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Pika T701 Turbine Installation & Service Manual
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1. Fishtape For fishing tower wire though assembled tower _ Messenger line For pulling wire through conduit to inverter Wirestrippers Needlenose pliers _ Metric ratchet drive or larger __ Ratchet extension Required for tail boom attachment __ Metric sockets 10mm 13mm 19mm For turbine assembly __ Torque wrench 5 65 ft lb For turbine assembly _ Torque screwdriver 4 15 in lb For turbine assembly Metric allen wrench set Ball end preferred for brake locking screw removal BN NN Flashlight Light cord 3 32 or string Hie oF uw pulling wire through tower and for prusik knots for pulling on guys wires Wooden stakes or flagging For tower anchor layout LL Tower installation tools Refer to tower installation manual Tower raising equipment Winch grip hoist anchoring chain for lifting device shiv shackles 7 Tarp or other ground cover For working on the ground under blade rotor Round flat and triangle files For repairing damaged threads etc 17 Copy of Turbine Installation Checklist Submission of a properly completed checklist and the 8 required photos is mandatory for warranty coverage Name of Owner Turbine serial number Installation Address Tower Make Model and Notes Mailing Address if Different Wireless Router Make Model Circle One Broadband Satellite Dial Up HotSpot Name of Installer Installation Finish Date
2. o _ X3001 REbus inverter converter or other inverter forgrid tiesystems o Chafing protection for tower wire pipe insulation is good Ducttape for securing chafing protection 1 conduit and fittings 6 x6 junction box Red and blue electrical tape for wiring the brush puck and lightning arrester grounding wire of same guage as tower conductors for grounding tower to lightning arrester _ Nn NEN Ld _ ied wi __ 4AWG grounding wire clamps and lugs if not supplied with tower _ MEN ing li NEN 16 Turbine Packing List The standard T701 shipment consists of three packages Please verify that all three packages are complete before beginning the installation Nacelle Package contents Got it Nacelle Package Got it Blade Package Got it Tail Vane Package aa Nacelle assembly 3 blades DEM Fore tail piece Blade hub Talboom Aftailpiece mansas Nxecm TT Lightning arrester Tools Checklist Tool O O Personal Protective Equipment PPE including hardhats safety glasses gloves and steel toed boots Digital camera For photo documentation for warranty __ Sawhorse cribwork or other tower support ll 2 Phillips Screwdriver EE Chain Wrench 4 5 capacity or 3 5 pipe wrench with bar NL C NNNM noel
3. initials Step Description Comment 15bladeboltstorquedto 25Nm 18 fl TT Q Yaw threads tightened 1 2 turns pasthandtigt TTT Yawjamscrewtorquedto 18Nm 3fl TT PHOTO of yaw showing threads and set screw TT Brake locking screws removed and replaced with plug screws PHOTO of plug screws in the place of brake locking screws 2clamp bar screws torqued to 0 4 Nm aint 5 tower wire leads torqued to1 5Nm i3inib TT PHOTO of brush block showing completed wiring O Blade bolts re torqued to 25 Nm 18 ft lb atleast 30 minutes after initial tightening _ 2PHOTOS of blades installed on hub 1 photoforeachside J Q Hub nut installed with Loctite and torqued counterclockwise to 76 Nm S6ftib PHOTO of nut washer and blade assembly on shat Nosecone screws attached and torqued to 0 4 Nm 4n TT ___ 7 5 TT Tail boom bolts torqued to 25 Nm 8f TT Shroud attach screws installed and torqued until rubber bulges slighty Q Spin test procedure completed per instructos _ Q Turbine started up and ran normaly PHOTO of the completed turbine instalation from the gin pole sial PHOTO ofthe tower base after completion of turbine instalation certify that this installation was performed in accordance with the T701 Turbine Installation manual Signed Date Please use this box to provide suggesti
4. RE terminal trim to length and strip approximately 20mm 3 Form a clockwise loop in the end of the wire slip the loop under the head of the screw and torque to 1 5Nm 1 1 ft lb or 13 in Ib WARNING The T70 brush disk uses captive nuts with built in anti vibration locking features DO NOT use thread locking compound Common threadlockers e g Loctite contain chemicals that will severely damage the polycarbonate brush block WARNING Do not tighten loosen or adjust the brush fasteners hex head screws closer to center of brush block 6 Connect Negative REbus Lead Mark the black wire with blue electrical tape route it to the RE terminal trim to length and strip approximately 20mm 34 Form a clockwise loop in the end of the wire slip the loop under the head of the screw and torque to 1 5Nm 1 1 ft lb or 13 in Ib 7 Form wires within safe volume Ensure that none of the three conductors extend beyond the diameter of the brush disk and that they do not extend above the top of the strain relief bracket If necessary gently form the wires into place around the brush disk TAKE A PHOTO Take a digital photo of the brush disk after wiring is complete 8 Take a digital photo of the completed brush disk wiring 25 Install Blade Assembly NOTE Trailing edges of blades can be sharp Pika Energy recommends wearing gloves while handling the blades NOTE The torque on the blade bolts must be rec
5. Press the center button to show the menu Select Enable from the menu options and press the center button Press the center button once more to confirm The wind turbine page on the inverter front panel will report the turbine s current state 34 6 Inspection and Maintenance The T701 turbine has been designed to give years of trouble free service Pika Energy recommends the following inspection and maintenance schedule 6 1 After first month of operation Perform the annual inspection described below 6 2 Monthly Check that turbine operation appears normal 6 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 6 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 movement of the brake mechanism and correct release torque Pen
6. m 2 RGY lt Pika 1701 Turbine Installation amp Service Manual Thon Xn D ES YER 4 a 5 o ECTS gt m i 3 lt gt sd LS ag 9 a gt T _ ap t x Tu aa S3 ri E 3 e a 2 lt e 5 E cud bec gt s dise J E E y x 5 gt gt 4 aa LES gt iA s SS Shar ee a n TC1317 Installation and Service Cover indd 1 fara M a Pave a De cp 6 5 15 11 22 AM Installation amp Service Manual Revision 1 4 Turbine Serial Turbine Serial Number The serial number of the turbine is stamped or scribed into the nacelle casting at the base of the tail pocket The serial number is required to simplify repair and maintenance The serial number is also recorded on the inside cover of the manual for future reference Revision Table wm M 2013 11 21 2014 01 30 Blade rotor assembly 2014 03 18 Formatting and diagram updates 2014 04 28 Diagram updates 1 4 2015 04 02 Brake locking screw removal and plug screw installation updates for installation checklist specification table wiring diagrams off grid applications lifting line redirection load warning yaw attachment tools checklist operations troubleshooting an
7. r 149 TOWERTOP IS 2 5 8 NPT MALE TAPER PIPE THREAD MAINTAIN 200MM MAINTAIN CLEARANCE ABOVE MAXIMUM EFFECTIVE BASE OF THREAD TOWER DIAMETER FOR TIP CLEARANCE d un 7 9 200 DO NOT CONNECT THE T701 TURBINE DO NOT CONNECT THE T701 TURBINE DIRECTLY TO AC POWER DIRECTLY TO BATTERIES BATTERY 12 3 2 Wiring Diagrams The following wiring diagram is for the basic system design including a T701 Wind Turbine and a X3001 REbus Inverter For other system configurations consult the REbus Microgrid Design and Installation Manual Under no circumstances should a T701 Wind Turbine be connected directly to AC or DC sources sinks other than REbus compatible devices DANGER Never connect a T701 Wind Turbine directly to AC wiring DANGER Never connect a T701 Wind Turbine directly to a battery WARNING Do not install a shorting switch across the output of the turbine Shorting the REbus may cause damage to the turbine and or inverter T701 WIND TURBINE AC BREAKER 3001 REbus INVERTER PANEL 12AWG 24G UF RATED Pd TOWER CABLE JUNCTION BOX DISCONNECT IF REQ D BY LOCAL CODE MNSPD300 LIGHTNING ARRESTOR BURIED WIRE RUN WIRE GAUGE PER TABLE 8 COPPER CLAD PROTECT PER LOCAL CODE GROUND ROD 13 3 3 Foundation Tower and field wiring installation 1 Install the tower and foundation per tower manufacturer s instructions The Pika Energy T701 turbine
8. install a tower or turbine See Section 3 T701 Turbine Installation for important tower safety information DANGER Do not climb any tower without manufacturer approved safety equipment Never climb a tower that was not designed to be climbed Carefully inspect the tower and all safety equipment before climbing WARNING Because the dynamic interaction between the tower and the turbine can cause damaging vibrations the T701 turbine must be installed on a Pika approved tower Failure to use a tower approved in writing by Pika Energy will void the turbine warranty The most important factor in the performance of any wind turbine is the quality of the wind resource at the location of the turbine Just as solar panels must be installed in a sunny location wind turbines must be installed where there is unimpeded access to a good wind resource 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 30 feet taller than surrounding obstacles within a 100m 300 ft 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 There are two basic types of towers guyed and un guyed towers In either case access to the turbine for service is an importan
9. 7 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 7 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 7 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 36 WARNING Engagement of the safety brake indicates a serious problem with the control circuit or alternator Do not attempt to reset the brake to put the turbine 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 factory or a qualified fi
10. Installation Manual for DC wiring 28 DANGER Be sure to install the rear shroud before powering up the inverter or REbus microgrid 4 Once wiring is complete and all covers are in place position the inverter circuit breaker to the ON position Toggle the power switch on the bottom of the unit to the ON position to power up the inverter 5 Enable the inverter using the front panel display Observe that the REbus microgrid voltage rises above 300V 6 Scroll to the T701 Wind Turbine device page Ensure that a new wind turbine device appears on the inverter s device list it should be automatically added to the display if wired correctly The wind turbine should arrive from the factory disabled by default 7 With the inverter enabled and the turbine disabled at the inverter front panel display don gloves and stand well clear of the swept area while rotating the blades slowly by hand Significant resistance should be felt even at low speed 8 Enable the turbine from the inverter front panel display The blades should spin noticeably more freely Listen carefully for any clicking or scraping sounds while the blades spin If the motion is not completely smooth do not raise the turbine Stop investigate and correct the issue At the inverter front panel display disable the turbine before raising the tower to prevent the turbine from spinning up with the tower partially raised It is recommended to power down the inverte
11. 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 32 Moderate Winds The T701 wind turbine will start in windspeeds 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 NOTE Many common types of smart meters do not deduct exported power from the recorded total If you have a smart meter be sure to contact 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 It is 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 wi
12. must be installed on an approved tower If questions arise consult with the tower manufacturer s customer service department Be sure to observe recommended curing times for concrete and carefully backfill and tamp disturbed soil around earth anchors as required DANGER Raising climbing and working around towers exposes workers to a number of hazards including but not limited to injury and death from falling objects recoil from snapping cables pinch points and spinning blades Do not install the T701 wind turbine without professional training In all cases do not rush but work carefully and deliberately and use common sense DANGER No personnel should stand within the drop zone of the tower while the tower is being raised or lowered and bystanders should be held far back from the turbine area DANGER Pika Energy strongly recommends against the use of over the road vehicles to raise or lower towers A high quality winch with ample load rating should be used DANGER Refer to the tower manufacturer s documentation to determine the raising line tension In most cases the raising line tension will be greater than the weight of the turbine and tower Ensure that the winch has a Working Load Limit WLL greater than the raising line tension DANGER Redirection links blocks and pulleys used in a lifting line system can be subjected to total loads greatly different from the lifting line tension The total load varies with the angle betw
13. must be securely connected to earth ground per manufacturers instructions At a minimum the tower should be grounded at its base by an eight foot long copper clad steel grounding rod driven vertically into the soil and bonded securely to the tower Non conductive towers require a heavy gage copper ground wire connecting the steel towertop flange with the foundation grounding system NOTE Grounding turbines in arid regions presents special challenges In many cases the standard grounding rod will not provide a sufficient low resistance path to earth ground where soil is dry Consult experienced electrical professionals in your area for best practices Pika Energy recommends the use of lightning arrestors at the tower base and inverter to prevent damage from lightning However no protection system can entirely eliminate the risk of damage from a direct lightning strike Pika Energy recommends the use of the Midnight Solar MNSPD 300 DC Surge Protection Device or equivalent for protection on all REbus devices The surge protection device should always be installed as close as possible to the hardware it is intended to protect Figure 2 1 Midnight Solar MNSPD 300 DC Surge Protection Device wiring diagram Wire coloring depicted ts reflective of Red wire GND Green wire 10 T701 Turbine Installation The T701 turbine has been designed to be fast and simple to install However it is important to carefully fo
14. that the greased surfaces on the main shaft and in the blade hub bore do not pick up dirt or grit Use a clean sheet of cardboard or tarp to assemble the blade rotor on to keep the hub out of the dirt If the wind is blowing dirt into the work area it may be necessary to protect the blade hub by masking the shaft bore with tape 3 Orient the blade hub so that the side with three lobed spline around the shaft is facing up 4 Assemble blade to hub Begin assembly by carefully fitting the three large holes on the blade to three bosses on the hub It does not matter which blade goes in which position Firm gentle pressure should seat the bosses fully in the mating holes Do not force the blades onto the hub 20 Install the two long downwind blade bolts paying careful attention to the order of the washers Put the conical washer on the bolt first with the cone side pointed toward the head of the bolt see image below The flat washer goes on the bolt after the conical washer Install the two 80mm 8 bolts and washers Tighten the bolts just enough to ensure that the blade is fully seated on the hub but wait to fully torque the bolts until all of the blade bolts have been installed com NOTE Proper orientation of the conical Belleville washer is critical Be sure the cone convex side is pointed toward the head of the bolt 6 7 10 11 12 Repeat for two more blades Flip the assembled rotor over Use ca
15. the Pika Energy T701 turbine as well as maintenance and troubleshooting of the unit It is important to carefully and thoroughly read the entire manual in a comfortable setting before venturing out in the field to install the turbine Symbols used in this document Throughout the manual the following symbols highlight important information DANGER Hazards that could cause death or serious injury WARNING Actions or situations that could permanently damage or destroy the T701 turbine or other system components NOTE Helpful tips and points of interest CHECKMARK installation checklist requires a check at this step TAKE A PHOTO installation manual requires a photo at this step EARTH GROUND Relates to proper grounding of the system critical for safety and lightning protection Turbine Specifications Parameter Turbine Type 3 blade HAWT upwind free yaw Rotor diameter 3 016 m Swept area 7 01 m Blade type REbus DC microgrid regulated 190VDC 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 7kW 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 with an exclusive patent pending mechanical overspeed brake that is entirely independent of t
16. 4 2 g UF underground feeder wire Attempts to use types of tower wire other than type UF may result in the wire slipping through the clamp or the clamp crushing the wires leading to an open circuit short circuit or other dangerous condition 15 6 Pull tower wire through tower Take care to avoid pinching or damaging the wire while installing the turbine Leave at least 2 of wire projecting from the top of the tower The REbus wiring that runs in the tower may be installed in the tower either before or after installing the turbine to the tower depending on which approach is more convenient If pulling wire after installing the turbine feed a fish tape down through the yaw and pull the wire from below 7 Install a Towertop Adapter if necessary to provide a 2 5 male NPT national pipe thread at the towertop Follow manufacturer s instructions use loctite or locking fasteners on all fasteners unless specifically advised otherwise ADAPTER FOR ADAPTER FOR XL 1 TYPE TOWER SKYSTREAM TYPE TOWER 3 4 Prepare to Install the Turbine Use of checklists Pika Energy strongly recommends using checklists to ensure that the installation is efficient and complete The installation checklist and associated installation photos are mandatory for warranty coverage Materials Checklist T701 Turbine 3 boxes Turbine blades tailvanes _ B801 REcharge Battery Charge Controller for off grid systems
17. T 32 5 9 Normal OBDeradtiQH ad woe 32 Ide LER TOTO ERR O RD ith cos 32 Moderate idend es eat disco oar DeL 33 aliat Aem tec I 33 OU IE CS MER TTD 33 5 5 Manually disaplinge TRE EUFDITe siidseoi 33 O INSPECTION AND MAINTENANCE as a 35 op Alter firs emon hOr operto 35 NOD EV E ORD O E O O O 35 GP 35 6 4 Every 10 years of operation 5 years in high wind site 35 COE IG e Mtn pn p 35 Z STATES FAULTS AND ERRORS 09 51 2 992 EIE TOADS RS PIN R EIE A E CSS RN EUIS cesses 36 Vi LSLALOS rcm UR 36 2 REESE 36 ENT OLS Ree 36 74A BACKUP isa ESSERE SRS 36 S TROUBLESHOOTING ssi vicina a RN EX iho ETUDE O OOO ESE 38 Introduction Congratulations on your purchase of the T701 wind turbine This manual will guide the installer through proper installation and setup of
18. additional safety hardware For most applications 12 14 AWG wire is appropriate For installations with very long wire run distances greater than 1000 feet 10 AWG wire is recommended to reduce energy losses The following tables indicate wire sizes needed for varying average wind speeds and run lengths The indicated run length is the measured distance along the path of the wire from the inverter to the turbine and should include the height of the tower Note that the total wire length will be 2X this distance The tables below are for a single turbine installation consult Pika Energy for wiring requirements for dual turbine and hybrid systems 296 Energy Loss Table Wire gauge for less than 296 loss one way wire length vs average wind speed 100m 150m 200m 250m 300m 350m 400m 328ft 492ft 656ft 820ft 984 ft 1148ft 1312ft om s 7m s 4 Energy Loss Table Wire gauge for less than 4 loss one way wire length vs average wind speed 100m 150m 200m 250m 300m 350m 400m 328ft 492ft 656ft 820ft 984ft 1148ft 1312ft emis NOTE The T701 wind turbine can only accept 12 2 g or 14 2 g AWG type UF Underground Feeder wire through the yaw into the nacelle If 10 AWG wire is used to get from the inverter to the tower base because of a very long wire run distance it should be transitioned at the tower base to 12 2 or 14 2 AWG type UF wire in a junction box Grounding and Lightning Protection Turbines towers and inverters
19. ar the ground than at the top to withstand the force of the wind freestanding towers nearly always taper being smaller at the top and largest where they connect to the ground Common types of freestanding towers include the tapered tubular monopole and the open tapered lattice type Monopole type towers present a cleaner appearance but may be heavier than an open lattice type tower Many freestanding towers may be raised with a winch and gin pole Foundations and Anchoring A tower is only as secure as its foundation Follow the tower manufacturer s instructions in all cases when installing a foundation Ensure the correct grade size and placement of reinforcing bars rebar use the recommended grade of concrete and the correct reinforcing fiber if specified Concrete must be tamped or vibrated per the instructions of the tower designer Excavated soil must be tamped back into place per the tower manufacturer s recommendations particularly when installing expanding e g bust anchors which depend on well compacted soil for much of their holding power Observe tower manufacturer recommendations for installation on sloped sites Non planar lumpy sites are especially dangerous for guyed towers Raising a tilt up guyed tower on a convex site can result in rapidly increasing guy tension as the tower is raised resulting in catastrophic collapse via buckling Raising a tilt up guyed tower on a concave site can result in slack guy lines lead
20. d maintenance sections added Contents INTRODUCTION P 4 SVMIBOI Used OOCUM ET RENTRER m 4 peci aU erca mm 4 L TURBINE OVERVIEW e 5 Whar REDUS I 5 2 TURBINE SYSTEM DESIGN mem 6 ALAPI TOES E E EE EI EEE EE EEE E 6 Ea 1 E SA LD y E 6 Grid Tie Wind PV Hybrid 6 OF STIG VICES SETTE 6 Oerd Wind PV Aybrid SYSTEMI 6 DE System EE E E E E E A E E 6 2 ORE and TONE ai EEE E 7 GUV O TOWEBES 7 FIPS SCE TOM CS 7 Foundation ANECDOTE tcm 8 Unconventional Mounting Situations 8 2 3 REbus DC wiring grounding and lightning protection system nnns 9 Groundimne and Eehthinpg Protectio Pha a iha 10 3 T701 TURBINE INSTALLATION c ios cix bRERuF EROR RIVE KR NEARE SEP E60 besiege 11 SW S di BB eai Rm 12 3 2 Wiring Diagrams mE 13 3 3 Foundation Tower and field wiring installation ccccccsessccceeccceeecsceeeceeeecseeneceeeeceseueeseeeeeeeseee
21. d to the tower foundation if none is provided by the tower manufacturer Local codes may require a DC disconnect 380VDC rated at the tower base or at another location between the turbine and the inverter NOTE Pika Energy has observed that mice snakes and other small animals love the dry protected spaces inside tower bases and wiring boxes Pika recommends filling all unused knockouts with metal plugs and stuffing stainless steel wool in any openings 4 in diameter or greater 5 Install chafing gear on tower wire Pika Energy recommends the use of chafing gear to protect the wire from sharp edges that may exist inside the tower Chafing gear may be improvised by applying short sections of tubular foam pipe insulation to the wire and securing with high quality electrical or duct tape before fishing the wire through the tower Pay special attention to the area where the wire passes through the base of a tilt up tower In many situations it is necessary to run the tower wire through a short stretch of flexible conduit at the base of the tower to adequately protect it during tower raising lowering NOTE The REbus wiring that runs in the tower may be installed in the tower either before or after installing the turbine to the tower depending on which approach is more convenient WARNING The T701 turbine features an integrated cable clamp in the wiring compartment under the blue shroud which is designed to clamp 12 2 g or 1
22. ding 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 6 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 35 7 States Faults and Errors 7 1 States Offline The turbine is not able to communicate with the Sometimes caused by a bad earth inverter this state is reported when REbus is not connection between turbine and inverter powered up Up can be the result of an unstable bus voltage oe P _ Voltage Disabled Turbine is manually disabled Turbine will not start up without user input Not enough wind to operate ee Making Normal operation mode Power Waiting Temporary timeout as result of startup sequence Turbine will automatically restart after or a fault timeout period has elapsed see Faults section below extreme wind event passes Errors section below
23. e turbine will not balance or orient properly without a complete tail Install the tail assembly by performing the following steps 1 Remove protective film If protective film is present on the tail vanes peel it off and discard Assemble upwind vane to boom Slide the crescent shaped tail vane into the slot in the tail boom and align with the forward holes Secure with two M6 phillips pan head screws and nylon insert locknuts from the hardware kit Torque to 7 Nm 5 ft lb Assemble downwind vane to boom Slide the teardrop shaped tail vane into the slot in the tail boom and align with the rearward holes Secure with two M6 phillips pan head screws and nylon insert locknuts from the hardware kit Do not remove anti seize tape that has been pre applied to the screws Torque 7 Nm 5 ft lb Install tail assembly Insert the tail boom into the tail socket in the nacelle casting The black rubber bulb gasket should face upwards Secure the tail to the nacelle with two M8 hex bolts and small 8mm washers Adjust the 27 rotation of the tail boom to ensure that the tail vanes will be parallel with the tower when the turbine is raised Thread locking compound has been pre applied to the hex bolts Torque to 25 Nm 18 ft lb 5 Stabilize yaw axis Using stakes and light cord stabilize the yaw axis to prevent rotation in such a way that the blades can still spin freely 6 Check mainshaft rotation Wearing gloves and stand
24. een the incoming and departing lines to the redirection equipment Ensure that ALL links in the tower raising system have a Working Load Limit WLL greater than the raising line tension multiplied by the angle factors listed in the table below 3 99 i4 NOTE Pika Energy strongly recommends raising the tower without the turbine installed prior to installation of the turbine This puts less hardware at risk in case of a malfunction 14 Pika Energy recommends the use of a heavy duty worm drive non backdrivable winch with a Working Load Limit WLL greater than the maximum raising line tension Check the duty cycle rating on the winch to be used as many consumer grade bumper winches are not rated for continuous duty and may overheat if used for more than a few seconds at a time DANGER Be aware that some equipment including hardware intended for rock climbing is rated by the actual failure strength rather than working load Confirm the Working Load Limit of all load line elements before raising the tower 3 Lower the tower nearly to the ground and prop it up on a sturdy support such as a strong sawhorse at a comfortable working height at least 36 off the ground 4 Install Field Wiring and grounding system per the wiring diagram above Install at least one grounding rod at the tower base Pika Energy recommends installation of a high quality lightning arrestor at the tower base A junction box may be mounte
25. eld service technician before the turbine is allowed to run again Do not attempt to reset the brake 37 8 Troubleshooting Use the table below to help diagnose issues with theT701 turbine Symptom What to do about it turbine disabled Check status of turbine at inverter front panel display Enable turbine Check REbus voltage at inverter front panel display If the REbus shorted 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 Turbine spins very power and troubleshoot REbus wiring slowly in wind that Fault in alternator or would normally cause control circuit operation Check turbine status at inverter front panel display Contact your installer or Pika Energy for more information active inverter and check REbus voltage 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 disconnected from REbus Safety brake engaged Turbine does not spin due to control circuit at all in moderate to failure high winds Failure of alternator Call your installer or bearings buildup of ice on Turbine vibrates or blades or hub makes grinding or chunking noise Failure of alternator Disable turbine immediately at inverter front panel display or bearings call your installer Blades whistle or howl in moderate to high w
26. er 2 Remove the rear shroud blue from the turbine and carefully set it aside The rear shroud is secured with tape for shipping Exercise caution to prevent damage to the control circuit board WARNING the control circuit board contains fragile components that can be damaged by rough handling Avoid contact with the circuit board or its components Two people should handle the nacelle to prevent damage 3 Remove the bladehub from the mainshaft and carefully set it aside Avoid getting dirt inside the mainshaft bore 4 Position the nacelle Taking care not to pinch or damage the wire lift the nacelle and position the threaded socket of the yaw casting near the towertop Two people should handle the nacelle to prevent damage to the circuit board 5 Feedthe tower wire Pass the free end of the tower wire upward through the hole in the yaw casting feeding any loop or excess slack through the yaw Ensure that the wire is not twisted kinked or over the threaded top of the tower and rotate the yaw gently to engage the thread One person must support the weight of the A turbine while another adjusts the alignment and threads the jammed It may be necessary to guide the wire past the curved strain relief bracket 6 Thread yaw onto tower Position the socket of the yaw casting parts together The yaw should rotate 4 5 full turns by hand so long as the bulk of the turbine s weight is supported to prevent jamming Ensure that the
27. from the menu options and press the center button 4 Pressthe center button once more to confirm 5 The wind turbine page on the inverter front panel display will report disabled To re enable 1 From the front panel display of the inverter scroll horizontally to the turbine page Press the center button to show the menu Select Enable from the menu options and press the center button Press the center button once more to confirm o qe d The wind turbine page on the inverter front panel will report the T701 s current state Refer to the Sections 5 8 below for further information on turbine operation and troubleshooting For off grid systems please refer to your Pika B801 Battery Charge Controller Operations Manual for information on operation and troubleshooting 31 5 Turbine System Operation Grid Tie 5 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 with the turbine from the front panel display of the X3001 REbus Inverter Please consult the Pika X3001 Inverter User Manual for instructions on using this interface 5 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 proper
28. he primary load control The basic elements of the T701 wind turbine are illustrated below 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 Guide for more information on setting up a REbus microgrid DANGER The REbus microgrid operates with a differential voltage of up to 420 VDC The T701 turbine incorporates advanced safety features however like 120 240VAC home wiring the REbus presents the hazard of potentially lethal voltages All wiring should be performed up to local code standards by a fully licensed and properly trained electrician WARNING Do NOT attempt to connect the turbine directly to AC wiring permanent damage may result Do NOT attempt to connect the turbine directly to a low voltage DC system e g 12VDC 24VDC 48VDC The T701 turbine should only be connected to a properly installed and tested REbus microgrid Read and understand this manual AND the accompanying REbus Microgrid Design and Installation Manual before attempting to install the T701 turbine NOTE Pika Energy recommends storing this manual in a sealed waterproof container located near the inverter for ready access What is REbus The underlying technology behind Pika Energy s X3001 I
29. hecked at least 30 minutes after the initial torqueing All blade fasteners should be torqued to 25 N m 18 ft lbs The blade hub assembly must be completed before attachment to the turbine Perform the following steps to recheck the torque on the blade rotor and install the blades onto the main shaft 1 Check the torque on the blade bolts At least 30 minutes after the initial bolt tightening use a torque wrench to ensure that the bolt torque on all 15 blade bolts is 25 N m 18ft Ibs It is normal to find that the torque has relaxed in the 30 minutes since the initial torqueing Check O ring Check that the orange O ring gasket is in place in the shaft seal rotor where it emerges Check orange from the front of the turbine gasket Wipe and lubricate mainshaft Wipe the mainshaft with a paper towel or clean rag and then apply a thin layer of the grease provided in the hardware kit to the mainshaft The layer should be thin enough that the color of the grease should not be visible Install bladehub Position the bladerotor assembly directly under the nacelle Rotate the rotor to align the three tangs of the spline on the turbine with the three gaps in the spline on the bladehub With two people supporting the bladerotor assembly from both sides carefully align the mainshaft with the bore on the bladehub and slide the hub onto the shaft engaging the spline and compressing the O ring Install nut and washer With one per
30. hreadlocker compound to prevent loosening over time Wipe off any excess grease from the threaded towertop NOTE Consult Pika Energy before using a non approved tower design TAKE A PHOTO Take a digital photo of the towertop yaw and jam screw in position 9 Take a Photo showing the connection between the towertop and the yaw casting and showing the yaw set screw locked in place 10 Remove the brake locking screws from the nacelle and replace them with the provided plug screws M8 x 12mm socket cap screws with pre applied anti loosening compound and rubber washers using a 6mm ball end hex wrench The brake locking screws ensure the overspeed brake does not accidentally deploy during shipping The brake locking screws must be removed and replaced with the supplied plug screws prior to installing the blade rotor TAKE A PHOTO Take a digital photo of the plug screws installed in place of the brake locking screws 11 Take a Photo of the plug screws installed in place of the brake locking screws 23 WARNING The brake locking screws must be removed and replaced with the supplied plug screws prior to installing the blade rotor The blades will not rotate with the brake lock screws in place Wire the Brush Disk Once the turbine is secured to the top of the tower and the tower wire is in place complete the tower wiring by executing the following steps DANGER Ensure that the tower wiring is de energized befo
31. ind Turbine does not orient Disable turbine immediately at inverter front panel display Seized yaw bearings to wind call your installer Call your installer Wait for ice to melt Damage to blade Disable turbine immediately at inverter front panel display from flying debris call your installer 38 Notes 39 40 oo 35 Bradley Drive Suite One Westbrook ME 04092 info pika energy com sales pika energy com pika energy com TC1317 Installation and Service Cover indd 2 6 5 15 11 22 AM
32. ing clear of the swept area rotate the blades slowly by hand You should feel a smooth resistance If scraping grinding or squeaking sounds are observed stop and correct the issue before proceeding 7 Position the shroud Position the rear blue shroud loosely place over the circuit board assembly with the front edge of the shroud downwind of the heat dissipation fins 8 Align mounting holes Using a flashlight gently guide the rear shroud into alignment with the four threaded holes in the nacelle casting 9 Install shroud fasteners Install four M4 truss head phillips machine screws with black rubber gasket washers to secure the shroud Apply manual pressure to the shroud while tightening screws to ensure that the shroud is well seated Tighten the screws until the washers bulge slightly but do not allow them to distort significantly or squirt out from under the screw head 3 6 Complete connections and perform pre flight checks NOTE The following instructions are for installations with REbus inverters For some installations another REbus device e g B801 charge controller may be used instead Read and understand T701 User Manual relating to turbine operating modes before raising the turbine Complete the connections between the turbine and the inverter before raising the tower according to the wiring diagrams Observe all local and national code requirements 3 Follow instructions in the REbus Microgrid Design and
33. ing to an unsupported tower and catastrophic collapse Unconventional Mounting Situations Historically the best performing wind turbines are installed on ground mounted towers in open exposed terrain Pika Energy strongly advises against mounting a wind turbine directly to the structure of a home Failure to use a Pika approved tower will void the turbine warranty Building mounted wind turbines have a history of poor performance noise issues and significant downtime Consult with an experienced structural engineer before mounting a T701 turbine to a steel or reinforced concrete commercial building to address structural issues noise vibration and potential leaks Attachment to a building does not substitute for a tower Poor performance is virtually guaranteed if the turbine does not project at least 10 meters above surrounding obstacles including buildings within a 100m radius 2 3 REbus DC wiring grounding and lightning protection system The T701 wind turbine features Rebus a plug and play microgrid standard developed by Pika Energy See the accompanying REbus Microgrid Introduction and Design Guide and REbus Quickstart Guide for important information before designing your REbus system Contact Pika Energy regarding availability of additional REbus microgrid products to expand your home energy system All site wiring must be installed and grounded in accordance with local building codes Local codes may require a disconnect or other
34. ll curtail its soeed and output power to prevent damage If the 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 5 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 5 9 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 horizontally 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 e From the front panel display of the inverter scroll horizontally to the turbine page 33
35. llow the instructions in this manual as well as the tower manufacturer s manual DANGER Do not install a T701 turbine unless you have read this entire installation manual and watched nstalling the Pika Energy T701 Turbine available at http vimeo com 104006485 DANGER Always wear appropriate OSHA approved Personal Protective Equipment including Hard hat Steel toed boots Safety Glasses Gloves DANGER Pika Energy does not recommend working alone when installing or servicing turbines or towers WARNING Never remove the front plate unless specially trained in alternator service The T701 alternator contains powerful magnets which may cause tools and fasteners to fly and shatter The magnets also attract metal particles from clothes skin and hair and these particles may damage the alternator Credit cards or other forms of magnetic storage may be erased or irreparably damaged if brought in close proximity to the alternator NOTE Professional or third party installers are required to go through Pika training before installing the T701 turbine for customers USE THE CHECKLIST A signed completed checklist with the required photos must be filed with Pika Energy for warranty registration TAKE PHOTOS Photos of key installation steps are required for warranty registration 11 3 1 Turbine Mechanical Diagram PIKA ENERGY T701 TURBINE MECHANICAL LAYOUT 118 6 53012 5 171 6 1818 7 14 SQ METER SWEPT AREA
36. ly 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 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 5 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
37. nverter is an innovative energy management platform or smart microgrid called REbus REbus is a DC energy network that operates alongside the existing AC infrastructure enabling customers to build cost effective scalable renewable energy systems The REbus network is designed to serve as an open interconnection standard for networking next generation energy technology like Wi Fi or USB for green energy 2 Turbine System Design To give good performance the T701 turbine must be installed as part of a well thought out system designed in accordance with industry best practices 2 1 Applications Grid Tie Wind System T701 Wind Turbine 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 feeds the power back 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 Introduction and Design Guide Grid Tie Wind PV Hybrid System T701 Wind Turbine 52001 PV Link X3001 REbus Inverter Pika Energy offers a PV hybrid option with unmatched perfo
38. ons to improve Pika s products Thank You Summary of Fastener Torque Specifications The following table of fastener torques is provided for the convenience of the installer This table is not a replacement for the full assembly instructions on the following pages When tightening DO NOT GUESS Use a torque wrench Component Fastener Tools needed Torque Nm Torque type ft lb Yaw casting 2 NPT at least a 24 chain Apx 540 hand tighten the yaw while wrench and a 3 pipe someone supports the weight of the wrench with extension turbine Then apply 200 pounds of force at to oppose torque on the end of a 24 wrench until the yaw will the tower not any further screw screw preferred or 00 hex wrench ll MN E bar screws head in feat leads head 25 re torque at least hr after initial tightening muss aan E da retention nut hand Or e e a a E screws head in Ib Tail vane M6 pan 10mm socket and 3 nuts head phillips SSS RR EE bolts screws extension Shroud M4 truss 2 phillips Apply hand pressure to shroud to help seal against attach head gasket Tighten until rubber washer bulges slightly see screws instructions on page 28 WARNING Be sure to tighten the yaw to the tower adapter with at least 200 pounds of force at the end of a 24 wrench while sufficient counter torque is being applied to the tower by a crew member to prevent the tower from rotating Failure to p
39. r while raising the turbine Note Wiring will remain live if inverter is powered up and enabled even if turbine is not spinning 3 7 Raising and Securing the Tower Raise and secure the tower according to manufacturer s instructions Once the tower is raised and secured perform any additional connections e g tower grounding as recommended by the tower manufacturer The following are general recommendations tower manufacturer s instructions shall take precedence DANGER Obtain training from the tower manufacturer before attempting to install a tower or turbine See the T701 Turbine Installation section for important tower safety information DANGER All personnel should wear appropriate PPE as recommended by the tower manufacturer including hard hats steel toed boots safety glasses work gloves and other equipment as appropriate DANGER Do not work on turbines or raise towers if electrical storms are nearby Lightning can strike many miles from the center of a storm 29 DANGER No personnel should be within the fall zone while the tower is raised or lowered Bystanders should keep well back from tower DANGER Do not use over the road vehicles to raise towers Pika Energy recommends the use of a high quality non backdrivable worm drive winch with a safe working load limit WLL rating well in excess of the maximum tension encountered at any point while raising the tower WARNING Do not raise towers in strong
40. re wiring the turbine WARNING Be very careful not to damage the circuit board especially when attaching the wires to the brush disk NOTE The T701 turbine features dual brushes on each channel of the turbine output There are six brushes but only three conductors to wire 1 Fit the tower cable Form the tower cable carefully over the half turn support on the strain relief bracket and mark the position of the cable clamp bar 2 Strip outer insulation Remove the cable clear of the strain relief bracket and carefully strip the outer insulation back to beyond the mark with a sharp utility knife 3 Secure wire under clamp Re position the wire over the strain relief bracket and tighten the 2 M4 pan head screws to secure the wire snugly to the bracket using the clamp bar Alternate back and forth between screws to ensure even clamping Ensure that the clamp bar bears only on the gray wire insulation not the black and white insulation of the individual conductors Torque the two M4 clamp bar screws to 0 4Nm 4 in Ib DO NOT OVER TIGHTEN to prevent damage to wire 4 Connect Ground Lead Route the bare copper ground wire to the ground screw marked with the GROUND symbol trim to length and form a clockwise loop in the end of the wire slip the loop under the head of the ground screw and torque to 1 5Nm 1 1 ft lb or 13 in Ib 5 Connect Positive REbus Lead Mark the white wire with red electrical tape route it to the
41. rmance and flexibility Up to 8 standard PV modules be connected to the X3001 inverter in parallel with the T701 turbine through Pika s 52001 PV Link maximum powerpoint tracking converter Contact Pika Energy for more information about this exciting option for boosting the performance of the T701 turbine system with solar photovoltaics Off grid Wind System T701 Wind Turbine B801 REcharge Battery Charge Controller The T701 Wind Turbine can be used in off grid applications when combined with a REbus B801 Battery Charge Controller Contact Pika to learn more about charge controller options that are currently available Off grid Wind PV Hybrid System T701 Wind Turbine S2001 PV Link B801 REcharge Battery Charge Controller Pika Energy offers a wind and PV hybrid option with unmatched performance and flexibility for off grid applications The T701 Wind Turbine can be combined with 3 4 kW of PV 12 16 standard PV modules in off grid applications when combined with a REbus B801 Battery Charge Controller Contact Pika to learn more about 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 Introduction and Design Guide for more details 2 2 Siting and Towers DANGER Obtain training from the tower manufacturer before attempting to
42. roperly torque the yaw could lead to the turbine falling off the tower 19 3 5 Turbine assembly Before beginning the installation carefully unpack and verify the contents against the nacelle box and remove the hardware kit verifying that all components of the packing list are present The T701 turbine ships in 3 boxes one for the nacelle one for the blades and tail boom and one for the tail vanes fh Build Blade Assembly NOTE Trailing edges of blades can be sharp Pika Energy recommends wearing gloves while handling the blades The blade hub assembly should be completed before assembling other turbine components to allow for adequate time for a two step blade bolt torqueing procedure Perform the following steps to assemble the blades and hub NOTE Gentle manual pressure may be required to fit the blade to the hub but if excessive force is required remove the blade and check the assembly for issues WARNING Dirt or grit on the greased main shaft and blade hub shaft bore surfaces can damage those precision surfaces Assemble the blade rotor on a clean surface and if necessary use tape to mask off the blade hub bore 1 Unpack the blades from the blade box Use caution to prevent damage especially to the thin trailing edges of the blades Blades come from the factory pre balanced The order of the blades does not matter 2 Unpack the nacelle and remove the blade hub from the main shaft It s very important
43. son holding the bladerotor upward install the thick stainless washer and reverse threaded M12 hub retention nut onto the threaded stud in the end of the shaft Be sure to use the supplied red Loctite on the reverse threaded stud Torque hub retention nut Using a 19mm socket and torque wrench torque the nut to 76 Nm 56 ft lb It may be necessary to insert a hex key size M5 or other small tool into the hole in the shaft to prevent rotation 26 7 NOTE It may be necessary to insert a hex key or small screwdriver in the cross drilled hole at the end of the shaft to prevent the shaft from spinning Double check gasket Check that the orange gasket O ring is in place and compressed but visible around the full diameter Take photos Take digital photos of the assembled hub on the turbine from upwind and downwind directions TAKE A PHOTO Take digital photos of the assembled hub on the turbine from upwind and downwind directions Install the nosecone by aligning the stepped features with the surface of the blades then fine tuning the alignment of the holes in the nosecone with the threaded holes in the hub casting Secure the nosecone with three M4 truss head screws from the hardware kit Thread locking compound has been pre applied to the screws DO NOT use rubber washers on the nosecone Torque the screws to 0 4 Nm 4 in Ib Install Tail Assembly and Shroud WARNING t is critical to install both tail vanes Th
44. t consideration Pika Energy strongly recommends the use of tilt up or climbable towers in case the turbine requires service Fixed non climbable towers significantly increase the cost of inspection and repair Guyed Towers Guyed towers are supported at intervals by cables guy wires which help the tower withstand side loading from the wind Guyed towers require more open space than freestanding towers but are more structurally efficient so they are often lighter and less expensive than monopole towers for a given height Depending on soil conditions guyed towers can often be installed without concrete The anchoring system required for each guy depends on the turbine size and soil conditions Common anchors include screw in earth augers expanding anchors and poured in place concrete anchors The central column will typically sit on a light metal spreader base or a small concrete pad Some guyed towers are designed to be tilted into place using a gin pole others are designed to be raised with a crane with subsequent maintenance performed by climbing Freestanding Towers Freestanding towers support both the weight of the turbine and the sideways force of the wind through the strength of the tower itself Freestanding towers require significantly less open space than guyed towers but will likely be heavier and require a more substantial foundation typically cast in place reinforced concrete Just as the trunk of a tree must be larger ne
45. tower wire rotates freely within the yaw casting to prevent excessive twist WARNING Take care to ensure that the yaw is not cross threaded on the towertop 7 Wrench tighten the yaw Once the threaded engagement is hand tight tighten using a chain type pipe wrench at least 24 in length and apply 400 foot pounds of torque This is the equivalent of a 200lb person putting all of their weight on the end of a 24 wrench until the yaw stops threading onto the tower This should be 17 to 2 turns beyond hand tight If no member of the installation crew is heavy 22 enough two people should work the chain wrench to ensure sufficient torque is applied It will be necessary to use a second wrench to apply opposing torque to the tower top to prevent the sections of tower from rotating A 3 capacity pipe wrench with an extension will be sufficient for a second person to oppose the torqueing of the yaw WARNING After torqueing the yaw on to the tower check that the guy plates are still properly aligned with the gin pole if using a tilt up guyed tower Yaw torqueing can result in inadvertent rotation of guy plates if tower sections are not held fast 8 Tighten yaw jam screw Once the yaw is secured to the tower install the jam screw from the hardware kit It threads into the tapped hole on the side of the yaw casting Tighten the screw until it binds into the tower top threads Torque to 18 Nm 13 ft lb The jam screw has pre applied t
46. ueseneneeens 14 3 4 Prepare TO the TUTDING M c 16 USE OL Ce CRISIS is 16 PFO eS CCC KS Oo 16 HEU gera 3 PG HN 17 S 17 Copy of Turbine Installation Checklist sss nnnm nnns 18 Summary of Fastener Torque eee 19 S A Ul TORT 20 BUNGE Blade TU 20 Attach TOWER 22 Wire Brush DISKS n 24 eee ene uM en 26 Install Assembly ane ShEOBQ N 27 3 6 Complete connections and perform pre flight CHECKS cccccssccccsssececesseccceeeceeeeeeccecsesecesseseceeeeeeseeeeeetes 28 35 7 Raising Securing THe TOW CI eec tes ict tes OS Lebe Datus Festes esee dO a 29 4 COMMISSIONING THE TURBINE cs rae se KE E cobain aS 31 5 TURBINE SYSTEM OPERATION GRID TIE 5 5 ERU A VE Pa SRM aene 32 5 1 How to Use the Front Panel Display ao oR 32 SZ UE OMe alates UE ET
47. ution when flipping the rotor to avoid damaging the thin trailing edges or tips of the blades Install and torque three short upwind blade bolts Insert three 25mm M8 bolts paying close attention to the order and orientation of the washers Put the conical washer on the bolt first with the cone side pointed toward the head of the bolt The flat washer goes on the bolt after the conical washer Torque each bolt to 25 Nm 18 ft lb with a reliable torque wrench Take photo Take a digital photo of the upwind side of the blade rotor Flip the assembled rotor over for a second time to access the previously installed bolts for proper torqueing The blade rotor should be supported near the blade tips as shown in the image to the right This allows for the downwind edge of the blade root opening to bear against the hub Torque to 25 Nm 18 ft Ibs Take photo Take a digital photo of the downwind side of the completed blade assembly Set the assembled rotor aside in a safe place 21 The torque on the blade bolts will need to be checked again at least 30 minutes after the initial torqueing but for now set the assembled blade rotor aside in a safe place where it won t get dirty or damaged during the next steps TAKE A PHOTO Take digital photos of the upwind and downwind sides of the completed blade assembly Attach Nacelle to Tower Top 1 Check cable length Ensure that at least 24 of tower cable extends beyond the top of the tow
48. winds Observe manufacturer recommendations concerning maximum windspeed for installation WARNING double check the torque of all tower fasteners guy wire tension and other key parameters before enabling the turbine 30 4 Commissioning the Turbine See T701 Operation Manual for detailed instructions relating to the user interface Once the tower is raised and secured double check all wiring then turn on power to the inverter at the breaker panel Enable the inverter if it is disabled Once the REbus microgrid is active enable the T701 turbine from the inverter front panel If the wind exceeds 3 5 m s about 8 miles per hour the turbine will start spinning Depending on the temperature it may take a few minutes for the bearings to warm up before the blades catch and come up to speed The T701 turbine generates power at rotational soeeds between 120 and 420 RPM Verify that the turbine is producing power by scrolling to the turbine page on the inverter front panel display and observing the real time power output Setting the altitude If your T701 Wind Turbine is installed at a greater than 300m 1000 ft altitude contact Pika Energy for instructions on adjusting the control algorithm for high altitudes Manually Disabling Enabling the turbine To disable the turbine 1 From the front panel display of the inverter scroll horizontally to the turbine page 2 Pressthe center button to show the menu 3 Select Disable
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