User Manual
Contents
1. 2 2 Identification and Markings The turbine generator body carries a stamped unique serial number and a rating plate Both the stamped serial number and rating plate are visible on the bottom yaw shaft housing If this e300 does not carry this stamp it does not carry a Kestrel warranty and may not be authentic kestrel wind turbines PRODUCT RATING LABEL TYPE 0503 SWT Class No 0612044 048 Eveready Diversified Products Pty Ltd I PO S St el Morth End CE SOU C OX ruandale North En A Port Elizabeth 6056 RSA Sr ESO Kesfrel wind turbines Evgeny Uversified Products Pty Ltd See provo Qf SOUTH AFRICAN NN 2 3 Applications and Uses The e300 is suitable for electrical power generation on various installations that include battery charging water delivery and grid tie applications Each application requires specific additional electrical equipment Consult the manuals supplied with this equipment 2 4 Charge Controllers and Inverters Any wind turbine produces uncontrolled power that varies with incident wind speed The open circuit generator voltage is directly proportional to generator speed rpm Some form of regulator must control this raw power A battery charging regulator is often referred to as a charge controller A charge controller is required for the Kestrel to charge a battery Kestrel can supply a standard charge controller for the e300 A suitable diversion resistor is availa2. 3 2 Tools Required The following hand tools are required for turbine assembly and installation 10mm metric ring spanner or socket wrench two required 13mm metric ring spanner or socket wrench 19mm metric ring spanner or socket wrench two required Small size electrical screwdriver Medium size electrical screwdriver 10mm Allen key wrench Wire strippers for electrical connections Tape measure to adjust the blades Torque wrench E kestrel wind turbines Eveready Uversified Products Pty Ltd See PROUDLY Va SOUTH AFRICAN NN 3 3 Unpacking Open the packaging container and check for any transit damage The parts contained are listed in section 3 1 and on the included packing slip Lay out the parts and identify them with the assembly drawing provided had Qty Description Nose Cone 30924 CIEN EGE EH EH EH DRC DOES E fen ron pem HEI OTE Ez CN cc E T E CO EA preesse E DECS E DCE E ef ue prem um mm perennes som EJEM rete um em ren ro mr omens so preme E DRM ES CO EE ema pee DEC ES em EII com on 7 peer ees pm com Kestrel wind turbines Evgeny Uversified Products Pty Ltd aln NEN or mor Of SOUTH AFRICAN N 4 Technical Requirements for Assembly Torque Settings DESCRIPTION BOLT TYPE TORQUE Metric TORQUE imperial NOSE CONE SCREWS M6 x 16 S S 5Nm 3 7 ft lb FRONT BOLT 12 9 HI TENSIL LOCTITE MIO X 3
3. NOTES Eveready Diversified Products Pty Ltd mou Of SOUTH AFRICAN N NOTES continued 24 Eveready Diversified Products Pty Ltd MI 11 CUSTOMER PEE ES Kestrel wind turbines a Customer enquiry and feedback sheet Customer Name Postal Address Turbine Number Phone Number E Mail Address Fax Number Complete the form and submit to Kestrel Wind Turbines Your feedback and queries are valuable to us Indicate your enquiry or feedback in the space provided below Date Replied Signature Comments Eveready Oiversified Products Pty Ltd
4. and suggestions may be adapted to suit local conditions Wind speed increases with height above the ground An installation site should be chosen which is free of obstructions like buildings trees mounds and hills A pure airflow is paramount for good performance Naturally some compromise can be reached but there should be a clear entry for the prevailing wind direction of the location The absolute minimum height of the structure should be 9m when placed clear of obstructions The general rule is that the e300 should be 8m 25 higher than any obstruction within a 150m 500 radius of the tower Otherwise mount the e300 as high as possible All obstructions add to possible turbulence which will cause undue stress on the unit and reduced performance Wind speed increases with height above the ground The power in the wind is a cubic function of wind speed Doubling the wind speed increases the power by eight times 4 1 Flange Mounting Detail The e300 is mounted using eight M8 Hi Tensile bolts and spring washers fitted through the bottom flange on the weather cocking swivel assembly TOP FLANGE MATERIAL M S 8 UFF TAPPED M8 UN 60 PCD 4 2 Roof Mounting Roof mounting is possible but the turbine performance may suffer as a result of wind shift and turbulence Roof mounting structures are beyond the scope of this document and must comply with the relevant structural standards that are in force 4 3 Towers Towers are re
5. further subject to the Customer returning the defective Turbine at its cost to the premises of Eveready within the warranty period and furnishing full details in writing of the alleged defect di Eveready s obligations under this warranty shall be limited to the repair or replacement of defective Turbines at its cost or to a refund to the Customer of the original cost thereof as Eveready may determine in its discretion Eveready shall not be responsible for any damages suffered by the Customer pursuant to any defects covered by this warranty 4 This warranty shall not apply to any damage to Turbines caused by winds exceeding 160 kilometres per hour or any other factors beyond the control of Eveready di The Customer may purchase an extended warranty from Eveready in respect of Turbines subject to Eveready s standard conditions 21 kesfrel wind turbines Evgeny Uversified Producta Pty Ltd aln NEN or mou Qf SOUTH AFRICAN NN _ __r___ocs k ee Kestrel Wind Turbines P O Box 3191 Eveready Diversified Products Pty Ltd North End Eveready Road Port Elizabeth Struandale 6056 North End Eastern Cape Port Elizabeth Republic of South Africa South Africa Tel 27 0 41 401 2500 Email kestrelwind eveready co za Registration Number 2006 005438 07 VAT Registration Number 4870231406 Web www kestrelwind co za 22 wind turbines Evgeny Uversified Producta Pty Ltd aln NEN or mou Of SOUTH AFRICAN N
6. secured with Locktite Eveready Divergifiod Products Pty Ltd row Y SOUTH AFRICAN NN 3 9 Blade Assembly e300 IMPORTANT The wheels of a car are balanced to allow smooth operation In the same way the propeller rotor must be assembled such that it is balanced Rotor imbalance will cause vibration unstable operation of the turbine and eventual damage Please follow the steps given below to assemble a balanced rotor GENERAL NOTE The blades are fitted on the front of the pitch control hub Refer to the assembly drawing and fit all three blades on to the hub as shown Each blade carries a serial number and a balance mark on the front face of the blade Be sure to fit the blades the correct way round The blade root is marked FRONT below the serial number on each The rotation is clockwise viewed at the front of the turbine Each blade mount has two bolt holes Fit the bolts with the washers provided and through the blade compression plate with the Nylock nuts behind the pitch control o The blades are factory balanced Note that exact balancing r requires that the three blade tips be equally spaced when fitted Please follow the instructions given below a Support the generator 02 such that the blades can be fitted to the pitch hub 03 b Fit two blade bolts 11 through a blade compression plate 09 such that they face toward the generator Now fit the first blade 08 on to the bolts and offer the blad
7. 5 E kestrel wind turbines Evuresady Onversified Products Pty Ltd dE OMM PROUDLY v SOUTH AFRICAN NN Disclaimer Kestrel Wind Turbines makes every effort to give accurate information in this manual and is in no way liable for any error or omission The user of this manual assumes full responsibility and risk We appeal to your common sense to read and apply the safety notes Consult professional engineers and take advice if you are unsure 1 SAFETY FIRST Although Kestrel s wind turbines are designed with your safety in mind accidents can easily occur and there are always inherent dangers associated with any type of machine Consult installation professionals if you lack experience or confidence 1 1 Mechanical Safety Use good handling methods and take precautions to avoid physical injury during installation and maintenance repair procedures The rotating blades of any wind turbine are a main hazard The e300i blades are extremely tough and will cause serious injury to the body Never install the e300 such that any person or animal could come into accidental contact with any part of the machine Never approach the machine if the blades are rotating 1 2 Electrical Safety The e300 output voltage can become dangerous and even lethal when running on open circuit Maintain a healthy respect for this wind turbine Always short the output wires together when the e300 is disconnected Do not work on the system when the turbine is
8. 5 60Nm 44 3 ft lb BLADE BOLT M12 x 80 S S WITH M12 NYLOCK NUT 35Nm 25 8 ft lb M8 NYLOCKS 25Nm 18 4 ft lb NACELLE SCREWS M6 x 16 S S 3Nm 2 2 ft lb M5 x 15 S S 3Nm 2 2 ft lb TAIL BOLTS M6 x 60 S S WITH M6 NYLOCK NUT 10Nm 7 4 ft lb MOUNTING BOLTS M8 x 25 8 8 HI TENSIL PLATED 35Nm 25 8 rb TAIL BOOM M8 BOLTS S S 30Nm 22 1 ftIb 3 5 Generator Assembly The alternator 01 is factory assembled 3 6 Pitch control Assembly The pitch control boss 03 is factory assembled Eve Kestrel wind turbines Eveready Diversified Products Pty Ltd n NM row Y SOUTH AFRICAN 3 7 Tail Assembly if not factory assembled Offer the tail boom 05 to the rear of the generator and align the three inner fixing holes with the inner studs Fasten the boom to the rear of the generator with the three M8 Nylock nuts 18 Now fit the four lower bolts 20 washers 19 and nuts 18 on to the generator sides by means of the side bars Level the boom with the generator secure the bolts through the rubber bushes so that the boom is held in place and tighten all fastenings to the required torque setting see 3 4 Pg 7 Slide the nacelle cover 0730 along the boom so that it is covering the generator Secure the nacelle cover to the rear of the generator with the two M6 screws to the required torque setting see 3 4 Pg 7 Slide the front closing plate between the underside of the generator and the nacelle cov
9. REU kestrel wind turbines PUTTI Registration Number 2006 005438 07 VAT Registration Number 4870231406 Tel 27 0 41 401 2500 Website www kestrelwind co za User Manual Revision 1 3 03 08 Revision 1 2 12 07 Revision 1 1 08 07 Revision 1 0 06 07 provo Qf SOUTH AFRICAN NN CONTENTS 1 Safety Considerations 1 1 Mechanical Safety 3 1 2 Electrical Safety 3 1 3 Installation Hazards 3 1 4 Operational Safety 3 2 Wind Turbine Overview 2 1 Turbine Description 4 2 2 Identification and Markings 4 2 3 Applications and uses 2 4 Charge Controllers and Inverters 2 5 Grid Tied Applications 2 6 Voltage Limiter 5 3 Unpacking and Turbine Assembly 3 1 Components Supplied 6 3 2 Tools Required 6 3 3 Unpacking 7 3 4 Technical Requirements for Assembly 8 3 5 Generator Assembly 8 3 6 Pitch control Assembly 8 3 7 Tail Assembly 9 3 8 Fitting the Pitch Control 10 3 9 Blade Assembly 11 4 Site Considerations and Mountings 4 1 Mounting Flange Detail 12 4 2 Roof Mounting 12 4 3 Towers 12 5 Wiring and Cable Sizing 5 1 Turbine Wiring 13 5 2 Lightning Protection 13 5 3 Wire and Cable Sizes 14 6 Battery Considerations 6 1 Lead Acid Batteries 15 6 2 Sealed Gel Batteries 15 6 3 Ni Cad Batteries 15 6 4 Temperature Compensation 15 7 Technical Details 7 1 Technical Specification 16 7 2 Declaration of Conformity 17 8 Trouble shooting 18 9 Maintenance 19 10 Warranty Conditions 21 11 Customer Feedback 2
10. al for a failed pitch control For normal operation thrust at 40ms is lt 1000N Speed Control Protection Eveready Uversified Producta Pty Ltd Passive pitch IP55 16 mou Qf SOUTH AFRICAN NN 7 2 DECLARATION OF CONFORMITY Declaration of Conformity Eveready Diversified Products Pty Ltd T A Kestrel Wind Turbines m South Africa declare under our sole responsibility that the product est 0 L Wind Turbine To which this declaration relates 15 m conformity with the following standards IEC 60033 Rotating Electrical Machines IEC 0204 safety of Machinery IEC 60033 IEC Standard Voltages IEC 60529 Degrees of Protection of Enclosures IRC 61000 Electromagnetic Compatibilit and follows the provisions m the directives IEC 14U0 2 Small wand Turbines Date 25 April 2007 Place Port Elizabeth South A Tra T uf Authonsimg Signature A dut US L James Carpy Technical Director Eestrel Wind Turbines PO Box 319 North End Port Elizabeth BU 6 Republic of South Africa Evgeny Uversified Products Pty Ltd provo Qf SOUTH AFRICAN NN 8 TROUBLE SHOOTING REST ASSURED THAT THE KESTREL WILL BE SERIOUSLY DAMAGED FROM POLARITY REVERSAL OVERCHARGING OF THE BATTERY CAN OCCUR WITH NO FITTED CHARGE CONTROLLER IT IS UNWISE TO DISCONTINUE CHARGING BY DISCONNECTING THE e300 FROM THE BATTERY THE TURBINE THEN HAS NO LOAD WHATSOEVER AND CAN REACH VERY HIGH ROTATIONAL SPEEDS Uncontrolle
11. ble from Kestrel An inverter can be connected to the battery and is used to convert the battery dc power to ac power An inverter therefore allows the use of standard electrical equipment that works on ac voltage 2 5 Grid Tied Inverter Applications The 200Vdc version of the e300 is suitable for connection to an approved Grid Tie Inverter Grid Tied installation is subject to local electrical codes of practice and is usually carried out by qualified personnel Prior approval from the local utility company must be obtained before connection to the mains 2 6 Voltage Limiter Grid tied applications require a Voltage Limiter to be connected between the e300 200Vdc version and the Grid Tie Inverter Certain operating modes of the inverter allow the Kestrel output voltage to rise beyond the limit of the inverter The Kestrel Voltage Limiter will restrict the rise in voltage as the inverter performs various functions Refer to the manual provided with the Kestrel Voltage Limiter EVEREAIN kestrel wind turbines Eveready Diversified Products Pty Ltd See 3 UNPACKING AND TURBINE ASSEMBLY 3 1 Components Supplied The following components are supplied Pitch hub assembly Shaft drive key Propeller blade set Generator assembly Tail boom two pieces Tail two pieces Tail Stabiliser two pieces Nacelle cover Nosecone All fasteners and bolts Assembly grease LLLI L EL EL LL CI CI L1 L3 L Locktite
12. d output voltage can reach LETHAL values IF THE e300 IS DISCONNECTED FOR ANY REASON SHORT THE GENERATOR OUTPUT WIRES THIS WILL LOAD THE GENERATOR AND MINIMISE ROTATION DO NOT ALLOW THE e300 TO OPERATE WITH DAMAGED BLADES OR TAIL DAMAGE TO THE BLADES WILL CAUSE VIBRATION THAT CAN INCREASE TO DESTRUCTIVE LEVELS DO NOT ALLOW THE e300 TO OPERATE WITH ANY SIGN OF UNBALANCE ANY REPETITIVE SWINGING OF THE TAIL INDICATES THAT THE MACHINE IS UNBALANCED Q There is wind but the e300 does not rotate or only rotates very slowly A The e300 output is shorted There is an electrical short elsewhere in the system The blades are fitted the wrong way round The e300 is restricted from swinging 360 degrees into the wind The charge controller is defective Other connected equipment is defective Disconnect the e300 from the equipment and check that the blades rotate easily There is a short within the turbine generator In very light wind the e300 may well not rotate This is quite normal as there is no useful power in such a light wind and bearing life is greatly extended On older machines check the generator bearings Q The e300 is rocking from one side to the other at low speed but appears to run smoothly at higher speeds A The blade rotor assembly is unbalanced Remove the rotor and check for damaged blades Rebalance the rotor if possible or fit a new blade set Q The e300 is vibrating or noisy A Check all fasteners on the u
13. e from the front to one blade mount Fit the two Nylock nuts 13 on to the blade bolts from the rear Do not tighten the nuts c Repeat b such that all three blades are sandwiched between the three compression plates 09 and the three blade mounts on the pitch control hub Now gently tighten all six blade bolts such that each blade can still move sideways d Using a tape measure accurately measure the distance between each of the three blade tips Move each blade sideways until all three blade tips have the same measured distance between them e Now tighten all the blade bolts to the required torque setting see 3 4 Pg 7 Do not over tighten the bolts such that any blade is damaged or crushed f Check the assembly for correctness Check the blades are fitted correctly the bolts are all tightened and that the rotor spins freely and evenly on the generator Check the distance between the three blade tips or balance marks to be equal g Now fit the nose cone 10 over the three spokes and fit the three washers 17 Eveready Oiversified Producta Pty Ltd mou Gf SOUTH AFRICAN NN 4 SITE CONSIDERATIONS AND MOUNTING The turbine is supplied with a weld on mounting flange for adaptation Custom structures must incorporate a 76mm 3 100mm 4 diameter pipe for machine mounting Larger pipes may interfere with the blades when pitch control operates There are infinite variations on sites and the information
14. er and secure with the four M5 screws to the required torque setting see 3 4 Pg 7 through the holes provided Fasten the tail 07 upper and lower halves to the boom with the ten stainless bolts 23 stainless flat washers 24 and with the ten stainless Nylock nuts 23 provided Now fit the tail stabilisers two on each side of the tail using the one longer stabiliser bolts 27 through the tail boom and the middle of each stabiliser on either side The other two stabiliser bolts 26 are fitted through the tail with the washers 28 and nuts 29 at each end of each stabiliser Do not over tighten such that the tail boom is crushed or distorted Always adhere to the torque settings provided Check once again that all bolts are fitted and tightened to torque settings 3 4 9 Eveready Diversifiod Products Pty Ltd onir O 3 8 Fitting the Pitch Control The generator is a complete unit The shaft drive key is factory fitted to the generator shaft with a cable tie Remove cable tie before fitting pitch control Smear waterproof grease 30 over the shaft and insert a little inside the front of the generator where the shaft projects out Offer the pitch control hub to the shaft and slide it onto the shaft Using a hexagon key fit the front shaft bolt 15 and washer 14 to the spring locking washer provided into the generator shaft and tighten the assembly It is important that the bolt is
15. ive Consult your battery supplier for details 6 4 Temperature Compensation Much has been documented on this subject and there are certain merits Generally lower and higher ambient temperatures allow higher and lower charging voltages respectively K1000 regulators do not have this facility Batteries should be sited in a cool area and temperature compensation is only useful in extreme temperature variations 15 kesfrel wind turbines Evgeny Oversified Products Pty Ltd ae 7 TECHNICAL SPECIFICATIONS 7 1 TECHNICAL SPECIFICATIONS mou Qf SOUTH AFRICAN NN Maximum Power Rated power at 11m s 200Vdc Rated power at 11m s 48Vdc Rated power at 11m s 24Vdc Rated power at 11m s 12Vdc Annual energy capture at 5m s average 200Vdc Annual energy capture at 5m s average 48Vdc Annual energy capture at 5m s average 24Vdc Annual energy capture at 5m s average 12Vdc Rated sound level Cut in wind speed Cut out wind speed Maximum voltage 200Vdc Maximum voltage 48Vdc Maximum voltage 24Vdc Maximum voltage 12Vdc Output power form Rotor swept area No of blades Tower top mass Lateral Thrust at 12ms 27mph and 40ms 90mph 1150W 1000W 1000W 900W 850W 2160kWh 2060kWh 1940kWh 1790kWh For average wind speed of 5ms and 12m tower at sea level lt 50dB 2 5ms N A 1000V dc 250Vdc 150Vdc 70Vdc Two wire DC 7 07 sqm 3 75kg 800N and 8600N NOTE Lateral Thrust at 40ms is theoretic
16. nit in particular the blade assembly Vibration or noise can only be caused by the imbalance of damaged blades Check for bearing wear on older machines Q Can the e300 be left running and disconnected A Theoretically yes but high voltages may be produced Always short the output wires when the e300 is disconnected from the regulator Q What should be done in storm conditions A Never approach the e300 during strong wind conditions The e300 has been tested up to winds of 160km h and is designed to survive such conditions It is acceptable to lower the turbine for predicted extreme weather conditions simply for peace of mind 18 Evuready Diversified Praducts Pty Ltd D E provo Of SOUTH AFRICAN 9 MAINTENANCE The e300 is designed for continuous operation on 100 duty cycle and requires no regular part replacement NEVER APPROACH A ROTATING TURBINE The e300 is designed to operate with minimum maintenance The frequency of visual inspections and integrity checks depends on the wind class of the installation site Wind Power Class definition for wind power density and average wind speed at a hub height of 10m is given below In general higher class wind sites require more frequent installation checks WARNING Pitch Control The pitch control mechanism is a factory assembly and is not user serviceable Specialist tools and knowledge is required to carry out any maintenance or repair procedures Do not make any unauth
17. or yaw shaft and pitch control years Every 8 10 years SO Other Auxiliary Inspections Inspections should also be done with regard to all other site equipment Specific procedures are contained within the relevant user manuals The following list illustrates typical topics a Inspection of the tower including all bolts fasteners ground anchors and guy wires b Inspection of the e300 tower securing bolts c Check all electrical connections for tightness and corrosion d Functionality and general checks on all other electrical equipment Maintenance Tips The pitch control hub should be checked in the following way Visually inspect the unit Check for any stress cracks broken or cracked springs and or corrosion Use gentle pressure to twist the blade in both directions There should be virtually no movement or slackness Push and pull the blade along its length There should be no movement of the blade If any wear or defect is detected consult your dealer or the Kestrel factory Do not under any circumstances strip the assembly down without the required knowledge The generator produces a slight humming sound This is quite normal Any other grinding clicking or scraping noises are abnormal and must be investigated Good rotor balance is very important for long and reliable operation The wind turbine must not be allowed to continue in operation if any unbalance is observed The most common symptom of imbalance is observed when
18. orized adjustments or modifications to any part of this assembly Do not force or twist the blades other than gently when checking for wear Wind Power Wind Power Density Wind Speed Wind Speed Class W sq m m IE mph Imperial Up to 100 Up to 4 4 Up to 9 8 100 150 4 4 5 1 9 8 11 4 150 200 5 1 5 6 11 4 12 5 200 250 5 6 6 0 12 5 13 4 250 300 6 0 6 4 13 4 14 3 300 400 6 4 7 0 14 3 15 7 Above 400 Above 7 0 Above 15 7 NOTE PRODUCT SPECIFICATIONS MAY CHANGE DUE TO CONTINUOUS DEVELOPMENT CONSULT THE FACTORY OR AN APPOINTED DEALER Eveready Diversifiod Products Pty Ltd mou Of SOUTH AFRICAN The following schedule is designed to avoid machine failure Component life will be reduced on sites that exhibit high turbulence Wind Power Class 1 2 3 4 5 6 7 First post installation visual check All sites 1 month after installation After extreme After extreme Visual Inspection listen for abnormal noise and weather and every weather and vibrations 3 months every 2 months Close inspection check for any loose bolts blade Six monthly intervals damage Check the integrity of the pitch control see 12 monthly intervals tips below Touch up paint Dismount the machine and check for transfer brush wear Check for wear on pitch control parts Replace as Every 5 years Every 3 years required Treat any corrosion and touch up paint Dismount the machine and replace all bearings generat
19. own before approaching This may be achieved by shorting the generator output Preventative maintenance is always the best Checks are best carried out in calm weather conditions Avoid any maintenance or 3 inspection during windy weather Evermacy Uversified Products Pty Ltd row Y SOUTH AFRICAN NN 2 WIND TURBINE OVERVIEW 2 1 Turbine Description The e300 is a unique wind turbine that incorporates superior technology The heart of the machine comprises of a unique twin axial flux permanent magnet brushless alternator The alternator contains no less than 96 poles and 52 magnets The polyphase high frequency output is internally rectified to give a dc output with extremely low ripple content The generated power is transferred to the output cables via heavy duty bronze slip rings and twin copper composite electrical brushes The prime mover on the e300 is a 3 0m 9 85 diameter three blade wind rotor fitted with quiet running high efficiency blades The blade hub incorporates passive pitch control The e300 pitch control changes the operating angle of the blades to achieve speed control in high wind The tail vane assembly is static and simply aligns the machine with the prevailing wind All steel components are electro galvanised and passivated for extra protection The standard finish consists of the application of an etching marine primer and an intermediate protective coat followed by polyurethane two pack finishing coats
20. p of your structure i e the e300 to the regulator Select the wire size for that distance from the table The double run of ve and ve is already accounted for The power cable should be run down the inside of the pole or structure and then buried in a suitable underground conduit at least 500mm below the ground surface Wire Size for 12V e300 65A maximum current 50sq mm 0 85sq mm 000 Wire Size for 24V e300 35A maximum current 10m 337 20m 66 30m 96 40m 130 50m 165 16sq mm 5 35sq mm 2 40sq mm 1 70 sq mm 00 85 sq mm 000 Wire Size for 48V e300 19A maximum current 6sq mm 9 10sq mm 7 16sq mm 5 20sq mm 4 25sq mm 3 40sq mm 1 50sq mm 0 Wire Size for 110V e300 12A maximum current Wire Size for 200V e300 6A maximum current 20m 66 40m 130 60m 200 80m 260 100m 330 0 5sq mm 20 1 5sq mm 15 2 5sq mm 14 2 5sq mm 14 4sq mm 11 14 kestrel wind turbines Everegdy OUnersified Products Pty Ltd aln NEN or mou Of SOUTH AFRICAN NN 6 BATTERY CONSIDERATIONS Batteries are available in many shapes sizes and chemistry Battery dealers will be pleased to assist The most common ones are reviewed below In general only Deep cycle batteries and cells should be used and automotive or vehicle batteries will have a short life as they are not designed for cyclic charging and discharging A cell is a single unit of 2V and a batte
21. quired to conform to relevant standards and must be designed to withstand the loading regime of the wind turbine Full details are included with any Kestrel tower kit supplied 12 pren kestrel wind turbines Evuresnady Orversified Products Pty Ltd Oss ss mou Qf SOUTH AFRICAN NN 5 WIRE AND CABLE SIZES 5 1 Turbine Wiring The e300 wind turbine produces dc power and therefore has two double insulated output wires tails The RED wire is POSITIVE and the BLACK wire is NECATIVE Observe the Polarity at all times Only connect VE RED cables to VE RED terminals and VE BLACK cables to VE BLACK terminals Otherwise equipment damage may result and any warranty will be invalidated The following suggestions are made as a guideline If you are in doubt consult an electrician The output wires must be extended as required for the installation Good wire connections are absolutely essential to avoid poor power delivery and high temperatures at the connection All electrical systems lose energy because cables have a resistance The mounting structure must be directly earthed for lightning The power cable is usually brought down the inside of the mounting structure to give some protection Supply cables should never be spanned or suspended from the turbine structure and should be buried at least one half metre deep in a suitable plastic or steel conduit 5 2 Lightning protection Proper grounding is essential to protect the s
22. running or when lightning is possible Disconnecting a running e300 may cause a spark and the presence of explosive hydrogen from battery charging is always a possibility Adequate ventilation must be provided for battery installations The wire size used for connections must be correct for the powers supplied The smaller the wire diameter the higher the wire losses and therefore the heat generated in the wire Use correct wire sizes throughout the installation The amount of energy stored in a battery is considerable and fire can result from shorts Fit a suitable fuse or circuit breaker in the battery cable In general respect the system and use common sense Consult a qualified electrician if you are unsure 1 3 Installation Hazards All installation work should be completed at ground level wherever possible Be very aware of the blades during installation Contact with the blades will only injure you not the blades The installations of poles or towers pose their own dangers Always work carefully and have an assistant wherever possible Short the generator output wires Red and Black throughout any installation procedure Consult a civil engineer or reputable builder if you are not sure about installing structures Always re check the work as you progress Slack bolts poor workmanship and loose electrical connections must be avoided 1 4 Operational Safety The turbine blades are dangerous Respect a rotating turbine Always shut the turbine d
23. ry consists of a number of cells joined in series The usual installation consists of 12V batteries arranged in series or parallel or both Batteries should not be exposed to temperature extremes and good ventilation is required as batteries can emit hydrogen while being charged The stored energy in a battery is given in Ampere Hours Ah or Watt hours Wh The capacity is often based on a 10 hour discharge rate A 100Ah battery will therefore supply a current of 5A for 20hrs or 10A for 10hrs or 20A of current for 5hrs It will not however supply 100A of current for 1hr There is much literature available on this subject It is recommended that the e300 should be charging at least 200Ah of battery capacity for a 12V system 6 1 Lead Acid Batteries These are the most popular choice of battery type and can be vented flooded Water may be added or semi sealed or low maintenance Water cannot be added Charging voltage is typically 13 8 14 0 27 6 28 0Vdc for these batteries 6 2 Sealed Gel Batteries Sealed gel batteries are more expensive but offer clean and safer operation as no acid can be spilled Since they are sealed they must never be boosted and the charging voltage is important Charging voltage is typically 14 0 28 0Vdc Consult your battery supplier 6 3 Ni Cad Batteries This type of battery is traditionally used where large currents must be delivered and where deep cycling is required They are however relatively expens
24. the turbine swings slightly from side to side as it speeds up The swinging action will be worse at a particular rotor speed and may well disappear at higher speeds The rotor blades can suffer chips and erosion mainly on their leading edge Small chips can be repaired with glass fibre filling compound All cracks must be carefully examined Surface cracks can be repaired but any structural cracks must render the blade inoperative If there is any doubt the blade set must be replaced for safety All blade damage can allow water to enter This will cause the blade set to become unbalanced which will cause 20 other mechanical failures and shortened bearing life RE gt EVERENI kestrel wind tu Eveready Diversified Products Pty Ltd SS ee bines NT 10 WARRANTY CONDITIONS WARRANTY AGREEMENT Kestrel s wind turbines are manufactured to the highest standards in accordance with Kestrel Wind Turbines standard and quality specifications and warrants that the wind turbine is in good working order upon delivery and for a period of 24 months Warranty terms and conditions are outlined below Ls Eveready warrants that Turbines will on delivery be free of defects in design material and workmanship and will be fit for their intended purpose for a period of two years calculated from the date of installation subject to proper installation maintenance and use in accordance with the User Manual 2 This warranty is
25. ystem from induced voltages and static Local requirements for electrical installations must be satisfied Ensure that the generator is electrically connected to the mounting structure and that the structure is earthed This is usually done by burying a 2 to 3m 6 10 length of water pipe steel or copper horizontally 1000mm 3 3 below the ground surface A good connection is made between the middle of the pipe and the structure An improved method is to bury a cross of pipe which requires a X shape to be excavated The connection is made in the centre of the cross The negative battery connection should also be grounded using a ground point close to the battery First consult the Charge Controller Manual to avoid earth loops The wire size for grounding should be the same size as the power cables Commercial lightning arrestors are available at electrical stores and can be fitted at the bottom of the structure or pole or at the 13 regulator input E kestrel wind turbines Eveready Uversified Products Pty Ltd See NT 5 3 Wire and Cable Sizes The copper wire sizes given in the tables are calculated for 3 power loss in wire resistance This is usually acceptable in low voltage installations A larger wire size will increase the delivered power but usually a compromise is reached as larger cables cost more It is recommended that the wire sizes given be taken as a minimum value Measure the distance from the to
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