Whisper 100 - Southwest Windpower
Contents
1. Attachment Point P d Use flashlight to align nose _ to rotor attachment before tightening Finger tighten blade to rotor attachment until nose cone attachment hole is aligned Any two tip distances should be equal distances apart to reduce vibration Only tighten blade to rotor 7 ose cone 22 to rotor attachment holes y are aligned Whisper 100 Owner s Manual Rev E 25 Nose Cone Attachment F Nose Cone Attachment Point Torque Bolts to 11 N m 8lb ft 2 Do not overtighten Blade to Rotor Attachment M8x55 Hex Bolt M8x24 Flat Washer 26 Whisper 100 Owner s Manual Rev Place nose cone over blades 5 4 Align nose cone to rotor attachment hole Torque Hex Bolts to 11N m 8lb ft Whisper Controller Mounting When performing preliminary turbine to controller tests temporarily mounting the controller close to wind turbine allows easy access while testing the turbine and controller functionality Perform turbine to controller tests prior to mounting blades Allow effective heat convection by mounting controller vertically against a wall The dump load side of the controller gets very hot DO NOT mount near flammable or heat sensitive materials Controller is NOT rated for outside use and must be protected from the elements Mount inside a protected buildin2. Q Torque all bolts to 11 N m 8 Ib ft Do not overtighten 1 2 3 Farwasner maraa a HexBotMexso Je 5 Lock washer us IMPORTANT for MARINE units The enclosed packet of Tef Gel should be used in threaded holes to prevent corrosion and Hex Bolt M8 x 55 7 Nylock Nut M8 l Blade Strap screws becoming permanently seized into place Whisper 100 Owner s Manual Rev E 23 BLADE INSTALLATION Torque Wrench 7 Saar 1 Blades 3 8 Blade Straps 3 eo KC Rounded Side of Blade Attachmen 3 M8x24 Flat Washer 9 cuit gt P i I 6 M8x55 Hex Bolt 3 n AM P 2 Nose Cone 7 M8 Nylock Nut 6 oes 4 M8x50 Hex Bolt 9 m 5 M8 Lock Washer 6 Attach Blade Straps Flat Side of Blade This side lies against rotor plate Blade to Rotor Attachment Point Blade Strap to Blade M8x24 Flat Washer M8 Nylock Nut Attachment Nose Cone Attachment Point ack Washer x 50 Hex Bolt Blade to Rotor Attachment 8 50 Blade Strap Rounded Side of Blade Blade Strap Nose Cone Attachment Point Blade Strap Attachment Points 24 Whisper 100 Owner s Manual Rev Blade to Rotor Attachment a _ F Nose Cone iT gt E Attachment Point Blade to Rotor
3. Model Number Whisper 100 Owner s Manual Rev 3 IMPORTANT SAFETY INSTRUCTIONS Read these instructions in their entirety before installing or operating Q SAVE THESE INSTRUCTIONS Enclosed are important instruc tions that must be followed during installation and maintenance Q Turn Whisper OFF and contact Southwest Windpower Technical Service if unusual noise or operation is observed Q Install Whisper on a calm day no wind at ground level 0000 In this manual IMPORTANT Please take note TIP Helpful information Q WARNING Risk of injury or death proceed with extreme caution ry MARINE Information specific to corrosive environments 4 Whisper 100 Owner s Manual Rev E C Locate your tower well away from occupied buildings and power lines a minimum of 76 m 250 ft is recommended 76m 250 ft High voltage systems present a shock hazard and should be wired and maintained by a qualified and licensed electrician NEVER place objects on top or near the Whisper Controller enclosure These devices must dissipate heat as part of normal operation FAILURE AND FIRE may result if airflow is blocked Q Recommended Tools Equipment and Materials for Installation Electrical Tape Electrical Wire and Voltmeter Torque Wrench 20N m or 15ft Ib and 13mm Socket Sodering Iron and Solder or Split Bolt Connectors Rounded File Ground Rod amp Clamp Wrenches 2 13mm or Ad
4. 30 Whisper 100 Owner s Manual Rev E 5 Setting Regulation Voltage without Display See page 22 Switch 5 Turning the potentiometer clockwise CW increases the voltage set points Use following chart for approximate potentiometer set points Note Determine the initial potentiometer position by turning fully counter clockwise CCW Count and record the number of turns Regulation Off Voltage Regulation On Voltage Fully CCW 12 0V 24 0v 36 0v 48 0v 13 0V 26 0v 39 0v 52 0v 1 4 Turns CCW 13 0V 26 0v 39 0v 52 0v 14 0V 28 0v 42 0v 56 0v Pot Position 6 Whisper Controller Display Optional B Menu Function Button j A Menu Function Button LCD Display Screen Green LED LCD Contrast Adjustment Designed to mount on Whisper controller base unit a short CAT5 Ethernet cable is provided or 4 wall type switch receptacle f mounted on controller connect CAT5 to jack closest to diversion Switch to disable controller LED Mounting on Whisper Controller Remove electronics cover Remove sheet metal insert where display will mount Use hardware provided to mount display to electronics cover Hardware 8 32 x 3 8 black oxide SS screws and 8 32 nuts with captive star washers e mounted remotely the display can be mounted up to 300 m 1 000 ft from controller longer CAT5 cable must be purchased by user Verify display function text should appear on LCD display aft
5. Straping or securing the casting as shown below while handling so it cannot pivot open Do not remove strap until casting is secure on tower Whisper 100 Owner s Manual Rev 5 EXAMPLE OF AN OFF GRID HYBRID INSTALLATION Whisper wind generator PV array Batteries provide electricity to home via inverter lt Inverter Battery bank Whisper Charge Controller Charge Whisper provides electricity to batteries PV panels provide electricity to batteries e 6 Whisper 100 Owner s Manual Rev E PRIOR TO INSTALLATION Siting Tips Q PROPER SITING Better Performance amp Increased Longevity ATYPICAL SITING CONSIDERATIONS Look at vegitation deformation to determine best area and prevailling wind direction Prevailing wind 1942VA3 Coastal or Lakeside Trees and taller structures can be down wind 14 0 II III VII No Deformity 5 9 mph 8 11 mph 10 13 mph 12 16 mph 14 18 mph 15 21 mph 22 higher mph Brush amp Slight Slight Flagging Moderate Complete Partial Throwing Complete Carpeting Flagging Flagging Flagging Throwing Q Good 2 Fair B Poor Gri Q gs Putn am Index Probable mean annual windspeed Data prepared by E W P NR Prevailing wind Hewson J E Wade and R W Baker of Oregon State University Ridge Tops Q EXCESSIVE TURBULENCE Fatigue Damage amp Shorter Turbine Life Wind compresses as it blows over the top of a hill increa
6. prevent shorts to tower 3 Support wires to avoid weight on slip ring wires and wire connections 20 Whisper 100 Owner s Manual Rev M8 x 35 Set Screw 4 Total Align holes on Wer insert and Tail Installation Assembled Generator Hex Bolts M8 x 55 SSTL Washer M8 x 24 Nylock Nut M8 Hex Bolt M8 x 25 Hex Bolt M8 x 70 Nylon Washer M8 x 31 ul S Tail Installation Kit 3 Tail Fin 2 Tail Boom X 13mm Wrench k E J P 13mm Socket IL cm 8 d 6 M8x31 Stainless 7 M8 PENH steel Washer 9 M8x70 Hex Bolt 8 M8x25 Hex Bolt a ar 4 M8x55 Hex Bolts x T 2 5 M8x31 Nylon Washer Whisper 100 Owner s Manual Rev E 21 Assemble Whisper Tail Fin Mounting Tail Boom Tail Boom 1 Attach tail fin 4 holes when pushing 5 Secure tail boom anchor Not shown M8 Nylock Nut tailboom into casting 6 Tighten casting to secure tail boom 2 Apply Whisper sticker to top and bottom of fin 3 Complete tailfin assembly 7 Secure M8 nylock nuts 13mm or k y wrench 22 Whisper 100 Owner s Manual Rev Blade and Nose Cone Installation Whisper 100 Blade Installation Q Make sure diversion switch is in the stop position 9 Q Flat ribbed side of blade lays against rotor front plate Use thread locking compound Loctite 242 or equivalent on all bolts
7. 0 volts for 24V systems 4 0 volts for 48V systems Votage regulation off point battery charging resumes is not affected Voltage hysteresis switch does not increase the regulation on and off set points using the optional display Switch 5 Potentiometer Enable Default Setting OFF Enables reading potentiometer voltage in real time Resolution limits are 0 2 volts for 12V systems 0 4 volts for 24V systems 0 8 volts for 48V systems Voltage regulation points must be set using potentiometer not optional display OFF Prevents changing the voltage regulation point using the potentiometer It is not necessary to Reset after changing the switch 4 amp 5 settings Before adjusting the Voltage Regulation On set point understand that increasing the voltage will not increase the turbine s output voltage or current This set point only adjusts the shut down voltage for battery charging Overcharging will significantly reduce a battery s life expectancy Switch 6 Default Setting OFF There is no function presently associated with this switch SWWP recommends leaving the switch in the OFF position Whisper 100 Owner s Manual Rev E 29 OPERATION AND ADJUSTMENTS Operation of the Whisper Controller 1 Overview Turbine Controls and converts turbine power Functions Rectifies power from wild AC to DC voltage Contains diversion load amp controls voltage regulation Monitors voltage cu
8. 30 5 Setting Regulation Voltage without Display aaa 30 O Whisper Controler Disblay 31 Display Ment Ring ntt 31 Display Mena 39 MAINTENANCE AND REPAIR Maintenance MODA id tp 33 Maintenance JA US u Q ueteri a sin prd loa eta dera tnu 33 ae ato uto 34 Troubleshooting Table Symptoms of Mechanical Problems 35 Troubleshooting Electrical 860616 36 Troubleshooting Voltmeter 37 Troubleshooting Table Symptoms of Controller Problems 37 Troubleshooting Table Symptoms of Electrical Problems 38 Whisper TOO Exploded VIC Ws saneti breast ed RE abend 39 Whisper 100 Exploded View Parts List tite heilen dto 40 Whisper Wind Turbine Warranty Agreemen t 41 Whipser 100 Owners Manual S CMET L03370 PBevrorom Southwest Windpower Congratulations on your purchase and welcome to our family Dear Whisper Owner Thank you for your purchase of a Whisper wind turbine We congratulate you on your choice and are confident you will experience years of dependable Service Before going any further please c
9. 44v depending on turbine model See Table of Electrical Problems Doesn t regulate red LED off and dump load is cold Doesn t regulate red LED on and dump load is cold Dumpload always on red LED on Shorted diode Dead or disconnected battery Short in wiring to turbine Battery volts below setting Bad circuit board Dump load burned out disconnected or wired incorrectly Bad connection from circuit board to power block Wrong battery voltage setting Bad circuit board Diversion switch set to Stop or disconnected Check battery with voltmeter see Voltmeter Test Adjust voltage setting Contact factory dealer distributor Contact factory dealer distributor Contact factory dealer distributor Check battery with voltmeter see Voltmeter Test Adjust voltage setting Contact factory dealer distributor Move diverson switch to Start Check and restore connection if needed Whisper 100 Owner s Manual Rev 37 Table Symptoms of Electrical Problems Symptom Probable Cause Blade rotor will not turn or turns slowly even in high wind Blade rotor runs too fast may whistle no output no unusual mechanical noise Blade rotor runs too fast may whistle output less than 50 for wind speed growling buzzing or Diversion switch is ON Battery is dead voltage less than 1 2 nominal Incorrect turbine wiring Short circuit in wiring from generator to controller Failed component in controll
10. DIRECTLY OR INDIRECTLY BY USE OF THE PRODUCT BY ANY PERSON ALL OTHER WARRANTIES ARE EXPRESSLY WAIVED BY THE CUSTOMER Limitation of Liability UNDER NO CIRCUMSTANCES WILL SOUTHWEST WINDPOWER OR ITS AFFILIATES OR SUPPLIERS BE LIABLE OR RESPONSIBLE FOR ANY LOSS OF USE INTERRUPTION OF BUSINESS LOST PROFITS LOST DATA OR INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES OF ANY KIND REGARDLESS OF THE FORM OF ACTION WHETHER IN CONTRACT TORT INCLUDING NEGLIGENCE STRICT LIABILITY OR OTHERWISE RESULTING FROM THE DEFECT REPAIR REPLACEMENT SHIPMENT OR OTHERWISE EVEN IF SOUTHWEST WINDPOWER OR ITS AFFILIATE OR SUPPLIER HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGE Note some states and provinces do not allow the exclusion or limitation of incidental or consequential damages so these limitations may not apply to you Neither Southwest Windpower nor its affiliates or suppliers will be held liable or responsible for any damage or loss to any items or products connected to powered by or other wise 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 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 Whisper 100 Owner s Manual Rev E 41 SOUTHWEST WINDPOWER S
11. Problem Observation Action Taken 34 Whisper 100 Owner s Manual Rev E Troubleshooting and Repair Table Symptoms of Mechanical Problems Symptom Blade rotor is stationary even in high winds Blade rotor will not turn at all except in high wind scraping or rubbing sound at low rpm always stops at same blade position Blade rotor is hard to start output is lower amp there is more blade noise than usual appears out of balance Tail generator and tower vibrate or shake excessively at all or some wind speeds SAFETY FIRST shut down turbine until a physical inspection can be performed Rattle or clunking from generator SAFETY FIRST shut down turbine until a physical inspection can be performed Probable Cause Ice generator or on blades Debris between rotor and stator Loose broken or rubbing magnet Bad or worn bearing Same as above except more likely to be high magnet or bad bearing Ice on blades Dirty blades Damaged blade s Blade s on backwards Blade out of balance Blade not tracking Rotor out of balance Shorted alternator or wiring Generator loose in tower Rotor loose on shaft loose tail missing rubber bumper wires slapping inside of mast governor pivot bolt loose b Worn bearings c Shaft broken Wait for warm weather Leave running unless vibration is substantial Turn blades gently by hand and use thin material to dislodge debris Remove rotor and re glue magnet
12. teinte dante etai eate 17 20 21 22 Blade andiNose Cone 23 26 Whisper ele rv uti 2 Whisper Controler Winn 21 29 Whisper Controller Circuit Board Switches and Reset Button 26 29 If it is necessary to print installation instructions these are the primary pages you will need 14 Whisper 100 Owner s Manual Rev E INSTALLATION Set Wind Turbine Voltage The Whisper 100 wind turbine and controller must be configured for the correct system voltage 12 24 or 48 volts Whisper controllers are shipped from the factory configured for 24 volt operation 69 IMPORTANT The stator wires are coated with varnish that MUST be removed to make a good connection Remove varnish by scrap ing with sharp edge or lightly sandpapering the wire The correct turbine voltage is set by altering the 12 stator wire and 3 Access wires by removing the Multi Voltage cover on the turbine housing The brush wires are interchangeable and not labeled The brush wires are the larger multi strand wires 10AWG The stator wires are numbered and color coded with a wire sleeve For example stator wire Red 3 has a red sleeve with the number 3 printed on it Wire Red has a red sleeve with no number The indicates there is no number Refer to table on nex
13. FF subpage menu button increases voltage to a maximum 2 Energy Page of one volt lower than Regulation ON voltage Displays accumulated kWh and kAh since last reset At maximum if pressed again the voltage rolls Accumulated data can be reset by selecting menu option back to 12V Menu option goes to the History page A menu button returns to Regulation Set page I Select B SKIP to return to Main Display Page 3 History Page Regulation Off voltage cannot be specified above Regulation On Displays average and peak windspeed and turbine power since reset voltage Note windspeed is only available if anemometer is installed Reset accumulation data by selecting menu option B Menu option A goes to the Main Display page 32 Whisper 100 Owner s Manual Rev E MAINTENANCE AND REPAIR Maintenance Monthly 1 Test Diversion Control check electrical wiring e Divert the load by setting the diversion switch to stop in a moderate wind charging but not furling No unusual difficulty or noise should be experienced in stopping the blade rotor noise during diversion can indicate a disconnected wire 2 Check Mechanical Condition Watch and listen from the tower base There should be cal noise rattle or vibration and the blades and tail must not wobble lf you hear mechanical noise rattle or vibration or see blade or tail wobbl
14. ONIC 1 3 1054 05 7 SPINDLE 100 200 3 CMBP 1139 WELD BEARING INNER SHIELDED 3 CABR 1007 BRUSH SPRING 1 3 3 CAOT 1050 34 TERMINAL FORK CONNECTOR 1 3 ELOT 1012 ee S 35 BRONZE WASHER 1 X 1 2 X 1 16 3 3 HDWA 904 8 YAW SHAFT ASSEMBLY 100 200 CMBP 1194 STATOR MARINE PATE 0 YAW SHAFT ASSEMBLY 100 200 1 3 1194 UPPER CASTING 100 200 MACHINED 3 CMBP 1225 02 37 SNAP RING 69MM ZINC 1 3 CAOT 1067 beu M6 3 1 1 sc orwes 2 3 CMBP 1225 03 UPPER CASTING 100 200 MACHINED MARINE LABEL WIRING DIAGRAM FLAT WASHER 3 8 X 13 16 SAE SS 2 NYLON WASHER NYLOCK NUT M10 2 2 x SOMO 1 COVER MUUTWOURGE 0000 1 9 ES L3 fenon D TOI K RhEWD 758 ro smonmue sosorm x BRONZE BUSHING j econo T LOWER CASTING MACHINED 100 200 1 3 CMBP 1226 02 LAND 3 CMBP 1226 03 LOWER CASTING MACHINED 100 200 MARINE 23 WIRE NUTS RED 3 CAOT 1168 24 1 4 NEOPRENE BUMPER 3 CMBP 1177 N N 40 Whisper 100 Owner s Manual Rev E Whisper Wind Turbine Warranty Agreement Hardware Warranty Southwest Windpower Inc Southwest Windpower will repair or replace free of charge any part or parts of the Southwest
15. Understanding Voltage Regulation Regulation On Controller is regulating battery voltage and diverting power to the dump load controller measures battery voltage above regulation on voltage for more than 30 40 seconds it begins diverting power Regulation Off Controller resumes battery charging controller measures battery voltage below regulation on voltage for more than 30 40 seconds it stops diverting power and begins battery charging 28 Whisper 100 Owner s Manual Rev E Whisper Controller Printed Circuit Board Switches and Reset Button Switches for setting system voltage i LI M Ls 3 2 D ems H T d sitae r 3 ipot Py rm quu TIT em gt M 11 That aO A c i i i B Potentiometer le L gt Fg e A gie cai 1 cu um pa d j L 1 Reset switch lii if Six switches on the PCB are used to set operating system parameters The default settings are suitable for most systems installations and should only be changed to alter system voltage Reset Switch Whisper Controller operation is controlled by a microprocessor PCB reset switch resets the microprocessor Depressing t
16. WIN DPOWER 4 SOUTHWEST Whisper 100 OWNER S MANUAL Installation Operation Maintenance All Rights Reserved TABLE OF CONTENTS VP E e D m dm 3 O telat m DUE 4 Whisper 100 Technical Specification S si 5 Example of Oi Gud a eda 6 PRIOR TO INSTALLATION ong M lorc 1 OWE FSC l COUN rt 8 rere ta n amaka ere 9 ev cuc cgo M 10 Battery SPATIO Ti a doas apa dr rca cnr oou ua Pu th 11 Battery Conng ratom and bob TOI Sa 12 Wind Turbine Elecmical Iesu u y y oUm ED 13 INSTALLATION For field installation it may be useful to print this section 14 seting Mind Turone 15 16 Mounting Wind Turbine TOWEL erem eara ba adn 17 20 qr 21 22 Blade and Nose Cone 23 96 Whisper ontollen MOUNUA netta st td 2 Whisper Controler a aN 21 28 Whisper Controller Circuit Board Switches and Reset Button 26 29 2 Whisper 100 Owner s Manual Rev E OPERATION AND ADJUSTMENTS Operation or the Whisper assieme qawa 30 T Whisper Controler 30 2 Normal Operation Whisper Controller sssr 30 eMe 30 AB ASE OS e waaqu
17. Windpower Whisper Wind Turbine determined by Southwest Windpower 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 Turbine Start Date This warranty extends only to the original purchaser The Customer s sole and exclusive remedy and the entire liability of Southwest Windpower its suppli ers and affiliates under the warranty is at Southwest Windpower s option either i to replace the Wind Turbine with new or reconditioned Wind Turbine ii to correct the reported problem or iii to refund the purchase price of the Wind Turbine Repaired or replaced products are warranted for the remainder of the original warranty period Restrictions Problems with the Wind Turbine Products can be due to improper use lack of maintenance non Southwest Windpower additions or modifications or other problems not due to defects in Southwest Windpower s workmanship or materials No warranty will apply if the Wind Turbine i has been altered or modified except by Southwest Windpower ii has not been installed operated repaired or maintained in accordance with instructions supplied by Southwest Windpower iii has been exposed to winds exceeding 120 mph 54 m s iv or has been subjected to abnormal physical thermal or electrical stress misuse negligence or accident If Southwest Windpower s rep
18. able Symptoms of Electrical Problems 3 Wind generator is running but e Use voltmeter to read the voltage across the leads Go to Voltmeter Test 36 Whisper 100 Owner s Manual Rev E Voltmeter Test What it tells you 1 Voltage increases and decreases slowly relative Everything is OK to wind speed across all combinations of paired wires 2 No voltage across one set of two wires wire from the wind generator is not carrying power Check the tower wiring and controller connections to ensure proper wiring e If the wiring is correct contact authorized factory dealer distributor for further assistance 3 Voltage significantly higher across one set of e Possibly a shorted diode Contact factory dealer distributor two wires than the others 4 Voltage significantly lower across one set of There is a bad connection at wind turbine voltage connections or faulty stator winding two wires than the others Contact factory dealer distributor Should these results appear inconclusive in determining the problem proceed directly to Table Symptoms of Electrical Problems or see Table Symp toms of Whisper Controller Problems below Table Symptoms of Whisper Controller Problems Symptom Probable Cause Blade rotor turns slowly even in strong wind a Brake switch ON Move switch to OFF Contact factory dealer distributor Ensure battery voltage at controller terminals is at least 10v 20v 32v or
19. air facility determines that the problem with the Wind Turbine is not due to a defect in Southwest Windpower s workmanship or materials then the party requesting warranty service will be respon sible for the costs of all necessary repairs and expenses incurred by Southwest Windpower Warranty Claims amp Return Procedures In order to be eligible for service under this warranty the Customer MUST return the warranty registration card included with this Warranty Agreement within 60 days of purchasing the Wind Turbine Additionally the Customer must submit a service request for Wind Turbine covered by this warranty within the warranty period by contacting Southwest Windpower in writing or via telephone and obtaining a Return Authorization number This RA must be obtained before returning any product under this warranty Notification must include a description of the alleged defect the manner in which the Wind Turbine 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 Southwest Windpower will provide the Customer with a RA number and the location to which the Customer must return the defective Wind Turbine Any Wind Turbine requiring warranty repair shall be transported at the expense and risk of the party requiring warranty service includ ing but not limited to proper packaging of the Prod
20. e lower the tower for inspection lf you experience any of these conditions refer to Troubleshooting and Repair 3 Inspect the Tower Follow all inspection and maintenance requirements of the tower manufacturer Tighten all nuts and bolts especially wire clips Check for cracks and bent broken parts at the anchors and base Check for broken strands and tighten wires 4 Check the Battery Consult your battery manufacturer maintenance guide Tighten battery connections Remove corrosion and protect terminals Maintenance Annual Lower the tower and give wind generator a complete inspection Fix or replace any warn or loose parts a Check tightness of all tower and blade nuts and bolts b Check all bearings c Clean the blades with a mild detergent to remove all dirt and debris Replace blades if they are cracked or damaged d Check the pivot bushing and bore Lay the turbine down while it is completely unfurled the normal operating position and see if you can wobble the lower half If it wobbles significantly noticeable play then the bushing and or bore is ovalized Replace the bushing first and retest it If it still wobbles then the castings need to be replaced Do not tighten pivot pin nut ne nosecone Tighten tower and blade mounting bolts Whisper 100 Owner s Manual Rev E 33 Maintenance Log Observe monthly and annual inspection requirements Record all maintenance and repair work
21. er Short circuit in brush card or slip ring assembly Short circut in turbine Two or three wires open between turbine and controller Controller diodes open or wire is disconnected at diode terminal Battery voltage over 50 Turbine may be in regulation but wind is too high for turbine to stop Load or battery disconnected Disconnect wire between turbine and controller Turn Diversion switch to Battery position Disconnect load and or battery from generator until it starts charge battery Rewire Check wiring from generator to controller See Voltmeter Test Contact factory dealer distributor Contact factory dealer distributor See Voltmeter Test See Voltmeter Test Examine battery specifications and regulation set point Replace improperly sized battery if necessary Wait for calmer conditions Engage diversion switch to determine proper operation Check all connections See Voltmeter Test See Voltmeter Test c Contact factory dealer distributor One open or disconnect diode One slip ring or brush not making good contact Blade rotor runs too slowly low output no a Battery voltage low or dead battery unusual mechanical noise b Incorrect turbine wiring Green charge light comes on momentarily during a The turbine and controller voltage settings may be set to different voltage configurations vibration felt by hand or mast a Disconnect loads and let battery charge b Check turbine wiring connectio
22. er display and batteries are connected to controller t may be necessary to adjust LCD contrast Locate small hole between buttons and LEDs Insert small screwdriver through display cover Turn clockwise to lighten Turn counter clockwise to darken If text is still not visible disconnect amp reconnect cable to display to reset Display Menu Ring Structure 5 Regulation Mode 4 3 P INNEN 8 ww A ed Me em R lati R lati a ET DEED c N Me Increase Set Point Set Point ee Whisper 100 Owner s Manual Rev E 31 Display Menu Functions Displ M Effect 4 Mode Page naro 00 A goto Arm Displays current charge mode go to Bring If ON is displayed the battery can be charged turbine will spin in adequate wind go to reset menu If OFF is displayed turbine power produced is 0000 Reset Menu ResetkWh A RESET B CANCEL A reset power return to reset menu diverted to dump load turbine will not spin in light winds menu button toggles the mode 00 0 00 0p B go to reset menu menu button returns to Regulation Set page 00 0a 00 Controller can switch to OFF mode in the following Reset Menu Reset Page RESET CANCEL reset readings conditi
23. g Controller can be mounted as shown below or rotated 90 degrees with dump load on top Dump Load Side Hot Side Turbine Inputs vere 8 wire LEDs and diversion oo switch X s P E odi Anemometer xm Connection 8 me o T SS LJ Battery Outputs 2 SL Earth Ground located lt inside controller between turbine amp Conduit Knockouts on bottom of controller accommodates 75 1 25 amp 1 5 Whisper Controller Wiring Connecting Remove the Controller electronic cover and connect the battery turbine and ground wires as shown in the accompanying schematic Controller MUST be connected to the batteries BEFORE making the wind turbine connections Correct polarity MUST be observed when connecting battery cables battery mounting blocks Setting dip switch voltages before connecting to battery See Printed Circuit Board Switch Settings section Avoid shorting battery leads together when connecting the battery Connect the battery to the controller Confirm the microprocessor is energized by moving the diversion switch to the stop position red LED should illuminate If not momentarily depress the reset switch on the controller PCB Return the diversion switch to the battery position and observe the red LED to turn off When connecting the battery do not allow the connection to power the microprocessor on and off quickly This could cause the microprocessor to lock
24. he reset switch has the same effect as disconnecting a battery cable To reset momentarily press the reset button If it is necessary to depress a second time wait approximately 15 seconds e Voltage regulation points set using the optional display setting will be lost if reset switch is depressed or a battery cable is disconnected controller will revert to potentiometer set points Printed Circuit Board Switch Settings Switches 1 and 2 System Voltage Select the correct system voltage by setting the position of switches 1 and 2 according to the following table System Voltage Switch 1 Switch 2 12 Volt After changing the system voltage depress the reset switch to read and save the new voltage setting Switch 3 Time Hysteresis Default Setting ON ON 380 40 second delay for controller to start or stop charging when regulation set point is reached OFF No delay charging will stop or start immediately when regulation set point is reached It is not necessary to depress the Reset Switch after changing the switch setting Southwest Windpower STRONGLY recommends Switch 3 remain in ON position Switch 4 Voltage Hysteresis Default Setting OFF OFF Controller starts or stops charging at the voltage regulation points set through optional display or by the PCB potentiometer Voltage regulation on point battery stops charging set using potentiometer increases by 1 0 volts for 12V systems 2
25. isper 100 Owner s Manual Rev Arrival Kit First Layer in Package IMPORTANT Properly complete the warranty registration card failure Bladestraps to complete and return the card may affect your warranty Nosecone amp Hardware Kit User s Packet User s Packet l asna a ASTE ea GR oie eee 4 Tail Fin Blades m Whisper 100 Second Layer in Package Generator User s Manual 5 Year Warranty amp Other Docs Tail Fin Stickers Whisper 100 Owner s Manual Rev 9 System Wiring TIP See the Whisper Controller installation Batteries emit explosive and irritating gas while charging section for complete wiring details Use protective gloves and safety glasses Distance A B Never make any electrical connection light a match or make a spark near a recently charged battery Controller Q Turn off all loads and look away when making a final battery connection A Wire size from wind generator to controller based on voltage configuration and distance Distance A B sze vf y 4mm 2awG e Semeen mm 0440 106 460 awe eam a roam 52 Jeemen m 27 mm 3 AWG 660 m 2168 ft 36 mm AWG AWG 66 m AWG e2 528 m 1730 If using aluminum wire multiply the distances in the table by 0 65 Distances are one way from the
26. justable Wrenches Electric Drill Motor amp 10mm 3 8 Metal Cutting Drill Bit Leather or Strong Fabric Strap secures casting while handling Metric Hex Wrench Set Cable Grip Strain Releif support wires inside tower Loctite 242 Center Punch Tool marks for drilling Pliers Small Flashlight Whisper 100 Technical Specifications WHISPER 100 Rated Power Monthly Energy Start Up Wind Speed Rotor Diameter Voltage Overspeed Protection Turbine Controller Mount Body Blades Survival Wind Speed Weight Shipping Dimensions Warranty 900 watts at 12 5 m s 28 mph 100 kWh mo at 5 4 m s 12 mph 3 4 m s 7 5 mph 2 1 m 7 ft 12 24 48 VDC Patented side furling Whisper controller Optional 6 35 cm pipe 2 5 in schedule 40 Cast aluminum Marinized version available 3 Carbon reinforced fiberglass 55 m s 120 mph 21 kg 47 Ib box 22 56 kg 74 Ib 1295 x 508 x 330 mm 51 x 20 x 13 in D year limited warranty Power ratings are normalized for sea level The Whisper Controller is factory set for 24 volt operation If your system is other than 24 volts the controller MUST be configured to your system voltage Ensure turbine voltage is consistent with rest of your system voltage O Note the weight above Use safe lifting techniques and protective footwear Turbine casting pivots open to a 45 angle creating a potential pinch point Southwest Windpower strongly recommends
27. ns or rewire a Verify the turbine output wiring the diversion load and the controller DIP switch are configured to the same voltage wind gusts or only comes on in very high wind conditions 38 Whisper 100 Owner s Manual Rev E Whisper 100 Exploded View Mechanical Repairs and Parts Replacement Use exploded view and parts list as guide for replacement parts and troubleshooting I on Southwest Windpower strongly recommends internal turbine 99 26 repairs be performed by an authorized service dealer or e Southwest Windpower x 25 e Unauthorized repairs leading to turbine damage may void the 24 warranty E LN Part desciptions on next page S 2 3 tm 1 24 B i Pi 18 eh s d 18 1117 7 ui JE fp j co l d Ji ue nn Do not attempt repairs on top of the tower 20 Perform repairs only after tower has been lowered Whisper 100 Owner s Manual Rev E 39 Whisper 100 Exploded View Parts List Description PartNo Description Oty 95 BRUSH ASSEMBLY 100 200 1 3 CMBP 1228 01 8 lt No SCREW SOCKET HEAD DOG POINT 3 HDBT 2003 031 1 29 RUBBER GROMMET 5 16 X 9 16 X 1 2 1 cowowrrwemG se oaee crame non sns x EN x ES EN 32 BRUSH TRANSMISSION NO S
28. omplete and return the enclosed Warranty Registration Card The conditions of your warranty are dependent upon the proper installation of Whisper Furthermore this will assure you of being kept up to date with the latest developments from Southwest Windpower 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 Again welcome to our family and thank you for investing in the future of wind energy with Whisper Sincerely Southwest Windpower CE Compliance The CE marking is a mandatory compliance requirement in EMEA and the UK and although it is self certification testing and evidence support testing is preferred from an independent test house All Southwest Windpower turbine are third party tested and fullfil all the relevant provisions of the following directives Machinery Directive 2006 42 EC Low Voltage Directive 2004 95 EC Electromagnetic Compatibility Directive 2004 108 EC The report and declaration of conformity are available for inspection on request The serial number refers to a specific Southwest Windpower product This product is considered compliant to CE Southwest Windpower Inc Southwest Windpower GmbH Flagstaff AZ 86001 USA 50996 Cologne customerservice windenergy com Germany 928 779 9463 Tel 49 0 221 16 53 94 50 www southwestwindpower eu
29. ons return to reset menu OFF turbine power is diverted to dump load Lino DN 2 OFF REM go to r OFF MAN turbine power is diverted to dump load bates when diversion switch is moved to Stop position Oh SI go to regulation set menu OFF REG turbine power Is diverted to dump load via Regulation REGULATION SET A change regulation point automatc regulation at present voltage Set 2 i return to Main Menu Diversion switch set to OFF overrides Remote Display ON function Regulation Regulation ON voltage go to regulation off menu On 15 8v Increase set voltage Regulation Regulation OFF voltage go to regulation set menu off 1257 ncrease OFF set voltage 5 Regulation Page Digitally set regulation and regulation off voltages using 1 Main Page the Regulation Setpage Menu Displays controllers measurements battery charging status voltage Select A CHANGE for Regulation ON subpage for and current and turbine power and windspeed if equipped voltage changes Leads to four sub pages by selecting or functions menu button increases voltage to 17V maximum Energy and History menu pages At 17V if pressed again the voltage rolls back to 13V Mode and Regulation menu pages A menu button brings up Regulation O
30. outhwest Windpower Inc 1801 West Route 66 Flagstaff Arizona 86001 USA t 1 928 779 9463 f 1 928 779 1485 www windenergy com Southwest Windpower GmbH Mannesmannstr 6 50996 Cologne Germany t 49 0 221 16 53 94 50
31. rrent energy production and wind speed if equipped Optional LCD Display Offers instant access to operational parameters and performance measurements voltage current power energy charge peak power and wind speed if equipped Display LEDs function same as controller LED Battery Remote E 2 Normal Operation Interface mechanisms LED diversion switch voltage regulation adjustment PCB configuration switches and LCD Whisper Contoller display if equipped with display Interface allows setting regulation voltage monitoring system Whisper Controller Components P 3 Diversion Switch Diverts power from batteries to dump load to avoid battery overcharging Considerations if activated Will not stop a spinning turbine but will not allow a stopped turbine to start spinning Ae ion Switchand If turbine blades are spinning it is normal and safe LED s Far Side Whisper Controller Display Whisper Controller Electronic Cover Whisper Controller Resistive Load bank Dumpload 4 LED Operation Red LED Power diverted to dump load Green LED Turbine is charging battery Whisper Controller LED INDICATORS Electronics GREEN INTERPRETATION Battery charging BLINKING Power to diversion load to regulate battery voltage Whisper Controller ON OFF Power to diversion load by operator request via Regulation Diversion Switch or remote Display Potentiometer
32. s contact factory dealer distributor Contact factory or distributor Same as above Wait for warm weather Leave running unless vibration is substantial Clean with mild detergent Replace damaged blade contact factory dealer distributor See blade installation Replace blade contact factory dealer distributor Contact factory dealer distributor Contact factory dealer distributor Perform phase to phase testing Inspect for damage and repair as required Retighten mounting hardware use Loctite or equivalent thread locking compound Replace bearings contact factory dealer distributor Replace shaft contact factory dealer distributor Whisper 100 Owner s Manual Rev 35 Electrical Diagnosis Determining the Type of Electrical Problem 1 Wind generator will not start blades turn slowly as if the diversion switch is engaged moderate wind disconnect wind generator wires at controller one at a time If generator starts the wire allowing it to start lead to a failed component 2 Wind generator still does not start In moderate wind disconnect any two wires If the wind generator starts the problem is most likely in the controller Go to table Symptoms of Whisper Controller Problems Replace failed component Contact factory dealer distributor If the generator does not start the problem is in the tower wiring or the wind generator may have an electrical problem Go to T
33. sing the wind speed 1 2 3 259 Prevailing wind Plateau Mesa Site the generator far enough from the cliff to avoid turbulent wind 76 m 250 ft 1 fer ai 2 Turbine should be a minimum of 76m 250 ft away from and 6m 20 ft above obtacles Good Far B Poor Whisper 100 Owner s Manual Rev E 7 Tower Selection and Installation Q Tower Selection Wind speed increases with height Higher towers also raise generators above the air turbulence that can exist close to the ground Guyed Towers Lattice Towers 150746 16 mph Less expensive More expensive 7 3m s Larger Footprint omaller Footprint 12037 15 5 mph radius is 1 2 3 4 7 m s of tower height 9027 14 7 mph 6 6 m s 5 E E 135mph amp 60 18m 45 14m 12 8 mph 5 7 m s 3310 5 4 m s 0 0 20 41 75 100 124 Calculations based on Power Law Exponenet 0 02 In area of tall row crops hedges a few trees 0 Prevent tower climbing by unauthorized persons or children Never climb without Guyed tower Self supporting proper safety equipment lattice tower Soil and wind conditions vary towers tower foundations Q Always stop the blades before climbing the tower must be designed for your specific location Both falling from the tower and contact with the spinning blades can be lethal 8 Wh
34. t page for specific stator and brush wire connections Cut off the twisted ends of the stator wires and strip off approximately 25 mm 1 inch of insulation Hold stripped ends of the wires parallel to each other and twist together clockwise before installing the wire nut Trim wires and twist on the appropriate color wire nut indicated in the table Push hard on the wire nut while twisting clockwise Coat wire nuts and terminal strip connections with dielectric grease to protect wires against corrosion 86V configuration has been removed from this manual Contact Southwest Windpower technical support for 36V configuration Whisper 100 Owner s Manual Rev 15 Voltage Configuration Wiring Table Reference the following table to determine the correct brush and stator wire connections for your voltage configuration Ba Red ack Red Wire Nuts Yellow Wire Nuts whites a Blacks Black Red Wire Nuts Yellow Wire Nuts 2 White 1 Black 1 Red 1 White Red 3 Black Black 3 16 Whisper 100 Owner s Manual Rev E Mount Turbine On Tower Use medium strength thread locking compound on all fasteners Tower Insert Kit For 64 mm insert 2 5 inch Schedule 40 Pipe 2 875 x 20in Wall K rem Description _ Engagement hole 1 Set Screw 2 m M6 X 20 2 Set Screw M8 4 X 35 64 mm 2 5 inch 3 M8SS Nylock 4 insert s Nut MARINE If you are installing
35. to Multiply result from Step 3 by this factor Result 45 000 x 1 11 49 950 Wh Cold temperatures reduced battery capacity is minimum Wh capacity of battery bank High temperatures shortened battery life Temp in degrees C F Factor 26 7 80 1 00 21 2 70 1 04 15 6 60 1 11 10 50 1 19 Q RECOMMENDATION Keep the number of parallel strings of bat 44 40 1 30 teries to three or fewer More than three strings of batteries risks 1 1 30 1 40 shortening battery life due to uneven charging 67 20 1 59 e Batteries in Series Voltage is Additive Batteries in Parallel Ah is Additive 5 Divide result from Step 4 by system voltage Result is 49 950 48 1 040 Ah Example 2 12V 100Ah Battery Bank the minimum Amp hour Ah capacity of your battery bank Series 24V 100 Ah Parallel 12V 200 Ah Whisper 100 Owner s Manual Rev E 11 Battery Configuration and Location Q RECOMMENDED e Locate battery in moderately stable room temperature dry unoccupied building e f battery is in an occupied building an enclosure with vent to outside is required Follow code e Batter enclosure Allow 5 cm 2 in on all sides for ventilation Allow 60 cm 2 ft vertical clearance for maintenace access minimize the possibility of EMI electromagnetic interference the line from the battery to the Whisper Controller should be less than 10 feet 3 m Battery Fuse Installation Consult local electrical codes Batter
36. turbine connection to Whisper Controller terminals 10 Whisper 100 Owner s Manual Rev Simple Tips for Deep Cycle Battery Bank Sizing CALCULATIONS calculate battery bank size use example below Q In preparation for battery sizing know A system load of 6 000 Watt hours per day Days of Autonomy back up needed ELECTRICAL USAGE the amount of energy consumed 1 day Planned Depth of Discharge DoD 40 ny Wat nurs WD Battery bank ambient average low 15 6 C 60 F DAYS OF AUTONOMY days of battery back up required if STEPS 48V system EXAMPLE unable to charge the batteries by any means DEPTH OF DISCHARGE limit of energy withdrawal to which 1 Identity total daily use in Watt hours Wh ou will subject the deep cycle battery bank iid I 2 Identify Days of Autonomy back up days multiply 3 days of Autonomy Deeper discharge Shortened battery life Whiday by this factor 6 000 x 3 18 000 Wh Recommeded never discharge a deep cycle battery below 5090 of its capacity e Off grid applications a 25 DoD will extend battery life significantly 3 Identify Depth of Discharge DoD and convert to a 4096 DoD decimal value Divide result of step 2 by this value 18 000 0 4 2 45 000 Wh TEMPERATURE Standard ormestbattemqatihads 4 Select the multiplier corresponding to the lowest 25 C 77 P average temperature your batteries will be exposed 15 6 C 60 F 2 1 11
37. uct The Customer must return the entire Wind Turbine kit within 30 days after issuance of the RA number Southwest Windpower will be under no obligation to accept any returned Wind Turbine that does not have a valid RA number Customer s failure to return the Wind Turbine within 60 days of its receipt of a RA number may result in cancellation of the RA All parts that Southwest Windpower replaces shall become Southwest Windpower property on the date Southwest Windpower ships the repaired Wind Turbine or part back to the Customer Southwest Windpower will use all reasonable efforts within five days of receipt of the defective Wind Turbine to repair or replace such Wind Turbine If a warranty claim is invalid for any reason the Customer will be charged at Southwest Windpower s then current rates for services performed and will be charged for all necessary repairs and expense incurred by Southwest Windpower Disclaimer EXCEPT FOR THE EXPRESSED WARRANTY SET FORTH ABOVE SOUTHWEST WINDPOWER DISCLAIMS ALL OTHER EXPRESSED AND IMPLIED WARRANTIES INCLUDING THE IMPLIED WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE MERCHANTABILITY AND NON INFRINGEMENT NO OTHER WARRANTY EXPRESSED OR IMPLIED WHETHER 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 SOUTHWEST WINDPOWER EXPRESSLY DISCLAIMS ALL LIABILITY FOR BODILY INJURIES OR DEATH THAT MAY OCCUR
38. up If the microprocessor locks up and reseting does not correct the problem contact Southwest Windpower for instructions After successful startup cycle red LED by toggling the diversion switch then switch to Stop Connect turbine wires to controller order is not important When the red LED is on the turbine will not spin as long as at least two of its wires are connected except in strong winds Whisper Controller Optional Anemometer NRG 40 Included Wire size for wiring to the battery 3 meters each way 12V system 1 0 gauge or larger 24V system 2 gauge or larger 48V system 6 gauge or larger Battery Bank Whisper 100 Owner s Manual Rev E 27 Dump Load Wiring Wire the resistive dump load for the correct system voltage Sufficient jumper wires are provided to achieve any system voltage configuration 12 wire 24 Volt 48 Volt Systems Systems 12 wire Optional Anemometer Connection Whisper Controller is designed to accomodate a model 40 NRG anemometer www nrgsystems com Item Number 1900 Connect anemometer wires to labeled PCB terminal block e Anemometers require specific polarity observe the labeling on the terminal block connections f applicable connect a grounding shield to the controller s grounding terminal Mount anemometer close to turbine without entering the turbine s swept area see manufacturer s installation instructions
39. y positive Nut and bolt Fuse included SWWP recommends using a fuse holder to support wire weight 12 Whisper 100 Owner s Manual Rev E Use the diagrams below to determine the series parallel arrangement for your system voltage Please note based on 6V batteries 12 Volt Configuration To controller To inverter To controller To inverter 48 Volt Configuration To controller To inverter 24 Volt Configuration To controller To inverter To controller To inverter To controller To inverter Wind Turbine Electrical Tests Complete these tests before mounting blades to rotor These tests con firm the wind generator is ready to install on the tower Ground Test Check resistance to ground on any wire Resistance must exceed 10 000 ohms on many digital meters this will show a reading of Open Circuit Test Short Circuit Test When all the wires are shorted together the alternator should turn hard When the wires are unconnected the wind generator rotor should spin freely Phase to Phase Test When any two wires are shorted together the alternator should turn lumpy as though there are smooth and bumpy portions of the rotor Whisper 100 Owner s Manual Rev 13 INSTALLATION SECTION This section of the manual includes pages 15 29 The pages cover WNA TUBINS VONAGE ccna tam 15 16 Mounting Wind Turbine On TOW
40. your Whisper in a corrosive environment use a marinized Whisper and apply Tef Gel to all threaded holes to prevent screws from becoming permanently seized into place Whisper 100 Owner s Manual RevE 17 Tower Preparation 3 a et KEE us Sira ro eae Sr a eee ges CUT ALIGN WITH TOP OF TOWER gs Z DASHED LINE EE R 375 P 3 5 w ore 4 524 4 114 91 lt E LL a M 2 5 SCHED 40 PIPE rd 4 9 048 229 81 1 2 500 375 ds ue Center punch SENSU A root i mark tower fo DONE drilling 2 Align with top of tower Wrap template around tower until tab arrows line up Secure template with tape 24 Drill center punch marks Recommended Begin drilling with small bit amp work up to 10MM 3 8 metal cutting drill bit 18 Whisper 100 Owner s Manual Rev E Install Tower Insert 1 Alignment Holes for M8 x 35 Set Screw 6 x 20 Set Sa Secures Tower Ins Whisper 100 Owner s Manual Rev 19 Mount Turbine to Tower Tower insert Support wires by attaching to the tower insert Wires from Solder or split bolt connector Tower Strain relief cable Wires to Whisper grip Controller 1 Solder or use split bolts to make electrical connections 2 Wrap connections thoroughly with electrical tape to
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