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GRID CONNECT INSTALLATION MANUAL

1. NEVER Use shackles with bent pins or deformed bodies amp Force hammer or wedge shackles into position e Eccentrically load shackles e Replace the pin with a bolt e Fit pins in contact with moving parts which may loosen or unscrew them e Shock load shackles Selecting the Correct Shackle Shackles are available in a range of material grades sizes and designs Select the shackle to ba used and plan the lift taking the following into account Type of shackle to ba used dee or bow British Standard or other dasign Type of pin screwed with collar and eye ara suitable for general purposes with countersunk head for where clearance IS limited bolt and nut for where the pin may be out of sight or subject to movement Full resultant imposed load when using shackles with multi leg slings remember that as the included angle increases and so does the load in the leg and any attachment to the leg When used to suspend pulley blocks account must be taken of the imposed load due to operating effort storing and Handllng Shackles Never return damaged shackles to storage They should be dry claan and protected from corrosion Do not alter modify or repair shackles and never replace missing pins with unidentified pins bolts etc but refer such matters to a Competent Person Never galvanise or subject a shackle to other plating processes without the approval of tha supplier Using Shackles Safely Do
2. With manual winches only tha slow speed should be used to raisa lower loads With power operated winches select a speed appropriate to the specific lifting operation Ensura oil water or other foreign matter does not come into contact with lined brakes If the direction of rotation is indicated the winch must raisa the load when turning in that direction v Check the rope and load travel paths are clear and you have a clear view so as to avoid accidents or collisions Co not over wind the rope on or olf the drum Two turns must always remain on the drum This is a requirement of the Construction Lifting Operations Regulations however some manufacturers design for more anc ther recommendations must be followed Kaep clear of ropes pulleys drums and other moving parts In service Inspection and Maintenance Follow the specific instructions for maintenance issued by the supplier These should be incorporated into the site mainte nanca programme oosarving any particular needs due to the site or working conditions Regularly inspect the winch and in the event of the following defects refer to a Competent Person for thorough examination mounting insecure locse or missing bolts winch frame distorted rope drum flanges chipped or cracked rope anchorage loose or pulled ratchet or pawi worn brake worn ar slipping rope worn or winding incorrectly broken wires gears worn or not positively locating any other visible damage c
3. info provenenergy com Tel 44 0 1560 485 570 6kW Installation Manual Proven6 300 2006Rev 01 3 4 Slip Ring Assembly 3 4 1 Description A slip ring is an electromechanical device that allows continuous electrical connection and transmission of power from a stationary to a rotating structure Additionally the slip ring helps prevent the down cable and brake rope from twisting The slip ring assembly consists of 1 Slip ring 3 ring including grub screws 2 Mount stand for slip ring brushes 3 Slip ring brushes for each ring Slip Ring lt Slip Ring N Brushes 3 4 2 Procedure e Smoothen the tower spigot surface to be fitted with the slip ring with a sand paper e If cable is fitted at this stage then feed cable through the slip ring and top hat If not the fit slip ring onto spigot fit top hat into the end of slip ring so that it butts up against the end of the tower top This is the position the slip ring should be secured in Slide back the slip ring and top hat and apply loctite to the spigot and then re fit and secure using the grub screws Use a 3mm allen key to fix grub screws in place use A118 on grub screws www provenenergy com info provenenergy com Tel 44 0 1560 485 570 6kW Installation Manual Proven6 300 2006Rev 01 Slip Ring Connections This assumes brake rope and cable are in position and are fitted through top
4. PROVEN 6 TM900 TM1500 GRID CONNECT INSTALLATION MANUAL PROVEN6 300 2006REV 01 Proven Energy Ltd Wardhead Park Stewarton Ayrshire KA3 5LH Scotland Tel 44 0 1560 485 570 Fax 44 0 1560 485 580 E mail info provenenergy com Web www provenenergy com 6kW Installation Manual Proven6 300 2006Rev 01 Table of Contents 1 0 Introduction 1 1 Package Content 1 2 Health and Safety Information 2 0 Electrical Installation 2 1 Schematic for Connection 2 2 GW6000 2 3 ECM6004ME 300 Control Box 2 4 WB 6000 WB 3000 Grid Connect nverter 2 5 Description of Typical System Operation 2 6 Method of Disconnection from Grid 2 7 Panel Layout 2 8 Proven 6 Grid Connect Electrical Schematic with WB 6000 2 9 Proven 6 Grid Connect Electrical Schematic with 2x WB 3000 2 10 kWh Meter Wiring Instructions 2 11 Typical 1 Phase Installation with WB 6000 2 12 Typical 2 Phase Installation with 2x WB 3000 2 13 Typical 3 Phase Installation with 3x WB 2500 2 14 WB 6000 Parameter Settings 2 15 WB 3000 Parameter Settings 2 16 WB 6000 Operating Mode Extract 3 0 Mechanical Installation 3 1 Tools Required 3 2 Tower Assembly 3 2 1 Procedure 3 3 Fitting the Turbine Head to the Tower Top 3 3 1 Procedure 3 4 Slip Ring Assembly 3 4 1 Description 3 4 2 Procedure 3 5 Preparing the Cable Termination at the Wind Turbine End 3 5 1 Procedure 3 6 Brake Rope Installations 3 7 Fitting the Covers 3 7 1 Fitting t
5. The successful range of A100 meters from Elster Metering Systems provide a cost effective solution for one or two rate domestic applications The new A100C meter is housed in an extremely compact case To further enhance security the main meter cover is permanently secured to the base during the manufacturing process The meter also provides the choice of IrDA communications or optical IEC 62056 21 formerly IEC 61107 communications The liquid crystal display has large 9 8mm high contrast characters that can be viewed from a wide angle Chevrons and multilingual legends on the nameplate identify the values being displayed The energy registers can be configured for the required number of digits and for the position of the decimal point The A100C offers high security and detects many of the most commonly used tamper techniques Security features of the meter include reverse run energy total and count power fail and elapsed time count hours in anti creep hours in Rate 1 Rate 2 and hours since last power up time These are stored as security data and can be included as part of the display sequence and read via the optical communications ports The A100C has the option of IrDA or optical IEC 62056 21 formerly IEC 61107 communications Both methods of communication allow the meter registers and security data to be read electronically from a laptop or hand held device greatly reducing the possibility of manual meter reading error
6. lt lt X R 25 SHACKLE ELASTIC 26 BRAKE ROPE CONDITION EX R 27 BRAKELEVERS N ELECTRICAL SYSTEM 28 CONTROLLER OPERATION EX S 29 V amp IMETER OPERATION EX 30 CABLECONNECTIONS XT A 31 CONDITION OF WIRING AND ph ph VOLTAGES X _ 132 INVERTER CONNECTIONS __ _ _y _W_rrr COVERS amp OTHER CHECKS 33 GENERATOR COVER CONDITION TX 34 YAW COVER CONDITION X 35 NACELLE COVER CONDITION EA JE 36 CABLE TIES x R www provenenergy com info provenenergy com Tel 44 0 1560 485 570 6kW Installation Manual Proven6 300 2006Rev 01 Service Schematic Cut away view showing main shaft bearings generator and slip rings Maintenance Schedule Once per year GENERATOR Grease the three bearings no maintenance required Clean slip rings Check Brake pads MAIN SHAFT BEARINGS Check nuts and bolts Grease occasionally once Check springs per year at most N BRAKE Operation No action is required during normal running the system is self regulating and automatic with passive fail safe speed and power control Proven Patent Passive Blade control system MAST BEARING Grease occasionally once per year at Slip rings Clean once per year www provenenergy com info provenenergy com Tel 44 0 1560 485 570 6kW Installation Manual Proven6 300 2006Rev 01 4 3 Spare Parts List VA OMN SP ARTS LIS PROVEN RECOMME
7. IEC 62056 21 formerly IEC 61107 two way communications The table below shows the functions available for each type of communications Configure Meter Register Security and Status Register Security and Status Data Via Optical Port Data Via Auxiliary Terminals IEC 62056 Yes Yes No IrDA No Yes Yes ELSTER EE le K a de Elster Metering Systems Our policy is one of continuous product development and the right is reserved Staffordshire to modify the specification contained herein without notice United Kingdom Tel 44 0 1785 812111 www elstermetering com EMS A100CBS 2 2004 A NI de u A aa AoH INNO D szwy Ze 84 L dy ied z TAR 5 4 Q CONNIE ISOLATING SWITCH gt ft p LM WB6000 Settings for Proven 6 May 2007 provin G Y PROVEN 6 INSTALLATION USING A WINDY BOY 6000 PROVEN PARAMETER SETUP LIST UK FOR WINDY BOY 6000 INVERTER SERIAL No CUSTOMER NAME INSTALLER NAME Upv Start 250 000v T Start 180 000 s T Stop 3000 000 s Usoll Konst 600 000 v P Limit 6000 W I NI TEST 0 00mA Uac Min 209 000 v Uac Max 264 000 v AcVtgRPro 264 000 v Vac Tavg 80 000ms Fac Delta 3 Hz Fac Delta 0 5 Hz Fac Tavg 80 000ms dFac Max 0 25 Hz s dZac Max 350 0 mOhm Hardware BFS 1 00 Version Software BFR 2 550 Version Software SRR 2 550 Version INST CODE INSTALLER Udc Wind Start 260 000v Udc Wind Mid 300 000V Udc Wind Max 320 0
8. e Place PU rubber hinge of blade on top of washer e Place further washer on top with metal clamp plate as final layer Secure blade using M10 bolts and lock nuts provided It is good practice to use Loctite Threadlock A118 or similar to lubricate and secure fixings against vibration Use only a small amount on each bolt Attach Zebedee springs to the blade bracket and spring anchor bracket It is very important that the M10 fixing bolt running through the spring ends is not fully tightened The spring ends should be allowed to freely rotate during normal operation However there should be no lateral play of the spring ends within the spring bracket Check all fasteners are tight and repeat for the other two blades www provenenergy com info provenenergy com Tel 44 1560 485 570 6kW Installation Manual Proven6 300 2006Rev 01 Spring Hub Plate Zebedee Spring Blade Leading Edge thick TA 3 EET attit TET rrr rrr OUA LLI R SA TUL ati Ea Polyprop Blade Clamp W 244 Spring Anchor Bracket FMM Blade Trailing Polyurethane Edge thin Rubber Hinge Wedge thick End Hub Plate www provenenergy com info provenenergy com Tel 44 0 1560 485 570 6 kW Installation Manual i Thicker end of wedge faces the same way as the trailing thinner edge of the blade www provenenergy com info provenenergy com Tel 44 0 1560 485 570 6 kW Installation Manual MID A 100 MIO X 80 MIO
9. or subjected to extremes of temperature Storing and Handling Winches Never return damaged winches ropes ete to storage They should be dry daan and protected from corrosion With winches used for temporary applications ramove the repe lor separate storage or wind it fully onto tha drum and lash in position to prevent damage With winches left In situ remove pulleys ate and wind the rope fully onto tha drum Where this is net possible pulleys etc should be positioned to protect them from damage and so as net present a danger to persons or other equipment Isolate any power supply Instructions for Safe Use of Winches Used For Lifting The information in this leaflet should be passed to the user of the equipment Installing and Commissioning Follow the specific instructions for installation and commission ing issued by the supplier Handle the rope carefully If tha winch fails to operate correctly contact the supplier Using Winches Safely Do not use defective winches ropes pulleys atc Check the rigging arrangement that mounting and suspension points ara secure and adequate for the imposed loads Do net use timber bearers Ensure sheaves are correct lor size and type of rope that fleet angles ara not too great the ropa is not twisted and the load is free to move Check operating handias ara secure Raisa the load just clear halt the lift to ensure the integrity ot the braka slinging arrangement ate
10. 000 12 000 kWh depending on site Downwind Self Regulating 3 Flexible Glassthermoplastic Composite 5 5 metres Tapered Hinged Self Supporting 9m or 15m 2 5x2 5x1m TM900 or 3x3x1 2m TM1500 Concrete W T6000 TM900 TM1500 Sample of Commercial Customers British Telecom Scottish Youth Hostel Association Saudi Aramco lrish Lighthouse Authority Welsh Water British Rail Shell Exploration T mobile Orange 6kW Installation Manual Proven6 300 2006Rev 01 PROVEN R Electrical Installation www provenenergy com info provenenergy com Tel 44 0 1560 485 570 6kW Installation Manual Proven6 300 2006Rev 01 2 0 Electrical Installation The Proven 6 300 is specially designed for connection to LV network at 230Vac 50Hz nominal by means of the WB 6000 or WB 3000 grid connect inverter SMA Windy Boy It is suitable for domestic agricultural and SME applications and will produce from 6 12 MWh per annum depending on the wind resource available A description of the main electrical component parts of the system 1s as follows 2 1 Schematic for Connection Please refer to the electrical schematic The main elements are e Proven 6 wind turbine containing GW6000 3 phase AC synchronous variable speed alternator e Proven grid connect inverter amp controller package comprising o DC Disconnect allowing the turbine to be isolated from the grid connect inverters o ECM6004ME 300 controller which displ
11. 46mm Spanner for TM1500 e g TM900 M24 Tower Bolts 36mm socket on 34 drive ratchet TM1500 M30 Tower Bolts with Im scaffold tube or similar for connecting tower onto base plate extension 4 to 6 socket extension sometimes useful Tube of glazing silicon amp gun Dr All Fixings must be used on all Loctite Studlock A118 or similar e acini Pliers Wirestrippers large crimping tool assorted crimp lugs Wiring etc Occasionally Stainless steel nuts lock during tightening Hacksaw Hacksaw is sometimes the last resort May also be used to trim foundation jJ bolts if required 46mm Spanner e g 46mm socket on drive ratchet with Im scaffold tube or similar for extension 4 to 6 socket extension sometimes useful M30 J bolt nuts connecting base plate to concrete foundation Removing any galvanising drips to Flat file allow tower fitting with yaw bearing www provenenergy com info provenenergy com Tel 44 0 1560 485 570 6kW Installation Manual Proven6 300 2006Rev 01 3 2 Tower Assembly The Proven TM900 tower is a single piece tower whereas the TM1500 is in three sections In certain instances e g an easily accessible site with a suitable lifting device the TM1500 can be supplied in one piece Where the tower is supplied in one piece please follow the installation procedure below and for all others please refer to Appendix B tower assembly and erection procedure for proce
12. balance Yaw rubber worn Cables disconnected Battery blown Controller ammeter circuit fuse open info provenenergy com Check to see if all fittings and components are tightly fitted Check if any bolt needs grease especially yaw rubber bolts Check connections Check brake lever Check connections Measure wind speed Check siting of turbine Check power usage Check inverter settings Check blade fittings Check yaw rubbers Check connections Tighten loose fittings or components Grease bolts Repair short circuit Replace diodes Replace bearings Remove brake rope from lever faulty Repair short circuit Replace diode Site turbine in a better location or height Economise power use Program inverters with correct settings from parameter list Fix blade properly and balanced Replace rubbers yaw Fix cables Replace fuse Replace meter Tel 44 0 1560 485 570 6kW Installation Manual Proven6 300 2006Rev 01 Appendices Appendix A Weights and Dimensions Appendix B TM1500 Tower Assembly and Erection Procedures Appendix C Lifting Equipment Instruction Sheets Appendix D Warranty Document www provenenergy com info provenenergy com Tel 44 0 1560 485 570 6kW Installation Manual Proven6 300 2006Rev 01 E N E R G Y Appendix A Weights and Dimensions www provenenergy com info prove
13. box bolts for tightness Check all power and signal connections and wires Listen for any abnormal noises or excessive vibrations as a check for possible loose fittings or components e Check brake pad thickness is more than 2mm and replace if worn beyond 2mm e Check brake operation before raising wind turbine e Check for general wear and tear and replace any worn parts e Pay particular attention to the blades especially the blade root A damaged or cracked blade should be repaired or replaced immediately Caution Any damaged or cracked blade should be repaired or replaced immediately www provenenergy com info provenenergy com Tel 44 0 1560 485 570 6kW Installation Manual Proven6 300 2006Rev 01 4 2 Maintenance Check List KEY e X Check e G Grease e A Adjust if need be e C Clean e R Replace if need be TOWER BASE I GENERAL CONDITION 2 FOUNDATIONS 3 NUT BOLT TIGHTNESS 4 S S SHIM 6 HINGE BOLTS 7 GIN POLE ASSEMBLY SLIP RING ASSEMBLY 8 SLIP RING CONNECTIONS 9 SLIP RING BODY 10 SLIP RING BRUSHES X 5 WELDS FILLETS X X 11 TOPHAT dz 12 NUT BOLTTIGHTNESS X A 13 TOPHAT Xx BLADES amp SPRINGS 14 BLADE CONDITION x 15 P U HINGES KT 16 BLADE FIXINGS Xf 17 SPRING HISINOS T X 18 SPRING CONDITION XK 19 NUT BOLT TIGHTNESS x A e wets H H 21 WASHERS CLAMPS X BRAKE SYSTEM 22 BRAKE ASSEMBLY PARTS X 23 BRAKE OPERATION X 24 BRAKEPADS O
14. but which should nevertheless be investigated and corrected without delay Despite all precautions it is possible that other errors may occur which cannot be displayed e g failure of the status display In order to recognize such errors the operator of the system should use the explanations in section 4 3 4 Description of the Operating Modes Page 17 to check the plausibility of the displayed normal operating modes Far more detailed diagnostics are possible using the communication options detailed in section 8 Extensions Page 43 4 3 4 Description of the Operating Modes No or Low Input Voltage The Windy Boy is in the so called Standby mode This mode occurs when the input Betrieb O power at the Windy Boy is too low for Operation feeding the grid and for satisfying the on 1 41 All LEDs are board power requirements Earth Fault off St rung Failure O Initialization The Windy Boy s on board computer is at present in the initialization phase Power Betrieb 6 for the on board power supply is present Operation I but output power is not yet sufficient for erdschluss G bai grid feeding or for data transfer Earih Fault l St rung Failure User Manual WB50A_60A 11 FE3706 Page 17 Unit Description Working Mode The Windy Boy has successfully passed the measurement electronics and SMA grid guard selftests and has begun feed in operation The Windy Boy is working normally and is feeding
15. electricity into the grid It processes the wind turbine system s DC voltage according to the programmable voltage power curve see section 6 Turbine Operation Page 31 Stop The Windy Boy is in Stop mode Among other functions the measurement electronics are calibrated then the device switches to Waiting mode The Stop mode can also be manually set by the system operator via the Sunny Boy Control or the Sunny Data PC program In this case the Windy Boy remains in Stop mode until a new operating mode e g Turbine mode has been set Waiting Grid Monitoring The Windy Boy checks if the initial conditions necessary for grid feeding are satisfied e g start voltage then begins monitoring the grid Page 18 WB50A_60A 11 FE3706 Betrieb Operation Erdschluss Earth Fault St rung Failure Betrieb Operation Erdschluss Earth Fault St rung Failure Betrieb Operation Erdschluss Earth Fault St rung Failure SMA Technologie AG The green LED is illuminated ls The green LED blinks 3 times per second ls The green LED blinks once per second User Manual SMA Technologie AG Unit Description Derating The temperature monitoring of the Windy Boy has reduced the output power to Betrieb DIT Tu prevent the device from overheating If Operation Is nn a a a NA Thererecn ED inadequate heat dissipation or excessive Earth Fault gaes oui biel Input current
16. hat assembly e Using two 17mm spanners attach the slip ring brushes to the turbine frame Again be careful not to over tighten as the tube can break e Loosen the 3 stud nuts on top of the slip ring unit and connect the down cable ends at the top hat to the 3 studs Tighten the stud nuts with a 13mm spanner Do not over tighten as you may shear the copper stud Vibration washers are included to ensure a secure fit Note any cable can be connected to any stud www provenenergy com info provenenergy com Tel 44 0 1560 485 570 6kW Installation Manual Proven6 300 2006Rev 01 e With a 10mm socket loosen the bolts on the brushes till the brushes can be moved freely Position the brushes in the middle of the aa for good contact and then tighten bolts e Connect the generator lead out wires to the top of the brushes and tighten using a 10mm socket www provenenergy com info provenenergy com Tel 44 0 1560 485 570 6kW Installation Manual Proven6 300 2006Rev 01 3 5 Preparing the Cable Termination at the Turbine Head End 3 5 1 Procedure e Assemble down cable installation rods not supplied so they are long enough to match tower height Alternatively a draw DE OT other suitable memes can be used to pull cable down oo ee a from the top of tower to the bottom e Feed the assembled installation rods now a long rod through the slip ring at the tower top to the bottom of the tower
17. immediately against the thimble The grips must be placed so that they are separated by a distance of approximately six rope diameters The U bolt must always be placed on the tail end of the rope non load bearing end During assembly and before the rope is taken mto service the nuts must be tightened to the prescribed torque After application of the load the torque must be checked and if necessary be corrected This action should be repeated within 24 hours of installation Further periodic checking and re torquing of the nuts is essential during service particularly during the early stages of operation ensure that the terminal efficiency is maintained Further details on D I N 1142 grips can be obtained from your local CERTEX UK sales office Lifting Products and Services 6kW Installation Manual Proven6 300 2006Rev 01 5 N 5 R G Y Appendix D Warranty Document www provenenergy com info provenenergy com Tel 44 0 1560 485 570 PRO UK Warranty Proven Wind Energy Products are carefully designed manufactured tested and inspected In consequence we undertake to replace any part found to be defective in material or workmanship free of charge for a period of two years from delivery to the end user This warranty covers only those products manufactured by Proven Energy Limited General Conditions This warranty does not cover damage to Proven Wind Energy Products resulting from una
18. inverters start monitoring grid AC voltage frequency and impedance After a few seconds the GREEN LED starts to flash First the inverter checks voltage and frequency are within allowed ranges and that grid impedance is gt 1 25Q If all is OK then it waits 180 seconds required by G83 and G59 and then starts its connect to AC network procedure After completion of this procedure will take approx 5 mins depending on wind conditions the GREEN LED will be continuously on e If the inverter input DC voltage is lt 180VDC for gt 300 seconds then there is not enough wind power available and the inverter shuts down and goes into sleep mode All LEDs off Higher input DC voltages will wake it up when wind speeds increase and it will then repeat this connection procedure 2 5 Description of Typical System Operation A typical operating strategy during a windy period is summarised by e Continuous and automatic monitoring of Vac and fac by the inverter e Inverter will disconnect from grid network in lt 0 5 seconds should Va or fac go out of their allowed ranges under the connection settings chosen www provenenergy com info provenenergy com Tel 44 0 1560 485 570 6kW Installation Manual Proven6 300 2006Rev 01 e Inverter continuously adjusts output AC amps to match the wind energy available A typical operating strategy during a calm period is summarised by e Inverter goes into sleep mode after disconnecting from grid netw
19. registers and security data to be read electronically using a hand held device This greatly reduces the possibility of manual meter reading errors As an option the same absolute data as the IrDA port ora pulsed output can be transmitted via the meters auxiliary terminals Meters can be supplied to meet accuracy Class 1 or Class 2 requirements They are approved to EN 61036 1996 plus Amendment 1 2000 and have an ingress protection of IP53 to IEC 60529 1989 ELS IER Z Display IrDA Communications The IrDA Infrared Data Association U 7 UC b rou communications port provides TOU 2 one way communications sta a rem transmitting a continual data ES stream from the meter to an L i faer am Gane OT external device An error RS 4 checking algorithm protects the integrity of the data As an p eg The LCD version of the A1100 displays register Option the same absolute data and security information by the use of chevrons is available via the meters auxiliary terminals and digits The mechanical register version has The port uses the OBIS IEC 62056 61 data five LED s for reporting status information identifiers Meter nameplates can be printed in any Important information is provided language Meter registers Security features Status information Identification f The port transmits over a distance of 250mm Security The A1100 offers high security with many useful security features The meter stores all re
20. that has been subject to damage such as fire corrosive chemicals or atmosphere or exposed to electric current Storage See section 7 11 MAINTENANCE INSTRUCTIONS The machine should be inspected cleaned and lubricated at regular intervals at least annually by an approved TRACTEL UK repairer Never use grease or Gil containing graphite additives or molybdenum disulphide To clean the machine alow the machine to soak in a bath of some proprietary cleansing fluid but not acetone and derivatives or eihylene trichioride and derivatives Then shake the machine vigorously to loosen foreegn matter and turn it upside down to allow the dirt to come out through the openings for the operating levers Allow the mechanism to drain and become dry Alter thes treatment ensure that the machine is well lubricated by applying a quantity of ol type SAE 90 120 onto the internal inigm through the openings for the operating levers and for the models TU 8 and TU 16 through the special lubrication holes To carry out this pro cedure it is best for the machine to be nol under load and in the released positon Alternatively operate the forward and reverse Rope travel forward reverse Including and fittings of the wire rope GENERAL WARNING A 1 Before using the TIRFOR machine it is essential for the safe and correct operation of the equipment that this manual be read and fully understood and that all the instructions be followed T
21. the rope release lever 4 towards the anchor point 2 Release he safety catch and continue lo push the rope release lever until it locks into position The internal mechanism is inthe released position Engaging 1 Push the rope release lever towards the anchor point 2 Press and maintain pressure on the rope release safety caich allowing the release lever to slowly travel back lo its original position Release the safety catch The release lever locks in position under the effect of its spring 4 3 T 5000 range Fig 9 Piace the anchdk point against a support Releasing Turn the rope release salety catch 5 and push the rope release lever 4 towards the anchor Bin until it locks into position when raised slightly at its limit Release the safety catch Engaging 5 Turn the rope release safety catch 2 Press the rope release lever vertically downwards aliowing the lever to travel back to its original position under the effects of its spring Release the safety catch i a A J V x Fig 9 T500D range Rope release lever RELEASED ENGAGED 5 J ANCHORING ZU Failure toanchorthe TIRFOR machine correctly runs the risk of a serious accident The user must always ensure before operation that the anchor point s for the machine and wire rope are of sufficient strength to hold the load lL is recommended that TIRFOR machines should be anchored to a fixed point or to the load using an ap
22. to connect grid connect inverter inverter if under erid fault normal inverters op disconnected condition from grid S Voc DC Vop Dc Minimum gt 25mph blades feather at Maximum higher Ba 200 rpm wind 225Vac 3 ph 450Vac 3 ph 300V DC 540V Dc speeds to maintain this max shaft rpm Typical Speed 100 200 5 25mph 200 225 400 450 240 300V 480 V DC during rpm P Vac 3 ph Vac 3 ph D 540 V DC operation Th There are no touching parts or brushes in the machine and it is maintenance free GW6000 has 12 poles and has a nominal AC frequency of 20Hz 200 rpm GW6000 GW6000 Output Output Voltage Vac Voltage Vac under if grid fault normal inverters operating disconnected conditions from grid Vop AC Voc AC Approx GW6000 RPM Wind Speed C The generator can be disconnected at any load without any problems in this case the winding voltage rises and the turbine will speed up slightly until the blades mechanically govern to the maximum rpm On reconnection of load the turbine winding voltage will fall gradually to normal operating value due to the intelligent switch on strategy of the inverters used after the switch on delay period has passed 2 3 ECM6004ME 300 Control Box The ECM6004ME 300 has the following functions e Converts output 3 phase AC variable voltage of the turbine to DC variable voltage for input to the grid connect inverters e Isolation point for the turbine e Displays V I
23. towards the flange and lock into position with dowel pin B with the handles just above the horizontal and to the left when facing the mast flange and looking towards the top See diagrams F and G 21 10 05 01 13 Thread the tirfor rope through the Tirfor following the Tirfor Operating Instructions and making sure that at the back of the Tirfor B the rope passes smoothly around the dowel on the side away from the handles and through the hole on the A frame 14 Take up the slack rope and position the anchorage assembly vertically across the end of the mast Ensure that there is sufficient thread to de tension at this end 22 10 05 01 Pulling Mast Together ave one or two men to agitate the joint up and down See diagram K This action keeps the joint advancing smoothly and reduces winding effort 16 Continue stressing until the following requirements are achieved Final load applied to extended handle i e 1100mm is approximately 65kg Joint is a good tight fit Seams are aligned Minimum lap is exceeded 17 De tension either with the Tirfor or if there is resistance by using the nut at the other end Release more rope from the Tirfor and pull anchorage assembly out of mast Disconnect the tirfor rope and either pull sufficient rope through the next section of mast or pull out all rope is stressing is completed Further Assembly 18 THREE SECTION MAST Regard the assembly achieved so far two sectio
24. 00v KP Wind Reg 0 015 KI Wind Reg 0 005 Fac Start delta 1 000Hz FacLimit delta 2 000Hz T Stop Fan 50 000grdC T Start Fan 70 000grdC T Max Fan 90 000grdC Fac Test 0 P Wind Ramp 1000 000W P Wind Mid 3000 000W Betriebsart Turbine Memeory Function Default Storage Keine Function GB G83 Permanent Please change the Default setting to GB G83 first before proceeding to change the rest of the parameters WB3000 Settings for Proven 6 May 2007 FR EN G PROVEN 6 INSTALLATION USING TWO WINDY BOY 3000 PROVEN PARAMETER SETUP LIST UK FOR WINDY BOY 3000 INVERTER SERIAL No Inverter 1 CUSTOMER NAME INSTALLER NAME INVERTER 1 INVERTER 2 Upv Start 290 000v 290 000v T Start 180 000 S 180 000 S T Stop 3000 000 s 3000 000 s Usoll Konst 600 000 v 600 000 v P Limit 3000 W 3000 W I NI TEST 0 00mA 0 00mA Uac Min 209 000 v 209 000 v Uac Max 264 000 v 264 000 v AcVtgRPro 263 000 v 263 000 v Fac Delta 3 Hz 3 Hz Fac Delta 0 5 Hz 0 5 Hz dFac Max 0 25 Hz s 0 25 Hz s dZac Max 350 0 mOhm 350 0 mOhm Hardware BFS 1 00 Version Software BFR 2 430 Version Software SRR 2 440 Version INST CODE INSTALLER INSTALLER Udc Wind Start 260 000v 280 000v Udc Wind Mid 300 000v 300 000v Udc Wind Max 320 000v 320 000v KP Wind Reg 0 015 0 015 KI Wind Reg 0 005 0 005 Fac Start delta 1 000Hz 1 000Hz FacLimit delta 2 000Hz 2 000Hz T Stop Fan 50 000grdC 50 000grdC T Start Fan 70 000grdC 70 000grdC T Max Fan 90 000
25. 2 The order of assembly is The base section and its adjoining section are assembled and strained together this assembly and the next section are assembled and strained together and so on 3 Stress equipment consist of a steel A frame a TIRFOR winch and compatible wire rope and an anchorage assembly Offload with Assembly Need in Mind Before offloading mast sections due consideration should be given to the assembly and erection and each section of the mast off loaded on site accordingly A completed mast assembly should be in a position whereby the lifting equipment can erect the mast in a single lift without transportation Mast Assembly Procedure 1 ASSEMBLY SITE gt Assemble each mast as near as possible to its installation site but preferably on level ground BASE SECTION Determine the approximate balance point of the base section by slinging it from a crane and adjusting the sling until it balances See diagram A Lower the balanced base section on to a clean bearer positioned beside the sling as in diagram B The bearer should be high enough to support the base section at approximately the angle shown in diagram B ADJOINING SECTION Place the adjoining mast section about 1 metre from the base section rest it on two clean bearers See diagram C It is advisable to pass a rope through the sections at this stage to facilitate the later job of pulling through wire ropes and cables roughness likely to p
26. A TUSZA specially designed for Ii ting people on suspended platforms For further information on equipment for lifting people and on any spe cial application please refer to TRACTEL UK TECHNICAL DATA Maximum working load S Weight machine telescopic operating handle kg standard 20 m of wire rope complete kg Total weight of standard equipment kg Machine dimensions length length with optional hook height width telescopic handle closed extended cm TIRFOR MAXIFLEX wire rope diameter guaranteed breaking strain weight per meter m eer se One complete cycle of ihe operating lever al maximum working load 1 DESCRIPTION OF EQUIPMENT The TIRFOR machine is a hand operated lifting and pulling machine lt is versatile portable and multi purpose not only for pulling and lifting but also for lowenng tensioning and guying The onginality of ihe TIRFOR machine is the principle of operation directly on the wire rope which passes through the mechanism rather than being reeled onto a drum of a hoist or conventional winch The pull is applied by means of two pairs al sell energised jaws which exert a grip on the wire rope in proportion to ihe load being tilled or pulled A telescopic operating lever fitted lo either the forward or the reverse lever transmits the effort to ihe jaw mechanism to give forward of reverse movement of the wire rope The machine is fitted with a hook or anchor pin depending
27. DO from the turbine www provenenergy com info provenenergy com Tel 44 0 1560 485 570 6kW Installation Manual Proven6 300 2006Rev 01 2 4 WB 6000 WB 3000 Grid Connect Inverter The WB 6000 WB 3000 grid connect inverter has the following functions Conversion of variable voltage DC input to synchronised 230Vac 50Hz nominal 180s delay after grid fault until re connect to grid Trip out on over under voltage Trip out on over under frequency The WB 6000 WB 3000 inverter has been type tested for suitability for use under G83 1 regulations 2 4 1 Description of Typical System Commissioning Procedure At the start of a typical commissioning procedure the following should be the situation e The turbine is mechanically braked e The turbine is isolated from the grid connect inverters e The grid connect inverter is isolated from the grid The typical start up sequence 1s e Connect the 3 phase ac supply from wind turbine to the inverters by switching on the 3 pole disconnect in the ECM6004ME 300 controller e Release the wind turbine mechanical brake The turbine starts to rotate if wind conditions are more than about Smph The inverter waits until input DC voltage is gt 250V before starting its self test and safety procedures at which point the ORANGE LED on the front of the inverter will flash approx once per second e Connect the inverters to grid AC by turning the lockable AC disconnect to the On position At this point the
28. Display Since 2006 the Windy Boy has been equipped with an LCD display in the housing cover as standard SMA Technologie AG Activating the Display Illumination The background illumination is switched on by tapping on the housing cover Tapping again switches the display to the next message After 2 minutes the illumination switches off automatically Display Messages in the Startup Phase The following messages are displayed during the Windy Boy s startup phase Since the Windy Boy is identical to the Sunny Boy apart from the operating poz mode the display shows Sunny Boy After 6 seconds the firmware versions of the operation control unit BFR and the current control unit SRR are displayed User Manual WB50A_60A 11 FE3706 Page 25 Unit Description SMA Technologie AG Display Messages During Operation The display shows the Windy Boy s most important operating data in a continuous cycle The following three screen images serve to clarify the display messages Each message is displayed for 5 seconds Then the cycle begins again The energy generated today and the current operating mode are displayed first The amount of energy shown under E today does not necessarily reflect the amount of energy produced over the last 24 hours This is rather the energy produced by the Windy Boy since the last deactivation activation Subsequently the present feed in power and the output voltage are displayed Th
29. Down cable and brake ropesat the bottom of we www provenenergy com info provenenergy com Tel 44 0 1560 485 570 6kW Installation Manual Proven6 300 2006Rev 01 e Using an adhesive tape attach the brake rope and down cable to the assembled installation rod Pull the end of the rod at the bottom of the tower till other end with the attached rope appears Now detach the rod from the down cable and brake rope e Feed the end of the down cable at the top of the tower through one hole of the top hat and similarly u w feed the remaining hole with the brake rope e Now fit the top hat to the slip ring www provenenergy com info provenenergy com Tel 44 0 1560 485 570 6kW Installation Manual Proven6 300 2006Rev 01 3 6 Brake Rope Installations The mechanical brake assembly is made up of the following components located in the nacelle of the turbine l gt 3 4 Brake disc Brake pads Nacelle brake levers which are already factor fitted and connected The first brake rope runs from nacelle brake lever to the pulley just below the brake guide 3 6 1 Procedure e Attach the end of the brake rope that comes out through the top hat to the shackle of the brake lever Note Shackle pin is removable Brake Rope Shackle pin Brake lever www provenenergy com info provenenergy com Tel 44 0 1560 485 570 6kW Installation Manual Proven6 300 2006Rev 01 e Ti
30. F FURTHER LAP IS PRACTICAL N B The above lap length should be regarded as a guide only for the vast majority of mast designs Different lap lengths may be specified for special designs and situations and on occasions lap lengths less than that indicated may be acceptable and guidance should be sought from the design office if required 28 If mast is supplied without winch assembled in mast assemble winch in mast in accordance with Fitting the CU Double Winch into a Mast Before Erection page 63 24 10 05 01 6kW Installation Manual Proven6 300 2006Rev 01 5 N 5 R G Y Appendix C Lifting Equipment Instruction Sheets www provenenergy com info provenenergy com Tel 44 0 1560 485 570 RIGHT SIDE LEFT SIDE Ensure that the labels indicated above in black are in place Replacement labels can be supplied on request A hs de a equipment in Hook 3 for TIRFOR accordance with T 5000 Pulley blocks a CE directives and TU 32 and side opening blocks 008608626 ind 01 09 2001 TRACTELS AS lF TRACTEL UK Ltd SECALT S A AN 19 Saint Hilaire sous Romilty Old Lane Hallway 4 rue du Fort Dumoulin F 10102 Romilly s eine SHEFFIELD 5 20 3GA B P 1113 L 1011 Luxembourg Tel 33 3 25 21 07 00 Tel 44 0114 248 2266 Tel 352 43 42 42 1 Fax 33 3 25 21 07 11 Fax 44 0114 247 3350 Fax 352 43 42 42 200 ISO 9001 ISU ST E ISO 5001 BALL RIGHTS R ALL RIGHTS RESERVED KMiantfartured in
31. Franca tirfor lifting and pulling machines operating and maintenance instructions models TU TU 8 TU 16 TU 32 T 500D T 508D T 516D CONTENTS Page General warning Technical data 1 Description of equipment 2 Rigging arrangements 4 Installing the wire rope 4 Releasing and closing the jaws 5 Anchoring Operation Releasing the wire rope and storage ove eH M M BM amp GF LS 6 7 8 Safety devices 9 Replacing the shear pins 10 Maxillex wire rope 11 Maintenance instructions 12 Wamings against hazardous operations 1 13 Troubleshooting 14 Health and safety at work mb E Always concerned to improve the quality of its products the TRAC TEL Group reserves he right ig modify the specifications of the equipment described in this manual The companies of the TRACTEL Group and their agents or distributors will supply on request descriptive documentation on the full range of TRACTEL products lifting and pulling machines permanent and temporary access equipment safety devices electronic load indicalors accessories such as pulley blocks hooks sings ground anchors ele The TRACTEL network is able to supply an after sales and regular maintenance service Should you have any Queries or require technical assistance please do not hesitate lo contact TRACTEL UK T 5080 T 516D T 5320 1 Hook anchor pin 2 Forward operating lever 3 Reverse operating lev
32. NDED SPARE PARTS LIST 4 G PROVEN 6 WIND TURBINE GENERATOR Lead Time Part Description Manufacturer M Part No M UOM Unit Price GBP weeks Set 3 of Glass Thermoplastic Composite Blades with PU amp Fixings Proven Energy Ltd BL6001 po fo Set 3 of Zebedee Springs Proven Energy Ltd ZB T6001 om Set 2 of Brake Pads Sliprings and Brushes Remarks Focal Point Supplier Description Wind Turbine Generator Rev No 01 Name Mr David Watson Supplier Proven Energy Ltd fix Works S awartan UE Date 28 11 06 Address W ardhead Park Stewarton KAJ 5LH Country United Kingdom sss Tel Fax 441560485570 44 1560485580 Client Email info provenenergy com Purchase Order No Prajeci Signature www provenenergy com info provenenergy com Tel 44 0 1560 485 570 6kW Installation Manual Proven6 300 2006Rev 01 5 0 Trouble Shooting Possible Louder than quoted noise level Turbine fails to turn in good wind turns good Turbine slowly in wind Low output Turbine vibrates excessively No output though turbine turns at high speed www provenenergy com Loose fittings or components Shorted cables Shorted diodes Failed bearings Brake rope on lever Partial short in cables Diode short Brake rope on lever Low wind speeds Obstructions around turbine High power usage Inverter setting not right Blades incorrectly fitted or out of
33. Operation Erdschluss Earth Fault St rung Failure SMA Technologie AG The yellow LED is constantly on User Manual SMA Technologie AG Unit Description Grid Fault reen Betrieb la Operation red The yellow LED illuminates le twice in quick succession Earth Fault yellow 4 St rung Failure 3s ls The code is repeated 3 times then begins again The yellow fault LED illuminates for 5 seconds when the fault occurs and then begins displaying the blink code of 3 seconds off then twice briefly on This code is displayed 3 times in succession If the fault is still present the fault display starts again from the beginning With this message the Windy Boy indicates a grid fault which can have the following causes e Grid undervoltage Uac lt Uac Min e Grid overvoltage Uac gt Uac Max e Grid underfrequency fac lt Fac Min e Grid overfrequency fac gt Fac Max e Grid frequency change dFac Check if a general grid dropout has occurred check the operation of other electrical consumer devices and check if the fuse of the Windy Boy s feed in connection is intact If none of these faults can be found then the Windy Boy s grid connection T must be checked by a qualified electrician User Manual WB50A_60A 11 FE3706 Page 21 Unit Description SMA Technologie AG Excessive Grid Impedance green Betrieb Operation red The yellow LED illumi
34. SE once per e Temperature derating an second To avoid unnecessary reductions in yield in this case it should be checked if the Windy Boy can be mounted in a more favorable position with better ventilation e Current derating The input current on the DC side exceeds the maximum possible input current The Windy Boy switches to the Current Derating mode in order to protect itself against overload Check the system layout Defective Varistor or Isolation Error The red LED on the Windy Boy is not constantly on A grounding error has Betrieb O relevant occurred or one o the thermally Operation monitored varistors on the DC input side is defective as a result of overvoltage sale Bd The red LED is St run constantly on PE O not relevant manual Consult a trained electrician to correct the fault using the installation T User Manual WBS50A_60A 11 FE3706 Page 19 Unit Description Permanent Disable In the event of a recurring fault the Windy Boy switches to Permanent Disable mode and ceases grid feeding A fault may exist that cannot be resolved on site You can attempt to correct the error with the aid of a communication interface and the corresponding communication product e g PC with Sunny Data or Sunny Boy Control If this is unsuccessful consult the Sunny Boy hotline section 12 Contact Page 79 to discuss further action to solve the problem Page 20 WB50A_60A 11 FE3706 Betrieb
35. X 70 MIU X 60 Ao 3 4 AC 7 of Wedge Thicker End db od b db dd of Wedge Thicker End of Wedge www provenenergy com info provenenergy com Tel 44 0 1560 485 570 6 kW Installation Manual Caution Ensure that the blades and wedges are put the right way or else the turbine would overspeed resulting in high voltage being transferred to the controller and inverter www provenenergy com info provenenergy com Tel 44 0 1560 485 570 6kW Installation Manual Proven6 300 2006Rev 01 3 9 Zebedee Spring Assembly 3 9 1 Description The Zebedee spring assembly consists of the following per blade 1 Zebedee spring assembly made up of 4 individual springs 2 U bracket for connection to spring hub plate 3 U bracket for connection to blade root These three items are normally supplied already fitted together Fitting the Zebedee Spring Assembly 3 9 2 Procedure NB U bracket for the blade end and rotor end are marked on the U brackets U brackets are bolted via the holes circled on them Squirt locktite on 2off M10 x 60 bolts Bolt the U bracket marked rotor end using the two M10 x 60 bolts to the hub plate Squirt locktite on loff M10 x 70 bolt Bolt the U bracket marked blade end using the M10 x 70 bolts to the blade root NB raise the blade at the tip end slightly to help insert bolt through the blade root e Repeat the steps above for the remaining two sets of springs www
36. ault is still present the fault display starts again from the beginning excessive input voltage can lead to irreparable damage Make sure that the input voltage never exceeds 600 V Immediately disconnect the Windy Boy s DC input The presence of T disconnects from the grid and ceases its power feeding activity When the Windy Boy is in operation you must always first disconnect the AC voltage grid voltage and only then should you disconnect the DC voltage from the Windy Boy When the Windy Boy receives an excessive DC input voltage it automatically User Manual WB50A_60A 11 FE3706 Page 23 Unit Description SMA Technologie AG Device Fault green Betrieb Operation red The yellow LED illuminates 5 Erdschluss times in quick succession Earth Fault yellow tx x St rung Failure 3s Is ls 15 The code is repeated 5 times then begins again ls The yellow fault LED illuminates for 5 seconds when the fault occurs then begins displaying the blink code of 3 seconds off then 5 times briefly on This code is displayed 3 times in succession If the fault is still present the fault display starts again from the beginning If the device fault leads to a major impairment of normal operation the Windy Boy and the entire system installation should be checked by a qualified electrician Page 24 WB50A_60A 11 FE3706 User Manual SMA Technologie AG Unit Description 4 4 Information on the
37. ays turbine voltage and current rectifies AC input from the turbine and outputs DC power to the grid connect inverters o l x WB 6000 6kW or 2 x WB3000 SMA Windy Boy grid connect inverters of the self commutating static type e AC Disconnect Lockable allowing the grid to be securely isolated from the inverter s The output from the AC lockable disconnect is normally connected to a spare fuse or breaker at the customer distribution board rated at gt 32A 2 2 GW6000 The Proven 6 contains a purpose built permanent magnet generator which is directly driven by the rotor at variable speed according to wind conditions All of the technical information on the GW6000 below is provided for information only the only bit of the system that is seen by the grid system is the grid connect inverter see following sections 2 2 1 Type of Generator The GW6000 is a permanent magnet synchronous 3 phase AC alternator suitable for variable speed operation 2 2 2 Selected Operating Characteristics The output voltage open circuit is proportional to RPM of the turbine The output voltage during normal operation is dependent on the load placed on the generator The output of the generator is connected to the ECM6004ME 300 control box which contains a 3 phase rectifier www provenenergy com info provenenergy com Tel 44 0 1560 485 570 6kW Installation Manual Proven6 300 2006Rev 01 Input DC Voltage Input DC to grid voltage
38. be equal lo or greater than twice the load 4 N B Whatever the rigging arrangement and if the machine is anchored directly lo a fixed point ensure that there are no obstructions around Ihe machine which could prevent the wire rope the machine and anchor from operating in a straight line It is therefore recommended to use a sling of an appropriate capacity between the anchor point and the nn 3 A WARNING 4 Any rigging arrangement which requires the calculation of the forces applied should be checked by a competent engineer with special attention to he appropriate strength of fixed point used For work such as guiding the trunk in tree felling the operator should ensure that he is outside the danger area by passing Ihe wire rope around one or more retum pulleys 8 SAFETY DEVICES 8 1 Overload limiting safety devices All TIRFOR machines incorporate a shear pin system In case of overload one or more pins depending on the model fitted to the forward operating lever shear and prevent further forward or lifting operations Reverse operation is stil possible to enable the load to be lowered or the wire rope to be slackened 8 2 Rope release safety device Models TU and T 5000 are fitted with a two handed rope release system which requires deliberate operation by the user to release the machine See section 4 Releasing and engaging the jaws 9 REPLACING THE SHEAR PINS Figures 17 18 19 and 20 show the position o
39. d customer advised Any works required which are not covered under Proven Warranty will be charged at standard rate Warranty on other products supplied by but not manufactured by Proven Energy Limited will be followed in accordance with the manufacture recommendation Proven Energy Ltd Wardhead Park Stewarton KA3 5LH Scotland UK Tel 44 0 1560 485 570 Fax 44 0 1560 485 580 Web www provenenergy com Email info provenenergy com Reg in Scotland No 71400 BOLT TORQUES Where Bolt Size amp Torque Turbine materia Brackets metal on A2 70 25 Nm metal 75 of bolt gira proof stress Brackets and blades M8 A2 70 25 Nm bolt passing through Stainless hinge rubber material WT2500 TM650 Tower base M20 G 8 8 441 Nm 75 of bolt proof LUBRICATED BOLTS stress TM1100 Tower base M24 G88 686 Nm 75 of bolt proof LUBRICATED BOLTS stress ee Ze Brackets metal on M10 A2 70 metal 75 of bolt Stainless oroof stress Brackets and blades M10 A2 70 25 Nm bolt passing through Stainless NoE hinge rubber material WT6000 TM900 Tower base G8 8 686 Nm 75 of bolt proof LUBRICATED BOLTS stress TM1500 Tower base G8 8 1363 Nm stress BLADE CHECK A check needs to be made that the blades have been set up correctly 1 Flex the blade until its tip is exactly in line with the hub plate if possible with a straight edge otherwise by eye If it is not lined up the tip will be a
40. d cannot fall out A Warning A It is essential for the sale operation of the machine to ensure that before loading the machine the anchor points hooks or Pins are correctly secured with the safety catch correctly located on the hook Fig 12 Fig 12 Machine anchor hook with catch in closed position 7 Instructions for Safe Use of Shackles The information in this leaflet should be passed to the user of the equipment This document is issued in accordance with the requirements of Section 6 of the Health and Safety at Work etc Act 1974 amended March 1988 It outlines tha cara and safe usa of SHACKLES and is based on Section 4 of the LEEA Coda ol Practica for the Safe Use of Lifting Equipment It should be read in conjunction with the requirements for general purpose slinging practice given overleaf the principles of which may ba applied to the use of shackles with or without slings This information is of a general nature only covering the main points for the safe use of shackles It may ba necessary to supplament this information for specific applications ALWAYS e Stora and handle shackles correctly e Inspect shackles before use and before placing into storage ch vro the correct pattern of shackle and pin for the applica ian e Allow for tha full resultant imposed load e Fully tighten the pin e Ensure the load acts through the centre line of the shackle using spacers if necessary to meat this requirament
41. diminishes the end user s statutory or legal rights Actions in the Event of a Defect Occurring During Warranty Period In the unlikely event of a defect arising first ensure the safety of people and equipment by electrical disconnection and application of the wind turbine brake as appropriate Please notify the Proven Service Department or the Proven Authorised Representative immediately who will advise on the correct procedure Minor Faults f the fault is a minor one and can be rectified by replacing components which could be simply fitted by the end user or a local fitter then a replacement part will be sent as soon as possible by post or courier Serious Faults In the unlikely event of a serious fault Proven Energy Limited or a Proven Authorised Representative will arrange for an engineer to attend the if required and rectify the fault The work will be charged at standard rates if the conditions of the Proven Warranty as set out above do not apply Warranty on other Products Supplied but not manufactured by Proven Energy Limited will be followed in accordance with the manufacturers recommendation Proven Energy Ltd Wardhead Park Stewarton KA3 5LH Scotland UK Tel 44 0 1560 485 570 Fax 44 0 1560 485 580 Web www provenenergy com Email info provenenergy com Reg in Scotland No 71400 PRO Export Outside UK Warranty Proven Wind Energy Products are carefully designed manufactured tested and inspected In co
42. dure TM1500 Base Section 2 a S as m TM1500 Middle Section www provenenergy com info provenenergy com Tel 44 0 1560 485 570 6kW Installation Manual Proven6 300 2006Rev 01 TM 1500 Top Section Gin Poles Being Positioned www provenenergy com info provenenergy com Tel 44 0 1560 485 570 6kW Installation Manual Proven6 300 2006Rev 01 www provenenergy com info provenenergy com Tel 44 0 1560 485 570 6kW Installation Manual Proven6 300 2006Rev 01 Proven 6 on a TM1500 ready to be raised Proven 6 on a TM900 ready to be raised www provenenergy com info provenenergy com Tel 44 0 1560 485 570 6kW Installation Manual Proven6 300 2006Rev 01 3 3 Fitting the Turbine Head to the Tower Top 3 3 1 Procedure e Prepare tower for fitting with the head e Fit yaw bearing on to spigot ensuring grease nipple is accessible and push turbine head fully home If slip ring brushes are fitted then be careful not to damage brushes when pushing head fully home e The yaw bearing fixing bolts M16 can now be tightened The turbine head can now rotate around the tower Withdraw the head assembly back off the tower approximately 50mm Spread some thread locking compound loctite A118 onto the spigot and push head fully home Tighten bearing grub screw using a 5mm allen key The thread lock compound ensures a secure fit between the spigot and the b
43. e the loose brake rope from the generator shaft with a rope to the turbine frame www provenenergy com info provenenergy com Tel 44 0 1560 485 570 6kW Installation Manual Proven6 300 2006Rev 01 3 7 Fitting the Covers The turbine is supplied with the following covers 1 Generator cover 2 Yaw cover 3 Nacelle cover also called the rotor shaft cover supplied in 2 pieces The covers are made from black or white U V stabilised polypropylene plastic They are fitted to the wind turbine frame using cable ties The two piece nacelle covers are stitched together after fitting to the turbine frame individually Nacelle Cover at Generator K Cover The yaw cover is fitted first NB Proven Energy Ltd does not recommend painting of the covers as the paint would peel off after a short while www provenenergy com info provenenergy com Tel 44 0 1560 485 570 6kW Installation Manual Proven6 300 2006Rev 01 3 7 1 Fitting the Generator Cover The generator cover is secured over the electrical generator by means of an SS Jubilee clip The generator is supplied with the cover already fitted 3 7 2 Fitting the Yaw Cover Procedure STEP 1 Offer up yaw cover to the frame and attach using the cable ties Feed cable tie from front through cover around the steel bar and back through the other hole secure tie but do not fully tighten until all ties have been fitted STEP 2 Fold
44. earing It is also recommended to glue in the grub screws to stop them vibrating loose www provenenergy com info provenenergy com Tel 44 0 1560 485 570 6kW Installation Manual Proven6 300 2006Rev 01 e Prepare yaw rubbers and bolts for fixing by greasing the bolts and rubber ends e Fit yaw rubbers Fit bolt through yaw frame hole as shown below and guide it M10 bolt ae N cz Da ra ese pi gt E 2 lt e i za Yaw rubber in place www provenenergy com info provenenergy com Tel 44 0 1560 485 570 6kW Installation Manual Proven6 300 2006Rev 01 through the rubber and nylon washer and through the lower frame hole e Tighten the yaw rubber bolts using a 19mm ratchet and 19mm spanner Do not over tighten the rubbers so that they can rotate e Check everything is tight and that the turbine will freely rotate within its yaw axis e Finally spin the rotor by hand to check that nothing rubs If the turbine has been roughly handled then the domed generator cover can get pushed against the magnet plates If this is the case gently tap the cover back into position and reseal if necessary with silicone WWW provenenergy com Important Mechanical and electrical installations will be required in the nacelle of the turbine Also if the turbine head is above normal working heights provision will have to be made for scaffolding or other access means
45. er 4 Rope release laver 5 Rope release safely calch 6 Rope guide 7 Maxiflex wire rope B Telescopic operating handie Fig 7 operating levers to allow the lubricant to penetrate all parts of the mechanism N B Excess lubrication cannot cause the machine or wire rope to slip Any machine where the side cases show signs of dente or damage or a which the hook is damaged imode s TU 8 and TU 16 should be returned to an approved repairer of TRACTEL UK 12 WARNINGS AGAINST HAZARDOUS OPERATIONS The operation of TIRFOR machines inaccordance with the instructions o this manual is a guarantee of safety Nevertheless it is useful to draw the attention of users to the following warnings TIRFOR machines as described in this manual must not be used for iling people Never attempt to motorise the models of TIRFOR machines described in ins manual TIRFOR machines must nol be used beyond their maximum working load TIRFOR machines must not be used for applications other than those for which they are intended Never attempt to operate the rope release mechanism whilst ihe machine is under load Never obstruct the operating levers or the rope release lever Never operate the forward and reverse operating levers at the same ume Never use a handle other than the telescopic operating handle supplied to operate the TIRFOR machine It is forbidden to replace sheared pins by anything other than genuine TIRFOR shear pins of
46. er as shown Loosely stitch the cover parts together using cable ties When stitching these parts together be sure to go around the frame as well STEP 4 Fit ties through the rest of the cover holes and around frame parts Finally tighten all cable ties and trim www provenenergy com info provenenergy com Tel 44 0 1560 485 570 6kW Installation Manual Proven6 300 2006Rev 01 Please note the way the cable ties are tied www provenenergy com info provenenergy com Tel 44 0 1560 485 570 6kW Installation Manual Proven6 300 2006Rev 01 Seal these edges with sealant Lise one long cable tie or join two ties together ea www provenenergy com info provenenergy com Tel 44 0 1560 485 570 6kW Installation Manual Proven6 300 2006Rev 01 3 8 Blades Assembly Caution Treat the blades with exceptional care especially the leading and trailing edges of the airfoil 3 8 1 Blade Description The blades are made of the following parts l Airfoil Glass Thermoplastic 2 Zebedee hinge at blade root polyurethane 3 Root of blade Galvanised steel These three parts are supplied already assembled Information The blades are bolted to the hub plate by means of 1 SS bolts provided 2 Galvanised steel clamp plates provided 3 Polypropylene clamp washer provided 3 8 2 Fitting the Blades Procedure e Put polyprop plastic washer on top of wedge
47. f the shear pins for the various models Spare shear pins are in the stub of the operating levers for models TU 8 and TU 16 and in the rope release lever for the other modeis behind the plastic cap Remove the sheared pins with a suitable punch For models TU 8 and TU 16 remove the forward operating handle stub by using an exiracior Remove the sheared pins Relit the forward operating handle stub on the crank and align the grooves for the shear pins Figs 17 and 18 For models T 5000 and TU 32 align the holes of the upper and lower sections of the forward operating lever Position the spare shear pin s and drive it them in with a hammer ZN Warning ZM It is forbidden to replace sheared pins by anything other than genuine TIRFOR shear pins of the same model Fig 18 TU 16 G Fig 19 TU 32 IL 3 Fig 20 T 500D Before putting the machine back into operation ensure thal the cause of the overload is removed lf necessary use multiple sheave blocks See Fig 6 Remember to re order sheared pins and pul them back in the correct place Fig 15 Spring clip closed 6 OPERATION TIRFOR machines are very easy lo use Place the telescopic operating handle on either the forward or reverse operating lever lock it into position by Iwisting and move the operating handle to and fro The operating arc is variable for ease of operation When operation stops both jaws aulomaticaliy grip the wire
48. fety hook fitted to a thimble fixed by a metal ferrule See Fig 21 The other end of the wire rope is fused and tapered See Fig 22 p KS GSG GOO ONA GE of safety to the same extent as a machine in good condition lt is necessary to continuously monitor the state of the wire rope to clean and oil it with a rag soaked with motor oil or grease Grease or oil containing graphite additives or molybdenum disulphide musi not be used Visual examination of the wire rope The wire rope should be examined daily to detect any signs of wear damage or broken wires See examples in Fig 23 In case of any apparent wear have the wire rope checked by a corapetent person Any wire rope with a reduction from the nominal diameter by more than 10 should be replaced See Fig 24 forthe correct method of measuring the diameter of a wire rope Fig 23 Examples of damaged wire rope 10 IMPORTANT It is recommended specially for lifting applications to ensure that the length of wire rope is greater than actually required Allow an extra meter approximately When lifting or lowering loads over long lengths of wire rope steps should be laken lo stop the load from rotating io prevent the wire rope from unlaying Never allow a tensioned wire rope lo TUD over sharp edges The wire rope must only be used with pulleys of an appropriate diameter Neverexpose he wire rope to temperatures beyond 100 degrees C Never use wire rope
49. g duties frees taxes and import charges incurred in returning Proven Wind Energy Products are to be met by end user Disclaimer Proven Energy Limited shall not be liable for any incidental or consequential damages resulting from the proper or improper use for any purpose whatsoever of Proven Wind Energy Products Statutory rights This warranty in no way diminishes the end user s statutory or legal rights Actions in the Event of a Defect Occurring During Warranty Period In the unlikely event of a defect arising first ensure the safety of people and equipment by electrical disconnection and application of the wind turbine brake as appropriate Please notify the Proven Service Department or the Proven Authorised Representative immediately who will advise on the correct procedure Minor Faults If the fault is a minor one and can be rectified by replacing components which could be simply fitted by the end user or a local fitter then a replacement part will be sent as soon as possible by post or courier For some locations it will be the customer s responsibility to arrange transport of these parts from our Stewarton factory site Serious Faults In the unlikely event of a serious fault the turbine should be packed in sturdy export crate and shipped to our Stewarton factory All shipping charges shall be responsibility of the customer An appraisal will then be carried out to determine whether works required are covered under warranty an
50. gistration and configuration data to non volatile memory Technical Data All data is retained for the life of the meter Recordable security features are illustrated below Current Range 10 100A 5 85A direct 5A 10A CT Voltage Range 220 240V L N or 220 240V L L Security Features Frequency SUSE lt Time in each rate augen al Elapsed time Voltage Circuits 230V 0 9W 9VA capacitive burden phase max gt ae Current Circuits 2VA 100A phase max gt Reverse run energy Insulation 4kV RMS 50Hz EE a SR est Impulse Withstand 12kV 1 2 50us 5000hm source a Dee Display LCD 9 8 x 3 5mm characters Meter errors gt High contrast wide angle Stepper Motor 6 7 x 3 5mm characters RA 0 sa IrDA Baud Rates 2400 4800 or 9600 Without serial port ua T Serial Baud Rates 2400 or 4800 As an option the kWh register can increment in sm 16 years flow insensitive mode i e it increments ed Product Life 10 years E dard f fl di Temperature 40 to 55 C Operational range regardless of energy flow direction 40 to 85 C Storage Humidity Annual mean 75 For 30 days spread Pulse Output over one year 95 ulse Width 10 to 250ms or equal mark space An opto isolated pulse output can provide the wn pulse 1 2 4 5 10 20 25 40 50 100 basis for an energy management system or AMR W eight 360 gia These pulses are output via the meters auxiliary EE fcations gt terminals The output conforms to IEC 61036 1996 p
51. grdC 90 000grdC Fac Test 0 0 P Wind Ramp 1000 000W 1000 000W P Wind Mid 1250 000W 1250 000W Operating Mode Turbine Turbine Memory Function No Function No Function Default GB G83 GB G83 Storage Permanent Permanent Please change the Default setting to GB G83 first before proceeding to change the rest of the parameters SMA Technologie AG Unit Description 4 3 Operating Modes The various operating modes are displayed using three light emitting diodes LEDs on the housing cover of the Windy Boy To allow the device to indicate its operating mode via the integrated LEDs the Windy Boy must be connected on the DC side There must be enough wind energy present so that the Windy Boy has adequate DC voltage Betrieb Operaion D Erdschluss Earth rast QD St rung Failure 0 Especially in the first year of operation the operator of the system should regularly check this display under different wind speeds A complete description of the possible displays can be found in section 4 3 4 Description of the Operating Modes Page 17 These can be split into three categories 4 3 1 Normal Operation If no LED or only the green control LED is on or blinking the inverter is operating normally The simultaneous illumination of all three LEDs is also an indication of normal operation initialization All other displays are a sign of abnormal operation User Manual WB50A_60A 11 FE3706 Page 15 Unit Description SMA Technol
52. he Generator Cover 3 7 2 Fitting the Yaw Cover 3 7 3 Fitting the Nacelle Cover 3 8 Blade Assembly 3 8 1 Blade Description 3 8 2 Fitting the Blades 3 9 Zebedee Spring Assembly 3 9 1 Description 3 9 2 Procedure 3 9 3 Testing www provenenergy com info provenenergy com Tel 44 0 1560 485 570 6kW Installation Manual Proven6 300 2006Rev 01 3 10 Raising the Tower 3 11 Lowering the Turbine 3 12 Testing with a Third Party Mast 3 13 Winch Set Up 4 0 Wind Turbine Maintenance 4 1 Annual Service 4 2 Maintenance Check List 4 3 Service Schematic 5 0 Troubleshooting 6 0 Appendices www provenenergy com info provenenergy com Tel 44 0 1560 485 570 1 0 Introduction 1 1 Package Contents It would be highly appreciated if you could check the contents of your delivery package against the accompanying delivery note to ensure it has all the parts and in their right quantities as listed Thank you j 5 RZE m z 07 N d Trailer conveying turbine package 1 2 Health and Safety Information Please refer installation and servicing to qualified service personnel only High currents are produced by this wind turbine system and incorrect installation or use may result in e risk of electric shock or fire e mechanical damage Warning Installation of the turbine involves handling heavy components such as the turbine nacelle blades and covers Appropriate lifting gear techniques and appropriate number of personnel sho
53. hich is locked onto the rope The TIRFOR machine should be thoroughly lubricaied and it will recommence working normally 3 Jerkiness This is also a symptom of lack of lubrication The TIRFOR machine should be thoroughly lubricated 4 Blockage If the wire rope becomes blocked in the machine generally because a damaged section of wre rope is stuck within Ihe jaws It is imperative lo stop opera ling the machine The load should be taken by ano ther machine on a separate wire rope or by another means whist ensuring that al safety i are taken When the blocked machine ts no longer under load the damaged rope may be released and removed Should this not be possible retum the machine and wire rope to TRACTEL LK or All lifting equipment must be supplied operated maintained and tested according to the applicable Statutory requirements and specially to the provisions of the Health and Safety at Work Act It is also the responsability of every company to ensure that their employees have been fully and properly trained in the safe operation of their equipment 10 MAXIFLEX WIRE ROPE i ZA To guarantee the safe operation of TIRFOR machines itis essential to use themexclusively with TIRFOR MAXIFLEX wire rope which has been specially designed to meel the requirements of the TIRFOR machine TIRFOR MAXIFLEX wire ropes have a red strand which is visible on new rope One end of the wire rope has an end fitting such as a sa
54. his manual should be made available to every operator Extra copies of this manual will be supplied on request 2 The TIRFOR machine allows Ihe operator to carry out work with complete safety Ensure that this machine is only handed over for use or rigging to an operator who is trained to operate it ina responsible manner 3 Never use a machine which is not in good working condition Replace any worn or damaged wire rope See Section 10 Continuous monitoring of the condition of the machine its wire rope and anchor sling is an important safety consideration d The manufacturer declines any responsibility for the consequences of dismantling or altering the machine by any unauthorised person Specially excluded is the replacement of original parts by parts of another manufacturer 5 The models as described in this manual must not be used for lifting people 6 Moreover these models are designed for manual operation and must not be motorised The TRACTEL Group has designed special motorised models TU 16H and TU 32H 7 Never altempt to overload the machine 8 Standard TIRFOR machines are not designed for use in explosive atmospheres 8 IMPORTANT If the equipment described inthis manual is supplied to an employed person check ihat you meet your obligations with respect to safety at work regulations see page 11 chapter 14 LIFTING PEOPLE AND SPECIAL APPLICATIONS TRACTEL UK markets a range of TIRFOR TUA machines TUBA TU16
55. ihe same model Never anchor ihe machine other than by its appropriate anchor point Never obstruct the machine which could prevent the machine the wire rope and the anchor paints from operating in a straight line Never use the TIRFOR MAXIFLEX wire rope as a sling I 14 HEALTH AND SAFETY AT WORK Never apply a load lo the loose wire rope exiting from the anchor point of the TIRFOR machine Never subject the controls to sharp knocks Never attempt to reverse the rope completely through the machine whilst under load Do not operate the TIRFOR machine when the rope ferrule gets to within 10 cm of the machine Otherwise the ferrule is likely to foul the casing and push the rope guide inside the machine 13 TROUBLESHOOTING 1 The forward operating lever moves freely and does not operate the mechanism ihe machine has been overloaded and Ihe shear pins have sheared See section 9 for replacing the shear pins 2 Pumping A lack of lubricant in a TIRFOR machine sometimes brings about a condition known as pumping which is not al all dangerous but which is inconvenient This situation occurs when the jaw which is gripping the rope becomes locked onto il preventing the other jaw from taking over the load As the operating lever is moved in one direction ihe machine travels a few centimeters bul when the operating lever travels in the other direction the machine moves back the same distance in sympathy with the jaw w
56. illing security and status data 12kV impulse withstand Compact design Double insulated glass filled polycarbonate case to DIN 43857 Part 2 and Part 4 except for top fixing centres IP53 in accordance with IEC 60529 1969 Options Liquid Crystal Display or mechanical stepper register One or two rates controlled by an external device LCD meter only Auxiliary terminals configured for rate selection two rate meters pulsing output or serial data output SO pulsed output IEC 62053 31 Extended terminal cover with or without cut out CT or direct connected The use of innovative metering technology provides cost effective metering that is highly secure and maintains a high degree of accuracy over its full operating range The A1100 meter is suitable for CT or direct connected domestic commercial and light industrial polyphase applications Two main versions of the A1100 meter are available The liquid crystal display version of the meter can be supplied as a one or two rate meter The meter is available as import only or import and export The display has a customer defined display sequence that can include security information Chevrons and legends on the nameplate identify the data being displayed The mechanical register version of the meter is available for kWh import one rate applications only Five LED s are used to identify the status of the meter Communications are provided via the IrDA port allowing the meter
57. is is then followed by the total energy produced so far and the operational hours of the device Fault Displays If an operational fault occurs the display immediately switches to Disturbance and the background illumination is switched on The cause of the fault is displayed for 5 seconds in the second line of the display If a measured value is responsible for the fault condition then the value measured at the time of the fault is displayed If another measurement is possible the present value is displayed in the second line After another 5 seconds normal operating data is again displayed If the fault is still present the fault display starts again from the beginning An overview of the status and error messages can be found in section 10 2 Error Messages Page 68 of this document Error ROM indicates that the Windy Boy has detected an error in the EEPROM firmware Contact SMA to have the error corrected Page 26 WB50A_60A 11 FE3706 User Manual SMA Technologie AG Unit Description Special Display Message Upon Excessive DC Input Voltage If an excessive DC input voltage is present at the Windy Boy this is indicated by rapid blinking of the background illumination and the message shown here to the right Immediately disconnect the Windy Boy s DC input The presence of excessive input voltage can lead to irreparable damage Make sure that ZN the input voltage never exceeds 600 V When the Windy Boy recei
58. le to a Competent Person for thorough examination illegible markings distorted worn stretched or bent body bent pin damaged or incomplete thread forms nicks gouges cracks or corrosion incorrect pin any other defect Lifting Equipment Engineers Association 1994 SI No 6 0 Further information Is given in The Code of Practica for the Safa Use of Lifting Equipment published by LIFTING EQUIPMENT ENGINEERS ASSOCIATION Waggoners Court The Streat Manuden Bishop s Stortford A Herts CM23 TOW FEET Tal 01279 816504 Fax 01279 816524 Lifting Products and Services This document is issued in accordance with the requirements of Section 6 of the Health and Safety at Work atc Act 1974 amended March 1988 It outlines the care and safe usa of WINCHES USED FOR LIFTING and is basad on Section 19 of the LEEA Code of Practica for the Sala Use of Lifting Equipment It should be read in conjunction with the require ments for lifting appliances for general purposes given overleaf which form an integral part of hasa instructions This information is of a general nature ony covering the main points for the safa usa of winches used or lifting It may be necessary to supplement this information for specific applica tions mf 16u6 T7EEE 05 55 II I Ai iI ALWAYS e Store and handle winches correctly Inscect the winch rope and accessories before usa and before placing into sicrage Ensurs mounting and s
59. lus Amendment 1 2000 IEC 62053 31 Case IP53 to IEC 60529 1989 System Connections Dimensions and Fixing Centres 2 Element 3 phase 3 wire 3 Element 3 phase 4 wire lt Tramm corm 2 phases of a 3 phase 4 wire 2 phase 3 wire A a mz 1 phase 3 wire L 7 1 phase 2 wire LCD meter only 221mm EL TERE 150mm gt Elster Metering Systems Our policy is one of continuous product development and the right is reserved Staffordshire to modify the specification contained herein without notice United Kingdom Tel 44 0 1785 812111 www elstermetering com EMS A1100 2 2004 A100C BS Electronic Single Phase Meter Compact yet advanced domestic metering Features Accuracy Class 1 or Class 2 kWh import or kWh import export 20 years certified life Large digit 9 8mm multilingual display with chevron information indication Extensive security data Communications as standard 12kV impulse withstand High security compact design 130mm Wide x 97mm High x 47mm Deep BS double insulated glass filled polycarbonate case Permanently fixed main cover IP53 in accordance with IEC 60529 1989 Options One or two rates controlled by external device s IrDA communications or IEC 62056 21 formerly IEC 61107 optical communications e Auxiliary terminals configured for SO Pulse output IEC 62053 31 Serial data output IrDA meter e A102C kWh and kvarh energy measurement Extended terminal cover
60. nates 3 Erdschluss O times in quick succession Earth Fault yellow v 4 St rung Failure s s The code is repeated 3 times then begins again The yellow fault LED illuminates for 5 seconds when the fault occurs and then begins displaying the blink code of 3 seconds off then 3 times briefly on This code is displayed 3 times in succession If the fault is still present the fault display starts again from the beginning The Windy Boy has detected a fault relating to an unacceptable grid impedance If the Windy Boy frequently deactivates and displays this error during grid monitoring the cause can be an excessive grid impedance A qualified electrician can usually assist with this problem by increasing the cross section of the grid connection cable Other measures can be taken to correct this fault but they require the explicit agreement and cooperation of the grid operator Page 22 WB50A_60A 11 FE3706 User Manual SMA Technologie AG Unit Description Excessive Input Voltage green Betrieb Operation red The yellow LED illuminates 4 Erdschluss O times in quick succession Earth Fault yellow v Vv NN St rung De Failure 3s ls ls The code is repeated 4 times then begins again ls ls The yellow fault LED illuminates for 5 seconds when the fault occurs then begins displaying the blink code of 3 seconds off then 4 times briefly on This code is displayed 3 times in succession If the f
61. nenergy com Tel 44 0 1560 485 570 6kW Installation Manual Proven6 300 2006Rev 01 Appendix A Weights and Dimensions Mem CS QTY Dimension ____ Weight Zebedee Spring 5 springs per 9kg per bracket 3 0 9m x 0 8m x 0 04m i TM900 6000 9m Tower QTY Dimension Weight FND6kW 9m foundation kit TM 1500 6000 15m Tower Item QTY Dimensions Weight 0 87m x 0 75m base dimension 0 34m Tower middle 1 0 36m base diameter 0 25m top 260k section diameter 5m length gt 0 28m base diameter 5m length 190kg 0 lm diameter x 7 2m length 100kg each re ment sim bz dmd x dh 280kg Tower Export Crate 5 9m 1 x 0 9m w x 1 3m h 350kg www provenenergy com info provenenergy com Tel 44 0 1560 485 570 6kW Installation Manual Proven6 300 2006Rev 01 E N E R G Y Appendix B Tower Assembly and Erection Procedures www provenenergy com info provenenergy com Tel 44 0 1560 485 570 TM1500 TOWER ASSEMBLY AND ERECTION PROCEDURES The mast should be handled offloaded assembled and erected strictly in accordance with our instructions Only workmen who have had experience in the erection of high lighting mast or similar work should be employed Outline of Mast Assembly 1 The joint between sections is in effect a tapered spigot and socket connection like a fishing rod which is first loosely assembled and then strained together into a permanent rigid assembly
62. not attempt lifting operations unless you understand the use of the equipment the slinging procedures and the mode factors to be applied Do not use defective shackles or unidentified pins Shackles should be fitted so that tha body takes tha load along its centre line and is not subjected to side bending loads When connecting a number of sling legs and similar applications position them so that they do not impose a side load on the shackle jaws Use spacers to position them if necessary Ensura the pin is correctly screwed into the shackle eye Tighten by Ga use a small bar to lock the collar to the shackle eye Check that the thread is fully engaged with the body but is not too long so that tightening causes the body to deform With bolt and nut pins ensure tha nut jams on the inner end of the thread and not on the eye of the shackle The bolt should be free to rotate with minimal side float The split cotter pin must be fitted before making a lift When using shackles with slings in choke hitch or in other appinatione where there ma is movement place the pe through the eye or link of tha slin and never in contact with the bight of the choke or moving paris which may cause the pin to unscrew In service Inspection and Maintenance Maintenance requirements ara minimal Keep shackles clean the threads free of debris and protect from corrosion Regularly inspect shackles and in the event of the following en voter the shack
63. ns as being the base section of your next assembly stage Now go back in the instructions to the heading Mast Assembly Procedure 19 FOUR SECTION MAST First treat as THREE SECTION MAST until that is complete and then continue as below 20 ASSEMBLY OF FOURTH SECTION Support the three section assembly on three or four bearers depending on length adjust alignment of bearers to support mast in a reasonably straight line 21 The next operation is to lift the fourth section and support it in alignment with the existing assembly 22 Check Mast Assembly Procedure requirements paragraphs and comply with all the preparation 23 Lift the fourth section and align its slung position with the existing assembly 23 10 05 01 24 Advance the fourth section into assembly 25 Reassemble anchorage assembly at the top of the next section of mast all as instructed under heading Assembiina Tirfor Stressing Gear and continue as detailed from there on Diagra 26 LENGTH OF MAS ITE JOINTS The length of a site joint is related to the diameter of the joint It will generally be between 1 5 and 2 times the diameter See diagram L 27 MINIMUM LENGTH OF SITE JOINTS A lap equal to 1 5 diameters is the minimum and to be acceptable it must also have had the specified force exerted on it and be tight fitting as a result IT IS NOT GOOD ENOUGH TO STOP STRAINING THE SECTIONS TOGETHER WHEN THE MINIMUM LAP HAS BEEN REACHED I
64. nsequence we undertake to replace any part found to be defective in material or workmanship free of charge for a period of two years from delivery to the end user This warranty covers only those products manufactured by Proven Energy Limited General Conditions This warranty does not cover damage to Proven Wind Energy Products resulting from unauthorised alteration or modification accident misuse improper installation operation or maintenance or failure to conduct periodic inspections and maintenance Proven Energy Limited reserves the right to repair or replace the defective component s at their sole option Proven Energy Limited does not accept any additional liability for defects from reasonable wear and tear Use of Proven Wind Turbines with Mast or Towers manufactured by others Poor mast design may cause vibration both in the mast and the nacelle of the wind turbine Faults arising from poor mast design shall be classed as improper installation see General Conditions Mast should be designed to avoid resonance within the operating frequency range of the wind turbine The onus shall lie with the owner to show their mast has not caused the fault Shipping and Transport Costs Warranty repairs will be made at the premises of Proven Authorised Representatives or our factory The end user must return the defective component s properly packed and with all freight and insurance charges prepaid All freight shipping and insurance costs includin
65. nual please consult TRACTEL SAS or a competent specialist Fig 6 1 Pulling 3 INSTALLATING THE WIRE ROPE N B When handling the wire rope it is recommended lo project the hands by using work gloves If ine wire rope is to be anchored to a high anchor paint the wire rope should be anchored before fitting the wire rope in the machine 1 Uncoll the wire rope in a straight line to prevent loops or KINKS 2 Release the internal mechanism See section 4 Releasing and engaging Ihe jaws 3 Insert the wire rope through the rope guide at the end opposite to the anchor point hook or anchor pin 4 Push the wire rope through the machine and il necessary helping it by operating the forward operating lever 5 When ihe wire rope appears through the anchor point pull the slack wire rope through the machine to the point required 6 Engage the jaws by operating the rope release mechanism See section 4 Releasing and engaging Ihe jaws 7 Anchor the TIRFOR machine or the wire rope to ihe appropriate fixed point See section 5 Anchoring taking care to ensure that ine anchor point hook or pin depending on the model is correcily fixed 8 Extend the telescopic operating handle until ihe spring locks into position If necessary twist ihe two sections of the handle one inside other to align the spring Fig 1 9 Replace the telescopic operating handle on the chosen operating lever forward
66. ogie AG 4 3 2 Critical Faulty Operation A comprehensive safety concept has limited the number of critical conditions that can occur to one single situation Input voltage exceeds the permitted value This is indicated by the following blink code on the yellow LED green Betrieb Operation red The yellow LED illuminates 4 Erdschluss 8 times in quick succession Earth Fault yellow vd x w St rung Failure 3s ls ls ls The code is repeated 3 times then begins again ls The yellow fault LED illuminates for 5 seconds when this fault occurs then begins displaying the blink code of 3 seconds off then 4 times briefly on This code is displayed 3 times in succession If the fault is still present the fault display starts again from the beginning The presence of excessive input voltage can lead to irreparable damage Immediately disconnect the Windy Boy s DC input When the Windy Boy receives an excessive DC input voltage it automatically disconnects from the grid and ceases its power feeding activity When the Windy Boy is in operation you must always first disconnect the AC voltage grid voltage and only then should you disconnect the DC voltage from the Windy Boy Page 16 WB50A_60A 11 FE3706 User Manual SMA Technologie AG Unit Description 4 3 3 Non Critical Faulty Operation All other display codes indicate some form of error condition which is not usually dangerous to people or equipment
67. on the model so that it can be secured Quickly to any Suitable anchor point TIRFOR machines intended for lifting and pulling materials are available in two ranges sach with three models of different capacities T 5000 range for light duty applications with safety release catch TU range for heavy duty applications with safety release catch Each machine is supplied with a telescopic operaling handle and usually witha 20 m standard length of special TIRFOR MAXIFLEX wire rope fitted with a salety hook and wound onto a metal raeler Longer or shorter lengths of wire rope are available on request This manual iogeiher with a guarantee Card are supplied with each machine as well as the CE declaration o conformity IMPORTANT TIRFOR MAXIFLEX wire rope has been specially designed to meet the particular requirements of the TIRFOR machine The manufacturer does not guarantee the sale operation olmachines used with wire rope other than TIRFOR MAXIFLEX wire rope 2 RIGGING ARRANGEMENTS Various ways of rigging are shown in Figs 2 1 2 2 2 3 and 2 4 Figs 4 and 5 show particular arrangements one forbidden and the other recommended The machine may be anchored to a fixed point with the wire rope travelling towards the machine Figs 2 1 2 2 2 3 or travel along the wire rope wath the load the wire rope itself anchored to a fixed point Fig 2 4 In example 2 2 the maximum working load ol the pulley and the anchor point should
68. or reverse and twist the handie to ensure thal it is locked in position about a half tum After this procedure the machine is ready for operation providing ihe load is correctly anchored to the machine or the wire rope See section 5 Anchoring and section 2 Rigging arrangements 4 RELEASING AND CLOSING THE JAWS Each machine is fitted with a lever Fig 1 Item 4 for releasing the jaw mechanism which should only be operated when the machine is not under load There are two positions for the rope release lever See Fig 7 8 and 9 released or engaged N B When notin operation itis recommended that the rope release lever should be in Ihe engaged position The machine must therefore be released before attempting to feed in the wire rope Fig 7 Releasing i Completely press the rope release safety catch 5 and lift the rope release lever 4 2 Release the safety catch and continue to lift the rope release lever until it locks into position The internal mechanism is in the released position Engaging 1 Lift the rope release laver slightly 2 Press and maintain pressure on the rope release safety catch allowing the release laver to slowly travel back to its original position Release the safety catch The release lever locks in position under the effect of its spring 4 2 TU 32 Fig 8 Place the anchor point against a support Releasing 1 Completely press rope release salety catch 5 and push
69. ork e If wind increases then the inverter will start up as described in the commissioning section 4 4 above A typical operating strategy during a loss of mains is summarised by e Inverter disconnects from grid network in lt 0 2s and monitors Va and fac continuously At this point the wind turbine will speed up slightly and the generator winding voltages will rise as described in section 4 1 2 e Should Vx and fx return to allowed ranges then the inverter will start up as described in the commissioning section 4 4 above 2 6 Method of Disconnection from Grid The WB 6000 WB 3000 inverter contains an independent disconnection device consisting of the following e Excerpt from WB 6000 WB 3000 manual For maximum safety this independent disconnection device consists of two separate MSDs Mains monitoring with allocated Switching Devices that are connected in series Each of these MSD constantly monitors the grid quality by checking the frequency voltage and impedance The redundant circuit and and automatic self test on each system start up ensure a reliable function of the disconnection device For use with a wind turbine or solar system this means that the disconnection device will be tested around 1 10 times per day on average e The allocated switch device for the MSDs is the Matsushita DEIA 16A single pole relay One relay is provided Live and one for Neutral The MSDs are energised from the dc source wind or solar power In
70. orrosion defects or operational faults Lifting Equipment Engineers Asscciation 1994 SI No 15 0 Further information is given in The Coda of Pracica for the Safe Usa of Lifting Equipment published by LIFTING EQUIPMENT ENGINEERS ASSOCIATION Waggonera Court The Straet SRP G KKB FRI RAH OLT ENERGY INSTRUCTIONS FOR SAFE USE OF WIRE ROPE GRIPS af should be passed ta he As a result of the shortcomings in B S wire rope grips as evidenced by research carried out by the Health and Safety Executive the relevant standard i e B 463 1983 has been withdrawn CERTEX UK market wire rope grips in accordance with D I N 1142 These grips have also been extensively tested by H S E and have been found to be efficient when installed correctly Having a flat faced bridge the D LN 1142 grip is compatible with six eight and multistrand ropes in either right or left hand lay size number of wire rope grips to attain 85 of rope win Breaking load efficiency N m tightening torque to attain required 5 3 2 0 6 5 3 3 5 5 4 6 0 10 d 9 0 13 d 33 0 16 4 49 0 19 4 68 0 22 3 107 0 26 3 147 0 30 D 212 0 34 6 296 0 40 6 363 0 For intermediate sizes of rope the next largest grip size should be used im conjunction with the corresponding torque The nominal size 5 grip should not however be used on ropes having nominal diameters of less than 4 0 mm The first grip must be placed
71. otary Isolator Switch Local Tower Lockable in off Earth Position NOTES D Wind turbine output is nominal 250Vac 3ph under normal operating conditions 20Hz but voltage WINDYBOY CONTROL SETTINGS G83 1 current and frequency proportional to rpm wind speed Upen circuit voltage approx 2 x normal TOT VALE operation Max output 6kW at approx 200 rpm p DEA y 2 SMA Windy Boy WB6000 inverter is EA approved for connection to UK grid UNDER VOLTAGE Sep It includes OVER FREQUENCY as HZ a over under voltage protection UNDER FREQUENCY 470 Hz b over under frequency protection ra c loss of mains protection by means of frequency drift ER DEER IEEE a 180s delay from return of mains after fault to start of self initialisation procedure DESCRIPTION REVISIONS DATE APPROVED Proven Energy Ltd Wardhead Park PREPARED BY KA CHECKED BY RC Stewarton KAS 5LH UK Tel 44 1560 485 570 REV Sip R O E N GDC6004 6kW Windy Boy Grid Connect Inverter ree Tome wym Jet HEES Schematic with protection settings Schematic for TT RCD system Using a Proven WIT6000 ESS 0000S 10mme Or i DNO S HRC Greater e core 6mm2 Point Fused SWA ee Double Insulated af AC Cut Dut Nominal Disconnection nominal 300V DC ole on i uve eo0vVac E Proven ECM6004 Fuse Consumer WT6000 3 ph WT Control Terminal RCD km Turbine AR ee NEUTRAL u eter N Plastic MCB SP Synchronous au zn Rotary 3 ph AC
72. permanent Z Isolator to L lockable in OE TT TT T magne off position rectifier generator Rotary Isolator Farth Rod Switch Local Tower Lockable in off Earth Position NOTES D Wind turbine output is nominal 250Vac 3ph under normal operating conditions 20Hz but voltage WINDYBOY CONTROL SETTINGS G83 1 current and frequency proportional to rpm wind speed Upen circuit voltage approx 2 x normal operation Max output 6kW at approx 200 rpm 2 SMA Windy Boy WB6000 inverter is EA approved for connection to UK grid UNDER VOLTAGE It includes OVER FREQUENCY a over under voltage protection UNDER FREQUENCY b over under frequency protection O NEGRO Gente c loss of mains protection by means of frequency drift a 180s delay from return of mains after fault to start of self initialisation procedure DESCRIPTION REVISIONS DATE APPROVED Proven Energy Ltd Wardhead Park PREPARED BY KA CHECKED BY RC Stewarton KAS 5LH UK Tel 44 1560 485 570 REV Kir R O E N GDC6004 6kW Windy Boy Grid Connect Inverter GdL 7 eee Tome seo Jet HEES Schematic with protection settings A1100 Electronic Polyohase Meter 111008 etn AA ah Advanced cost effective polyphase metering Features Accuracy Class 1 or Class 2 kWh import or kWh import export 3 phase 4 wire or 3 phase 3 wire 16 year product life Large figure display Extensive security data IrDA Infrared Data Association output for transmitting b
73. propriate capacity sling It is forbidden to use ihe machine s wire rope as a sling by passing it around the load and hooking it back onto itself Fig t0 incorrect anchoring arrangement Fig 10a correct anchoring arrangement The anchoring arrangement of models TU 8 and TU 16 is a hook fitted with a safety catch Figs 11 and 12 In allcases when anchoring the machine Ihe safety catch of the anchor hook should be correctly closed in its position al ne tip of the hook Fig 12 This advice for the machine anchor hook also applies to the hook fitted to the wire rope TIRFOR machines TU 32 and T 5000 are anchored by means of a removable anchor pin fitted across the two ends of the side cases Fig 13 and 14 and lacked in position by a spring clip See Figs 15 and 16 Fig 11 Machine anchor hook with catch in open position Optional hooks are available to fit ihe anchor point of models T 5000 and TU 32 To anchor using the anchor pin follow the procedure below 1 Open the spring clip of the anchor pin 2 Remove the spring clip from ihe anchor pin 3 Slide the anchor pin out of the side cases Fig 14 4 Fit the anchoring arrangement such as a sling between the side Cases 5 Refit the anchor pin through the side cases and anchoring arrangement such as the eyes of a sling 6 Refit the spring clip to the anchor pin 7 Close the spring clip ensuring that il fits correctly over the end of the anch r pin an
74. provenenergy com info provenenergy com Tel 44 0 1560 485 570 6kW Installation Manual Proven6 300 2006Rev 01 U Bracket bolte to hub plate www provenenergy com info provenenergy com Tel 44 0 1560 485 570 6kW Installation Manual Proven6 300 2006Rev 01 KRKA i ann a A 044444 04444 N sob U UAT MA E RER Haiii TETTEIT A PRADY 10444444 Fr Prey AM E 0 P oa eS L AW www provenenergy com info provenenergy com Tel 44 0 1560 485 570 6kW Installation Manual Proven6 300 2006Rev 01 3 10 Raising the Turbine Procedure Check hinge pin is in position and split pins at each end Fit gin pole to bottom of pole to bottom of pole and strut to mid pole bracket check nuts are tight on bolts Hook Tirfor wire rope to mid pole bracket Hook Tirfor to winch anchor feed rope through Tirfor as per Tirfor instructions Check that cables will not be trapped under pole base Apply wind turbine parking brake Pull wind turbine up slowly with Tirfor When upright keep tension on rope until all base bolts are in and tight When base bolts are tight release rope Dismantle tackle and gin pole If putting into service release wind turbine and check rotation is OK if breezy Caution Clear lifting area of all non essential personnel Do not allow anyone to be in the vicinity of the wind turbine whilst raising and lowering www provenenergy com info Q pro
75. revent a satisfactory joint See diagram D JOINT LENGTH LAP Determine the minimum lap The minimum site lap joint should be equal to 1 5 times the diameter of the female section Measure this amount back from the male end to be joined and mark with a chalk or crayon See diagram D 18 10 05 01 7 ALIGNMENT OF SEAM WELDS ETC Before commencing assembly note these requirements When assembled the seam welds of adjoining sections must be in line and assembly numbers if any facing the same way see diagram E 8 ENGAGING SECTIONS TOGETHER Find the balance point of the adjoining section using sling and crane Lift the adjoining section advance it to the base section and engage the two ends together You will find that the two sections will readily self align with each other if you have them balanced and pivoted on bearer and sling as instructed Engage the two sections as far as possible manually Diagram F 9 ASSEMBLING TIRFOR STRESSING GEAR Bolt A frame to base of mast as shown A slight angle up to 30 from the horizontal in a clockwise direction will assist stressing See diagram G 19 10 05 01 Diagram G 10 Assemble anchorage assembly at top end of section to be stressed and connect tirfor rope at the eye end See diagram H 11 Pass tirfor rope through both sections of the mast from top to flange 20 10 05 01 Diagram H 12 Locate the Tirfor on the A frame with end A
76. rmation can be printed in any ad a T High contrast wide angle language i IrDA Baud Rates 2400 4800 or 9600 Without serial port Security Data IEC 62056 21 Rate 9600 The A100C offers many useful security features Serial Baud Rates 2400 or 4800 The meter stores all registration and security data to Certified Product Life 20 years OFGEM model non volatile memory This data can be shown on the Temperature 20 to 55 C Operational range display All data is retained for the life of the meter 25 to 85 C Storage Recordable security features are listed below Humidity Annual mean 75 For 30 days spread over one year 95 s Reverse run event count Pulse Output 100ms pulse 100p kWh 10Wh pulse Reverse run energy total Other pulse rates durations available Reverse run indication on LCD Weight 345 grams Power fail count Specifications kWh Class 1 or 2 EN 62053 21 2003 s Elapsed time count kvarh Class 2 or Class 3 En 62053 23 s Time in rate 1 and rate 2 Case IP53 to IEC 60529 1989 Hours since last power up Hours spent in anti creep As an option the kWh register can increment in power Terminal Arrangements flow insensitive mode i e it increments regardless of energy flow direction Communications single Rate Pulsed Output Dimensions and Fixing Centres 130mm 4 mm Optical Port IrDA Port The A100C has the option of IrDA Infrared Data Association data stream communications or optical
77. rope and hold the load which is spread equally between the jaws The to and fro operation of the forward or reverse lever gives continuous movement of the load Fig 14 Anchor pin removed Fig 16 Spring clip open 7 RELEASING THE WIRE ROPE AND STORAGE It is essential to take the load off the machine before attempting to release the jaws Todothis operate the reverse operating lever until there is no tension in Ihe wire rope Remove the telescopic operating handle and return it to the closed position Release the machine and follow the instructions for installing the wire rope in the reverse order Re engage the jaws of the machine before putting it into storage siora the machine and wire rope in a dry place away from the effects of the weather The wire rope should be completely removed from the machine and rewound onto its reeler Before reeling the wire rope it is recommended to inspect it clean it with a brush and then grease it See section 10 The capacily of the machine may be inc C considerably for the same effort by the operator by using multiple sheave blocks See the examples set out in Figs 6 1 and 6 2 The increase in the capacity shown is reduced depending on the efficiency of the pulleys The diameter of the pulleys used shouid be equal to al least 18 times the damele of the wire rope Refer to the applicable regulations For any rigging arrangement other than those described in this ma
78. s The A100C can be a simple import meter or for import export for domestic or small scale generation sites The meter offers one or two rate operation The rate select for the two rate meter is switch to neutral The A102C measures reactive energy in addition to active energy and is ideally suited for utilities who wish to bill or monitor energy consumption based on kvarh measurement The meter can measure import or import and export energy Meters can be supplied to meet accuracy Class 1 or Class 2 requirements They are approved to EN 62053 21 2003 have an ingress protection of IP53 to IEC 60529 1989 and comply with EMC standard EN 50081 1 1992 I YT Kl e Display Pulse Output An opto isolated pulse output can provide the basis ELSTER CE om A100C for an energy management system or AMR i x These pulses are output via the auxiliary terminals SKIDABE ATV RIE U 0882 1 M cose Sza amg am Ti E 100 mp sn Technical Data Ir en 5 VARI 4 ACB creep ue a VITA PROPERTY OF ELSTER METERING san 0123456789 AAMT Current Range 10 100A 20 100A Voltage Range 210 250V 105 127V Frequency 50 or 60Hz System Connection 1 phase 2 wire The liquid crystal display is programmable to meet a customer s requirements A typical display for an A100C ZEN mot IE lea u En ee KK po E I Denn Impulse Withstand 12kV 1 2 50us 400hm source and index digit indicate the information being displayed 5 S L 4 M The nameplate info
79. t a different angle 2 Sight down the length of the blade so that only the tip end can be seen Is the blade mounted the right way round The flat surface should face upwind toward the generator the curved surface downwind 4 There should be a small angle between the blade profile as seen in this position and the hub plate 5 The leading edge the rounded nose of the profile should be angled very slightly upwind toward the generator the trailing edge the sharp edge should be very slightly downwind Downwind direction Upwind direction towards hub and blades towards generator This line runs through This line is parallel to the blade section the hub plate Leading Hub plate edge Flat blade surface gt upwind downwind Straight edge Trailing edge
80. the case that there is no wind or solar power then the MSDs are unpowered and the relay status is open safe www provenenergy com info provenenergy com Tel 44 0 1560 485 570 O PANEL LAYUUT D C FROM 3 PHASE TO RECTIFIER RECTIFIER THROUGH DOOR FUSE TERMINALS ISOLATOR SWITCH 20 Amp 1 Ak HEATSINK RECTIFIER JAILVDIN O U O U 3 PHASE FROM WIND TURBINE JAILISOdO D C OUTPUT TO SMA WINDY BUYS Proven Energy Ltd Wardhead Park Stewarton KA3 5LH UK Tel 44 1560 485 570 info provenenergy com All rights reserved PANEL LAYOUT pow PH MT an EE 005 reva 3 6000 EE 005 rev3 GSu sur N A APRIL 2002 s OO Schematic for IN C S PME System Using a Proven WI6000 3 core 10mme Ur Greater e core 6mme Point SWA Wind Turbine Double Insulated O Point of nominal 300VDC or gt 50Vac Disconnection Isolation US 3 ph WT Control Terninol Unit eure N SMA UTO L I R Windy Boy e oo WB6000 N Inverter EJ Plastic Synchronous_ _Hsuaton Rotary 3 ph AC permanent peri Isolator Da magnet off position rectifier generator Rotary Isolator Switch Local Tower Lockable in off Earth Position NOTES 1 Wind turbine current and frequency proportional to rpm wind speed operation M 2 SMA Windy Boy WB6000 It includes a b c A procedure output is nominal 250Vac 3ph under normal operating conditions 20Hz but voltage Upen circuit voltage approx 2 x normal ax o
81. the cover around the frame under the generator end and secure the cover to the frame as in step 1 STEP 3 Finally tighten all ties and trim www provenenergy com info provenenergy com Tel 44 0 1560 485 570 6kW Installation Manual Proven6 300 2006Rev 01 Ex a 3 i LO wi e s Eog yee be Z sa P pci e ze Pc G I M oh Wer Ta en bas Le a Far do i H L r i N a S E LC ee a gt gt k ne Hn 7 T ii i ii m RR ji io da kok h e ew 3 pas i IE e a Wh Ber z Em er E uai Bl sk 6 LAT a e O ASS ZPAS ee et a zdj se B i n i y 4 ies r PSI I e TI La Sele ec FO kn Please note the way the cable ties are tied www provenenergy com info provenenergy com Tel 44 0 1560 485 570 6kW Installation Manual Proven6 300 2006Rev 01 3 7 3 Fitting the Nacelle Cover Procedure STEP 1 Offer up the first nacelle cover to the frame attach using the cable ties Feed cable ties through cover then through plate and back through cover and secure This joins cover to frame It may be necessary to join cable ties together to get the required length STEP 2 Fold the cover over and around the frame and secure as in step 1 www provenenergy com info provenenergy com Tel 44 0 1560 485 570 6kW Installation Manual Proven6 300 2006Rev 01 STEP 3 Offer up second nacelle cover to the frame Fold around the frame and fit this cover under the edge of the first nacelle cov
82. tion Recommended Tirfor Hand Winches Model T532 e Safe working load for lifting 800kg with a 5 1 safety factor e Weight 24kg e 20m wire rope o Weight 26 6kg o Diameter 16 3mm o Breaking strain 16000kg e Telescopic Operating handle o Weight 2 3kg o Length closed extended 65 1 15cm Model T516 e Safe working load for lifting 1600kg with a 5 1 safety factor e Weight 13 5kg e 20m wire rope o Weight 13kg o Diameter 11 5mm o Breaking strain 8000kg NB Refer to appendix for detailed instructions on winch usage and safety information www provenenergy com info provenenergy com Tel 44 0 1560 485 570 6kW Installation Manual Proven6 300 2006Rev 01 www provenenergy com info provenenergy com Tel 44 0 1560 485 570 6kW Installation Manual Proven 6 300 2006Rev 01 4 0 Wind Turbine Maintenance Your Proven 6 like all Proven Energy turbine models requires minimal maintenance We recommend regular visual inspection to spot any unusual occurrence We however believe that if the following maintenance activities are carried out at the recommended times then very little could go wrong 4 1 Annual Maintenance e Lower wind turbine as described previously Grease Lithium EP 2 multi purpose grease recommended main rotor bearings and yaw bearing housing Check slip ring assembly with emery cloth and grease as necessary Check flange bolts tower base bolts base
83. uld be used at all times Personal Precautions Proven recommends a two person team as a minimum for mechanical installation of a Proven Wind Turbine they should use standard protective clothing Use only certified lifting straps and strops Weather The turbine should be installed in periods of wind speeds less than 12 m s 25 mph or 43 km h and generally calm weather conditions W gt Proven 6 6kW Wind Turbine Proven Patented Furling In winds above 12m s 25mph the blade twist to limit the power in response to high rpm Marine Build Quality All turbines are manufactured with galvanised steel Stainless steel or plastic Low Speed Equals Durability Low rotor speed half of the speed of comparable machines ensures extended durability of blades and bearings It also means that Proven WTs are the quietest in the world Proven TM900 TM1500 9m 15m Un Guyed Mast WT6000 Power Curve Power kW 0 5 10 15 20 25 Wind speed m s Cut in Wind Speed 2 5 metres second 5 6 mph Cut out Wind Speed gt 70 metres second gt 155 mph Rated Wind Speed 12 metres second 26 mph Type Number of Blades Blade Material Rotor Diameter Rated RPM Rotor Thrust KN Brushless Direct Drive permanent Magnet No gear box zero maintenance Grid connect 300V DC 50Hz or 300V DC 60Hz Battery Charging 48V DC Direct Heating 240V Switch DC 6000 watts 6
84. uspension points ara secure and suitable for tna full loads that will be imposed Lift the load just clear halt for a short period to ensure tha integrity of the brake or sustaining mechanism before completing the lift a Use a speed appropriate to the specific application Kaep hands and feet clear of ropes drums atc NEVER e Raisa loads by revolving the drum in the opposite direction to that indicated ae Usa winches with loosa or insecure handlas Usa the pawl to arrest descending loads Usa winches if the ropa is twisted or trapped Over wind the rope on or off the drum e Usa winches for man riding applications unless they are specifically designed for that purposa Selecting the Correct Winch inches ara available for manual or power operation in a range Capacities designs and mounting arrangements Select the winch to be used and plan the lift taking any statutory requirements and the following into account Type of winch manual electric pneumatic or other operation mounting eg wall floor lorry etc capacity and rape drum storage atc Speeds and control single speed dual speed push button pull cord lever remote atc Rigging arrangement diverters pulley blocks anchorage and suspension points imposed loads Consult the supp er if the winch is to be used in areas of high risk axposed to the elements water steam etc with hazardous substances eg acids or chemicals
85. uthorised alteration or modification accident misuse improper installation operation or maintenance or failure to conduct periodic inspections and maintenance Proven Energy Limited reserves the right to repair or replace the defective component s at their sole option Proven Energy Limited does not accept any additional liability for defects from reasonable wear and tear Use of Proven Wind Turbines with Mast or Towers manufactured by others Poor mast design may cause vibration both in the mast and the nacelle of the wind turbine Faults arising from poor mast design shall be classed as improper installation see General Conditions Mast should be designed to avoid resonance within the operating frequency range of the wind turbine The onus shall lie with the owner to show their mast has not caused the fault Shipping and Transport Costs Warranty repairs will be made at the premises of Proven Authorised Representatives or our factory The end user must return the defective component s properly packed and with all freight and insurance charges prepaid All freight shipping and insurance costs including duties taxes and import charges incurred in returning Proven Wind Energy Products are to be met by end user Disclaimer Proven Energy Limited shall not be liable for any incidental or consequential damages resulting from the proper or improper use for any purpose whatsoever of Wind Energy Products Statutory rights This warranty in no way
86. utput 6kw at approx 200 rpm inverter is EA approved for connection to UK grid over under voltage protection over under frequency protection loss of mains protection by means of frequency drift 180s delay from return of mains after fault to start of self initialisation DESCRIPTION REVISIONS or oro Te wor REV 4 PROVEN PROVE HE RQ Y Consumer DNO S HRC Fused Cut Out r LIVE Fai NEUTRAL m Inport Meter WINDYBOY CONTROL SETTINGS G83 1 MEJ E GvERvOLAGE H Z VI UNDERVOLTAGE 26 V OVER FREQUENCY UNDER FREQUENCY Proven Energy Ltd Wardhead Park Stewarton KA3 5LH UK Tel 44 1560 485 570 info provenenergy com All rights reserved GDC6004 6kW Windy Boy Grid Connect Inverter Electrical Schematic with protection settings Schematic for IN Ss Cable Sheath System Using a Proven WI6000 ZCONO EOO OT T TTTATT ZZZ 10mme Or 1 DNO S HRC Greater e core 6mm2 Point Fused SWA BBE Ur one Double Insulated Cut Out nominal lust nominal 300VDC S a Disconnection NOMINA Isolation Ir l UWE eo0vVac E R Cro u consuner TOTO A 3 ph Terminal Unit 324 Turbine a EJ MCB SP Export KZ A IT Meter Import N Meter NEUTRAL ia El Plastic sem Synchronous_L a A Rotary 3 ph AC permanent Isolator 0 L lockable in DO magnet off position rectifier generator R
87. venenergy com Tel 44 0 1560 485 570 6kW Installation Manual Proven6 300 2006Rev 01 3 11 Lowering the Turbine Procedure e Apply wind turbine parking brake Place trestle or support to offer support lowered to pole e Fit gin pole and rope tackle as for raising Check all shackles bolts and fittings are secure check again before lowering Take up slack in Tirfor Put handle in lowering position Make sure hinge pin and its splits are in place Take out base fixing bolts Pay out a little rope and lift end of gin pole to tilt wind turbine over balance point until strain comes on Tirfor e Now lower wind turbine gradually with Tirfor 3 12 Testing with a Third Party Mast A cautious approach should be taken to testing the turbine in operation with a new design of third party mast It is not fully known initially if the mast is suitable for the dynamic operation rpm range 0 200 rpm of the turbine An engineer should maintain a close view of the turbine under operation in a wide range of wind speeds and rpms This may last some days depending on the wind conditions Important If serious wobble or vibration occurs then the turbine brake should be applied immediately Report the any problem during testing to Proven and mast manufacturer www provenenergy com info provenenergy com Tel 44 0 1560 485 570 6kW Installation Manual Proven6 300 2006Rev 01 3 13 Winch Set Up Specifica
88. ves an excessive DC input voltage it automatically disconnects from the grid and ceases its power feeding activity When the Windy Boy is in operation you must always first disconnect the AC voltage grid voltage and only then should you disconnect the DC voltage from the Windy Boy reconnecting the DC voltage to the Windy Boy Since the Windy Boy is identical to the Sunny Boy apart from the operating mode the display shows PV photovoltaic as the input source Before resuming operation the input voltage must be checked before User Manual WB50A_60A 11 FE3706 Page 27 Unit Description SMA Technologie AG Page 28 WB50A_60A 11 FE3706 User Manual 6kW Installation Manual Proven6 300 2006Rev 01 PROVEN R Mechanical Installation www provenenergy com info provenenergy com Tel 44 0 1560 485 570 6kW Installation Manual Proven6 300 2006Rev 01 3 0 Mechanical Installation 3 1 Tools Required Number Description Used For 10 mm Spanners 1 open ended Slip Rings 13 mm Spanners 1 open ended Blade and Spring Fixings Blade fixing bolts 17 mm Spanners 1 open ended S SR Se 19 mm Spanners 1 open ended Lower Yaw Bearing Upper Yaw Bearing plus main 24 mm Spanners 1 open ended shaft bearimg at generator end normally factory tightened 3 mm Allen Key Slip Rings grub screw 5 mm Allen Key Yaw Bearing grub screw Pair of Wire Snips Trimming cover cable ties 36mm Spanner for TM900 or

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