USER’S MANUAL
1000W and 2000W
1108 Summit Avenue, Suite 8
Plano, TX 75074
866-WND-PWRD
www.acgreenenergy.com
© CMS Magnetics 2007, 2008
CONTENTS
Model & Parameters List ------------------------------------------------------------------------- 3
Installation Specifications (Guyed Tower) --------------------------------------------------- 4
Installation Specifications (Tapered Tower) ----------------------------------------------- 11
Connection of the Charger Controller ------------------------------------------------------- 12
Connection of Storage Batteries -------------------------------------------------------------- 12
Electric Wiring ------------------------------------------------------------------------------------- 13
Maintenance --------------------------------------------------------------------------------------- 14
FAQ (Frequently Asked Questions) --------------------------------------------------------- 14
Appendix One: Off-Grid Electric Wiring ----------------------------------------------------- 17
Appendix Two: Controller Specification (3kW and Higher) ---------------------------- 18
Appendix Three: Wind Speed Monitor Specification ------------------------------------ 19
Appendix Four: Analyzing System for Wind Speed Gathering ------------------------ 24
PH3000 Operation ------------------------------------------------------------------------------- 26
FS200 and Computer Connection ------------------------------------------------------------ 29
Confidential
2
© CMS Magnetics 2007, 2008
Models and parameter List
Model
Rated Power (w)
Rated Voltage
Rotor Diameter (ft.)
Startup Wind Speed (mph)
Nominal Wind Speed (mph)
Shutdown Wind Speed (mph)
Rated Rotate Speed (rpm)
Tower Height (ft)
Inverter Type
Suggested Battery Capacity
PowerMax+300W
300
24VDC
8.20
5.6
15.7
35.8
400
20 (Guyed Wire)
Modified Wave
12V150AH x 2
Model
Rated Power (w)
Rated Voltage
Rotor Diameter (ft.)
Startup Wind Speed (mph)
Nominal Wind Speed (mph)
Shutdown Wind Speed (mph)
Rated Rotate Speed (rpm)
Tower Height (ft.)
Inverter Type
Suggested Battery Capacity
PowerMax+2KW
2,000
120VDC
10.50
4.5
20
35.8
400
26
Sine Wave
12V200AH x 10
Model
Rated Power (w)
Rated Voltage
Rotor Diameter (ft.)
Startup Wind Speed (mph)
Nominal Wind Speed (mph
Shutdown Wind Speed (mph)
Rated Rotate Speed (rpm)
Tower Height (ft.)
Inverter Type
Suggested Battery Capacity
Confidential
PowerMax+500W
500
24VDC
8.20
4.5
17.9
35.8
400
26
Modified Wave
12V200AH x 2
PowerMax+3KW
3,000
240VDC
14.80
4.5
22.4
55.9
220
39.37
Modified Wave
12V200AH x 20
PowerMax+10KW
10,000
240VDC
26.25
4.5
22.4
55.9
180
39.37
Sine Wave
12V400AH x 20
PowerMax+1KW
1,000
48VDC
8.86
4.5
20
35.8
400
26
Modified Wave
12V200AH x 4
PowerMax+5KW
5,000
240VDC
21.00
4.5
22.4
55.9
200
39.37
Modified Wave
12V300AH x 20
PowerMax+20KW
20,000
360VDC
32.81
4.5
26.84
100
90
59
Sine Wave
12V800AH x 30
3
© CMS Magnetics 2007, 2008
Confidential
4
© CMS Magnetics 2007, 2008
Special attention should be paid to the following when laying out the base and anchor:
1. The two anchors should line up with the pin holes on the hinge. i.e. if you draw a line
between the two anchors, the line should go through the center of the two pin holes.
2. All the anchors should be on the same level with the tower base so that the pulling force
from the two side anchors will be equal. Otherwise, the tower will bend or breakdown
when you fasten the rear cable.
Disclaimer: Since the soil conditions vary from location to location, please consult with a soil analysis company or structural engineering firm in your area about the structural data in this manual. Please understand that A&C will not responsible for the structural failure caused by the base problems. Step 2. Preparing the Concrete Bases for the Tower and the Anchors
1. Dig the holes to follow the pattern as shown in Fig. 1. Please refer to the Table 1 for the
dimensions of the holes.
Confidential
5
© CMS Magnetics 2007, 2008
2. Please choose cement C25. The 4 anchors should be installed with the bolts being
plugged in the cement. The 4 anchors should be oriented in the way which is described
in step 1. Put the bolts in the cement before it cures. (As shown in the graph 2).
3. The anchors should have a 60° to 80° angle to the horizontal plane. Make sure the
anchors are evenly distributed along the circle and they all have the same distance to the
center base. All the connection rings should be on the same level.
Confidential
( Graph 3)
6
© CMS Magnetics 2007, 2008
Step 4 Assembly the tower and wind turbine
1. Insert the main section of tower into the base, then slide the pin through the tower and base, lock it with the split pin. (As shown in the graph 4) 2. Connect each section of tower one by one, and place the tower on the supporting stand after assembly. 3. Insert the generator cables into the tower, and pull the cables out of the main section of the tower. 4. Position the generator on the top of the tower and bolt the running flange and tower flange together. Make sure the hub faces upward in order to install blades. 5. Put the three blades on the hub and put on the press pad. Slide the screws into the holes and put on the nuts. Before tightening the nuts, please make sure the 3 blades are evenly installed by measuring the distance between the blade tips. (Graph 5) Confidential
7
© CMS Magnetics 2007, 2008
Make sure L1=l2=l3 ( Tolerance +/- 5mm)
Torque
System
Notes: Please use torque wrench to tight up the blades. Set the torque based on the followings tables,
200 W
300W
500W
1KW
2KW
3KW
5KW
10KW
20KW
15NM+/-
15NM+/-
30NM+/-
30NM+/-
30NM+/-
50NM+/-
50NM+/-
50NM+/-
50NM+/-
1
1
1
1
1
1
1
1
1
Disclaimer: Please follow the above table for the torque settings. Make sure the
wrench is calibrated properly. A&C will not be responsible for any damages caused
by improper tightening.
6. Tighten the screws following the order indicated in graph 6, except 300W system. The 300W system has three blade bolts so tight them up one by one. Confidential
8
© CMS Magnetics 2007, 2008
7. Install the nose cone. 8. For the 3kw and above systems, connect the aviation plug on the generator to the socket of the anemometer, and then install the anemometer onto the generator. Step 5: Preparation before erecting the tower (For 3kw and above 3kv wind turbine)
1. Attach the guy‐wire onto the tower. The two side guy‐wires should be directly connected to side anchor through the turn buckle. The back guy‐wire should be connected to the back anchor. Make sure all the guy‐wires are not tangled. 2. The Jin‐pole is shipped in two segments. Connect the two segments to make one pole. 3. Attach the two thinner wires onto the two ears of the Jin‐pole, and then attach the front guy‐wire to the front ear on the tower and fix it onto the upper pulley. 4. Insert the Jin‐pole into the tower. Attach the two side wires onto the two side anchors, and tighten them. 5. Attach the lower pulley to the front anchor. Attach one end of the longest thinner wire on the pulley of the Jin‐pole. Make sure the other side passes through the lower pulley, and then go through the upper pulley. Finally, attach it onto a hoist or tractor (graph 7). Confidential
9
© CMS Magnetics 2007, 2008
(For 2KW and smaller systems)
1. Connect one end of the 16 meter wire to the winch or tractor. 2. Pass the other end of the wire cable or bracing cord through one end of the ladder (2*4 or 2*5), which will serve as a Jin‐pole. Step 6: Erecting the tower 1. Drive the winch or tractor slowly and the tower will be raised up gradually. Stop at each 15° rising and check the tension of the guy‐wires on both sides. If you find the tension is not balanced, either too loose or too tight, please lower the tower slowly and adjust the length of the guy‐
wires accordingly. Otherwise keep pulling until the tower stands upright. Separate the cord and fix the front guy‐wire to the front anchor. 2. Check and adjust the tension of each guy‐wire so that they are evenly balanced. The tension should not be too tight or too loose. Guy wires that are too tight may cause the tower to bend, while being too loose may cause the tower to be unstable. ----------------------------------------------------------------------------------------- Confidential
10
© CMS Magnetics 2007, 2008
Installation of Tapered Tower Step 1: Choosing Installation Sites Please refer to the installation specification of guyed tower (step 1) Step 2: Make the Concrete Base Refer to the following graphs with the different product models. Confidential
11
© CMS Magnetics 2007, 2008
Step 3: Assembly of the tower and the generator Please refer to the installation specification of guyed tower (step 4) Step 4: Lifting the tower While installing the tapered tower a professionally operated crane is needed. Non‐working people should be far away from the site when hoisting. Step 5: Connect the cable to the upper end of the pole and lift gradually. Step 6: When the tower is at the upright position, align the holes on the tower flange to the holes on the base flange and tighten them. Connection of the Charger Controller There are 3 leads coming from the wind generator and they are to be connected to the charge controller. The connectors to be connected should be marked as wind generator inputs. For the 500 W and 1KW change controllers, there are 4 input connectors, 3 red and one black. Please connect to the red connectors only. Do not connect to the black connector. Please make sure that generator is not generating power when you connect the charge controller and make sure that all the three wires are connected. Not doing so may cause the system damage. Connection of the Batteries 1. Note‐ batteries should remain inside dry buildings with a constant temperature environment. Lay out the batteries, controller and inverter. 2. Connect the batteries in series. 3. Lubricate the connectors for better conductance. Install a fuse on the positive electrode of the battery. The distance between the batteries and the controller should not exceed 3m. 4. Suggested battery capacity for various models (as shown in table 3) Confidential
12
© CMS Magnetics 2007, 2008
5. Charge Voltages for batteries (as shown in table 4) Electric Wiring 1. Off‐grid electric wiring (annex 1) To ensure safety and easy maintenance, please install the switch and fuse according to the diagram. Check for output voltage consistency of the generator, battery and input of inverter. A mistake in wire connection could destroy the generator, batteries and inverter. (For 3kw Systems and Above) a) There are two cables extending from the generator head. One cable has an aviation plug and is the anemometer signal cable. The aviation plug should plug into the socket. The other cable has 5 leads (3 thick leads are for power and the 2 thin leads are for controlling signal, one positive and one negative.) These cables should be connected to the back panel of the charge controller accordingly. b) The anemometer should be installed on top of the generator and vertical to the ground. One end of the anemometer cable should be inserted into the socket under the anemometer and the other end inserted into the socket accordingly. c) Please refer to appendix 2 for controller specification Confidential
13
© CMS Magnetics 2007, 2008
2. Grid‐tied electric wiring All the models can be used as grid‐tied, with the approval of the local authorities. To do so, the grid‐tie controller and inverter are needed when you place the order. Previously quoted prices may vary. Maintenance The wind generators may operate under harsh environments and extreme weather situations. Regular inspection and maintenance are necessary to keep the system operating efficiently. * Using heavy grease, coat the tail connection furling rod. Failed furling can cause your generator to overheat and cause permanent damage. Also grease the generator shaft. Using oil, coat the outside blade mounting brackets. These steps are crucial in preventing possible corrosion of these parts and also could cause generator damage. 3‐month maintenance schedule: 1. Check tensions of the guy‐wire. Make sure the wires are evenly tightened. The wire should be neither too tight nor too loose. This check has to be done at the installation time and again one week later, to correct any stretching or climactic adjustment. 2. Check electrical wires for connectivity and make sure they are not damaged or corroded. 3. Maintain the batteries as per the battery owner’s manual. 4. If at all possible with proper warning before a big storm, lay down the tower to avoid unnecessary loss. FAQs and Trouble Shooting • Why the system may not have output power after the inverter is connected? o Check the diversion load and the charge controller. The charge controller has voltage and current indicators. So if there is not enough power generated, the system will not output energy. Also check the battery voltage, since if the battery Confidential
14
© CMS Magnetics 2007, 2008
voltage is low, it will not output energy either. But in case the energy is enough and there is still not output, please check the electrical wire connections between batteries and inverter and make sure there is no open wire shorts. • Why the batteries cannot be charged? o Check whether or not the rotor is rotating. The generator has no output at too high or too low wind speed. If the rotor works normally, disconnect the generator’s wire from the charge controller and check the generator output with a multi‐meter. If the generator output is normal, please check if the batteries are ok, otherwise check the generator wiring. • Why the rotor may not rotate at a normal wind speed? o Check if the generator output is short circuited. The generator won’t rotate when the generator is short circuited. Be sure to disconnect the batteries from the charge controller when you perform this checking. • How to lay down the generator? (For 3kw & above 3kw) 1. Stop the generator. Change control manner to “manual”, and then hold on the “REVERSE” or “TURN” to make the generator turn a 90 degree to the wind direction. 2. After the blades stop rotating, disconnect the three generator leads. 3. Hold down the “REVERSE” or “TURN” to make the generator’s tail face the direction of the ground. 4. Do the reverse steps of installation to lay down the generator. (For 2kw & below 2kw) 1. Disconnect the generator from the controller. Disconnect the generator output to prevent the generator from running. 2. Perform the reverse steps of the installation to lay down the generator. Confidential
15
© CMS Magnetics 2007, 2008
o Can I increase the battery capacity to increase the running time for electrical appliances? ƒ Increasing the battery capacity may cause the batteries to be under charged and shorten the battery life. o Wind turbine which is 3KW or above cannot follow wind direction automatically. 1. Check and make sure the controller has been set to “AUTO” position. 2. Observe the wind speed indication on the controller to check whether the anemometer is broken or not. 3. Check whether the dogvane is broken or not. First, unplug the dogvane from the controller. There are three plug wires marked
resistance between and
the resistance between ,
,
. Using a multi‐meter, measure the . The resistance should be approximately 1000Ω. Then measure and , along with and
. The resistance figure of these two should be equal to the resistance figure between and 3. Even if after any suggested checks and/or adjustments, the system still cannot follow the wind direction, the cause is most likely a low wind speed. A properly operating system needs wind speeds of at least 3m/s (about 7mph). ƒ How long is the generator’s lifespan o Under normal care and maintenance, your generator will efficiently produce energy for 15 years. If you have further questions, please contact us by phone or email. A&C Green Energy 1108 Summit Ave, Ste 8 Plano, TX 75074 866‐WNDPWRD techsupport@acgreenenergy.com
• Images and photographs may vary. • This manual may be modified without notice. • Turbine warranty is 2 years • Controller and inverter warranties are one year from the date of delivery Confidential
16
© CMS Magnetics 2007, 2008
Confidential
17
© CMS Magnetics 2007, 2008
Appendix Two: Controller Specification (3kw & above 3kw) 1. Upon system startup, the controlling board will indicate “auto” and “turn‐on”. When the wind speed reaches at least 2 m/s under this state, the wind turbine will automatically track the wind direction. If the batteries are full or the wind speed is too strong, the turbine will furl automatically until shutdown. 2. The system can also be manually adjusted for wind direction using “forward” or “reverse”. When the wind speed is strong or the batteries are charged fully, the turbine will not shut down automatically. 3. When the operation of wind turbine is not needed, press the shutdown button or simply turn‐off the system. The turbine will automatically face the wind and achieve shutdown. 4. The system will continuously check the batteries’ voltage when the system is under a normal state of generating power. The system has an automatic alarm when over voltage or under voltage. When over voltage, a shutdown order will be transmitted. The over‐voltage alarm is set on 300V, alarm voltage cancellation 280V and under voltage alarm 210V when it leaves the factory. 5. The function of the anemoscope is to check the real‐time wind speed. This is indicated by “working” or “non‐working”. Under working state, the system will automatically face the wind and generate electricity. There are “non‐wind” and “over‐wind” in the “non‐working” state. When in the “non‐wind” state, the system moves into sleeping state. In the “over‐wind” state, the system will immediately send out a furling order, and then will go into the shutdown mode. Confidential
18
© CMS Magnetics 2007, 2008
Following table indicates the factory settings: Note: anemoscope should be installed on the wind turbine system of 3kw and above 3kw; otherwise the system will not operate normally. Appendix Three: Specification of wind­speed monitor (FS01) The function of the wind speed monitor (WSM) is to indicate the real‐time wind speed and wind scale, sending an alarm when the wind is too weak or too strong. The WSM consists of a wind speed sensor (FS10), wind speed scope (FS100) and connecting wire. System owners are encouraged to use their local wind resources to learn more about using these monitors. Front of wind speed scope (Picture 9) Confidential
19
© CMS Magnetics 2007, 2008
Back of wind speed scope & wire‐connecting way (Picture 10 Wind speed sensor (FS10) (Picture 11) Confidential
20
© CMS Magnetics 2007, 2008
Structural features (Picture 12) 1. Specification of each part 1) Anemoscope board 2) Liquid crystal: turn‐on, the background light is on. (It will shut down automatically after 5 second if there is no operation.) Wind speed figure is displayed, such as 8.4m/s. and wind scale, such as 5. 3) Operation indicating light: The green light is on if it is under normal operation 4) Under wind speed (Wmax) indicating light: When the wind speed is under W≤Wmin state, there will be alarming. Press any key will make the alarming sound nonexistent. 5) Over wind speed (Wmax) indicating light: When the wind speed is under W≥Wmax state, there will be an alarm indication. Pressing any key will make the silence the alarm. 6) Function key: after pressing this key, you will enter into the menu to set the parameters. 7) Figure key: While in the parameters menu, press this key to advance the cursor one space; pressing this key continuously will allow the requisite figure to be set. 8) Shift key: press this key to switch among different figures; combined with figure key, you can set the requisite Wmin, Wmax and return difference. Confidential
21
© CMS Magnetics 2007, 2008
2 parameter setting: a. Press the function key to enter into the setting menu of Wmin and Wmax (as shown in the diagram 13). Unit: m/s; the cursor on the second figure 2; press shift key, modify the figure; press the figure key to modify the figure. b. When the above procedures have been done, press the function key again once, and you will enter into settings menu of Wmin and Wmax (as shown in the diagram 14). Navigating the settings menu is the same. c. After having all the figures set, press the function key once again; the LCD screen will display the menu: parameter has been set. 3 Alarming & relevant display 1) Over wind speed alarm (wind speed W≥Wmax): e.g.: (diagram 15): background light is on, alarming; meanwhile, over wind speed indicator light is on. When under the state of W < Wmax‐, the alarming will be unchanged. Wmax‐: return difference of over wind speed. Wmax‐ <= Wmax should be set. Confidential
22
© CMS Magnetics 2007, 2008
2) Under wind speed alarm (wind speed W≤Wmin): e.g.:(diagram 16): background light is on, alarming; meanwhile, under wind speed indicator light is on. When under the state of W>Wmin+, the alarming will be unchanged. W min+: return difference of under wind speed. Wmin+ >= Wmin should be set. If under wind speed alarming is not needed, please set W min+ and Wmin on zero. 3) Press any key, and the alarming sound will be unchanged. But the indicator light is still on. The background light will be on again when alarming. Confidential
23
© CMS Magnetics 2007, 2008
Appendix Four: Specification of Analyzing System for Wind-speed Gathering
(FS02)
The system of measuring wind consists of wind‐speed sensor (FS10), dogvane (FS20), data collector (FS200) and matched cable. Usually, data collector (FS200) can display the information of wind speed, wind direction and set the parameter. Meanwhile, the following will show the procedure of connecting the wind‐measuring system and computer. FS200 is served as measuring and recording wind speed and wind direction (ready for use). It has a capacity of cycle record of 8000 history record. Targeted ‐ design nixie tube, an LCD screen and keyboard make operation of FS200 easy and convenient. It can also communicate with the computer to record the wind speed and wind direction data, which will be observed and analyzed by FS200. Feature: 1. Running mode of low power consumption: FS200 will automatically turn off the nixie tube and the LCD screen, so it can run in low power consumption mode. 2. The wind cup of the dogvane sensor is made of carbon fiber, which enhances strength and contributes to the longevity of the equipment. Confidential
24
© CMS Magnetics 2007, 2008
Installation & Connection 1. Wind ‐ speed Sensor installation Install the wind‐speed sensor on the supporting frame. If there is wind available, the three cups of wind‐speed sensor will run. 2. Connection of FS200 and wind‐speed sensor Insert the aviation plug of the wind‐speed sensor’s signal line into the aviation socket of FS200. 3. Connecting FS200 to power supply 12V power supply is applied to FS200. Connect FS200 to 12V power supply. Special attention is paid to the anode and cathode and do not reverse them. Check the wind‐speed sensor, the connection between wind‐speed sensor, and the correct connection of the FS200 power supply. If there is no problem concerning these aspects, you can power it up. When the FS200 is running, the present wind speed is displayed on the nixie tube while the present wind direction is displayed on the LCD screen. Confidential
25
© CMS Magnetics 2007, 2008
PH3000 Operation Note: Illumination: the four direction keys control the movement of the cursor, press “Æ” to enter the menu option, press “Å” to return to the up menu, press “+” (“‐“) to increase (decrease) the parameter. Confidential
26
© CMS Magnetics 2007, 2008
“+” “‐“ to change the system time, “Å” to exit the set of system time, then auto update the system time, then auto update the system time. Confidential
27
© CMS Magnetics 2007, 2008
It is used to set interval of the history data, 1 min~60 min adjustable. Suppose that it is set 2 minutes, and then the time of PH3000 can record is: 8000/30 min/24 hours = 11 days When wind speed exceeds the upper limit, relay is closed and an alarm will sound. This function is optional. It is used when communicating with the computer and corresponds to the weather station ID of the computer software. After correct set‐up, the PH3000 will work persistently. FS200 and Computer Connection Connect the RS232 serial of the FS200 to the RS200 serial of the computer and have the FS2000 computer software run. The PH computer software reads the present wind direction monitored by the dogvane. This history data can be saved to a Microsoft ASSEDD database and can be analyzed through either a table or curve view. The computer software can also set the parameters of the real time clock and history data recording interval of the dogvane. Operation of software FS200 (diagram 23)
Confidential
28
© CMS Magnetics 2007, 2008
Choosing weather station The system default is weather station 10, which is consistent with the address of the wind‐speed dogvane. Open serial Choose the serial, and set the communication baud rate on 9600bps, and then open the serial port.
Read the setting data Click the download button to get the current wind speed and wind direction data. Or click “update the settings data automatically” to choose the time interval for automatic updating. The software can automatically gather wind speed and direction at a programmed interval. Confidential
29
© CMS Magnetics 2007, 2008
Download the history data Read the history data of the anemoscope by clicking the “reading history data” button. The history data is saved in the Microsoft Access database. Users can observe and analyze history data of wind speed by either table or curve view. Setting system parameter (Diagram 24) The system parameters of the anemoscope include clock parameter, time interval of history record and alarm set. Setting of supporting angle (Picture 25) Confidential
30
© CMS Magnetics 2007, 2008
Curve view (Diagram 26) To view a curve diagram of a certain history, select the data scope of the history you need to check, and then click the curve view. Rose diagram of wind (Diagram 27) A rose diagram of wind can illustrate the distribution and scope of different wind directions all the year around. Confidential
31