USER MANUAL Gaia-Wind 11 kW Turbine
Contents
1. er A V L Wa S OO e GW UK 18 User Manual 24 of 84 Issue Number 2 Date of Issue 17th Nov 2009 3 2 Nacelle The nacelle of the turbine refers to the housing that contains all of the drive train and machinery necessary for the conversion of the incoming wind to electrical energy The principle components included within the nacelle are the main bearing shaft gearbox brake sensor equipment and the generator All these components are protected underneath the Nacelle cover Figure 3 1 shows schematically the location of these components within the nacelle Ki ji ii SI iii el Cal fi fei Of K GW UK 18 User Manual Issue Number 2 Date of Issue 17th Nov 2009 VODO D Cl lr Si LJ KZ oes mmm Figure 3 2 Nacelle Components Rotor Blade Hub fork Main Bearing Main shaft Vibration Sensor Gearbox Brake Disc Flexible Coupling Generator 0 Generator RPM Sensor ON MU e e V 11 Anemometer 12 Brake Sensor 13 Mechanical Brake 14 Rotor RPM Sensor 15 Retaining Magnet 16 Spindle motor 25 of 84 3 3 Generator The Gaia wind turbine uses a 3 phase 11 kW induction generator This generator is renowned for its robustness and reliability and is particularly well suited for utility grid connection 3 4 Braking System The brake is the active part of the turbin2. Manual stop on the operating panel screen It shows all active status codes SE Scroll onto the error and press enter to gain more information on the error This will detail the date and time at which the error occurred Step 5 Revert back to the start Escape menu by pressing escape 5 3 3 Error Types A Status Code is an error code which becomes active when a particular error occurs or if the controller detects that a certain parameter has been exceeded For example if the grid voltage is too high if there is a loss of mains supply or if the rotor or generator speeds are excessive For each status code a set of parameters determines the consequences of the code activation error which can include stopping the turbine re setting the error after a delay etc Each status code will be dealt with depending on its assigned re set level To obtain information about a given status code place the cursor at the code and press ENTER There are three error re set levels Auto Manual and Remote classified as follows GW UK 18 User Manual Issue Number 2 47 of 84 Date of Issue 17th Nov 2009 Auto A The active status code is automatically reset by the controller of the turbine when the conditions for resetting are present in other words when the original reason for its activation has stabilised and is no longer present Alternatively the status code may be reset manually or by remote control by use
3. d y H Lem e GENERATING BETTER VALUE USER MANUAL Your own Wind Turbine Copyright 2009 Gaia Wind Lid 1 Ainslie Road Hillington Park Glasgow G52 4RU United Kingdom Tel 44 0 845 871 4242 E ukmail gaia wind com Document Reference number GW UK 18 User Manual Date of Original Issue August 2008 Original Document Author Scott Love Issue Number 2 Date of Revised Issue 17th November 2009 All illustrations and photographs Copyright Gaia Wind Ltd No part of this manual may be transmitted into any form by any means without permission from Gaia Wind Ltd The information given in this user manual is believed to be accurate and reliable at time of printing However Gaia Wind Ltd Accepts no liability for the details contained herein All specifications are subject to change without prior notice GW UK 18 User Manual Issue Number 2 Date of Issue 17th Nov 2009 Table of Contents Health and Safety Information cccccceeseeeseeeeeeeeeeeeeeeeeeeeseseeeeeeeaeeeeeeeneeeeeeeenees 5 To Tv dee TN Le iE E 8 er IER len NEE 8 1 2 INTRODUCTION TO THE TURBINE cccc0eccccceeceeceeeeeeseeeeeeseneeesaeeeeeseeeeesaes 10 1 3 TURBINE SPECIFICATIONS ccccccccceceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 11 1 4 THREE LEVEL SAFETY FEATURES ccccssssssseeeecccssessseeeeeessseasseeeeeeees 12 to OW INGISE DESIGN EE 14 Wes ACOREDITATIONS asst coc ccerees pirena O E i r
4. Subsequent to pressing the Stop button a manual stop error message will appear on Figure 6 2 Stop Button the operating panel display This error must be reset to restart the turbine see resetting errors in section 5 3 4 Please note that it is not necessary to gain active status to stop the turbine this way Immediately upon pressing stop the mechanical break is activated and the rotor speed will decrease until stationary GW UK 18 User Manual Issue Number 2 Date of Issue 17th Nov 2009 6 4 Braking Procedure The results of a completed braking procedure are a stationary rotor and generator The brake pads are designated as wearing parts Over time the pads will require replacement In the event of excessive wear on the brake pads an error will be registered by the turbine controller After the brake brings the turbine to a stop the controller will automatically attempt to align the turbine blades horizontally This is Known as blade parking and ensures that the blades are placed in the optimal position for avoiding uneven wind loading on the rotor Figure 6 4 Figure 6 4 Parked Rotor Blades GW UK 18 User Manual Issue Number 2 63 of 84 Date of Issue 17th Nov 2009 GW UK 18 User Manual 64 of 84 Issue Number 2 Date of Issue 17th Nov 2009 rT we e a Servicing and Maintenance pernaan EE x j ah J be Or E C E a v
5. cccseeeessssssesseeeessecesssneeeeseeeeensneeeees 69 NOX E 71 Annex 1 Glossary Of Terims ccccccsscseeessesseeesceenseeeseeesseeeseesnneeeseeeseeessonens 72 Annex 2 Technical Data cccccccseeeseeeeeeeeseeeeeeeaseeeeneaseeeeaeeaneeeeaneaneeeeanonss 76 Annex 3 Error Message Status Codes cccccsssssseeeeeseeesssenseeeeeeeeesenseeees 78 GW UK 18 User Manual Issue Number 2 Date of Issue 17th Nov 2009 Health and Safety Information Gaia Wind Ltd strongly recommends that all servicing amp maintenance procedures other than cursory visual inspection be carried out by adequately trained and experienced personnel Personnel deemed to be adequately qualified will e Be specifically trained to work at heights ideally with a BWEA Working at Height Certificate or equivalent using peak less climbing helmet safety harness with double lanyards and shock absorber work positioning device tower rescue kit high visibility vest and steel toe cap boots e Have experienced working on the Gaia Wind 11kW Turbine e Ensure that only one person is permitted inside of the working basket at any one time e Ensure that a proper and comprehensive risk assessment has been carried out prior to starting any work GW UK 18 User Manual Issue Number 2 Date of Issue 17th Nov 2009 Further advice to the turbine owner e Alterations to the control parameters can only be made by Gaia Wind
6. 11 5kW Ensure that the operating deis 57 1021RPM l RUNNING G1 panel display shows the Start Status OK Accessrights 50 Menu Release Active stat Step 2 i Gl 249 LI Sky p Navigate the start menu d e ie 57 102 1RPH l RUNNING G1 down until the cursor Status OK Accessrights 50 indicates Release active EE EE stat Press enter on the keypad Enter The display remains on the l Gl 2497 11 5kwW start menu with active status 9 5m s 57 1021RPM RUNNING G1 Status OK released Accessrights 50 Request Active stat Step3 Navigate the start menu to G1 249V 11 Sky 9 5m s 57 1021RPM EE S RUNNING G1 the line Access Rights Statue OK Accessrights 50 Request Active stat Press enter on the keypad Ai Ai SEN two times Step 4 Ihe display will revert to the en 2497 11 Skw Original start menu You are now logged out of the turbine 9 5m s 57 10271RPM RUNNING G1 Status OK Accessrights 0 Request Active stat GW UK 18 User Manual Issue Number 2 44 of 84 Date of Issue 17th Nov 2009 5 3 Error menu 5 3 1 Overview oe B 251 0 0kW The turbine is equipped with 7 2m s 00 0000RPM numerous sensors These sensors STOPPED Status ERROR Accessrights 50 Request Active statl continuously monitor the turbine and the information they record is Figure 5 2 Start Menu used by the controller Indicating Errors When the sensors detect an error the controller will automaticall
7. 55 of 84 Date of Issue 17th Nov 2009 5 4 5 RPM Submenu This menu simply displays the current speed revolutions per minute of the turbine rotor and of the generator Access this menu by pressing enter on the keypad in the menu line RPM Independent Energy Environmentally Friendly Energy GW UK 18 User Manual 56 of 84 Issue Number 2 Date of Issue 17th Nov 2009 Operating Procedures 6 Operating Procedures 6 1 Auto Start Auto start refers to the process by which the turbine starts automatically when the control measures a pre defined wind speed of at least 3 5 metres per second for 30 seconds This is the cut in speed and is the point at which the turbine will start to generate electricity Through a soft starter the controller uses the generator as a motor to bring the rotor up to the operating speed Auto start enables maximum exploitation of lower wind speeds and hence greatest electrical energy production 6 2 Automatic Shutdown The turbine will shutdown automatically when the wind speed registered by the anemometer is too high This is important to protect components such as the rotor and drive train from excessive stress GW UK 18 User Manual 58 of 84 Issue Number 2 Date of Issue 17th Nov 2009 6 2 2 Rotor Over Speed Rotor over speed is when the rotor speed is greater than the rated speed For the Gaia Wind turbine the rated rotor speed is nomi
8. A 50 Os or your servicing defect company GW UK 18 User Manual Issue Number 2 81 of 84 Date of Issue 17th Nov 2009 GW UK 18 User Manual 82 of 84 Issue Number 2 Date of Issue 17th Nov 2009 GW UK 18 User Manual Issue Number 2 83 of 84 Date of Issue 17th Nov 2009 GENERATING BETTER VALUE Gaia Wind Ltd 1 Ainslie Road Hillington Park Glasgow G52 4RU Tel 44 0 845 871 4242 E ukmail gaia wind com Gaia Wind document reference GW UK 18 User Manual Website www gaia wind co uk
9. Foundation preparation 2 Electrical installation 3 Mechanical installation 4 Commissioning It may be more economic for the customer to arrange a contract for foundation works independently However there are strict requirements and guidelines relating to the foundations that must be considered during construction The foundation specifications must be obtained from Gaia Wind and followed strictly GW UK 18 User Manual Issue Number 2 17 of 84 Date of Issue 17th Nov 2009 Step 1 Foundations The Gaia Wind turbine foundation has a footprint of approximately 5 meters square The foundation is composed of multiple layers of steel reinforcement mesh bound together with braces to form a steel frame that will form the base of the tower The metalwork is placed inside the excavated hole and levelled before being filled with concrete Foundation preparations are required to be completed a minimum of 10 days in advance of the installation date This is to ensure adequate curing of the concrete Also the controller stand will be cast in the concrete during the foundation work On the installation day the controller will be mounted on this stand Gaia Wind maintain the right to refuse installation of the turbine on the grounds of safety if it has been determined that the foundation or electrical preparation work is unsatisfactory or when proper and safe site access has not been provided GW UK 18 User Manual 18
10. R I pi R AE E asses 14 2 Installing Your Gaia Wind Turbine ccccesssesseeesseeeeeeeeeeeeeeeeeeeeeeennes 16 2 1 PRE INSTALLATION INSTRUCTIONS 16 22 THE INSTALLATION DAY seccicccntendashanctxasencenderioncebeasniendestanctencuadsonsaineaceess 17 2 3 FIRST DAYS OF OPERATION 2 ccccccsseeeecccsseeeeccceseeeesccaseeeescceseeeessoes 21 3 PUIRDING COMDONGING saorsainn eaan a aaan 24 Sle COMPETE TURBINE E 24 Se PAO e E 25 33s EENEG 26 3 4 BRAKING SYSTEM ENEE 26 3 4 1 Mechanical Drake 26 3 4 2 RR e E 27 BOs ANEMOMETER eae ceca casecneceneiteceenstcasucntecanwcasiasedcnenporhses tcadacasenetecnseentet 28 a0 TON EE 29 J s MOTOR BLADES geen aae E EC ERENER EiS 30 4 Controller and Operating Panel cccsscsssssssssseeeeeeeeeeeseseseeeeneneeeessnees 32 4 1 INTRODUCTION ccccccseeeccseeecesececeaseeccaseeccaseeeeeaseessaseeessaseeesegeeees 32 4 2 OPERATING PANEL 220ccccccsseceeccceeeeeescceseeeeseceseeeesccsneeesccaseeeeseoes 34 5 TURDING Operatora aa aR 38 Sls INTRODUCTION EE 38 Se TARE Etterbeek 38 5 2 1 CV VA ee 38 5 2 2 Access Rights and Active Status cccccccsssseeeeeeeeeeeeeeeeeeeees 40 e ERROR MIEN dates eccctics heaterrecareiiecsen tin ecomeenceceseeceeaneidioaseacinanscauecatouas 45 GW UK 18 User Manual Issue Number 2 Date of Issue 17th Nov 2009 5 3 1 OVvervV W eivciehewaseneeavavedebacnsacscecdsevaheenxeudeatasebebacaiausceclveselenevardeatel
11. Sixth Lines The fifth and sixth lines indicate the level of access rights and active status request Access rights and active status must be attained in order to use the operating panel Normal Users will have access level 50 If access rights and active status are not obtained only the start menu will be visible and navigation to other menus prohibited See the section 5 2 2 on access rights and active status for further details 5 2 2 Access Rights and Active Status The Start Menu displays the lines Access Rights and Request Active Status Permission to use the operating panel can only be acquired if the access rights and active status are obtained The following steps should be followed in order to attain access rights and active status GW UK 18 User Manual 40 of 84 Issue Number 2 Date of Issue 17th Nov 2009 Acquiring Access Rights amp Active Status Step1 Ensure that the operating el 249 11 5kw 9 5m s 57 1021RPM panel is displaying the Start ee ae Accessrights 0 Menu Request Active stat Step 2 Scroll down to the menu until Scroll down the cursor line indicates tb b ID Gl 2494 11 kw Access Rights 9 5m s 57 1021RPM RUNNING GI e eae OK _Accessrignts Request Active stat The cursor is indicated by an underscore 4l Enter Press enter on the keypad GW UK 18 User Manual Issue Number 2 41 of 84 Date of Issue 17th Nov 2009 42 of 84 Step 3 St
12. T timer counter Brake timer counter result will generate the display TC1000 OK tim fcoun Grid OK tim f counter o fi wind OK tim counter shown in figure 5 5 left Figure 5 5 System Submenu The information below describes the data contained in each of the menu lines GW UK 18 User Manual 52 of 84 Issue Number 2 Date of Issue 17th Nov 2009 System Submenu Lines Production and Production of the turbine The total Consumption kilowatt hours produced by the turbine will be counted and recorded Pressing enter once again on this line enables data to be viewed from the previous month 12 months and 20 years Operation timer counter Counts the number of hours of production from the turbine Stop timer counter Counts the hours and times the turbine has been stopped Brake timer counter Counts the hours and times that the turbine brake has been activated IC 1000 OK timer Counts the hours and times that the IC counter 1000 control unit has been switched on Grid OK timer counter This counts the hours and times that the grid has been OK GW UK 18 User Manual Issue Number 2 53 of 84 Date of Issue 17th Nov 2009 5 4 3 System Production Accessing System Production Step 1 Ensure that the Status Menu is displayed on the keypad screen see section 5 4 1 Press enter on the Menu Line System The system submenu will appear on the screen Step 2 Na
13. l l 51 Watchdog rebooting A 50 Os No Action required 78 of 84 GW UK 18 User Manual Issue Number 2 Date of Issue 17th Nov 2009 Status Error Error Main ctrl The main controller is Watchdog rebooting Os No Action required Main ctrl Man The controller has been 55 Bence reset manually by the A 50 10s No Action required user The park control has sent a command to 99 Parkmaster stop the turbine The R 50 Os No Action required stop status code is reset when the park control sends a start command Errors relating to the voltage and frequency Contact Gaia Wind 100 Se eie of the mains supply M 50 Os or your turbine have been occurring servicing company too often No voltage in one or SE resol 102 Phase drop more phases A 50 3m when the voltage is detected The phase angle has Automatic reset 103 Vector surge changed by more than A 50 10s when phase angle 3 is smaller than 3 The grid voltage has The error will be 110 Voltage high exceeded the A 50 3m reset when the grid maximum limit voltage is OK The grid voltage has The error will be 111 Voltage low dropped below the A 50 3m reset when the grid minimum limit voltage is OK The grid frequency has The error will be 120 ae SE the A 50 3m reset when the grid igh e maximum limit frequency is OK The grid frequency has The error will be 121 Frequency low dropped below the A 50 3m reset when the grid minimum limit frequency is OK The error will be reset when t
14. panel entry functions GW UK 18 User Manual 34 of 84 Issue Number 2 Date of Issue 17th Nov 2009 STOP Stop the turbine Release the brake and start the turbine Move cursor line up Navigate to next menu Navigate to previous menu Move cursor line down RESET Reset erase error status HEo0S Shift to last menu line Leave a submenu GW UK 18 User Manual Issue Number 2 35 of 84 Date of Issue 17th Nov 2009 36 of 84 GW UK 18 User Manual Issue Number 2 Date of Issue 17th Nov 2009 E s d eg e A l _ an ine Operation Turb p i m l Tag Fas P gyan gpm Yo a gpm H mm P l 1 i gt P V GW UK 18 User Manual Issue Number 2 37 of 84 Date of Issue 17th Nov 2009 5 Turbine Operation 5 1 Introduction This section will explain how to navigate the menus of the operating panel and monitor the data relating to the performance of the turbine This is achieved using the operating panel functions outlined in section 4 2 5 2 Start Menu 5 2 1 Overview The most convenient menu is the start menu This menu shows real time and time averaged information and displays the current status of the turbine The status will show whether there is an error with the turbine or whether it is running free of errors see Figure 5 1 below Note that the backlight of the screen illuminates when any key is p
15. stop the turbine Excessive vibrations are displayed as an error message on the operating panel 6 2 6 Cable Twist The turbine extracts the maximum energy possible from the wind by automatically seeking its direction This is known as free yaw A consequence of this free yaw design is that the cables that extend Figure 6 1 Cable Twist Arm and down the tower can twist in Sensor either direction The turbine is equipped with a cable twist sensor and the controller will stop the turbine if cable twist becomes excessive The cables must be untwisted manually and this should be done by an accredited service engineer GW UK 18 User Manual 60 of 84 Issue Number 2 Date of Issue 17th Nov 2009 6 3 Emergency and Manual Stop The information above details the conditions by which the turbine will stop automatically However in the interest of safety the turbine can be stopped immediately by pressing the emergency stop button on the exterior of the controller figure 6 3 When the emergency stop button is pressed it will physically lock in the stopped position The button should be released by giving it a slight counter clockwise rotation and the button will pop out Emergency Stop Figure 6 3 Emergency Stop Button GW UK 18 User Manual Issue Number 2 61 of 84 Date of Issue 17th Nov 2009 62 of 84 Manually stopping the turbine is achieved by pressing the Stop button on the operating panel
16. 45 5 3 2 Accessing the Error Menu 46 0 3 3 ENO TYDE Saiar rne E ent EE 47 5 3 4 Resetting Of Errors ccccccssscccceseeeceeseecceeseeceeeeeeseeseesseseesssess 49 Sie STATUS E 51 5 4 1 Vy aueren ie arn E ROEE EERE 51 5 4 2 SYSTEM Gubmenus 52 5 4 3 System PEOGUCHON sscpeaseccosssvenaceeneneacaetvecssbwscbasenavestseesecencadteeese 54 5 4 4 Wind SUDIMG AU aiacscetsccecatvereeetesdeceaubietavedetecdavshuesterteaietaentindnedeks 55 5 4 5 ELE ege Ee 56 6 Operating PrOCCQUT EE 58 et PUTO OA WEE 58 6 2 AUTOMATIC SHUTDOW E 58 6 2 1 Max WING WEE 58 6 2 2 Rotor Over Speed sreci Ea raii 59 6 2 3 Generator Over Charge cccccecccccecceeeseeeeeeesseeeeeeeeeeeeseaaaaeees 59 6 2 4 Minimin POWO EE 60 6 2 5 VOD AOS serea E E a 60 6 2 6 Scl Seca A E E 60 6 3 MANUAL AND EMERGENCY Erop 61 6 4 BRAKING PROCEDURE EN 63 7 Servicing and Maintenance cccccceeeeeeessssseessssseseseeeneeeeeeeeeseeeeenenes 66 Pele Bh EH 66 7 1 1 Resetting d wicscsescss nercarntencendcesdisesreeasensdenadscsetereeseserdiondsecsts 66 Se Visual INSPECTIONS cccceeceeceeeeeeceeeeeeeeeeeeeeeeeeseeeeessaeeeeseneeeeas 66 7 2 SERVICING INTERVALS svetonctsctacasterintinicucawsevenecepecddinvadiasietaesiniastatsneeeaunce 67 7 2 1 Three Month Service scseseeeeeceeeeeeeeeeeeseaeeesseeeeeeeeeeeeeeeees 67 7 2 2 Annual SErviGE eege deeg 67 T REPLACEMENT Eegeregie 68 8 Frequently Asked Questions
17. abinet can be seen in figure 4 1 GW UK 18 User Manual Issue Number 2 33 of 84 Date of Issue 17th Nov 2009 The controller also allows for the monitoring of the turbine performance Instantaneous and time averaged readings relating to energy production wind speed and power output can be accessed through the operating panel Daily energy production is archived by the controller for one month back The total monthly production is stored for a period of 12 months and total yearly production is archived for 20 years The controller will produce an error message should a fault be detected in the normal running of the turbine Details of the error will appear on the operating panel The most common errors and the recommended actions are detailed in section 5 4 2 Operating Panel MitaTeknik ais The IC 1000 operating panel ACTIVE includes a screen and keypad oy The keys are activated by pressing WW Lt x down on the relevant symbol A pt pp successful Keypad entry is KN ESES signalled by the illumination of the cogon LED labelled Key accompanied by an electronic beep Figure 4 2 Figure 4 2 The Gaia Wind Operating Panel displays the operating panel The operating panel has 8 main menus corresponding to different aspects of turbine control Submenus exist within each of these menus Navigation between all menus is achieved using the keypad The information below details the primary operating
18. aged over a period average of 18 m s of 10 minutes over a 10 minutes period The error will be automatically reset G peak Production from the when the wind 53m power generator exceeds the A 50 10m speed is below an peak value of 18 kW average of 18 m s over a 10 minutes period The power from one Cute phase deviates by Contact Gaia Wind 601 asymmetry more than 25 M 50 Os or your turbine compared with the servicing company other phases Reset error If ie The turbine motor start error persists then 607 EE has been activated M 50 30s contact Gaia wind more than 20 times or your turbine servicing company Automatic reset 609 Thyrister Block e S SE A 50 Os when thyristor hot block temperature SE lt Clr stat 609 C Cut in time of G1 via 651 Cut in 0 gt G1 WP4060 increases A 50 30s No Action required 0 gt G1 xxS 30 sec Cut in error The status code is not tested when output 524 G1 662 WP4060 error contactor is low A 50 10s or when output 525 generator bypass is high Automatic reset when the turbine is not moving rpm 0 The cable twist sensor Contact Gata Wind 722 Cable twisted M 50 Os or your servicing has been activated company Ratio between the Reset error If RPM of the generator error persists then 1311 SE G and rotor does not M 50 Os contact Gaia wind H match the gear ratio or your turbine 2 servicing company PT100 A connection to one of Contact Gaia Wind 1544 E E the PT100 sensors is
19. an 28 71 78 ROP ae ene A ea Auto start aaaeeeaa nenea Sg E eegen Brake 26 28 29 39 Nacelle aiana 25 73 TA D E 26 58 Vleit 14 ID EE 2 7 58 Planning consent 16 Controller cccccecceceessseeseeseeeees 32 Power CUTIVE cccccceeessseeeeeeeeeeees 11 ODi a ee 71 73 Power Output nnnoooannnnnnnnneaanni 39 CGut JnGpoeed 11 Rated Speed nnooannnnnnneeenanni 12 Cut Out Speed ceeeeeeeeees 12 Resetting Error See Errors Delivery cccceeececeeseeeceeeeeeeeeeees 19 MOLO E 73 Distribution Network Operator 71 Blades 0 0 ecccceeceeceeeeeseeeeeeeeees 30 Downwind osoennnnnennnennnnnnnnnennnni 71 RPM Submenu See Status Menu Error SE 12 Menu EEN 44 Gerviclmg See Maintenacne ee Site ACCESS eesesececseteneneeen 16 Error Messages ssccccsseecsseeeessee 77 EE 40 Errors Status Men 50 Hesettfng eeeeeeeee 65 oe ee Foundation 16 Wind Gubmenu 54 Freewheeling no000nnnnnn00aaani 72 Stopping ceeeeeeceeeeeeeeeeeeeeeees 60 Frequently Asked Questions 68 Tel e 60 Generator 26 39 Eeer zez Glossary of Temms 71 SEHR Grid voltage cceeeeeeeeeeteees 39 PE AN A a DC 72 Eegen We IC 1000 oseriiecicocesiinensctemsosvocencadecet 52 Ge Installatton 17 TO eer 29 ASSEN E 20 Wind Submenu See Status Menu SE e ageet 74 bRevpad ee 34 GW UK 18 User Manual Issue Number 2 71 of 84 Date of Issue 17th Nov 2009 Annex 1 Glossary of Terms A
20. ate your own electricity 2 3 First Days of Operation During the first days of operation the turbine may be a bit stiff and may require higher wind speeds to start i e 4 5 5 m s to start instead of the normal 3 5 m s Typically the brake can stick a bit and also the yaw bearing will initially need more force to turn After several days running the turbine the stiffness disappears and the turbine will start yaw and run smoothly During the first days of operation the turbine will need higher winds to start This stiffness disappears after several full days of running GW UK 18 User Manual Issue Number 2 21 of 84 Date of Issue 17th Nov 2009 GW UK 18 User Manual 22 of 84 Issue Number 2 Date of Issue 17th Nov 2009 a Turbine Com O 3 Turbine Components 3 1 Complete Turbine The diagram below shows the Gaia Wind 11kW Turbine indicating the location of the principal components Please note that although the diagram shows a lattice tower the drawing is consistent for the tubular tower EG Figure 3 1 Main Components Blade Tip Rotor Blade Nacelle Anemometer Working Basket Hub Fork Cable Guide Tower Lattice Ladder 10 Cable Twist Sensor 11 Controller eS E a Se be Q OY ai ma a aw W A VAVAVaw JAZ ANINA NIV INZS 12 Foundation VAAZ AAN ZAIN IN TAr TE Smet T ECLA ELLAELL LIA LIH L IN
21. ce It is necessary that a full inspection of the turbine is performed at least once a year This annual check up must be performed by an accredited service engineer This check up will commonly involve tightening of bolts replenishment of lubricants and oil and visual checks for any excessive wear or damage to the turbine During the annual service the performance of the turbine will be checked and any error messages will be evaluated This information and a record of the required work and use of consumables and replacement parts during the service will be issued to the customer GW UK 18 User Manual Issue Number 2 67 of 84 Date of Issue 17th Nov 2009 7 3 Replacement Parts The Gaia Wind 11 kW turbine is designed to have a minimum lifetime of 20 years However some of the parts will require replacement during this time period These components are known as wearing parts and include the rubber mountings for the gearbox and for the generator hub bushings and brake pads The wearing parts will be checked during servicing according to the instructions in the servicing manual Scheduled gearbox oil changes will be made every 3 5 years GW UK 18 User Manual 68 of 84 Issue Number 2 Date of Issue 17th Nov 2009 8 Frequently Asked Questions Does the turbine have lightning protection What should do if ice forms on the turbine blades Why is my turbine not generating any electricity despite g
22. des a useful System a l Generator Gl tool for viewing data relating to a GE tors Win range of performance characteristics Heating system RPM Temperatures Oper timers l Communi cati on can be reviewed over a range of Inputs Outputs such as production data The data time frames including daily monthly and yearly Figure 5 4 Status Menu The submenus of the status menu are shown in figure 5 4 The submenus are accessed by pressing enter on the keypad when the cursor is on the relevant menu line Accessing the Status Menu Step 1 Ensure that the Start Menu is GI 249V 11 Sky displayed on the keypad 9 5m s 57 1021RPM RUNNING G1 Status OK Accessrights 50 If you have not done so Release Active stat obtain Access Rights and Active Status before continuing See section 5 2 2 for details GW UK 18 User Manual Issue Number 2 Date of Issue 17th Nov 2009 51 of 84 Step2 Toggle through the menus Toggle Left using the cursor directions buttons until the heading Toggle Right displays Status Step 3 The Status menu is displayed System Generator Gl on the keypad screen ea tors Heating system RPM Temperatures Oper timers Communication Inputs Outputs Revert back to the start menu by toggling left or right 5 4 2 System Submenus To access the system submenu Production consumpt Elements consumption Operate timer count the Status menu System The
23. e protection system The Gaia Wind turbine employs two independent braking procedures 3 4 1 Mechanical Brake The mechanical brake is located along the turbine drive train on the high speed shaft just where it emerges from the gearbox This brake operates in a similar manner to that of a disc brake on a car a caliper pushes brake pads onto a steel disc that rotates with the turbine shaft The main elements of _ this system the caliper brake disc and retaining magnet Can Figure 3 3 Gaia Wind Mechanical Brake be seen in figures 3 2 above and 3 3 right The brake operation is fail safe if the electricity is disconnected a spring will engage the brake and stop the turbine The turbine s automatic controller has accurately set time limits for braking procedures and in all normal situations the mechanical brake GW UK 18 User Manual 26 of 84 Issue Number 2 Date of Issue 17th Nov 2009 will stop the turbine quickly However under extreme circumstances it is possible that the turbine fails to stop which may occur for example in the event of excessive wear on the pads If this event should occur the turbine tip brakes will perform the braking of the turbine see section below Your own ELECTRICITY 3 4 2 Tip Brakes In the event that the mechanical brake should fail to stop the turbine within sufficient time the tip brakes will deploy These are centripetally activated aerodynamic b
24. ements Requirements will depend on your degree of direct involvement with the project but could include digging the foundation hole contracting a foundation builder digging a cable trench providing a three phase grid connection with import export meter achieving planning consent and ensuring suitable access for a crane and for the delivery lorry You must fulfil these obligations prior to the agreed installation day This will be covered in the contract GW UK 18 User Manual 16 of 84 Issue Number 2 Date of Issue 17th Nov 2009 2 2 The Installation Day The installation of a Gaia Wind Turbine must be done either by Gaia Wind or through a Gaia Wind accredited installer Please contact Gaia Wind if you want to check verify whether your contact person is an accredited Gaia Wind installer The installation of the turbine should normally take only one day The Installation Team will consist of two engineers a crane driver and an electrician depending on circumstances One of the engineers will be introduced as Installation Manager and this person will be in charge of everything that takes place that day All people on site should follow swiftly the instructions given by this person All questions and remarks should be directed to the Installation Manager it should be noted that installation is dependent on suitable weather ground and wind conditions There are 4 main components to the installation of the turbine 1
25. ep 4 Step 5 The screen display will change to that on the right Enter the default user code 123 using the numbers on the operating panel and confirm by pressing enter The display will return to the start menu with Accessrights 50 Navigate the start menu down until the cursor indicates Request active stat Press enter on the keypad Enter the user ID 1 and Confirm by pressing enter on the keypad The screen will revert back to the start menu with both access rights and active status REMOTE Editor Accessrights e el 249 11 5kW 9 5m s 57 1021RPM RUNNING G1 Enter Status OK Accessrights 50 Request Active stat Scroll down Enter Ai Enter G1 49 11 5kW 9 5m s 57 1021RPM RUNNING GL Status OK Accessrights 50 Release Active stat GW UK 18 User Manual Issue Number 2 Date of Issue 17th Nov 2009 Step 6 Ensure that the LED labelled ACTIVE KEY Active on the top right hand side of the keypad is illuminated This confirms that active status has been RESET i granted It is important that prior to leaving the turbine that the access rights and active status are disabled Therefore the following procedure should be followed upon completion of using the controller GW UK 18 User Manual Issue Number 2 43 of 84 Date of Issue 17th Nov 2009 Releasing Active Status amp Access Rights Step 1 i el 249
26. er 100 m lt 40 Rural Night Time Background 1 6 Accreditations The Gaia Wind 11 kW turbine has received the UK Clear Skies accreditation accreditation number WT5038 This denotes that the turbine is eligible for all grant schemes for small wind turbines The Gaia Wind 11 kW turbine has the Danish Type Certificate RIS DTU 2009 01 GW UK 18 User Manual Issue Number 2 Date of Issue 17th Nov 2009 Installing your Gaia Wind Turbine GW UK 18 User Manual Issue Number 2 15 of 84 Date of Issue 17th Nov 2009 2 Installing Your Gaia Wind Turbine 2 1 Pre Installation Instructions Suitable locations for your turbine will have been discussed with a Gaia Wind representative prior to installation The final location will take into account the local topography and proximity to obstacles such as trees and nearby buildings Also safety issues related to the proximity of roads overhead lines or public spaces will have been taken into account Prior to the installation of your turbine it is necessary to obtain planning consent from the relevant authorities Customers can apply for planning directly or use a consultant to apply on their behalf In each case Gaia Wind will provide support If any planning restrictions are most commonly imposed on the basis of anticipated noise emission and visual impact on the landscape At the time of signing the contract with Gaia Wind you will be provided with a list of requir
27. he phase angles are f The phase angle 130 L1 L2 L3 120 between the L1 E2 A 50 10s and L3 is larger than 6 OK Grid Param Contact Gaia Wind 138 Warni Internal Calculations M 50 Os or your turbine arning ge servicing company Grid Param Contact Gaia Wind 139 Stop Internal Calculations M 50 Os or your turbine servicing company The error will be reset automatically Anemometer recording when the wind 297 Anemometer wind speed below 2 A 50 es Speed recorded defect m s with turbine output over 30 seconds power over 1 kW averages the start wind speed 3 m s The wind sped is too 240 Awaiting Wind low and freewheeling is M 50 Os No Action required disabled GW UK 18 User Manual Issue Number 2 79 of 84 Date of Issue 17th Nov 2009 Status Error Error The error will be recorded wind automatically reset n averages 20 m s when the wind 250 Wind gt max over a 10 minute period A 50 600s speed is below an or the wind speed is average of 18 m s higher than 25 m s over a 10 minutes period The generator speed is e He SC eg 50 0s contact Gaia wind efect the rotor speed is above 8 RPM or your turbine servicing company Reset error If R tacho Ge KEE RE error persists then 302 M 50 Os contact Gaia wind defect generator speed is greater then 600 RPM or your turbine servicing company Botog The rotor speed Contact Gaia Wind 311 overspeed exceeds the maximum M 50 Os or your turbine rotor speed 62 RPM servicing co
28. ial for ensuring the efficient and safe operation of the turbine All procedures are controlled automatically based upon signals from various sensors throughout the turbine User intervention is only required when errors have occurred To open the controller cabinet use the supplied key inserting into the 2 keyholes at the top and bottom of the left hand side of the cabinet door Push in firmly and turn clock wise to release the latch on each The door should then easily swing open Be careful to hold the door to prevent the wind catching it Figure 4 1 Controller Cabinet GW UK 18 User Manual 32 of 84 Issue Number 2 Date of Issue 17th Nov 2009 e DONOT open the control cabinet door in wet conditions e There are no user serviceable parts inside the cabinet e Customers should only touch operating panel keypad see Section 4 2 e DONOT place any metal objects in or near cabinet e If you see any sign of water in the cabinet isolate the controller and do not operate Contact Gaia Wind or your accredited Gaia Wind installer Operating Panel Computer keypad Contactors amp Automatic Fuses Current and Voltage Measurement Soft Starter Capacitor Bank at Ee Figure 4 1 Turbine Controller Cabinet All of the turbine s necessary electrical switchgear fuses contactors and connectors are housed in a weatherproof unit located at the foot of the tower The interior of the controller c
29. mpany The generator speed Contact Gaia Wind 312 G overspeed exceeds the maximum M 50 Os or your turbine generator speed servicing company The rotor speed exceeds the maximum Reset error If rotor speed 62 RPM error persists then 314 Rice KEE before the generator M 50 Os contact Gaia wind H has cut in Most or your turbine commonly the result of servicing company a large gust of wind Warning that the brake Contact Gaia Wind 415 Se ZE pads are worn out and M 50 Os or your turbine should be replaced servicing company Replace brake The brake pads worn Contact Gaia Wind 416 pads error has occurred four M 50 Os or your turbine times servicing company Reset error If error persists then 421 ae d ZS ee Rees M 50 Os contact Gaia wind or your turbine servicing company The turbine braking Contact Gaia Wind 434 SZ brake procedure took longer M 50 Os or your local time gt max St than 10 seconds servicing company Reset error If Bawer The turbine consumes error persists then 501 consumption more than limit of PKW M 50 Os contact Gaia wind of power or your turbine servicing company Reset when The generator generator 521 G hot 50 1h temperature temperature is too high decreases GW UK 18 User Manual 80 of 84 Issue Number 2 Date of Issue 17th Nov 2009 Status Error Error The error will be Production from automatically reset generator SE a when the wind 530 ra BEE Tuer ot 15 We 50 10m speed is below an aver
30. nally 56 rom but can vary between 55 and 57rpm There are two defining conditions of rotor over speed e At 10 above the rated rotor speed 62 RPM the mechanical brake is activated e At 15 above the rated rotor speed 65 RPM the aerodynamic tip brakes are activated Following shutdown due to rotor overspeed the tip brakes may need to be reset You should contact Gaia Wind or a Gaia Wind accredited servicing company Generator overspeed is when the generator rom sensor detects speed greater than 1116 rpm 6 2 3 Generator Over Charge The turbine brake is activated if the recorded power output of the generator is large This is referred to as over charge and is necessary to protect the generator from damage The conditions are e An average power output of 15 kW averaged over a 10 minute period e The generator power exceeds 18 kW GW UK 18 User Manual Issue Number 2 Date of Issue 17th Nov 2009 59 of 84 6 2 4 Minimum Power If the turbine power output is less than 0 1kKW over a period of one minute the generator will cut out Le it will stop producing Under these circumstances the rotor will continue to rotate without producing electrical energy freewheeling This will continue until favourable conditions for generation are resumed 6 2 5 Vibrations A vibration sensor is situated inside the nacelle If the sensor records excessive vibrations the controller will engage the brake to
31. nemometer l l The anemometer is a device used for measuring the instantaneous wind speed Bearing In the wind turbine the function of the bearing is to allow the shaft to rotate freely Cut In Speed This is the wind speed at which the turbine will start to deliver electrical power Cut in will occur when the speed of the generator achieves its synchronous speed OT oT E The maximum wind speed at which the turbine is permitted to deliver power The operating range of a turbine is limited due to engineering design and safety constraints The cut out speed for the turbine is 25 m s although wind speeds this high are rare Distribution This is the low and medium voltage under 33 kV HEt or that typically connects into homes and businesses BEEN The companies which operate the Distribution No Network in the UK Operator This refers to a wind turbine in which the hub and blades point away from the wind direction The opposite of an upwind turbine GW UK 18 User Manual 72 of 84 Issue Number 2 Date of Issue 17th Nov 2009 Freewheeling Gearbox Horizontal Axis Wind Turbine Induction Motor Kilowatt Hour kWh Leading Edge GW UK 18 User Manual Issue Number 2 The wind turbine is said to freewheel when it is not connected to a load but continues to rotate A mechanical system used to match the slow rotational speed of the rotor to the high rotational speed of the gene
32. nted on 4 legs that are embedded in the concrete foundation The principal advantage of this design is less material and hence reduced cost The tower can also be supplied as a tubular structure This tower is conically shaped increasing in diameter towards the base This increases structural integrity and makes an elegant presentation Figure 3 7 Turbine Towers Lattice Left and Tubular Right GW UK 18 User Manual Issue Number 2 Date of Issue 17th Nov 2009 29 of 84 30 of 84 Aside from the issue of cost the main difference between the two tower types is aesthetics Both the tubular and lattice tower are designed to cause minimal visual intrusion on the landscape The sleek tubular tower compliments modern structures and when viewed at a distance the open structure of the lattice tower causes the outline to fade 3 Rotor Blades The rotor blades are constructed of the composite material GRP Glass Fibre Reinforced Polyester There are many advantages for the use of GRP for this purpose principally a good strength to weight ratio and resistance to degradation from environmental factors GW UK 18 User Manual Issue Number 2 Date of Issue 17th Nov 2009 s a KL NW K a WN crn a Se 47 j A 4 Controller and Operating Panel 4 1 Introduction This section gives a brief overview of the Gaia Wind 11 kW Wind turbine controller and operating panel The controller is essent
33. of 84 Issue Number 2 Date of Issue 17th Nov 2009 Step 2 Delivery and Unloading The Gaia Wind turbine is delivered on a single lorry The delivery will consist of e Multi part tower both lattice and tubular towers arrive in several sections to be assembled in situ e Ladder and Working Basket e Turbine blade and hub e Pre assembled and tested nacelle e Pallet of loose items fasteners and fittings e Controller All the above items are carefully offloaded from the truck with a crane by the Installation Team GW UK 18 User Manual Issue Number 2 19 of 84 Date of Issue 17th Nov 2009 Step 3 Assembly The tower sections are assembled The nacelle is mounted onto the top section of the tower Ladder sections and working basket are fixed onto the tower The rotor assembly is mounted onto the main shaft Step 4 Raising the Turbine The turbine is raised by the crane Once vertical the tower is securely fixed to the foundation steelwork The tower will be carefully levelled to ensure it is in an exactly vertical position GW UK 18 User Manual 20 of 84 Issue Number 2 Date of Issue 17th Nov 2009 Step 5 Commissioning amp Starting the Turbine Once fully erected and fastened to the foundation the turbine commissioning procedure takes place Upon completion of all commissioning checks the turbine can be started and your turbine will begin to gener
34. ood wind conditions Is it necessary that a turbine inspection is undertaken subjection to severe conditions over 25 m s GW UK 18 User Manual Issue Number 2 Date of Issue 17th Nov 2009 after wind The turbine tower is connected to a dedicated earth electrode This acts to protect the turbine in the event of a direct lightning strike The turbine should be manually turned off to prevent potential injury from flying ice See section 6 3 on manually stopping the turbine The turbine has been switched off There is an error in the turbine refer to section 5 3 of this manual The wind speed is too high and the turbine has shut down for safety reasons The turbine should not be damaged by such an event Even so a brief inspection of the exterior is encouraged See section 7 1 69 of 84 70 of 84 Why is it that cannot use the Active status has not been granted control menus in order to observe see Section 5 2 for instructions my turbine performance The necessary level of access rights has not been attained see Section 5 2 for details Somebody with higher access rights has active status of the turbine possibly remotely through a modem GW UK 18 User Manual Issue Number 2 Date of Issue 17th Nov 2009 Index Access Rights 40 42 49 69 Maintenance essseeeeeeeeeenereeen 65 Active Status 40 42 49 60 69 Intervals 66 Anemometer nos
35. or a Gaia Wind accredited servicing company e In the event of abnormal noise or unusual operation being observed turn off the turbine and contact Gaia Wind or a Gaia Wind accredited servicing company e Shut off the turbine should ice accumulate on the blades e Do not paint the blades or the turbine as this will degrade the coating on the blade surface e lf in doubt on any procedural issues contact Gaia Wind or a Gaia Wind accredited servicing company GW UK 18 User Manual Issue Number 2 Date of Issue 17th Nov 2009 introduction 1 Introduction 1 1 Welcome Note Thank you for choosing to purchase a Gaia Wind 11 kW Wind Turbine Gaia Wind are delighted that you have decided to install our small wind turbine We believe that with Your Own Wind Turbine you will very quickly notice the benefits gained by your home or business The turbine allows you to substantially reduce your annual energy bills and take sizeable steps towards lowering your carbon footprint and achieving energy sustainability This document has been written specifically with the turbine user in mind It is therefore strongly recommended that you read this manual carefully and ensure that it is retained for future reference The manual provides a comprehensive overview of the turbine operating procedures and the control system This will allow you to monitor the turbine whilst it is in operation and determine how much electricity yo
36. quired SE Contact Gaia Wind 5 Vibration E M 50 Os or your turbine servicing company a Contact Gaia Wind 7 ec d 2 e EE DU Os or your turbine servicing company Stop S Stop command Contact Gaia Wind 11 DE received via modem or R 50 Os or your turbine direct link servicing company The turbine has been stopped manually via Reset error and Is RE the STOP button on the y ae ue restart turbine turbine operating panel First check for good reason for Emergency Stop CE a 50 0s activation Once p satisfied release emergency stop and reset Repeating An error code has been Contact Gaia wind 23 SE recorded too many M 50 Os or your turbine times servicing company 29 New Program EE M 50 Os EE EES servicing company eee Call Alarm Call test in the Contact Gaia wind 38 DEE Service Menu is set to R 50 Os or your turbine ON servicing company Division by Contact Gaia wind 39 SE Parameter error value M 50 Os or your turbine servicing company Parameter crash due to eegen flat battery Battery Contact Gaia wind 40 each must be replaced and M 50 Os or your turbine all parameters servicing company set to default values Internal Battery Contact Gala wind 42 ne Battery needs replaced M 50 Os or your turbine servicing company There has been a Error will be reset Main ctr power failure in the automatically when 45 Supply mains supply and the A 50 10s mains supply is turbine controller has detected after a reboot delay of 3 minutes DSP DSP processor is
37. rakes concealed in the blades In this instance the blade tips rotate through 90 degrees spoiling the rotors aerodynamic properties and subsequently causing the rotor to stop In the unlikely event that the tip brakes deploy you should contact Gaia Wind or your accredited Gaia Wind Figure 3 5 Re setting Tip Brakes installer in order to arrange for the tip brake to be safely reset Since this involves climbing the tower and working at height using special equipment this task should be undertaken only by personnel with the appropriate training and safety equipment Contact Gaia Wind or your accredited Gaia Wind installer in order to arrange for the tip brake to be safely reset DO NOT attempt to perform this task yourself as it requires specialist training and equipment 3 5 Anemometer An anemometer is located on the upwind side of the nacelle The purpose of this device is to measure the wind speed at the turbine hub height The wind speed measurements recorded by the anemometer are used by the controller to monitor and control the Figure 3 6 Anemometer turbine mainly during start up and shut down GW UK 18 User Manual 28 of 84 Issue Number 2 Date of Issue 17th Nov 2009 3 6 Tower There are two tower types available for the Gaia Wind 11 kW Turbine traditional lattice and tubular The traditional lattice tower is composed of welded galvanised steel profiles and is mou
38. rator Tertiary Level Passive In the extremely unlikely event that neither the base nor secondary level safety mechanisms stop the turbine centripetally activated aerodynamic brakes concealed in the rotor tip are released The effect of this is to spoil the aerodynamic lift of the rotor and hence stop it rotating In addition there is an emergency stop function on the turbine controller At any time the user can override the turbine control system and stop the turbine More details can be found in section 6 of this manual GW UK 18 User Manual Issue Number 2 13 of 84 Date of Issue 17th Nov 2009 14 of 84 1 5 Low Noise Design As with all rotating machinery some noise will be produced Minimising this effect is a key objective for Gaia Wind s engineers The principal source of noise originates from the turbine blades and this aerodynamic noise increases exponentially with the rotational speed of the blades The constant and low rotational speed of the Gaia Wind turbine makes it among the quietest in its class In practice the turbine noise is often masked by background noises such as wind or traffic The table below provides indicative noise levels at various distances from the base of the turbine The data is derived from independent measurements on several Gaia Wind turbines Noise Level dB A Comparator Conversational Speech ue 39 Car at 100 m Driving at 40 mph At 60 m 45 Living Room Ov
39. rator This is a standard in wind turbine design The shaft is parallel to the ground and the rotor area is perpendicular to the ground The centre of the rotor of the wind turbine The purpose of the hub is to hold the blades in place and attached to the turbine shaft An AC motor in which the rotating part has no windings and brushes on it The kilo watt hour is the standard unit for measuring electric energy in the UK 1 kWh is equivalent to the energy consumed by a 1 kW device operating for 1 hour Note that this is equivalent to a 3 kW device operating for 20 minutes The edge of the blade that faces towards the direction of rotation Date of Issue 17th Nov 2009 73 of 84 Housing that contains all of the components necessary for the conversion of wind energy to electrical energy The important components include the bearings shafts gear box brake and generator The name given to the assembly of the blade and hub in a wind turbine Revolutions Per Minute This is the number of times a shaft completes one full revolution during one minute The purpose of the main shaft is to transfer the power from the rotor to the gearbox This is the wind speed at which the turbine rotor will commence rotating This does not mean that the turbine will produce any electrical output which will occur at the Cut In speed The end of a turbine blade furthest away from the hub The measure of turning fo
40. rce The structure that supports the rotor and nacelle GW UK 18 User Manual 74 of 84 Issue Number 2 Date of Issue 17th Nov 2009 Wind Turbine GW UK 18 User Manual Issue Number 2 75 of 84 Date of Issue 17th Nov 2009 Annex 2 Technical Data Type Gaia Wind 11kW Hub Height 18 3 m Yaw System Free Yaw Cut In Wind Speed 3 5 m s Rated Wind Speed 9 5 m s Cut out Wind Speed 25 m s Rated Power 11 kW Nacelle Weight 900 kg Operating Temperature 20 gt 50 deg C as Diameter 13 0 m Blade Material Glass Fibre Reinforced Polyester GRP Nominal Speed 56 rom Weight 200 kg Power Regulation Stall Regulated Air Brake Tip brakes centripetal activation GW UK 18 User Manual 76 of 84 Issue Number 2 Date of Issue 17th Nov 2009 Generator 3 phase induction generator 400 V 50Hz Type Marine Grade Nominal Power 11 kW Weight 138 kg Transmission Ratio 1 18 Lubrication Centrifugal Weight 143 kg Mechanical Brake System Calliper Brake Disc Location High Speed Shaft Height 18 0 m Lattice 1600 kg Weight Tubular Tower 2200 kg GW UK 18 User Manual Issue Number 2 77 of 84 Date of Issue 17th Nov 2009 Annex 3 Error Message Status Codes Error Reset Types A denotes Auto M denotes Manual amp R denotes Remote Reset Delay Error Required SE g ere e Description Reset password Type level errors Turbine System OK e A 50 Os No Action re
41. ressed making the screen easier to read especially in low light or at night The backlight will switch off when the keypad has not been pressed for a short period GW UK 18 User Manual 38 of 84 Issue Number 2 Date of Issue 17th Nov 2009 G1 249 V 11 5kW E 251V 0 Okw 9 5m s 57 10271RPM 7 2m s 00 O000RPM RUNNING G1 STOPPED Status OK status ERROR Accessrights 90 Accessrights 40 Request Active stat Request Active stat Figure 5 1 Start Menu Running Left Braked Right First Line B The brake is engaged G1 Indicates that the generator is cut in connected to the grid 249 V Grid voltage average per phase 11 5 kW Average power output over 30 seconds Second Line 9 5 m s Average wind speed over 30 seconds 57 1021 rpm Rotor Generator speeds Third Line The third line indicates the most recent event registered by the turbine In the example above this is the cut in of the generator left and stopping of the turbine right GW UK 18 User Manual Issue Number 2 39 of 84 Date of Issue 17th Nov 2009 Fourth Line This shows the status of the turbine The display in figure 5 1 left indicates that the system is OK i e there are no errors in the turbine Alternative status messages that may appear in this line include Error and Warning see figure 5 1 right Further information regarding errors is included in section 5 3 of this document Fifth amp
42. rs with a password level higher than that indicated in the status code OI OO The active status code can be reset by the user via the operating panel by users with a password level equal to or higher than the one indicated in the status code Remote R The status code may be reset manually or by remote control only by users with a password level higher than that indicated in the status code The table in Annex 3 gives a full list of potential error messages Each error is accompanied by a short description and indentified as Auto Manual or Remote reset and also given a re set delay and required password level to be able to re set Instructions on how to manually reset errors are detailed in section 5 3 4 below Although it is possible to manually reset many of the errors in Annex 3 please read and adhere to the instructions for each error This is essential for ensuring the continued performance of your turbine GW UK 18 User Manual 48 of 84 Issue Number 2 Date of Issue 17th Nov 2009 5 3 4 Resetting of Errors The turbine will only operate when no error signals are detected Therefore errors must be reset to resume turbine operation The method for resetting errors is dependent on the type of error The following procedure should be followed to reset manual errors Resetting Error Menu Step 1 Ensure that the Start Menu is E 251 0 0kW 7 2m s 00 O0000RPM STOPPED displayed on the opera
43. ssue Number 2 11 of 84 Date of Issue 17th Nov 2009 Rated Speed The wind speed at which the rated power 9 5 m s 11kW is reached Cut Out Speed The maximum wind speed at which the turbine is permitted to deliver power The operating range of a turbine Is limited due 25 0 m s to engineering design and safety constraints The cut out speed for the turbine is 25 m s although wind speeds this high are rare Turbine Specifications See Annex 2 Technical Data 1 4 Three Level Safety Features Safety features are a vitally important aspect of any turbine design The Gaia Wind turbine has a number of safety features that ensure that rotor soeed and power generation are kept under control There are three distinct levels of protection Base Level Passive The design of the blades introduces a gradual Stalling effect as wind speeds rise above 9 m s which limit power output from the turbines GW UK 18 User Manual 12 of 84 Issue Number 2 Date of Issue 17th Nov 2009 Secondary Level Controller Initiated Active At wind speeds above 25 m s the turbine controller automatically activates the mechanical brake This stops the turbine running The brake is automatically released when the wind speed drops below an average of 18 m s over a period of 10 minutes The mechanical brake is also activated in case of a fault in the electrical grid excessive vibrations or over speeding of the rotor or gene
44. ting Status ERROR Accessrights 50 Request Active stat panel If you have not done so obtain Access Rights and Active Status See Section 5 2 for details Step 2 Scroll down to the menu line Scroll down until the cursor is on the fourth line Status Press enter on the keypad enter Step3 The screen displays the recent active errors N B if no Scroll down information can be seen then there are no active errors Scroll up Navigate through the error list using the cursor arrows GW UK 18 User Manual Issue Number 2 49 of 84 Date of Issue 17th Nov 2009 If any errors re appear after resetting exercise caution before resetting the turbine again If the error persists then please contact Gaia Wind Step 4 In the error menu press the reset button on the keypad The error messages will be erased If the messages are not erased then the error has not been corrected Step 5 Press the escape button to Escape return to the main menu Step6 The turbine will start automatically within 60 seconds subject to sufficient wind Alternatively the turbine can be started immediately by 232 Start pressing the start button Step7 Release access rights and See section 5 2 2 active status if finished operating the turbine GW UK 18 User Manual 50 of 84 Issue Number 2 Date of Issue 17th Nov 2009 5 4 Status Menu 5 4 1 Overview The status menu provi
45. u are generating and thus how much money you are saving In addition you can determine the equivalent carbon dioxide savings that you will achieve Please take careful note of the health and safety information summarised on the opening page If you have any additional concerns on the health and safety aspects of the turbine please contact Gaia Wind GW UK 18 User Manual Issue Number 2 Date of Issue 17th Nov 2009 We would like to congratulate you once again on your purchase and hope that you enjoy Generating Better Value with your own Gaia Wind turbine Regards Gaia Wind _ Independent Energy Environmentally Friendly Energy GW UK 18 User Manual Issue Number 2 Date of Issue 17th Nov 2009 1 2 Introduction to the Turbine The Gaia Wind turbine is in the small wind turbine category and has a rated output of 11kW It produces an energy yield that is practical for supplying electricity to premises such as private houses farms offices small businesses and public buildings where the primary goal is to either reduce the amount of electricity imported or generate specifically for export to the grid The turbine has been developed according to Danish design the design basis for most of the large commercial turbines used today Like its bigger relatives it has a slow rotation speed which is independent of the wind speed It also incorporates many of the control and safety feat
46. ures from the large turbines The Gaia Wind turbine is configured to give an optimal yield in moderate wind speed sites i e those with an annual average wind speed in the range of 4 5 7 5 m s As such it complements the wind conditions found in many rural areas of mainland Britain Components used in a Gaia Wind turbine have been carefully selected for their quality reliability and low maintenance The outstanding electricity production in moderate wind speeds typically 30 000 kWh per year is due to the large rotor With a 13 metre rotor diameter the Gaia Wind 11 kW sweeps an area of 133 square metres which is more than double that of most competing machines GW UK 18 User Manual 10 of 84 Issue Number 2 Date of Issue 17th Nov 2009 1 3 Turbine Specifications The power output of a wind turbine varies with the wind speed This is represented by a turbine power curve Figure 1 1 below represents the power curve for the 50Hz version of the Gaia Wind 11kW turbine This curve provides a good indication of what the electrical power output of the turbine will be over a range of wind speeds 14 Cut In Speed Rated Speed Cut Out Speed 12 10 af EH WEE e m A o K CH M P On amp Wind Speed m s With its large rotor diameter an attribute of the Gaia Wind turbine is high performance in moderate wind speeds The key points of the power curve are outlined in the table below GW UK 18 User Manual I
47. v v W I EE _ y Cae H Mis GW UK 18 User Manual Issue Number 2 Date of Issue 17th Nov 2009 65 of 84 7 Servicing and Maintenance 7 1 User Maintenance 7 1 1 Resetting Errors As detailed previously when the turbine sensors detect an error the controller will automatically stop the turbine Information relating to the error will be displayed in the operating panel display 7 1 2 Visual Inspections It is advisable to perform brief periodic inspections of the turbine in particular following severe winds This should consist of a visual check for loose bolts and connectors visual inspection of the whole turbine and listening for any unusual noises or vibrations Should such an inspection identify any potential faults with your turbine then contact Gaia Wind or a Gaia Wind representative immediately GW UK 18 User Manual 66 of 84 Issue Number 2 Date of Issue 17th Nov 2009 7 2 Servicing intervals The information below details the servicing requirements for the Gaia Wind 11 kW turbine All servicing activities must be performed by a Gaia Wind accredited service engineer 7 2 1 Three Month Service A full inspection must be performed three months after the installation of the turbine The turbine operation and control system will be checked Additionally all bolt connections are tightened and the levelling of the tower will be inspected 7 2 2 Annual Servi
48. vigate to the submenu line prod consump and press enter Step 3 The display should give a selection of time frames over which to view data Scroll to the desired time frame and press enter 54 of 84 System Generator Gl Capacitors wind Heat ng system HHN Temperatures Oper timers Communication Inputs Outputs Production consumpt House consumption Elements consumption Operate timer count a timer counter Brake timer counter TC1000 OK tim f coun Grid OK tim fcounter Wind OK tim Zcounter Scroll Down 4l Enter eE 1 Subtotal 2 One month back 12 months back 20 years back GW UK 18 User Manual Issue Number 2 Date of Issue 17th Nov 2009 Step 4 The final screen shows the 0 kw production data The o kVArh 223 kVArh important information here is the top line the energy produced by the turbine Step 5 To return to the previous menu Return to ress escape p P Submenu Return to To return to the Status menu Status Menu hold control and escape 5 4 4 Wind Submenu This menu provides a more comprehensive indication of the wind Wind unawr Wind 30s speeds on site This includes the Wind 10m instantaneous unaveraged and the Figure 5 7 System Menu winds speed averaged over both the last 30 seconds and 10 minutes Access this menu by pressing enter on the keypad in the menu line Wind GW UK 18 User Manual Issue Number 2
49. y stop the turbine Confirmation of the error is indicated on the start menu under status see figure 5 2 By accessing the error menu the source of the error can be obtained see section 5 3 2 The error menu on the operating Error result Active statuscodes panel contains the following Manual stop menu lines Figure 5 3 Error Menu First Line Error Result Press enter on this line to access the Error Results Menu This line gives all active status codes GW UK 18 User Manual Issue Number 2 45 of 84 Date of Issue 17th Nov 2009 Third Line Displays the most recently activated error N B the error in figure 5 3 indicates that the turbine has been manually stopped This is one example of an error message An overview of errors is detailed in Annex 3 5 3 2 Accessing the Error Menu Accessing the Error Menu Zeg Ensure that the Start Menu is l l B O 251 0 0kW displayed on the operating 7 2m s 00 0000RPM 5 TOPPED Status ERROR panel Accessrights 50 Request AcCtT1Tve stTat If you have not done so obtain Access Rights and Active Status before continuing See Section 5 2 for details Step2 Scroll down the menu line l Scroll down until the cursor is on the fourth line Status Error Press enter on the operating panel GW UK 18 User Manual 46 of 84 Issue Number 2 Date of Issue 17th Nov 2009 Step 3 Error result P The error menu is displayed rverzresult o ges
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