USER`S MANUAL 2000GT 2000W/48V Grid-Tie
Contents
1. PowerMax USER S MANUAL 2000GT 2000W 48V Grid Tie A amp CGREENENERGY Renewable Energy for Life 1108 Summit Avenue Suite 8 Plano TX 75074 866 WND PWRD www enenergy CMS Magnetics 2007 2008 CONTENTS Technical Specifications and Output Graphs 3 Installation Specifications Guyed Tower 4 Installation Specifications Tapered Tower 10 Connection of the Charger Controller 11 Connection of Storage Batteries 12 Electric Wiring 12 Z m le EE a a ee ae E 14 FAQ Frequently Asked QUeSTIOMS nnns 14 Controller Specification 17 Confidential pi CMS Magnetics 2007 2008 45 5 6 20 78 T OUTPUT POWER 13 16 19 20 22 25 26 29 31 33 36 38 40 Average Wind Speed mph D z Oo D gt Q Dec gt O MONTHLY ENERGY OUTPUT 13 16 19 20 22 25 26 29 31 33 36 38 40 Average Annual Wind Speed mph Monthly Energy Output kWh Confidential 3 CMS Magnetics 2007 2008 Installation Specification of Guyed Tower Ste2. of guyed tower step 1 Step 2 Make the Concrete Base Refer to the following graphs with the different product models F T WN p a ws Lu d O S at THF Al d ei Ski enlace by Pas SR is d E i AL amp Lee ee E p br V i i NM RB dei vd Vd et ae he ay ra A 7 d Ki Ki Bai zk o e E ed planform Graph amp Confidential 10 CMS Magnetics 2007 2008 Model Code in the 1000 2000W 3000 S000 W 10KW 20KW graph 8 Ground diameter m en 10 10 12 15 18 1 2 2 0 18 Layout diameter of cotter bolt kaka F600 Y 600 F790 J 3009 3209 mim Table 2 Step 3 Assembly of the tower and the generator Please refer to the installation specification of guyed tower step 3 Step 4 Lifting the tower While installing the tapered tower a professionally operated crane is needed Non working people should be far away from the site when hoisting Step 5 Connect the cable to the upper end of the pole and lift gradually Step 6 When the tower is at the upright position align the holes on the tower flange to the holes on the base flange and tighten them Connection of the Charger Controller e IMPORTANT Refer to Appendix One e To prevent bodily injury or property damage please follow these instructions precisely With personal safety as a primary focus in design this charge controller has been engineered to function properly and efficiently There are 3 leads coming from th
3. d pull the cables out of the main section of the tower It may be easier to feed the cables through each tower section before assembly instead of trying to feed the cables through the entire length of the assembled tower 4 While one person positions the generator on the top of the tower the second person needs to bolt the running flange and tower flange together Make sure the shaft faces upward in order to install the blades hub assembly 5 Position the stand so that the generator is elevated about 5 6 off the ground so that the tail can be connected with enough ground clearance Confidential 7 CMS Magnetics 2007 2008 6 Assemble the tail and fins Attach the tail to the generator so that the tail is pointing toward the ground otherwise the weight of the tail will cause the generator to flip around resulting in possible personal injury or property damage 7 Put the three blades on the hub and put on the press pad Slide the screws into the holes and put on the nuts Before tightening the nuts please make sure the 3 blades are evenly installed by measuring the distance between the blade tips Graph 5 BLADE S CENTER LINE d wh ee ne i gt gr Y d Graph 5 Make sure L1 l2 I3 Tolerance 5mm Notes Please use torque wrench to tight up the blades Set the torque based on the followings tables system OKW Confidential g CMS Magnetics 2007 2008 Disclaimer Please follow the above table f
4. e wind generator and they are to be connected to the charge controller The connectors to be connected should be marked as wind generator inputs Please make sure that generator is not generating power when you connect the charge controller and make sure that all the three wires are connected Not doing so may cause the system damage Confidential 11 CMS Magnetics 2007 2008 Connection of the Batteries 1 Note batteries should remain inside dry buildings with a constant temperature environment Lay out the batteries controller and inverter 2 Connect the batteries in series 3 Lubricate the connectors for better conductance Install a fuse on the positive electrode of the battery The distance between the batteries and the controller should not exceed 3m 4 Suggested battery capacity for various models as shown in table 3 pg iis of single battery V Capacity of single battery AH 100 200 200 200 150 100 200 400 200 an lilitiis tet stele Table 3 5 Charge Voltages for batteries as shown in table 4 Battery voltagetV 360 Table 4 Electric Wiring 1 Off grid electric wiring To ensure safety and easy maintenance please install the switch and fuse according to the diagram Check for output voltage consistency of the generator battery and input of inverter A mistake in wire connection could destroy the generator batteries and inverter Please refer to appendix 2 for contr
5. eck electrical wires for connectivity and make sure they are not damaged or corroded 3 Maintain the batteries as per the battery owner s manual 4 f at all possible with proper warning before a big storm lay down the tower to avoid unnecessary loss FAQs and Trouble Shooting e Why the system may not have output power after the inverter is connected o Check the diversion load and the charge controller The charge controller has voltage and current indicators So if there is not enough power generated the system will not output energy Also check the battery voltage since if the battery voltage is low it will not output energy either But in case the energy is enough and there is still not output please check the electrical wire connections between batteries and inverter and make sure there are no open wire shorts e Why the batteries cannot be charged Confidential 14 CMS Magnetics 2007 2008 o Check whether or not the rotor is rotating The generator has no output at too high or too low wind speed If the rotor works normally disconnect the generator s wire from the charge controller and check the generator output with a multi meter If the generator output is normal please check if the batteries are ok otherwise check the generator wiring e Why the rotor may not rotate at a normal wind speed o Check if the generator output is short circuited The generator won t rotate when the generator is short circuited Be su
6. il conditions vary from location to location please consult with a soil analysis company or structural engineering firm in your area about the structural data in this manual Please understand that A amp C will not responsible for the structural failure caused by the base problems Step 2 Preparing the Concrete Bases for the Tower and the Anchors 1 Dig the holes to follow the pattern as shown in Fig 1 Please refer to the Table 1 for the dimensions of the holes Confidential CMS Magnetics 2007 2008 2 Please choose cement C25 The 4 anchors should be installed with the bolts being plugged in the cement The 4 anchors should be oriented in the way which is described in step 1 Put the bolts in the cement before it cures As shown in the graph 2 Graph 2 3 The anchors should have a 60 to 80 angle to the horizontal plane Make sure the anchors are evenly distributed along the circle and they all have the same distance to the center base All the connection rings should be on the same level Graph 3 Graph 3 Confidential 6 CMS Magnetics 2007 2008 Step 3 Assembly the tower and wind turbine 1 Insert the main section of tower into the base then slide the pin through the tower and base lock it with the split pin As shown in the graph 4 Graph 4 2 Connect each section of tower one by one and place the tower on a supporting stand after assembly 3 Insert the generator cables into the tower an
7. m cable If applicable connect the output of your solar panel to the SOLAR INPUT terminals on the PowerMax controller Positive to positive negative to negative Using 10mm cables connect the battery s positive pole to the positive battery terminal on the controller and connect the battery s negative pole to the negative battery terminal on the controller The length of the cables should be no longer than three 3 feet Tighten the nut on each battery terminal by hand Do not over tighten Turn the manual brake to the RUN position Confidential 16 MODEL Maximum Wind Input Power Maximum PV Input Power Rated Battery Voltage Floating Charge Voltage Control Mode Display Mode Displayed Parameter Protection Type Size W x H x D mm Weight KG CMS Magnetics 2007 2008 PM20 48 2kW 470x230x410 amer LEET Tee BATTERY INPUT WIND INPUT Fees Z Confidential 17
8. oller dry Do not clean with a wet or damp cloth This is an electric device and cannot get wet at all Prevent any spills on or near the controller Keep all children and any person with limited understanding and or decreased mental capacity away from the controller Keep the controller away from direct sunlight or any other heat source Please check the rated voltages of your wind turbine solar panel and battery before connection Their rated voltages all should be the same Pay close attention to the connection of your wind turbine solar panels and batteries to make sure positive goes to positive and negative goes to negative Smaller gauge wires should not be used with higher current equipment Ensure that all component connections are tight and secure DO NOT TOUCH any bare parts on the controller The high voltage can cause lethal shock 2 General Description Your PowerMax wind solar hybrid controller is designed to control the wind power charging battery under constant voltage In addition it includes a solar charging control which makes it good for wind solar hybrid application At the right side of the controller there is a manual brake switch If the switch is turned to the brake position the wind turbine will be manually stopped 3 Connection l 2 3 4 Turn the manual brake to the BRAKE position and then connect the output of the wind generator to the WIND INPUT terminals using 10m
9. oller specification Confidential 12 CMS Magnetics 2007 2008 Appliances Controller Switch game E 4 NIT Inverter KZ E Generator i Battery Bank Typical Off Grid System Fuses 2 Grid tied electric wiring All the models can be used as grid tied with the approval of the local authorities To do so the grid tie controller and inverter are needed when you place the order Previously quoted prices may vary ppliances mv Controller Switch A Bi Fuses To Utility Grid Generator Typical Grid Tie System Confidential 13 CMS Magnetics 2007 2008 Maintenance The wind generators may operate under harsh environments and extreme weather situations Regular inspection and maintenance are necessary to keep the system operating efficiently Using heavy grease coat the tail connection furling rod Failed furling can cause your generator to overheat and cause permanent damage Also grease the generator shaft Using oil coat the outside blade mounting brackets These steps are crucial in preventing possible corrosion of these parts and also could cause generator damage 3 month maintenance schedule 1 Check tensions of the guy wire Make sure the wires are evenly tightened The wire should be neither too tight nor too loose This check has to be done at the installation time and again one week later to correct any stretching or climactic adjustment 2 Ch
10. or the torque settings Make sure the wrench is calibrated properly A amp C will not be responsible for any damages caused by improper tightening 6 Tighten the screws following the order indicated in graph 6 CO0w o00w Lkwiekw akw okw 10kw CIK w Graph 6 7 Bolt the hub and blades to the shaft then install the nose cone Step 4 Preparation before erecting the tower 1 Connect one end of the 16 meter wire to the winch or tractor 2 Pass the other end of the wire cable or bracing cord through one end of the ladder 2 4 or 2 5 which will serve as a Jin pole Step 5 Erecting the tower Confidential 9 CMS Magnetics 2007 2008 1 Drive the winch or tractor slowly and the tower will be raised up gradually Stop at each 15 rising and check the tension of the guy wires on both sides If you find the tension is not balanced either too loose or too tight please lower the tower slowly and adjust the length of the guy wires accordingly Otherwise keep pulling until the tower stands upright Separate the cord and fix the front guy wire to the front anchor 2 Check and adjust the tension of each guy wire so that they are evenly balanced The tension should not be too tight or too loose Guy wires that are too tight may cause the tower to bend while being too loose may cause the tower to be unstable Installation of Tapered Tower Step 1 Choosing Installation Sites Please refer to the installation specification
11. p 1 Choosing Installation Sites The wind turbine should be erected as high and far away from obstacles in order to get relatively high wind speeds Meanwhile soil quality of the installation location should be taken into consideration Areas with loose sand uneven soil or those easily influenced by weather conditions should be not be chosen for wind turbine installation When selecting the locations it s necessary to consider the distance between the generator and pile Shorter distances require less cable and help minimize energy waste during the transmission When circumstances call for longer distances a thicker standard cable for transmission is recommended Size of side base m long wide deep Semidiameter m L n Leg Lan Jeng 0 8 0 8 0 8 1 0 1 0 1 0 Size of side base m long wide deep 1 0 1 0 1 0 Table 1ext Confidential 4 CMS Magnetics 2007 2008 Rea a So base SE Figure 1 layout of concrete base Special attention should be paid to the following when laying out the base and anchor 1 The two anchors should line up with the pin holes on the hinge i e if you draw a line between the two anchors the line should go through the center of the two pin holes 2 All the anchors should be on the same level with the tower base so that the pulling force from the two side anchors will be equal Otherwise the tower will bend or breakdown when you fasten the rear cable Disclaimer Since the so
12. re to disconnect the batteries from the charge controller when you perform this checking e How to lay down the generator o 1 Disconnect the generator from the controller Disconnect the generator output to prevent the generator from running 2 Perform the reverse steps of the installation to lay down the generator e Can lincrease the battery capacity to increase the running time for electrical appliances o Increasing the battery capacity may cause the batteries to be under charged and shorten the battery life How long is the generator s lifespan o Under normal care and maintenance your generator will efficiently produce energy for 15 years If you have further questions please contact your authorized PowerMax agent e Images and photographs may vary e This manual may be modified without notice Confidential 15 CMS Magnetics 2007 2008 Turbine warranty is 2 years Charge controller and inverter warranties are each one year from the date of delivery Controller Specification 1 Security IMPORTANT To prevent bodily injury or property damage please follow these instructions precisely With personal safety as a primary focus in design this charge controller has been engineered to function properly and efficiently l 2 oF T 8 9 Professional installation and guidance is always recommended Otherwise please contact your authorized PowerMax agent before installation Keep the charge contr
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