Manual_Alize_V3.4 - Fortis Wind Energy

FORTIS Wind Energy
Alizé Wind Turbine
Instruction Manual
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including photocopying and recording, for any purpose without the express written permission of FORTIS WIND
ENERGY.
FORTIS WIND ENERGY reserves the right to make changes to any and all parts of the documentation, at any time,
without obligation to notify any person or entity of such changes.
© Copyright 2013, FORTIS Wind Energy all rights reserved.
Fortis Wind BV
9751 AC Haren
The Netherlands
Manual Alizé
Page 2 of 42
§ Table of Contents §
Index:
Page
Important security notice
6
1
Introduction
7
2.
Selection of location and tower height
7
3
Assembling Power head:
8
4
5
6
3.1
- Generator
8
3.2
- Rotor blades
8
3.3
- Tail and Tail vane
8
3.4
- Mast Adapter
8
Instructions Mast:
9
4.1
- Producing a Mast yourself
9
4.2
- Foundations
9
4.3
- Installation preparations
10
Electric Installations:
11
5.1
- Transmission lines
11
5.2
- Rectifier & Battery Charging system
11
5.3
- Grid connection
12
5.4
- Batteries
12
5.5
- LC Filter
12
5.6
- Brake switch
12
Final assembly of system/electronics:
Manual Alizé
13
Page 3 of 42
§ Table of Contents §
7
8
Erecting the turbine in the upright position:
7.1
- Safety first
14
7.2
- Conditions during installation
14
7.3
- The installation erection procedure
14
7.4
- Guy wire tensioning
15
7.4.1 - Determining the proper
frequency of the cable
16
7.4.2 - How to oscillate the cable
16
7.4.3. - Procedure for tensioning the cable
16
7.4.4 - Cautions, Hints and Suggestions
17
7.5
17
- Start-up procedure
Appendix:
Manual Alizé
14
18
8.1
- Torque specifications
18
8.2
- Required tools
19
8.3
- Technical data Alizé
20
8.3.1 - Power Curve Alizé
21
8.4
- Trouble shooting list
22
8.5
- Maintenance/ checklist
23
8.6
- Drawings foundation
24
8.7
- Drawing foundation blocks
25
8.8
- Drawing Mast
26
8.8.1 - Drawing mast specifications
27
8.8.2 - Drawing mast specifications
28
Page 4 of 42
§ Table of Contents §
9
8.8.3 - Drawing mast specifications
29
8.8.4 - Picture of Alizé with guyed tower
30
8.9
- Dimensions Alizé wind turbine
31
8.10
- Tail assembly
32
8.11
- Tail & Vane of Alizé
33
Parts list
34
9.1
- GFI – 10K2 Grid Feed Inverter
35
9.2
- Electric schema Alizé to 3 phase network
40
10 Safety and control procedures
41
11 Declaration of Conformity
42
Manual Alizé
Page 5 of 42
Important security notice
Note: For successful operation of your wind turbine, it is
essential to read this manual carefully prior to installation.
Important security notice
This Instruction Manual contains important operational guidelines and security considerations that
require your attention. Before installation, it is essential that the user first studies this user's manual
in detail and keeps in mind the safety matters that need attention. During user installation and
operation one must refer to this handbook's documentation. If you are unfamiliar with installation
as shown below, DO NOT CONTINUE and let a qualified Technical Engineer proceed with correct
installation. Failure to comply with the guidelines and instructions will void your warranty.
WARNING!
Do not change anything of the wind turbine parts or do not paint the blades. If you do so you lose
the right of warrantee. Any change can have effect in the behaviour of the wind turbine.
Manual Alizé
Page 6 of 42
1. Introduction
Thank you for choosing FORTIS Energy
systems. Your choice means proven
reliability, low maintenance costs (if any) and
the convenience of an independent power
supply.
FORTIS Wind turbines are designed to
withstand most of the environmental
condition at the earth. Even Siberian as well
Tropical conditions can have benefited from
the reliable power the FORTIS Wind turbine
produces. FORTIS tests their systems under
the worst possible weather conditions.
FORTIS Wind turbines will be installed at all
over the earth Therefore the FORTIS
products are designed on such a way that they
can be installed and erected successfully with
a minimum of tools and technical know-how.
Also unskilled people are capable of
maintaining the system with a minimum of
tools and knowledge.
A FORTIS-system is almost always
composed of various components: the wind
turbine itself is only one component of this
system. We can supply controllers for battery
charging and for grid connection. For hybrid
systems, controllers are available to couple a
photovoltaic solar generator or to a diesel or
petrol generator together to a FORTIS Wind
turbine. In other words, the possibilities with
an FORTIS Wind turbine are endless in the
sense that they can be adapted to suit almost
every conceivable application.
2. Selection of location and
tower height
For a good performance of your wind turbine
it is necessary to install the FORTIS ALIZE
in such a way that the wind has an
uninterrupted flow from all directions to the
propeller.
Any obstructions such as trees, hills or
buildings, even if they somewhat lower than
the wind turbine, will cause “rough” air
Manual Alizé
current which seriously decrease the
generator output. The rough air current have
lost a large part of their original power and
continually shift both horizontally and
vertically which may cause the generator to
vibrate to some extent. The higher the wind
turbine is situated the better, as the air current
are smoother and steadier further from the
ground. All of these factors should be
considered when selecting a satisfactory
location for the wind turbine.
Read more about this issue in the publication
of Paul Gipe: “Windpower Renewable
Energy for Home, Farm and Business”
Chelsea Green Publishing Company;
www.chelseagreen.com
The wind turbine hub should be
mounted at least 10 meters above
any obstruction within 400 meters
Another important fact to keep in mind is that
the wind turbine should be mounted as close
as possible to the battery bank. The further it
is mounted from the battery bank, the greater
the loss of energy in the wires. In order to
minimize this loss of energy in the wires, we
have provided information about the wiredimensions in section 5.1.
This list also shows that if the wind turbine is
placed further from the battery, the wiring
costs will be higher. There are two reasons for
this: firstly, a greater length of wire will be
required and secondly, the diameter of the
wire will have to be larger.
Install the wind turbine close to the
house and high enough to receive an
unobstructed sweep of the wind
Page 7 of 42
3. Assembling the power head
The FORTIS ALIZE power head consists of
the following parts;
-
Generator
-
Rotor blades
-
Tail and Tail vane
-
Frame/Mast adapter
3.1 Generator
When you first open the crate, check the
contents carefully starting with the generator
and its support-frame. First make a visual
check to determine any existing scratches,
dents or cracks. Then rotate the shaft of the
generator by hand. This must rotate smoothly
(<10.0N/m). If it does not, check whether
there is no short-circuit in one of the phases.
(out coming wires might be connected
somehow)
Normally the generator is already attached to
the support frame with a specified torque
(appendix 7.1) so there is no need to tighten
the eight M14 bolts. The power head is
bolted to the crate it is transported in, before
you undo these bolts, remove all other
components inside the crate. We advise to
wait with unpacking the power head till its
mast is ready to receive it. The power head
can then be moved straight from the crate on
to the mast top.
3.2 Rotor blades
The large cardboard box contains the rotor
blades and parts of the tail frame. Unpack the
rotor blades and make a visual check for any
existing cracks or scratches. When nothing is
visible at all, the blades can be mounted on
the hub. Every single blade has its unique fit
to the hub, and in addition to this the blades
are marked with a number (serial number +
blade nr. 1, 2 or 3 ) that corresponds with
number on the hub plates. The numbers are
Manual Alizé
always on the front side of the hub plates. The
flat side of the blades should face the wind as
is the front side of the hub.
There is only one way to fit the rotor blades
to the generator. The bolts are positioned in
such a way that assembling in another way is
not possible.
First assemble the rotor blades to the hub
plates. Use a flat and clean area to work. Fix
the rotor blades with the 3x M12 bolds.
Assemble first the complete tower and
generator with tail. The final part should be
the rotor blade set. You need 3 people to put
the rotor over the 3 x 3 M14 bolds on the
generator. It’s possible that you need some
pressure to put the rotor to the generator. Use
a gummy hammer or use a piece of wood
together with a heavy steel hammer to move
the rotor to the generator.
3.3 Tail vane
The tail vane assembly is composed of 3
sections. The 3 parts are the tail vane which is
bolted inside the crate with hinge section and
the tail beam which is packed together with
the rotor blades in the cardboard box. The tail
& vane can be fully assembled according to
the instructions on page 34.
Note: on the stainless steel shaft of 22 mm,
there are 2 lock pins assembled and a glider
ring.
When you assemble the tail hinge to the
frame don’t forget this ring. It avoids noise
when tail furls. Put this ring between the two
stainless steel bushes at the top.
3.4 Mast adapter
The mast adapter is a part of the support
frame supplied with the ALIZE system.
Before you bolt it on top of the mast, make
sure that it fits well in the support frame and
can be rotated by hand. The azimuth bearing
is a special bearing with high friction. It is
normal to use some force rotate the mast
adapter.
Page 8 of 42
When any parts of the wind turbine show
damage that might have occurred during
transportation, inform your local supplier
or FORTIS directly about this. If you do
not report such damage or the turbine is
already in operation, you lose the right to
your warranty !
In most cases FORTIS advises the use of the
guyed steel tubular mast as it is inexpensive,
easy to build, easy to erect and FORTIS can
provide all the required calculations. These
calculations can be very important when
planning permission has to be obtained.
The drawings for a guyed steel tubular mast
are provided in this manual. The masts are
designed according to a modular system with
6 – 8 m modules, guyed every 12m.
(Appendix 8.8)
4 Instructions Mast
3.1
-Producing a Mast yourself
4.2 Foundations
3.2
-Foundations
3.3
-Installation preparations
When FORTIS has delivered the tower for
your wind turbine this owner’s manual
include a full set of drawings and
specifications of the foundation. If you plan
to produce your own guyed tower follow the
instructions below.
4.1 Producing a mast yourself
FORTIS can deliver for your wind turbine a
steel tube towers of 12,15,18 and 24 m high
and guyed towers of 18, 24 and 30 m high.
Producing a mast for your FORTIS wind
turbine is relatively simple. Various
constructions are possible but in most cases a
steel tubular mast with guy wires is used. It is
also possible to use wooden poles, free
standing steel tubular masts or free standing
lattice masts. Even concrete masts are a
possible option.
On request we give forces at the top of the
tower, which enable you to make the
necessary stress calculation of your own build
tower. For these stress calculations you take a
safety factor of at least 2 (two) for the peak
loads and at least 10 (ten) for the amplified
(fatigue) loads.
FORTIS does not take any responsibility for
own build towers and its foundation based on
the tower top loads and drawings supplied by
Fortis
Manual Alizé
As there is such a wide variety of masts
possible, we only describe here the
foundations for the standard guyed steel
tubular mast according to the standard
FORTIS design. There are three ways to
make a proper foundation for the mast and
guy wires:
1) The first type of foundation is for very soft
and unstable ground: for this type, concrete
blocks of a certain weight have to be used.
Drawings for this type of foundation are
provided in appendix 8.6.
2) The second type of foundation is for rocky
ground: this type requires the use of rockbolt's for the tower and the guy wires. Make
sure that the rocks are heavy enough.
FORTIS can provide and specify the rockbolts on request. The size and weight of the
rocks must be about the same as the concrete
blocks described in the foundation drawings.
3) The third type of foundation is for medium
soft but stable ground: for the guy wires,
earth-screw-anchors are used and for the
mast, a small concrete block will be
sufficient. The earth-screw-anchors can be
Page 9 of 42
specified and provided by FORTIS. The
concrete block is the same as in appendix 8.6.
4.3 Installation preparations
If you plan to use a steel tube tower or
concrete tower you need a crane to erected
the wind turbine. It is important to follow the
instructions of the crane driver for safety
reasons.
In case of a guyed tower is used without help
from professionals follow the instructions
below.
Before the mast is placed in a horizontal
position, bolted to the base-plate, make sure
the mast will be lifted towards the main wind
direction. Lift and support the top of the mast
in such a way that it is possible to assemble
the support frame mast adapter to the mast
top. Check if the mast adapter will rotate
freely in to the support frame. Before you
assemble the tower to the support frame, it is
necessary to pull the power lines through the
mast. For your FORTIS ALIZE machine, 3
flexible wires of 4 to 10 mm² will be needed
to transport the power from generator. They
must be pulled through the mast first, and
then through the pull release glands in the
support frame adapter. It is important to fix
the cables in the glands very well because
they have to carry the full weight of 18 to 24
m cable hanging in the tower The connecting
wires must not get stuck anywhere on any
part of the wind turbine. Make sure the wires
can move and rotate freely inside the mast.
Any possible problems in this area can cause
a short circuit. For the power line use three
wires with the same colour to indicate the
three similar phases. These three wires must
be connected to the three wires coming from
the generator, the connector block can be
found in the box that is attached to the
generator. The order of connection is not
important since all three lines are equal at
both sides.
When have connected the power lines and the
tower to the support frame check the
Manual Alizé
generator and rotor hub rotating smoothly.
You can rotate the hub with a force of 10 Nm.
If not or if only with a very large force it is
possible that there is a short circuit in the
system. Check all the cables and connections
Loose the power cable from the terminals. If
it is still difficult to move the rotor hub there
is short circuit in the generator, or something
wrong with the generator bearings or another
failure. Contact your agent or FORTIS.
The next stage involves the guy wires: a
standard FORTIS ALIZE mast according to
FORTIS specifications is guyed every 10 12m, in four directions. Make a calculation of
the length of each individual guy wire. The
guy wire is prepared with a length of the
calculated value + 1 m ( necessary for the
connection with cable clamps). Then connect
the guy wires to the mast and to its
foundation. The only guy wire that cannot be
connected is the one directly opposite the
direction in which the mast is pointing. This
guy wire should be connected when the mast
is in the upright position. All guy wires are
connected to the mast with a bow shackle and
cable thimble, to the foundation with a cable
thimble, rigging screw and at least twin cable
clamps. The cable clamps must be fully
tightened before lifting the mast.
The next component to install is the tail vane.
The tail assembling is given in section 3.3.
The tail uses a stainless steel pin as spindle.
This pin must slide into the tubular section of
the tail frame where it passes through two
Teflon bearings The Teflon bearings don’t
need any additional lubrication; however,
applying grease extends the life of the
bearings to some extent.
Next to install are the rotor blades as
described above in section 3.2
Before assembling and close the polyester cover we
will make an operational test of all vital components.
Page 10 of 42
5 Electric Installations
5.1
-Transmission lines
5.2
-Voltage control/ dump load
5.3
-Grid connection
5.4
-Batteries
5.1 Transmission lines
The electric wires have to be flexible and
should not consist of a single solid copper
core. Furthermore, the isolation wrapping of
the wires should be UV-resistant (PVCisolation cannot stand UV light).
Prevent the damaging of the electric wires by
sharp edges. Any damage to the electric wires
will lead to short-circuiting and the rotor will
stop rotating, or even worse, the rectifier
bridge might be destroyed because of too
many amperes. Never let the wires hang with
their full weight on the cable terminals.
For the wire-gauge dimensions see the next
table:
The FORTIS ALIZE generator is a 3 phase
generator and 3 electric wires are needed to
connect the generator with the rectifier
bridge. The maximum rectified current is 60A
and peak voltage is 600 VDC. The working
temperature of the components is –40°C to
+50°C.
Length (m) including tower
Permitted power loss
240VDC systems
< 5%
> 10%
0 - 50
10 mm²
4 mm²
50 – 85
16 mm²
6 mm²
> 85
25 mm²
10 mm²
450VDC system grid system
0 – 100
4 mm²
2,5 mm²
100 – 160
6 mm²
4 mm²
> 160
10 mm²
6 mm²
5.2 Rectifier and battery charging
system
Use always the Fortis UN_Voltage Controller
240VDC and dumploads with the Alzé
system for battery charging. The Fortis
UN_Voltage Controller is an active rectifier
to make DC form the AC power form the
wind turbine. The microprocessor prevents
over-charging of the batteries by switching
power to the dump load.
Manual Alizé
When the batteries reach a threshold value,
the microprocessor will keep the charge
voltage constant and reducing the charging
current by switching wind turbine power
partly to dump load.
It is advisable to mount the rectifier and
microprocessor as close to the batteries as
possible to minimise electrical losses. When
the controller is housed in the same room as
the batteries, the room must be well
ventilated.
Page 11 of 42
WARNING: The brake-switch short circuit the generator and will bring the
rotor stop rotating up to wind speeds of 8 - 9 m/sec. Never let the brake switch
on for more than ten minutes if the rotor does not stop because of high wind
speeds. The generator can be overheated and destroyed.
5.3 Grid connection
5.5 LC Filter
Grid connection is one of many options with
a FORTIS system. In a grid-connected
FORTIS ALIZE system, a Fortis GFI-10K2
Controller is used, all in one housing.
The controller is needed to rectify the AC
output of the wind turbine and to protect the
inverter against peak voltages when the load
is disconnected. The grid controller is build
for max operation voltage of 400VDC. Use
always the Fortis GFI-10K2 and Brake
Switch for save operation with the dumploads
supplied by Fortis.
5.4 Batteries
Batteries need to be kept in a place with
sufficient ventilation and no risk of freezing.
Charged batteries can stand temperatures of
up to minus 20°C, but uncharged batteries
cannot withstand frost at all. Place the
batteries underneath the voltage control in the
same room if possible as this minimises
energy loss in the wires. A battery is normally
2, 6 or 12 V so you need 120, 40 or 20
batteries connected in series for 240 VDC.
Connect the minus terminal of one battery
with the plus terminal of the other battery.
The remaining terminals are the plus and
minus of the 240 V battery group. For a
FORTIS ALIZE we advise a minimum
battery capacity of 500 -600 Ah – 240V (10
h), but a capacity of 1000 Ah is even better.
For lead/acid batteries the charging /
discharging current should not exceed 20% of
the capacity.(preferable 10%)
Manual Alizé
Together with the Fortis UN_Voltage
Controller a Filter is supplied. This filter is
installed between wind turbine and the Fortis
UN_Voltage Controller. See installation
wiring diagram 9.1.1. The filter is needed to
avoid EMC noise in the cable from wind
turbine to controller.
5.6 Brake switch
As shown in wiring diagram 9.1.1. install a
brake switch between Wind turbine generator
and filter. In this way it is easy to stop the
turbine in case of service or maintenance. The
brake switch should be used only in case of
service and not for emergency. The brake
switch stops the rotor only at low wind speed.
If the rotor keeps on turning when you put the
brake switch on, release the brake switch
within 10 minutes because the generator gets
to hot in case of running is short circuit.
Page 12 of 42
6. Final assembly
electronics
of
system/
can either be a battery-bank, an inverter for
grid connection or a Pump controller for
water pumping.
When mounting the controller, it is very
important to choose a wall or surface which is
non-conductive.
The last component to connect is the
consumption circuit. The consumption circuit
IMPORTANT!
There is, however, a specific sequence in
which all the above mentioned connections
must be made. This is very important as if the
connections are not made in this order, the
generator or controller can be damaged
during the installation procedure.
1. Set brake switch on stop
2.Connect first always the dump load to the
Fortis Controller before any other cable
3. Connect the 3 phase wire from generator
to the controller
5.The batteries are the last component to be
connected. If batteries are connected to the
rectifier with volt and ampere meters, the volt
meter must show the battery voltage as soon
as they are connected.
Before the wind turbine is erected and during
the process of erection the three phases of the
generator should be short-circuited. See
wiring diagram 9.1.1. for Brake switch
solution. Any other (temporary) way of shortcircuiting the three phases is allowed. It is not
necessary to disconnect the batteries as they
are protected from short-circuiting by the
rectifier bridge. In addition to this, the
batteries and any other consumption circuit
should be properly fused. The fuse for the
battery bank is supplied together with the
controller. FORTIS advises to fuse all other
consumption circuits in accord with their
specifications as required.
Check that all your connections are tightly
and correctly connected.
WARNING: Never connect the wires from the generator to the
controller when the wind turbine is in operation. The open
circuit voltage can be 10x the nominal voltage. This voltage can
destroy the electronics.
Manual Alizé
Page 13 of 42
7
Erecting the turbine in the upright position
7.1
-Safety first
7.2
-Conditions during installation
7.3
-The installation
7.4
-Guy wire tensioning
7.5
-Start-up procedure
7.1 Safety first!
Safety becomes very important when you
consider the amount of serious damage and
injuries that can be caused if a wind turbine
topples over. Firstly, therefore, make sure that
all the nuts and bolts of the wind turbine are
tightened securely. We advise you to make
one person responsible for the final overall
check of all the nuts and bolts. Then let the
same person check all the guy wires, rigging
screws and foundations. During hoisting of
the mast and wind turbine, everybody who is
not directly involved with the process must
keep a distance of (at least) mast height to the
base plate! If a winch is used to erect the mast
and wind turbine, only 2 men are necessary
for the process; one for the actual lifting
(jacking) and one to check the guy wires
during erection. This person should make sure
that the wires do not get stuck somehow or
work themselves loose.
7.2
Conditions during installation
It is not absolutely necessary to wait for a
windless day to erect the mast of an FORTIS
ALIZE wind turbine. The maximum wind
speed for erection of the mast and wind
turbine must not exceed 8m/sec. Only a
FORTIS specialist who is present during
Manual Alizé
installation and erection can decide to
proceed during higher wind speeds. Snowfall
during installation is not necessarily a
problem provided the snow is not sticking to
the blades in large amounts. Snow or ice can
cause rotor unbalance and thus damage the
bearings of the generator.
7.3 The
procedure
installation
(erection)
The simplest way to erect a FORTIS-mast is
to use a gin-pole. It is also the method most
often used owing to the fact that it is usable
under a wide range of circumstances. The
length of the gin-pole must be somewhere
between 1/2 and 1/3 of the length of the mast
and a set of guy wires are required to prevent
the mast from toppling to one side. If only
one set of guy wires is used, connect this one
guy wire to the top section of the gin-pole.
When several sets of guy wires (at different
levels) are used, a guy wire of every set must
be connected to the top section of the ginpole. The last attachment point of the gin-pole
is used for the cable of the winch or cablejack. The gin-pole is now held in place by at
least four cables.
Page 14 of 42
If it is possible to climb the mast when it is in
a vertical position, we advise you to fix a rope
to one of the blades to prevent the turbine
from rotating. Even when it is possible to fix
one of the blades with a rope, the three phases
of the generator must always be connected
(short-circuited).
Be very careful with short circuiting the three
phases when the rotor blades are moving, the
voltage can easily reach dangerous levels !!
The mast and wind turbine can now be
erected!
7.4 Guy wire tensioning
FORTIS has developed and recommends a
method for setting the pretension on guy
wires for all guyed towers. This simple
procedure utilises the relationship between
cable tension and the rate of cable vibration to
give a preload which is proportional to cable
size. It is based on the time required for the
guy cable to complete 20 oscillations at the
fundamental natural frequency.
The approximate desired preloads for the various cable sizes are given below:
EHS Cable size
1/2"(12mm)
7/16"
3/8"(10mm)
5/16"(8mm)
1/4"(6mm)
Manual Alizé
Preload
900 kg
675 kg
450 kg
337.5 kg
225 kg
Page 15 of 42
7.4.1 Determining the proper frequency of the cable
1.
Determine the length of the cable in metres from the guy bracket to the
ground.
2.
Divide this length by 3.
3.
This gives the number of seconds which are required for the cable to make 20
complete cycles.
4.
The process is very sensitive to this time period. Doubling the time required to
make the 20 oscillations will result in 1/4 of the desired guy tension. We
recommend therefore that the tension be adjusted until the time period is
within 1 second of the recommended value.
Calculation example: assume the following geometry:
Height of guy fixing point = 12m
Distance mast-foundation point = 6m
This gives a total cable length of 13.4m. Dividing by 3 gives 4.5 seconds to complete the 20
oscillations.
7.4.2 How to oscillate the cable
Any cable under tension will tend to oscillate at a certain natural or fundamental frequency
which is dependent upon its tension, weight per meter and length. It is very important that the
cable be moved back and forth at this frequency. The cable should trace out the pattern
shown below in a regular, consistent way without whipping or distorting into other shapes.
IMPORTANT: the frequency of oscillation is independent of the magnitude of oscillation.
The idea is then to vary the tension of the cable until the proper frequency of oscillation is
observed.
7.4.3 Procedure for tensioning the cable
1.
Stand at one anchor and move the guy wire back and forth at its natural frequency.
2.
Measure the number of seconds required for the cable to make 20 complete cycles.
3.
Compare this time period with the recommended value.
4.
If necessary, adjust the tension and go back to point 1.
Manual Fortis Alizé
Page 16 of 42
7.4.4 Cautions, hints and suggestions
1.
Use your common sense. If the guy wires start making noises something like a
guitar, they may well be too tight, so stop tensioning. You may be doing
something incorrectly.
2.
This procedure cannot be used under all wind conditions. If the wind speed is
above 7m/sec., then your readings will not be accurate owing to the additional
forces on the tower caused by the wind. Furling the wind turbine and stopping
the rotor will reduce these additional forces and allow the use of this procedure
in winds of up to 10 m/sec.
3.
Do not use this procedure if the cable size is different from that recommended
by FORTIS. For example, if the cable is larger, the result will be tension
forces which are much greater than the recommended value.
4.
On an FORTIS tilt-up tubular mast with 4 anchor points the cables which are
at the same height but opposite to one another will tend to develop the same
pretension. Both cables may require adjustment, however, for the tower to
remain straight.
5.
Do not attempt this procedure if ice is present on the cable. The extra weight
of the ice will give incorrect results.
7.5 Start-up procedure
Provided the wind turbine and mast are in the final position and there is some wind (more
than 2,5 m/sec.), the start-up procedure can take place.
Provided all the electric connections are correct, you can release the brake switch and he will
automatic run the start-up procedure. If there is sufficient wind, the turbine will start to rotate
and power will be produced. Evidence of power being produced is provided as soon as the
ampere meter of the voltage control indicates anything above zero. When the controller is not
equipped with volt and ampere meters, a multi meter can be used to check the system; even
the slightest increase in voltage indicates power coming from the turbine. Do not be
disappointed when the wind turbine does not start up in winds slightly above 3 m/sec., as it
sometimes needs a short running-in period. When lifted the windturbine with generator short
circuit, the wind turbine will start to rotate very slowly if there is sufficient wind,(less than 5
revs/min.).
A final check can be made when the turbine is producing some power; check the voltage over
a period of several hours. If all the connections are made correctly, the voltage will increase
slightly although the difference may be minimal.
Manual Fortis Alizé
Page 17 of 42
8 Appendix:
8.1 Torque specifications
Specification bolt/nut
M16*50
M12*100
M14 nuts
M18*60
M8* 40
M12*100
M14*50
M8*20
Manual Fortis Alizé
Description
Main shaft
Rotor hub
Rotor hub
Mast top and mast flanges
Tail vane
Tail boom assembling
Generator-chassis mounting
Nose cone
Torque (N/m)
120 Nm
80 Nm
100 Nm
100 Nm
50 Nm
80 Nm
120 Nm
10 Nm
Page 18 of 42
8.2 Required tools
The following tools are the minimum that required for successful installation:
For tower assembling:
Tractor or lifter to put tower sections together max weight tower section is 600kg
One spanner and one socket wrench size 46 for M30 bolds
To lift turbine with 18m tower max weight 2200kg
Crane 16 m or 22m heigth:
With 16 m the crane remains below rotorblades
With 22 m the crane remains above rotorblades
Rope nylon ( 20m) to remove lifting rope from crane
For windturbine assembling:
Set of spanners 10, 11, 13,17, 19 , 22 and 27 mm
Socket wrench 10, 13,17 , 19 , 22 and 27 mm
Hexagonal key 3 mm / 6mm
Set of screw drivers for electrical terminals
Rubber hammer 2,5 kg
Multimeter (AC/DC voltages 0-500V)
Ratchet
Pincers
Cable stripping tool and cutting tools
For installing controllers and dumploads:
Drilling machine with drills for wood or stone for wall plugs and screw size from 5 up to
12 mm
Mechanical crimping tool for 6 and 10 mm2 cable
Manual Fortis Alizé
Page 19 of 42
8.3 Technical data ALIZE
Max. output
Output @ 11m/sec
10 kW
8.5 kW
Wind speed:
cut in
rated
survival
3,0 m/sec.
13 m/sec.
60 m/sec.
Rotor blades:
number
diameter
area
airfoil
tip speed ratio
material
3
6,3; 6,6 or 6.9 m
31,2 / 34,2 / 37,4 m²
NLF 416
7
Glass-fibre reinforced Epoxy
Generator:
type
rated rpm.
max. rpm.
voltage
frequency
brushless permanent magnet 48-pole
300
350
100 - 400VAC standard
other voltages on request
0-50 Hz
Other:
gearbox
braking mechanism
rotor speed control
output control
rectifiers
hub type
yaw system
rotor position
tower
Head weight
Manual Fortis Alizé
none
generator short circuit
Inclined hinged vane
microprocessor controlled
rigid
tail vane
upwind
steel tubular or guyed tower
(height: 18, 24 or 30 mm)
385 kg
Page 20 of 42
8.3.1 Power Curve ALIZE
Rated Capacity (kW)
12
11
10
9
8
7
6
5
4
3
2
1
0
0
5
10
15
20
25
Windspeed at hub height [m/s]
Type:
Manufacturer :
Rated power
Output ( 11m/s)
Fortis Alizé
Fortis Wind Energy
10.000 Watt
8.500 Watt
Rotor with fixed pitch
Generator and hub
Type
Direction of rotation
Upwind rotor with fixed pitch
Pitch control
Fixed pitch
Hub
Rigid
Clockwise
Number of baldes
3
Generator
Permanent Magnet FORTIS
Synchron Machine
Length of blades
3,0 /3,15/ 3,30 m
Grid feeding
3 x 230V by inverter
Break systems
Rotor Diameter
6,3 / 6,6 / 6,9 m
Ecliptic safety system by inclined
hinged vane 90° setting of tail
short circuit of generator
Rotor area
31,2 / 34,2 / 37,4 m²
Yaw control
Passive Aligned by Tail Vane
Tower
Various types of towers designed
for different sites 18 - 36 m
Weight tower head
385 kg
Profile
NLF 416
Manufacturer
Fortis Wind BV
Blade material
Glass-fibre reinforced Epoxy
Rated speed
variable, max 350 rpm
Rotor axis angle
100
Cone angle
0°
Manual Fortis Alizé
Page 21 of 42
8.4 Trouble shooting list
The rotor blades run very slowly, possible causes:
-
Insufficient wind
-
Short-circuit in the electrical wires *
-
Diodes are damaged *
-
The rotor is mounted in the wrong way (the flat side has to face the wind)
The wind turbine shakes, possible causes:
-
The rotor blades are not in balance * (please stop the wind turbine immediately)
-
Own frequency of blades
-
The rotor blades are not running on the same plane (the hub is misaligned) *
Batteries are discharged, possible causes:
-
Owing to a short circuit the wind turbine is not able to produce power *
-
Damaged diodes, no power is coming from the wind turbine *
-
Batteries are old or in a bad condition and are unable to store power
Rotor blades run very fast, possible causes:
-
Power lines coming from the wind turbine are disconnected
-
Most of the time no problem at all !!!
* Contact FORTIS Wind Energy or your local supplier (FORTIS agent)
BE ALWAYS AWARE ABOUT SHAKING OF THE WIND TURBINE:
The wind turbine can shake because of its own frequency at a specific speed
The shaking becomes worse at higher speed , this means unbalance 'stop wind
turbine'
Also shaking of tail or tower top section can mean unbalance in rotor Blades
Manual Fortis Alizé
Page 22 of 42
8.5 Maintenance / checklist
In principle, FORTIS wind turbines do not require any maintenance at all. On the other hand,
it would be unwise not to check the wind turbine occasionally. FORTIS advises that you
should check the wind turbine at least twice a year. The following points should be checked:
-
Check noises; the noise level should not have increased and should sound
normal
-
Check nuts and bolts; they might have worked themselves loose
-
Check the yaw bearing and the bearings of the tail blade, they must be able to
move smoothly; if they do not, apply some grease to the bearings
-
Check the electrical wires that are hanging through the inside of the mast; the
tension must not be too high; this can occur if the wires have been wound too
far.
-
Check the leading edge of the blades, small damages can be caused by small
objects carried by the wind; such damages will speed up the process of wear
and tear and should be repaired
-
Check the tension of the guy wires, if you have a guyed tower, in the first 6
months regular.
-
Check if the turbine, tail or tower is shaking more than usual. If this shaking
occur only at a specific low speed this means own frequency. If it become
stronger with higher wind speed, stop wind turbine and contact your dealer or
agent or contact Fortis direct.
Manual Fortis Alizé
Page 23 of 42
8.6 Drawing Foundation
Manual Fortis Alizé
Page 24 of 42
8.7 Drawing foundation blocks
Manual Fortis Alizé
Page 25 of 42
8.8 Drawing mast
Guyed tower Alizé
Manual Fortis Alizé
Page 26 of 42
8.8.1 Drawing mast specifications
Manual Fortis Alizé
Page 27 of 42
8.8.2 Drawing mast specifications
Manual Fortis Alizé
Page 28 of 42
8.8.3 Drawing mast specifications
Manual Fortis Alizé
Page 29 of 42
8.8.4 Picture of Alizé with guyed tower
Manual Fortis Alizé
Page 30 of 42
8.9 Dimensions Alizé wind turbine
Manual Fortis Alizé
Page 31 of 42
8.10 - Tail assembly
Tail beam
Tail hinge section
Tail Vane
Manual Fortis Alizé
Page 32 of 42
8.11 Tail & Vane of Alizé
Tail Vane mounted on
left side of tail beam.
(seen from the front of
rotor blades)
Note: TOP remark on
upside tail hing section.
Place the Teflon glider
ring on top of the shaft.
On top and bottom
mount the lock pins.
(See also note on
chapter 3.3).
Manual Fortis Alizé
Note: Tail hing section
should turn to the right.
(seen from the front of
rotor blades)
Page 33 of 42
9. Parts list
9.1
GFI – 10K2 Grid Feed Inverter
9.2
Electric schema Alizé to 3 phase network
Note: For detail description of the GFI-10K2 Inverter see Manual:
Version 2.4 - 716004 GFI Installers Manual (GB)
Brake Resistor with Connection Cable:
Version 2.0 - 716005 DL-35K - DL-57K user manual_GB
Manual Fortis Alizé
Page 34 of 42
9.1
GFI – 10K2 Grid Feed Inverter
Manual Fortis Alizé
Page 35 of 42
Technical data GFI-10K2
-----------------------------------------------------------------------------------------------------------------------------------GENERAL
Description Integrated 3-phase inverter.
Operating temperature -20 °C to 60 °C ambient, full power up to 40 °C ambient air temperature.
Storage temperature -20 °C to 60 °C
Relative humidity protected against humidity and condensing air by PCB coating
Protection degree IP42
Safety class class I (metal enclosure with earth connection)
-----------------------------------------------------------------------------------------------------------------------------------INVERTER INPUT
Nominal power 10.000 W
Continuous power @ 40 °C 10.000 W
Operating voltage 40-340 V AC
Nominal voltage @ full load 220-340 V AC
Maximum voltage 390 V AC
Rated current 3 x 20 A (rms)
Maximum current 3 x 30 A (rms)
Frequency range 0-150 Hz
-----------------------------------------------------------------------------------------------------------------------------------DUMP LOAD OUTPUT
Nominal power 10.000 W
Maximum power (120sec duration) 15.000 W
Maximum current 2x15A
-----------------------------------------------------------------------------------------------------------------------------------GRID OUTPUT (AC)
Voltage 230 V AC 3-phase + N +PE (4 Wire Y ±20%)
Nominal power 10.000 VA
Maximum power 10.500 VA
Nominal current 3 x 16 Arms
Frequency AC frequency 50 Hz: 45 - 55 Hz programmable
AC frequency 60 Hz: 55 - 63 Hz programmable
Nominal power factor > 0.99 at full power
Reactive power 0.80 inductive – 0.80 capacitive
Harmonic distortion THD < 3% THD
DC current injection < 20mA
AC connector AC glands on detachable plate in bottom of connection compartment.
Fuse External fuses is mandatory, Recommended 25A (B) characteristics
Not installing a properly rated fuse (Icu > 2.1 kA) will pose a safety hazard and will void the warranty
of the inverter.
Maximum inrush current 28.2A
Short circuit L-N 150A peak/12.9A RMS(3 cycl) during 8ms
Short circuit L-L 298A peak/21.8A RMS (3 cycl) during 4ms
----------------------------------------------------------------------------------------------------------------------------------SYSTEM INFORMATION / DIAGNOSTICS / COMMUNICATION
User interface 10 status LED’s or TFT Touch display
Inverter external communication 1 USB Interface
Manual Fortis Alizé
Page 36 of 42
Additional technical data for GFI inverter
------------------------------------------------------------------------------------------------------------------------------------SAFETY DEVICES
Island protection
An AC fault in any of the phases will disable the inverter.
Redundant voltage and frequency window monitoring
(QNS). Independent cut-off by means of 2 pole relay and
solid state switch (ENS) according to VDE 0126-1-1:2006.
Temperature protection
thermal switch off at inverter internal over temperature
Safety devices AC grid side
Integrated RCD (AC/DC sensitive), trip levels 30 mA Jump
300 mA continuous
Voltage / Frequency window, AC current limiting, DC
current injection protection, transients surge protection
(varistors class lll)
Reclosure time
wait 10 - 300 s (country selection dependant) after AC grid
fault
----------------------------------------------------------------------------------------------------------------------------------SYSTEM INFORMATION / DIAGNOSTICS / COMMUNICATION
RS485 communication channels (DVE-SBUS)
Standard
Wind direction / Wind (anemometer) interface
Standard 3 (1 x Wind direction / 2 x Wind
speed)
Vibration sensor (VM102)
Standard 1
Galvanic isolated user input (digital / analogue)
Standard 8 x DI / 4 x AI
Relay contacts user output (change over)
Standard 3 x changeover
Free space for customer parts on internal DIN-rail
Standard
Thermal sensor input (NTC/PTC)
Standard 2 (1 x Generator / 1 x Dump load)
Prepared for 4.3” TFT colour touch display
Yes, optional add-on
----------------------------------------------------------------------------------------------------------------------------------NORMATIVE STANDARDS APPLIED
Emission
Harmonics
Flicker
Immunity
Electrical safety
Grid compliance
Manual Fortis Alizé
EN 61000-6-3
EN 61000-3-2
EN 61000-3-3
EN 61000-6-1
EN 60950
EN 50438
DIN VDE0126
DIN VDE AR-N 4105
G83/2
G59/2 /3
DK5940
Page 37 of 42
Dimensions: 644 x 819 x 370mm (bxhxd)
Manual Fortis Alizé
Page 38 of 42
IMPORTANT!
Dump load matrix for Alizé wind turbine:
Battery charging
Alize
240V
Dump load:
2x 6 kW / 230V
Connection:
Parallel
Cable type:
Length:
Manual Fortis Alizé
Single Phase
230V/50Hz
2x 6 kW / 230V
Serial
3 Phase
400V /50Hz
2x 6 kW / 230V
Serial
Page 39 of 42
9.2
Electric schema Alizé to 3 phase network
10 Safety and control procedures
___________________________________________________________________________________________________________________
www.fortiswindenergy.com
Page 40 of 42
WARNING: What’s dangerous!
1.
2.
3.
4.
5.
Spinning Rotor
High tension on electric wires
Falling from tower
Crane drops tower/wind turbine
Gin pole/winch fault during erection of guyed tower
 Choose a supervisor of the team who will be responsible for these procedures
 Do not fix a rope to the rotor blades and tower during erection. It can damage the blades.
Only a rope which can mover free around the tower is possible
 Before erection check if the generator is on the brake or on short circuit
 Check all bolds and nuts of the wind turbine and tower before erection if they have the
right tension
 During erection all persons has to be at a distance from the foundation of more than the
height of the tower
 All electrical connections and electronics installation has to be completed before erection.
If possible the final connection should be the plug in the tower base
 Check if the earth cables are connected well
 Check if isolation of all cables is made well
 Ask crane drive for their safety and control procedures and their responsibilities
 Do not erect the windturbine during high winds. The crane driver has always instructions
at which max wind speed he can operate safely
 Never climb into the tower when the wind turbine is not set on the brake. This will be very
dangerous
 Never disconnect any electrical wire if the wind turbine is not set on the brake
 When climbing in the tower use always position belts and full body harnesses. Follow
always the rules. Get aware of the local rules of save work
 If you use a gin pole for erection read first the special instructions in the manual
 Do you have insurance public liability insurance product warranty and liability
professional indemnity erection all risks
11 Declaration of Conformity
___________________________________________________________________________________________________________________
www.fortiswindenergy.com
Page 41 of 42
Declaration of Conformity
According to type II-A without external approval
Declaration of approval (according to appendix II-A of the machine guideline)
Manufacturer: Fortis Wind Energy
Address: Botanicuslaan 14, 9751 AC Haren, The Netherlands,
Herewith declare under our sole responsibility that the products:
- Passaat 1.4 kW
- Montana 5 kW
- Alizé 10 kW
to which this declaration is regarded, confirms to the :
- Construction products (89/106/EEG);
- the low voltage electricity (73/23/EEG);
- the EMC (89/336/EEG) and
- the machinery (98/37/EEG)
- IEC 61400-2 "Design requirements for small wind turbines" which has been adopted as
European Standard EN 61400-2 guidelines of the EEG.
Instructions for installation, operation and maintenance are according to the Instruction Manuals.
Haren, 2011-08-22
Johan Kuikman
CEO
Fortis Wind Energy
___________________________________________________________________________________________________________________
www.fortiswindenergy.com
Page 42 of 42