to e300 Limiter Manual - Kestrel Wind Turbines-Home
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1. The Kestrel Type 0702 Voltage Limiter is designed for continuous operation on 100 duty cycle and requires no regular part replacement Keep the unit clean and ensure that no foreign objects reduce the airflow through the bottom inlet grill or the top front outlet Clean the case only with a soft damp cloth Do not use any form of solvent This product controls and limits voltages that can cause a shock Always take extreme care when the cover is removed In the unlikely event of failure the unit should be returned to the dealer or direct to the factory for repairs 9 WARRANTY CONDITIONS Kestrel s wind turbines and voltage limiters are manufactured to the highest standards in accordance with Kestrel Wind Turbines standard and quality specifications and warrants that the voltage limiter is in good working order upon delivery and for a period of 24 months Warranty terms and conditions are outlined below 1 Eveready warrants that Limiters 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 further subject to the Customer returning the defective Limiter at its cost to the premises of Eveready within the warranty period and furnishing full details in writing of the alleged defect 3 Everea2. Aine kestrel wind turbines ao Registration Number 2006 005438 07 VAT Registration Number 4870231406 Tel 27 0 41 401 2500 Website www kestrelwind co za Kestrel Voltage Li m iter Type 0702 User Manual Revision 1 1 04 08 Revision 1 0 12 07 For the following models of type 0702 voltage limiter Type 0702 1000 135 e300 009 110 1000W 10A Type 0702 1000 280 e300 009 200 1000W 4A prov GY j SOUTH AFRICAN NN CONTENTS PAGE 1 Safety Considerations 1 1 Mechanical Safety 3 1 2 Electrical Safety 3 1 3 Installation Hazards 3 1 4 Operational Safety 3 2 Voltage Limiter Overview 2 1 Voltage Limiter Description 4 2 2 Identification and Markings 4 2 3 Applications and uses 4 3 Voltage Limiter Assembly 3 1 Components Supplied 5 3 2 Components not Supplied 5 3 3 Tools Required 5 3 4 Unpacking 5 4 Installation Instructions 4 1 Typical Installation Example 6 4 2 Mounting the Voltage Limiter 7 4 3 Electrical Wiring 8 4 4 Securing the Voltage Limiter 9 5 Wire and Cable Sizes 5 1 Wind Turbine Wiring 10 5 2 Lightning Protection 10 5 3 Wire Tables 1 6 Technical Specifications 12 7 Trouble Shooting 13 8 Maintenance 14 9 Warranty Conditions 14 10 Customer Feedback 17 eready Diversified Products Pty Ltd i SE provoi Of 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
3. Limiter uses electronic means to restrict the incoming voltage at a pre designed value The product uses linear technology causing no electrical disturbance during operation This quality is paramount when powering any communication or computer equipment The Voltage Limiter is passive and uses no energy whatsoever during normal operation If for any reason the generator voltage rises the limiter restricts this voltage rise to a preset value It achieves this limiting by loading the generator The product is housed in a steel enclosure for wall mounting It is extremely reliable in operation and incorporates a failsafe design Unit cooling is achieved by convection and three assisting fans 2 2 Identification and Markings Removing the front cover reveals the product rating plate if the Voltage Limiter does not carry this stamp it does not carry a Kestrel warranty and may not be authentic A connection diagram is adhered inside me cover Kestrel CE wind turbines ee O PRODUCT RATING LABEL Eveready Diversified Products Pty Ltd MADE IN T A Kestrel Wind Turbines SOUTH AFRICA By P O Box 3191 Struandale North End A Port Elizabeth 6056 RSA fi NOTE Product Rating label example above is for format only specifications do not apply 2 3 Applications and Uses The Kestrel Voltage Limiter Type 0702 is primarily intended for use with the e300 1kW Kestrel wind turbine that has either been installed with an in line batter
4. 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 Voltage Limiters 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 Be responsible when using all tools whether manual or powered 1 2 Electrical Safety Read and adhere to the installation instructions for this product Do not work on the system when the wind turbine is running or when lightning is possible Disconnecting and re connecting wires 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
5. AWG Wire Size for e220 200V 4A maximum current zome aom oomo aoma omn Wire Size for e300 110V 12A maximum current BEC 20m 66 som 66 E E E room 07 om DT a E E E One OT Tomo Wire Size for e300 200V 6A maximum current somiasoy 00m 8307 oases mn Team Rama Ram TT ia x MA kestrel Eveready Diversified Products Pry Ltd its ee ee on 6 TECHNICAL SPECIFICATIONS General Linear controlled voltage limiter to telecommunication specification with 800 and 1000W capability for the over voltage protection of suitable series connected charge controllers and grid tie inverters Supplied to order for system voltages of 110Vdc and 200Vdc Maximum Current Controller Model Rated Power Type 0702 1000 135 1000W 10A Type 0702 1000 280 1000W 4A Input voltage and variation 110Vdc nominal 135Vdc 0 400Vdc 200Vdc nominal 280Vdc 0 800Vdc Efficiency gt 99 at full load Input frequency N A dc input Input power factor N A dc input 135 126Vdc 280 245Vdc Output Voltage 135Vdc Factory set no user adjustment Output Voltage 245Vdc Factory set no user adjustment Output voltage ripple N A Output voltage regulation 8 2 User control Turbine brake and output isolate circuit breaker User controls external None LED Indication None Cooling Natural Convection with fan assist Maximum Ambient 40 C Weight 30kg IP Rating IP35 Cabinet Dimensions wall mounting 500Wx620Hx300D Certifica
6. ER FEEDBACK EVERENN kesi el wind turbines i a Customer enquiry and feedback sheet Customer Name Postal Address Serial 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 17 fi Kesh el d turbines Eveready Diversified Products Pry Ltd ss ene es
7. Q1 is off There is no reaction i Complete the external wiring to the charge controller or Grid Tie inverter Follow the manufacturer s instructions for this work Only after all wiring is complete and secure the Voltage Limiter output circuit breaker may be switched on and the turbine brake switch switched off Switch the turbine switch OFF The instructions are reversed for de commissioning First isolate the additional equipment switch the Voltage Limiter output breaker OFF and then operate the turbine brake switch A disconnected turbine should always be shorted 4 4 Securing the Voltage Limiter Always switch the turbine brake on S1 ON and the output circuit breaker off Q1 OFF before any maintenance or service Remember to re fit all covers and guards on all equipment installed before switching on NOTE The Voltage Limiter controls high voltages and the internal components can cause a shock hazard Be aware and consult a professional if you are in any way unsure 9 FEM kestret urbines Eveready Diversified Products Pty Ltd E E prouir GY j SOUTH AFRICANN 5 WIRE AND CABLE SIZES 5 1 Wind Turbine Wiring Kestrel wind turbines produce dc power and output on two double insulated output wires tails The RED wire is POSITIVE and the BLACK wire is NEGATIVE 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
8. RCUIT BREAKER is designated Q1 The turbine brake switch stops the turbine by creating an electrical short on the turbine input When operated this prevents high turbine open circuit voltages being developed The wind turbine should not be rotating during this installation If turbine access is not possible short the two turbine power wires together Observe the Polarity at all times Only connect VE RED cables to VE RED terminals and VE BLACK cables to VE BLACK terminals ONLY THE RIGHT FRONT PANEL IS REMOVED FOR INSTALLATION a Arrange the wires from the turbine and the battery ready for connection b Check that the turbine wires are shorted Check that the output wires are isolated from the charge controller or Grid Tie inverter c Check that the Voltage Limiter OUTPUT CIRCUIT BREAKER Q1 is switched OFF and that the TURBINE BRAKE SWITCH S1 is switched ON d Connect the output wires to the Voltage Limiter output terminals VE and VE observing polarity e Connect an electrical earth wire to the marked earth screw terminal provided f Separate the turbine wires and connect the turbine negative wire to the Voltage Limiter negative terminal You may have to improvise by maintaining a short on the turbine wires as this connection is made g Finally connect the turbine positive wire to the Voltage Limiter positive terminal h Check that the turbine brake switch S1 is ON and that the output circuit breaker
9. all around the unit for cooling FIXINGS 540 21 25 Do not place any objects on the top of the enclosure The unit relies on the free passage of air through the heat sink for cooling NOTE The Voltage Limiter uses cooling fans Make sure that the bottom air entry is kept free of obstructions Unit cooling relies on the free passage of air through the cabinet a CUSED a SEO ISOILLE N Ce tat LA 620 24 3 308 20 Check again that the wall hanger is secure to the fixing surface Now raise the voltage limiter and clip the upper rear angle on to the wall hanger Centre the limiter and fit the single bottom fixing screw through the limiter enclosure screwing it fast into the wall hanger 7 E kestrel wind turbines Eveready Diversified Products Pty Ltd EO E os Pee 4 3 Electrical Wiring 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 OUTPUT TSOLATOR Eveready Diversified Products Pty Ltd eee prov GY j SOUTH AFRICANN PLEASE FOLLOW THE INSTRUCTIONS BELOW CONSULT SECTION 5 FOR WIRE SIZE RECOMMENDATIONS The Voltage Limiter is provided with two pairs of VE and VE clearly marked terminals for TURBINE and OUTPUT at the bottom of the regulator The TURBINE BRAKE switch is designated S1 and the OUTPUT CI
10. dy s obligations under this warranty shall be limited to the repair or replacement of defective Limiters 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 Limiters caused by winds exceeding 160 kilometres per hour or any other factors beyond the control of Eveready 5 The Customer may purchase an extended warranty from Eveready in respect of Limiters subject to 14 Even Kestrel wind turbines Eveready Diversified Products Pty Ltd Se ee Eveready s standard conditions prouir GY j SOUTH AFRICANN CONTACT KESTREL WIND TURBINES OO O O O Kestrel Wind Turbines Eveready Diversified Products Pty Ltd Eveready Road Struandale North End Port Elizabeth 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 P O Box 3191 North End Port Elizabeth 6056 Eastern Cape Republic of South Africa provo GY j SOUTH AFRICAN NOTES EE wind turbines Eveready Diversified Products Pty Ltd Pos Ss coun Run Of 10 CUSTOM
11. e controller and storage battery Note that other electrical equipment will be required to comply with local installation requirements KESTREL VOLTAGE LIMITER TURBINE OUTPUT OUTBACK TYPE 0702 BRAKE CIRCUIT OTHER SWITCH BREAKER CHARGE e CONTROLLER IS kestrel TURBINE OUTPUT INPUT OUTPUT t EARTH BATTERY A typical Grid Tie installation is shown below The system comprises an e300 1kW Kestrel wind turbine voltage limiter and an alternative manufacture Grid Tie inverter Note that other electrical equipment will be required to comply with local installation requirements KESTREL VOLTAGE UMITER TYPE 0702 TURBINE OUTPUT BRAKE CIRCUIT SWITCH BREAKER kestrel EARTH GRIDTIE INVERTER AC MAINS OUT lb Consult the Grid Tie inverter and charge controller manuals for full installation procedures 6 EE kec wind turbines Eveready Diversified Products Pty Ltd provoi Of SOUTH AFRICAN NN INDOOR ENCLOSURE WALL HANGER 4 2 Mounting the Voltage Limiter E FIXING CENTRES 370 14 5 The Kestrel Voltage Limiter Type 0702 is only suitable for indoor installation ia The unit must be vertically mounted using the wall hanger supplied Fix the wall hanger using secure fastening with suitable wall plugs or bolts Check that a minimum of 100mm 4 space
12. 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 Choose the wire size that is suggested for the size of turbine electrical current and the distance from the turbine to the charge controller 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 system from induced voltages and static The installation must comply with local requirements for electrical installations 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 800mm 2 5 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 requi
13. res an 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 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 regulator input EE Kestrel wind turbines Eveready Diversified Products Pty Ltd Ss E ee provo GY j SOUTH AFRICANN 5 3 Wire Tables 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 top of your structure ie the e150 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 lengths account for a double cable run both ve and ve together being given in metric metres m and imperial feet Wire cross sectional area is given in metric square millimetres sq mm and American Wire Gauge
14. tion Complies with EMC requirements CIS22 Class B 12 EE Kestrel t ee Eveready Diversified Products Pty Ltd coun VQ 7 TROUBLE SHOOTING THE KESTREL TYPE 0702 VOLTAGE LIMITER MAY BE SERIOUSLY DAMAGED FROM POLARITY REVERSAL wrong connection of ve and ve wiring VOLTAGE LIMITER DEGRADATION CAN OCCUR FROM IMPROPER INSTALLATION CAUSING OVERHEATING IF FOR ANY REASON THE WIND TURBINE IS DISCONNECTED SHORT THE GENERATOR OUTPUT WIRES THIS WILL LOAD THE GENERATOR AND MINIMISE ROTATION Q The cooling fans never switch on A The turbine stop switch is ON The fans are automatic and only operate when voltage limiting occurs Q The Output circuit breaker trips A There is a fault on the output cables The output cables are reversed Q The Voltage Limiter is always working at a high temperature A The unit is diverting energy The output circuit breaker has tripped The charge controller or inverter has failed The mains have failed inverter only Internal limiter components have failed Q Will damage the Voltage Limiter if disconnect the charge controller or the inverter A No the Voltage Limiter will continue to control with nothing connected It may however become quite hot as it has to divert all the energy from the wind turbine It is best to operate the turbine stop switch rather than have the controller working so hard for no reason Eveready Diversified Products Pty Ltd ea E on 8 MAINTENANCE
15. use common sense Consult a qualified electrician if you are unsure 1 3 Installation Hazards Be sure to read and adhere to the installation instructions for this product Always work carefully and have an assistant wherever possible Always re check the work as you progress Slack bolts poor workmanship and loose electrical connections must be avoided 1 4 Operational Safety Be aware that the voltage limiter will become hot during certain operation modes This is quite normal but be aware of high temperatures on the rear heatsink System checks are best carried out in calm weather conditions Avoid any maintenance or inspection during windy weather Be aware that internal voltages can cause a shock 3 fa Zane wind turbines Eveready Diversified Products Pty Ltd Se ae provo GY SOUTH AFRICANN IMPORTANT This product is not designed to be used on a Kestrel Battery charging system The Voltage Limiter is solely to restrict the output voltage of a Kestrel wind turbine in Grid Tie applications and hybrid applications using an Outback MX60 Sustainable renewable energy sources such as wind turbines and hydro generators are often connected to a charge controller or a Grid Tie inverter Such components can exhibit operational modes that reduce the demand or disconnect the system from the generator Any operational generator or alternator will exhibit high output voltages when no output is demanded The Kestrel Type 0702 Voltage
16. y charge controller such as the Outback MX60 or a Grid Tie inverter Each application may require specific additional electrical equipment Consult the manuals supplied with this equipment Eveready Diversified Products Pty Ltd CO ee PROUDLY j SOUTH AFRICAN 3 VOLTAGE LIMITER ASSEMBLY 3 1 Components Supplied The following components are supplied Voltage Limiter assembly Steel Wall Hanger 3 2 Components Not Supplied The following components are necessary to complete an installation Electrical crimp terminals C Wall fixing screws or bolts 20mm cable glands 3 3 Tools Required The following hand tools are required for the charge controller installation Small size electrical screwdriver C Medium size electrical screwdriver Wire strippers for electrical connections Electrical crimping pliers Tape measure for positioning C Spirit Level Optional Hand drill and suitable drill bits 3 4 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 and identify the parts Eveready Diversified Products Pry Ltd ong prov GY SOUTH AFRICAN N 4 INSTALLATION INSTRUCTIONS 4 1 Typical Installation Example A typical battery charging installation is shown below The system comprises an e300 1kW Kestrel wind turbine voltage limiter alternative charg
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