User`s manual
Contents
1. HOPEFUL WIND ENERGY TECHNOLOGY Airforce4 1 SKW grid tied system User s manual e D HOPEFUL WIND ENERGY TECHNOLOGY Hopeful Wind Energy Technology Co Ltd Congratulations on your purchase and welcome to our family DearAirforce 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 notsell 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 infoQhopefulenergy com Again welcome to our family and thank you for investing in the future of wind energy with Airforce 4 1 Sincerely Hopeful Wind Energy Technolo2. 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 subjected 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 Airforce4 1 5KW grid tied system user s manual EB QD HOPEFUL WIND ENERGY TECHNOLOGY Airforce 4 1 Limited 5 Year Warranty WIND TURBINE WARRANTY AGREEMENT returning any product under this warranty Notification must include a description of the alleged defect the manner in which the wind generator was
3. 4800 4400 4000 3600 3200 2800 Power w 2400 2000 1600 1200 800 400 m s 2 A 6 W We 4 mph 9 19 10 22 27 M Wind Speed 6 Airforce4 1 5KW grid tied system user s manual 16 18 20 22 36 40 45 49 Important Safety Instructions Read these instructions in their entirety before installing or operating O Professional installation Hopeful Wind Energy strongly recommends Airforce 4 1 be installed by trained professionals 1 2 3 4 5 6 7 8 9 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 mach
4. cable connection handle refer to figure 1 on page 23 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 23 Position Airforce 4 1 to the top of the tower and bolt it to the tower Note the wire size that can be connected directly to Airforce 4 1 is 12AWG 4mm x3 and 14AWG 2 5mm x2 Refer to Wire Sizing Section of this manual for instructions on selecting correct size wire With controller connected to the circuit process the basic test of braking by applying the braking switch on one side of the controller box Do not shut the braking switch to on vvait approximately 5 minutes and attempt to rotate main blade shaft blade should be noticeably easier to turn than with braking switch shut to on e Shut the braking switch to on 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 measurements on live electrical systems EH Airforce4 1 5KW grid tied system user s manual Installation The installation of the cable connection handle Cables connected byuser H
5. source V 220V 110V 100W The protection grade of controller s crust 20 Applied temperature C 0 50 Operating height above sea level m 5000 The external size of controller mm 370 W x260 H x184 D The total weight of controller kg 10 7 Controller for 5 kw grid tied system 4 Airforce4 1 5KW grid tied system user s manual Technical Specifications 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 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 450 RPM 580 RPM 3 4 09 M 2 02 M FRP 3 phase PM generator Electromagnetic braking system control Downwind rotor passive 95KG 5 years Protection controller for generator 120 240VAC 50 60HZ optional 18 M optional Woodruff key Generator Airforce4 D HOPEFUL WIND ENERGY TECHNOLOGY Blade root shim Short U bolt M10 95mm Spring washer 31mm Nut M30x2 Nosecone Bolt M10 65mm lt lt 1 5KW grid tied system user s manual EB HOPEFUL WIND ENERGY TECHNOLOGY Curves of Performance Curves of Performance 5 kw grid tied system 6000 5600 5200
6. the whole power generation system you must install the blades to the hub accurately following the tick mark requirements based on the annual average wind speed f atthe operating site EJ 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 washers supplied by Hopeful Energy refer to Item 5 in figure 4 and pay attention to the installing positions of the bolts with different lengths refer to figure 4 e Leave the nuts loose until all blades are installed and then tighten the bolts just enough to clamp the blades between the hub and the U bolt refer to figure 4 TIP DO NOT substitute nuts bolts or washers Contact Hopeful Energy for item Descriptions Quantity replacements DO NOT apply lubricants to 1 Hub 1 nuts or bolt threads RECHECK bolt torque 1 2 Blade 3 after lightening bolts 3 Short U bolt M10 95mm 3 4 Long U bolt M10 105mm 3 5 Washer 3 6 Washer 10 5mm 12 TA M10 Nut 12 Figure 4 Airforce4 1 5KW grid tied system user s manual E D HOPEFUL WIND ENERGY TECHNOLOGY Installation Blades and Nosecone Assembly Bolt Tightening Seguence Torque the blade bolts to 55 N min two stages e Following the Blade Bolt Tightening Sequence shown torque each bolt to 55 N min two stages Woodruff key e After completing the
7. to the table below and based on the measured distance and system voltage select the appropriate wire size Battery charging systems may utilize smaller gauge wire than indicated in the Wire Size Table The smaller wires are based on allowing 4 voltage line loss for battery charging systems compared to 2 line losses indicated in the Wire Size Table Wire Size Table Maximum Distance MOR 120v 120 208 V 230V 120 240 v 4 AWG 25 mm 197 m 270 m 285 m 310 m 6 AWG 16 mm 124 m 170 m 179 m 195 m 8 AWG 10 mm 78 m 93 3 m 113 m 123 m 10 AWG 6 mm 49 m 67m 70 7 m 77 m 12 AWG 4 mm 31 m 42 4m 44 5m 48 5m 14 AWG 2 5 mm 20 m 26 5 m 28 m 30 5 m Airforce4 1 5KW grid tied system user s manual HOPEFUL WIND ENERGY TECHNOLOGY 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 Grounding hole charge build up 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 properly or the gr
8. OPEFUL 5 connected to BR2 3 connected to W3 4 connected to BR1 1 connected to W1 l 2 connected to W2 Cables connected by manufacturer uu Wi we w3 Vl B B BR BR L N Connection terminals of controller Figure 1 Airforce4 1 5KW grid tied system user s manual E D HOPEFUL WIND ENERGY TECHNOLOGY b120mm thickness10mm seamless steel pipe Installation gt Installing Airforce 4 1 d n 2 5m on a tovver 4 1m b720 500mm thickness10mm steel rim There are severaltypes of b160mm towers that can be used with 12 icosahedral Airforce 4 1 Itis essential that Airforce 4 1 is installed on a i 7 5m properly engineered tower One MPANA SAW Smm of the leading causes of wind material Q235 generator failure is use ona 18m poorly designed tower Construction of tower refer to the figure beside 36mm round steel EARP TWN s 12mm 7 5m AAS round steel za 2m 5 sm 7 10mm copper wire V an v SAJI gt 500mm i b 50mm copper tube 12 icosahedral fl El Airforce4 1 5KW grid tied system user s manual O HOPEFUL WIND ENERGY TECHNOLOGY Installation Installation of the to
9. ations may vary greatly depending upon country state city and local townships Be sure to obtain all the required building permits BEFORE beginning installation Additionally be sure to contact the local electrical utility company Many utility companies will require an Interconnection Agreement prior to installation Some utilities may also require installation of a separate power metre for Airforce 4 1 Airforce4 1 5KW grid tied system user s manual HB O 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 Airforce 4 1 is designed for easy installation Please complete the electrical connections to Airforce 4 1according to the figure depicted below Controller Switch of Inputing Wires HE W385B Connection GRD Switch R of braking Terminals Municipal Grid Input 110V 220V AC Output to the Grid 24V 100Ah SSSI 2 12AWG Charging battery Inverter 2 14AWG Connection Area Airforce4 1 5KW grid tied system user s manual Installation Wire Sizing D HOPEFUL WIND ENERGY TECHNOLOGY Measure the distance from the electrical utility panel and Airforce 4 1 include the tower height Refer
10. cts 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 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 H 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 les
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12. electrical connections as described in the ELECTRICAL CONNECTIONS section of this manual 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 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 training and should only be attempted by trained professionals e As depicted in figure 3 insert the suspension rubber washer B to the vibration isolator base tighten the suspension rubber washer B and A through the vibration isolator base e Install the washer on the bolt insert the bolt through the suspension 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 e Torque the vibration isolator bolts to 5 N min two steps First torque all bolts to 3 N m then tighten all bolts to 5 N m e Mount the covers of vibration isolator using six M6 socket head screws Refer to figure 3 HOPEFUL WIND ENERGY TECHNOLOGY 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 Suspension rubber washerA M6 Socket Flat gasket head
13. es 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 observantof any unusual sounds E Airforce4 1 5KW grid tied system user s manual vibrations or erratic behavior f 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 of Airforce 4 1 that may experience damage is the blades for example from flying debris during a high vvind storm For this reason 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 Remove the yaw shield and wipe off any grease that may have seeped from the yaw bearing e Verify the yaw bearing snap ring is still properly seated in the snap ring groove within the nacelle this is the snap ring located just below the yaw bearing e Check the tightness of the 6 yaw bolts with a torque wrench All yaw bol
14. first torque of 30 N m following the Blade Spring washer Bolt Tightening Sequence and tighten each bolt to 55 N m e The blades are now assembled to the hub and ready for Nut installation onto the turbine rotor shaft Nosecone e Coat the inside diameter of the blade hub with a multipurpose lithium grease to prevent corrosion between the hub and shaft e 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 M10 Bolt e Put the spring washer on the shaft tighten the shaft nut to 150 N m and secure the hub Installing the Nosecone Figure 5 Install the nosecone with one M10 socket head bolt refer to figure 5 EJ Airforce4 1 5KW grid tied system user s manual QD 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 yaw shield 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 With power turned off attempt to rotate the blades there should be noticeable resistance although the leverage provided by t
15. gy Co Ltd HOPEFUL WIND ENERGY TECHNOLOGY Table of Contents 1 Basic Components maa 1 Introduction of the controller 3 Main functions of the controller 3 Electrical circuit chart of the controller seese 3 Technological specifications of the controller 4 2 Technical Specifications icc eee 5 3 Curves of Performance 6 4 Important Safety Instructions 5 5 6 5 The content of your Airforce 4 1 shipment 8 6 Airforce 4 1 Limited 5 Year Warranty ee 9 WIND TURBINE WARRANTY AGREEMENT eee 9 lu 1167 7 12 Prior to Installation intended Wee deal ree ea Unintended US6 cece aaa eer eee es 12 Installation Personnel ee 13 Sequence of Installation mm 13 Typical Airforce 4 1 Installation eee 14 Sitting Finding the Best Location for Airforce 4 1 15 LocalRequiremef tewassceawiawa aaa 15 Installation 16 Electrical Connections to Airforce 4 1 n 16 Wire Sizing e 17 Grounding wa 18 Requirements of Installation controller for 5 kw grid tied system ma 19 The use of cable connection handle 22 Installing Airforce 4 1 on a tower 24 Bolting Airforce 4 1 to the Tower 27 Blades and Nosecone Assembly vr 28 Final Electrical TESTS ue aa a A
16. he blade will make it possible to rotate the blades e Turn on power and attempt to rotate the blades after approximately 5 minutes There should be noticeably less resistance required to rotate the blades e Turn off the power and 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 Airforce4 1 5KW grid tied system user s manual HOPEFUL 2 WIND ENERGY TECHNOLOGY Operation and Maintenance Manual Operation of Airforce 4 1 When there is an abnormal over speed happens to Airforce 4 1 under 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 returnedto normal turn the red button 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 as a set Do not attempt to replace individual blades All blade mounting hardware hub bolts nuts and washers 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 blad
17. ia 31 8 Operation and Maintenance vis 32 Manual Operation of Airforce 4 1 32 Maintenance 32 Sasi ae Ge eee 33 Troubleshootin 33 Emergency Shutdown 33 Key Operating Characteristics 34 Disposal of Airforce 4 1 ei 35 Frequently Asked Questions vein 35 Warranty registration Card ma Attachment HOPEFUL WIND ENERGY TECHNOLOGY Basic Components I b x 7 Item Descriptions Quantity 2008 Hub 2 Blade 3 Short U bolt M10 95mm 3 1 4 Long U bolt M10 105mm 3 5 Blade root shim 3 6 Washer 10 5mm 12 7 M10 Nut 12 8 Nosecone 1 9 Bolt M10 65mm 1 12 10 Nut M30x2 1 13 11 Spring washer 31mm 1 12 VVoodruff key 1 13 Generator 1 Airforce4 1 5KW grid tied system user s manual D HOPEFUL WIND ENERGY TECHNOLOGY 15 16 Item Descriptions Quantity 18 14 Bolt M12 x 85mm 8 15 Washer 50 12 5mm 8 19 16 Suspension rubber washerA 8 17 Suspension rubber washer B 8 20 18 Tower flange 240 120 1 19 Flat gasket 25 12 5mm 8 20 M12 Nut 8 21 Cover of vibration isolator 3 A S 22 Socket head screw M6 x 15mm 6 23 M6 bolt 2 E Airforcea 1 5KW grid tied system user s manual QD HOPEFUL WIND ENERGY TECHNOLOGY Introduction of the controller This manual is applicable for 5KW grid tied wind power generator unit and its powe
18. ine and contact authorized service personnel Important Safety Instructions 10 Shut Airforce 4 1 OFF if ice accumulates on blades to avoid possible injury 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 16 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 N In this manual Q IMPORTANT Plea
19. information about recycling of 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 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 it is always a good idea to shut Airforce 4 1 down if there is going to be a severe storm to protect against any flying debris Airforce4 1 5KW grid tied system user s manual EB HOPEFUL WIND ENERGY TECHNOLOGY Operation and Maintenance Frequently Asked Questions 4 How do I shut down Airforce 4 1 To turn offAirforce 4 1 all you need to do is turn off the breaker Airforce 4 1 is connected to This will cause NO damage to the unit 5 Can leave Airforce 4 1 unattended Yes the Airforce 4 1 is designed to operate without any user input If there is any fa
20. l 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 El Airforce4 1 5KW grid tied system user s manual 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 120 rpm Once it has started producing power it will continue to produce power at lower speeds down to 80 rpm and less than 3m s 7mph As the wind speed increases the blade speed will also increase If a condition occurs that causes the rotational speed to exceed 580 rpm Airforce 4 1 will shut down for approximately 36 hours after which it will resume normal operation unless a fault is detected causing it to remain shut down Itis 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 20 m s 45mph then the Airforce 4 1 will shut down for 36 hours Howeve
21. nergy Disclaimer EXCEPT FOR THE EXPRESSED WARRANT SET FORTH ABOVE HOPEFUL ENERGY DISCLAIMS ALL OTHER EXPRESSED AND IMPLIED WARRANTIES INCLUDING THE IMPLIED WARRANTIES OF FITNESS FORA PARTICULAR PURPOSE MERCHANTABILITY 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 D 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 OR ITS 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 produ
22. not started D 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 charging 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 solar 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 the manual braking switch of the wind generator to on Airforce4 1 5KW grid tied system user s manual El D 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
23. ounding and the installation of suspension rubber washers would be affected B Airforce4 1 5KW grid tied system user s manual Installation HOPEFUL WIND ENERGY TECHNOLOGY Requirements of Installation controller for 5 kw grid tied system Installation of components According to its protection grade the controller should be installed in an indoor environment with dryness and ventilation and beside the controller there should not be any substance of flammability e The controller should be installed vertically and hanged firmly e Before the cable connection push the manual braking switch of wind generator to on in case electric shock accidents will occur from the operation of wind generator during the connection e Follow the signs below the connection terminals connect the cables of related equipments properly The section of cable refers to table 2 e After the correct connection shut the manual braking switch of wind generator to off then the generator is under operation Table 2 Section table of external connective cables YAI Wind generator Spec ofcharging Spec of ode Spec battery brake 12AWG 12AWG 14AWG HE W385B 4mm x3 4mm x2 2 5mm x2 W1 W2 W3 Wind generator input phase sequence free V1 V2 V3 Wind generator output phase sequence free B Positive pole of charging battery B Negative pole of charging battery BR1 Brake input
24. r 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 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 HOPEFUL WIND ENERGY TECHNOLOGY Operation and Maintenance Disposal of Airforce 4 1 gt Warning Power to Airforce 4 1 MUST BE TURNED OFF prior to servicing This symbol shown on Airforce 4 1 or its packaging indicates it may not be Frequently Asked Questions treated as household waste Dispose 1 What happens if I lose power from my utility company of Airforce 4 1 properly by handing the entire turbine assembly over to the If there is a power outage the Airforce 4 1 will shut down within one second It will resume normal operation when power is applicable collection point for restored There are many safety requirements of a utility tied recycling of electrical equipment inverter We strongly suggest our users apply an inverter in 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
25. r generation system Main functions of the controller It 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 and current and emergency stop Protection from over charging of battery Protection from reverse connection of charging battery Protection from electrical shock and voltage surges Electrical circuit chart of the controller Rectifier Charging Charging Electromagnetic Stable Power supply Transformer bridge control battery braking control for braking system AC Municipal grid input E gt VVind povver generator circuit input Svvitch of automatic Svvitch of manual emergency brake emergency brake Voltage meter Current meter Airforce4 1 5KW grid tied system user s manual E D HOPEFUL WIND ENERGY TECHNOLOGY Introduction of the controller Main technological specifications of the controller refer to table 1 Table 1 Item Spec Max output alternating current voltage V 438 Max output current A 8 Max output power ofthe generator kw 6 The capacity of charging battery 100Ah 24V The protection voltage of over charging V 28 8 The recovery voltage of over charging V 26 Time of automatic braking resuming 36 hours Electrical source output of electromagnetic braking _ 150W 24V Voltage of exterior working electrical
26. r replacement EB 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 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
27. s 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 wear and require more frequent Do not install blades other than those supplied with Airforce 4 1 inspections Use only genuine replacement blades supplied by us Unintended Use 9 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 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 12 Airforce4 1 5KW grid tied system user s manual HOPEFUL WIND ENERGY TECHNOLOGY Installation Prior to Installation Installation Personnel 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 sy
28. screw 2 p T 2 Earthing wir Cover of vibration Nut isolator M6 bolt Figure 3 Airforce4 1 5KW grid tied system user s manual D HOPEFUL WIND ENERGY TECHNOLOGY Installation Blades and Nosecone Assembly Installing the Blades Hub Noton 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 are provided with Airforce 4 1 Carefully follow these instructions to obtain secure bolted joints and maximum corrosion protection particularly in corrosive marine environments e Start the assembly by positioning a blade between the hub and the U bolt Assemble the blade to the hub with the tick mark on the blade root corresponding accurately to the mouth of the hub at sites with average wind speeds less than 5m s 11mph use the 2 tick mark at sites with average wind speeds between 5m s 11mph and 7m s 16mph use the 0 tick mark at sites with average wind speeds above 7m s 16mph use the 2 tick mark Refer to the figure beside 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 6 Important The applied installation angle of the blade may affect directly the performance of
29. se take note TIP Helpful information to ease the installation O Professional installation highly recommended Q Warning Risk of injury ordeath proceed with extreme caution 2 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 14 Bolt M12 x 85mm B24 8 2 Blade A06 3 15 Washer 50 12 5mm B32 8 3 Short U bolt M10 95mm A09 3 16 Suspension rubber vvasher A B22 8 4 Long U bolt M10 105mm A10 3 17 Suspension rubber washer B B23 8 5 Blade root shim A07 3 18 Tower flange 240 0 120mm B21 4 6 Washer 10 5mm A11 12 19 Flat gasket 25 12 5mm B25 8 7 M10 Nut A12 12 20 M12 Nut B26 8 8 Nosecone A02 1 21 Cover of vibration isolator B29 3 9 Bolt M10 65mm A01 1 22 Socket head screvv M6 x 15mm B30 6 10 Nut M30x2 A03 1 23 Controller HE VV385B B33 1 414 Spring washer 31mm A04 1 24 Cable connection handle B31 1 12 Woodruff key A13 1 25 M6 bolt B28 2 18 Generator A33 1 26 Earthing wire10 AWG 6 mm 100mm B27 1 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 o
30. stems is required for a safe installation Sequence of Installation Hoist Airforce 4 1 Electrical dthet t 7 gt Install Airforce 4 1 gt installation of hub gt a to the tower blades and the a PISP 9 to Airforce 4 1 n s the entire installation finished Complete the Preparation of all installation parts a Airforce4 1 5KW grid tied system user s manual HOPEFUL WIND ENERGY TECHNOLOGY Installation Prior to Installation Typical Airforce 4 1 Installation 24V 100Ah Charging battery Controller HE W385B Inverter 5 14 Airforce4 1 5KW grid tied system user s manual Installation Prior to Installation Sitting Finding the Best Location for Airforce 4 1 The best location to install a wind turbine is often a compromise Local building restrictions the height of surrounding structures wire length and available open space may require Airforce 4 1 be installed in a less than optimum location In general Airforce 4 1 will produce more power if installed on a taller tower However towers are expensive so it is important to balance performance tower height to installed cost in order to achieve the lowest cost of energy and the quickest payback ya Prevailing wind gt 6 5m 35m XX HOPEFUL WIND ENERGY TECHNOLOGY Local Requirement Building codes and installation regul
31. terminal polarity free BR2 Brake input terminal polarity free L Grid power input N Grid power input Airforce4 1 5KW grid tied system user s manual 19 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 lights When the controller is working the display screen and indicator lights will show the operating conditions in different working status Details refer to the figure below and table 3 PV 380V PI 1 01A BV 24 54V O O O Battery Charging Brake capacity Descriptions in the display screen PV 380V The voltage from the wind generator is 380 V PI1 01A The current from the wind generator is 1 01A BV 24 54V The charging voltage is 24 54 V El Airforce4 1 5KW grid tied system user s manual Table 3 Table of operation indicator lights State of lights System operation condition ndicator light of the capacity of charging battery green Charging indicator light green Constantly on Flashing The charging battery is in full capacity The charging battery is not in full capacity ndicator light of automatic braking orange Off Flashing The charging battery is under over discharging The wind generator is charging the battery Automatic braking There is an interval or the automatic braking is
32. ting 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 20 in this manual Emergency Shutdown Manual emergency shutdown When a serious 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 Airforce4 1 5KW grid tied system user s manual HOPEFUL WIND ENERGY TECHNOLOGY Operation and Maintenance section of this manual for a complete description of the Airforce 4 1 s various shut down 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 interna
33. ts should be torqued to 5 N m Operation and Maintenance e Reinstall the yaw shield and secure the fasteners e Check tightness of blade bolts with torque wrench All blade bolts should be torqued to 55 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 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 be performed as necessary by the user operator Troubleshooting Check the connections as close to Airforce 4 1 as possible HOPEFUL WIND ENERGY TECHNOLOGY Depending on the installation this may be at the utility panelorata disconnect switch The connections may also be checked atyaw terminals see Electrical Connections Section in this manual however this will require removing Airforce 4 1 from the tower Measure this voltage and additional troubleshoo
34. ult it will shut down on its own 6 What do I do if Airforce 4 1 is facing upwind even though there is astrong 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 Eg Airforce4 1 5KW grid tied system user s manual 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 the blades TIP Anything else you vvant to ask please log on our website www hopefulenergy com we ll answer your questions within 3 business days 4us8wun su siyj A no2 Jaye sAep og UIUJIM p s siB i LON S Jonpoud y J PIOA se aq IM AJUEJIE UL 4211ON yonpoi
35. 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 Hopeful Energy will provide the Customer with a RAnumber 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 aRAnumber 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 10 Airforce4 1 5KW grid tied system user s manual use all reasonable efforts within five days of receipt 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 E
36. wer base 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 2 Lift up the tower by a crane and move it to a proper position 1 Preparation of all installation parts 3 Bolt the tower to the ground and adjust the verticality W m Airforce4 1 5KW grid tied system user s manual D HOPEFUL 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 7 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 Figure 2 26 Airforce4 1 5KW grid tied system user s manual Installation Bolting Airforce 4 1 to the Tower The following section provides directions for bolting Airforce 4 1 to the tower Before Airforce 4 1 is bolted to the tower complete the
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