00 0 Anticlockwise rotation signal ofyawshah Generator rotation signal PE Wind direction signal O 12 3 Wire connection Diagram of power box and the whole system NM p 0 ge ja e ap o 3 i O Nn Ss U9 3 B 10 82 19u93 PUIM pue xoq JaMod Jes MEX Yaw shaft NC NC 3 17 18 i mae i power box Signal transmission line 12 0 3mm power supply box yaw shaft 4 56 7 We AM A 2 Ih DDD B O D O D1 D O 1D PB DB DB D1 O O O 91 O SD Lt M a V V 71 2 3 4 5 6 7 17 118 19 20 21 VHVqVHV DDD P D D O DY YD 1D DB PDP DDD O GO OOO
16. rnally mounted assembly can t bear the tightening force of the spanner Only the screw driver is used to tighten screws ee ys 7 Erect the Tower After finishing all the above wire connection on yaw shaft and the protection cover assembly erect up the tower During this process blades are needed to protect from the damage Suggested Method Using a Crane When hoisting iron wires are used to thread the lifting lug of wind turbine and hang in the hook of the crane Gradually uplift the tower until it is vertical with the ground Align screw holes of the tower flange and the anchor rods Slowly lower the tower and fasten the tower flange with nuts flat washers and spring washers While aligning the personnel need to turn the tower with caution to avoid any hurt CAUTION 7 1 Itis important for you to consult with the specialized tower installation technicians 7 2 Make sure the two output cables are short circuited and connected together to avoid blades rotation during the process of erecting up 7 3 Operation method Insert two generator output cables U1 V 1 U2 V2 into the corresponding Wind Generator switch on Rectifier Dumping controller fasten them and put this switch at the ON position Then place Wind Generator Stop Operate Switch at the Stop position which means that wind generator will be short circuited 7 4 Safety shall be first concern in the process of erection and adjustment to avoid tower falling 7 5 The d
17. rotate too fast owing to high wind speed the controller will alarm for over rotation speed And the controller will drive DC direction regulating motor with yaw shaft to deflect about 30 off wind direction at this time If the blades still rotate too fast the controller will further drive blades to deflect 60 off wind direction and then the blades will be parallel to wind direction and stop running In 5 minutes the controller will drive DC direction regulating motor to seek wind direction again If the alarm signal isn t released the blades will keep parallel to wind direction The controller will drive DC direction regulating motor to make the blades deviate 90 and parallel to wind direction if any of below situations occurs 2 3 1 When the wind generator s temperature is up to 145 C the controller indicates over temp 2 3 2 When wind speed is over the system alarm wind speed the controller indicates over wind speed CAUTION All above functions are based on the Auto mode 2 4 Manual Tracking Function Select Manual window on the screen of the controller click Mode switch and then the track mode will be switched from Auto mode into Manual mode Under Manual mode when users press the anticlockwise rotation or corotation buttons yaw shaft will stop at any angle of 270 270 to realize the function of Manual Tracking CAUTION When wind speed is over than 18m s in order to protect the wind gener
18. t be inspected and maintained regularly to ensure the system s normal operation 9 1 Screw Inspection Check and fasten screws on the blades flange yaw shaft and tower regularly This work should be done at least one time every year 9 2 Oil Exchange The lubrication in the gear box has to be renewed every two years 9 3 Transmission Line Inspection Check whether the connecting points ofthe cables are well connected or corroded 9 4 Battery Maintenance Regularly check and maintain battery bank as per the maintenance requirements of batteries If there is no wind for a long time batteries should be fully charged by the state grid to avoid the loss of capacity eee o 10 Safety Precautions SOK W wind turbine is designed under strict safety regulations However any electrical or mechanical equipment during installation or operation can cause potential inherent dangers if proper safety precautions are not taken Please read the following safety precautions thoroughly before you choose the installation location plan to install or operate wind turbine 10 1 Mechanical hazards Blades rotation is the most serious mechanical hazards Please don t install wind turbine where anyone can get in touch with the blades 10 2 Electrical hazards SOK W wind turbine is equipped with needed protection device so that it will be short circuited under over voltage or over current Don t forget that the potential dangers still exist So please
19. th inside hexagon bolts from the direction the generator connects the flange 6 3 3 Fasten the brake calipers at the other side with inside hexagon bolts in the same way Inside hexagon bolts the brake caliper with pipeline the brake pad Generator connection base CAUTION 1 When out of factory the brake calipers the pipeline and hydraulic braking assembly have been well connected When do the above connection users only need to directly fix the brake calipers onto the generator and then connect it to the flange Separation between the pipeline and the brake calipers is forbidden If the pipeline is removed from the brake calipers the air will get into the hydraulic system and prevent the system from normal operation 2 The final settlement of the brake calipers is finished when the generator is connected to yaw shaft Therefore it will be ok to directly fix the brake calipers onto the generator and then connect to the flange Please note that inside hexagonal bolts don t need to be locked tightly to easily go through the following steps 6 3 4 Installation of Generator and Yaw Shaft Align screw holes in the generator connection base with those in the yaw shaft soleplate and then fix the generator to yaw shaft with outside hexagonal bolts flat washers and spring washers CAUTION There are 3 outside hexagonal bolts on the generator connection base and all bolts need to be fastened tightly after connection Thread
20. together as a ground cable to prevent from being disturbed during signal transmission L DC220V Power wire of direction M regulating motor V DC 24V Power wire of hydraulic Vs braking motor D Wind generator V1 output cables U2 V2 Signal transmission wires 12x0 3mm PE 4 Technical Parameters TT E r RE 5 Power Curve of 50K W Wind Generator P ower 0N Wind speed m s 6 SOKW Wind Generator Assembly 6 1 Blades Assembly 6 1 1 Grip the blades pressing plate with acrane take out the generator and then put it on the floor or the sponge cushion Jak az a Lifting lug of the generator a N Blades pressing plate Generator body 6 1 2 Take off all nuts and bolts of the blades pressing plate lift up the blades pressing plate and put one blade root into it Then tighten the blade with bolts as the below picture shows As blades need accurate position bolts must be fastened tightly against blades Please usea hammer to hit bolts into the corresponding holes on the blades 6 1 3 Assemble the second and the third blades in proper order If the lifting lug hinders the assembly please move it to another direction and continue to assemble blades CAUTION The side marked with FRONT shall be adown and windward Every 3 rotor blades of each wind generator have passed balance test they need to be used together Please do not disorderly use the blades belonging to other win
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