USER`S MANUAL 1000W and 2000W
Contents
1. 29 Confidential 2 CMS Magnetics 2007 2008 Models and parameter List Model PowerMax 300W PowerMax 500W PowerMax 1KW Rated Voltage Startup Wind Speed mph Nomina Wind Speed mph J 157 TT Shutdown Wind Speed mph Rated Rotate Speed apm 4o w 400 Tower Height ft 20 Guyed Wir 26 2 Suggested Battery Capacity Model PowerMax 2KW PowerMax 3KW PowerMax 5KW Rated Voltage Startup Wind Speed mph Nominal Wind Speed mph A 220 22 Shutdown Wind Speed mph Rated Rotate Speed rpm ao 0220 S 20 Tower Height ft INNEN ENIM NEMINEM Suggested Battery Capacity Model PowerMax lO0KW PowerMax 20K W Rated Voltage Startup Wind Speed mph Shutdown Wind Speed mph Rated Rotate Speed rpm 180 90 Tower Height ft Suggested Battery Capacity Confidential 3 CMS Magnetics 2007 2008 Installation Specification of Guyed Tower Step 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 soll 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 dis2. Confidential 29 CMS Magnetics 2007 2008 Download the history data Read the history data of the anemoscope by clicking the reading history data button The history data is saved in the Microsoft Access database Users can observe and analyze history data of wind speed by either table or curve view Setting system parameter Diagram 24 A SRET x sit ir x m B pm B m mt m m PERRET UE DEERME I e Diagram 24 The system parameters of the anemoscope include clock parameter time interval of history record and alarm set Setting of supporting angle Picture 25 SIIiIliT Egi eS neo nw ERRE sec iT RO YH em mx SB EBENE Diagram 25 Confidential 30 CMS Magnetics 2007 2008 Curve view Diagram 26 TT j gt a pur mm mw mI pt s Et IE im bie m Diagram 26 To view a curve diagram of a certain history select the data scope of the history you need to check and then click the curve view Rose diagram of wind Diagram 27 MEHE x iL HEL ls LATO Tet mmmm m s A m iie Elstree I oime Fidem 100 03 E ras ENENN D O re RL Diagram 27 A rose diagram of wind can illustrate the distribution and scope of different wind directions all the year around Confidential 31
3. 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 Confidential 10 CMS Magnetics 2007 2008 Installation of Tapered Tower Step 1 Choosing Installation Sites Please refer to the installation specification of guyed tower step 1 Step 2 Make the Concrete Base Refer to the following graphs with the different product models ut o LOWE PE Te oo planform Graph 8 Model Code in the 1000W 2000W 3000W 3000W 1OKW 20KW graph 8 Burial depth of cotter bolt 02 os 12 12 12 16 20 ici oci el Ke Keil bl nd nd mm j 12 12 12 16 2 50 18 Quantity ofcotterbolt mw ai z 2 1 36 Table 2 Confidential 11 CMS Magnetics 2007 2008 Step 3 Assembly of the tower and the generator Please refer to the installation specification of guyed tower step 4 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 Con
4. PewerlMax USER S MANUAL 1000W and 2000W 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 Model amp Parameters List MMMMMM 3 Installation Specifications Guyed Tower 4 Installation Specifications Tapered Tower 11 Connection of the Charger Controller 12 Connection of Storage Batteries 12 Electric Wiring 2 20e 862 2 50 Ie sees cL Te rc see cie eT 4e 23 AM 13 MallfBlaance By presvapey yt es ET OPT FPN OT TZ 14 FAQ Frequently Asked Questions 14 Appendix One Off Grid Electric Wiring 17 Appendix Two Controller Specification 3KW and Higher 18 Appendix Three Wind Speed Monitor Specification 19 Appendix Four Analyzing System for Wind Speed Gathering 24 PH3000 Operation 26 FS200 and Computer Connection
5. CMS Magnetics 2007 2008 o Can increase the battery capacity to increase the running time for electrical appliances Increasing the battery capacity may cause the batteries to be under charged and shorten the battery life o Wind turbine which is 3KW or above cannot follow wind direction automatically 1 Check and make sure the controller has been set to AUTO position 2 Observe the wind speed indication on the controller to check whether the anemometer is broken or not 3 Check whether the dogvane is broken or not First unplug the dogvane from the controller There are three plug wires marked D 3 Using a multi meter measure the resistance between Dand The resistance should be approximately 10000 Then measure the resistance between and G along with 2 and GG The resistance figure of these two D and and should be equal to the resistance figure between Pand E 3 Even if after any suggested checks and or adjustments the system still cannot follow the wind direction the cause is most likely a low wind speed A properly operating system needs wind speeds of at least 3m s about 7mph 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 us by phone or email A amp C Green Energy 1108 Summit Ave Ste 8 Plano TX 75074 866 WNDPWRD techsupport acgreenenergy com e Images and pho
6. these aspects you can power it up When the FS200 is running the present wind speed is displayed on the nixie tube while the present wind direction is displayed on the LCD screen Confidential 25 CMS Magnetics 2007 2008 PH3000 Operation Bia Wind speed fly Wind direction SPSL Adjustment Far in A Cursor BE Wind speed Filey Winddirecton R5232 Note Illumination the four direction keys dre FGM dL of the cursor press gt ltd enter lt the menu option press to return to the up menu press to increase decrease the parameter Confidential 26 CMS Magnetics 2007 2008 MENU Picture 18 Picture 18 System time setting Pic19 Picture 19 4 4 t to change the system time to exit the set of system time then auto update the system time then auto update the system time Record interval Picture 20 Picture 20 Confidential 27 CMS Magnetics 2007 2008 It is used to set interval of the history data 1 min 60 min adjustable Suppose that it is set 2 minutes and then the time of PH3000 can record is 8000 30 min 24 hours 11 days Alarm set Picture 21 Picture 1 When wind speed exceeds the upper limit relay is closed and an alarm will sound This function is optional Local address Picture 22 It is used when communicating with the computer and corresponds to the weather station ID of the computer softwa
7. 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 4 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 the supporting stand after assembly 3 Insert the generator cables into the tower and pull the cables out of the main section of the tower 4 Position the generator on the top of the tower and bolt the running flange and tower flange together Make sure the hub faces upward in order to install blades 5 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
8. atteries voltage when the system is under a normal state of generating power The system has an automatic alarm when over voltage or under voltage When over voltage a shutdown order will be transmitted The over voltage alarm is set on 300V alarm voltage cancellation 280V and under voltage alarm 210V when it leaves the factory 5 The function of the anemoscope is to check the real time wind speed This is indicated by working or non working Under working state the system will automatically face the wind and generate electricity There are non wind and over wind in the non working state When in the non wind state the system moves into sleeping state Inthe over wind state the system will immediately send out a furling order and then will go into the shutdown mode Confidential 18 CMS Magnetics 2007 2008 Following table indicates the factory settings 3000W 5000W 10KW 20KW Furl 30 degree Furl 60 degree Furl 90 degree shutdown 20m s Table 5 Note anemoscope should be installed on the wind turbine system of 3kw and above 3kw otherwise the system will not operate normally Appendix Three Specification of wind speed monitor FSO1 The function of the wind speed monitor WSM is to indicate the real time wind speed and wind scale sending an alarm when the wind is too weak or too strong The WSM consists of a wind speed sensor FS10 wind speed scope FS100 and connecting wire System
9. by measuring the distance between the blade tips Graph 5 Confidential 7 CMS Magnetics 2007 2008 BLADE S CENTER LIME F CN Firthi y i 5 Ui Y u u FLANGE BOLTS AND NETS Fi Mc i TEZ bcd Graph 5 Make sure L 1212213 Tolerance 5mm Notes Please use torque wrench to tight up the blades Set the torque based on the followings tables E o o i Mud o 15NM 15NM 30NM 30NM 30NM 50NM 50NM 50NM 50NM 1 1 1 Disclaimer Please follow the above table for 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 except 300W system The 300W system has three blade bolts so tight them up one by one Confidential g CMS Magnetics 2007 2008 a dq 1 Mj j T a Mi j l Le Wt A Le Wy 3 H UL J 3 H LU j 1 U H WW cw Graph 6 7 Install the nose cone 8 For the 3kw and above systems connect the aviation plug on the generator to the socket of the anemometer and then install the anemometer onto the generator Step 5 Preparation before erecting the tower For 3kw and above 3kv wind turbine 1 Attach the guy wire onto the tower The two side guy wires should be directly connected to side anchor through the turn buckle The back guy wire should be co
10. e figure to be set 8 Shift key press this key to switch among different figures combined with figure key you can set the requisite Wmin Wmax and return difference Confidential 21 CMS Magnetics 2007 2008 2 parameter Setting a Press the function key to enter into the setting menu of Wmin and Wmax as shown in the diagram 13 Unit m s the cursor on the second figure 2 press shift key modify the figure press the figure key to modify the figure b When the above procedures have been done press the function key again once and you will enter into settings menu of Wmin and Wmax as shown in the diagram 14 Navigating the settings menu is the same c After having all the figures set press the function key once again the LCD screen will display the menu parameter has been set Over Speed 25 0 Over Speed 20 0 Under Speed 03 0 UnderSpeed 05 0 diagram 18 diagram 19 Diagram 13 Diagram 14 3 Alarming amp relevant display 1 Over wind speed alarm wind speed W gt Wmax e g diagram 15 background light is on alarming meanwhile over wind speed indicator light is on When under the state of W lt Wmax the alarming will be unchanged Wmax return difference of over wind speed Wmax Wmax should be set Confidential 22 CMS Magnetics 2007 2008 Wind Speed Hight 16 5m s 7 level Diagram 15 Note wind speed High means the wind speed is too high 16 5m s means wind speed is 16 5
11. en batteries and inverter and make sure there is no open wire shorts e Why the batteries cannot be charged 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 Checkifthe generator output is short circuited The generator won t rotate when the generator is short circuited Be sure to disconnect the batteries from the charge controller when you perform this checking e How to lay down the generator For 3kw amp above 3kw 1 Stop the generator Change control manner to manual and then hold on the REVERSE or TURN to make the generator turn a 90 degree to the wind direction 2 After the blades stop rotating disconnect the three generator leads 3 Hold down the REVERSE or TURN to make the generator s tail face the direction of the ground 4 Do the reverse steps of installation to lay down the generator For 2kw amp below 2kw 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 Confidential 15
12. m s 7 level means wind scale is 7 2 Under wind speed alarm wind speed W lt Wmin e g diagram 16 background light is on alarming meanwhile under wind speed indicator light is on When under the state of W gt Wmin the alarming will be unchanged W min return difference of under wind speed Wmin gt Wmin should be set If under wind speed alarming is not needed please set W min and Wmin on zero Wind Speed Low 02 2m s 2 level Diagram 16 Note wind speed Low means the wind speed is too low 02 2m s means wind speed is 02 2m s llevel means wind scale is 1 3 Press any key and the alarming sound will be unchanged But the indicator light is still on The background light will be on again when alarming Confidential 23 CMS Magnetics 2007 2008 Appendix Four Specification of Analyzing System for Wind speed Gathering FSO2 The system of measuring wind consists of wind speed sensor FS10 dogvane FS20 data collector FS200 and matched cable Usually data collector FS200 can display the information of wind speed wind direction and set the parameter Meanwhile the following will show the procedure of connecting the wind measuring system and computer FS200 is served as measuring and recording wind speed and wind direction ready for use It has a capacity of cycle record of 8000 history record Targeted design nixie tube an LCD screen and keyboard make operation of FS200 easy and co
13. nection of the Charger Controller There are 3 leads coming from the wind generator and they are to be connected to the charge controller The connectors to be connected should be marked as wind generator inputs For the 500 W and 1KW change controllers there are 4 input connectors 3 red and one black Please connect to the red connectors only Do not connect to the black connector 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 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 Confidential 12 CMS Magnetics 2007 2008 dece of single battery V Capacity of single battery AH 100 200 200 200 iso 100 200 400 s00 IQuntiyinsres 2 2 2 4 10 20 20 20 30 Table 3 mE M 5 Charge Voltages for batteries as shown in table 4 Battern Float charge voltage V Overvoltage V Table 4 Electric Wiring 1 Off grid electric
14. ng 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 Check 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 If 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 Confidential 14 CMS Magnetics 2007 2008 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 betwe
15. nnected to the back anchor Make sure all the guy wires are not tangled N The Jin pole is shipped in two segments Connect the two segments to make one pole UO Attach the two thinner wires onto the two ears of the Jin pole and then attach the front guy wire to the front ear on the tower and fix it onto the upper pulley 4 Insert the Jin pole into the tower Attach the two side wires onto the two side anchors and tighten them 5 Attach the lower pulley to the front anchor Attach one end of the longest thinner wire on the pulley of the Jin pole Make sure the other side passes through the lower pulley and then go through the upper pulley Finally attach it onto a hoist or tractor graph 7 Confidential 9 CMS Magnetics 2007 2008 Graph 7 For 2KW and smaller systems 1 Connect one end of the 16 meter wire to the winch or tractor 2 Passthe 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 6 Erecting the tower 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
16. nvenient It can also communicate with the computer to record the wind speed and wind direction data which will be observed and analyzed by FS200 Feature 1 Running mode of low power consumption FS200 will automatically turn off the nixie tube and the LCD screen so it can run in low power consumption mode 2 The wind cup of the dogvane sensor is made of carbon fiber which enhances strength and contributes to the longevity of the eguipment Technical index Measuring range Wind speed 07 60m s Wind direction 07 360 Accuracy t0 3m s 3 Power supply AC 220V420 SOHZ DC12V 5V are for choice Recording interval Imin to 60mins Communicating joint RS 232 Operating environment temperature 40 C 50 C Confidential 24 CMS Magnetics 2007 2008 Installation amp Connection 1 Wind speed Sensor installation Install the wind speed sensor on the supporting frame If there is wind available the three cups of wind speed sensor will run 2 Connection of FS200 and wind speed sensor Insert the aviation plug of the wind speed sensor s signal line into the aviation socket of FS200 3 Connecting FS200 to power supply 12V power supply is applied to FS200 Connect FS200 to 12V power supply Special attention is paid to the anode and cathode and do not reverse them Check the wind speed sensor the connection between wind speed sensor and the correct connection of the FS200 power supply If there is no problem concerning
17. owners are encouraged to use their local wind resources to learn more about using these monitors Front of wind speed scope Picture 9 Picture 9 Confidential 19 CMS Magnetics 2007 2008 Back of wind speed scope amp wire connecting way Picture 10 L p AZ J sS AL m LU i ul k ji a LN Jam L Picture 10 Wind speed sensor FS10 Picture 11 Picture 11 Confidential 20 CMS Magnetics 2007 2008 Structural features Picture 12 Wind Speed 08 4m s 5 leve Diagram 12 1 Specification of each part 1 Anemoscope board 2 Liquid crystal turn on the background light is on It will shut down automatically after 5 second if there is no operation Wind speed figure is displayed such as 8 4m s and wind scale such as 5 3 Operation indicating light The green light is on if it is under normal operation 4 Under wind speed Wmax indicating light When the wind speed is under W lt Wmin state there will be alarming Press any key will make the alarming sound nonexistent 5 Over wind speed Wmax indicating light When the wind speed is under W2Wmax state there will be an alarm indication Pressing any key will make the silence the alarm 6 Function key after pressing this key you will enter into the menu to set the parameters 7 Figure key While in the parameters menu press this key to advance the cursor one space pressing this key continuously will allow the requisit
18. re After correct set up the PH3000 will work persistently FS200 and Computer Connection Connect the RS232 serial of the FS200 to the RS200 serial of the computer and have the FS2000 computer software run The PH computer software reads the present wind direction monitored by the dogvane This history data can be saved to a Microsoft ASSEDD database and can be analyzed through either a table or curve view The computer software can also set the parameters of the real time clock and history data recording interval of the dogvane Operation of software FS200 diagram 23 Confidential 28 CMS Magnetics 2007 2008 4m FS200 RUE FUR Om s BUR OER FEE YE HUMA DY eas e EE _ i m amd ue sla sla iu gt m u x mi 2m s s io n o e B u zu ims ewm ex sj miRCm5 AMC 20083240 IO Diagram 23 Choosing weather station The system default is weather station 10 which is consistent with the address of the wind speed dogvane Open serial Choose the serial and set the communication baud rate on 9600bps and then open the serial port Read the setting data Click the download button to get the current wind speed and wind direction data Or click update the settings data automatically to choose the time interval for automatic updating The software can automatically gather wind speed and direction at a programmed interval
19. tances 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 Iong wide deep 3000W 5000W 10KW 20KW Semi diameter m ao eo _ eo so Size of central base m long wide deep 0 8 0 8 0 8 1 0 1 0 1 0 Size of side base m long wide deep 0 6 0 6 0 6 1 0 1 0 1 0 Table 1ext Confidential 4 CMS Magnetics 2007 2008 Rea 2 2 o Figure 1 layeut af concrete base opecial 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 soil 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 otep 2 Preparing the Concrete Bases for the Tower and the Anchors 1 Dig the holes to follow the pattern as shown in Fig 1
20. tographs may vary e This manual may be modified without notice e Turbine warranty is 2 years e Controller and inverter warranties are one year from the date of delivery Confidential 16 CMS Magnetics 2007 2008 Annex 1 Off grid electric wiring AMOS AMOT HNG ANE Satie PI Be ee 3 Or proz lae mu IB ISA LI TAI l a set yueudrnDg adcozousuy 102112 N 5 5B Xp Ew He sew ANZ AMT MOOS Mode MDOE zalla ey SaT13 eg HH 19 12 AIT AS YTS JT amg y pilas asna y Uo AS TUN H i r prawd mg roye1eus4 IO B18 4 EIS DEE Ui WPX EW 17 Confidential CMS Magnetics 2007 2008 Appendix Two Controller Specification 3kw amp above 3kw 1 Upon system startup the controlling board will indicate auto and turn on When the wind speed reaches at least 2 m s under this state the wind turbine will automatically track the wind direction If the batteries are full or the wind speed is too strong the turbine will furl automatically until shutdown 2 The system can also be manually adjusted for wind direction using forward or reverse When the wind speed is strong or the batteries are charged fully the turbine will not shut down automatically 3 When the operation of wind turbine is not needed press the shutdown button or simply turn off the system The turbine will automatically face the wind and achieve shutdown 4 The system will continuously check the b
21. wiring annex 1 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 For 3kw Systems and Above a There are two cables extending from the generator head One cable has an aviation plug and is the anemometer signal cable The aviation plug should plug into the socket The other cable has 5 leads 3 thick leads are for power and the 2 thin leads are for controlling signal one positive and one negative These cables should be connected to the back panel of the charge controller accordingly b The anemometer should be installed on top of the generator and vertical to the ground One end of the anemometer cable should be inserted into the socket under the anemometer and the other end inserted into the socket accordingly c Please refer to appendix 2 for controller specification Confidential 13 CMS Magnetics 2007 2008 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 Maintenance The wind generators may operate under harsh environments and extreme weather situations Regular inspection and maintenance are necessary to keep the system operati
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