silentwind 12v / 24v / 48v - Silentwind

silentwind 12v / 24v / 48v - Silentwind
Instructions for use / installation manual
SILENTWIND
12V / 24V / 48V
Dear customer
We thank you having bought our product. You have decided on a new generation of
windgenerator.
Compared to traditional windgenerators the essential advantages of our product are:
•
•
•
safety,
efficiency
very low noise emission.
You will also profit from our experience of more than 30 years with various
windgenerators used at offshore sailing. For long distance cruising the availability of
electric energy without the possibility of grid connection is essential.
Fair winds at any time
The Silentwind Team
Please note that this manual is part of the product and must be read closely. Please
study the information carefully before installing the SILENTWIND. This manual
should always be kept near the product and passed on to future owners.
This manual is addressed to the person installing the SILENTWIND. This person
should be familiar with electric wiring and the use of appropiate tools. Otherwise the
SILENTWIND should be installed by a specialist.
1
Contents:
1. Operation and use
3
2. Safety instructions
3
2.1. Mechanical risks
3
2.2. Electrical risks
4
2.3. Installation risks
4
3. Technical data
5
3.1. Windgenerator
5
3.1.1. Electrical data
5
3.1.2. Mechanical data
5
3.2. Charge controller
5
3.2.1
Electrical data
5
3.2.2
Mechanical data
6
3.3. Dimensions
6
3.4. Power diagram
7
4. List of enclosed parts
8
5. Operation description
9
6. Diameters of cables
9
7. Installation
10
8. Getting started
11
9. Run and stop
12
10. Charging indicator
12
11. Check ups
12
11.1. Blades
13
11.2. Screw terminals
13
11.3. Bearings / Gaskets
13
11.4. Corrosion protection
13
11.5. Mounting construction
13
11.6. Electrical system
14
12. Maintenance
14
13. Trouble shooting
14
14. Attachment / sketches
16
15. Warranty
19
16. Certificate of warranty
21
2
1. Operation and use
It´s most efficient to use the regenerative electric sources of both, wind and sun,
combined to charge your batteries so that you can make use of daylight and wind for
24 hours. Our hybrid charge controller is suitable for both sources, windpower and
max. 550Wp (40A) solarpower Hybrid-charge controller.
You can also charge the batteries of an electric vehicle with this unit.
Further applications are:
Any application without grid connection, research units, traffic management systems,
emergency systems, street lamps, billboard illumination, projects in developing
countries, wireless LAN access points, holiday homes with inverters for independent
provision of electricity, wherever there is no grid connection available or too
complicated to install.
The SILENTWIND is ultralight and aerodynamic, so that it is possible to connect
various windgenerators in case your need for energy is high. As noise emission is
very low you can operate the SILENTWIND in neighbourhoods and on sailing yachts
without annoying your neighbours.
Our charge controller HYBRID 1000 is suitable for 12 and 24 volt usage and can be
connected to the SILENTWIND and solar panel.
Another advantage of the SILENTWIND is that it does not have any inbuilt
electronics which means that there is hardly any maintenance work on the mounted
windgenerator. The electric power is led down to the charge controller by 3 cables.
The hand laminated carbon fiber blades were successfully tested in a wind tunnel up
to wind speeds of 35m/s 63 knots according to DIN EN 61400-2. Therefore you need
not worry about the SILENTWIND in any storm conditions. For maintenance work
there is an additional manual stop switch.
2. Safety instructions
Due to the high RPM and the electric energy that windgenerators generate their use
may be dangerous. Therefore carefully read the following safety instructions.
2.1.
Mechanical risks
For various reasons the turning rotor system must be handled with caution. You
cannot see the end of the blades in high wind speeds so that you do not recognise
the inherent danger. Due to their aerodynamic shape the blades have very sharp
edges that may hurt you in high wind conditions.
Never ever try to touch the turning rotor system!
Never ever try to stop the turning rotor system manually!
Make sure that you install the windgenerator in a position that nobody can touch the
blades. Especially on boats ensure a sufficient height above deck.
The blades are produced from carbon fibre, which is extremely solid even in high
wind speeds. Therefore keep away from the turning blades in any case. However
3
they can break because of ropes or other parts touching the blades in very strong
winds.
If one of the blades is damaged, activate the brake function manually with the stop
switch of the charge controller. If one of the blades is damaged, the rotor system will
be out of balance which may be a risk for the whole mounting construction. This has
to be considered before mounting the windgenerator in a safe position.
Before you install the windgenerator on a mast construction make sure that the 3phase wiring is disconnected from the charge controller or fix one blade so that the
system cannot turn. You can also connect the 3 AC wires to block the system during
mounting. Another possibility to install the system is to screw the hub with the blades
to the shaft at the very end of the mounting procedure. The mast must be well fixed
so that it is safe in strong wind and sea conditions. Furthermore the mast-fixation and
the mast-stays should be well assembled that applied vibrations will be not
enhanced. Please ask a professional who is able to assess the load that the system
generates in strong wind conditions.
2.2.
Electrical risks
An idle running windgenerator can generate a considerable AC voltage per phase.
Only connect all components if you are familiar with electric wiring. The high voltage
can cause serious injuries and fire if you do not pay attention to safety. Caution at
use of cardiac pacemakers, etc. Never ever touch the open end of the wires. The
currents on charging the batteries can reach more than 30 A DC. The whole wiring
electric components and connection points must be able to carry a current of 40 A.
Find information about suitable cable dimensions on page 9.
Warning:
Wires with insufficient diameters can cause fire.
Make sure that the wires are run so that mechanical damages cannot occur. A
damaged cable is a severe safety risk. Install a fuse (50A, included) to the batteries
positive pole as close as possible to the battery. In any case a short circuit of the
poles must be avoided.
Warning:
A short circuit can cause fire and explosion. Never ever install batteries
where sparks can cause this risk. Always ensure sufficient ventilation!
The electrical installation should be carried out by persons with suitable skills who
know what they do. Before a storm the SILENTWIND should be manually stopped
with the stop switch on the charge controller. In case of storms we recommend to fix
one rotorblade to the mast because of the risk of flying objects.
2.3.
Installation risks
Only use mounting constructions that can take the load of the generator and the blast
pressure of the wind in any condition.
Working on the mounting unit should only be carried out on a calm day. Make sure
that nobody is close to the mast.
4
Disconnect the battery from the charge controller when working at the system.
The turning of the blades must be avoided by fixing one blade to the mast. If
not the charge controller will be destroyed.
3. Technical data
3.1. Windgenerator
3.1.1. Electrical data
Permanent magnet generator,
3 phases, AC
12 VDC / 24VDC
420 Watt / 450 Watt
14,5 m/s
2,2 m/s
2,5 m/s
Blue LED on the buttom of housing
Type of generator
Rated voltage
Rated power
Rated peak power at
Start up speed
Start of charging
Charge indicator
3.1.2.
Mechanical data
Safety test in wind tunnel
Rotordiameter
Number of blades
Weight of blades
Material of blades
RPM range
weight
Package dimensions
Colour
Warranty
3.2.
•
•
•
122 km/h without failure
1,15m
3
150g/blade
Carbon fibre, hand laminated
550 - 1700 Upm
6,8kg (Generator)
780x400x210mm weight: 10 kg
white RAL 9010, powder coated
36 months
Charge controller
Charge and power management of the provided external hybrid-charge
controller Hybrid 1000
Maximum voltage adjustable for acid-, gel- and AGM-batteries.
Brake mode: electronically or manually with integrated Stopp-switch
(see enclosed manual)
3.2.1.
Electrical data
System voltage
Max. power input windgenerator
Max. current input windgenerator
Max. power input solar
Max. current input solar
Max. open circuit voltage input solar
LCD + LED displays
12/24 VDC
600 W
40 A
550Wp
40A
50VDC
W, V, A, kWh, Ah, load data
5
3.2.2
Mechanical data
Weight
Package dimensions
Warranty
3.3
1,50kg (controller)
270x130x80mm
24 months
Dimensions
6
3.4.
Power diagram
7
4. List of enclosed parts
48V version – Delivery without Charge Controller
All information is reliable. The producer does not take any responsibility for
inaccuracies. The user of both the instructions and the product takes any
responsibility and any risk. All specifications are subject to change without notice.
8
5. Operation description
All windgenerators use the kinetic energy of the wind. This energy is turned into a
turning motion by the blades and thereby changed into 3-phase AC power. The
power of the energy increases in line with the wind speed exponentionally. This
means that a double wind speed generates octuple power. This must be especially
considered in storm conditions.
Our spbΩ blades are produced of high-tensil carbon fibre and are hand laminated
with epoxy resin. This material provides the maximum consistency at lowest weight.
This material is also used in Formula 1 and airspace industry. Therefore these CFblades are extremely light, but resist even strongest wind conditions. They have been
successfully tested at German WindGuard – according to DIN EN 61400-2
(VDE 0 127-2) at windspeed of 122 km/h at 5480 RPM. This is an equivalent of sonic
velocity at the tips of the blades. For every-day use and safety reasons we have
equipped the charge controller with an electronical and manual stop switch.
6. Diameters of cables
System voltage 12 Volt
Distance from wind generator
to the charge controller in m
Cable cross section mm2
AWG
Distance from the charge
contr. to the battery in m
Cable cross section mm2
AWG
System voltage 24 Volt
Distance from wind generator
to the charge controller in m
Cable cross section mm2
AWG
Distance from the charge
contr. to the battery in m
Cable cross section mm2
AWG
0 - 9 10 – 19 20 – 29 30 – 44
45 – 69
70 – 110
6
10
16
25
10
8
6
4
0 - 9 10 – 19 20 – 29 30 – 44
35
2
45 – 69
50
1
70 – 110
-----
-----
0 - 9 10 – 19 20 – 29 30 – 44
45 – 69
70 – 110
2.5
4
6
10
14
12
10
8
0 - 9 10 – 19 20 – 29 30 – 44
16
6
45 – 69
25
4
70 – 110
-----
-----
16
6
16
6
25
4
25
4
System voltage 48 Volt
Distance from wind generator to the charge
controller / inverter in m
Cable cross section mm2
AWG
Distance from the charge contr. to the battery
in m
Cable cross section mm2
AWG
9
35
2
---
35
2
---
0 - 29
30 – 79
80 – 99 100 – 150
2.5
14
0 - 29
4
12
30 – 69
6
10
10
8
70 – 99 100 – 150
4
12
6
10
10
8
16
6
7. Installation
Before mounting the SILENTWIND onshore find a suitable position for the
windgenerator. It is an ideal position if the wind flows against the blades without any
obstructions. This means that the generator is mounted as high as possible.
Fixed installation:
The height depends on the distraction of the wind by surrounding objects. You can
simply test this by fixing a 3 m long – 4cm wide plastic band at the top of a min. 4
meter pole. You can use a 2nd band at 2 meter height. This does not apply to
mounting the generator on boats.
If the upper band flows horizontely straight or up to 30 degrees only you have found
the suitable position. In case the band shows more than 30 degrees or turns round
the mast, the position is unsuitable. This test should be carried out at moderate wind
conditions and only gives an orientation.
We recommend doing various tests to get a better assessment. You do not need to
do this test if the windgenerator is mounted far away from obstructions.
Mobile installation on a sailing boat:
The assembly height must be chosen such that no member of the crew is
endangered by the rotor. The mechanical fixation of the foot of the mast has to
withstand the mechanical loads occurring especially in rough seas. We recommend
additional rigging to the sea rail or the deck of the ship.
Note:
Please note that the SILENTWIND can never be fully efficient if it is
not mounted in the prevailing wind direction or distracted by
obstructions. Therefore it is important to find a position that is not
obstructed by obstacles!
Having found the suitable position an appropriate mast with suitable equipment must
be chosen. The outer mast diameter must have 48mm and it should be stainless
steel or aluminum. Please also consider possible maintenance work. The mast with
mounted windgenerator should be able to take a wind blast pressure of 250Nm.
Grounding of the mast is highly recommendable. On boats you can use the central
ground for mast and engine. Ask a specialist for advice.
Once the mast is mounted you can start the relatively simple installation of the
SILENTWIND. First connect the 3 CF blades to the assembly hub (see page 15,
sketch 4) with the enclosed screws (page 16, sketch 9, assembly- and safety
instructions attached to the rotor-blade box). The enclosed nylon discs protect
against electrolytic corrosion. The fastening torque is 7-8Nm equivalent to a weight of
7-8 kg on a 10cm long lever arm, upright to the lever arm.
If the fastening torque is too high, this will destroy or damage the blades. If the
fastening torque is not high enough, the blades can get lose. A wrong fastening
torque is a considerable safety risk.
10
Before you are doing the final tightening of the blade screws, move each rotorblade
in running direction towards the edge of the blade guide of the hub. The running
direction is clockwise looking from the front. Then fix the blades as described above.
The blades should not be out of balance then. The blades have been balanced
statically and dynamically. In case of damage of only one blade you can buy a single
one. When ordering one blade the purchasing department needs the exact weight of
the undamaged blades.
An incorrect tightening torque represents a significant security risk.
Regularly control the fixation of the blades!
After connecting the blades the set is fixed to the generator shaft with the enclosed
screw nut and enclosed hexagon socket screw key. After that you snap the nose
cone into place on the assembly hub. (see page 17, sketch 5,6 and 7)
Then you connect the three AC outlet cables which have to be led from the
SILENTWIND to the charge controller.
Attention During this procedure the 3 AC wires of the extention cable at the end
must be connected together. Otherwise the rotor system may start
running and you can get injured.
At last you mount the SILENTWIND to the mast. Fix the 4 hexagon screws to the
yaw clamp after having put in the rubber pad (see page 18, sketch 8)
When tightening the screws take care for a uniform, circumferential tightening of the
4 screws. The steps of tightening should be done in small increments to avoid
damaging of the screws.
8. Getting started
Before getting started your SILENTWIND check the correct mounting and installation
according to the following check list:
OK
Test
Mast construction:
Optional;
check according to instruction, especially all screw connections, bracing, vertical
position. Grounding and lightning protection according to local regulations?
Electric installation:
Check battery status and correct polarity
Charge controller:
Charge controller securely fastened to the mounting location?
battery connected with correct polarity, otherwise controller will be destroyed
Caution: Connect always first the battery to the charge controller.
Are all screw terminals firmly tightened?
Is stop switch in position ON?
Fuse:
50 A fuse connected as close as possible to the battery?
11
OK
Test
STOP switch:
Should be installed from a previous installation a stop switch at the connection
cable at the AC- or DC-side ot the charge controller, it must always be removed
or secured against switching off. The actuating of the stop switch during the
windgenerator is running will destroy immediately the windgenerator or the
charge controller.
Wiring:
All cables connected in line with plan? Check the polarity of all wires on the
screw connection poles. Is the 3-phase cable of the SILENTWIND connected to
the charge controller? Are the cables correctly crimped and is the strain relief
mounted?
Yaw shaft:
Is the rubber pad well placed?
Rotor blades:
Mounted in line with instructions?
Assembly hub:
Is the assembly hub fixed to the generator shaft? Is the central screw nut
fastened with 30 Nm?
Connection to 3-phase rectifier (optional) or the enclosed charge controller.
According to the charge controller ordered please read the enclosed manual.
Now you can go ahead!
9. Run and Stop
Switch the enclosed stop-switch or the stop-switch of the charge controller in position
“RUN”. If the wires are correctly connected to the battery (without having mixed up
the polarity) the SILENTWIND should start charging if windspeed is sufficient. You
can control this on the LCD-display of the charge controller.
10. Charging indicator
A blue LED at the bottom of the windgenerator-body shows you if the generator
produces electrical energy. The charging-amount is shown on the display of the
charge controller.
11. Check ups
Your SILENTWIND was constructed for long term use without any maintenance.
However, simple and regular check ups ensure the necessary security.
12
Saftey first!
Before you start the check up, make sure that the blades are stopped and the battery
is not connected to the charge controller.
The following check ups should be carried out at regular 12 months intervals:
11.1
Rotor blades
Check if the blades show damages like broken edges, damaged surface or cracks. If
you notice any damage, the generator must not be used any longer. Check the
screwing one day after mounting and after that every 3 months. Eventually then you
can turn to a longer interval.
11.2
Screws
Check that all accessible screws are correctly fixed. Especially the hexagon srews of
the connection to the hub, the central shaft nut and the fixing of the mast must be
checked (see page 17, sketch 4, 5 ,6 ,7 and page 18, sketch 8, 9).
11.3
Bearings and gaskets
The bearing of the generator shaft and the bearing of the yaw shaft are permanently
lubricated. Please check these bearings as to free movement, bearing play and
watertightness. Deficient bearings must be replaced.
11.4
Corrosion protection
The complete housing is made of seaworthy aluminum and additionally powder
coated. If the outer layer is damaged, there is a risk of corrosion. Please paint these
spots with suitable varnish (RAL9010)
11.5
Mounting construction
Check this construction in line with the instructions concerned (optional).
13
11.6
Electrical system
Please first stop the SILENTWIND generator so that all wires carry no voltage. Check
if all connections are properly fixed and not corroded. Possible corrosions must be
removed and treated with contact spray. Give special attention to the battery
connections: they must be clean and greased with vaseline. Check the battery in line
with the instructions of the producer and (if necessary) refill with destilled water. In
case more than 1 battery is used check that all batteries have the same capacity and
state of charge.
12. Maintenance
Maintenance of the SILENTWIND is not necessary.
The SILENTWIND is produced for troublefree long-term use.
13. Trouble shooting
In case of problems, however, these can be easily solved by using the following
check list:
Windgenerator doesn´t start to run:
Possible Cause
Not enough wind
Test
Measure the wind speed
(Anemometer)
Wait for more wind,
start up speed from 2,2m/s
Switch to „RUN“
Turn manually
Connection windgeneratorcharge controller damaged,
short circuit of AC cables,
short circuit of generator,
customer service
Stop switch activated
Generator shaft sluggish
Solution
14
Windgenerator doesn´t charge:
Possible cause
Not enough wind
Test
Solution
Measure the wind speed at
the rotor.
(Wind speed on the main
mast-top may be higher)
Start up of charging
depends on the battery
status,
check the adjustment of
the charge controller
Electric wiring interrupted Check wires, connections Replace damaged wires or
and gadgets
gadgets
Fuse is gone
Check fuse
Replace fuse or cool down
the automatic circuit
breaker
Carbon brushes in the yaw Check carbon brushes and Replace carbon brushes
shaft have no contact
springs
and reactivate springs
Battery is not fully charged:
Possible cause
Test
Solution
Old, damaged battery
deficient
Test battery status and
liquid of every battery
Fuse gone
Check fuse
Charge controller wrongly
installed
Charge controller stopswitch is in position
“STOP”
Deficient generator
Check in line with manual
Replace battery,
refill destilled water (not
necessary for gel- or AGMbattery)
Replace fuse,
find cause of deficiences
Correct installation
Switch stop switch in
position “RUN”
Observe manual
instructions
Check AC voltage,
AC screw terminals
Check all 3 AC cables after
disconnecting from charge
controller as to short circuit
Repair customer service /
replacement
Deficient charge controller, Check adjustments
mix up of polarity
according to instructions
15
14. Attachment / sketches
sketch 1
sketch 2
sketch 3
16
sketch 4
sketch 5
sketch 6
sketch 7
17
sketch 8
sketch 9
sketch 10
18
15. Warranty
RULIS Electrica Lda. guarantees that all appliances sold by the company do not
show any material or processing defects within the period of warranty.
Period of warranty for
Silentwind generator:
Charge controller HYBRID 1000
36 months
24 months
If material or processing defects are detected in this period, RULIS Electrica Lda. will
repair the appliance or replace broken parts of the appliance at their expense.
Guaranty is only provided if the warranty note (page 21) is filled in properly and the
original invoice can be presented.
Guaranty does not cover:
•
•
•
•
Regular checkups, maintenance, repair or replacement of worn out parts.
Charges for transport, freight and the risk of transport which are directly
related to the case of warranty.
Damages that have been caused by wrong use or mistreatment of the
appliance, especially if the damage is due to mounting the system to an
inappropriate / unsuitable mast (construction). In case of damage the
customer will have to prove that the windgenerator has been mounted to an
appropriate mast (construction).
Damages caused by acts of nature beyond control, RULIS Electrica Lda.
cannot be held responsible for, especially lightning, flooding, snow (ice) load,
fire etc.
If the appliance must be demounted for a warranty case and mounted again after
repair or replacement, the expenses for these procedures are not covered by RULIS
Electrica Lda. Whether repair or replacement is appropriate or necessary, is up to
Rulis Electrica Lda. decision only. If neither repair nor replacement are possible, the
customer is only entitled to withdraw the order.
As far as mandatory law provides otherwise, the rights of the buyer against the
company Rulis Electrica Lda. restrict to this warranty terms, and neither Rulis
electrica Lda. nor the distributor of the products take over additional liability for direct
or indirect damages.
Otherwise the general terms of delivery for products and services of the electricity
industry in Portugal are applied.
19
Notes:
20
Certificate of warranty
--------------------------------------------------------------------------------------------------------------
Garantieschein
Warranty card
Name und Anschrift des Käufers /
Name and address of the purchaser:
Seriennummer Windgenerator /
Serialnumber windgenerator:
Seriennummer Laderegler
Serialnumber charge controller:
Verkäufer (Firmenstempel / Unterschrift) /
Purchaser (company stamp / signature):
Kaufdatum /
date of purchase:
Die genauen Garantie-Bedingungen finden Sie in der Gebrauchsanweisung auf Seite 19.
The exact warranty conditions you can find in the user manual on page 19.
--------------------------------------------------------------------------------------------------------------
21
Rulis Electrica, Lda.
Loteamento Industrial de Linhares, Lote 19
PT-4805-486 Santo Estevão de Briteiros / Guimarães
Portugal
VAT/Contribuinte / EORI-N. PT 502 995 530
Tel. 00351-253-572763
Fax 00351-253-572764
Tm/Handy 00351 96 790 79 33
e-mail:
info@silentwindgenerator.com
site:
www.silentwindgenerator.com
22
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