Manual_Alize_V3.4 - Fortis Wind Energy
Contents
1. Tower section Fortis Alize d d 15 04 01 tek nr 10 10 01 4 Manual Fortis Aliz Page 29 of 42 8 8 4 Picture of Aliz with guyed tower ne gga Manual Fortis Aliz Page 30 of 42 FORTIS WIND ENERGY 8 9 Dimensions Aliz wind turbine Fortid Aliz wind turbine rated output 10 kW Manual Fortis Aliz Page 31 of 42 FORTIS WIND ENERGY Q GREAT IN SMALL TURBINES 8 10 Tail assembly Tail beam Tail hinge section Tail Vane Manual Fortis Aliz Page 32 of 42 FORTIS WIND ENERGY 8 11 Tail amp Vane of Aliz Tail Vane mounted on left side of tail beam seen from the front of rotor blades Note TOP remark on upside tail hing section Place the Teflon glider ring on top of the shaft On top and bottom mount the lock pins See also note on Note Tail hing section chapter 3 3 should turn to the right seen from the front of rotor blades Manual Fortis Aliz Page 33 of 42 FORTIS WIND ENERGY 9 Parts list 9 1 GFI 10K2 Grid Feed Inverter 9 2 Electric schema Aliz to 3 phase network Note For detail description of the GFI 10K2 Inverter see Manual Version 2 4 716004 GFI Installers Manual GB Brake Resistor with Connection Cable Version 2 0 716005 DL 35K DL 57K user manual_GB Manual Fortis Aliz Page 34 of 42 FORTIS WIND ENERGY GREAT IN SMALL TURBIN Co 9 1 GFI 10K2 Grid Feed Inverter Manual Fortis Aliz2. Glass fibre reinforced Epoxy brushless permanent magnet 48 pole 300 350 100 400VAC standard other voltages on request 0 50 Hz none generator short circuit Inclined hinged vane microprocessor controlled rigid tail vane upwind steel tubular or guyed tower height 18 24 or 30 mm 385 kg Page 20 of 42 FORTIS WIND ENERGY 8 3 1 Power Curve ALIZE Rated Capacity kW 12 11 10 9 8 7 6 5 4 3 2 1 0 0 5 10 15 20 25 Windspeed at hub height m s Type Fortis Aliz Manufacturer Fortis Wind Energy Rated power 10 000 Watt Output 11m s 8 500 Watt Rotor with fixed pitch Generator and hub Type Upwind rotor with fixed pitch Pitch control Fixed pitch Direction of rotation Clockwise Number of baldes Length of blades Rotor Diameter Rotor area Profile Manufacturer Blade material Rated speed Rotor axis angle Cone angle Manual Fortis Aliz 3 0 3 15 3 30 m 6 3 6 6 6 9m 31 2 34 2 37 4 m NLF 416 Fortis Wind BV Glass fibre reinforced Epoxy variable max 350 rpm Hub Generator Grid feeding Break systems Yaw control Tower Weight tower head Rigid Permanent Magnet FORTIS Synchron Machine 3 x 230V by inverter Ecliptic safety system by inclined hinged vane 90 setting of tail short circuit of generator Passive Aligned b
3. In principle FORTIS wind turbines do not require any maintenance at all On the other hand it would be unwise not to check the wind turbine occasionally FORTIS advises that you should check the wind turbine at least twice a year The following points should be checked Check noises the noise level should not have increased and should sound normal Check nuts and bolts they might have worked themselves loose Check the yaw bearing and the bearings of the tail blade they must be able to move smoothly if they do not apply some grease to the bearings Check the electrical wires that are hanging through the inside of the mast the tension must not be too high this can occur if the wires have been wound too far Check the leading edge of the blades small damages can be caused by small objects carried by the wind such damages will speed up the process of wear and tear and should be repaired Check the tension of the guy wires if you have a guyed tower in the first 6 months regular Check if the turbine tail or tower is shaking more than usual If this shaking occur only at a specific low speed this means own frequency If it become stronger with higher wind speed stop wind turbine and contact your dealer or agent or contact Fortis direct Manual Fortis Aliz Page 23 of 42 FORTIS WIND ENERGY 8 6 Drawing Foundation Allowable pull misalignment max 5 Afmetingen Dimensions block B C D and E 1200 x 1500
4. can move and rotate freely inside the mast Any possible problems in this area can cause a short circuit For the power line use three wires with the same colour to indicate the three similar phases These three wires must be connected to the three wires coming from the generator the connector block can be found in the box that is attached to the generator The order of connection is not important since all three lines are equal at both sides When have connected the power lines and the tower to the support frame check the Manual Aliz FORTIS WIND ENERGY generator and rotor hub rotating smoothly You can rotate the hub with a force of 10 Nm If not or if only with a very large force it is possible that there is a short circuit in the system Check all the cables and connections Loose the power cable from the terminals If it is still difficult to move the rotor hub there is short circuit in the generator or something wrong with the generator bearings or another failure Contact your agent or FORTIS The next stage involves the guy wires a standard FORTIS ALIZE mast according to FORTIS specifications is guyed every 10 12m in four directions Make a calculation of the length of each individual guy wire The guy wire is prepared with a length of the calculated value 1 m necessary for the connection with cable clamps Then connect the guy wires to the mast and to its foundation The only guy wire that cannot be conne
5. Aliz 7 1 Safety first 7 2 Conditions during installation 7 3 The installation erection procedure 7 4 Guy wire tensioning 7 4 1 Determining the proper frequency of the cable 7 4 2 How to oscillate the cable 7 4 3 Procedure for tensioning the cable 7 4 4 Cautions Hints and Suggestions 7 5 Start up procedure 8 1 Torque specifications 8 2 Required tools 8 3 Technical data Aliz 8 3 1 Power Curve Aliz 8 4 Trouble shooting list 8 5 Maintenance checklist 8 6 Drawings foundation 8 7 Drawing foundation blocks 8 8 Drawing Mast 8 8 1 Drawing mast specifications 8 8 2 Drawing mast specifications 14 14 14 14 15 16 16 16 17 17 18 18 19 20 21 22 23 24 25 26 27 28 Page 4 of 42 FORTIS WIND ENERGY 8 Table of Contents 8 8 8 3 Drawing mast specifications 8 8 4 Picture of Aliz with guyed tower 8 9 Dimensions Aliz wind turbine 8 10 Tail assembly 8 11 Tail amp Vane of Aliz 9 Parts list 9 1 GFI 10K2 Grid Feed Inverter 9 2 Electric schema Aliz to 3 phase network 10 Safety and control procedures 11 Declaration of Conformity Manual Aliz 29 30 3l 32 33 34 35 40 41 42 Page 5 of 42 FORTIS WIND ENERGY Important security notice Note For successful operation of your wind turbine it is essential to read this manual carefully prior
6. indicates anything above zero When the controller is not equipped with volt and ampere meters a multi meter can be used to check the system even the slightest increase in voltage indicates power coming from the turbine Do not be disappointed when the wind turbine does not start up in winds slightly above 3 m sec as it sometimes needs a short running in period When lifted the windturbine with generator short circuit the wind turbine will start to rotate very slowly if there is sufficient wind less than 5 revs min A final check can be made when the turbine is producing some power check the voltage over a period of several hours If all the connections are made correctly the voltage will increase slightly although the difference may be minimal Manual Fortis Aliz Page 17 of 42 FORTIS WIND ENERGY 8 Appendix 8 1 Torque specifications Specification bolt nut Description Torque N m M16 50 Main shaft 120 Nm M12 100 Rotor hub 80 Nm M14 nuts Rotor hub 100 Nm M18 60 Mast top and mast flanges 100 Nm M8 40 Tail vane 50 Nm M12 100 Tail boom assembling 80 Nm M14 50 Generator chassis mounting 120 Nm M8 20 Nose cone 10 Nm Manual Fortis Aliz Page 18 of 42 FORTIS WIND ENERGY 8 2 Required tools The following tools are the minimum that required for successful installation For tower assembling Tractor or lifter to put tower sections together max weight tower section
7. losses When the controller is housed in the same room as the batteries the room must be well ventilated Page 11 of 42 FORTIS WIND ENERGY WARNING The brake switch short circuit the generator and will bring the rotor stop rotating up to wind speeds of 8 9 m sec Never let the brake switch on for more than ten minutes if the rotor does not stop because of high wind speeds The generator can be overheated and destroyed 5 3 Grid connection Grid connection is one of many options with a FORTIS system In a grid connected FORTIS ALIZE system a Fortis GFI 10K2 Controller is used all in one housing The controller is needed to rectify the AC output of the wind turbine and to protect the inverter against peak voltages when the load is disconnected The grid controller is build for max operation voltage of 400VDC Use always the Fortis GFI 10K2 and Brake Switch for save operation with the dumploads supplied by Fortis 5 4 Batteries Batteries need to be kept in a place with sufficient ventilation and no risk of freezing Charged batteries can stand temperatures of up to minus 20 C but uncharged batteries cannot withstand frost at all Place the batteries underneath the voltage control in the same room if possible as this minimises energy loss in the wires A battery is normally 2 6 or 12 V so you need 120 40 or 20 batteries connected in series for 240 VDC Connect the minus terminal of one battery with the plus te
8. the mast of an FORTIS ALIZE wind turbine The maximum wind speed for erection of the mast and wind turbine must not exceed 8m sec Only a FORTIS specialist who is present during Manual Aliz installation and erection can decide to proceed during higher wind speeds Snowfall during installation is not necessarily a problem provided the snow is not sticking to the blades in large amounts Snow or ice can cause rotor unbalance and thus damage the bearings of the generator 7 3 The procedure installation erection The simplest way to erect a FORTIS mast is to use a gin pole It is also the method most often used owing to the fact that it is usable under a wide range of circumstances The length of the gin pole must be somewhere between 1 2 and 1 3 of the length of the mast and a set of guy wires are required to prevent the mast from toppling to one side If only one set of guy wires is used connect this one guy wire to the top section of the gin pole When several sets of guy wires at different levels are used a guy wire of every set must be connected to the top section of the gin pole The last attachment point of the gin pole is used for the cable of the winch or cable jack The gin pole is now held in place by at least four cables Page 14 of 42 If it is possible to climb the mast when it is in a vertical position we advise you to fix a rope to one of the blades to prevent the turbine from rotating Even when it is p
9. these factors should be considered when selecting a satisfactory location for the wind turbine Read more about this issue in the publication of Paul Gipe Windpower Renewable Energy for Home Farm and Business Chelsea Green Publishing Company www chelseagreen com The wind turbine hub should be mounted at least 10 meters above any obstruction within 400 meters Another important fact to keep in mind is that the wind turbine should be mounted as close as possible to the battery bank The further it is mounted from the battery bank the greater the loss of energy in the wires In order to minimize this loss of energy in the wires we have provided information about the wire dimensions in section 5 1 This list also shows that if the wind turbine is placed further from the battery the wiring costs will be higher There are two reasons for this firstly a greater length of wire will be required and secondly the diameter of the wire will have to be larger Install the wind turbine close to the house and high enough to receive an unobstructed sweep of the wind Page 7 of 42 3 Assembling the power head The FORTIS ALIZE power head consists of the following parts Generator Rotor blades Tail and Tail vane Frame Mast adapter 3 1 Generator When you first open the crate check the contents carefully starting with the generator and its support frame First make a visual check to determine any exist
10. x 900 mm lx w x d Afmetingen Dimensions block A 1200 x 1200 x 900 mm Ix wx d Fundatie getuide mast Foundation quyed tower Fortis Aliz Tekening Drawing 10 10 003 Manual Fortis Aliz Page 24 of 42 FORTIS WIND ENERGY 8 7 Drawing foundation blocks 6 BOWS 98 PAD B C D E 3 RINGS 96 S BONS 2S 5 RINGS 08 2 RINGS 96 ELFE IRASE concrete requirements 2 76 m 10N 1k cement 1m concrete 24000N sand gravel reinforcement steel FeB360 covered with a minimum of 40 mm concrete all pads must be level and be at the same elevation guy wire attachments and other fixtures are bolted to the pads using hilti type concrete fasteners Aliz FOUNDATION GUYED TOWER DRAWING 10 10 4 Manual Fortis Aliz Page 25 of 42 e FORTIS WIND ENERGY 8 8 Drawing mast Guyed tower Aliz F M Manual Fortis Aliz Page 26 of 42 FORTIS WIND ENERGY 8 8 1 Drawing mast specifications Door 150 x 250 mm Tower section 1 Fortis Alize d d 15 04 01 tek nr 10 06 01 1 Page 27 of 42 Manual Fortis Aliz FORTIS WIND ENERGY 8 8 2 Drawing mast specifications Tower section 3 Fortis Alize o d 15 04 01 tek nr 10 06 01 01 3 Manual Fortis Aliz Page 28 of 42 FORTIS WIND ENERGY 8 8 3 Drawing mast specifications top flange see drawing 10 10 01 05 6 x ribs see drawing 10 10 01 07 273 x 9 Zie detail tek 10 10 01 06 Quy wire attachment
11. FORTIS WIND ENERGY FORTIS Wind Energy Aliz Wind Turbine Instruction Manual FORTIS WIND ENERGY No part of this document may be reproduced or transmitted in any form or by any means electronic or mechanical including photocopying and recording for any purpose without the express written permission of FORTIS WIND ENERGY FORTIS WIND ENERGY reserves the right to make changes to any and all parts of the documentation at any time without obligation to notify any person or entity of such changes Copyright 2013 FORTIS Wind Energy all rights reserved Fortis Wind BV 9751 AC Haren The Netherlands Manual Aliz Page 2 of 42 FORTIS WIND ENERGY Table of Contents 8 Index Important security notice 1 Introduction 2 Selection of location and tower height 3 Assembling Power head 3 1 Generator 3 2 Rotor blades 3 3 Tail and Tail vane 3 4 Mast Adapter 4 Instructions Mast 4 Producing a Mast yourself 4 2 Foundations 4 3 Installation preparations 5 Electric Installations 5 1 Transmission lines 5 2 Rectifier amp Battery Charging system 5 3 Grid connection 5 4 Batteries 5 5 LC Filter 5 6 Brake switch 6 Final assembly of system electronics Manual Aliz Page 10 11 11 11 12 12 12 12 13 Page 3 of 42 8 FORTIS WIND ENERGY Table of Contents Erecting the turbine in the upright position Appendix Manual
12. Page 35 of 42 FORTIS WIND ENERGY Technical data GFI 10K2 GENERAL Description Integrated 3 phase inverter Operating temperature 20 C to 60 C ambient full power up to 40 C ambient air temperature Storage temperature 20 C to 60 C Relative humidity protected against humidity and condensing air by PCB coating Protection degree IP42 Safety class class metal enclosure with earth connection INVERTER INPUT Nominal power 10 000 W Continuous power 9 40 C 10 000 W Operating voltage 40 340 V AC Nominal voltage full load 220 340 V AC Maximum voltage 390 V AC Rated current 3 x 20 A rms Maximum current 3 x 30 A rms Frequency range 0 150 Hz DUMP LOAD OUTPUT Nominal power 10 000 W Maximum power 120sec duration 15 000 W Maximum current 2x15A GRID OUTPUT AC Voltage 230 V AC 3 phase N PE 4 Wire Y 20 Nominal power 10 000 VA Maximum power 10 500 VA Nominal current 3 x 16 Arms Frequency AC frequency 50 Hz 45 55 Hz programmable AC frequency 60 Hz 55 63 Hz programmable Nominal power factor 0 99 at full power Reactive power 0 80 inductive 0 80 capacitive Harmonic distortion THD 396 THD DC current injection 20mA AC connector AC glands on detachable plate in bottom of connection compartment Fuse External fuses is mandatory Recommended 25A B characteristics Not installing a properly rated fuse Icu 2 1 kA will pose a safety hazard and will void the warranty of the in
13. TIS can provide all the required calculations These calculations can be very important when planning permission has to be obtained The drawings for a guyed steel tubular mast are provided in this manual The masts are designed according to a modular system with 6 8 m modules guyed every 12m Appendix 8 8 4 2 Foundations When FORTIS has delivered the tower for your wind turbine this owner s manual include a full set of drawings and specifications of the foundation If you plan to produce your own guyed tower follow the instructions below As there is such a wide variety of masts possible we only describe here the foundations for the standard guyed steel tubular mast according to the standard FORTIS design There are three ways to make a proper foundation for the mast and guy wires 1 The first type of foundation is for very soft and unstable ground for this type concrete blocks of a certain weight have to be used Drawings for this type of foundation are provided in appendix 8 6 2 The second type of foundation is for rocky ground this type requires the use of rock bolt s for the tower and the guy wires Make sure that the rocks are heavy enough FORTIS can provide and specify the rock bolts on request The size and weight of the rocks must be about the same as the concrete blocks described in the foundation drawings 3 The third type of foundation is for medium soft but stable ground for the guy wires earth s
14. ake Switch close to tower Fuse 25A Plug and socket at the Three core cable size 3 x 10mm UVWN basement of the tower 10 Safety and control procedures www fortiswindenergy com Page 40 of 42 CA GUT rt FORTIS WIND ENERGY A WARNING What s dangerous VV V WV Spinning Rotor High tension on electric wires Falling from tower Crane drops tower wind turbine Gin pole winch fault during erection of guyed tower Choose a supervisor of the team who will be responsible for these procedures Do not fix a rope to the rotor blades and tower during erection It can damage the blades Only a rope which can mover free around the tower is possible Before erection check if the generator is on the brake or on short circuit Check all bolds and nuts of the wind turbine and tower before erection if they have the right tension During erection all persons has to be at a distance from the foundation of more than the height of the tower All electrical connections and electronics installation has to be completed before erection If possible the final connection should be the plug in the tower base Check if the earth cables are connected well Check if isolation of all cables is made well Ask crane drive for their safety and control procedures and their responsibilities Do not erect the windturbine during high winds The crane driver has always instructions at which max wind speed he can operate safely Never climb into the tower when
15. connected WARNING Never connect the wires from the generator to the controller when the wind turbine is in operation The open circuit voltage can be 10x the nominal voltage This voltage can destroy the electronics Manual Aliz Page 13 of 42 FORTIS WIND ENERGY 7 Erecting the turbine in the upright position 7 1 Safety first 7 2 Conditions during installation 7 3 The installation 7 4 Guy wire tensioning 7 5 Start up procedure 7 1 Safety first Safety becomes very important when you consider the amount of serious damage and injuries that can be caused if a wind turbine topples over Firstly therefore make sure that all the nuts and bolts of the wind turbine are tightened securely We advise you to make one person responsible for the final overall check of all the nuts and bolts Then let the same person check all the guy wires rigging screws and foundations During hoisting of the mast and wind turbine everybody who is not directly involved with the process must keep a distance of at least mast height to the base plate If a winch is used to erect the mast and wind turbine only 2 men are necessary for the process one for the actual lifting jacking and one to check the guy wires during erection This person should make sure that the wires do not get stuck somehow or work themselves loose 7 2 Conditions during installation It is not absolutely necessary to wait for a windless day to erect
16. crew anchors are used and for the mast a small concrete block will be sufficient The earth screw anchors can be Page 9 of 42 specified and provided by FORTIS The concrete block is the same as in appendix 8 6 4 3 Installation preparations If you plan to use a steel tube tower or concrete tower you need a crane to erected the wind turbine It is important to follow the instructions of the crane driver for safety reasons In case of a guyed tower is used without help from professionals follow the instructions below Before the mast is placed in a horizontal position bolted to the base plate make sure the mast will be lifted towards the main wind direction Lift and support the top of the mast in such a way that it is possible to assemble the support frame mast adapter to the mast top Check if the mast adapter will rotate freely in to the support frame Before you assemble the tower to the support frame it is necessary to pull the power lines through the mast For your FORTIS ALIZE machine 3 flexible wires of 4 to 10 mm will be needed to transport the power from generator They must be pulled through the mast first and then through the pull release glands in the support frame adapter It is important to fix the cables in the glands very well because they have to carry the full weight of 18 to 24 m cable hanging in the tower The connecting wires must not get stuck anywhere on any part of the wind turbine Make sure the wires
17. cted is the one directly opposite the direction in which the mast is pointing This guy wire should be connected when the mast is in the upright position All guy wires are connected to the mast with a bow shackle and cable thimble to the foundation with a cable thimble rigging screw and at least twin cable clamps The cable clamps must be fully tightened before lifting the mast The next component to install is the tail vane The tail assembling is given in section 3 3 The tail uses a stainless steel pin as spindle This pin must slide into the tubular section of the tail frame where it passes through two Teflon bearings The Teflon bearings don t need any additional lubrication however applying grease extends the life of the bearings to some extent Next to install are the rotor blades as described above in section 3 2 Before assembling and close the polyester cover we will make an operational test of all vital components Page 10 of 42 5 Electric Installations 5 1 Transmission lines 5 2 Voltage control dump load 5 3 Grid connection 5 4 Batteries 5 1 Transmission lines The FORTIS ALIZE generator is a 3 phase generator and 3 electric wires are needed to connect the generator with the rectifier bridge The maximum rectified current is 60A and peak voltage is 600 VDC The working temperature of the components is 40 C to 50 C FORTIS WIND ENERGY The electric wires have to be flexible and should not consi
18. d Energy www fortiswindenergy com Page 42 of 42
19. djusted until the time period is within 1 second of the recommended value Calculation example assume the following geometry Height of guy fixing point 12m Distance mast foundation point 2 6m This gives a total cable length of 13 4m Dividing by 3 gives 4 5 seconds to complete the 20 oscillations 7 4 2 How to oscillate the cable Any cable under tension will tend to oscillate at a certain natural or fundamental frequency which is dependent upon its tension weight per meter and length It is very important that the cable be moved back and forth at this frequency The cable should trace out the pattern shown below in a regular consistent way without whipping or distorting into other shapes IMPORTANT the frequency of oscillation is independent of the magnitude of oscillation The idea is then to vary the tension of the cable until the proper frequency of oscillation is observed 7 4 3 Procedure for tensioning the cable 1 Stand at one anchor and move the guy wire back and forth at its natural frequency 2 Measure the number of seconds required for the cable to make 20 complete cycles 3 Compare this time period with the recommended value 4 If necessary adjust the tension and go back to point 1 Manual Fortis Aliz Page 16 of 42 FORTIS WIND ENERGY 7 4 4 Cautions hints and suggestions 1 Use your common sense If the guy wires start making noises something like a guitar they may well be too tight so stop tensioni
20. er a specific sequence in which all the above mentioned connections must be made This is very important as if the connections are not made in this order the generator or controller can be damaged during the installation procedure Set brake switch on stop 2 Connect first always the dump load to the Fortis Controller before any other cable 3 Connect the 3 phase wire from generator to the controller 5 The batteries are the last component to be connected If batteries are connected to the rectifier with volt and ampere meters the volt meter must show the battery voltage as soon as they are connected FORTIS WIND ENERGY can either be a battery bank an inverter for grid connection or a Pump controller for water pumping Before the wind turbine is erected and during the process of erection the three phases of the generator should be short circuited See wiring diagram 9 1 1 for Brake switch solution Any other temporary way of short circuiting the three phases is allowed It is not necessary to disconnect the batteries as they are protected from short circuiting by the rectifier bridge In addition to this the batteries and any other consumption circuit should be properly fused The fuse for the battery bank is supplied together with the controller FORTIS advises to fuse all other consumption circuits in accord with their specifications as required Check that all your connections are tightly and correctly
21. ge 8 of 42 When any parts of the wind turbine show damage that might have occurred during transportation inform your local supplier or FORTIS directly about this If you do not report such damage or the turbine is already in operation you lose the right to your warranty 4 Instructions Mast 3 1 Producing a Mast yourself 3 2 Foundations 3 3 Installation preparations 4 1 Producing a mast yourself FORTIS can deliver for your wind turbine a steel tube towers of 12 15 18 and 24 m high and guyed towers of 18 24 and 30 m high Producing a mast for your FORTIS wind turbine is relatively simple Various constructions are possible but in most cases a steel tubular mast with guy wires is used It is also possible to use wooden poles free standing steel tubular masts or free standing lattice masts Even concrete masts are a possible option On request we give forces at the top of the tower which enable you to make the necessary stress calculation of your own build tower For these stress calculations you take a safety factor of at least 2 two for the peak loads and at least 10 ten for the amplified fatigue loads FORTIS does not take any responsibility for own build towers and its foundation based on the tower top loads and drawings supplied by Fortis Manual Aliz FORTIS WIND ENERGY In most cases FORTIS advises the use of the guyed steel tubular mast as it is inexpensive easy to build easy to erect and FOR
22. ing scratches dents or cracks Then rotate the shaft of the generator by hand This must rotate smoothly 10 0N m If it does not check whether there is no short circuit in one of the phases out coming wires might be connected somehow Normally the generator is already attached to the support frame with a specified torque appendix 7 1 so there is no need to tighten the eight M14 bolts The power head is bolted to the crate it is transported in before you undo these bolts remove all other components inside the crate We advise to wait with unpacking the power head till its mast is ready to receive it The power head can then be moved straight from the crate on to the mast top 3 2 Rotor blades The large cardboard box contains the rotor blades and parts of the tail frame Unpack the rotor blades and make a visual check for any existing cracks or scratches When nothing is visible at all the blades can be mounted on the hub Every single blade has its unique fit to the hub and in addition to this the blades are marked with a number serial number blade nr 1 2 or 3 that corresponds with number on the hub plates The numbers are Manual Aliz FORTIS WIND ENERGY always on the front side of the hub plates The flat side of the blades should face the wind as is the front side of the hub There is only one way to fit the rotor blades to the generator The bolts are positioned in such a way that assembling in an
23. is 600kg One spanner and one socket wrench size 46 for M30 bolds To lift turbine with 18m tower max weight 2200kg Crane 16 m or 22m heigth With 16 m the crane remains below rotorblades With 22 m the crane remains above rotorblades Rope nylon 20m to remove lifting rope from crane For windturbine assembling Set of spanners 10 11 13 17 19 22 and 27 mm Socket wrench 10 13 17 19 22 and 27 mm Hexagonal key 3 mm 6mm Set of screw drivers for electrical terminals Rubber hammer 2 5 kg Multimeter AC DC voltages 0 500V Ratchet Pincers Cable stripping tool and cutting tools For installing controllers and dumploads Drilling machine with drills for wood or stone for wall plugs and screw size from 5 up to 12 mm Mechanical crimping tool for 6 and 10 mm2 cable Manual Fortis Aliz Page 19 of 42 8 3 Technical data ALIZE Max output Output 11m sec Wind speed cut in rated survival Rotor blades number diameter area airfoil tip speed ratio material Generator type rated rpm max rpm voltage frequency Other gearbox braking mechanism rotor speed control output control rectifiers hub type yaw system rotor position tower Head weight Manual Fortis Aliz FORTIS WIND ENERGY 10 kW 8 5 kW 3 0 m sec 13 m sec 60 m sec 3 6 3 6 6 or 6 9 m 31 2 34 2 37 4 m NLF 416 7
24. ng You may be doing something incorrectly 2 This procedure cannot be used under all wind conditions If the wind speed is above 7m sec then your readings will not be accurate owing to the additional forces on the tower caused by the wind Furling the wind turbine and stopping the rotor will reduce these additional forces and allow the use of this procedure in winds of up to 10 m sec 3 Do not use this procedure if the cable size is different from that recommended by FORTIS For example if the cable is larger the result will be tension forces which are much greater than the recommended value 4 On an FORTIS tilt up tubular mast with 4 anchor points the cables which are at the same height but opposite to one another will tend to develop the same pretension Both cables may require adjustment however for the tower to remain straight 5 Do not attempt this procedure if ice is present on the cable The extra weight of the ice will give incorrect results 7 5 Start up procedure Provided the wind turbine and mast are in the final position and there is some wind more than 2 5 m sec the start up procedure can take place Provided all the electric connections are correct you can release the brake switch and he will automatic run the start up procedure If there is sufficient wind the turbine will start to rotate and power will be produced Evidence of power being produced is provided as soon as the ampere meter of the voltage control
25. ossible to fix one of the blades with a rope the three phases of the generator must always be connected short circuited Be very careful with short circuiting the three phases when the rotor blades are moving the voltage can easily reach dangerous levels The mast and wind turbine can now be erected FORTIS WIND ENERGY 7 4 Guy wire tensioning FORTIS has developed and recommends a method for setting the pretension on guy wires for all guyed towers This simple procedure utilises the relationship between cable tension and the rate of cable vibration to give a preload which is proportional to cable size It is based on the time required for the guy cable to complete 20 oscillations at the fundamental natural frequency The approximate desired preloads for the various cable sizes are given below EHS Cable size Preload 1 2 12mm 900 kg 7 16 675 kg 3 8 10mm 450 kg 5 16 8mm 337 5 kg 1 4 6mm 225 kg Manual Aliz Page 15 of 42 FORTIS WIND ENERGY 7 4 1 Determining the proper frequency of the cable 1 Determine the length of the cable in metres from the guy bracket to the ground 2 Divide this length by 3 3 This gives the number of seconds which are required for the cable to make 20 complete cycles 4 The process is very sensitive to this time period Doubling the time required to make the 20 oscillations will result in 1 4 of the desired guy tension We recommend therefore that the tension be a
26. other way is not possible First assemble the rotor blades to the hub plates Use a flat and clean area to work Fix the rotor blades with the 3x M12 bolds Assemble first the complete tower and generator with tail The final part should be the rotor blade set You need 3 people to put the rotor over the 3 x 3 M14 bolds on the generator It s possible that you need some pressure to put the rotor to the generator Use a gummy hammer or use a piece of wood together with a heavy steel hammer to move the rotor to the generator 3 3 Tail vane The tail vane assembly is composed of 3 sections The 3 parts are the tail vane which is bolted inside the crate with hinge section and the tail beam which is packed together with the rotor blades in the cardboard box The tail amp vane can be fully assembled according to the instructions on page 34 Note on the stainless steel shaft of 22 mm there are 2 lock pins assembled and a glider ring When you assemble the tail hinge to the frame don t forget this ring It avoids noise when tail furls Put this ring between the two stainless steel bushes at the top 3 4 Mast adapter The mast adapter is a part of the support frame supplied with the ALIZE system Before you bolt it on top of the mast make sure that it fits well in the support frame and can be rotated by hand The azimuth bearing is a special bearing with high friction It is normal to use some force rotate the mast adapter Pa
27. rminal of the other battery The remaining terminals are the plus and minus of the 240 V battery group For a FORTIS ALIZE we advise a minimum battery capacity of 500 600 Ah 240V 10 h but a capacity of 1000 Ah is even better For lead acid batteries the charging discharging current should not exceed 20 of the capacity preferable 10 Manual Aliz 5 5 LC Filter Together with the Fortis UN Voltage Controller a Filter is supplied This filter is installed between wind turbine and the Fortis UN Voltage Controller See installation wiring diagram 9 1 1 The filter is needed to avoid EMC noise in the cable from wind turbine to controller 5 6 Brake switch As shown in wiring diagram 9 1 1 install a brake switch between Wind turbine generator and filter In this way it is easy to stop the turbine in case of service or maintenance The brake switch should be used only in case of service and not for emergency The brake switch stops the rotor only at low wind speed If the rotor keeps on turning when you put the brake switch on release the brake switch within 10 minutes because the generator gets to hot in case of running is short circuit Page 12 of 42 6 Final electronics assembly of system When mounting the controller it is very important to choose a wall or surface which is non conductive The last component to connect is the consumption circuit The consumption circuit IMPORTANT There is howev
28. rts on internal DIN rail Standard Thermal sensor input NTC PTC Standard 2 1 x Generator 1 x Dump load Prepared for 4 3 TFT colour touch display Yes optional add on NORMATIVE STANDARDS APPLIED Emission EN 61000 6 3 Harmonics EN 61000 3 2 Flicker EN 61000 3 3 Immunity EN 61000 6 1 Electrical safety EN 60950 Grid compliance EN 50438 DIN VDE0126 DIN VDE AR N 4105 G83 2 G59 2 3 DK5940 Manual Fortis Aliz Page 37 of 42 FORTIS WIND ENERGY 4 1 3 Mechanical drawing three 3 phased inverter GFI types of three phased systems GFI 10K Grid Feed Inverter GFI 15K Grid Feed Inverter LEEEEEEEEEEEEEELEELE WANA NAN AAN NAN ANA ANI 4 4 LL Dimensions 644 x 819 x 370mm bxhxd Manual Fortis Aliz Page 38 of 42 FORTIS WIND ENERGY IMPORTANT Dump load matrix for Aliz wind turbine Alize Battery charging Single Phase 3 Phase 240V 230V 50Hz 400V 50Hz Dump load 2x 6 kW 230V 2x 6 kW 230V 2x 6 kW 230V Connection Parallel Serial Serial Cable type Length Manual Fortis Aliz Page 39 of 42 FORTIS WIND ENERGY 9 Electric schema Aliz to 3 phase network Dumpload 2 x 5000W Alize with 3 phase AC PM generator 1x GFI 10K Grid Feed In Inverter 230V AC 50 60Hz 3 phase N PE kWh Disconnect Switch meter Br
29. st of a single solid copper core Furthermore the isolation wrapping of the wires should be UV resistant PVC isolation cannot stand UV light Prevent the damaging of the electric wires by sharp edges Any damage to the electric wires will lead to short circuiting and the rotor will stop rotating or even worse the rectifier bridge might be destroyed because of too many amperes Never let the wires hang with their full weight on the cable terminals For the wire gauge dimensions see the next table Length m including tower Permitted power loss 240VDC systems lt 5 gt 10 0 50 10 mm 4mm 50 85 gt 85 16 mm 6 mm 25 mm 10 mm 450VDC system grid system 0 100 100 160 gt 160 5 2 Rectifier and battery charging system Use always the Fortis UN_ Voltage Controller 240VDC and dumploads with the Alz system for battery charging The Fortis UN Voltage Controller is an active rectifier to make DC form the AC power form the wind turbine The microprocessor prevents over charging of the batteries by switching power to the dump load Manual Aliz 4 mm 2 5 mm 6 mm 4mm 10 mm 6 mm When the batteries reach a threshold value the microprocessor will keep the charge voltage constant and reducing the charging current by switching wind turbine power partly to dump load It is advisable to mount the rectifier and microprocessor as close to the batteries as possible to minimise electrical
30. the wind turbine is not set on the brake This will be very dangerous Never disconnect any electrical wire if the wind turbine is not set on the brake When climbing in the tower use always position belts and full body harnesses Follow always the rules Get aware of the local rules of save work If you use a gin pole for erection read first the special instructions in the manual Do you have insurance public liability insurance product warranty and liability professional indemnity erection all risks 11 Declaration of Conformity www fortiswindenergy com Page 41 of 42 FORTIS WIND ENERGY Declaration of Conformity According to type II A without external approval Declaration of approval according to appendix II A of the machine guideline Manufacturer Fortis Wind Energy Address Botanicuslaan 14 9751 AC Haren The Netherlands Herewith declare under our sole responsibility that the products Passaat 1 4 kW Montana 5 kW Aliz 10 kW to which this declaration is regarded confirms to the Construction products 89 106 EEG the low voltage electricity 73 23 EEG the EMC 89 336 EEG and the machinery 98 37 EEG EC 61400 2 Design requirements for small wind turbines which has been adopted as European Standard EN 61400 2 guidelines of the EEG Instructions for installation operation and maintenance are according to the Instruction Manuals Haren 2011 08 22 Johan Kuikman CEO Fortis Win
31. to installation Important security notice This Instruction Manual contains important operational guidelines and security considerations that require your attention Before installation it is essential that the user first studies this user s manual in detail and keeps in mind the safety matters that need attention During user installation and operation one must refer to this handbook s documentation If you are unfamiliar with installation as shown below DO NOT CONTINUE and let a qualified Technical Engineer proceed with correct installation Failure to comply with the guidelines and instructions will void your warranty WARNING Do not change anything of the wind turbine parts or do not paint the blades If you do so you lose the right of warrantee Any change can have effect in the behaviour of the wind turbine Manual Aliz Page 6 of 42 1 Introduction Thank you for choosing FORTIS Energy systems Your choice means proven reliability low maintenance costs if any and the convenience of an independent power supply FORTIS Wind turbines are designed to withstand most of the environmental condition at the earth Even Siberian as well Tropical conditions can have benefited from the reliable power the FORTIS Wind turbine produces FORTIS tests their systems under the worst possible weather conditions FORTIS Wind turbines will be installed at all over the earth Therefore the FORTIS products are designed on such a way that the
32. verter Maximum inrush current 28 2A Short circuit L N 150A peak 12 9A RMS 3 cycl during 8ms Short circuit L L 298A peak 21 8A RMS 3 cycl during 4ms SYSTEM INFORMATION DIAGNOSTICS COMMUNICATION User interface 10 status LED s or TFT Touch display Inverter external communication 1 USB Interface Manual Fortis Aliz Page 36 of 42 FORTIS WIND ENERGY Additional technical data for GFI inverter SAFETY DEVICES Island protection An AC fault in any of the phases will disable the inverter Redundant voltage and frequency window monitoring QNS Independent cut off by means of 2 pole relay and solid state switch ENS according to VDE 0126 1 1 2006 Temperature protection thermal switch off at inverter internal over temperature Safety devices AC grid side Integrated RCD AC DC sensitive trip levels 30 mA Jump 300 mA continuous Voltage Frequency window AC current limiting DC current injection protection transients surge protection varistors class III Reclosure time wait 10 300 s country selection dependant after AC grid fault SYSTEM INFORMATION DIAGNOSTICS COMMUNICATION RS485 communication channels DVE SBUS Standard Wind direction Wind anemometer interface Standard 3 1 x Wind direction 2 x Wind speed Vibration sensor VM102 Standard 1 Galvanic isolated user input digital analogue Standard 8 x DI 4x Al Relay contacts user output change over Standard 3 x changeover Free space for customer pa
33. y can be installed and erected successfully with a minimum of tools and technical know how Also unskilled people are capable of maintaining the system with a minimum of tools and knowledge A FORTIS system is almost always composed of various components the wind turbine itself is only one component of this system We can supply controllers for battery charging and for grid connection For hybrid systems controllers are available to couple a photovoltaic solar generator or to a diesel or petrol generator together to a FORTIS Wind turbine In other words the possibilities with an FORTIS Wind turbine are endless in the sense that they can be adapted to suit almost every conceivable application 2 Selection of location and tower height For a good performance of your wind turbine it is necessary to install the FORTIS ALIZE in such a way that the wind has an uninterrupted flow from all directions to the propeller Any obstructions such as trees hills or buildings even if they somewhat lower than the wind turbine will cause rough air Manual Aliz FORTIS WIND ENERGY current which seriously decrease the generator output The rough air current have lost a large part of their original power and continually shift both horizontally and vertically which may cause the generator to vibrate to some extent The higher the wind turbine is situated the better as the air current are smoother and steadier further from the ground All of
34. y Tail Vane Various types of towers designed for different sites 18 36 m 385 kg Page 21 of 42 FORTIS WIND ENERGY 8 4 Trouble shooting list The rotor blades run very slowly possible causes Insufficient wind Short circuit in the electrical wires Diodes are damaged The rotor is mounted in the wrong way the flat side has to face the wind The wind turbine shakes possible causes The rotor blades are not in balance please stop the wind turbine immediately Own frequency of blades The rotor blades are not running on the same plane the hub is misaligned Batteries are discharged possible causes Owing to a short circuit the wind turbine is not able to produce power Damaged diodes no power is coming from the wind turbine Batteries are old or in a bad condition and are unable to store power Rotor blades run very fast possible causes Power lines coming from the wind turbine are disconnected Most of the time no problem at all Contact FORTIS Wind Energy or your local supplier FORTIS agent BE ALWAYS AWARE ABOUT SHAKING OF THE WIND TURBINE The wind turbine can shake because of its own frequency at a specific speed The shaking becomes worse at higher speed this means unbalance stop wind turbine Also shaking of tail or tower top section can mean unbalance in rotor Blades Manual Fortis Aliz Page 22 of 42 FORTIS WIND ENERGY 8 5 Maintenance checklist
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