SWWP Whisper 500 Manual
SWWP Whisper 500 Manual
Owners Manual
Installation, Operation and Maintenance
Owners Manual
Installation, Operation and Maintenance For Battery Charging Applications
SOUTHWEST WINDPOWER
April 2006
BEFORE YOU BEGIN: Read this entire manual. Following the instructions and recommendations in this manual will help assure safe and enjoyable use of your new renewable energy system. SAFETY INFORMATION: These systems present mechanical, electrical and chemical (battery) hazards that can be life threatening. The tower or support structure could fall and cause injury or death and property destruction. A component of the wind generator could come loose causing injury or death and property destruction. Contact with the high speed propeller can result in severe injury or death. High voltage from the wind generator or the inverter can cause injury or electrocution. A burn injury can result from an electrical short. A severe chemical burn including blinding can occur from a battery explosion or contact with the sulfuric acid in a leadacid battery. These conditions are addressed in the following safety messages: STOP! DANGER! It is your responsibility to obtain all required permits and engineering certifications for your tower and tower location. Soil and wind conditions vary and towers and tower foundations must be designed for your specific location. Tower must not be able to fall on occupied buildings, neighbor's property or power lines. Tower climbing is dangerous and should be attempted only by experienced personnel using proper safety equipment. A fold-over tower can eliminate climbing. Locate your mounting mast (tower) well away from occupied buildings and power lines; a minimum of 100m (300 ft) is recommended. STOP! DANGER! If the generator appears or sounds loose in the tower or is making an unusual sound, the condition must be corrected immediately. A loose generator or component will soon damage itself further and may fall from the tower or lose parts that could be lethal. Never stand in line with an operating propeller. STOP! DANGER! Provide climbing protection against all unauthorized persons or children. Never allow an untrained person or someone without the proper safety equipment to climb the tower. Always stop the propeller before climbing the tower. Both falling from the tower and contact with the operating propeller can be lethal. STOP! DANGER! High voltage systems (that is, systems with battery voltages of 64 volts and above or the primary side of any system with a transformer) represent a dangerous shock hazard and could be lethal. All high voltage systems should be wired and maintained by a qualified and licensed electrician. STOP! DANGER! Batteries may emit explosive and irritating gas while charging. Never turn on a light switch or make any other electrical connection or light a match or make any type of spark near a recently-charged battery. Use protective gloves and eyeglasses when working around a battery. Turn off all loads, wear safety glasses, and look away when making a final battery connection. STOP! DANGER! NEVER place objects on top or near the Whisper Controller enclosure, diversion load, transformer, Aurora Wind Interface or inverter, when applicable. These devices must dissipate heat as part of normal operation. FIRE AND FAILURE can result if airflow is blocked.
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TABLE OF CONTENTS
Section
1. Introduction 2. Controller and Diversion Load Installation 3. Wire Connections Controller to Battery Connections Controller to Wind Generator Wiring Brake Switch Diversion Load Wiring and Configuration Transformer 4. Wind Generator Installation Electrical Tests Install Tower Insert Install Tail Fin Install Tail Boom Install Blades and Nosecone 5. Whisper Controller Printed Circuit Board Switch Settings Optional Equipment Controller Operation 6. Maintenance 7. Troubleshooting Mechanical repairs and parts replacement
Page
4 6 7 7 8 10 11 11 13 13 14 17 19 20 22 22 24 26 32 35 38
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1. Introduction
System Voltage
All system components, Wind Generator, Whisper Controller, diversion load, transformer and inverter ( if applicable), must be configured to the correct system voltage. The Whisper 500 Low Voltage (LV) Wind Generator is factory set at 48 volts, and the Whisper 500 High Voltage (HV) Wind Generator is factory set at 240volts. The Whisper 500 Controller is also factory set at 48 volts. for the See TROUBLE SHOOTING AND REPAIR section to change the Whisper 500 voltage from the standard voltage. Refer to the appropriate sections in this manual to configure the Wind Generator or Controller to different voltages.
Tower
The Whisper 500 Wind Generator is designed to fit on a 5-inch schedule 40 steel pipe. The minimum recommended tower height is 7 meters (20 feet) above trees or obstacles within 100m (300ft). The lateral thrust load produced by the Whisper 500 at a wind speed of 45 m/s (100 mph) is 3.6 kN (800 lbs). The highest point on your property is generally best location to site the wind generator but the distance to the batteries and the system voltage will figure in the determining the correct installation location.
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Diversion Load
Note: Size the DC wire between the Whisper Controller and Diversion Load using the DC Wire Size Table on page XX
Whisper Controller
+
Battery Bank
Note: Size the three phase wire between the turbine and Whisper Controller using the Wire Size: Mast top to Whisper Controller table on page XX
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The 4600 Diversion Load MUST be mounted against a wall to provide adequate heat transfer. The controller must be mounted within 5 feet (1.5 meter) of the diversion load due to the precut wire length. Do not mount the diversion load within 10 feet ( 3 meters) of flammable materials or near heat sensitive components. Do not mount the controller above the diversion load since the heat from the diversion load may overheat the controller.
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3. Wire Connections
Controller to Battery Connections
Remove the Whisper Controller Electronic Cover and connect the battery and ground wires as shown in the accompanying figures. Caution: Southwest Windpower strongly recommends connecting the Controller to the batteries BEFORE making the wind turbine connections. Optional Whisper Controller LCD Display Panel
Refer to the following sections to select the correct gauge wire to connect the controller to the batteries. Use caution when connecting the battery leads to avoid shorting them together. Correct polarity MUST be observed when connecting the battery cables. LEDs and Diversion Switch
Wind Generator Connections Terminal Block under cover . Earth Ground Battery Connections
Depending on your system voltage, wire the controller to the battery system by select the appropriate size wire from the list below: 24 Volt Systems Use 2 AWG wire or larger 48 Volt Systems Use 6 AWG wire or larger
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Note: Refer to the following section to install the Brake Switch in parallel with the Whisper 500 and the Whisper Controller.
The size of the wire required to connect the Whisper Controller to the wind generator is determined by the power produced by the generator, system voltage and the distance between the generator and controller. Distances are one way and should include the height of the tower. Refer to the accompanying charts to determine the correct wire size for your system. The wire sizes listed in the charts provide a 95% transmission efficiency in an area with a 12 mph average wind speed. To use the charts measure distance from Whisper Controller to wind generator. Find the closest distance listed in the column for your system voltage and read the wire size to the left of the distance. Note if your measured distance is nearly midway between two distances on the chart it is probably best to select the larger size wire. This is particularly true in areas with higher wind speeds. Distances are listed in both feet and meters.
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Distance (Feet)
Distance (Meters)
** Note: The Whisper 500 High Voltage cannot be wired directly to the Whisper Controller. A step down voltage transformer is required to reduce the voltage to 24, 36 or 48 volts before connection to the Whisper Controller.
AWG to Metric Wire Size Conversion Chart AWG gauge 0000 (4/0) 000 (3/0) 00 (2/0) 0 (1/0) 1 2 3 Diameter (mm) 11.68 mm 10.40 mm 9.27 mm 8.25 mm 7.34 mm 6.54 mm 5.83 mm AWG gauge 4 6 8 10 12 14 16 Diameter (mm) 5.19 mm 4.11 mm 3.26 mm 2.59 mm 2.05 mm 1.63 mm 1.29 mm
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To Stop the Wind Turbine Move brake switch handle up. If the wind turbine blades do not stop in 30 seconds. Move handle down, wait for wind speed to decrease and retry.
Brake Switch
Brake Switch
# 6 AWG
24 Volt System
48 Volt System
No wire in
Black Red
Red 1
Red Black 1
Black 1
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12
H1 H2 H2 H2 H1 H1
x1 x2 x4 x2 x4 x4 x2
x3
x1
x3
x1
x3
Secondary - to Controller (See Below) Large Wires Secondary to Whisper Controller (See Below) Large Wires
Install transformer on heat resistant surface with adequate ventilation. The Whisper 500 voltage is stepped down to 24, 36 or 48 volts with utilizing the transformer. Refer to the chart below for specific wiring directions for configuring the transformer voltage.
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A B
x1 x2 x3 x4 x1 x2 x3 x4 x1 x2 x3 x4 x1 x2 x3 x4 x1 x2 x3 x4
C B A
C
x1 x2 x3 x4
A
x1 x2 x3 x4
B
x1 x2 x3 x4
C
x1 x2 x3 x4
x1 x2 x3 x4
x1 x2 x3 x4
x1 x2 x3 x4
SOUTHWEST WINDPOWER To Blue WindWires Terminals of To of Controller Whisper Controller 24 Volt Battery 24 Volt Battery
To Wind Terminals of To Blue Wires of Controller Whisper Controller 12 Volt Battery 12 Volt Battery
ToBlue Wind Terminals of To Wires of Controller Whisper Controller 30-36 Volt Battery 30-36 Volt Battery
Wind Terminals of ToTo Blue Wires of Controller Whisper Controller 48 Volt Battery 48 Volt Battery
When the wires are shorted together the generator rotor should turn hard and smooth.
GROUND TEST
Check resistance to ground on each wire. Resistance must exceed 10,000 ohms.
When the wires are open the wind generator rotor should spin freely.
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Mounting Instructions A) Check the fit and hole alignment of the tower insert inside tower, before installing it on the yaw shaft. The six holes you just drilled in the tower pipe should line up with the six holes in the tower insert. A maximum of 1.5mm (1/16in) play is allowed. Tower Pipe or tube must be tight against insert when the mounting bolts are tightened.
B) Install the tower insert onto the yaw shaft. Place the three M10x55 screws into the tower insert and thread them into the yaw shaft. Be sure to use the three M10 zinc lock washers on these screws. Tighten with a 17mm socket.
C) Finger-tighten the nylock nuts over the three M8x30 set screws. Tighten the three M8x30 set screws on the upper holes using the supplied allen wrench. After the set-screw is tightened with the allen wrench, tighten the nylock nut over the set-screw using a 13mm deep socket. You must use a deep socket with this nut because a regular socket will slip off the nut before the nut is fully tight, and result in an unsafe attachment between the turbine and tower.
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B) Attach some type of strain relief inside the tower to support the weight of the wires. See figure on the right. It is important that the full weight of the wires is not being supported by the slip rings on the yaw shaft.
C) Install the turbine, without the blades, onto to the tower top. Be careful not to pinch or short any of the wires. Rotate the tower insert so the six holes in the tower match the corresponding threaded holes in the tower insert.
D) Tighten the six M10x25 screws through the holes on the outside of the tower pipe into the tower insert. Be sure to use the lockwasher on each of these screws. Tighten these six screws with a 17mm socket. E) The turbine should now be fully attached to the tower top.
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Hardware
Lay out the hardware contained in the Whisper 500 Hardware Kit and separate as appropriate. You will need metric sockets and wrenches to complete the installation.
Item 1
Part # IAR15
Qty 10
Place used Tail strap to tail fin & Tail strap to tail boom & Tail boom through-bolt & Nose cone Tail fin to tail boom & Tail strap to tail fin Nose cone Nose cone Tail fin to tail boom & Tail boom to lower weldment Tail boom through-bolt Blades Tail strap to tail boom Tail strap to tail fin Nose cone Tail strap Tail strap to tail fin & Tail strap to tail boom & Tail fin to tail boom & Tail boom through-bolt & Tail boom to lower weldment Blades
2 3 4 5 6 7 8 9 10 11 12
IAR16 IAR52 IAR07 IAR35 IAR42 IAR59 IAR31 IAR30 IAR14 IAQ13 IAR17
M8x31 nylon flatwasher M8x24 nylon flatwasher M8x20 SS hex screw M8x30 SS bolt M8x90 SS bolt M10x80 zinc bolt M8x80 SS bolt M8x40 SS bolt M8 SS lockwasher 3/4 tube spacer M8 SS nylock
16 2 2 7 1 8 1 2 2 2 11
13
IAR50
M10 SS nylock
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2 12 5
Mounting Instructions A) Connect one of the fins to the tail boom with a nylon washer sandwiched between the metal tabs on the tail boom and the tail fin. Repeat so the fin is secured with three bolts B) Repeat the above step for the second fin, but use only two of the three holes so the fin looks like the picture below (minus the tail strap).
C) Attach the through-bolt as show with SS washers outside the tail strap. The 3/4 tube spacer is between the tail strap and the tabs on the tail boom. The nylon flatwashers are between the tail boom tabs and the tail fin. At this point, only finger tighten the nylock nut.
8 1 11
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D) Note how one side of the tail strap has a hole and the other is a slot. Attach the side with the hole to the tail fin as show to the right. A stainless steel washer is used on the outside of the tail strap. A nylon washer is sandwiched between the tail strap and tail fin. At this point, only finger tighten the nylock nut. E) Then place the bolt in the side of the strap with the slot. Finger tighten the nylock nut. F) Use a 13mm socket and a wrench to tighten all three bolts connecting the tail strap to the tail fin. G) The tail fin should now be securely fasten to the tail boom and should look like the last picture on this page.
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Install the long through-bolt with stainless steel washers and a nylock nut and tighten with a socket and wrench.
Install the two compression bolts to the lower weldment, and tighten with a socket and wrench. The tail boom should now be securely attached to the lower weldment.
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7
Install the blade bolts with the head of the bolt against the hub plate as shown in the figure to the right. It is important that the threads of the bolts are pointing into the wind.
13
Place the blade straps across the front of the blades, and tighten the nuts to 18 foot-lbs of torque.
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Whisper 500 Battery Charging Manual Install the nosecone using the two M8x20 stainless steel hex screws. Use a M8 split lockwasher, M8 flat stainless steel washer, and the M8x24 nylon washer, as shown in the close-up view. The nylon washer is sandwiched between the nose cone and the stainless steel flat washwer. A removable threadlocking compound should be used on these to screws.
3 1 10 4
The blades and nosecone should now be securely fastened to the wind generator.
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Default Switch Settings for 24 Volt Operation 1. OFF 2. ON 3. ON 4. OFF 5. OFF 6. OFF Potentiometer Reset Switch
After changing the system voltage depress the Reset switch to read and save the new voltage setting.
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Optional Equipment
Display (Liquid Crystal Display - LCD) Display Installation The optional LCD display may be mounted either on the Whisper Controller base unit, or in a standard 4 wall type switch receptacle. Mounting hardware is provided with the display. An ethernet CAT5 cable is provided to mount the display on the Controller base. To mount the display directly on the Whisper Controller remove the electronics cover and knock out the sheet metal insert where the display is to be mounted. Refer to the figure below. There are pre-drilled holes to mount the display. Use the 8-32 x 3/8, black oxide, stainless steel screws, and 8-32 nuts with captive star washers provided to mount the display on the electronics cover. Connect the display cable to the CAT5 jack located nearest the diversion switch. This will indicate to the display that it is locally mounted and it will disable its LED features, since these are redundant to those mounted on the Whisper Controller base. Leave the cover off until the display function is verified. Whisper Controller Display
Remote LCD Display Installation The display may be located up to 300 meters / 1000 feet from the Whisper Controller. Use Category 5 ethernet cable. The cable with connectors may be purchased at electronics supply stores. Install the display in the desired location and connect the ethernet cable to the display. Remove the electronics cover on the Whisper Controller. If necessary, knock out one of the sheet metal plugs in the Whisper Controller base unit and route the ethernet cable inside the unit. Plug the ethernet cable into the jack in the lower right corner of the controller board. Leave the cover off until the display function is verified. LCD Display Function Verification Once the display is plugged into the controller base and the batteries are connected to the controller there should be text displayed on the LCD display. If the display is blank there is a contrast adjusting potentiometer that can be adjusted to brighten the display. Insert a bladed screwdriver into the hole on the display between the buttons and the LEDs. Turn the potentiometer to adjust the brightness. If a display is still not visible disconnect and reconnect the cable to the display to reset the display. Once display function is verified re-install the electronics cover on the controller base.
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Anemometer Connection The Whisper Controller has been designed to accommodate a Model #40 anemometer, manufactured by NRG. Other equivalent anemometers may work, compare manufacturers specifications. A terminal block on the circuit board is the connection point for the two anemometer signal wires. The terminal block connections are labeled +/- and the polarity should be observed since some anemometers require specific polarity connections. A ground shield (if applicable) should be connected to the controllers grounding terminal. Reference the picture below to locate the anemometer terminal block.
To achieve the most meaningful air speed data the anemometer should be mounted on the turbine tower as near as possible to the turbine without entering the turbines sphere of operation. See the manufacturers recommended installation instructions.
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Controller Operation
Whisper Controller Overview
The Whisper Controller provides all of the necessary functions and displays for safe and productive wind generator operation. It includes interface features for setting the regulation voltage, monitoring the state of the system, and manually disabling battery charging. The Whisper Controller interface mechanisms include the LED Display, the Diversion Switch, and the Voltage Regulation Potentiometer, PCB configuration switches and the LCD display. The Controller contains all of the Whisper Generators power electronics including rectification and load diversion. Additionally, it continuously monitors voltage, current, energy production, and wind speed (optional). These parameters are measured to ascertain system parameters (i.e. battery voltage) and turbine state (i.e. whether power is being generated). The LCD Display is an interface to the many operational parameters and system measurements of which the Controller is capable. The display may be mounted at the Controller or in a remote location or (with two Displays) both places. From the Display, instant and easy access is gained to voltage, current, power, energy, charge, peak power, and wind speed (with optional anemometer).
Remote Display
Diversion Switch
The diversion switch is located on the top of the controller to the left of the LEDs. Setting the switch to OFF causes the power produced by the generator to be diverted the Diversion Load. The Diversion Load is located with the controller enclosure for Whisper 100 and 200s. Whisper 500 s have an external Diversion Load. Note: x The switch may not stop a rapidly spinning wind generator, however, once stopped setting the switch to OFF will keep the generator from spinning in most winds.
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LED Operation
Steady illumination of the Green LED indicates that batteries are being charged by the wind generator. Steady illumination of the Red LED indicates that all available power produced by the wind generator is being diverted to the Diversion Load as a result of operator request. The operator may select this mode by setting the Diversion Switch to OFF or through the LCD Display. A blinking Red LED indicates power is being diverted to the diversion load in order to regulate the battery voltage. The table below summarizes the operational state of the controller indicated by the LEDs.
LED INDICATORS RED LED OFF GREEN LED ON INTERPRETATION BATTERY CHARGING POWER TO DIVERSION LOAD TO REGULATE BATTERY VOLTAGE POWER TO DIVERSION LOAD BY OPERATOR REQUEST DIVESION SWITCH OR DISPLAY
BLINKING
OFF
ON
OFF
Potentiometer Position
Full Turn CCW 4 Turns CCW Factory Preset 9 Turns CW 13 Turns CW Full Turn CW
Regulation On Voltage
13.0V 14.0V 14.4V 15.0V 16.0V 17.0V 26.0v 28.0v 28.8v 30.0v 32.0v 34.0v 39.0v 42.0v 43.2v 45.0v 48.0v 51.0v 52.0v 56.0v 57.6v 60.0v 64.0v 68.0v
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Green LED
Red LED
Functions Available Through the Display Functions available through the display are accessed using two Menu Function Buttonsthe A button and B button. See the figure above. Depressing one of the buttons selects another Menu Page according to the Page Structure Chart on Page 21. For example depressing the A Button from the Main Page causes selection of the Energy Page. Depressing the A Button a second time causes selection of the History Page. Refer to the Menu Chart and Menu Navigation Map on the following pages to see all the Menu Pages and information available for display. The following sections present detailed information about the information and functions available on each page. Note that each of the menu pages in this is an access point for various controller and display settings. The A and B buttons scroll between the menu pages, or change parameters on the menu, or sub-pages. The Reference Numbers in the following paragraph headings refer to Ref # column in the following chart.
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Main Page (1) When first connected, the Display begins with the Main Page. The Main Page displays all of the Controllers measured parameters, including battery charging status, windspeed, charging voltage, battery charge current, and turbine power. There are four sub-pages associated with this page. From the Main Display the A Function button moves through the Energy and History menu pages. From the Main Display the B Function button moves through the Mode and Regulation menu pages. Energy Page (2) Displayed on the Energy page is the accumulated kilowatt-hours and kiloamp-hours since the last reset. These can be reset from the reset sub-menu. The leftmost numbers are reset at the factory. From the Energy page the A menu button will go to the History page. The B menu button will go to the Energy Reset page. History Page (3) Displayed on this page are the average and peak windspeed and turbine power since the last reset. Windspeed is only available if the optional anemometer is installed. Both of these readings can be reset via the reset menu. From the History page the A menu button will go to the Main Display page. The B menu button will go to the History Reset page. Mode Page (4) This page displays the current charge mode. When ON is displayed the batteries are being charged, provided that adequate windspeed is turning the turbine. This mode allows the turbine to turn all of the time unless regulating battery voltage or disabled with the Diversion Switch or from this Mode page. When OFF is displayed any power being produced by the turbine is diverted to the dumpload by the controller. The OFF mode will brake the turbine and prevent it from turning in light winds. The Controller can switch to OFF (Stop) mode in any of the following three conditions: OFF_REM indicates turbine power is diverted to the dumpload due to a request from the Remote Display. OFF_MAN indicates turbine power is diverted to the dumpload due to a request from the Diversion Switch being placed in the Stop position. OFF_REG indicates turbine power is diverted to the dumpload due to automatic regulation at the prescribed voltage. NOTE: The Diversion Switch set to OFF (Stop) manually overrides the Remote Display ON function. The mode can be toggled using the A menu button. The B menu button will go to the Regulation Set page. Regulation Set Page (5) Once the Whisper Controller Display is hooked to a Controller, the Controller no longer looks to its potentiometer for setting the regulation voltage. Instead, the regulation on and off voltages are set digitally at the Regulation Page. This page displays a menu allowing change to the Regulation On and Regulation Off set voltages. Selecting change using the A menu button will bring up a sub-page allowing the Regulation On voltage to be changed. Pressing the B menu button will increase the voltage to a maximum of 17.0v and will then roll back to 13.0v. Pressing the A menu button will go to the Regulation Off voltage sub-page. Pressing the B menu button will again increase the voltage to a maximum of one voltage setting lower than the Regulation On voltage and will then roll back to 12.0v. Pressing the A menu button will return back to the Regulation Set page. Pressing the B menu button from this page will return to the Main Display page. Clearly the Regulation Off voltage cannot be specified above the Regulation On voltage.
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00.0A
Energy
KWh kAh Reset Menu Reset kWh? Mph: pow: Reset Menu Reset Page?
A Ring 0000 000.00 0000 000.00 A: RESET B: CANCEL 00.0a 00.0a A: RESET 00.0p 00.0p B: CANCEL
History
Mode: Off A: ON_REM B: SKIP REGULATION SET: A: CHANGE B: SKIP Regulation ON voltage: 15.8v Regulation OFF voltage: 12.8V
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Reset
B B B
Reset
B
History
A
Energy
Main Display
B B
Mode
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6. MAINTENANCE
Monthly Maintenance 1. TEST BRAKE
(This checks electrical wiring.) STOP THE WIND GENERATOR IN A MODERATE WIND (CHARGING BUT NOT FURLING) No unusual difficulty or noise should be experienced in stopping the propeller. A noise during braking can indicate a disconnected wire. NOTE: If the propeller does not stop within 15 seconds of activating the brake, then turn it back on, and try again later when there is less wind. Attempting to stop the turbine in high winds can damage the alternator.
Brake switch
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Annual Maintenance
2. COMPLETE MECHANICAL CHECK A) Gain access to turbine and give the turbine a
complete mechanical check. Fix or replace any worn or loose parts. B) Check tightness of all tower mounting nuts and bolts and propeller mounting bolts. C) Check all bearings. Just perceptible play is acceptable. D) Clean the propeller with mild scrubbing agent to remove all insect deposits. Replace missing leading edge tape. Fill small surface cracks on fiberglass blades (white) with silicone sealant. Repair or replace all white fiberglass blades if either cracked or damaged. Rebalance the blade after modification.
Clean blade and replace missing blade tape on the leading edge
Maintenance Log Observe Monthly and Annual Inspection Requirements! Record ALL maintenance and repair work!
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Date
Problem/Observation
Action Taken
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Date
Problem/Observation
Action Taken
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Troubleshooting
WIND GENERATOR SYSTEM Refer to the following two trouble shooting charts. Determine if the problem is mechanical or electrical. If mechanical see table, Symptoms of Mechanical Problems. Electrical problems can be in the generator or the Whisper Controller. Determine which as follows: a) Wind generator will not start (blades turn slowly as if the brake is on): On a day of moderate wind, disconnect the three wires from the wind generator one at a time at the Whisper Controller. If the wind generator starts, the wire that allowed it to start leads to a bad diode in the Whisper Controller. Replace the diode. b) Wind generator still does not start. On a day of moderate wind, disconnect any two wires. If the wind generator starts, the problem is in the Whisper Controller and contact Southwest Windpower. If the wind generator still does not start the problem is in the tower wiring or the wind generator. Go to Table: Symptoms of Electrical Problems. c) Wind generator is running, but may have an electrical problem. See TEST FIXTURE below.
Propeller does not turn = Mechanical Problem See Table: Symptoms of Mechanical Problems Propeller turns slowly = Electrical Problem See Table: Symptoms of Electrical Problems
TEST FIXTURE In moderate winds, read the phase-to-phase AC voltage between each of the three phases from the wind generator with a multimeter. When the blades are spinning at a constant rpm, there should be a balanced reading of the AC voltage readings for each of the three readings.
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Possible Cause
a. Ice in generator, or uneven ice on propeller b. Debris between rotor and stator c. Loose or high magnet d. Bad bearing
Correction
i. Wait for warm weather i. Turn propeller gently by hand and blow or use piece of paper to dislodge debris i. Remove rotor and re-glue magnet i. Replace bearing i. Same as above
2. Propeller will not turn at all except a. Same as above, except more likely in high wind, scraping or rubbing to be high magnet or bad bearing. sound at low rpm, always stops at same propeller position b. Swelled wire keepers due to high moisture
3. Propeller is harder starting, output a. Ice on propeller is lower & there is more propeller noise than usual. Seems out of b. Dirty propeller balance. c. Eroded leading edge or damaged leading edge tape d. Split, warped or damaged prop e. one or more blades on backwards 4. Propeller turns a little, never starts a. Blades on backwards. (See blade installation)
i. Prop will eventually shed ice, leave running unless excess vibration i. Clean with soap or bug cleaner i. Refinish prop and replace tape i. Replace or repair propeller i. See blade installation i. Turn blades over. Leading edge advances clockwise from upwind view.
5. Tail, generator and tower vibrate or shake at all or some wind speeds
c. Rotor (magnet can) out of balance d. blade plate out of balance 6. Rattle or clunking from generator a. Generator loose in tower b. Loose rotor (magnet can) on shaft loose tail, missing rubber bumper, wires slapping inside of tower, governor pivot bolt loose c. Worn bearings d. Shaft (spindle) broken
i. Balance or replace propeller i. Replace mounting plate ii. Shim at mounting bolts iii. Replace propeller i. Send to factory or balancing shop i. Send to factory or balancing shop i. Retighten mounting hardware, use lock tight or equivalent i. Repair as required
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Possible Cause
a. WIND switch is OFF (brake on) b. Battery is dead (voltage less than (1/2 nominal) c. Incorrect generator wiring d. Short circuit in wiring from generator to Whisper Controller (in tower) e. Shorted diode in Whisper Controller f. Short circuit in brush card or slip ring assembly g. Short in generator
Correction
i. Turn WIND switch ON i. Charge batteries with external generator i. Rewire to match battery voltage i. See Installation Step #15 i. See TEST FIXTURE / WIND GENERATOR SYSTEM i. See BRUSHES AND BRUSH HOLDERS i. Rewind i. Check battery fuse and all connections. i. See TEST FIXTURE i. See TEST FIXTURE
2. Propeller runs too fast, may whistle, no output, no unusual mechanical noise
a. Load disconnected b. Two or three wires open between generator and Whisper Controller. c. Whisper Controller diodes open or wire is disconnected at diode terminal a. Battery voltage over 50% high
b. Incorrect generator connection 4. Propeller runs too fast, may whistle, output less than 50% for wind speed , growling ,buzzing or vibration felt by hand or mast a. Disconnected wire between the generator and the Whisper Controller b. One open or disconnected diode c. One slip ring or brush not making good connection. d. Incorrect generator wiring a. Battery voltage low, or a dead battery. b. Incorrect generator wiring
i. Battery too small ii. Battery out of water iii. Bad, corroded battery connections iv. Battery worn out i. Rewire i. See TEST FIXTURE
i. See TEST FIXTURE i. See BRUSHES AND BRUSH HOLDERS i. See WIND GENEREATOR ELECTRICAL CONNECTIONS i. Disconnect loads and let battery charge. i. See WIND GENEREATOR ELECTRICAL CONNECTIONS
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April 2006
SOUTHWEST WINDPOWER
From Winding
None
1 2 3 1
From Winding
Black None
1 2 3 1
Red
2 3 1
Red
2 3 1
Black
2 3 -
To Brush Card
To Brush Card
From Winding
None
1 2 3 1
From Winding
Black None
1 2 3 1
Red
2 3 1
Red
2 3 1
Black
2 3 -
To Brush Card
To Brush Card
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April 2006
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April 2006
SOUTHWEST WINDPOWER
Wire Assembly
Balancing Blades
1. Set round side of blade on knife edge with leading edge parallel to table. Mark the balance point precisely. 2. Weigh each blade separately (use a grocery store scale) and mark weight on each blade. 3. Cut one (or two) sheet lead weights equal to the difference in weight between the heaviest and the other blade (or blades). 4. Measure the balance point of the heaviest blade from the butt end and mark this BALANCE POINT on the other blade or blades. 5. Place the lighter blade or blades back on the knife edge at the BALANCE POINT of the heavier blade. Locate the balance weight lengthwise until the blade balances. You now have two blades of identical weight and center of gravity (balance point). Balance point
Use the lead weight to adjust the lighter blades balance point to equal the heaviest one.
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Item 1 2 3 4 5 6 7 8 9 10 11 12 13 15 16, 17 18 19 20 21 22 23 24 25 26 27 29 32 33 34 35 36 37 38 39 41
Description Rotor Spindle Stator Yaw Housing Yaw Shaft Brush Card Assembly Brush Card Plate Wire Box and Gasket Spacer Hex Head Screw M8x40 CL10.9 Flat Washer M8x17 TP200 Retaining Ring 35mm External Retaining Ring 72mm Internal Bearing 6206-2RS Bearing 6207-2RS Nylock Nut 7/8-14 Bolt 7/8-14 x 4 3/4 Cord Grip 3/4NPT Lock Washer M5 SS Screw M5 x 16 SS Screw M4 x 10 SS Screw 8-32 x 1/2 BRASS Screw 8-32 x 3/4 BRASS Light Amber Light Wire Blade Plate Shock Spring Shock Spacer Light Adapter Hex Head Cap Screw Nylock Hex Nut 7/16 Flat Washer 5/8 SS Flat Washer 7/16 April 2006
SOUTHWEST WINDPOWER
April 2006
42