the Gaia-Wind Turbine Installation and user manual pdf
Contents
1. Figure 3 1 Main Components o 1 Blade Tip c 2 Rotor Blade O 3 Nacelle 0 4 Anemometer 5 Working Basket 1 6 Hub Fork i x 7 Cable Guide sii ai 8 Tower Lattice S Hi 9 Ladder Lt 9 10 Cable Twist Sensor D EE 11 Controller LES 29 11 12 Foundation 3 2 Nacelle The nacelle of the turbine refers to the housing that contains all of the drive train and machinery necessary for the conversion of the incoming wind to electrical energy The principle components included within the nacelle are the main bearing shaft gearbox brake sensor equipment and the generator Figure 3 1 shows schematically the location of these components within the nacelle Figure 3 2 Nacelle Components Rotor Blade Hub fork Main Bearing Main shaft Vibration Sensor Gearbox Brake Disc Flexible Coupling Generator 0 Generator RPM Sensor Anemometer 12 Brake Sensor 13 Mechanical Brake 14 Rotor RPM Sensor 15 Retaining Magnet DISS SHOES 16 Spindle motor SIGSO 3 2 Generator The Gaia wind turbine uses a 3 phase 11 kW induction generator This generator is renowned for its robustness and reliability and is particularly well suited for utility grid connection 3 3 Braking System The brake is the active part of the turbine protection system The Gaia Wind turbine employs two independent braking procedures 3 3 1 Mechanical Brake2. 1 1 1 1 1 1 im AJ r OWA In TIIR Ni j JU PF OWN Vis FUSES ING USER MANUAL Gaia Wind 11 kW Turbine 1 1 a1 x 4 Your own Wind Turbine Copyright 2008 Gaia Wind Ltd 1 Ainslie Road Hillington Park Glasgow G52 4RU United Kingdom Tel 44 0 845 871 4242 E mail gaia wind com Document Reference number GW UK 18 0808 User Manual Document revised August 2008 All illustrations and photographs Copyright Gaia Wind Ltd No part of this manual may be transmitted into any form by any means wihtout permission from Gaia Wind Ltd The information given in this user manual is believed to be accurate and reliable at time of printing However Gaia Wind Ltd Accepts no liability for the details contained herein All specifications are subject to change without prior notice Table of Contents HEALTH AND SAFETY INFORMATION 1 INTRODUCTION 1 1 WELCOME NOTE 1 2 INTRODUCTION TO THE TURBINE 1 3 TURBINE SPECIFICATIONS 1 4 THREE LEVEL SAFETY FEATURES 1 5 Low NOISE DESIGN 1 6 ACCREDITATIONS 2 INSTALLING YOUR GAIA WIND TURBINE 2 1 PRE INSTALLATION INSTRUCTIONS 2 2 THE INSTALLATION DAY 3 TURBINE COMPONENTS 3 1 COMPLETE TURBINE 3 2 NACELLE 3 2 GENERATOR 3 3 BRAKING SYSTEM 3 3 1 MECHANICAL BRAKE 3 3 2 TiP BRAKES 3 4 ANEMOMETER 3 5 TOWER 3 6 ROTOR BLADES 4 CONTROLLER AND OPERATING PANEL
3. 4 1 INTRODUCTION 4 2 OPERATING PANEL 5 TURBINE OPERATION 5 1 INTRODUCTION 5 2 START MENU 5 2 1 OVERVIEW 5 2 2 ACCESS RIGHTS AND ACTIVE STATUS 5 3 ERROR MENU 5 3 1 OVERVIEW 18 18 19 26 26 26 27 28 28 29 30 31 32 34 34 36 40 40 40 40 42 46 46 5 3 2 ACCESSING THE ERROR MENU 47 5 3 3 ERROR TYPES 48 5 3 4 RESETTING OF ERRORS 50 5 4 STATUS MENU 52 5 4 1 OVERVIEW 52 5 4 2 SYSTEM SUBMENUS 54 5 4 3 SYSTEM PRODUCTION 55 5 4 4 WIND SUBMENU 57 5 4 5 RPM SUBMENU 57 6 OPERATING PROCEDURES 60 6 1 AUTO START 60 6 2 AUTOMATIC SHUTDOWN 60 6 2 1 Max WIND 60 6 2 2 ROTOR OvER SPEED 61 6 2 3 GENERATOR OVER SPEED 61 6 2 4 MINIMUM POWER 62 6 2 5 VIBRATIONS 62 6 2 5 CABLE TWIST 62 6 3 MANUAL AND EMERGENCY STOP 63 6 4 BRAKING PROCEDURE 64 7 SERVICING AND MAINTENANCE 68 7 1 USER MAINTENANCE 68 7 1 1 RESETTING ERRORS 68 7 1 2 VISUAL INSPECTIONS 68 7 2 SERVICING INTERVALS 69 7 2 1 THREE MONTH SERVICE 69 7 2 1 ANNUAL SERVICE 69 7 3 REPLACEMENT PARTS 70 8 FREQUENTLY ASKED QUESTIONS 71 INDEX 73 ANNEX 1 GLOSSARY OF TERMS 75 ANNEX 2 TECHNICAL DATA 78 ANNEX 3 ERROR MESSAGES 80 Health and Safety Information Gaia Wind Ltd strongly recommends that all servicing amp maintenance procedures other than cursory visual inspection be carried out by adequately trained and experienced personnel Personnel deemed to be adequately qualified will e specifically trained to
4. Active statuscodes on the operating panel Manual stop screen It shows all active status codes Step4 Scroll onto the error and press enter to gain more information on the error This will detail the date and time at which the error occurred Step5 Revert back to the start Escape menu by pressing escape 5 3 3 Error Types A Status Code is an error code which becomes active when a particular error occurs or if the controller detects that a certain parameter has been exceeded For example if the grid voltage is too high if there is a loss of mains supply or if the rotor or generator speeds are excessive For each status code a set of parameters determines the consequences of the code activation error which can include stopping the turbine re setting the error after a delay etc Each status code will be dealt with depending on its assigned re set level To obtain information about a given status code place the cursor at the code and press ENTER There are three error re set levels Auto Manual and Remote classified as follows Auto A The active status code is automatically reset by the controller of the turbine when the conditions for resetting are present in other words when the original reason for its activation has stabilised and is no longer present Alternatively the status code may be reset manually or by remote control by users with a password level higher than that indicated in the stat
5. The mechanical brake is located along the turbine drive train on the high speed shaft just where it emerges from the gearbox This brake operates in a similar manner to that of a disc brake on a car a caliper pushes brake pads onto a steel disc that rotates with the turbine shaft The main elements of this system the caliper brake disc and retaining magnet can Figure 3 3 Gaia Wind Mechanical Brake be seen in figures 3 2 above and 3 3 right The turbine s automatic controller has accurately set time limits for braking procedures and in all normal situations the mechanical brake will stop the turbine quickly However under extreme circumstances it is possible that the turbine fails to stop which may occur for example in the event of excessive wear on the pads If this event should occur the turbine tip brakes will perform the braking of the turbine see section 3 2 2 below 3 3 2 Tip Brakes Your own ELECTRICITY In the event that the mechanical brake should fail to stop the turbine within sufficient time the tip brakes will deploy These are centripetally activated aerodynamic brakes concealed in the blades In this instance the blade tips rotate through 90 degrees spoiling the rotor s aerodynamic properties and subsequently causing the rotor to stop In the unlikely event that Figure 3 4 Deployed Tip Brake either of the tip brakes deploy you should contact Gaia Wind or your ac
6. Turbine Operation SA QW 39 5 Turbine Operation 5 1 Introduction This section will explain how to navigate the menus of the operating panel and monitor the data relating to the performance of the turbine This is achieved using the operating panel functions outlined in section 4 2 5 2 Start Menu 5 2 1 Overview The most convenient menu is the start menu This menu shows real time and time averaged information and displays the current status of the turbine The status will show whether there is an error with the turbine or whether it is running free of errors see Figure 5 1 below Note that the backlight of the screen illuminates when any key is pressed making the screen easier to read especially in low light or at night The backlight will switch off when the keypad has not been pressed for a short period Gl 249v 11 5kw 251 9 5m s 57 1021RPM RUNNING GI status Status ERROR Accessrights 30 Accessrights 30 Request Active stat Request Active stat Figure 5 1 Start Menu Running Left Braked Right First Line B The brake is engaged Indicates that the generator is cut in connected to G1 the grid 249 V Grid voltage average per phase 11 5 kW Average power output over 30 seconds Second Line 9 5 m s Average wind speed over 30 seconds 57 1021 rpm Rotor Generator speeds Third Line The third line indicates the most rec
7. and generator Is it necessary that a turbine The turbine should not be damaged inspection is undertaken after by such an event Even so a brief subjection to severe wind inspection of the exterior is conditions over 25 m s encouraged See section 7 1 Why is it that cannot use the control menus in order to observe my turbine performance ik Active status has not been granted see section 5 2 1 for instructions The necessary level of access rights has not been attained see section 5 2 1 for details Somebody with higher access rights has active status of the turbine possibly remotely through a modem Index Access Rights 37 38 47 65 IC 1000 50 Active Status 37 38 40 47 65 Installation 18 Anemometer 67 Assembly 21 Auto start o4 Foundations 19 Brake 26 28 36 58 Foundations 18 Mechanical 26 Pre Installation 17 Tip 27 58 Keypad 32 Controller 31 32 Maintenance 61 Cut In 68 7O Intervals 62 Cut In Speed 11 Replacement Parts 63 Cut Out Speed 12 Max Wind 54 Delivery 20 Nacelle 25 69 Distribution Network Operator Noise 14 68 Planning consent 17 Downwind 10 68 Power curve 10 Error Power output 37 Menu 41 Rated Speed 11 Resetting 45 Resetting Error See Errors Type 44 Rotor 69 Error Messages 72 Blades 29 Errors RPM Submenu See Status Resetting 61 Menu Foundation 17 oafety 13 Free Yaw 10 Servicing See Maintenance Freewheeling 68 oite access 17 Frequently Asked Questions 64 otatus 37 Generator 36
8. continues to rotate Horizontal Axis Wind Turbine Induction Motor Kilowatt Hour kWh Leading Edge A mechanical system used to match the slow rotational speed of the rotor to the high rotational speed of the generator This is a standard in wind turbine design The shaft is parallel to the ground and the rotor area is perpendicular to the ground The centre of the rotor of the wind turbine The purpose of the hub is to hold the blades in place and attached to the turbine shaft An AC motor in which the rotating part has no windings and brushes on it The kilo watt hour is the standard unit for measuring electric energy in the UK 1 kWh is equivalent to the energy consumed by a 1 kW device operating for 1 hour Note that this is equivalent to a 3 kW device operating for 20 minutes The edge of the blade that faces towards the direction of rotation Housing that contains all of the components necessary for the conversion of wind energy to electrical energy The important components include the bearings shafts gear box brake and generator The name given to the assembly of the blade and hub in a wind turbine Revolutions Per Minute This is the number of times a shaft completes one full revolution during one minute The purpose of the main shaft is to transfer the power from the rotor to the gearbox This is the wind speed at which the turbine rotor will commence rotating This does not mean that the
9. of 18 m s over a period of 10 minutes The mechanical brake is also activated in case of a fault in the electrical grid excessive vibrations or over speeding of the rotor or generator Tertiary Level Passive In the extremely unlikely event that neither the base nor secondary level safety mechanisms stop the turbine centripetally activated aerodynamic brakes concealed in the rotor tip are released The effect of this is to spoil the aerodynamic lift of the rotor and hence stop it rotating In addition there exists an emergency stop function on the turbine controller At any time the user can override of the turbine control system and stop the turbine More details can be found in section 6 of this manual 1 5 Low Noise Design As with all rotating machinery noise will be produced and minimising this effect is a key objective for Gaia Wind s engineers The principal source of noise originates from the turbine blades and this aerodynamic noise increases exponentially with the rotational speed of the blades The constant and low rotational speed of the Gaia Wind turbine makes it among the quietest in its class In practice the turbine noise is often masked by background noises such as wind or traffic The table below provides indicative noise levels at various distances from the base of the turbine The data is derived from independent measurements on several Gaia Wind turbines Noise Level dB A Comparator
10. servicing company above 8 RPM Rotor speed is below 2 Reset error If error persists then 302 R see SEN 50 Os contact Gaia wind or your turbine defect generator speed is greater then 600 RPM R The rotor speed otor 311 overspeed exceeds the maximum 50 Os rotor speed 62 RPM The generator speed 312 G overspeed exceeds the maximum M 50 Os generator speed The rotor speed exceeds the maximum servicing company Contact Gaia Wind or your turbine servicing company Contact Gaia Wind or your turbine servicing company rotor speed 62 RPM Reset error If error persists then 314 USES 9 before the generator M 50 Os contact Gaia wind or your turbine has cut in Most servicing company commonly the result of a large gust of wind Warning that the brake 415 Bue pee pads are worn out and M 50 0s Contact es udine NE worn turbine servicing company should be replaced The brake pads worn Replace brake Contact Gaia Wind or your 416 pads aud has occurred four M 50 0s turbine servicing company Reset error If error persists then 421 a d d 12 82 50 0s contact Gaia wind or your turbine servicing company The turbine braking 434 B200 brake procedure took longer M 50 0s Contact Gaia Wind or your local time gt max servicing company than 10 seconds Powar The turbine consumes Reset error If error persists then 501 more than limit of 5 KW 50 0s contact Gaia wind or your turbine consum
11. turbine will produce any electrical output which will occur at the Cut In speed Tip The end of a turbine blade furthest away from the hub Torque The measure of turning force Tower The structure that supports the rotor and nacelle Wind Turbine A device that transfers the kinetic energy from the wind to an electrical power output Yawing Yawing is the rotation of the nacelle around the tower Annex 2 Technical Data Type Gaia Wind 11kW Hub Height 18 3 Yaw System Free Yaw Cut In Wind Speed 3 5 m s Rated Wind Speed 9 5 m s Cut out Wind Speed 25 m s Rated Power 11 kW Nacelle Weight 900 kg Operating Temperature 20 gt 50 deg C Diameter 13 0 Blade Material Glass Fibre Reinforced Polyester GRP Nominal Speed 56 rpm Weight 200 kg Power Regulation Stall Regulated Air Brake Tip brakes centripetal activation Generator 3 phase induction generator 400 V 50Hz Type Marine Grade Nominal Power 11 kW Weight 138 kg Transmission Ratio 1 18 Lubrication Centrifugal Weight 143 kg Mechanical Brake System Caliper Brake Disc Location High Speed Shaft Height 18 0 Lattice Tower 1600 kg Tubular Tower 2200 kg Weight Annex 3 Error Message Status Codes Error Reset Types A denotes Auto M denotes Manual amp R denotes Remote Status Error Error Required Reset Eque Messaae Description Reset password Type level errors Turbine Sy
12. 7 Turbine Towers Lattice Left and Tubular Right Aside from the issue of cost the other main difference between the two tower types is aesthetics Both the tubular and lattice tower are designed to cause minimal visual intrusion on the landscape The sleek tubular tower compliments modern structures and when viewed at a distance the open structure of the lattice tower causes the outline to fade 3 6 Rotor Blades The rotor blades are constructed of the composite material GRP Glass Reinforced Polyester commonly referred to as fibreglass There are many advantages for the use of GRP for this purpose principally a good strength to weight ratio and resistance to degradation from environmental factors C aede r v 15 6 4 3 om be E ocn T 18 Ni Y v 6 4 2 cr 3 n 109 3 E ari en 5 ero LAE u g E u ce m 1 5 o E OX i 1 gt E 157 2 F j 3 x N SSS NS E E P4 a gt g 4 r 3 4 Controller and Operating Panel 4 1 Introduction This section gives a brief overview of the Gaia Wind 11 kW Wind turbine controller and operating panel The controller is essential for ensuring the efficient and safe operation of the turbine All procedures are controlled
13. Conversational Speech a Car at 100 m Driving at 40 mph At60 m 45 Living Room Over 100 m 40 Rural Night Time Background 1 6 Accreditations The Gaia Wind 11 kW turbine has received the UK Clear Skies accreditation accreditation number WT5038 This denotes that the turbine is eligible for all grant schemes for small wind turbines The Gaia Wind 11 kW turbine has been approved under the official HB standards of the Danish Government Gaia Wind is the only manufacturer of small wind turbines ever to achieve this approval eur ET Le lt T 5 v4 Me di E pe pattes RE a N your aia Wind Turbine 2 Installing Your Gaia Wind Turbine 2 1 Pre Installation Instructions ouitable locations for your turbine will have been discussed with a Gaia Wind representative prior to installation The final location will take into account the local topography and proximity to obstacles such as trees roads and nearby buildings Prior to the installation of your turbine it is necessary to obtain planning consent from the relevant authorities Customers can apply for planning directly or use a consultant to apply on their behalf In each case Gaia Wind will provide support If any planning restrictions are most commonly imposed on the basis of anticipated noise emission and visual impact on the landscape At the time of signing the contract with Gaia Wind you will be provided with a list of require
14. Rated Speed Cut Out Speed X O Power kW O N A 0 2 4 06 8 10 12 14 16 18 20 22 24 26 Wind Speed m s With its large rotor diameter an attribute of the Gaia Wind turbine is high performance in moderate wind speeds The key points of the power curve are outlined in the table below Rated Speed The wind speed at which the rated power 9 5 m s 11kW is reached Cut Out Speed The maximum wind speed at which the turbine is permitted to deliver power The operating range of a turbine is limited due 25 0 m s to engineering design and safety constraints The cut out speed for the turbine is 25 m s although wind speeds this high are rare Turbine Specifications See Annex 2 Technical Data 1 4 Three Level Safety Features Safety features are a vitally important aspect of any turbine design The Gaia Wind turbine has a number of safety features that ensure that rotor speed and power generation are kept under control There are three distinct levels of protection Base Level Passive The design of the blades introduces a gradual Stalling effect as wind speeds rise above 9 m s which limit power output from the turbine Secondary Level Controller Initiated Active At wind speeds above 25 m s the turbine controller automatically activates the mechanical brake This stops the turbine running The brake is automatically released when the wind speed drops below an average
15. ation 4 Commissioning It may be more economic for the customer to arrange a contract for foundation works independently However there are strict requirements and guidelines relating to the foundations that must be considered during construction The foundation specifications must be obtained from Gaia Wind and followed strictly Step 1 Foundations The Gaia Wind turbine foundation has a footprint of approximately 5 meters square The foundation is composed of multiple layers of steel reinforcement mesh bound together with braces to form a steel frame that will form the base of the tower The metalwork is placed inside the excavated hole and levelled before being filled with concrete Foundation preparations required to be completed a minimum of 10 days in advance of the installation date This is to ensure adequate curing of the concrete Also the controller stand will be cast in the concrete during the foundation work On the installation day the controller will be mounted on this stand Gaia Wind maintain the right to refuse installation of the turbine on the grounds of safety if it has been determined that the foundation or electrical preparation work is unsatisfactory or when proper and safe site access has not been provided Step 2 Delivery and Unloading The Gaia Wind turbine is delivered on a single lorry The delivery will consist of e Multi part tower both lattice an
16. automatically based upon signals from various sensors throughout the turbine User intervention is only required when errors have occurred To open the controller cabinet use the supplied key inserting into the 2 keyholes at the top and bottom of the left hand side of the cabinet door Push in firmly and turn clock wise to release the latch on each The door should then easily swing open Figure 4 1 Controller Cabinet e DO NOT open the control cabinet door in wet conditions e There are no user serviceable parts inside the cabinet e Customers should only touch operating panel keypad see Section 4 2 e DO NOT place any metal objects in or near cabinet e If you see any sign of water in the cabinet isolate the controller and do not operate Contact Gaia Wind or your accredited Gaia Wind installer Operating Panel Computer keypad Contactors amp Automatic mrn 2 Fuses Current and Voltage Measurement Soft Starter Capacitor Bank _ Figure 4 1 Turbine Controller Cabinet All of the turbine s necessary electrical switchgear fuses contactors and connectors are housed in a weatherproof unit located at the foot of the tower The interior of the controller cabinet can be seen in figure 4 1 The controller also allows for the monitoring of the turbine performance Instantaneous and time averaged readings relating to energy production wind speed and power output can be accessed t
17. credited Gaia Wind installer in order to arrange for the tip brake to be safely reset Since this involves climbing the tower and working at height using special apparatus this task should be Figure 3 5 Re setting Tip Brakes undertaken only by personnel with the appropriate training and safety equipment Contact Gaia Wind or your accredited Gaia Wind installer in order to arrange for the tip brake to be safely reset DO NOT attempt to perform this task yourself as it requires specialist training and apparatus 3 4 Anemometer An anemometer is located on the upwind side of the nacelle The purpose of this device is to measure the wind speed at the turbine hub height The wind speed measurements recorded by the anemometer are used by Figure 3 6 Anemometer the controller to monitor and control the turbine mainly during start up and shot down 3 5 Tower There are two tower types available for the Gaia Wind 11 kW Turbine traditional lattice and tubular The traditional lattice tower is composed of welded galvanised steel profiles and is mounted on 4 legs that are embedded in the concrete foundation The principal advantage of this design is less material and hence reduced cost The tower can also be supplied as a tubular structure This tower is conically shaped increasing in diameter towards the base This increases structural integrity and makes an elegant presentation Figure 3
18. ctive errors N B if no Scroll down information can be seen then there are no active errors Scroll up Navigate through the error list using the cursor arrows If any errors re appear after resetting exercise caution before resetting the turbine again If the error persists then please contact Gaia Wind Step 4 In the error menu press the reset button on the keypad The error messages will be erased If the messages are not erased then the error has not been corrected Step 5 Press the escape button to return to the main menu zus Step 6 The turbine will start automatically within 60 seconds subject to sufficient wind Alternatively the turbine can STAR Start be started immediately by pressing the start button Step 7 Release access rights and See section 5 2 1 active status if finished operating the turbine 5 4 Status Menu 5 4 1 Overview The status menu provides a useful System tool for viewing data relating to a Generator Gl win range of performance characteristics Heating system RPM such as production data The data Temperatures Oper timers can be reviewed over a range of Communication Inputs Qutputs time frames including daily monthly and yearly Figure 5 4 Status Menu The submenus of the status menu are shown in figure 5 4 The submenus are accessed by pressing enter on the keypad when the cursor is on the relevant menu lin
19. d tubular towers arrive in several sections to be assembled in situ e Ladder and Working Basket e Turbine blade and hub e Pre assembled and tested nacelle e Pallet of loose items fasteners and fittings e Controller All the above items are carefully offloaded from the truck with a crane by the Installation Team Step 3 Assembly The tower sections are assembled The nacelle is mounted onto the top section of the tower Ladder sections and working basket are fixed onto the tower The rotor assembly is mounted onto the main shaft Step 4 Raising the Turbine The turbine is raised by the crane Once vertical the tower is securely fixed to the foundation steelwork The tower will be carefully levelled to ensure it is in an exactly vertical on position Mae Step 5 Commissioning amp Starting the Turbine Once fully erected and fastened to the foundation the turbine commissioning procedure takes place Upon completion of all commissioning checks the turbine can be started and your turbine will begin to generate your own electricity Turbine Compon nt 3 Turbine Components 3 1 Turbine The diagram below shows the Gaia Wind 11kW Turbine indicating the location of the principal components Please note that although the diagram shows a lattice tower the drawing is also consistent for the tubular tower
20. defect 50 50 50 50 50 50 Os Os 30s 10s Os Os Os Reset error If error persists then contact Gaia wind or your turbine servicing company Automatic reset when thyristor block temperature Clr stat 609 No Action required Automatic reset when the turbine is not moving rpm 0 Contact Gaia Wind or your servicing company Reset error If error persists then contact Gaia wind or your turbine servicing company Contact Gaia Wind or your servicing company WWW gaia wind com Gaia Wind YOUR OWN WIND TURBINE Gaia Wind Ltd 1 Ainslie Road Hillington Park Glasgow G52 4RU Tel 44 0 845 871 4242 E mail gaia wind com Gaia Wind document reference GW UK 18 0808 User Manual
21. e Accessing the Status Menu Step 1 Step 2 Step 3 Ensure that the Start Menu is displayed on the keypad If you have not done so obtain Access Rights and Active Status before continuing See section 5 2 1 for details Toggle through the menus using the cursor directions buttons until the heading displays Status The Status menu is displayed on the keypad screen Revert back to the start menu by toggling left or right Gl 249v 11 5kw 9 5m s 57 1021RPM RUNNING Gl Status OK Accessrights 50 Release Active stat Toggle Left Toggle Right System Generator Gl Capacitors wind Heating system Temperatures Oper timers Communi cation Inputs Outputs 5 4 2 System Submenus To access the system Production consumpt House consumption Elements consumption Operate timer count submenu press enter on the first line of the Status Stop timer counter 4 t1 mer counter menu oystem 4 The result IC1000 OK tim coun Grid OK tim counter will generate the display wind OK tim counter shown in figure 5 5 left Figure 5 5 System Submenu The information below describes the data contained in each of the menu lines System Submenu Lines Production and Production of the turbine The total Consumption kilowatt hours produced by the turbine will be counted and recorded Pressing enter once again on this line enables data to be viewed fro
22. ence greatest electrical energy production 6 2 Automatic Shutdown 6 2 1 Max Wind The turbine will shutdown automatically when the wind speed registered by the anemometer is too high This is important to protect components such as the generator and gearbox 6 2 2 Rotor Over Speed Rotor over speed is when the rotor speed is greater than the rated speed For the Gaia Wind turbine the rated rotor speed is nominally 56 rpm but can vary between 55 and 57 There are two defining conditions of rotor over speed e At 10 above the rated rotor speed 62 RPM the mechanical brake is activated e At 15 above the rated rotor speed 65 RPM the aerodynamic tip brakes are activated Following shutdown due to rotor overspeed the tip brakes may need to be reset You should contact Gaia Wind or a Gaia Wind accredited servicing company Generator overspeed is when the generator rpm sensor detects speed greater than 1116 rpm 6 2 3 Generator Over Charge The turbine brake is activated if the recorded power output of the generator is large This is referred to as over charge and is necessary to protect the generator from damage The conditions are e An average power output of 15 kW averaged over a 10 minute period e The generator power exceeds 18 kW 6 2 4 Minimum Power If the turbine power output is less than 0 1kW over a period of one minute the generator will cut out i e it will stop producing Under th
23. ent event registered by the turbine In the example above this is the cut in of the generator left and stopping of the turbine right Fourth Line This shows the status of the turbine The display in figure 5 1 left indicates that the system is OK i e there are no errors in the turbine Alternative status messages that may appear in this line include Error and Warning see figure 5 1 right Further information regarding errors is included in section 5 3 of this document Fifth amp Sixth Lines The fifth and sixth lines indicate the level of access rights and active status request Access rights and active status must be attained in order to use the operating panel Normal Users will have access level 50 If access rights and active status are not obtained only the start menu will be visible and navigation to other menus prohibited See the section 5 2 1 on access rights and active status for further details 5 2 2 Access Rights and Active Status The Start Menu displays the lines Access Rights and Request Active Status Permission to use the operating panel can only be acquired if the access rights and active status are obtained The following steps should be followed in order to attain access rights and active status Acquiring Access Rights amp Active Status Step 1 Step 2 Step 3 Ensure that the operating panel is displaying the Start Menu Scroll down to
24. ere the primary goal is to reduce the amount of electricity imported rather than generate specifically for export to the grid The turbine has been developed according to Danish design the design basis for most of the large commercial turbines used today Like its bigger relatives it has a slow rotation speed which is independent of the wind speed It also incorporates many of the control and safety features from the large turbines The Gaia Wind turbine is configured to give an optimal yield in moderate wind speed sites i e those with an annual average wind speed in the range of 4 5 7 5 m s As such it complements the wind conditions found in many rural areas of mainland Britain Components used in a Gaia Wind turbine have been carefully selected for their quality reliability and low maintenance The outstanding electricity production in moderate wind speeds typically 30 000 kWh per year is due to the large rotor With a 13 metre rotor diameter the Gaia Wind 11 kW sweeps an area of 133 square metres which is more than double that of most competing machines 1 3 Turbine Specifications The power output of a wind turbine varies with the wind speed This is represented by a turbine power curve Figure 1 1 below represents the power curve for the 50Hz version of the Gaia Wind 11kW turbine This curve provides a good indication of what the electrical power output of the turbine will be over a range of wind speeds Cut In Speed
25. ese circumstances the rotor will continue to rotate without producing electrical energy freewheeling This will continue until favourable conditions for generation are regained 6 2 5 Vibrations A vibration sensor is situated inside the nacelle If the sensor records excessive vibrations the controller will engage the brake to stop the turbine Excessive vibrations are displayed as an error message on the operating panel 6 2 5 Cable Twist The turbine extracts the maximum energy possible from the wind by automatically seeking its direction This is known as free yaw consequence of this free yaw design is that the cables that extend Figure 6 1 Cable Twist Arm and Sensor down the tower can twist in either direction The turbine is equipped with a cable twist sensor and the controller will stop the turbine if a cable twist becomes excessive The cables must be untwisted manually and this should be done by an accredited service engineer 6 3 Manual and Emergency Stop The information above details the conditions by which the turbine will stop automatically However it is also possible to manually stop the turbine This is simply achieved by pressing the Stop button on the Figure 6 2 Stop Button operating panel Subsequent to pressing the Stop button a manual stop error message will appear on the operating panel display This error must be reset to restart the turbine see resettin
26. g wind speed below 2 m s with turbine output power over 1 kW The wind sped is too low and freewheeling is disabled The recorded wind speed averages 20 m s over a 10 minute period or the wind speed is higher than 25 m s 50 50 50 50 50 50 50 50 50 50 50 50 50 50 0s 0s 0s 3m 10s 3m 3m 3m 3m 10s 0s 0s 1m 0s 600s No Action required No Action required Contact Gaia Wind or your turbine servicing company Error will be reset when the voltage is detected Automatic reset when phase angle is smaller than 3 The error will be reset when the grid voltage is OK The error will be reset when the grid voltage is OK The error will be reset when the grid frequency is OK The error will be reset when the grid frequency is OK The error will be reset when the phase angles are OK Contact Gaia Wind or your turbine servicing company Contact Gaia Wind or your turbine servicing company The error will be reset automatically when the wind speed recorded over 30 seconds averages the start wind speed 3 m s No Action required The error will be automatically reset when the wind speed is below an average of 18 m s over a 10 minutes period Status Error Description Error 50 Code Message p Type The generator speed is Reset error If error persists then 300 TUE one 50 0 contact Gaia wind or your turbine
27. g errors in section 5 3 4 Please note that it is not necessary to gain active status to stop the turbine this way Immediately upon pressing stop the mechanical break is activated and the rotor speed will decrease until stationary In the interest of safety the turbine can be stopped immediately by pressing the emergency stop button on the exterior of the controller figure 6 3 When the emergency stop button is pressed it will physically lock in the stopped position The button should be released by giving it a slight counter clockwise rotation and the button will pop out Emergency Stop Figure 6 3 Emergency Stop Button 6 4 Braking Procedure The results of a completed braking procedure are a stationary rotor and generator The brake pads are designated as wearing parts Over time the pads will require replacement In the event of excessive wear on the brake pads an error will be registered by the turbine controller After the brake brings the turbine to a stop the controller will automatically attempt to align the turbine blades horizontally This is known as blade parking and ensures that the blades are placed in the optimal position for avoiding uneven wind loading on the turbine Figure 6 4 Figure 6 4 Parked Rotor Blades c SS uf in d M RL SESTO Servicing 7 Servicing and Maintenance 7 1 User Maintenance 7 1 1 Resetting Errors As detailed
28. hrough the operating panel Daily energy production is archived by the controller for one month back The total monthly production is stored for a period of 12 months and total yearly production is archived for 20 years The controller will produce an error message should a fault be detected in the normal running of the turbine Details of the error will appear on the operating panel The most common errors and the recommended actions are detailed in section 5 4 2 Operating Panel The IC 1000 operating panel i MitoTeknikas WP3059 includes a screen and keypad The keys are activated by pressing 22000 down on the relevant symbol OG signalled by the illumination of the Gli 63 EJ LED labelled Key accompanied successful Keypad entry is by an electronic beep Figure 4 2 Figure 4 2 The Gaia Wind displays the operating panel Operating Panel The operating panel has 8 main menus corresponding to different aspects of turbine control Submenus exist within each of these menus Navigation between all menus is achieved using the keypad The information below details the primary operating panel entry functions RESET Stop the turbine Release the brake and start the turbine Move cursor line up Navigate to next menu Navigate to previous menu Move cursor line down Reset erase error status Shift to last menu line Leave a submenu
29. ights and active status are disabled Therefore the following procedure should be followed upon completion of using the controller Releasing Active Status amp Access Rights Step 1 Step 2 Step 3 Step 4 Ensure that the operating panel display shows the Start Menu Navigate the start menu down until the cursor indicates Release active stat Press enter on the keypad The display remains on the start menu with active status released Navigate the start menu to the line Access Rights Press enter on the keypad two times The display will revert to the Original start menu You are the now logged out of turbine eGl 249 11 5kw 9g 5m s 5 1021 RUNNING Gl status OK Accessrights 50 Release Active stat eGl 249 11 5kw 9g 5m s 5 1021RPM RUNNING Gl status OK Accessrights 50 Release Active stat 61 249 11 5 9 5m s 5 1021 RUNNING Gl Status Accessrights 50 Request Active stat Gl 249v 11 5 9 5m s 5 1021 RUNNING Gl Status Accessrights 50 Request Active stat Enter eGl 249v 11 5kw 9 5m s 57 1021RPM RUNNING Gl Status OK Accessrights 0 Request Active stat 5 3 Error menu 5 3 1 Overview B 251V 0 0kw The turbine is equipped with 7 2 5 00 0000RPM S TOPPED numerous sensors These sensors Status ERROR Accessrights 50 continuously monitor the turbine Request Active stat he inf io
30. ine During the annual service the performance of the turbine will be checked and any error messages will be evaluated This information and a record of the required work and use of consumables and replacement parts during the service will be issued to the customer 7 3 Replacement Parts The Gaia Wind 11 kW turbine is designed to have a minimum lifetime of 20 years However some of the parts will require replacement during this time period These components are known as wearing parts and include the rubber mountings for the gearbox and for the generator hub bushings and brake pads The wearing parts will be checked during servicing according to the instructions in the servicing manual Scheduled gearbox oil changes will be made every 3 5 years 8 Frequently Asked Questions Does the turbine have lightning The turbine tower is connected to a protection dedicated earth electrode This acts to protect the turbine in the event of a direct lightning strike What should do if ice forms onthe The turbine should be manually turbine blades turned off to prevent potential injury from flying ice See section 6 3 on manually stopping the turbine Why is my turbine not generating 1 The turbine has been any electricity despite good wind switched off conditions 2 here is an error in the turbine refer to section 5 3 of this manual 3 The wind speed is too high and the turbine has shut down to protect the gearbox
31. m the previous month 12 months and 20 years Operation timer counter Counts the number of hours of production from the turbine Stop timer counter Counts the hours and times the turbine has been stopped Brake timer counter Counts the hours and times that the turbine brake has been activated IC 1000 OK timer Counts the hours and times that the IC counter 1000 control unit has been switched on Grid OK timer counter This counts the hours and times that the grid has been OK 5 4 3 System Production Accessing System Production System Step 1 Ensure that the Status Menu is Capacitors wind Heating system RPM screen see section 4 4 1 Temperatures Oper timers Communication Inputs Outputs Press enter on the Menu Line Enter System displayed on the keypad Production consumpt iss consumption Elements consumption The system submenu will perite Lrmer count Son Brake timer counter appear on the screen IC1000 OK tim coun Grid OK tim counter wind OK tim counter Step 2 Step 3 Step 4 Step 5 Navigate to the submenu line prod consump and press enter The display should give a selection of time frames over which to view data Scrol to the desired time frame and press enter The final screen shows the production data The important information here is line the top the energy produced by the turbine To retu
32. ments Requirements will depend on your degree of direct involvement with the project but for example could include digging the foundation hole contracting a foundation builder digging a cable trench providing a three phase grid connection with import export meter achieving planning consent and ensuring suitable access for a crane and for the delivery lorry You must fulfil these obligations prior to the agreed installation day This will be covered in the contract 2 2 The Installation Day The installation of a Gaia Wind Turbine must be done either by Gaia Wind or through a Gaia Wind accredited installer Please contact Gaia Wind if you want to check verify whether your contact person is an accredited Gaia Wind installer The installation of the turbine should normally take only one day The Installation Team will consist of two engineers a crane driver and an electrician depending on circumstances One of the engineers will be introduced as Installation Manager and this person will be in charge of everything that takes place that day All people on site should follow swiftly the instructions given by this person All questions and remarks should be directed to the Installation Manager It should be noted that installation is dependent on suitable weather ground and wind conditions There are 4 main components to the installation of the turbine 1 Foundation preparation 2 Electrical installation 3 Mechanical install
33. n th and the information they record is Figure 5 2 Start Menu used by the controller Indicating Errors When the sensors detect an error the controller will automatically stop the turbine Confirmation of the error is indicated on the start menu under status see figure 5 2 By accessing the error menu the source of the error can be obtained see section 5 3 2 Error result Active statuscodes The error menu on the operating Manual stop panel contains the following menu lines Figure 5 3 Error Menu First Line Error Result Press enter on this line to access the Error Results Menu This line gives all active status codes Third Line Displays the most recently activated error N B the error in figure 5 3 indicates that the turbine has been manually stopped This is one example of an error message An overview of errors is detailed in Annex 3 5 3 2 Accessing the Error Menu Accessing the Error Menu B 251V 0 0kw Step 1 Ensure that the Start Menu is 7 2m s 00 0000RPM STOPPED displayed on the operating Status ERROR Accessrights 50 Request Active stat panel If you have not done so obtain Access Rights and Active Status before continuing See section 5 2 1 for details Step 2 Scroll down the menu line until the cursor is on the Scroll down fourth line Status Error Press enter on the operating panel Step3 error menu is displayed Error result
34. otatus Menu 47 Generator 26 RPM Submenu 52 Glossary of Terms 67 System Submenu 49 50 Grid voltage 36 Wind Submenu 52 Hub 69 Stopping 57 Automatic Manual System Submenu Menu Technical Data Tower 57 14 57 See Status 70 70 Height Lattice Tubular Wind Submenu Menu Yaw 28 28 28 See Status 70 Annex 1 Glossary of Terms Anemometer Bearing Cut In Speed Cut Out Speed Distribution Network Distribution Network Operator Freewheeling The anemometer is a device used for measuring the instantaneous wind speed In the wind turbine the function of the bearing is to allow the shaft to rotate freely This is the wind speed at which the turbine will start to deliver electrical power Cut in will occur when the speed of the generator achieves its synchronous speed The maximum wind speed at which the turbine is permitted to deliver power The operating range of a turbine is limited due to engineering design and safety constraints The cut out speed for the turbine is 25 m s although wind speeds this high are rare This is the low voltage under 33 kV that typically connects into homes and businesses The companies which operate the Distribution Network in the UK This refers to a wind turbine in which the hub and blades point away from the wind direction The opposite of an upwind device The wind turbine is said to freewheel when it is not connected to a load but
35. previously when the turbine sensors detect an error the controller will automatically stop the turbine Information relating to the error will be displayed in the operating panel display 7 1 2 Visual Inspections It is advisable to perform brief periodic inspections of the turbine in particular following severe winds This should consist of a visual check for loose bolts and connectors visual inspection of the whole turbine and listening for any unusual noises or vibrations Should such an inspection identify any potential faults with your turbine then contact Gaia Wind or a Gaia Wind representative immediately 7 2 Servicing intervals The information below details the servicing requirements for the Gaia Wind 11 kW turbine All servicing activities must be performed by a Gaia Wind accredited service engineer 7 2 1 Three Month Service A full inspection must be performed three months after the installation of the turbine The turbine operation and control system will be checked Additionally all bolt connections are tightened and the levelling of the tower will be inspected 7 2 1 Annual Service It is necessary that a full inspection of the turbine is performed at least once a year This annual check up must be performed by an accredited service engineer This check up will commonly involve tightening of bolts replenishment of lubricants and oil and visual checks for any excessive wear or damage to the turb
36. ption We of power servicing company The generator Reset when generator d e net temperature is too high 2 al 1 temperature decreases Eu de a The error will be automatically 530 G power too eue de NIA 50 10m reset when the wind speed is high below an average of 18 m s over averaged over a period a 10 minutes period of 10 minutes Produccion rom ihe The error will be automatically 537 5 enerator exceeds the A 50 10m 000215 power 9 below average of 18 m s over peak value of 18 kW a 10 minutes period The power from one phase deviates by Current Contact Gaia Wind or your turbine servicing company 601 more than 25 50 0s compared with the other phases asymmetry Status Error Descriotion Error Code Message p Type Auto motorstart 609 hot 651 Cut in 0 gt G1 662 WP4060 error 722 Cable twisted 1311 Coupling G gearbox PT100 defective Thyrister Block The turbine motor start has been activated more than 20 times Thyristor block temperature gt Set stat 609 xx C Cut in time of G1 via WP4060 increases 0 gt G1 xxS 30 sec Cut in error The status code is not tested when output 524 G1 contactor is low or when output 525 generator bypass high The cable twist sensor has been activated Ratio between the RPM of the generator and rotor does not match the gear ratio 2 A connection to one of the PT100 sensors is
37. rn to the previous menu press escape To return to the Status menu hold control and escape Scroll Down CUN l Subtotal One month back 12 months back 20 years back Enter Ww 0 kvArh 223 kvArh Return to Submenu Return to Menu 5 4 4 Wind Submenu This menu provides a more comprehensive indication of the wind wind unavr wind 30s speeds on site This includes the wind 10m instantaneous unaveraged and the winds speed averaged over both the MEN last 30 seconds and 10 minutes Access this menu by pressing enter on the keypad in the menu line Wind 5 4 5 RPM Submenu This menu simply displays the current speed revolutions per minute of the turbine rotor and of the generator Access this menu by pressing enter on the keypad in the menu line RPM Independant Energy Environmentally Friendly Energy Procedures Operating 6 Operating Procedures 6 1 Auto Start Auto start refers to the process by which the turbine starts automatically when the control measures a pre defined wind speed of at least 3 5 metres per second for 30 seconds This is the cut in speed and is the point at which the turbine will start to generate electricity Through a soft starter the controller uses the generator as a motor to bring the rotor up to the operating speed Auto start enables maximum exploitation of lower wind speeds and h
38. s servicing company There has been a Main Power failure in the Error will be reset automatically 45 Sun mains supply and the A 50 10s when mains supply is detected turbine controller has after a delay of 3 minutes reboot DSP DSP processor is i 51 Watchdog rebooting A 50 Os No Action required 53 Main ctrl The main controller is A 50 10s No Action required Watchdog rebooting Status Error Error Main ctrl Man Reboot Parkmaster 2 stop Repeated grid ur error 102 Phase drop 103 Vector surge 110 Voltage high 111 Voltage low 120 Frequency high 121 Frequency low 130 L1 L2 L3 120 Grid Param me Warning Grid Param 139 Stop Anemometer 221 defect 240 Awaiting Wind 250 Wind max The controller has been reset manually by the user The park control has sent a command to stop the turbine The status code is reset when the park control sends a start command Errors relating to the voltage and frequency of the mains supply have been occurring too often No voltage in one or more phases The phase angle has changed by more than 3 The grid voltage has exceeded the maximum limit The grid voltage has dropped below the minimum limit The grid frequency has exceeded the maximum limit The grid frequency has dropped below the minimum limit The phase angle between the L1 L2 and L3 is larger than 6 Internal Calculations Internal Calculations Anemometer recordin
39. stem OK A 50 0s No Action required d Vibrations detected Contact Gaia Wind or your z within the nacelle b 08 turbine servicing company Turbine is Turbine is in service Contact Gaia Wind or your 7 M 80 0s se Serviced mode turbine servicing company Stop command 11 Stop received via modem 50 Os Contact Gala Wind AE i communication turbine servicing company direct link The turbine has been stopped manually via 13 Manual Stop the STOP button on the M 50 Os Reset error and restart turbine turbine operating panel First check for good reason for Emergency Emergency stop button Emergency Stop activation Once 18 M 50 Os aoe stop has been activated satisfied release emergency stop and reset Repeating EET Contact Gaia wind or your turbine 23 recorded too many M 50 0s gen error servicing company times The program firmware Contact Gaia wind or your turbine Arete lela has been updated b 96 Ue servicing company Alarm call test in the TE Alarm Call Contact Gaia wind or your turbine 38 Test Re Menu is set to 50 0s servicing company Division by Contact Gaia wind or your turbine 39 ERA Parameter error value M 50 Os servicing company Parameter crash due to flat battery Battery APT Parameter Contact Gaia wind or your turbine 40 com must be replaced and M 50 0s servicing company all parameters set to default values Internal Battery Contact Gaia wind or your turbine 42 pos Battery needs replaced M 50 0
40. tantially reduce your annual energy bills and take sizeable steps towards lowering your carbon footprint and achieving energy sustainability This document has been written specifically with the turbine user in mind It is therefore strongly recommended that you read this manual carefully and ensure that it is retained for future reference The manual provides a comprehensive overview of the turbine operating procedures and the control system This will allow you to monitor the turbine whilst it is in operation and determine how much electricity you are generating and thus how much money you are saving In addition you can determine the equivalent carbon dioxide savings that you will achieve Please take careful note of the health and safety information summarised on the opening page If you have any additional concerns on the health and safety aspects of the turbine please contact Gaia Wind We would like to congratulate you once again on your purchase and hope that you enjoy generating your own energy with Your Own Wind Turbine Regards Gaia Wind M L HN Independent Energy Environmentally Friendly Energy 1 2 Introduction to the Turbine The Gaia Wind turbine is in the small wind turbine category and has a peak rated output of 11kW It produces an energy yield that is practical for supplying electricity to premises such as private houses farms offices small businesses and public buildings wh
41. the menu until the cursor line indicates Access Rights The cursor is indicated by an underscore Press enter on the keypad The screen display will change to that on the right Enter the default user code 123 using the numbers on the operating panel and confirm by pressing enter The display will return to the start menu with Accessrights 50 Gl 249 11 5kW 9 5m s 57 1021RPM RUNNING Gl Status Accessrights 0 Request Active stat Scroll down Gl 249v 11 5kw 9 5m s 57 1021RPM RUNNING Gl Status Accessrights 0 Request Active stat REMOTE Edi tor Accessrights Enter eGl 249v 11 5 9 5m s 5 1021 RUNNING Gl status OK Accessrights 50 Request Active stat Step 4 Step 5 Step 6 Navigate the start menu down until the cursor indicates Request active stat Press enter on the keypad Enter the user ID 1 and Confirm by pressing enter on the keypad The screen will revert back to the start menu with both access rights and active status Ensure that the LED labelled Active on the top right hand side of the keypad is illuminated This confirms that active status has been granted Scroll down Enter Enter Gl 249 11 5 9 5m s 57 1021RPM RUNNING Gl Status OK Accessrights 50 Release Active stat ACTIVE e KEY It is important that prior to leaving the turbine that the access r
42. us code Manual M The active status code can be reset by the user via the operating panel by users with a password level equal to or higher than the one indicated in the status code Remote R The status code may be reset manually or by remote control only by users with a password level higher than that indicated in the status code The table in Annex 3 gives a full list of potential error messages Each error is accompanied by a short description and indentified as Auto Manual or Remote reset and also given a re set delay and required password level to be able to re set Instructions on how to manually reset errors are detailed in section 5 3 4 below 5 3 4 Resetting of Errors The turbine will only operate when no error signals are detected Therefore errors must be reset to resume turbine operation The method for resetting errors is dependent on the type of error The following procedure should be followed to reset manual errors Resetting Error Menu Step 1 Ensure that the Start Menu is EO ONERE CU BU 7 2m s 00 0000RPM displayed on the operating STOPPED Status ERROR Accessrights panel Request Active stat If you have not done so obtain Access Rights and Active Status See section 5 2 1 for details Step 2 Scroll down to the menu line until the cursor is on the Scroll down fourth line Status Enter Press enter on the keypad Step3 screen displays the recent a
43. work at heights ideally with a BWEA Working at Height Certificate or equivalent using peak less climbing helmet safety harness with double lanyards and shock absorber work positioning device tower rescue kit high visibility vest and steel toe cap boots e Have experienced working on the Gaia Wind 11kW Turbine e Ensure that only one person is permitted inside of the working basket at any one time e Ensure that a proper and comprehensive risk assessment has been carried out prior to starting any work Further advice to the turbine owner e Alterations to the control parameters can only be made by Gaia Wind or a Gaia Wind accredited servicing company e Inthe event of abnormal noise or unusual operation being observed turn off the turbine and contact Gaia Wind or a Gaia Wind accredited servicing company e Shut off the turbine should ice accumulate on the blades e Do not paint the blades or the turbine as this will degrade the coating on the blade surface e fin doubt on any procedural issues contact Gaia Wind or a Gaia Wind accredited servicing company introduction 1 Introduction 1 1 Welcome Note Thank you for choosing to purchase a Gaia Wind 11 kW Wind Turbine Gaia Wind are delighted that you have decided to install our small wind turbine We believe that with Your Own Wind Turbine you will very quickly notice the benefits gained by your home or business The turbine allows you to subs
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