Southwest Windpower, Whisper 200, Owners Manual
Contents
1. Suggested Mounting Configuration o L LED s and Diversion Switch 7 NES D On ur pa i GS 5 22022202 22 22022022 LOOSE OO OOO Oe Anemometer nate vol e e o o Connection optional O O Ore Tere O _ fee o QUO QUO Ce 2022 eue ale olo ee rcs s E n Battery Outputs 0 0 d OO UO 208 h Ground o cz Ne 32 vo Ke 5 2 nia O 0 0 0 0 0 0 0 0 dE 227 Dump Load Side Hot Side OO Knockouts on bottom ee MS P 2 controller O ES Turbine Inputs N 18 WHISPER CONTROLLER WIRING Connecting Connect the battery and grounding wires as shown in the schematic on the next page Caution connect the Control ler to the batteries BEFORE connecting to the turbine otherwise the Controller will be damaged Please use caution when connecting the battery leads to avoid shorting them together After connecting the battery check that the microprocessor is energized correctly by flipping the Diversion Switch to the stop position The red LED should illu minate If not disconnect the battery and reconnect it Return the diversion switch to the battery position and observe the red LED to turn off Try not to allow the connection to bounce causing the microprocessor to power up an2. Maintenance LOWER TOWER AND GIVE WIND GENERATOR A COMPLETE MECHANICAL CHECK FIX OR REPLACE ANY WORN OR LOOSE PARTS 1 Check tightness of all tower mounting nuts and bolts and propeller mounting bolts 2 Check all bearings Just perceptible play is acceptable 3 Clean the propeller with mild detergent to remove all dirt and debris Avoid scratching the surface Replace blades if they are cracked or damaged SOUTHWEST WINDPOWER Document 0212 REV B Tighten tower and blade mount ing bolts Do not tighten pivot pin nut 11 22 2004 24 Whisper 80 Manual Maintenance Document 0212 REV B Observe Monthly and Annual Inspection Requirements Record ALL maintenance and repair work Date Problem Observation Action Taken SOUTHWEST WINDPOWER 11 22 2004 2 Whisper 200 Operators Manual Troubleshooting and Repair Document 0212 REV B 15 TROUBLESHOOTING AND REPAIR WIND GENERATOR SYSTEM First one must determine if the problem is mechanical or electrical Refer to the two illustrations below and then proceed to the appropriate section Propeller does not turn Mechanical Problem Propeller turns slowly Electrical Problem or turns slowly Proceed to ELECTRICAL DIAGNOSIS PAGE Page 26 Proceed directly to Table Symptoms of Mechanical to diagnose the type of electrical problem the turbine 18 ex Problems Page 25 periencing SOUTHWEST WINDPOWER 11
3. indicates turbine power is diverted to the dumpload due to a request from the Remote Display OFF MAN indicates turbine power is diverted to the dumpload due to a request from the Diversion Switch being placed in the Stop position OFF REG indicates turbine power is diverted to the dumpload due to automatic regulation at the prescribed voltage NOTE The Diversion Switch set to OFF Stop manually overrides the Remote Display ON function The mode can be toggled using the A menu button The B menu button will go to the Regulation Set page Regulation Set Page 5 Once the Whisper Controller Display is hooked to a Controller the Controller no longer looks to its potentiometer for set ting the regulation voltage Instead the regulation on and off voltages are set digitally at the Regulation Page See a de scription of the function of these settings in Section 11 5 Setting Regulation Parameters page 17 This page displays a menu allowing change to the Regulation On and Regulation Off set voltages Selecting change using the menu but ton will bring up a sub page allowing the Regulation On voltage to be changed Pressing the B menu button will in crease the voltage to a maximum of 17 0v and will then roll back to 13 0v Pressing the A menu button will go to the Regulation Off voltage sub page Pressing the B menu button will again increase the voltage to a maximum of one
4. 10 on outside mounting bolt Using bolts 11 Washers 9 and 10 and Nuts 7 tighten all bolts to 18 Ft Ibs 24Nm torque Repeat for remaining Blades Note Tapered ground end of extensions faces towards blades WHISPER 200 Leading Edge Blade Installation Rounded Trailing Edge Sharp 1 SS Blade Extension 3 Important Assembly Note 2 Lock her M1 epee Nader P Each turbine blade has a dot of paint on the 3 SS Hex Bolt M10 x 40 6 front of the blade between the blade 4 Kosto 1 mounting holes The blades should be bolted to the front of the blade extensions item 5 SS Flat Washer M10 x 20 3 1 as shown in the above figure so that the Thin paint dot is VISIBLE after the blades are 6 Blade 3 mounted 7 SS Nylock Nut M10 6 9 SS Flat Washer M10 x 30 3 Thick 10 SS Shaved Flat Washer 3 MIO x 30 11 SS Hex Bolt M10 x 50 6 SOUTHWEST WINDPOWER 11 22 2004 17 Normal Operation Whisper Controller Document 0212 REV B Whisper 200 Operators Manual 12 BECOMING FAMILIAR WITH THE WHISPER CONTROLLER 1 Normal Operation Whisper Controller Overview The Whisper Controller is a one or two part system specifically designed to control the operation and convert the power of a Southwest Windpower Whisper 100 or 200 Its basic functions are rectification regulation and resistive power dump ing However to best accommodate many individual customers the Whisper Controller offers many feature
5. 0212 REV B J CHOOSE BATTERY LOCATION Locate battery in moderately stable room temperature dry unoccupied building Battery performance is optimal at room 24 Volt Configuration temperatures Run AC power from inverter to house or load If battery is in an occupied building an enclosure with vent to outside is required Follow code See the following Whisper diagrams for package system series parallel arrangement Controller Inverter Determine series parallel arrangement and construct a rack or mount from heavy treated lumber or other suitable material Allow 5 cm 2 in on all sides for ventilation Allow 60 cm 2 ft vertical clearance for access to terminals and checking water Coat all connections with grease or corrosion protector available at auto parts store Install Whisper Controller and Inverter fuse if used at battery positive To minimize the possibility of EMI electromagnetic interference the line from the battery to the Whisper Controller should be less than 10 feet 3 meters Whisper Recommended Battery Fuse Installation Controller Consult local electrical codes Inverter 48 Volt Configuration Battery Positive Nut and Bolt Whisper Inverter Drill one end of fuse to fit battery post if necessary Fuse Included Use the diagrams below to determine the series parallel arrangement for your system voltage typical 6 volt batter
6. 20 Brush with wire 3 IAF02 21 Brush wire with terminal 1 2 IAF0I 22 Ground Screw M6 10 I IAR03 23 Casting Bottom I IAB07 24 Washer M8 16 1 48 25 Nylock Nut M8 1 17 26 Yaw Shaft 1 IAD03 27 Snap Ring 62mm 1 IAR21 28 Seal 1 22 29 Light Assembly Not Available 1 6 30 Bronze Thrust Washer 1 2 31 Hex Bolt M8 25 SS 1 9 32 Hex Bolt M8 70 SS 1 13 33 Tail Stock 1 14007 34 Nylock Nut 8 3 17 35 Nylon Washer M8 x 31 3 16 36 SS Washer M8 x 24 3 IARI5 37 Hex Bolts M8 x 55 SS 2 12 39 1 4504 39 Yaw Bearing 2 202 40 Yaw Shaft Snap Ring 1 19 SOUTHWEST WINDPOWER 11 22 2004 32 Document 0212 REV B Troubleshooting and Repair Whisper H 80 Manual 8t N IA pepojdx3 08H 33 11 22 2004 SOUTHWEST WINDPOWER Proprietary rights are included in the information disclosed herein This information is REVISIONS submitted in confidence and neither the document nor the information disclosed here in shall be reproduced or transferred to other documents for manufacturing or for any other purpose except as specifically authorized in writing by Southwest Windpower e yy pm 2 e m e N c d O0 ort LR CN C epee 1 L CN OF TOWER TUBE Z gt 4B ll KI N AM i d 2 500 63 50 102 3 05 4 0 X 120 wall tube 2
7. 22 2004 26 Troubleshooting and Repair Whisper H 80 Manual Document 0212 REV B Table Symptoms of Mechanical Problems Symptom Possible Cause Correction 1 Propeller is stationary even in high winds 2 Propeller will not turn at all except in high wind scraping or rubbing sound at low rpm always stops at same propeller position 3 Propeller is harder starting output 18 lower amp there is more propeller noise than usual Seems out of bal ance 4 Propeller turns a little never spins rapidly 5 Tail generator and tower vibrate or shake excessively at all or some wind speeds 6 Rattle or clunking from generator a Ice in generator or ice on propeller b Debris between rotor and stator c Loose broken or rubbing magnet d Bad or worn bearing a Same as above except more likely to be high magnet or bad bearing b Swelled wire keepers due to high moisture a Ice on blade b Dirty blade c Split warped or damaged blade d One or more blades on backwards a Blades on backwards See blade installation a Blade out of balance b Blade not tracking c Rotor magnet can out of balance d blade plate out of balance a Generator loose in tower Loose rotor magnet can on shaft loose tail missing rubber bumper wires slapping inside of mast governor pivot bolt loose c Worn bearings d Shaft broken i Wait for warm weather i Turn propeller gently by hand and
8. See Voltmeter Test page 26 i See Voltmeter Test page 26 3 Propeller runs too fast may whistle low output no unusual mechanical noise a Battery voltage over 5096 high b Turbine may be in regulation but the wind may be too high for the turbine to stop i Examine battery specifications and regulation set point replace improperly sized battery if necessary ii Wait for calmer conditions and engage diversion switch to determine proper operation 4 Propeller runs too fast may whistle output less than 50 for wind speed growling buzzing or vibration felt by hand or mast a Disconnected wire between the turbine and the Whisper Controller b One open or disconnected diode c One slip ring or brush not making good connection i See Voltmeter Test page 26 i See Voltmeter Test page 26 i Contact distributor or factory 5 Propeller runs too slowly output low no unusual mechanical noise a Battery voltage low or a dead battery b Incorrect turbine wiring 1 Disconnect loads and let battery charge i Check wind generator wiring connections or rewire SOUTHWEST WINDPOWER 11 22 2004 29 Whisper 200 Operators Manual Troubleshooting and Repair Document 0212 REV B Symptom Possible Cause Table Symptoms of Whisper Controller Problems Correction 1 Propeller turns slowly even in strong wind a Brake Sw
9. blow or use piece of paper to dislodge debris 1 Contact factory or distributor to remove rotor and re glue magnets 1 Contact factory or distributor to replace bearing s i Same as above 1 Contact factory 1 Wait for warm weather Prop will eventually shed ice leave running unless there is substantial vibration 1 Clean with mild detergent 1 Contact factory or distributor to re place broken or damaged blade 1 See blade installation i Turn blades over Leading edge ad vances clockwise from upwind view 1 Contact factory to replace blade i Contact factory to replace mounting plate i Return to factory or distributor i Return to factory or distributor i Inspect for damage Repair as required Retighten mounting hardware use Loctite or equivalent thread locking compound i Contact factory to replace bearings i Contact factory to replace shaft SOUTHWEST WINDPOWER 11 22 2004 Whisper 200 Operators Manual Troubleshooting and Repair Document 0212 REV B ELECTRICAL DIAGNOSIS DETERMINING THE TYPE OF ELECTRICAL PROBLEM Electrical problems can be in the generator wiring or in the Whisper Controller Determine which as follows 1 Wind generator will not start blades turn slowly as if the diversion switch is engaged On a day of moderate wind disconnect the three wires from the wind generator one at a time at the Whisper Controller If the wind generator starts the wire that allowed it to
10. bolts and blade strap See exploded view Typical Blade Assembly 2 Blade Mount Bolts Nosecone MECHANICAL REPAIRS AND PARTS REPLACEMENT The following two sheets provide a complete exploded view and parts list of the Whisper 200 It is included as a guide for replacement parts and troubleshooting It is however recommended that any internal repair of the turbine be performed by the factory or your authorized distributor Any unauthorized attempt to repair the turbine leading to damage is not covered by warranty SOUTHWEST WINDPOWER 11 22 2004 31 Whisper 200 Operators Manual Troubleshooting and Repair Exploded View Parts List Whisper 200 Document 0212 REV B Item No Description Quantity Southwest Windpower Part H80 I Casting Top I IAA07 2 Nylock Nut M8 1 17 3 Hex Head Screw M8 x20 I IAR07 4 Stator I IAR019 5 Snap Ring 20 mm 2 18 6 Bearing 3 201 7 Spindle 1 IAP06 8 Snap Ring 47 mm 1 22 9 Rotor 3 20 10 Washer M6 SS 3 IAROS5 11 Socket Head M6 x 16 3 06 12 Stop Head Rubber Pad I IAL03 13 Stop Head Rubber Pad I IAL04 14 Pan Head Screw 5 x 60 4 IAR02 15 Bronze Bushing 1 704 16 Pivot Shaft 1 IAGO6 17 Brush Cover 1 IAF09 18 Brush Holder 3 IAF06 19 Spring 4 IAF03
11. instructions and recommendations in this manual will help assure safe and enjoyable use of your new renewable energy system SAFETY INFORMATION These systems present mechanical electrical and chemical battery hazards that can be life threatening The tower or support structure could fall and cause injury or death and property destruction A component of the wind generator could come loose causing injury or death and property destruction Contact with the high speed propeller can result in severe injury or death High voltage from the wind generator or the inverter can cause injury or electrocution A severe chemical burn including blinding can occur from a battery explosion or contact with the sulfuric acid in a lead acid battery These conditions are addressed in the following safety messages STOP DANGER It is your responsibility to obtain all required permits and engineering certifications for your tower and tower location Soil and wind conditions vary and towers and tower foundations must be designed for your specific location Tower must not be able to fall on occupied buildings neighbor s property or power lines Tower climbing is dangerous and should be attempted only by experienced personnel using proper safety equipment A fold over tower can eliminate climbing Locate your mounting mast tower well away from occupied buildings and power lines a minimum of 100m 300 ft is recommended STOP DANGER If the generator appears or sounds
12. loose in the tower or is making an unusual sound the condition must be corrected immediately A loose generator or component will soon damage itself further and may fall from the tower or lose parts that could be lethal Never stand in line with an spinning propeller STOP DANGER Provide climbing protection against all unauthorized persons or children Never allow an untrained person or someone without the proper safety equipment to climb the tower Always stop the propeller before climbing the tower Both falling from the tower and contact with the spinning propeller can be lethal STOP DANGER High voltage systems that 15 systems with battery voltages of 64 volts and above or the primary side of any system with a transformer represent a dangerous shock hazard and could be lethal All high voltage systems should be wired and maintained by a qualified and licensed electrician STOP DANGER Batteries may emit explosive and irritating gas while charging Never turn on a light switch or make any other electrical connection or light a match or make any type of spark near a recently charged battery Use protective gloves and eyeglasses when working around a battery Turn off all loads wear safety glasses and look away when making a final battery connection STOP DANGER NEVER place objects on top or near the Whisper Controller enclosure These devices must dissipate heat as part of normal operation FAILURE AND FIRE can result if airflow is blocke
13. start leads to a failed component in the Whisper Controller Call the factory or the distributor to replace the failed component OR 2 Wind generator still does not start On a day of moderate wind disconnect any two wires If the wind generator starts the problem is most likely in the Whisper Controller Go to Table Symptoms of Whisper Controller Problems page 28 If the wind generator still does not start the problem is in the tower wiring or the wind generator Go to Table Symptoms of Electrical Problems page 27 OR 3 Wind generator is running but may have an electrical problem As directed below use a voltmeter to read the voltage across the leads and see the voltmeter test section below as a guide to possible problems To Whisper Controller Terminals From Wind Generator Voltmeter Test 1 1 Voltage increase and decreases slowly relative to the wind speed across all combinations of paired wires Every thing ok 2 No voltage across two wires One wire from wind generator not carrying power Check in order Check the tower wiring and Whisper Controller connections to insure proper wiring If the wiring is correct contact authorized dis tributor or factory for further assistance 3 Voltage significantly higher across two wires than the others Contact the distributor or the factory possibly a shorted diode 4 Voltage significantly lower across two wires than the others Bad connection at wind turbine
14. voltage connections or faulty stator winding Report this failure to your distributor or the factory 5 Should these results appear inconclusive in determining the problem proceed directly to Table Symptoms of Elec trical Problems page 26 or Table Symptoms of Whisper Controller Problems page 28 SOUTHWEST WINDPOWER 11 22 2004 28 Troubleshooting and Repair Whisper H 80 Manual Document 0212 REV B Table Symptoms of Electrical Problems Symptom Possible Cause Correction 1 Propeller turns slowly even in strong wind but will not start a Diversion switch is ON b Battery is dead voltage less than 1 2 nominal c Incorrect turbine wiring d Short circuit in wiring from generator to Whisper Controller e failed component in Whisper Controller f Short circuit in brush card or slip ring assembly g Short in turbine h Load or battery disconnected 1 Turn DIVERSION switch to BATTERY position 1 Disconnect loads and or battery from Whisper Key until generator starts 1 Rewire i Check wiring from tower p lt 1 See Voltmeter Test page 26 1 Contact distributor or factory 0 Contact distributor or factory Check all connections 2 Propeller runs too fast may whistle no output no unusual mechanical noise a Two or three wires open between turbine and Whisper Controller b Whisper Controller diodes open or wire is disconnected at diode terminal Ee
15. 30 860 1720 3439 10750 42990 2 33 131 262 524 1048 3277 13100 1 137 549 1098 2195 4390 13723 1 41 167 335 669 1340 4183 0 171 682 1364 2727 5455 17050 0 52 208 416 831 1663 5200 2 0 217 865 1731 3462 6923 12860 2 0 66 264 928 1055 2110 6600 3 0 273 1088 2177 4355 8710 27230 3 0 83 332 604 1327 2655 8300 4 0 345 1378 2755 5510 11020 4 0 105 420 840 1679 3360 250 402 1607 3214 6429 12860 250 123 490 980 1960 3919 300 482 1929 3857 7714 15430 300 147 588 1180 2351 4700 350 963 2250 4500 9000 350 172 686 1370 2740 400 650 2596 5192 10390 400 198 791 1580 3160 500 805 3214 6429 500 245 980 1960 AWG SIZE 14 12 10 8 6 4 3 2 1 0 2 0 3 0 Diam inches 0 064 0 081 0 102 0 129 0 162 0 204 0 229 0 258 0 289 0 325 0 365 0 409 Diam mm 1 628 2 057 2 591 3 277 4 115 5 182 5 817 6 553 7 341 8 255 9 271 10 389 SOUTHWEST WINDPOWER 11 22 2004 Whisper 200 Owners Manual Installation Document 0212 REV B Li 1 INSTALLATION 1 TOWER LOCATION TYPE AND HEIGHT INSTALL TOWER DR trees or obsta Install tower following manufacturer s instructions Tower height minimum is 7 meters 20 feet above trees or obstacles within 100m 300ft The highest point on your property is generally best but wind generator dis tance to battery and the battery voltage determine the cor rect wire size Refer to wire size table pg 6 A self sup porting tower occupies less ground area than a guyed tower but is more
16. 9 SCHED 40 PIPE 102 x 3 05 4 0 X 120 wall tube Dimensions in brackets are in inches Instructions This sheet should be printed full scale 1 Align template to top of tower tube and tape in place 2 With centre punch mark hole centres for your tower configuration 3 Remove template check dimesnions and drill ron otherwise specified CAD generated drawing Southwest Windpower imensions are in mm Ido not manually update Flagstaff Arizona U S A distances angles APPROVALS DATE ower Too 53 0905 e drilling template ART O CLA A A s MAERAL EE H MATERIAL J G Lonjaret dec 3 FILE 1387 tower top drilling template NO IDENTIFYING SPECIFICATION NEXT ASSY USED ON PARTS LIST APPLICATION DO NOT SCALE DRAWINGPUAEENG J SCALET T REV A SIZE A sheet 1 of 1
17. OLS AND EQUIPMENT YOU WILL NEED SOUTHWEST WINDPOWER 11 22 2004 2 Whisper 200 Owners Manual Introduction Document 0212 REV B WELCOME TO YOUR RENEWABLE ENERGY SYSTEM ELECTRICITY FROM THE WIND AND SUN Renewable electric power systems provide independent no utility grid electric power for boats homeowners farms villages and commercial applications such as telecommunications If utility power is available your renewable energy system can reduce the electric bill and with a battery system provide back up electricity during storms or line failure The most common sources of renewable electric power in these systems are small wind powered generators and solar photovoltaic PV modules that convert sunlight directly to electricity Renewable means power sources that do not deplete the world s finite fossil fuel resources do not pollute or warm the atmosphere and do not generate hazardous waste Electricity means your children can study at night for a better future and you can benefit from appliances power tools and communication technologies that make life easier and more rewarding Nearly three billion people in the world do not have electricity and by necessity most will ultimately get their electricity from renewable resources to the benefit of everybody You are a pioneer and part of the solution BEFORE YOU BEGIN Read this entire manual Identify and note your model wind generator where it appears in this manual Following the
18. Set Screw M6 X 20 2 Bolt M8 X 35 M8 SS Nylock Nut SOUTHWEST WINDPOWER 1 1 22 2004 12 Installation Whisper 200 Owners Manual Document 0212 REV B 1 7 WHISPER CONTROLLER MOUNTING PRELIMINARY MOUNTING INSTRUCTIONS FOR WHISPER CONTROLLER Please note that for preliminary turbine to controller tests it may be convenient to temporarily mount the Whisper Controller close to the Wind Turbine This will allow the user easy access to the controls and displays while testing the turbine and controller functionality Please observe the following recommendations for mounting the controller The tests should be performed prior to mounting the blades Mounting The Whisper Controller should be mounted against a vertical wall with the LEDs and Diversion Switch to the top Vertical mounting is required to provide good heat convection for the resistor bank dump load Since the dump load side of the controller may get very hot do not mount the unit near anything flammable or heat sensitive Conduit knockouts on the bottom of controller unit accommodate 0 75 1 25 and 1 5 nominal size conduit An earth ground connection terminal 15 provided inside the controller between the turbine and battery mounting blocks
19. Tower Tail Stalk Nose Cone Tower Insert Kit Hardware Kit Whisper Controller if ordered with a controller 100 amp Fuse SOUTHWEST WINDPOWER 11 22 2004 Whisper 200 Owners Manual Introduction Document 0212 REV B Typical Renewable Energy System Wiring You will need to make the electrical connections as shown below See the WHISPER Controller Whisper Controller installation section for complete wiring de tails See wire size table below Included 10 Feet or 3 Meters Maxi mum Distance L 4 L P mE WIRE SIZE FROM WIND GENERATOR WHISPER CONTROLLER The following tables are used to determine the wire size based on your system voltage and the distance required to connect your Whisper 200 to the WHISPER Controller Distances are one way distances from the turbine connection to Whisper Controller terminals VOLTS 12 24 30 36 48 60 72 120 240 VOLTS 12 24 32 36 48 64 72 120 240 COPPER All COPPER All WIRE SIZE F E ET WIRE SIZE RS AWG 14 XX XX XX 108 217 678 2710 AWG 14 XX XX XX 33 66 207 826 12 XX XX 87 173 346 1082 4327 12 XX XX 2 53 105 330 1319 10 XX 69 138 276 551 1722 6888 10 XX 21 42 84 168 525 2099 8 XX 109 218 436 879 2730 10910 8 XX 33 66 133 268 831 3320 6 42 170 339 678 1357 4241 16960 6 13 52 103 207 414 1293 5170 4 68 271 542 1084 2169 6779 27110 4 21 83 165 330 661 2066 8260 3 85 341 682 1364 2727 8525 34090 3 26 104 208 416 831 2598 10390 2 108 4
20. V 28 8v 43 2v 57 6v Turn 5 CW 14 0 28 0v 42 0v 56 0v 15 0V 30 0v 45 0v 60 0v Turn 54 CW 14 0V 28 0v 42 0v 56 0v 16 0V 32 0v 48 0 04 0v Full Turn CW 14 0 28 0v 42 0v 56 0v 17 0V 34 0v 51 0v 68 0v SOUTHWEST WINDPOWER 11 22 2004 19 Whisper 200 Operators Manual Normal Operation Whisper Controller Document 0212 REV B 6 Whisper Controller Display Normal Operation Whisper Controller Display The Whisper Controller Display adds a tremendous set of features to your wind turbine system Controller measure ments can be monitored and operational parameters can be adjusted Take the time to learn about your Whisper Con troller Display to take advantage of its many features B Menu Function Button LCD Display Screen Menu Function Button Green LED n miseen 2 f Di ONTRO 7 SPLay LER LCD Potentiometer 200 Contrast Adjustment 7 4 Red LED x LED Display Functionally the Display unit s LEDs operate the same as the Controller s LEDs see Section 11 4 LED Operation page 17 Due to communication lag times there may be subtle difference in these two sets of LEDs Therefore it 1s recommended that if the Display 18 mounted in the lid of the Controller that the Display be plugged into the Controller board jack in the lower right corner of the Controller board This will automatically disable the Display s LEDs The Controller board jack closest to the Diversion switch
21. Whisper 200 Owners Manual Document 0212 REV B REPS Southwest Windpower Inc Renewable Energy Renewable Energy Made Simple Bockholm FIN 21760 Houtsk r www reps fi 358 40 5883344 Owners Manual Installation Operation and Maintenance WHISPER WIND GENERATORS MODEL 200 For the NEW Whisper Controller Southwest Windpower Inc 1801 W Route 66 Flagstaff Arizona 86001 Phone 928 779 9463 Fax 928 779 1485 Email info windenergy com Web page http www windenergy com O January 2005 Southwest Windpower Inc All Right Reserved WIND GENERATOR SERIAL NUMBER SOUTHWEST WINDPOWER 11 22 2004 Whisper 200 Owners Manual Coments Document 0212 REV B Table of Contents INTRODUCTION INSTALLATION PURCHASE BATTERIES OF PROPER SIZE SETTING TURBINE VOLTAGE CHOOSE BATTERY LOCATION WIND GENERATOR ELECTRICAL TESTS MOUNT WIND GENERATOR ON TOWER WHISPER CONTROLLER MOUNTING WHISPER CONTROLLER WIRING WHISPER CONTROLLER DISPLAY INSTALLATION 10 INSTALL TAIL ASSEMBLY 11 INSTALL BLADES AND NOSE CONE 12 BECOMING FAMILIAR WITH THE WHISPER CONTROLLER 13 MAINTENANCE MONTHLY 14 MAINTENANCE ANNUAL 15 TROUBLESHOOTING AND REPAIR 16 MECHANICAL REPAIR AND REPLACEMENT p FOLLOW STEP BY STEP INSTALLATION LOOK FOR THE SHADED BOXES AND FOLLOW THE STEPS IN ORDER CHECK THE PROVIDED BOX WHEN COMPLETE OO 00 P c SUGGESTED TO
22. a bladed screwdriver into the hole on the display between the buttons and the LEDs Turn the potentiometer to adjust the brightness If a display is still not visible disconnect and reconnect the cable to the display to reset the display Once display function is verified re install the electronics cover on the controller base The system wiring is now complete Proceed to assembling the turbine and mounting blades to rotor SOUTHWEST WINDPOWER 11 22 2004 15 Whisper 200 Operators Manual Installation Jo INSTALL TAIL Assembled Generator 1 Tail Stalk 1 Tail Fin 1 Hex Bolts M8 x 55 2 Nylon Washer M8 X 31 2 SSTL Washer M8 x 24 2 Nylock Nut 8 4 Hex Bolt M8 x 25 1 Hex Bolt M8 x 70 1 SOUTHWEST WINDPOWER 11 22 2004 GO A a A WO N Document 0212 REV B 16 Whisper 80 Manual Installation Document 0212 REV B Li 11 INSTALL BLADES AND NOSE CONE INSTALL BLADE AND NOSE CONE DIVERSION SWITCH IN STOP POSITION 1 Bolt down Blade Extension 1 to rotor using only the one bolt 3 and lock washer 2 nearest center of rotor In sure remaining Extension bolt hole lines up with rotor by loosely inserting bolt in outer hole and tighten inner bolt securely Repeat for each Blade Extension 2 Line up bolts 3 through Nose Cone 4 using Flat Washers 5 and lock washers 2 Tighten to 18 Ft Ibs 24Nm torque 3 Install blade 6 rounded edge advancing clock wise on Extension 1 using cut washer
23. before installing the wire nut The wires should be twisted in a clockwise direction Cut of the untwisted ends of the wires and twist on the appropriate color wire nut Push hard on the wire nut while twisting clockwise Coat wire nuts and terminal strip connections with dielectric grease to protect wires against corrosion A tube of dielectric grease is supplied with each Whisper 200 SOUTHWEST WINDPOWER 11 22 2004 Document 0212 REV B Whisper 200 Owners Manual Wel IUM Ped I Pela I WYM HOA 8T c Pela c 9MWAA JIAN ysg JHAA ysg 90M USniq SINN AM JULIO SINN 9JIAA MOJO A I pod Pela IM your your I WYM HOA 96 C WYM c xoe g ysg onm usnug onm SINN IM 280210 SINN OTA MOJA orl XoeIg E IM I pow I La I YM C WYM usnug ysnig orm usnug SINN MOTJOA XoeIg cpeu zag coma JXoeId I pou 9uw suoroorp orgroods 23ed 8 14 HOA CI I pu S E c3 bn u Q oO 51 S 2 uono uuoo YLI 10 poj orpul SI MU 9718 10 1931102 SON uoneunsrjuoo 26 INOA 10 SUOTJ29UUOO ITIM 101615 OTN USTED UST UST pue YSNIQ 03 38010110 99U919J SINN poy 11 22 2004 SOUTHWEST WINDPOWER Whisper 200 Owners Manual Installation Document
24. d SOUTHWEST WINDPOWER 11 22 2004 3 Whisper 200 Owners Manual Introduction Document 0212 REV B DESCRIPTION OF SYSTEMS The illustration below depicts a typical installation For more information regarding specifications of wind wind solar and inverter systems contact Southwest Windpower Note that the illustration below is for information purposes only See the appropriate section to properly wire your own wind system Whisper Wind Generators Whisper 100 and 200 include the Whisper Controller System Center The user supplies the battery tower inverter and wiring During windless periods solar panels may supplement your usage of renewable energy Solar PV photovoltaic panels make electricity directly from sunlight Batteries store electricity so you have power during windless and sunless periods as well as periods of high demand A deep cycle type of battery must be used If you have the wind generator only use this manual to help size the battery and inverter The Whisper Wind Turbine is whisper quiet hisses nverter From Grid SOUTHWEST WINDPOWER 11 22 2004 Whisper 200 Owners Manual Introduction Document 0212 REV B Overview of Wind Generator Whisper 200 Shown Blade Tail Fin Assembled Generator Blade Extender 44 Tail Stalk What you should have with your Whisper wind generator Assembled Generator Blades Nose Cone Tail Fin lt q
25. d Assembly Notes The correct Whisper 200voltage is set by altering the 12 stator wire and 3 brush wire connec tions The wire connections are made using appropriate size wire nut connectors To access the wire nuts remove the metal cover on the side of the Whisper turbine housing Re fer to the following Voltage Configuration Wiring Table for specific stator and brush wire con nections Observe the following notes when changing the voltage configuration The three brush wires are interchangeable and are not labeled The brush wires are easily identifiable as they are larger multi strand wires and stator wires are solid wire 8 awg compared to 20 awg Stator wires are numbered and color coded with a wire sleeve For example stator wire Red 3 has a red sleeve with the number 3 printed on it Wire Red has a red sleeve with no number The indicates there is no number There is a Red White and Black stator wire When changing the voltage configuration cut off the twisted ends of the wires stator wires only and strip off approximately 25mm 1 inch of insulation Important Note In addition to the PVC insulation the stator wires are also coated with varnish that MUST be removed to make a good connection The varnish can be removed by scraping with sharp edge or lightly sandpapering the wire Hold the stripped ends of the wires to be joined parallel to each other and twist together with pliers
26. d then power down quickly This kind of quick on off cycle can cause the microprocessor to latch up If it latches and the Red LED 18 unresponsive contact Southwest Windpower for instructions on resetting the microprocessor SOUTHWEST WINDPOWER 11 22 2004 13 Whisper 200 Owners Manual Installation Document 0212 REV B Whisper Controller Wiring Diagram WHISPER Controller Optional Anemometer NRG 40 Fuse Included Wire size for wiring to the battery 3 meters each way 12V system 1 0 gauge or larger E 24V system 2 gauge or larger 48V system 6 gauge or larger Battery Bank Dump Load Wiring Make sure the Controller 18 wired correctly for the volt age of your turbine 24v amp 36v 12 48 Diversion Switch lt looooooooooc O Flo o oO oO o jo o Mo Once startup is successful and the red LED can be cycled by toggling the Diversion Switch then set the switch to Stop Red LED on and connect the turbine wires to the controller order of the turbine wires is not important If the Red LED is on the turbine will not spin as long at least two of its wires are connected For further operational informa tion refer to Whisper Operation on page 16 Optional Anemometer Connection The Whisper Controller has been designed to accommodate a Mo
27. del 40 anemometer manufactured by NRG Other equivalent anemometers may work refer to manufacturers specifications Terminal blocks on the circuit board are the connection points for the two anemometer signal wires A ground shield 1f applicable may be connected to the control ler s grounding terminal Either wire from the anemometer may connect to either terminal on the terminal block For best results the anemometer should be mounted on the turbine tower as near as possible to the turbine without entering the turbine s sphere of operation See the manufacturer s recommended installation instructions SOUTHWEST WINDPOWER 11 22 2004 14 Whisper 200 Owners Manual Installation Document 0212 REV B Whisper Controller Components Whisper Controller Display Whisper Controller Electronic Cover Whisper Controller Resistive Loadbank Dumpload Di ion Switch and iversion Switch an LED s Far Side Whisper Controller Electronics Whisper Controller Regulation Potentiometer 19 DISPLAY INSTALLATION OPTIONAL The optional display was designed to be mounted either on the Whisper Controller base unit or in a wall type switch re ceptacle Hardware is provided with the display There is a short ethernet 5 cable provided for Controller base instal lation Local Display Installation If the display is to be mounted directly on the Whisper Controller you will need to remove the electronics cover and knock
28. egulation menu pages Energy Page 2 Displayed on the Energy page is the accumulated kilowatt and kiloamp hours since the last reset These can be reset from the reset sub menu The leftmost numbers are reset at the factory From the Energy page the A menu button will go to the History page The B menu button will go to the Energy Reset page History Page 3 Displayed on this page are the average and peak windspeed and turbine power since the last reset Windspeed is only available if the optional anemometer is installed Both of these readings can be reset via the reset menu From the History page the A menu button will go to the Main Display page The B menu button will go to the History Reset page SOUTHWEST WINDPOWER 11 22 2004 20 Whisper H 80 Manual Normal Operation Whisper Controller Document 0212 REV B Mode Page 4 This page displays the current charge mode When ON is displayed the batteries are being charged provided that ade quate windspeed is turning the turbine This mode allows the turbine to turn all of the time unless regulating battery volt age or disabled with the Diversion Switch or from this Mode page When OFF is displayed any power being produced by the turbine is diverted to dumpload by the controller The OFF mode will brake the turbine and prevent it from turning in light winds The Controller can switch to OFF Stop mode in any of the following three conditions OFF REM
29. expensive A tilt up design permits easy installation and maintenance on the ground and 1 Mounting eliminates the need for climbing Beckel Tower The Whisper Model 200 is suitable for side of building mounting on unoccupied buildings such as garage or 2 barn Some vibration transmission will be noticeable from mounts to structure Foundations must be designed and approved for local wind soil conditions Consult with a professional engineer to determine proper type and location of tower installation Side of Building Mount 2 PURCHASE BATTERIES OF PROPER SIZE See Table below for minimum battery size MINIMUM BATTERY SIZES ind Generator Model Whisper 200 Battery System Volts 12 24 36 48 Minimum Amp x Hours 20 hour rate Min kwh Volts x Amps x Hours 1000 SOUTHWEST WINDPOWER 1 1 22 2004 Whisper 200 Owners Manual Document 0212 REV B 1 3 SETTING TURBINE VOLTAGE Introduction The Whisper 200 Wind Generator must be configured for the correct system voltage 12 24 36 or 48 volts All Whisper Wind Generators are shipped from the factory configured for 24 volt operation unless specially ordered To check the voltage configuration or to change the configuration refer to the following notes and wiring table Your Whisper Dealer may also be of assistance configuring your Wind Gen erator to the voltage for your application if different from 24 volts Wiring an
30. ied on the last page of this man ual drill holes in the tower tube Check to see that the holes in the tower line up with the threaded holes in the insert Install insert on yaw shaft with slot facing down The slot is used for tower cable grip strain relief Use medium strength thread locking compound on all fasteners M6 X 20 Allen head set screws must engage both engagement holes in yaw shaft Solder or use split bolts to make electrical connections A good wire connection is crucial Any wind generator wire can go to any tower wire Wrap connections thoroughly with electrical tape to prevent shorts to tower Support wires to avoid weight on slip ring wires and wire connections Slide generator without propeller into tower and install mounting hard ware as shown Make sure the top flange of the tower insert is resting on the top end of the tower pipe Insert and torque all four insert mounting bolts M8 x 35mm to 10 11 ft Ib 12 14 N m repeating any tightening sequence used at least four times As an option the tower tube may be insulated with pipe insulation to prevent the wires from rattling Tower Insert Kit For 2 5 Schedule 40 Pipe 2 875 O D x 20Wall Tower Insert Support Wires by Attaching to the Tower Wires From Insert Turbine Tel N Solder or Tower 1 Split Bolt 22 Connector a Wires to Whisper Cable Grip Controller Wire Strain Relief System Description 1
31. itch ON b Shorted diode c Dead or disconnected battery d Short in wiring to turbine i Move switch to OFF i Contact distributor or factory i Insure battery voltage at Controller terminals 1s at least 10v 20v 32v or 44v depending on turbine model i See Table of Electrical Problems page 27 2 Doesn t regulate red light off and dumpload 18 cold a Battery volts below setting b Circuit Board bad 0 Adjust setting Check battery with voltmeter See page 17 Contact distributor or factory 0 3 Doesn t regulate red light on and dumpload 18 cold a Dumpload burned out or discon nected or wired wrong b Bad connection from Circuit Board to power block Contact distributor or factory 0 Contact distributor or factory 4 dumpload always on red light on a Wrong voltage setting b Circuit Board bad c Diversion switch set to Stop or disconnected 0 Adjust setting Check battery with voltmeter See page 17 Contact distributor or factory E SOUTHWEST WINDPOWER 11 22 2004 30 Whisper 80 Manual Troubleshooting and Repair Document 0212 REV B 16 MECHANICAL REPAIRS AND PARTS REPLACEMENT Warninc Do not attempt these repairs on top of the tower Perform repairs only after tower has been lowered BLADE UNMOUNTING Remove blade see Installation step 10 page 15 Disassemble reverse order Remove rotor
32. out the sheet metal insert where the display will mount There are pre drilled holes to mount the display Use the provided 8 32 x 3 8 black oxide stainless steel screws and 8 32 nuts with captive star washers to mount the display to the elec tronics cover Connect the display cable to the CATS jack located nearest the diversion switch This will indicate to the display that it 1s locally mounted and it will disable its LED features since these are redundant to those mounted on the Whisper Controller base Leave the cover off until the display function 18 verified Remote Display Installation The display may up to 300 meters 1000 ft from the Whisper Controller An appropriate length of Category 5 CATS cable will have to be purchased Install the display the desired location and connect the ethernet cable Remove the electronics cover on the Whisper Controller If necessary knock out one of the sheet metal plugs in the Whis per Controller base unit and route the ethernet cable inside the unit Plug the ethernet cable into the jack in the lower right corner of the controller board Leave the cover off until the display function 18 verified Display Function Verification Once the display is plugged into the controller base and the batteries are connected to the controller there should be text displayed on the LCD display If the display is blank there is a contrast adjusting potentiometer that can be adjusted to brighten the display Insert
33. pretation Off o charge is going to the batteries either the windspeed is too low or power is being di verted see Red LED On batteries are being charged 5 Setting Regulation Voltage without Display The battery voltage at which the controller begins regulating the battery 1 e diverting power to the dumpload can be ad justed by turning a potentiometer on the controller s circuit board The potentiometer is accessed by removing the Whis per Controller electronics cover When the controller measures a battery voltage above the regulation voltage for more than approximately one minute it begins diverting power If the controller measures a battery voltage below the Release Voltage for approximately one minute it will stop diverting power and start charging the battery again When replacing electronics enclosure cover do not over tighten screws The controller will automatically determine the proper nominal voltage Before you adjust the regulation setpoint understand that turning up the regulation voltage will not increase the turbine s output voltage or current This setpoint only adjusts the shut down voltage for battery charging Over charging will significantly reduce a battery s life expectancy Pot Position Regulation Off Voltage Regulation On Voltage Full Turn CCW 12 0V 24 0v 36 0 48 0v 13 0V 26 0v 39 0v 52 0v Turn CCW 13 0V 26 0v 39 0v 52 0v 14 0 28 0v 42 0v 56 0v Factory Preset 13 4V 26 8v 40 2v 53 6 14 4
34. s and adjust able operation parameters The main Whisper Controller block hereafter the Controller is a functionally autonomous unit The Controller contains all of the Whisper turbine s power electronics including rectification and load diversion Additionally it continuously monitors voltage current energy production and wind speed if equipped These parameters are measured to ascertain system parameters 1 e battery voltage and turbine state 1 e whether power is being generated The auxiliary Whisper Controller Display block hereafter the Display offers an interface to the many operational pa rameters and system measurements of which the Controller is capable It can be mounted at the Controller or in a remote location or with two Displays both places From the Display instant and easy access 18 gained to voltage current power energy charge peak power and wind speed Battery Turbine Whisper Controller with Display 2 Normal Operation Whisper Controller The Whisper Controller provides all of the necessary functions and displays for safe and productive turbine operation It includes interface features for setting the regulation voltage monitoring the state of the system and manually disabling bat tery charging The interface mechanisms of the Whisper Controller are the LED Display the Diversion Switch and the Regulation Adjustment 3 Diversion Switch The diversion switch is located on the top of
35. should be used for a remotely mounted display LCD Contrast Potentiometer The contrast potentiometer can be accessed through the cover of the Display unit via a hole situated between the but tons and the LEDs The pot is optimized at the factory for room temperature operation however deviations from room temperature can cause the LCD to appear too dark or too light Carefully insert a screwdriver through the dis play lid and turn the potentiometer counter clockwise to increase the darkness of the LCD Display Operation Overview The basic navigational structure of the display pages are rings with the structure shown in the figure on page 20 Each of the menu pages in this main ring structure is an access point for various controller and display settings The A and B Function buttons scroll between the menu pages or change parameters on the menu or sub pages The Ref erence Numbers in the following paragraph headings refer to menu pages shown in the table on page 19 Main Page 1 When first connected the Display begins with the Main Page The Main Page displays all of the Controller s meas ured parameters including battery charging status windspeed charging voltage battery charge current and turbine power There are four sub pages associated with this page From the Main Display the A Function button moves through the Energy and History menu pages From the Main Display the B Function button moves through the Mode and R
36. the controller to the left of the LEDs This switch will divert turbine power to the dumpload to keep the batteries from being charged While this switch does not necessarily stop a spinning turbine once the turbine has stopped this switch will keep it from spinning Therefore it should be noted that in most situations this switch can be used as a stop switch however spinning blades with an activated diversion switch is a normal and safe operational state SOUTHWEST WINDPOWER 11 22 2004 18 Whisper H 80 Manual Normal Operation Whisper Controller Document 0212 REV B Whisper Controller Electronic Cover Whisper Controller Display Whisper Controller Resistive Loadbank Dumpload Diversion Switch and LED s Far Side Whisper Controller Electronics Whisper Controller Regulation Potentiometer 4 LED Operation In short the Red LED indicates that turbine power is being diverted to the dumpload and the Green LED indicates that the turbine 1s spinning and the battery is being charged The LED operation 18 detailed in the tables below Red LED operation description State Interpretation Off n Off Available turbine power directed to battery Blinking Available turbine power directed to dumpload for battery regulation Available turbine power directed to dumpload by operator request via either Diversion Switch or remote Display Green LED operation description State Inter
37. volt age setting lower than the Regulation On voltage and will then roll back to 12 0v Pressing the A menu button will re turn back to the Regulation Set page Pressing the B menu button from this page will return to the Main Display page Clearly the Regulation Off voltage cannot be specified above the Regulation On voltage Menu Functions Page Display u Main On or Off 00 0mph go to A ring 11 3V 00 0A 000W a go to B ring go to reset menu B returntoresetmenu Mu NEN NU _ pow 00 0a 00 0p Reset Menu Reset Page A RESET B CANCEL A reset readings lee B TT A OFF REM B go to regulation set menu See diverted A ON REM B SKIP gt go to regulation set menu 5 Regulation REGULATION SET change regulation point Set A CHANGE B SKIP 8 return to Main Menu Regulation Regulation ON voltage go to regulation off menu ncrease ON set voltage Regulation Regulation OFF voltage regulation set menu Off 12 8V Increase OFF set voltage SOUTHWEST WINDPOWER 11 22 2004 21 Whisper 200 Operators Manual Normal Operation Whisper Controller Document 0212 REV B N LLL 4 fu EUN e ju 1 NL g 8 Main E Displav mi AT A Charge NCC d EUN Regulation Regulation Off On s A m m NL N EF Increase Increase Set Point Set Point U
38. y arrangement shown 12 Volt Configuration Whisper Controller Inverter Inverter Whisper Whisper Controller Inverter Controller SOUTHWEST WINDPOWER 1 1 22 2004 Whisper 200 Owners Manual Installation Document 0212 REV B 1 5 WIND GENERATOR ELECTRICAL TESTS SHORT CIRCUIT TEST Complete these tests before mounting blades to rotor These tests confirm that the wind generator was not damaged in shipment and 16 ready to install on the tower GROUND TEST OPEN CIRCUIT TEST When the wires Check resistance ate incon to ground on any nected the wind wire Resistance generator rotor must exceed should spin 10 000 ohms freely When all the wires horted toseth When two wires are ni shorted together the 5 generator rotor generator rotor should turn hard and as though there are smooth smooth and bumpy portions of the rotor PHASE TO PHASE TEST SOUTHWEST WINDPOWER 11 22 2004 11 Whisper 200 Owners Manual Installation Document 0212 REV B 6 CONNECT WIRES AND MOUNT WIND GENERATOR TO TOWER Mounting Instructions Check fit of insert by placing it inside the tower A maximum of 1 5 mm 1 16 in play is allowed You must be able to pull pipe or tube tight against insert with mounting bolts Next using the template suppl
39. y y y N AEN Display Menu Ring Structure SOUTHWEST WINDPOWER 1 1 22 2004 22 Whisper H 80 Manual Maintenance Document 0212 REV B 13 MAINTENANCE MONTHLY Whisper Controller 1 TEST BRAKE This checks electrical wiring STOP THE WIND GENERATOR IN A MODERATE WIND CHARGING BUT NOT FURLING No unusual difficulty or noise should be experienced in stopping the propeller A noise during braking can indicate a disconnected wire 2 CHECK MECHANICAL CONDITION WATCH AND LISTEN FROM THE TOWER BASE Use binoculars There should be no mechanical noise rattle or vibration The propeller and tail must not wobble Lower or climb the tower for inspection if indicated There should be no buzzing either heard or felt with your hand on the tower mast Go to Electrical Problems if indicated 3 INSPECT THE TOWER Follow all inspection and maintenance requirements of the tower manufacturer Tighten all nuts and bolts especially wire clips Check for cracks and bent or broken parts at the anchors and base structure Check for broken strands and tighten guys 4 CHECK THE BATTERY Add only distilled water if needed Consult your battery manufacturer guide Tighten battery connections Remove corrosion and protect terminals Wipe tops with baking soda solution SOUTHWEST WINDPOWER 11 22 2004 Whisper 200 Operators Manual 14 MAINTENANCE ANNUAL
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