Excel 10 Owners Manual
Contents
1. then you will have a second utility meter to register excess production and your utility will pay or credit you for this typically at less than full value If your utility experiences an outage blackout the wind system will cease to produce power so that it does not present an electrical safety hazard to utility repair crews Although the wind turbine will continue to operate no power will be transferred from the Powersync II inverter to your circuit breaker panel When utility power is restored the Powersync II will automatically return the wind system to full working status following a five minute delay and then a two minute countdown These time delays are dictated in the UL standards required by the utilities The rotor of the EXCEL 10 should begin to rotate when the wind speed reaches approximately 8 mph 3 6 m s Once started the rotor may continue to turn in winds below 5 mph 2 2 m s but the system will not be producing power below this wind speed Page 7 Owner s Manual Bergey EXCEL 10 Turbine NOTE All operational wind speeds given assume steady winds sea level conditions and moderate temperatures Hot weather high altitude turbulence and gusting winds will reduce system performance The rotor speed will increase with increasing wind speed and the system will produce a higher output This output increases rapidly because the energy available in the wind varies as the third power cube of the wind speed For example2. C copper wire only The inverter s earth 4 AWG minimum recommended ground connection must Run the phase wires underground between the tower and the be bonded directly to the inverter This will help reduce lightning surges The bare service entrance s earth solid copper ground wire is run outside the conduit _ ground which in turn is bonded to neutral 3 Markings a Enclosure Type 1 for INDOOR USE ONLY b Earth ground is indicated by the following marking 4 Operation This equipment is a UL 1741 certified Utility Interactive Inverter and complies with the requirements of IEEE1547 which is the standard for interconnecting distributed resources with electric power systems The Normal Operation of the inverter is as follows When single phase 240VAC is applied to the inverter the display will power up and a message stating that the unit is initializing is shown A countdown timer set for 5 minutes 300 seconds starts before the inverter is ready to transfer power to the utility grid The inverter will automatically transfer power to the utility when AC voltages in the range of 30VAC to 400VAC are present at the Turbine input Page 6 AMFA 27 AMFA 29 Operators Manual 5 Touch Screen Display a The touch screen display located on the front panel of the enclosure provides manual over ride and status of the inverter s operation The touch screen display also provides a Stop and a Reset button The Stop button is used when it
3. if the wind speed increased form 5 mph to 10 mph a factor of two the energy in the wind would increase from one unit to eight units a factor of eight 2 to the 3 power One result of this relationship is that there is very little energy available in light winds For the average site winds in the range of 12 20 mph 5 5 9 m s will provide most of the system s energy production on an annual basis B HIGH WINDS AUTOFURL During periods of high wind speeds the AutoFurl system will automatically protect the wind turbine Furling means that the rotor is turned away from the wind When furled the power output of the turbine will be reduced In winds between 33 mph 15 m s and 45 mph 20 m s it is normal for the turbine to repeatedly furl and then unfurl and then furl again During intermittent cycling the turbine may produce output surges up to 13 000 watts C UNLOADED OPERATION If an abnormal condition occurs on the utility line such as a voltage fluctuation or a complete interruption the Powersync II inverter will automatically disconnect the wind turbine from the power grid If sufficient wind is present the rotor will continue to operate Since it is unloaded it will spin at a higher soeed and some increase in blade sound is to be expected This is a perfectly safe and permissible condition as the AutoFurl system will continue to protect the turbine A DANGER During unloaded operation the alternator can still generate high vo
4. Bergey EXCEL 10 Turbine June 8 2009 Return to Bergey Windpower Company 2200 Industrial Blvd Norman Oklahoma 73069 405 364 4212 BWC WIND TURBINE SYSTEM REGISTRATION CARD OWNER NAME Address City Slate Postal Code Country Phone DEALER NAME Address City Slate Postal Code Country Phone LOCAL UTILITY COMPANY INFORMATION if grid connected system Name of Utility Net Metering Yes O No HYBRID SYSTEM lf applicable Is turbine part of hybrid wind PV diesel system O Yes O No PV array O Yes O No PV Power rating kW Diesel Gen set 1 Yes L No Generator rating kW OWNER S or DEALER S SIGNATURE DATE SYSTEM INSTALLED WIND SYSTEM MODEL Serial No e g 2009866 near top of mainframe tube Controller O PowerSync Il O VCS 10 CT Powercenter Controller Serial No Blade Serial Numbers e g 10080025 stamped on blade root pad Tower Type Height Anchor Type Wiring Run Length Tower to Controller ft Wire Size gauge Wire Type DO Copper O Aluminum BATTERY BANK INFORMATION if applicable Battery Manufacturer amp Model Battery Bank Voltage 024V 048V 01120V LI240V Battery Bank Amp Hours Number of Battery Strings Inverter Manufacturer and Model WARRANTY REPAIR IS PERFORMED ONLY AFTER FACTORY AUTHORIZATION PLEASE RETURN THIS CARD AND PHOTOGRAPHS OF INSTALLATION PROMPTLY IN ORDER TO ASSURE COVERAGE Required Photographs Complete tower turbine system view Anchor photos
5. Check the tail pivot pin and particularly its fasteners Close the nacelle and check that all of its fasteners are secure While descending the tower inspect the following A Check that the tower wiring is properly secure B Check all fasteners C Look for any cracks in the tower structure D Check the condition of the guy wire attachment E Check the furling cable Check the furling winch and make sure that the furling cable is not twisted up If the cable is twisted up check the swivel Check the connection on all ground rods and hardware Remove the alternator shorting connection Check the disconnect switch Switch the disconnect switch to OFF and unfurl the wind turbine Listen to the sound of the machine as it speeds up No mechanical sounds such as a clunking or banging should be heard Also watch for any new or significant vibration The turbine operation should be smooth Inspect the wire run particularly all electrical connections Use a Meggar to check the three phase wiring from the turbine to the controller the procedure is the same as used for commissioning Page 1 7 Owner s Manual Bergey EXCEL 10 Turbine 23 Use a VOM to check that the three legs of the AC output of the wind turbine are balanced 24 Check condition of all wiring connections into and out of the Powersync Il 25 Check the fan filters on the Powersync Il At the second annual inspection and at each alternate inspection therea
6. Conductors The following symbols are used as markings on this product with the following meanings Equipment grounding conductor This inverter is intended for operation in an indoor NEMA 1 compatible environment having a maximum ambient temperature of 45 degrees C This unit or system is provided with fixed trip limits and shall not be aggregated above 30 kW on a single Point of Common Connection CAUTION To reduce the risk of fire connect only to a circuit provided with 80 amperes maximum branch circuit over current protection in accordance with the National Electrical Code ANSI NFPA 70 Note that the input and output circuits are isolated from the enclosure In accordance with Clause 15 2 1 1 of CAN CSA C22 2 No 107 1 system grounding when required by the Canadian Electrical Code Part I is the responsibility of the installer Page 3 AMFA 27 AMFA 29 Operators Manual 2 Installation a Mounting i The enclosure having a NEMA 1 rating is designed for indoor installation ii The enclosure is provided with four mounting feet with 0 281 dia mounting holes iii For mounting to a 0 10 thick metal surface use M6 7 20 or 7 28 bolts grade 3 or higher with nuts and flat washers iv For mounting to concrete use M6 or 7 bolts using concrete anchors with an 800 pound or greater tension rating v The required bolt length is such that the internal threads need to be 100 engaged vi The enclosure is to be
7. Power Curve Sea Level USDA Data per IEC 61400 12 1 m s 2 237 mph 0123 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Wind Speed m s at Hub Height Owner s Manual Bergey EXCEL 10 Turbine INTRODUCTION This manual contains important information concerning your Bergey EXCEL 10 wind turbine system and its operational characteristics We strongly recommend that you read and familiarize yourself with its contents At several points in this manual items of special interest or significant impact are highlighted by one of the following symbols A DANGER Hazards or unsafe practices that could cause personal injury or death Hazards or unsafe practices which could cause product damage NOTE Significant points of interest Serial Numbers Each Bergey EXCEL 10 wind turbine has a serial number located on the tower adapter The turbine serial number can also be found on the outside of the shipping carton and on the warranty registration card We recommend that the serial number be copied to this manual for possible future reference Bergey EXCEL 10 Serial No The Powersync II inverter has a serial number label on its right side We recommend that this serial numb
8. is indicated 3 The most likely problem is a shorted alternator Diagnosis requires tower climbing Rotor does not turn even when winds exceed 15 mph 6 7 m s 1 Do nothing ice will dislodge in a few days No need to furl the turbine 2 Contact your dealer 3 Contact your dealer Contact your dealer 1 Turn off utility power to inverter using the dedicated breaker in your breaker panel for a minimum of 20 seconds Then turn power back on using the breaker Wait 300 seconds 5 minutes If inverter does not resume operation with full display functionality contact your dealer Page 21 Owner s Manual Bergey EXCEL 10 Turbine Appendix Page 22 Owner s Manual Bergey EXCEL 10 Turbine F 1 10 Year Limited Warranty BWC Excel Wind Turbine Bergey Windpower Company Wind turbines their associated electronics and towers supplied by Bergey Windpower Company BWC are warranted against defects in design material and workmanship under normal use for which intended BWC Excel wind turbines and blades carry a ten 10 year warranty after date of installation Electronic components and towers supplied by BWC carry a five 5 year warranty after date of installation During the warranty period BWC will repair or replace at its discretion defective components or assemblies BWC will also pay one way shipping charges For customers not in the USA shipping and insurance charges will be pre paid t
9. is desired to disconnect the inverter from the power grid and the wind turbine After Stop is pressed the inverter will remain in a powered up stand by mode until Reset is pressed or Grid voltage is removed When Reset is pressed the inverter will resume normal operation b Status i Status of the inverters operation is shown on the lines one and two of the display The following table lists the status messages that may appear Status Message Initializing in progress For Wind voltage threshold AG Running The active rectifier is regulating the internal DC Boost voltage The inverter is transferring power to the utility grid Fault A fault has occurred See fault messages SE The manual stop button has been pressed Press Reset pe Three faults have occurred in an hours time Press Reset Here Indicates that a communication problem exists between the display and the inverter Check for bad cable connection The inverter has detected that the output voltage is approaching the Soft Grid over voltage limit and is reducing its output to compensate for the less than ideal current carrying ability of grid connection Running Output Power 12000 Watts Page 7 AMFA 27 AMFA 29 Operators Manual c Fault Messages i Fault messages are displayed when a fault occurs and when the last fault parameter is selected The following table is a list of possible faults that may be displayed Fault Description Fault Message Fault
10. on pre 2004 turbines when design was changed 2 Requires inspection 3 Excessive grease leakage Squeaking sounds at low speed Sound comes and goes but occurs at the same wind speed s Switch fused disconnect on tower to OFF If growling disappears an electrical problem is indicated If growling continues a mechanical problem is indicated 1 Check fuses Check wiring for continuity phase to phase fault or short to ground 2 After completing the wiring check disconnect the inverter and reconnect wiring to the turbine If the noise disappears an inverter problem is indicated 1 Have spinner inspected 2 Have alternator inspected 3 Have alternator inspected This is normal but contact your dealer or the Bergey Service Department if the noise is excessive 1 Repair or replace as needed 2 Contact your dealer 3 Have the alternator inspected Page 20 Owner s Manual Rotor turns slowly and does not speed up in higher winds Rotor does not turn at all Powersync II display not functioning 2 Short circuit in wiring or inverter 3 Short circuit in tower wiring slip rings or alternator Mechanical failure inside alternator 1 No power to inverter 2 Display or other inverter component not functioning properly Bergey EXCEL 10 Turbine Ice build up on blades 1 Check for ice 2 Open tower disconnect If turbine spins freely an electrical system problem
11. CEL WIND TURBINE and TOWER Please refer to the BWC EXCEL Installation Manual and any addendum for the specific tower design for instructions on installing the wind turbine and tower B FUSED DISCONNECT SWITCH The electrical output of the wind turbine is a three phase alternating current AC We strongly recommend the installation of a fused three phase AC disconnect switch between the wind turbine and the Powersync II as shown in the drawing on Page 16 This switch is commonly referred to as an Accessible Disconnect Switch ADC and most utilities will require one to be installed A 60A weather tight switch box with 45A fuses for the 240 VAC 60Hz or 220VAC 50Hz system is recommended The fuses will help protect the alternator in the event of a wiring controller or load short circuit The fused disconnect switch is normally installed at the base of the tower A CAUTION Do not install a short circuiting switch that will provide dynamic braking of the alternator These switches can be easily misused leading to serious damage to the alternator Such damage is not covered by the BWC warranty C WIRE RUN AND WIRE SIZES Please refer to the BWC EXCEL Installation Manual for recommended wire and conduit sizes for the tower to Powersync II wire run Refer to the row labeled BWC Excel S for appropriate wire sizes D POWERSYNC II INVERTER The Powersync Il inverter should be installed indoors near the main breaker enclosure i
12. I Inverter Alternator Spinner Nacelle Rotor Mainframe Blades Assembly Powersyncll Assembly Inverter Page 4 Owner s Manual Bergey EXCEL 10 Turbine A ROTOR SYSTEM The rotor system consists of three PowerFlex fiberglass blades Acting like aircraft wings the blades convert the energy of the wind into rotational forces that drive the alternator The PowerFlex blades are rigidly attached to the alternator and they are fixed pitch The Excel 10 rotor blades have a proprietary airfoil the BWC 7 which was custom designed to provide high efficiency and low noise The blades for the EXCEL 10 are extremely strong because they are made in a pultrusion process that puts more high strength glass fibers in the structure than any other molding technique This contributes to their long life and toughness Blade sets are carefully matched for balance at the factory to ensure smooth operation of the wind turbine Each blade has a serial number inscribed on its root pad at the inboard end B ALTERNATOR The alternator converts the rotational energy of the rotor into electricity The alternator utilizes permanent magnets and has an inverted configuration in that the outside housing rotates while the internal windings are stationary It was specifically designed for the Bergey EXCEL 10 and produces power at low speeds eliminating the need for a speed increasing gearbox Since it uses permanent magnets the alternator is gener
13. Message Code Description IGBT Desat or control logic fault An occurrence of this INTERNAL ERROR fault requires that the unit be completely powered down to reset it DC OVER VOLT 1 1000 The DC Bus voltage has exceeded its maximum threshold DC OVER VOLT 2 1500 The DC Input voltage has exceeded its maximum threshold DC UNDER VOLT 4250 The internal DC Boost voltage has dropped below its minimum threshold AC OVER VOLT 2030 The AC line voltage has exceeded its maximum threshold AC UNDER VOLT 2280 The AC line voltage has dropped below its minimum threshold TURBINE PHASE 2500 Indicates that there is a problem with one or more of the turbine input phases Bad connection missing phase OVER CURRENT 3000 Phase A line current sensed by the converter module has exceeded its maximum current threshold OVER CURRENT 3020 Phase C line current sensed by the converter module has exceeded its maximum current threshold OVER CURRENT 3050 The DC Boost phase of the converter module has exceeded its maximum current threshold OVER TEMP 4000 The internal high temperature threshold has been exceeded UNDER TEMP 4250 The internal low temperature threshold has been exceeded GROUND FAULT 7000 An input phase appears to be shorted to chassis ground AC UNDER FREQ 8000 The frequency of the utility grid voltage went out of range The upper range threshold was crossed AC OVER FREQ 8100 The frequency of the utility grid voltage went out of range The lower range thre
14. Owner s Manual Bergey EXCEL 10 Grid Intertie L Wind Turbine amp s s P site T Powersync II Inverter ea 3 xe N y z KE m r a gt A L7 ra 2 CH SZ X Ap Bergey Windpower Co 2200 Industrial Blvd Norman OK 73069 TEL 405 364 4212 BERGEMN Fax 405 364 2078 E mail sales bergey com WINDPOWER Web Site www bergey com Rev 1 March 2011 BERGEY EXCEL 10 SPECIFICATIONS PERFORMANCE START UP WIND SPEED 5 mph 2 2 m s CUT IN WIND SPEED 5 mph 2 2 m s RATED WIND SPEED 26 mph 11 6 m s AWEA RATED POWER at 11 m s or 25 mph 8 9 kW AWEA ANNUAL ENERGY at 5 m s average 000 13 600 kWh CUT OUT WIND SPEED erreurs none FURLING WIND SPEED eresnovvornesvesvevessessonveressennonveresnnnvene 36 40 mph 16 18 m s MAXIMUM DESIGN WIND SPEED 134 mph 60m s RATED POWER cannes t s 10 kW ROTOR SPEED E S 0 400 RPM MECHANICAL PE E E S 3 Blade Upwind Horizontal Axis ROTOR DIAMETER sa anus 23 ft 7 0m NE 1020 Ibs 460 kgs GEARBOX EE one none BLADE PITCH CONTROL none OVERSPEED PROTECTION AUTOFURL TEMPERATURE RANGER 40 to 140 deg F 40 to 60deg C ELECTRICAL OUTPUT FRY eis stecerderasasarestecteaeed acsuenesuinnosaees 240VAC 1 Phase 60Hz or 220VAC 1 Phase 50Hz GENERATOR GN Permanent Magnet Alternator POWER PROCESSOR ssssstssesscsanseaaenigsassaecsaetetsdvapaciaesaetiens Powersync II Inverter Bergey Excel 10
15. al straight position The rotor continues to spin even in very high winds and this actually makes the blades stiffer The AutoFurl system works whether or not the Powersync II inverter is on or not Unlike many other turbines designs the Bergey EXCEL 10 can operate safely without an electrical load connected to the turbine F SPINNER AND NACELLE The spinner nose cone and nacelle provide additional weather protection for the bearings and the slip ring assembly The nacelle also improves lightning protection G Powersync II Inverter The UL approved Powersync Il inverter converts the variable AC from the Bergey EXCEL 10 turbine into utility grade electricity so that it can be connected to the wiring in your home This conversion requires sophisticated electronics and is designed to operate automatically The Powersync II has a digital display that provides information on the status of the system its current output power and its cumulative energy production Page 6 Owner s Manual Bergey EXCEL 10 Turbine 2 SYSTEM OPERATION A NORMAL OPERATION The Bergey EXCEL 10 produces utility compatible power in the form of 240VAC 60 Hz single phase electricity 208 VAC 60Hz and 220 VAC 50 Hz options are available It is connected through the Powersync II inverter to the utility distribution network in the same manner as household appliances When the wind speed is too low to operate the wind turbine all of the electrical power need
16. ating voltage whenever the rotor is turning A DANGER The output wiring of the BWC EXCEL presents shock hazard whenever the rotor is turning Caution must be exercised at all times to avoid electrical shock C MAINFRAME The mainframe is the structural backbone of the wind turbine It serves as the attachment point for the yaw bearing and the housing for the yaw axis slip ring brushes The yaw axis is the full 360 degree pivot that allows the turbine to freely align itself to the wind direction D SLIP RINGS AND BRUSHES The slip rings and brushes conduct the electricity generated in the alternator from the moving as it orients with the direction wind turbine to the fixed tower wiring The slip rings are Page 5 Owner s Manual Bergey EXCEL 10 Turbine enclosed in a metallic housing to help protect them from lightning E TAIL ASSEMBLY AND AUTOFURL OPERATION The tail assembly keeps the rotor aligned into the wind at wind speeds below approximately 35 miles per hour 16 m s At about 35 mph the AutoFurl action turns the rotor away from the wind to limit the rotor speed in high winds The tail appears to fold but in reality the tail stays Stationary as the rotor turns sideways to the wind The rotor furls to a maximum angle of 75 degrees limited by rubber tail stops so that the unit continues to produce power in high winds When the high winds subside the AutoFurl system automatically restores the turbine into the norm
17. e leading edge tape 1 Replace tape as blade sound such as edge tape inspected necessary whistling or buzzing 2 Blade pultrusion 2 Have blades inspected 2 If blade damage is structural damage Cracks outboard of the suspected the turbine molded hub can lead to should be furled until it is blade failure inspected Contact your dealer Rotor is unbalanced 1 Uneven ice build up on 1 Ice on turbine and 1 Do nothing ice will causing the turbine to blades tower Turbine ran dislodge in a few days No move slightly back and smoothly before ice need to furl the turbine forth as it spins storm Slow rotor speed 2 Blade damage 2 Noice Turbine ran 2 If blade damage is smoothly before suspected the turbine should be furled until it is inspected Contact your dealer Page 19 Owner s Manual Bergey EXCEL 10 Turbine Turbine makes a banging or rattling sound once per revolution particularly at low speeds Turbine makes a fog horn sound at certain typically low wind speeds Turbine makes a continuous growling or rumbling sound which reduces at higher wind speeds 1 Loose spinner 2 Alternator rear bearing ring fasteners loose or missing 3 Alternator bearings Electro mechanical interaction between alternator and inverter that causes transient vibrations in the turbine 1 Wiring fault 2 Inverter fault 3 Alternator bearings 3 Check for excessive grease loss 1 More likely
18. ed directly onto the display could possibly leak inside and cause damage Dirt and fingerprints do not affect the operation of the touch screen display Page 9
19. ed for the home will be supplied by the utility company During these idle periods the Powersync II will consume approximately 0 3 kilowatt hours of electricity per day When the system begins producing power the amount of power which must be purchased from the utility is reduced by an amount equal to the output of the wind system From the perspective of the utility company the wind system output reduces the electrical load they have to supply just as if you turned off lights and appliances The output of the wind system fluctuates with the speed of the wind so the instantaneous amount of electricity being saved will be constantly changing Quite often your home will be served simultaneously by the utility and your Bergey wind turbine When the output of the wind system exceeds the power requirements of the house the excess electricity is sold back to the utility Both the consumer s right to interconnect a wind system and the utilities obligation to purchase excess power are prescribed by federal law PURPA Section 210 The amount you will be credited or paid for this excess production varies state to state and sometimes utility to utility If your utility company offers net metering then your meter is allowed to turn backwards so that you essentially bank energy at full value for less windy periods This banking can be done over a month or over a year depending on the policy of your state or your utility If you do not get net metering
20. er also be copied to this manual Powersync II Serial No Page 2 Owner s Manual Table of Contents Section Title Bergey EXCEL 10 Turbine 1 System Description A B Alternator C Mainframe D E F G Rotor System Slip Rings and Brushes Tail Assemble and AutoFurl Operation Spinner and Nacelle Powersync II Inverter 2 System Operation A High Winds AutoFurl Unloaded Operation Manual Furling Furling Procedure Powersync II Inverter 1monNw Normal Operation 3 Installation A B C D Bergey EXCEL 10 Wind Turbine and Tower Fused Disconnect Switch Wire Sizes Powersync II Inverter 4 Inspections and Maintenance 5 Trouble Shooting Problems 6 Appendix A B C Warranty Warranty Registration Vendors Manual for Powersync II inverter Page No MM on on U1 U1 U1 U1 D WOU O oNN me O 14 14 14 14 14 16 19 22 23 24 25 Page 3 Owner s Manual Bergey EXCEL 10 Turbine 1 SYSTEM DESCRIPTION The Bergey EXCEL 10 is an upwind horizontal axis wind turbine designed for distributed generation applications connected to the power grid on the customers side of the utility meter The complete unit consists of the following major components as shown in the figure below 1 Spinner 6 Slip ring and Brushes 2 PowerFlex Blades 7 Tail Assembly 3 Alternator 8 Nacelle Assembly 4 Mainframe 9 Furling Winch 5 Yaw Bearing 10 Powersync I
21. f possible The Powersync Il is designed to operate in a clean environment and should never be Page 14 Owner s Manual Bergey EXCEL 10 Turbine installed outdoors as it is not weatherproof and will be damaged by rain A minimum of six inches of clearance is required on the top bottom and sides of the Powersync II to ensure adequate air flow through the enclosure The Powersync II should be connected to a dedicated 70A breaker installed in the main breaker box System grounding is accomplished by attaching a wire 8 AWG minimum from the grounding lug inside the Powersync II enclosure to the panel ground inside the main breaker box Additionally the tower bond ground wire should be connected to the grounding lug inside the Powersync Il enclosure A typical system wiring schematic for the Bergey EXCEL 10 is shown below The three AC connections from the wind turbine can be connected to the Powersync Il terminals in any order there is no required phase orientation A DANGER Do not attempt to make the Powersync II connections with energized leads Always have the wind turbine fully disconnected and the circuit breaker switched to off before making the Powersync II connections All wiring should conform to the National Electric Code or other governing local electrical code The use of electrical conduit for wiring between components is highly recommended All terminations should be coated with an anti oxidation compound to prevent c
22. fter the right nacelle half should be opened and the slip ring cover removed This will allow the condition of the brushes and slip rings and internal fasteners to be checked A DANGER Only qualified personnel with proper safety equipment should climb the tower Never climb the tower when the rotor is turning Page 18 Owner s Manual Bergey EXCEL 10 Turbine 5 Trouble Shooting Problems The following guide can help to pin point the cause of operational problems with the Bergey EXCEL 10 wind turbine and the Powersync Il inverter For problems or symptoms not found in the following listing please contact the Service Department at Bergey Windpower Co at Tel No 1 405 364 4212 Telefax No 1 405 364 2078 or E mail service bergey com Broken furling cable 1 Over tightening of When replacing cable Replace cable and conduit furling cable check for free play inside as indicated 2 Jammed cable furling furling cable conduit cable conduit Check swivel 3 Leaving turbine furled for long periods 4 Swivel not installed or not working Oil stain at rear of nacelle Tail damper failure Check for damper If damper fails the test effectiveness by furling the turbine should be the turbine and then furled during high winds rapidly unwinding the until the damper is furling cable It should replaced take at least three 3 seconds for the tail to return to the straight position Turbine makes an unusual 1 Damaged blade leading 1 Hav
23. including all anchor hardware Photos showing all grounding connections Turnbuckle photos showing safety cables Installed rebar cages for anchors pads piers and any other concrete items gr Go D 6 Controller location and environment Controller interior showing wiring connections Interior of tower base disconnect switch showing fuses and wiring connections go N Page 24 Owner s Manual Bergey EXCEL 10 Turbine Powersync Il 240 VAC AMFA 27 and Powersync Il 208 VAC AMFA 29 Operator s Manual amp Installation Instructions Rev 2 6 Date 22 November 2010 Page 25 AMFA 27 AMFA 29 Operators Manual Permanently connected utility Interactive single phase inverters Model AMFA 27 WIND TURBINE INVERTER 240 VAC nominal output The phase angle between L1 and L2 is 180 Line to Neutral is 120 VAC nominal Model AMFA 29 WIND TURBINE INVERTER 208 VAC nominal output The phase angle between L1 and L2 is 120 Line to Neutral is 120 VAC nominal USL Evaluated to the requirements of the Standard for Safety for Inverters Converters Controllers and Interconnection System Equipment for Use with Distributed Energy Resources UL 1741 2nd Edition dated January 28 2010 CNL Additionally evaluated to CAN CSA C22 2 No 107 1 1 General Use Power Supplies 3rd Edition Dated September 1 2001 with revision through 2006 The Diversified Technology Inc Model AMFA 27 and AMFA 29 inverters are intended for
24. irectly to the service entrance s earth ground which in turn is bonded to neutral e AC Input Connection Turbine i Connect the three phase turbine wires to the DIN rail terminal block located on the lower right side of the enclosure ii The inverter s wind turbine input must be connected to a 3 phase delta or wye connection with the neutral not connected to earth ground left floating ili The inverter must be provided with 3 UL listed fuses rated 400 VAC minimum 50 Amp maximum for proper protection from the wind turbine input to the unit as well as an appropriate UL listed fuse holder to accommodate the fuses iv Tightening torque allowable wire size and type for the Field Wiring Terminals 1 22 Ibf in tightening torque 2 6 AWG to a maximum of 2 AWG for Copper Conductors Only 3 Wire type rated 90C minimum v An input ground connection must be made between the inverter and the ground terminal of the tower disconnect wire size minimum of 8 AWG f Earth Ground Connection i Earth ground is to be connected to the two terminals provided inside the enclosure as indicated by the earth ground equipment marking li Allowable wire size range is 8 AWG 4 AWG iii 50 Ibf in tightening torque Page 5 AMFA 27 AMFA 29 Operators Manual g Connection Example i Surge arrestors are not required but are recommended for a minimum amount of lightning and surge protection No lightning protection system provide
25. ltages so the EXCEL 10 electrical system should be handled with the same caution used during normal operation In order to enhance the systems reliability the power output of the Excel is limited to approximately 12 5 kilowatts Since this output is reached at 31 mph 14 m s the rotor will become progressively unloaded as wind speeds increase up to the furling point at Page 8 Owner s Manual Bergey EXCEL 10 Turbine approximately 35 mph 15 6 m s D MANUAL FURLING The Bergey EXCEL 10 is designed for unattended operation over an extended period of time Exceptional situations may occur however in which the wind turbine should be manually furled These situations include 1 EXCESSIVE VIBRATION Uneven ice build up ice shedding or blade damage may cause the wind turbine to experience excessive vibration Always furl the turbine as soon as an increase in vibration is detected Any new or excessive vibration in the turbine when ice is not present should be investigated immediately 2 UNUSUAL SOUND If the turbine begins making clinking growling or other unusual sound it should be furled and fully inspected as soon as possible 3 INSPECTION AND MAINTENANCE Whenever someone has to climb the tower the wind turbine must be manually furled and the alternator dynamically braked ie electrically shorted even if the wind speed is very low Manual furling of the EXCEL 10 is accomplished by operating the furling winch located a
26. me NOTE RATCHET SHOWN ENGAGED FURLING WINCH Figure 2 A CAUTION Do not over tension the furling cable Tightening the cable beyond the amount required to furl the wind turbine will reduce its ability to track the wind and may damage the furling system To return the turbine to the straight normal operation position grasp the winch handle firmly and then release the ratchet mechanism The cable can now be slowly unwound until the turbine has fully straightened out and the cable is slightly slack It is a good idea to then reengage the ratchet A DANGER Hold the winch handle firmly before the ratchet is released and until all tension is removed from the cable The winch handle could whirl dangerously if it is released before the cable tension is reduced F POWERSYNC II INVERTER The Powersync II inverter is connected to the household circuit through a dedicated 70 amp breaker Before opening the Powersync II enclosure the breaker must be turned off and the tower disconnect switch must be switched OFF to avoid electrical shock Page 10 Owner s Manual Bergey EXCEL 10 Turbine A DANGER Always remember that the system operates at 240 volts so electrical shocks can be fatal Using the utility grid as a reference the Powersync Il inverter converts the output of the wind turbine into utility compatible alternating current AC The Powersync Il inverter has been designed for automatic unattended operation and it is programmed to pr
27. ng itself or the power grid When a FAULT occurs the Powersync II will shut down no power production and a Fault Code will be displayed on the digital display A list of the Fault Codes can be found in the detailed instructions for the Powersync Il inverter provided in the Page 12 Owner s Manual Bergey EXCEL 10 Turbine Appendix FAULTS will reset themselves automatically assuming the underlying cause of the fault has been cleared unless the inverter experiences three 3 FAULTS of any type in a one hour period In this case a manual RESET is required on the digital display A CAUTION If a manual reset is required we highly recommend that you check the FAULT CODE list for indications that there is an equipment or wiring problem that needs addressing One unique feature of the Powersync II inverter is its Soft Grid power limiting capability that can reduce the number of nuisance FAULTS on weak power lines during periods of high turbine power output On a weak power line the EXCEL 10 wind turbine can on a windy day raise the local utility voltage above the UL 1741 threshold causing a FAULT The Soft Grid feature tries to prevent these FAULTS by reducing power output from the wind turbine When the Powersync Il is in this mode the digital display will show Soft Grid The STOP pad on the digital display will shut down the Powersync II inverter Press the RESET pad to restart which will start the 300 sec countdown If the circuit b
28. ng the Soft Grid over voltage limit and is reducing its output to compensate for the less than ideal current carrying ability of grid connection Using the Up and DOWN arrows you can scroll through the additional Powersync II information available as shown below Description Grid Voltage Magnitude of the connected single phase grid voltage Grid Frequency Frequency of the connected single phase grid voltage Bus Voltage Magnitude of the actively rectified DC bus voltage DC Current Averaged value of the DC current Turbine Volts Averaged value of the rectified AC voltage from the Input Output Power Output power displayed in watts Accum Energy Output Power accumulated over time of operation Accuracy within 10 Used for factory setup Used for factory setup Displays the last fault that occurred since the inverter was powered up along Last Fault with a fault code that may be useful when troubleshooting When the Powersync Il is starting up after initialization or after the RESET button has been pushed or after a power outage it will go through a 300 second 5 minute countdown that is required by UL 1741 This UL standard also dictates high and low limits for utility voltage and frequency outside of which the inverter is required to shut down until they return to the acceptable range This is called a FAULT condition There are a number of possible FAULT conditions during which the Powersync II will be protecti
29. o the port of entry into the customer s country This limited warranty is transferable and covers only products shipped after January 2009 Warranty coverage is extended only to customers who have submitted a properly completed BWC Warranty Registration Form and acceptable proof of correct system installation as requested in the BWC Registration Form Customer must also perform and document recommended inspections and any maintenance tasks that may be identified during inspections This limited warranty does not cover 1 Towers and equipment materials or supplies not manufactured or supplied by BWC BWC equipment that has been modified without prior factory approval Repairs performed by personnel not authorized by BWC Damage resulting from use of equipment not supplied by BWC Damage or loss of function sustained during periods when wind speed exceeds 60 m s 135 mph Acts of God 7 Incidental or consequential damages gr ja lt This limited warranty is in lieu of all other BWC guarantees or warrantees expressed or implied No employee agent dealer or other person is authorized to offer warranties on behalf of BWC BWC reserves the right to make design changes improvements and additions to its products without obligation to install such in products previously manufactured Page 23 Owner s Manual RETURN THIS CARD TO BWC ALONG WITH PHOTOS DOCUMENTING INSTALLATION NOTE DIGITAL PHOTOGRAPHS PREFERRED IF AVAILABLE
30. of operation and will not affect the strength or reliability of the blade B Condition of the leading edge protection tape Torn or peeling tape will need replacing C Leading or trailing edge damage D Condition of the paint Remove the spinner and hang it from the machine Check the torque on the blade nuts the recommended value is 150 ft lbs Check the front bearing for seal integrity and grease loss Reattach the spinner and check that it is secure Open the hatch on the nacelle Use a small rope to lash the hatch open At the 180 day inspection only Inspect the flanged connection between the mainframe and alternator Check the torque on each of the bolts the recommended value is 80 ft lbs Page 16 Owner s Manual Bergey EXCEL 10 Turbine 8 g 10 11 12 13 14 15 16 17 18 19 20 21 22 Check the rear alternator bearing for seal integrity and grease loss Inspect the mainframe for cracks Remove the slip ring cover plate Make the following inspections A Check brushes for ease or movement in the brush holder B Check slip rings for signs of arcing damage C Check that no grease from the yaw bearings has leaked on to the slip rings Inspect damper Some leakage around the front seal is okay Inspect the furling cable particularly at the ball end fork attachment to the tail boom and furling cable conduit Check for cracks or loose hardware on the tail boom and fin
31. oriented with the conduit openings facing toward the floor vii Enclosure ventilation is to be provided such that the following guidelines are satisfied 1 Provide a minimum of 12 inches clearance to the air inlet filters 2 Provide a minimum of 6 inches clearance to the outlet side vents 3 Use in a well ventilated area within the maximum ambient temperature rating 22 650 Page 4 AMFA 27 AMFA 29 Operators Manual 2X 62 000 2 260 2 000 19 900 23 900 b Electrical Connections are made to the unit via the holes in the bottom of the enclosure Holes are sized for 1 5 rated conduit Wiring methods in accordance with the National Electrical Code ANSI NFPA 70 are to be used c The input and output circuits are isolated from the enclosure System grounding when required by the Canadian Electrical Code Part I is the responsibility of the installer d AC Output Connection Utility i The AC output is single phase and not bonded to ground ii Connect the two single phase 240VAC wires to the dual fuse block located on the lower left side of the enclosure iii Tightening torque allowable wire size and type for the Field Wiring Terminals 1 100 Ibf in tightening torque maximum 2 6 AWG to a maximum of 1 0 AWG for Copper Conductors Only 3 4 AWG to a maximum of 1 0 AWG for Aluminum Or Copper Clad Aluminum Conductors Only 4 Wire type rated 90C minimum iv The inverter s earth ground connection must be bonded d
32. orrosion A CAUTION All loads should be equipped with fuses or circuit breakers to avoid hazards from accidental short circuits 10 kW Wind Turbine l Safety Cummulative J Switch l Production Meter l P n AC Load Unit Inverter Center Power rocessing FL Page 15 Owner s Manual Bergey EXCEL 10 Turbine 4 INSPECTIONS AND MAINTENANCE The Bergey EXCEL 10 turbine and tower should be inspected 30 days after installation and then again 180 days after installation Following these two inspections the installation should be inspected every two years and after any particularly severe weather Inspections should be done on days when the wind is below 16 mph 7 m s Check List for Inspections 1 Inspect each of the anchor points Ensure that all hardware is secure and the guy wires are properly tensioned Check to ensure that no strands are broken and the turnbuckle safety cables are in place Furl the wind turbine and check that the damper restricts the tail s unfurling to a period of at least three seconds when the winch cable is rapidly unwound Disconnect the inverter furl the turbine and short the alternator using the procedure given in the installation manuals Climb the tower Always use proper safety climbing gear and safe climbing practices Inspect the blades for A Cracks outboard of the hub pad in the blade pultrusion itself Cracks in the molded hub pad are normal after a few weeks
33. ovide maximum performance from your Bergey EXCEL 10 wind turbine It is also programmed to safely disconnect the wind turbine in the event of a problem with the utility power and to automatically reconnect the turbine after the problem is remedied The LCD digital display on the front of the Powersync II provides information on the status of your Bergey EXCEL 10 wind turbine The contrast can be adjusted UP or DOWN using hidden buttons on the right side of the display Running Output Power 12000 Watts In normal operation the Powersync II will show the status as Running and will display the instantaneous Output Power in Watts Other operating modes that may be indicated are as follows Page 11 Owner s Manual Bergey EXCEL 10 Turbine Waiting The inverter has been reset or that the 5 minute countdown delay is Initializing in progress Waiting The voltage from the turbine is lower than the factory set auto start For Wind voltage threshold AC Running The active rectifier is regulating the internal DC Boost voltage The inverter is transferring power to the utility grid A fault has occurred See fault messages lig a The manual stop button has been pressed Press Reset Fault Limit Three faults have occurred in an hours time Press Reset Indicates that a communication problem exists between the display and the inverter Check for bad cable connection The inverter has detected that the output voltage is approachi
34. reaker in your home or business load center circuit breaker panel trips it should be reset by first switching it to the OFF position and then to the ON position If the breaker trips again immediately or if it continues to trip after brief periods of normal operation switch the breaker OFF and contact your Bergey dealer for assistance The following recommendations will help ensure the safe operation of the Powersync II inverter 1 Keep all sources of moisture away from the Powersync II enclosure 2 Do not work near the Powersync II with gasoline paint thinner or any material which produces flammable vapor Do not store flammable materials near the Powersynce II enclosure 3 Do not open the Powersync II enclosure unless the circuit breaker and Accessible Disconnect Switch ADC at the base of the tower have been switched OFF Note that even with the circuit breaker and ADC switched OFF a shock hazard will still be present inside the Powersync II enclosure for approximately 15 minutes as the capacitor voltage drains down 4 Do not block airflow around the Powersync II enclosure in any way A six inch clearance must be maintained around the sides top and bottom of the enclosure for adequate air circulation Page 13 Owner s Manual Bergey EXCEL 10 Turbine 3 INSTALLATION Please use the following instructions in assembling and commissioning your system If you need any additional information please contact us A BWC EX
35. s complete protection Lightning damage is not covered under your warranty Wind Turbine y Wiring methods in accordance Electrical Connections are made to the with the National Electrical unit via the 1 5 conduit holes in the Code ANSI NFPA 70 are to be bottom of the enclosure Use at least used 12 of flexible conduit below inverter for f input and output connections In outside or wet locations use rain tight or wet location hubs that comply with UL 514B LA1503 Surge Utility Connection 12KW inverter Arrasto Tower Disconnect Switch wer Di wi AMFA 27 29 Locate at base Both input and output ONNE An additional disconnect disconnects must be opened switch may be needed if before making connections the inverter is not installed to the inverter conveniently close to the main breaker panel i Delta LA302R installed Main Breaker inside inverter on grid Panel output Turbine Disconnect Switch au With 3 UL listed 400V 50A fuses at Grid disconnect The inverter s earth ground connection must be bonded directly to the tower disconnect box which in turn should be connected to a ground rod at the tower Delta LA1503 installed inside inverter on turbine input Surge J Arrestor Surge Arrestor 60A 2 pole Single phase 240 208 Vac Backfeed 6 1 0 AWG 90 C copper wire Breaker or 4 1 0 AWG 90 C Aluminum wire 4 AWG minimum recommended Isolated 3 phase 400 Vac maximum 6 2 AWG 90
36. shold was crossed Page 8 AMFA 27 AMFA 29 Operators Manual d Parameters i The Up and Down arrow that is visible on the left side of the touch screen display is used to scroll through a list of parameters The list of viewable parameters is as follows nace Eau Displays the last fault that occurred since the inverter was powered up along with a fault code that may be useful when troubleshooting A hidden feature of the display is the contrast adjustment The right side of the display has invisible up and down arrows that can be used to increase and decrease the contrast of the display Vref is used as an index look up into a virtual table used for a customizable power curve the graph of which is configured by parameters 81 through 93 called Iref request values The virtual size of the table is 768 points The table parameters configure every 64th value of the look up curve for Iref Iref is the current request in counts for a given DC input voltage tracked by Vref Using this configuration the inverter can be adjusted to provide any power curve required 6 Equipment Maintenance a Periodically check the ventilation screen for the cooling fans When necessary use a vacuum to clean the screen from the outside of the enclosure Do not force air or spray water into the enclosure b The touch screen display may become dirty over time To clean the display use clean water applied to a soft non abrasive cloth Water spray
37. t the base of the tower The winch cable is connected to the tail boom such that as the cable is tightened the tail folds and the rotor is pulled away form the wind Furling the wind turbine will not stop the rotor completely and it may take some time for the rotor to be pulled around away from the wind Fully furled the rotor will still be partly facing into the wind and will normally turn at a reduced rate The rotor can only be brought to a complete stop by shorting the output leads of the turbine A DANGER Do not attempt to furl the wind turbine or approach any part of the tower when there is lightning in the area E FURLING PROCEDURE The furling winch is located at the base of the wind turbine tower To furl the wind turbine first make sure that the winch ratchet is engaged a strong clicking sound should be heard as the handle is turned The winch handle may then be turned until the tail comes to rest against its rubber stop When the stop is reached the tail will stop rotating towards the blades and the force required to turn the handle will greatly increase When fully furled the tail will have come around approximately 70 degrees it does not come around parallel to the blades The turbine may not come out of the wind immediately because the rotor forces will sometimes resist the sideways force acting of the tail This situation will correct itself after a Page 9 Owner s Manual Bergey EXCEL 10 Turbine short ti
38. variable frequency un rectified 3 phase AC input from Wind Powered Turbines Table of Contents 1 Ratings 2 Important Safety Instructions 3 Installation a Mounting b Electrical Connections 4 Markings 5 Operation 6 Touch Screen Display a Stop Reset b Status c Faults d Parameters l Equipment Maintenance Page 1 AMFA 27 AMFA 29 Operators Manual Ratings Turbine Input Input Current Maximum 40 Amps Input Short Circuit Current Maximum 462 Amps AC Backfeed Current to Input Source Utility Interactive Output AMAT AMFA 29 Page 2 AMFA 27 AMFA 29 Operators Manual Important Safety Instructions SAVE THESE INSTRUCTIONS This manual contains important instructions for Model AMFA 27 and AMFA 29 that shall be followed during installation and maintenance of the inverter The output field wiring terminal can be used for connection of a maximum of One 1 0 AWG wire per terminal 1 wire for each line The input field wiring terminal can be used for connection of a maximum of One 2 AWG wire per terminal 1 wire per phase per terminal provided The field wiring terminals shall be connected using the following wire types Copper Conductors Only Input connection Use No 6 2 AWG 90 C copper wire only Copper Aluminum or Copper Clad Aluminum Conductors Only Output connection Use No 6 1 0 AWG 90 C Copper Conductors Use No 4 1 0 AWG 90 C Copper Clad Aluminum or Aluminum
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