the manual - Kestrel Wind Turbines-Home
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1.2. This warranty shall not apply to any damage to Resistors 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 Resistors subject to Eveready s standard conditions 14 kestrel wind turbines Evuready Products Pty Ltd um mou Qf SOUTH AFRICAN NN CONTACT KESTREL WIND TURBINES 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 Evuready Uversified Products Pty Ltd P O Box 3191 North End Port Elizabeth 6056 Eastern Cape Republic of South Africa Tm wind turbines mou Of SOUTH AFRICAN NOTES Eveready Diversified Products Pty Ltd 10 CUSTOMER FEEDBACK kestrel wind turbines NER c V 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 us Indicate your enquiry or feedback in the space provided below Date Replied Signature Comments Eveready Divergified Products Pty Ltd
3. intended for use with Kestrel Charge Controllers connected to Kestrel wind turbines that have been installed to charge batteries Each application may require specific additional electrical equipment Consult the manuals supplied with this equipment 2 4 Application List The following table shows the appropriate diversion resistor that must be used with each Kestrel turbine and charge controller The electrical current rating gives a guide to the wire size requirements given in Section 4 of this manual TURBINE CHARGE CURRENT TURBINE MODEL VOLTAGE CONTROLLER DIVERSION RESISTOR Amps dc e150 e220i 12Vdc 0102 or 0401 12Vdc 0601 OR23 800W 62 e150 e220i 24Vdc 0102 or 0401 24Vdc 0601 94 800W 32 e150 2201 36Vdc 0102 or 0401 36Vdc 0601 3ROO 800W 19 e150 e220i 48Vdc 0102 or 0401 48Vdc 0601 800W 19 e150 e220i 110Vde 0102 or 0401 110Vdc CONSULT FACTORY e300i 12 0102 or 0401 12Vdc 0601 OR23 1200W e300 24Vdc 0102 or 0401 24Vdc 0601 OR75 1200W e300i 36Vdc 0102 or 0401 6 0601 2R50 1200W e300i 48Vdc 0102 or 0401 48Vdc 0601 2R50 1200W e300i 110Vdc 0102 0401 110Vdc 0601 11800 1200W 5 2 EVEREADY Kestrel S wind turbines Eveready Diversified Producta Pty Ltd Of SOUTH AFRICAN 3 DIVERSION RESISTOR ASSEMBLY 3 1 Components Supplied The following components are supplied Diversion Resistor assembly 800 or 1200W User Manual 3 2 Components Not Suppl
4. m wind turbines mm Registration Number 2006 005438 07 VAT Registration Number 4870231406 Tel 27 0 41 401 2500 Website www kestrelwind co za Kestrel Diversion Resistors o User Manual Revision 1 0 03 08 mou Qf 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 Diversion Resistor Overview 2 1 Diversion Resistor Description 4 2 2 Identification and Markings 4 2 3 Applications and uses 5 2 4 Application List 5 3 Diversion Resistor Assembly 3 1 Components Supplied 6 3 2 Components not Supplied 6 3 3 Tools Required 6 3 4 Unpacking 6 4 Installation Instructions 4 1 Typical Installation Example 7 4 2 Mounting the Diversion Resistor 8 4 3 Electrical Wiring 9 4 4 Securing the Diversion Resistor 9 5 Wiring and Cable Sizes 5 1 Diversion Resistor Wiring 10 5 2 Lightning Protection 10 6 Technical Specifications 14 7 Trouble shooting 15 8 Maintenance 16 9 Warranty Conditions 16 10 Customer Feedback 19 WARNING Kestrel Charge Controllers Type 0401 0801 and 0102 must have a Kestrel Diversion Resistor fitted before operation The Diversion Resistor fitted must be of the correct type and value for the turbine and controller voltage turbines i n Evirremady Liryersihod Producta Pty Ltd amm C PROUDLY 7 SOUTH AFRICAN NN Disclaimer Kestrel Wind Turbin
5. 1 BREAKER o Y DIVERT 15 RIB RIA RIB kestrel wind turbines Eveready Urveersified Producta Pty Ltd um PROUDLY 7 SOUTH AFRICAN NN 4 2 Mounting the Diversion Resistor The Kestrel Diversion Resistor Type 0601 is only suitable for indoor installation The unit must be vertically mounted using the four internal fixing holes provided Use secure fastening with suitable wall plugs or bolts Allow a minimum of 200mm 8 space all around the unit for cooling It is normal for the voltage limiter to become quite hot at times as it dissipates unwanted energy Do not place any objects on the top of the enclosure Make sure that air can freely enter at the bottom of the enclosure The unit relies on the free passage of air through the enclosure for adequate cooling HOLES n 131 5 15 123 4 85 ux e ae v 5 C ea T C lt ONE RESISTOR ENCLOSURE Do not make any electrical connections prior to mounting It is beneficial to place four spacers not supplied on the mounting screws such that an air space exists between the wall and the diversion resistor HOLES 157 6189 208 9 29 123 4 855 f qM v Qo 5 e R E an in 59 DUAL RESISTOR ENCLUSURE Kestrel wind turbines Evuready Uversified Products Pty Ltd amm CN PROUDLY SOUTH AFRICAN NN 4 3 Electrical Wir
6. Diversified Products Pty Ltd T A Kestrel Wind Turbines in South Africa declare under our sole responsibility that the product Diversion Resistor Type 0601 To which this declaration relates is in conformity with the following standards IEC 60204 1 Safety of Machinery IEC 60038 IEC Standard Voltages IEC 60529 Degrees of Protection of Enclosures IEC 61000 Electromagnetic Compatibility Date 25 December 2007 Place Port Elizabeth South Africa Authorising Signature 2 boty James Carpy Technical Director Shepstone Rayner Sharad Saxena Ind Johan Ferreria James Carpy UK Yusuf Vorajee ind Brian Das pirectors amp 2 Eveready Diversified Products Pty Ltd Eveready Road Struandale Port Elizabeth PO Box 3191 North End Port Elizabeth 6056 South Africa PROUDLY SOUTH AFRICAN mou SOUTH AFRICAN NN 7 TROUBLE SHOOTING THE KESTREL TYPE 0601 DIVERSION RESISTOR MAY BE SERIOUSLY DAMAGED BY THE INGRESS OF WATER DEGRADATION CAN OCCUR FROM IMPROPER INSTALLATION THAT CAUSES OVERHEATING SHORT OR BRAKE THE WIND TURBINE AND ISOLATE ALL BATTERIES BEFORE ANY MAINTENANCE PROCEDURE Q system voltage is high A The diversion resistor connections are poor A The resistors are broken or open circuit A The connection wire is undersize Q Does it matter what divert resistor wire up to the controller A Yes The divert resistor must be matched to the turbine and controller v
7. SISTOR ELEMENTS Winding former High temperature moulded ceramic Type of resistance wire Copper Nickel Cupro 49 Oxidised RESISTOR ELEMENT VARIATIONS Wound elements wired in series parallel DESIGN DESIGN POWER RATING FOR MAJOR VOLTAGE CURRENT BLACK OPERATION DIMENSIONS OR94 DIA 63 x 250mm DIA 63 x 250mm 66 DIA 63 x 250mm 500 62 DIA 63 x 250mm 550 64 DIVERSION ENCLOSURE VARIATIONS TURBINE TURBINE CURRENT OR37 300 57 DIA 63 x 250mm e150 e220i 12 0102 0401 12Vdc 0601 0823 800W e150 e220i 24V dc 0102 or 0401 24Vdc 0601 0894 800W e150 e220i 36Vdc 0102 or 0401 36Vde 0601 800W 149 e150 e220i 48Vdc 0102 0401 48Vde 0601 800W e150 e220i 110Vdc 0102 or 0401 110Vdc CONSULT FACTORY 08 e3000 7 12V d 0801 or 0401 12Vdc 0601 0823 1200W e3000 24 0801 or 0401 24Vdc 0601 OR75 1200W e3000 36Vdc 0801 or 0401 36Vdc 0601 2R50 1200W e3000 48Vdc 0801 0401 48Vdc 0601 2R50 1200W 110 4 0801 0401 110 0601 11 00 1200W Cooling Natural Convection Maximum Ambient 40 IP Rating IP23 Cabinet Dimensions wall mounting 800W 130Wx120Hx350D 1200W 260Wx120Hx350D Mass 800W 3 4kg 1200W 7 1kg Certification Complies with EMC requirements 522 Class 11 EVEREAIN Eveready Diversified Products Pty Ltd mou SOUTH AFRICAN NN 6 2 DECLARATION OF CONFORMITY Eveready
8. bit operational modes where excess electrical energy must be dissipated The controller then diverts any unwanted energy to a power resistor The power resistor converts the electrical energy into heat energy The Kestrel Type 0001 range of diversion resistors consist of wall mounted enclosures that contain electrical resistors which dissipates the energy in the atmosphere Each version is designed to have a specific electrical resistance and power capability The product is housed in a steel enclosure for wall mounting Unit cooling is achieved by natural convection 2 2 Identification and Markings On the Diversion Resistor enclosure is a product rating plate and serial number if the controller does not carry this stamp it does not carry a Kestrel warranty and not authentic wind PRODUCT RATING LABEL 50 Vdc SERIAL NUMBER 00000000 0 0 Eveready Diversified Products Pty Ltd MADE IN T A Kestrel Wind Turbines c SOUTH AFRICA BY P O Box 3191 Strundale North End Port Elizabeth 6056 RSA NOTE Product Rating label example above is for format only details may vary CHECK THE IDENTIFICATION NUMBER TO BE CORRECT FOR THE APPLICATION REFER TO THE APPLICATION LIST IN SECTION 2 4 Page 5 frel Eveready Diversitied Producta Pty Ltd uL Of SOUTH AFRICAN 2 3 Applications and Uses Kestrel Diversion Resistors Type 060 primarily
9. es makes every effort to give accurate information in this manual and is in no way liable for any error or omission The user of this manual assumes full responsibility and risk We appeal to your common sense to read and apply safety notes Consult professional engineers and take advice if you are unsure 1 SAFETY FIRST Although Kestrel s diversion resistors 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 7 7 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 considerab
10. ge controller Good wire connections between the charge controller and the diversion resistor are absolutely essential to maintain good charge controller operation and to avoid high temperatures at the connection All electrical systems lose energy because cables have a resistance The cable connections between the charge controller and the diversion resistor will increase the overall resistance presented to the charge controller Poor connections may cause battery overcharging Surplus correctly sized wire that has been fitted to the wind turbine output may be used to wire the diversion resistor Refer to section 1 for the electrical current value of the Kestrel turbine being installed Wire Size for Electrical Current Maximum distance 2m 6 2sq mm 15 3sq mm 12 5sq mm 10 6sq mm 9 8sq mm 8 1054 mm 7 TOsqmm 7 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 casing of the Diversion Resistor is electrically connected to the system earth kesirel wind turbines Eveready Products Pty Ltd um Qf SOUTH AFRICAN NN 6 1 TECHNICAL SPECIFICATIONS General High power resistor enclosure for the diversion and conversion of excess electrical energy into heat Available in different ratings for suitable applications RE
11. ied The following components are necessary to complete an installation Electrical crimp terminals Wall fixing screws 20mm cable glands 3 3 Tools Required The following hand tools are required for Diversion Resistor installation Small size electrical screwdriver Medium size electrical screwdriver Wire strippers for electrical connections Electrical crimping pliers Tape measure for positioning 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 Bub keslirel wind turbines Eveready Diversified Products Pty Ltd Mum CE mou Gf SOUTH AFRICAN NN 4 INSTALLATION INSTRUCTIONS 4 7 Typical Installation Example typical battery charging installation is shown below The system comprises of Kestrel wind turbine Kestrel charge controller Kestrel diversion resistor and storage battery Note that other electrical equipment will be required to comply with local installation requirements such as an additional inverter which converts the battery dc power into standard ac power such that common mains powered appliances can be supplied Consult the relevant charge controller manual and inverter manuals for full installation procedures KESTREL CONTROLLER TYPE 0401 KESTREL 0102 0801 DIVERSION RESISTOR BATTERY CIRCUIT TYPE 060
12. imits 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 controllers and diversion resistors are manufactured to the highest standards in accordance with Kestrel Wind Turbines standard and quality specifications and warrants that the diversion resistor is in good working order upon delivery and for a period of 24 months Warranty terms and conditions are outlined below l Eveready warrants that Resistors 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 Resistors at its cost to the premises of Eveready within the warranty period and furnishing full details in writing of the alleged defect 3 Eveready s obligations under this warranty shall be limited to the repair or replacement of defective Resistors 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
13. ing The diversion resistor is not polarity sensitive and can be connected either way round It is usual to connect the positive terminal on the left CHECK THAT THE DIVERSION RESISTOR IS THE CORRECT TYPE FOR THE TURBINE AND CHARGE CONTROLLER PLEASE FOLLOW THE INSTRUCTIONS BELOW CONSULT SECTION 5 FOR WIRE SIZE RECOMMENDATIONS The Kestrel charge regulator is provided with one pair of clearly marked terminals for RESISTOR at the bottom of the regulator marked RIA and The diversion resistor connections are also marked and R2A Cut suitable lengths of cable and make the connections between the two R1A terminals and the R1B terminals The wind turbine should not be rotating during this installation If turbine access is not possible either operate the Turbine Brake Switch S1 or short the two turbine power wires together tot huka Observe the Polarity at all times BATTERY DIVERT DIVERT E The following procedure applies to Kestrel charge controllers If you lack confidence or experience consult a professional or your dealer re seller a Arrange that the turbine is shorted out or the turbine brake switch S1 is ON b Isolate or switch OFF any battery feeds to the charge controller c Check that the charge controller OUTPUT CIRCUIT BREAKER Q1 is switched OFF and that the TURBINE BRAKE SWITCH S1 is switched ON d Connect the two wires from the charge controller to the divert resistor e Connect an elec
14. le and fire can result from shorts Fit a suitable fuse or circuit breaker the battery cable In general respect the system and use common sense Consult a qualified electrician if you are unsure 1 3 Installation Hazards Be sure to read and adhere fo 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 Standard Controller will become hot during certain operation modes This is quite normal but be aware of high temperatures within the case System checks are best carried out in calm weather conditions Avoid any maintenance or inspection during windy weather kestrel wind turbines Eveready Uversified Fraducts Pty Ltd eee SOUTH AFRICAN NN 2 DIVERSION RESISTOR OVERVIEW 2 1 Diversion Resistor Description IMPORTANT This product is designed for use with Kestrel Charge Controllers that are installed to charge batteries known as Battery Charging systems Failure to fit a divert resistor to Kestrel Charge Controllers Type 0102 0801 and 0401 will cause malfunctions and damage to the controller Sustainable renewable energy sources such as wind turbines hydro generators and solar panels when used to charge batteries are often connected to a charge controller Such components can exhi
15. oltage and current Fitting the wrong diversion resistor will cause malfunctions and damage Q The diversion resistor is always working at a high temperature A The batteries are fully charged and full energy diversion is occurring Consider using more electrical energy and fitting additional battery storage A The battery circuit breaker has tripped A The battery is defective and cannot receive charge Q Will damage the charge controller if disconnect the diversion resistor A Yes the charge controller is now unable to divert any energy and cannot control the system voltage This will almost certainly damage the controller and overcharge the battery Always disable the turbine and disconnect any battery before disconnecting the diversion resistor Q Can remove the diversion resistor and short the resistor output terminals on the controller 13 A No This will result in controller failure due to overheating Producta Pty Ltd mou Qf SOUTH AFRICAN NN 8 MAINTENANCE Check that all connections are in good condition and tight on the Diversion Resistor during routine system checks The Kestrel Type 0601 Diversion Resistor 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 case Clean the case only with a soft damp cloth Do not use any form of solvent This product controls and l
16. trical earth wire to the marked earth screw terminal provided f Check that all connections to the divert resistor are good and tight g After all wiring is complete and secure the charge controller battery circuit breaker may be switched on and the turbine brake switch switched off The instructions are reversed for de commissioning First isolate the additional equipment by operating the turbine brake switch and switching the battery circuit breaker off A disconnected turbine should always be shorted 4 4 Securing the Diversion Resistor Always switch the turbine brake on 1 ON and the output circuit breaker off OFF before any maintenance or service The Kestrel Diversion Resistor Type 0601 has a single bottom screw for removal of the front cover NOTE The diversion resistor 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 IMPORTANT It is quite normal for the casing to become hot during extended operation 9 Evuready Uversified Products Pty Ltd mou SOUTH AFRICAN NN 5 WIRING AND CABLE SIZES 5 1 Diversion Resistor Wiring 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 char
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