ARE110 Wind Generator (2.5 kW) Grid-Connect...

ARE110 Wind Generator (2.5 kW) Grid-Connect Model

Owners Manual Installation, Operation, & Maintenance

Manufactured in the USA by:

ABUNDANT RENEWABLE ENERGY 22700 NE Mountain Top Road

Newberg, OR 97132

www.AbundantRE.com

(503) 538-8298 (Telephone) (503) 538-8782 (Fax)

of 26

Table of Contents

1. Safety Warning 3 2. Introduction 4 3. Wind Generator Specifications 5 4. Equipment Supplied 6 5. Required Installation Tools 7 6. Choosing Sites for Wind Generators 7 7. Electronics Installation

A. Resistor Load 8 B. Inverter 9 C. Voltage ClampTM 9 D. Electrical Schematic 10

8. Towers & Rigging 11 9. Wire Size Recommendations 11 10. Turbine Assembly Instructions 11

A. Position the Tower 11 B. Check the Yaw Head Axle 12 C. Electrical Connection: Yaw Head to Tower 12 D. Mount Yaw Head to Tower 13 E. Mount Alternator to Yaw Head 13 F. Wire the Yaw Head Terminal Strip 14 G. Test the Electrical Connections 16 H. Install Tail Boom to Yaw Head 16 I. Install Blades & Nose Cone 19

11. Generator Start-up, Shut-down, & Reset 20 A. Prior to Generator Start-up… 21 B. Generator Start-up Procedure 21 C. Voltage Clamp™ Operation in Decreasing Wind… 21 D. Generator Shut-down & Reset Procedures 21

12. Voltage ClampTM Operation & Faults 22 13. Inspection & Maintenance 23 14. Troubleshooting 23 15. Component List & Drawing 24 16. Warranty 25

of 26

1. SAFETY WARNING!

• Electrical shock hazard: The wind generator can produce high voltages – sometimes more than 400 volts. These voltage levels can cause serious injury or death. No wires or electrical connections should be touched or handled without ensuring that the wind generator has been braked to a complete stop and the AC power to the inverter and Voltage Clamp™ (grid-tie controller) is off. After these steps are taken, approximately five (5) minutes is required for system voltage to decay to safe levels.

• The ARE110 is a powerful machine and can cause injury

if not assembled and erected properly (according to the instructions and using appropriate equipment).

• Do not approach the machine while the blades are spinning

– they can cause serious injury!

Please Note:

ABUNDANT RENEWABLE ENERGY has made every effort to ensure that the information presented in this manual is accurate but assumes no responsibility for any errors or omissions. Users of this information and ARE products assume full responsibility and risk.

of 26

2. Introduction

This manual contains all necessary information for assembling, operating, and maintaining the ARE110 (2.5 kW) direct grid-connect wind generator. Please read it carefully and retain it for future reference. The ARE110 is ruggedly built. It operates at a relatively low rotational speeds (low RPM), which – together with a small number of moving parts – ensures a very long life with little maintenance. Its large swept area, high-efficiency blades and alternator, and optimized power electronics ensure maximum energy capture from low and high wind speeds. The simple, upwind side furling system (with gravity return) protects the machine by reliably swinging the rotor out of winds higher than 11 m/sec (25 mph).

Figure 1. ARE110 wind generator

of 26

3. Wind Generator Specifications

Configuration Three-blade upwind Over-Speed Control, Mechanical Side furling with gravity return Over-Speed Control, Electrical Pulse-width modulated resistor loading Rated Power 2.5 kW (2500 watts) Rotor Diameter 3.6 m (11.8 ft) Swept Area of Blades 10.2 m2 (110 sq. ft.) Cut-in Wind Speed 2.5 m/s (6 mph) Start-up Wind Speed 3 m/s (7 mph) Rated Wind Speed 12 m/s (25 mph) Blade Quantity, Construction Three (3), molded fiberglass Blade Rotational Speed 0–340 rpm Alternator Type/Construction Neodymium permanent magnet Alternator Electrical Output 3-phase, variable voltage (0 - 410 VAC) Tower-Top Weight 143 kg (315 lbs.) Maximum Lateral Thrust 160 Kg (350 lbs.)

Table 1. ARE110 specifications

ARE110 Wind Generator

Power Curve

0

1000

2000

3000

0 5 10 15 20 25 30 35 40

Wind Speed (mph)

Pow

er (

wat

ts)

ARE110 gen power curve based on measured data; power data above 25 mph based on a

small number of data points

Figure 2. ARE110 power curve

of 26

A R E 1 1 0 W in d G e n e ra to rsM o n th ly E n e rg y E s tim a te s

0

2 0 0

4 0 0

6 0 0

8 0 0

8 1 0 1 2 1 4A v e ra g e L o c a l W in d S p e e d (m p h )

Ener

gy P

rodu

ctio

n (

kWh)

Figure 3. ARE110 monthly energy estimates graph

4. Equipment Supplied

Qty. Item Description 1 Alternator (high-voltage) 3 Bolts (alternator-mount) with star washer – M16-2.0 x 30mm 1 Yaw head with slip rings 4 Bolts (tower-mount) with self-locking nut - M16-2.0 x 70mm 3 Blades 6 Studs, hex (blade-mount) with self-locking nut - M12-1.75 1 Plate (blade-clamping) 1 Nose cone 3 Bolts (nose-cone mount) with washers & lock washers - M6-1.0 x 16mm 1 Tail boom, inner (gusset) with tail hinge pin, tail pin latch, & E-clip retainer 1 Tail boom, outer (sq. tube 1.5" x 92") 1 Bolt (tail boom) - M16-2.0 x 70mm 1 Tail fin (with ARE logo) 3 Bolts (tail fin mount) with (2) washers and self-locking nuts – M14-2.0 x 60mm 1 Tail weight (approx. 3 lbs.) 1 ARE Voltage ClampTM (grid-tie controller) 1 ARE resistor load 1 Inverter - 2500U SMA Windy Boy (2.5 kW)

Table 2. Equipment Supplied with grid-connect ARE110 wind generators

To Be Purchased from Other Suppliers: • Appropriately sized wiring, as described in Section 9 (“Wire Size

Recommendations”) and in Section 7 (“Electrical Schematic”) • Cable support grips for wires (see Section 10, Part C) • Sub-panel or AC circuit breakers

of 26

5. Required Installation Tools

Ratchet for sockets 8” extension for ratchet Sockets: 10, 13, 17, 19, 22, & 24mm Wrench, Allen – 4 mm Wrench, adjustable – 8” Screwdrivers – Phillips (#2) & flat-head (1/8” max width) Wire Strippers Torque wrench – range: 10–170 N-m (7–120 lb-ft) Locking pliers (Vise-Grips) Thread-locking compound (e.g. Loctite® 242® Threadlocker, Med-Strength/Removable) Hole saw or stepped drill bit for ½” conduit (suggested size)

6. Choosing Sites for Wind Generators

To ensure satisfactory performance from the wind generator, care must be taken in the choosing the site for the machine. Buildings, trees, and rocky outcrops can disrupt the smooth flow of wind, creating “wind shear”. This results in significantly lower wind velocities and higher turbulence near the ground. Turbulence is detrimental to wind generators, as the swirling air causes the turbine to yaw continually, which unduly stresses mechanical components, greatly increases wear and tear, and reduces the useful life of equipment.

Figure 4. Turbulence illustrations (courtesy of P. Gipe)

As a general rule, therefore, wind turbines should be mounted at twice the height of any “bluff body” obstructions. Alternatively, locate the turbine 10 meters (30 feet) plus the blade length above the tallest trees, buildings, or other (non-bluff body) obstructions within 150 meters (500 feet). The power (P) obtainable from the wind is proportional the cube of the wind speed (v3), and wind speed increases with height (H) from the ground. [P α v3 and v α H]. According to this principle, a 26% increase in wind speed from a higher tower will yield a 100% increase in power from the turbine. A little more money spent on a taller tower harvests the same power as two (2) machines! Preference should be given to the prevailing wind direction, but please note that tall features downwind of the generator can also slow wind flow passing through the turbine’s blades.

H 2 H

20 H2 H

Turbulent airflow

Smooth, laminar airflow

Sharp edges create turbulence Turbulent air flow created by obstructions

of 26

7. Electronics Installation

It is important to install the ARE Voltage ClampTM (grid-tie controller), resistor load, and Windy Boy inverter prior to installing the wind turbine. This will provide a control system for the turbine and allow the brake to be used during turbine installation.

Figure 5. ARE Voltage ClampTM, ARE resistor load, & SMA Windy Boy inverter

Installation Instructions It is suggested that a piece of 3/4” plywood be mounted to the wall where your wind turbine electronic equipment will be installed. This will provide a secure substrate to which to mount equipment. It also provides for adequate flexibility in mounting the equipment without needing to rely on stud spacing or special wall anchors.

A. Resistor Load The resistor load enclosure must be mounted so that the resistors are horizontal and that the terminal block is in the lower right hand corner. Do not locate this device near flammable substances or loose cloth. Ensure a minimum of 12” clearance on all sides of the resistor load enclosure, as air must be permitted to flow freely through the box.

B. Inverter Follow the instructions included with the SMA Windy Boy inverter for mounting procedures and requirements. CAUTION: The SMA Windy Boy 2500U inverter is heavy (approximately 30 kg / 65 lbs.) and requires proper mounting. Please see SMA installation instructions.

C. Voltage ClampTM The ARE Voltage Clamp™ should be mounted on a vertical surface in a dry location. It should be mounted in suitable location to provide easy access to the red “STOP” button and so that the enclosure door may be opened fully. Conduit holes must be sawed or drilled in the bottom of the Voltage Clamp™ (see Figure 6 below).

of 26

Figure 6. Suggested drilling/sawing locations on bottom of Voltage Clamp™

See the Wiring Diagram for proper connection and wire sizes. Ensure all wiring is in accordance with local codes and laws. Wire the Windy Boy to the “– OUT” and “+ OUT” slots of the Voltage Clamp’s din-rail mounted terminal block (pictured below in Figure 7)

POLARITY IS IMPORTANT! Wiring the Windy Boy inverter with reverse polarity will damage the equipment and result in an expensive repair bill. See your SMA Windy Boy manual for instructions on wiring and operating the Windy Boy inverter.

Figure 7. Control board mounted on Voltage ClampTM door & main din rail terminal block mounted inside Voltage ClampTM

After all electrical equipment has been installed and all connections made, press the “STOP” button to ensure that the brake is engaged. Also turn off the circuit breakers to the inverter and to the Voltage ClampTM. This will ensure that the equipment will not be energized while the wind turbine is being installed.

Bi-metallic temperature switch terminal locations (+TS, -TS)

of 26

D. Electrical Schematic

Figure 8. ARE110 electrical schematic

NO

TE: A

ll w

ire s

izes

12

– 10

A

WG

, 60

0V m

inim

um u

nles

s no

ted

othe

rwis

e (s

ee T

able

3

for

run

from

tu

rbin

e to

V

olta

ge C

lam

p)

of 26

8. Towers & Rigging

Great care should be taken in the selection and preparation of the wind turbine tower, as this can be the most difficult and most crucial aspect of a wind energy equipment installation. Guyed, tilt-up pipe tower kits manufactured by ARE are specifically designed for the ARE110 and are recommended. ARE assumes no responsible for assuring the suitability of towers provided by other suppliers. ARE tilt-up towers can be easily lowered for servicing and do not require climbing. Consult with ARE for assistance with alternative tower selection and qualification.

9. Wire Size Recommendations

The following table lists the recommended MINIMUM wire gauge, based on the one-way wire run distance from the tower top to the building entrance (where it connects to system electronics). These recommendations are intended to limit the voltage loss to less than 5%. Ensure that the wire insulation is rated for outdoor use and for at least 600 volts. NOTE: The Voltage Clamp’s main terminal block does not accept wire sizes larger than 10 AWG. If a larger wire size is used, the wire size must be “stepped down” prior to insertion into this terminal block.

150 feet 300 feet 500 feet 1000 feet 2500 feet 12 AWG 12 AWG 12 AWG 12 AWG 10 AWG

Table 3. Wire size recommendations

10. Turbine Assembly Instructions

If using an ARE tilt-up tower kit, the tower should first be assembled, raised, and all rigging adjusted so that the tower stands vertically and can be raised and lowered properly. See the tower installation manual for details. Assemble the wind turbine onto the lowered tilt-up tower. Although one person can assemble the machine with mechanical aids, it is advisable to have an assistant, as many parts are heavy and cumbersome to maneuver into position. Keep the alternator covered as long as possible to prevent dirt or metal objects from entering the alternator and becoming lodged between the magnets and rotor. Assembly Procedure:

A. Position the Tower If using an ARE tilt-up tower kit, the top of the lowered tower should be supported at approximately 1 meter (3 feet) above the ground.

of 26

B. Check the Yaw Head Axle Ensure that the yaw head axle rotates freely within the outer housing (see Figure 9 below).

Figure 9. Yaw head axle

C. Electrical Connection: Yaw Head to Tower Splice the three power wires and the ground wire with suitable splices. Ensure they are insulated for 600 volts. Use wire support devices such as cable support grips (see Figure 10 below) to bear the wire weight and remove tension from wire splices. On ARE tilt-up towers, the bolt which holds the tower top flange may be used to carry wire support devices (see Figure 11). Four (4) wire connections are made at the yaw head – three (3) for the power from the generator leads (black) and one (1) for the ground (green).

Figure 10. Cable support grip (a.k.a. “Kellem’s grip”)

NOTE: DO NOT TIGHTEN THIS NUT. It is intended to be loose in order to allow yaw head rotation.

Yaw head axle

NOTE: Each wire should be supported individually.

of 26

D. Mount Yaw Head to Tower Attach the yaw head to the tower top flange using M16-2.0 x 70mm bolts, washers, and self-locking nuts (provided). Fasteners should be tightened to 163 N-m (120 lb-ft) torque. Ensure that the wires are not pinched between the top flange and the yaw head mounting flange (see Figure 11 below).

Figure 11. Mating the tower top to the yaw head flange

E. Mount Alternator to Yaw Head Line up the alternator mount holes with the yaw mount. CAUTION: The alternator weighs approximately 84 kg (185 lbs.) and is very awkward to hold, so plan this step carefully. The tail gate of a pick up truck works well; alternatively, a wheelbarrow or large storage drum could be used. The tower may need to be raise or lowered slightly to facilitate aligning the yaw head and alternator holes.

Line up the bolt holes and pass the alternator lead wires through the hole provided, taking care not to pinch the lead wires between mating surfaces. Apply thread-locking compound and tighten the three (3) M16-2.0 x 30mm bolts (with star washers) to a 163 N-m (120 lb-ft) torque (see Figure 12 below).

Figure 12. Bolting the yaw head to the alternator

Install M14 bolts so that bolt heads face the generator (i.e. bolt heads face upward on the erect tower).

Ensure wires are not pinched during assembly.

This bolt may be used to bear the weight of cable support grips.

Three (3) M16 bolts attach the alternator to the yaw head. It may be necessary to remove the yaw head access door in order to fasten all bolts.

of 26

F. Wire the Yaw Head Terminal Strip Connect the alternator lead wires to the terminal strip mounted on the yaw head access door. Match the label of each wire to labels on the terminal strip (see Figure 13 below). Alternator power output leads are labeled ‘A’, ‘B’, and ‘C’; lead ‘Z’ is used with ARE’s optional Lightning Protection System and must also be attached to the terminal strip. The ground stud is used for the Lightning Protection System. Do not attach any of the generator wires to the ground stud.

Figure 13. Yaw head terminal block wire connections

Figure 14. Yaw head ground stud location

Attach alternator lead wires to the

terminal block on the yaw head

access door and secure wire with

screw and clamping plate.

Ground Stud – Do NOT attach generator wires here

of 26

Examine all the slip ring brushes to verify firm contact with the slip rings (see Figure 15 below). Check to see that brushes can be pulled back from the rings and return freely. If a brush sticks: Loosen the top nut in quarter-turn increments until the brush springs back. CAUTION: Do not loosen the top nut excessively, as this may result in improperly seated brushes.

Figure 15. Close-up view of yaw head slip rings Reattach and close the yaw head access door (if removed in prior step). While closing the access door, make certain that wires are not pinched and do not interfere with the slip ring mechanisms. Use the M6 bolt to hold the door in place (as shown in Figure 16 below).

Figure 16. Access door lock

Slip Ring

Slip Ring Brush

Adjustment Nut

Spacer

Use this bolt to hold the door in the closed position. Tighten bolt fully to ensure that it does not back out.

Yaw head access door.

Bottom slip ring to be used only for ground connection

of 26

G. Test the Electrical Connections Manually rotate the turbine blades at a steady rate while another person (at the tower base junction box) uses a voltmeter to verify consistent AC voltage readings across the three wires lead wires. This verification will require three voltage readings: A-B, B-C, A-C). During this step, the lead wires should not be connected to electronic equipment (Voltage ClampTM / grid-tie controller). If the measured voltages between lead wires are approximately equivalent, the turbine’s lead wires can be connected to the lines that run to the Voltage ClampTM and subsequent electronic equipment. If the measured voltages are not approximately equivalent, check all connections in the yaw head and tower to ensure there are no short-circuits or open connections. Verify that the slip ring brushes are making positive, firm contact with their respective slip rings.

H. Install Tail onto Yaw Head

Figure 17. Tail pin latch plate

Pin latch plate on inner tail boom section

of 26

Remove the pin latch plate from the inner tail boom section (see Figure 17 above). Align the two (2) hinge eyes of the inner tail boom section with the two (2) bronze bushings (inserted in holders on the rear of the yaw head). Install the tail pivot pin to join the tail to the yaw head (see Figure 18 below).

Figure 18. Tail pin installation onto yaw head

Align the notch in the hinge pin with the pin latch plate and secure in place. Apply thread-locking compound and tighten the two M6-1.0 x 16mm bolts to 10 N-m (7 lb-ft) torque. Install the E-clip retainer into the groove at the bottom of the hinge pin. Vise grips are a useful tool for the E-clip retainer installation (see Figure 19 below).

Figure 19. Close-up views of tail pin latch plate & E-clip retainer installation

Notch

E-clip: Install in groove.

Tail Pin

Groove

Latch plate: Install in notch

of 26

Note Figure 20 below for the correct holes to use when mounting the tail fin to the tail boom. Mount the tail fin to the outer tail boom section (square tube) with the two (2) inner bolt holes. Use M14-2.0 x 60mm bolts with washers and self-locking nuts.

Figure 20. Mounting the tail fin Figure 21. Inserting the tail weight

Install the tail weight in the end of the outer tail boom, as shown in Figure 21 (above). Install the last (outermost) bolt to secure the tail fin. The tail weight will be captured between the two (2) outer bolts (see Figure 21 above). Tighten the M14 fasteners to 60 N-m (45 lb-ft) torque. Install the outer tail boom into the inner tail boom, and secure with an M16-2.0 x 60mm bolt and self-locking nut (see Figure 22 below). Tighten the M16 fastener to 80 N-m (60 lb-ft) torque.

Figure 22. Assembling the outer & inner tail booms

Install these two bolts first

Install tail weight into tail boom

The bolt in this hole acts as a “stop” for the tail weight [Bolt & tail fin omitted for clarity]

Outer tail boom

Inner tail boom

M16-2.0 x 60mm bolt with self-locking nut

Use these holes to mount tail fin to tail boom [All round holes – no slots]

of 26

I. Install Blades & Nose Cone Apply thread-locking compound and screw the six (6) blade stud bolts into the threaded holes on the front of the alternator drum. IMPORTANT: The shorter threaded section of the stud must screw into the alternator drum (see Figure 23 below). Tighten the blade studs to 80 N-m (60 lb-ft) torque.

Figure 23. Mounting blades to alternator

Install the three blades onto the blade studs. The studs are equally spaced, so you may start with any two studs. Orient the blades so that the blue leading edges will rotate clockwise (CW – see Figure 24 below).

Figure 24. Blade edges & rotation direction After placing the three (3) blades, install the blade clamping plate over the six (6) blade studs with the nose cone mounting brackets between the blades and pointing toward the alternator (see Figure 25 below). Secure the plate with M12-1.75 self-locking nuts, tightened to 20 N-m (15 lb-ft) of torque.

Blade stud for mounting blades

Leading edge of blade

Trailing edge of blade

of 26

Figure 25. Close-up view of nose cone mounting bracket

Install the nose cone and secure with three (3) M6-1.0 x 16mm bolts, washers and lock washers (see Figure 26 below).

Figure 26. Nose cone installation

Rotate the blades slightly about the alternator’s axis to verify that the rotor can turn freely. Double check all fasteners and electrical connections are secure.

Ensure that the turbine will not encounter any physical interference prior to beginning the tower-raising.

IMPORTANT: Ensure that the STOP button on the Voltage ClampTM (grid-tie controller) is pressed. This will engage the brake and keep the turbine from rotating during the tower raising. Raise the tower and secure base and/or guy cables. Ensure that the tower is vertical so that the turbine can properly yaw (turn to face into the wind).

11. Generator Start-up, Shut-down, & Reset

CAUTION: ALLOWING THE WIND GENERATOR TO ROTATE UNLOADED CAN RESULT IN VERY HIGH VOLTAGES WHICH CAN CAUSE INJURY OR DEATH AND CAN DESTROY EQUIPMENT.

Nose cone mounting brackets: locate between blades and orient pointing toward the alternator.

M6-1.0 x 16mm bolts, washers, and lock washers

of 26

A. Prior to Generator Start-up (Verify the Following): • All electronic equipment installed per Section 7 of this manual. • All electronic equipment wires double-checked for proper location. • Circuit breakers to electronic equipment placed in the OFF position. • STOP button on the Voltage Clamp™ is in the depressed position. • Wind turbine installed per Section10 of this manual. • Wind turbine and tower erected and properly secured per tower instructions.

B. Generator Start-up Procedure: 1. Turn ON the circuit breaker for the SMA Windy Boy inverter. Rotate the STOP

button clockwise (CW) 1/6th of a turn and release. NOTE: The Windy Boy will not immediately show signs of turning on, as its display only energizes once the turbine starts to run.

2. Turn on the circuit breaker for the Voltage ClampTM. This will start a 5 minute wait period. The RED and GREEN lights will flash. NOTE: If STOP button is still depressed, the RED light illuminate steadily.

3. After the 5 minute wait the flashing RED light will turn off. The GREEN light will continue flashing slowly. Once sufficient wind is available, the turbine blades will start to spin, activating the Voltage Clamp’s “START UP MODE”.

4. When the generator’s rectified voltage reaches approximately 180 VDC, the Voltage ClampTM will perform a test to verify proper installation and functioning of the resistors (load and brake). Upon successful test results, the GREEN light’s flash rate will accelerate -- flashing ON and OFF in approximately ½-second intervals. This is the Voltage Clamp’s “WAITING MODE”.

5. The Voltage ClampTM will attempt to maintain a generator output range of 300-325 VDC while the Windy Boy inverter comes online and synchronizes waveforms with the utility grid (approximately five minutes). The Voltage ClampTM will perform a test approximately once per minute to verify that the inverter is connected to the grid.

6. After the Windy Boy inverter is connected to the utility grid, the turbine will enter the “RUN MODE” and the GREEN light will be illuminated steadily (not flashing).

7. The system will operate automatically, and monitoring is not required.

C. Voltage ClampTM Operation in Decreasing Wind Speeds • If the generator’s rectified voltage drops below 240 VDC, the Voltage ClampTM

returns to the WAITING MODE. • If the generator’s rectified voltage drops below 90 VDC, the Voltage ClampTM

returns to the START UP MODE.

NOTE: If the wind speed and conditions are such that the system voltage remains between 250 VDC and 280 VDC, the GREEN light may flash while the Windy Boy continues sending power to the utility power grid. Also in light winds the GREEN light may go between flashing and steady as the DC voltage of the system rises and falls with wind gusts. Both of these conditions are normal in light winds.

D. Generator Shut-down & Reset Procedures To shut down the wind energy system, press the red mushroom emergency STOP pushbutton. To reset the system, depress the STOP button, then rotate the STOP button clockwise (CW) 1/6th turn and release.

of 26

12. Voltage ClampTM Operation & Faults

Lights Mode Green Yellow Red Mode / Fault Description Solution / Comments

Slow Flash

START UP MODE: The system is initializing and going through system checks.

Slow flash: ON for 2 seconds, OFF for 2 seconds

Fast Flash

WAITING MODE: The generator’s rectified voltage has reached approximately 180 VDC, and the Voltage Clamp™ is performing a test to verify proper installation and functioning of the resistors (load & brake).

Fast flash: ON for 1/2 second, OFF for 1/2 second

Steady On

RUN MODE: The system is producing energy, which is being used by domestic loads or being sent to the utility grid.

N/A

Nor

mal

Ope

ratio

n

Steady On

Variable Intensity

RESISTOR LOADING: The system voltage is approaching the upper limits of the WB inverter's acceptable range. The load resistors are being used to slow the turbine rotor.

The light intensity increases approximately in proportion to the quantity of energy being diverted to the load resistors.

Steady On Flash

OVER-VOLTAGE FAULT (560 VDC): The rectified system voltage exceeds 560 VDC, and the brake is applied.

After a 5 minute delay, the system will automatically reset.

Slow Flash

OVER-VOLTAGE FAULT (570 VDC): The rectified system voltage exceeds 570 VDC, the brake is applied.

After a 5 minute delay, the system will automatically reset. This is a separate, redundant over-voltage protection fault from the "Over-voltage fault (560 VDC)".

Slow Flash

OVER-TEMPERATURE FAULT: One of the two bi-metallic temperature switches has tripped and the turbine's brake has been applied. Temper-ature switches are set at 60°C (140°F) and located inside the resistor enclosure and the Voltage Clamp™.

The system will not reset until the temperature decreases below 60°C and the bi-metallic switch closes again.

Faul

ts

Aut

o-R

eset

LOSS OF GRID POWER: If at any time the grid power to the system is lost, the Windy Boy inverter will disconnect from the grid and the Voltage Clamp™ will activate the brake. All system lights will go out.

When grid power is restored the system will start up automatically and follow the START UP MODE procedure detailed above.

Faul

t

M

anua

l Res

et

Req

uire

d

Steady On

LOAD/BRAKE RESISTOR TEST FAILED: The once-per-minute test performed by the Voltage Clamp™ to verify proper connection and function of load & brake resistors has failed.

Check all electrical connec-tions and ensure that brake and load connections are correct in Voltage Clamp™ enclosure. Manually reset the system.*

Table 4. Voltage Clamp™ Operation & Faults

* TO MANUALLY RESET THE SYSTEM: Depress the STOP button, then rotate the STOP button clockwise (CW) 1/6th turn and release.

of 26

13. Inspection & Maintenance

Frequency Category Task Comments

Continually Turbine

Listen for unusual alternator or blade noise, and look for excessive vibration.

If detected, such warning signs should prompt a detailed inspection.

Tower Verify that tower guy cables, saddle clamps, and shackles are tight. Every 6

months Tower Check all cables for

excess fraying or rust

These tasks apply only to ARE guyed tilt-up towers. For other towers, please reference manufacturer's documentation for maintenance schedules

Turbine Inspect the blades for leading edge wear.

This should be done by close visual inspection: by lowering the tower (if tilt-up) or by climbing it (if free-standing).

Tower Check the upper guy joints for wear and/or rust

Every 12 months

Tower

Verify (with torque wrench) that all cable clamps continue to firmly grip guy cables

These tasks apply only to ARE guyed tilt-up towers. For other towers, please reference manufacturer's documentation for maintenance schedules

Table 5. Inspection & Maintenance Schedule

14. Troubleshooting

Symptoms Possible Causes Solutions Shorted wires or alternator windings Remove short

Shorted diodes Replace faulty diode(s) Failed bearings Replace bearings

Turbine fails to turn (or turns very slowly) in significantly windy conditions

Foreign body in generator Remove obstruction Low output Insufficient wind Improve tower location/height Turbine vibrates excessively Blades out of balance Check blades for water intrusion

Tower top not vertical Adjust guy cables Turbine fails to swing into the wind Yaw bearing worn Replace yaw bearing

Cables disconnected Fix cables Turbine running at high speed no output Slip Rings Failed Replace Slip Rings Voltage Clamp RED light illuminates (solid) See “Voltage ClampTM Operation & Faults” section above.

Table 6. Troubleshooting Guide

of 26

15. Component List & Drawing NOTE: Exploded drawing and component list to be added in an addendum.

Item Description Qty Item Description Qty Item Description Qty

Table 7. Component list

of 26

Five-Year Limited Warranty for ABUNDANT RENEWABLE ENERGY

Wind Generators WARRANTY AGREEMENT

In order to validate this Warranty Agreement, the Customer must detach, complete, and return the ARE Mail-in Warranty Form (page 2 of this Agreement) within one (1) month of installation or seven (7) months of receipt of warranted ARE products, whichever occurs first.

Abundant Renewable Energy (ARE) warrants that the wind turbines it manufactures will be in good working order, in accordance with ARE standard specifications, upon delivery to its customers and for a period of 66 months from the date of delivery or 60 months from the date of installation, whichever occurs first. During the warranty period ARE will, at its sole discretion, repair, replace, or refund the purchase price of defective components and assemblies. Repair parts or replacement product may be new, remanufactured, or refurbished, at the sole discretion of ARE. ARE is not responsible for any costs associated with the installation, removal, reinstallation, or transportation to ARE (or to an ARE dealer) of defective ARE products. Return freight to the customer will be provided by ARE. Product or components returned to ARE, which are not defective or which sustained damage not covered under this warranty, will be tested and/or repaired at ARE’s standard labor rates. Only warranty claims submitted to ARE in writing within 15 days of problem origin will be honored. GOVERNING LAW AND DISPUTE RESOLUTION

This Agreement will be interpreted and enforced according to Oregon state laws or U.S. federal laws, whichever has jurisdiction. Oregon law, without reference to conflicts of laws principles, shall control the interpretation and enforcement of this Agreement. In the event that any dispute, controversy, or claim between the Parties arising out of or relating to this Agreement cannot be settled by negotiation or mediation, the parties agree to have the dispute or claim submitted for private arbitration. Any arbitration is to be conducted in Multnomah or Yamhill County, Oregon. Judgment upon the award may be entered into the Circuit Court of Multnomah County. EXCLUSIONS

This warranty does not cover the following: • Towers, equipment, materials, or supplies not manufactured or supplied by ARE (Towers

manufactured or sold by ARE are covered by their own separate warranty.) • ARE equipment which has been improperly installed or modified without approval from ARE • Damage or loss from winds in excess of 45 m/s (100 mph) • Lightning damage or other “acts of God”. (The ARE lightning protection package provides its

own individual warranty related to lightning damage to wind generators and related controls) • Incidental or consequential damages • Damage to product incurred during shipping

PRODUCT CHANGES

ARE reserves the right to make design changes, improvements, or additions to its products without obligation to install such changes or improvements in existing products.

of 26

ARE Wind Generators Warranty Agreement Form

Customer / End User Name _________________________________________

Customer Address ________________________________________________

______________________________________________________________

______________________________________________________________ Customer Phone ______________________ Email _____________________

ARE Dealer / Installer Name & State (if applicable) ________________________

______________________________________________________________

Product Part Number (e.g. ARE110) ____________________________________

Alternator Serial # _________________________________________________ Mainframe / Yaw Head Serial # _______________________________________ Controller / Voltage ClampTM Serial # _________________________________ Inverter Serial # (grid-tie systems only) ____________________________________ Resistor Load Serial # ______________________________________________ Date Product Received _______________ Installation Date ______________

Dealer Signature (if applicable) ________________________________________ End User Signature ________________________________________________

Send Completed Form to:

ABUNDANT RENEWABLE ENERGY 22700 NE Mountain Top Road

Newberg, OR 97132 Phone: (503) 538-8298

Fax: (503) 538-8782 Email: [email protected]

Website: www.AbundantRE.com

ARE110 Wind Generator (2.5 kW) Grid-Connect...

Documents

Transcript of ARE110 Wind Generator (2.5 kW) Grid-Connect...