Pika T701 Turbine Operation Manual
Contents
1. Pika 1701 Turbine Operation Manual rg 0 Fr N E f at p Tun v T PR von k n T 4 Operation Manual Revision 1 3 Turbine Serial Introduction Congratulations on your purchase of the T701 wind turbine This manual will help the user operate the Pika Energy T701 turbine most effectively Pika Energy recommends storing this manual in a sealed waterproof container located near the inverter for ready access Symbols used in this document Throughout the manual the following symbols highlight important information A WARNING Actions or situations that could permanently damage or destroy the T701 turbine or other system components A NOTE Helpful tips and points of interest Revision Table Revision Date Changes 1 1 2013 11 10 Draft 1 3 2014 01 30 Remove slow fast Contents Introduction de dd n dhe nd k nda hie Mace hie ena duhe du ees 1 Symbols used ST 2 autrui E 2 d rfe 5 1 1 Turbine Components rito rere obe der n ora cess debenseeeseesdosdobunevetesse essubesaeedesesdesddbeseaeteseeeys 5 A te 5 A dd 5 ICON r id E 5 Safety Brake iii des 5 CERE 5 GA te a os abncauecbaae cs a e sees ceeucasseectecepeetuenseoticecreieacu2. Ue di 11 A A RE h 11 LAIT ret 11 A ien tete tox Le ark k do tUe Terre eee tee tees eed ee tue ba ee veterea ulen a Een Re N PR EE e Rus 11 4 4 Backup Safety Brake sieneen eniinn a nene eee eee ene enen nennen ee penne rete eee ee pend t eee sinensis rete Raan EAER ESSEE NEA 12 5 Inspectior and Maintenarnce net dd i th dr hu t dekretoi 13 5 1 After firstmonth of operation oreet dd dha dv 13 A O O ei E 13 BS VAN Ula lV erases inet te daa 13 5 4 Every 10 years of operation 5 years in high Wind Site aa uuanaa aaa nana aa ananas anen ne es anen eres enen eces even eees eee eee ese 13 5 5 End ofilites ass th da de hd at thes 13 GB Troubleshooting t A RI I TUS IR E 14 1 Turbine overview The T701 turbine is a horizontal axis three blade passive yaw upwind turbine with a rotor diameter of 3 0 meters and a peak output of approximately 1 8kW The turbine features high performance molded blades and a quiet efficient permanent magnet alternator Rotor speed is maintained within a safe operating range by the alternator through active load control An exclusive patent pending mechanical overspeed brake can operate entirely independent of the primary load control to ensure that the turbine can never overspeed even in the case of component failure The basic elements of the T701 wind turbine are illustrated in FIGURE 1 1 Turbine Components Blades The T701 turbine s blades capture wind energy and convert it into mechanical energy You
3. status at inverter front panel display Contact your installer or Pika Energy for more information REbus microgrid not active Check REbus status at inverter front panel display enable the inverter and check REbus voltage turbine disconnected from REbus Check turbine status at inverter front panel display Offline indicates turbine is not communicating with inverter Make sure DC disconnects are closed Check wiring for open circuits Turbine does not spin at all in moderate to Safety brake engaged due to Call your installer high winds control circuit failure Failure of alternator Call your installer or bearings Turbine vibrates or buildup of ice on No cause for concern Turbine will sense vibration and makes grinding or blades or hub limit speed Wait for ice to melt chunking noise Failure of alternator or bearings Disable turbine immediately at inverter front panel display call your installer Blades whistle or howl in moderate to high wind Damage to blade from flying debris Disable turbine immediately at inverter front panel display call your installer Turbine does not orient to wind Seized yaw bearings Disable turbine immediately at inverter front panel display call your installer 14 gg Pika 35 Bradley Drive Suite One VVestbrook ME 04092 info pika energy com 1 sales pika energy com pika energy com rmm
4. alified trained small wind turbine installer Refer to the installation manual for specific instruction on system design and installation 2 1 Applications Base system T701 Wind Turbine t X3001 REbus Inverter The T701 turbine is connected to the building wiring and the AC grid through a REbus inverter such as Pika Energy s X3001 This converts the turbine s REbus DC output to standard 60 Hz AC current for use in your home s appliances If extra energy is available the inverter automatically backfeeds the power into the grid Unlike other inverters Pika s X3001 REbus inverter provides the ultimate in system design flexibility enabling multiple turbines or a combination of wind and solar to feed directly into the inverter More information is available in the inverter manual and REbus Microgrid Design and Installation Manual PV Hybrid T701 Wind Turbine S2001 PV Link X3001 REbus Inverter Pika Energy offers a PV hybrid option with unmatched performance and flexibility Up to 8 standard PV modules can be connected to the X3001 inverter in parallel with the T701 turbine through Pika s S2001 7 PV Link maximum povverpoint tracking converter Contact Pika Energy for more information about this exciting option for boosting the performance of the T701 turbine system with solar Off grid installations The T701 Wind Turbine can be used in off grid applications when combined with a REbus charge controller Contact Pika to learn more ab
5. ct your utility for a bi directional smart meter or dual meter installation to ensure credit for excess energy production High Winds In high winds the turbine will continue to operate but the controller will limit the power output and speed Itis normal for the turbine to briefly exceed the rated power during high or gusty winds In winds exceeding 30 m s 66 mph the turbine will curtail its speed and output power to prevent damage Ifthe wind turbine controller shuts down the turbine for self protection it will enter high wind mode High wind shutdown will last for at least 10 minutes and will be longer if the wind continues at an extreme speed When the wind returns to more moderate speed the turbine will resume normal operation 3 4 Power Outages In the event of a power outage the inverter is required to shut off to prevent a hazard to utility repair personnel The turbine will enter the disabled state until power is restored Ask your dealer about battery backed system options that will allow your turbine system to operate and provide power to your home during power outages 3 5 Manually disabling the turbine The turbine may be temporarily disabled from the inverter The turbine should be disabled for raising and lowering and owners may also choose to disable it in extreme weather such as an approaching hurricane or tornado To disable the turbine e From the front panel display of the inverter scroll hori
6. h Wind High wind shutdown mode Turbine will restart 10 minutes after extreme wind event passes Error Error mode Turbine will not automatically restart see Errors section below 4 2 Faults The T701 turbine features sophisticated microprocessor control and is capable of sensing and responding to events including high winds extreme temperature variations and vibration due to imbalance e g caused by ice If the turbine seems to behave in an unusual way check the inverter front panel display for status messages A turbine that is frequently in the Waiting state might be experiencing multiple faults Contact Pika Energy to investigate what can be done to improve your system s performance 4 3 Errors An Error state results from a serious condition detected by the wind turbine that has caused it to shutdown permanently It will not restart automatically Contact Pika Energy to understand the nature of the error and how to rectify it 11 4 4 Backup Safety Brake The T701 turbine is equipped with a centrifugally operated cam brake that engages in the unlikely event that the primary control fails to prevent extremely high speed operation and the risk of damage to the turbine and surrounding property If the safety brake engages the turbine will not spin until the turbine can be serviced WARNING Engagement of the safety brake indicates a serious problem with the control circuit or alternator Do not attempt to reset the b
7. ide for more information on setting up a REbus microgrid Parameter Value Turbine Type 3 blade HAWT upwind free yaw Rotor diameter 3 016 m Swept area 7 01 m Blade type Optimum twist taper injection molded glass reinforced polypropylene resin Speed control Digitally controlled alternator torque Redundant control One shot centripetal overspeed brake Towertop mass 45 kg Rated power approx 1800W 9 11 m s Monthly output approx 230 kWh at 5 m s avg Rayleigh Cut in windspeed 3 3 m s Survival windspeed 60 m s Turbine electrical output REbus DC microgrid regulated 190VDC Electrical parameters Nominal Maximum REbus Power 1800 W 2400 W REbus voltage 380 V 420 V REbus current 4 7 A 6 7 A 1 3 Turbine Mechanical Diagram PIKA ENERGY 1701 TURBINE MECHANICAL LAYOUT 92 8 2356 3 1187 D3016 7 14 SQ METER SWEPT AREA ISl TOWERTOP IS 2 5 8 NPT MALE TAPER PIPE THREAD MAINTAIN CLEARANCE ABOVE BASE OF THREAD 7 9 200 2 Turbine System Design and Installation To give good performance the T701 turbine must be installed as part of a well thought out system MAINTAIN 200MM MAXIMUM EFFECTIVE TOWER DIAMETER FOR TIP CLEARANCE designed in accordance with industry best practices Pika s warranty agreement requires that the turbine be installed by a qu
8. ndsaieaess 5 1 2 TUPDING S PECIFICATIONS eene eai ense ee eri ann n ne Doda n t du k n 6 1 3 Turbine Mechanical Diagram ana a aaa aa nana na aaa nene e nene enes eses epe nennen ente nene eres e eee ee nene er z eee eee venien eren 7 2 Turbine System Design and Installation aaa nanen nene asesi enen enne nennen nnn nnn nennen 7 2T Applicablons eee 7 Base system T701 Wind Turbine X3001 REbus Inverter aaa aa aa anen nene nene eee venien enen rez ene zene 7 PV Hybrid T701 Wind Turbine S2001 PV Link X3001 REbus Inverter nane nene ezan even enen 7 Off grid installations ue c d ad n ERU La da ad ke ndre Tuned n deca dod 8 Other system designS skenarin nda sta in cies ndo oce Rte dha oe c ee RN Ron DOR eee E Ie RR iai e aeii 8 2 2 Stine and TOWNS taa 8 2 3 Installing the T701 turbine ceti add a eke rn e 8 Sa SST 9 3 1 How to Use the Front Panel Display aaa aaaanaaaaaaaaanannn aa aaa nen nenen area eee s ee nene eee z enet ese e nene e rere teve eren ne ene r eneve eee 9 3 2 T rbine Startups A mu D pfe bu e ebd ia ds 9 3 3 Normal Operation soie er rr Ee NUS GER td dd dt 9 Light WIS er akte 9 nicam 10 High ltee e ce 10 O O AA 10 3 5 Manually disabling the turbine c cccccccsccsssssssecececeesssesneseeeeecessesesaeeeseeecesseseeaeeeeeesesseeaeaeeeeeesseesegs 10 4 States Faults and Errors eed raro aes oe sir doe cae EUR e a
9. out charge controller options that are currently available Other system designs The REbus microgrid is designed to be a very flexible infrastructure that allows many configurations including multiple wind turbines on the same inverter See the REbus Microgrid manual for more details 2 2 Siting and Towers The most important factor in the performance of any wind turbine is the quality of the wind resource experienced by the turbine One of the most common causes of poor performance is installation on a tower that is too short For acceptable performance the tower must be at least 10 meters taller than the mature height of trees and other surrounding obstacles within a 100m radius This is a minimum requirement and more height exposure is better Remember that trees grow rapidly in height and are likely to significantly decrease the wind exposure of nearby turbines over a few years If in doubt choose a taller tower 2 3 Installing the T701 turbine The T701 turbine has been designed to be fast and simple to install However it is important to carefully follow the instructions in the T701 Installation and Service Manual as well as the installation manuals for the other system components 3 Turbine System Operation 3 1 How to Use the Front Panel Display Most T701 Wind Turbine installations will include a REbus system component with a user interface for assessing the state of the wind turbine controller This section describes interfacing wi
10. r turbine features tough high performance aerodynamic blades made of glass reinforced thermoplastic Alternator The alternator converts mechanical energy to electrical energy Your turbine features a custom engineered quiet powerful generator and uses powerful rare earth magnets for high efficiency The alternator also controls the speed of the rotor to limit power in high winds Nacelle The nacelle is the backbone of the turbine connecting the blades mainshaft alternator bearings and tail The T701 nacelle features a strong aerodynamic casting made from recycled aluminum Safety Brake The T701 turbine features an exclusive fast acting safety brake that stops the rotor in case of an overspeed runaway condition See the TROUBLESHOOTING section for more information on operation of the safety brake Tail The tail assembly of the T701 turbine operates like a wind vane to ensure that the turbine always points upwind Yaw The yaw assembly connects the turbine securely to the top of the tower and contains ball bearings that allow the turbine to rotate smoothly to face the wind 1 2 Turbine Specifications The T701 turbine produces a regulated DC current output and is designed exclusively for connection to a REbus DC microgrid REbus is an advanced DC microgrid platform developed by Pika Energy for small scale wind solar and hybrid systems Read and understand the accompanying REbus Microgrid Introduction and Design Gu
11. rake to put the turbine Z N back into service without first correcting the underlying issue WARNING The safety brake cam is a single use part and must be replaced by the A factory or a qualified field service technician before the turbine is allowed to run again Do not attempt to reset the brake 12 5 Inspection and Maintenance The T701 turbine has been designed to give years of trouble free service Pika Energy recommends the follovving inspection and maintenance schedule 5 1 After first month of operation Perform the annual inspection described below 5 2 Monthly Check that turbine operation appears normal 5 3 Annually Inspect the turbine carefully from the ground while it is operating in moderate winds Put your ear against the tower and listen for any unusual clicks rattles scrapes thumps or grinding noises It is normal to hear a low hum that changes pitch with the speed of the rotor Check condition of tower including turnbuckles turnbuckle safety cables anchor rods tower base bolts and tension of guy wires with reference to tower manufacturer s instructions With turbine disabled tighten or adjust as necessary 5 4 Every 10 years of operation 5 years in high wind site A qualified installer should lower the tower and carefully inspect the turbine paying special attention to the blades hub shaft bearings and shrouds The backup safety brake cartridge should be inspected to ensure free mo
12. th the turbine from the front panel display of the X3001 REbus Inverter Please consult the X3001 User Manual for instructions on using this interface 3 2 Turbine Startup Quickstart Summary assuming turbine installation is complete and tested e Turn on AC power to the X3001 inverter e Enable the inverter from the front panel display In order to start up the turbine must be properly installed and connected to an active REbus microgrid If power is disconnected to the inverter the inverter is disabled or a fault is detected in the REbus microgrid the turbine will not come up to speed Turn on AC power to the inverter by switching on the circuit breaker and AC disconnect if present When AC power is restored to the X3001 inverter it resumes its previous state of operation from before the power interruption The inverter is programmed at the factory to power up in the disabled state when first energized Enable the inverter from the front panel display by selecting the X3001 inverter device in the device menu then selecting enable and confirming the selection The inverter will perform a series of internal and external checks then activate the REbus microgrid by raising the voltage to above 300V activating the T701 turbine s internal controller When the T701 turbine s internal controller becomes active it resumes its previous state of operation from before the power interruption The turbine is programmed at the factory
13. to power up in the disabled state when first energized Enable the T701 turbine from the inverter front panel display by selecting the T701 turbine device in the device menu then selecting enable and confirming the selection 3 3 Normal Operation Light Winds In winds below 3m s the wind does not provide enough torque to spin the blades The wind turbine page on the inverter front panel display will report LOW WIND Light winds do not contain much energy Every doubling of windspeed results in an 8X increase in energy so in most sites the turbine will capture the majority of its energy output in winds above 6 5 m s 15 mph Moderate VVinds The T701 wind turbine will start in vvindspeeds of 3 4 m s 7 9 mph and will produce a small amount of power in winds as light as 2 5m s 6 mph The wind turbine page on the inverter front panel display will report Making Power In most installations the power produced by the T701 is fed directly into the home s central distribution panel and is used directly by the electrical loads of the home decreasing the current draw from the utility If the power output of the turbine exceeds the total demand of the home excess power flows back into the utility grid turning the meter backwards and reducing the customer s electric bill K NOTE Many common types of smart meters do not deduct exported power from R the recorded total If you have a smart meter be sure to conta
14. vement of the brake mechanism and correct release torque Pending real world lifetime data from the field Pika Energy provisionally recommends replacing the mainshaft bearing assembly bladeset and blade attachment fasteners every 10 years Contact Pika Energy tech support for updated recommendations While the tower is lowered the installer should carefully check the tower for chafing wear or loose fasteners and tighten or replace parts as appropriate 5 5 End of life Pending real world lifetime data from the field Pika Energy provisionally recommends a factory re build of your T701 turbine after 30 years in the field 20 years in high wind sites Major components of the T701 turbine including blades hub and nacelle castings are recyclable Pika Energy strongly recommends recycling your turbine when its useful life is over 13 6 Troubleshooting Use the table below to help diagnose issues with theT701 turbine Symptom Possible cause What to do about it Turbine spins very slowly in wind that would normally cause operation turbine disabled Check status of turbine at inverter front panel display Enable turbine REbus shorted Check REbus voltage at inverter front panel display If the inverter is not able to enable and bring up the bus voltage it may be the result of a bus short Disconnect all sources of power and troubleshoot REbus wiring Fault in alternator or control circuit Check turbine
15. zontally to the turbine page e Press the center button to show the menu e Select Disable from the menu options and press the center button e Press the center button once more to confirm e The wind turbine page on the inverter front panel display will report disabled To re enable 10 e From the front panel display of the inverter scroll horizontally to the turbine page e Pressthe center button to show the menu e Select Enable from the menu options and press the center button e Press the center button once more to confirm e The wind turbine page on the inverter front panel will report the turbine s current state 4 States Faults and Errors 4 1 States State Name Description Comment Offline The turbine is not able to communicate Sometimes caused by a bad earth with the inverter this state is reported connection between turbine and inverter when REbus is not powered up Powering Up The turbine s internal systems are Prolonged time in the Powering Up state settling can be the result of an unstable bus voltage Low Bus REbus voltage is too low to operate Voltage Disabled Turbine is manually disabled Turbine will not start up without user input Low Wind Not enough wind to operate Making Power Normal operation mode Waiting Temporary timeout as result of startup Turbine will automatically restart after sequence or a fault timeout period has elapsed see Faults section below Hig
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