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Summary of Contents for Bergey Powersync II
- Page 1 Owner’s Manual BWC EXCEL 10 Wind Turbine & Powersync II Grid-Intertie Inverter Revision 2.0 April 2014 Part # MANXLS Bergey Windpower Co. 2200 Industrial Blvd. Norman, OK 73069 USA TEL: 405-364-4212 FAX: 405-364-2078 E-mail: sales@bergey.com Site:www.bergey.com...
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Page 2: Table Of Contents
MAINFRAME ...................... 7 SLIP-RINGS AND BRUSHES ................7 TAIL ASSEMBLY AND AUTOFURL OPERATION ..........7 SPINNER AND NACELLE ................. 8 Powersync II Inverter ..................8 SYSTEM OPERATION ..................9 NORMAL OPERATION ..................9 HIGH WINDS - AUTOFURL® ................10 UNLOADED OPERATION ................10 MANUAL FURLING .................. - Page 3 INSTALLATION ....................25 BWC EXCEL WIND TURBINE and TOWER ............ 25 FUSED DISCONNECT SWITCH ..............25 WIRE RUN AND WIRE SIZES ................. 26 POWERSYNC II INVERTER ................26 VII. INSPECTIONS AND MAINTENANCE..............28 VIII. Trouble-Shooting Problems ................. 31 Page 3...
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Page 4: Introduction
Bergey EXCEL 10 Serial No.: ________________________ Bergey EXCEL 10 BLADES Serial No.: ________________________ The Powersync II inverter has a serial number label on its right side. We recommend that this serial number also be copied to this manual. Powersync II Serial No.: __________________________... -
Page 5: Excel 10 Specifications
OUTPUT FORM 240VAC, 1-Phase, 60Hz GENERATOR Permanent Magnet Alternator POWER PROCESSOR Powersync II Inverter Bergey Excel 10 Power Curve (Sea Level) USDA Data per IEC 61400-12 Power Output (AC kW) 1 m/s = 2.237 mph 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20... -
Page 6: System Description
BWC EXCEL 10 Turbine III. SYSTEM DESCRIPTION The Bergey EXCEL 10 is an upwind horizontal-axis wind turbine designed for distributed generation applications, connected to the power grid on the customer’s side of the utility meter. The complete unit consists of the following major components, as shown in the figure below: 1. -
Page 7: Rotor System
It was specifically designed for the Bergey EXCEL 10 and produces power at low speeds, eliminating the need for a speed-increasing gearbox. Since it uses permanent magnets, the alternator is generating voltage whenever the rotor is turning. -
Page 8: Spinner And Nacelle
The rotor continues to spin even in very high winds and this actually makes the blades stiffer. The AutoFurl® system works whether or not the Powersync II inverter is on or not. Unlike many other turbines designs, the Bergey EXCEL 10 can operate safely without an electrical load connected to the turbine. -
Page 9: System Operation
IV. SYSTEM OPERATION NORMAL OPERATION The Bergey EXCEL 10 produces utility compatible power in the form of 240VAC, 60 Hz, single phase electricity (other voltage options are available). It is connected through the Powersync II inverter to the utility distribution network in the same manner as household appliances. -
Page 10: High Winds - Autofurl
If an abnormal condition occurs on the utility line, such as a voltage fluctuation or a complete interruption, the Powersync II inverter will automatically disconnect the wind turbine from the power grid. If sufficient wind is present, the rotor will continue to operate. -
Page 11: Manual Furling
Owner’s Manual BWC EXCEL 10 Turbine MANUAL FURLING The Bergey EXCEL 10 is designed for unattended operation over an extended period of time. Exceptional situations may occur, however, in which the wind turbine should be manually furled. These situations include: 1. - Page 12 Owner’s Manual BWC EXCEL 10 Turbine CAUTION Do not over tension the furling cable. Tightening the cable beyond the amount required to furl the wind turbine will reduce its ability to track the wind and may damage the furling system. To return the turbine to the straight, normal operation, position, grasp the winch handle firmly and then release the ratchet mechanism.
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Page 13: Powersync Ii Inverter
Wait at least 5 minutes before opening the inverter door. Using the utility grid as a reference, the Powersync II inverter converts the output of the wind turbine into utility-compatible power (AC). The Powersync II inverter has been designed for automatic, unattended operation and it is programmed to provide maximum performance from your Bergey EXCEL 10 wind turbine. -
Page 14: Inverter Specifications
Owner’s Manual BWC EXCEL 10 Turbine INVERTER SPECIFICATIONS Input – From Turbine Input Voltage Maximum (3 Phase Input) 400 VAC Input Start Voltage Minimum 30 VAC Input Operating Voltage Range 200 to 400 VAC Input Frequency Maximum 400 Hz Input Current Maximum 40 Amps AC Backfeed Current to Input Source Output –... -
Page 15: Important Inverter Safety Instructions
Owner’s Manual BWC EXCEL 10 Turbine Important Inverter Safety Instructions SAVE THESE INSTRUCTIONS This manual contains important instructions for Models PSII12 and PSII126208 that shall be followed during installation and maintenance of the inverter. The output field wiring terminal can be used for connection of a maximum of: One 1/0 AWG wire per terminal (1 wire for each line) The input field wiring terminal can be used for connection of a maximum of: One 2 AWG wire per terminal (1 wire per phase per terminal provided). -
Page 16: Installation
Owner’s Manual BWC EXCEL 10 Turbine Installation 1. Dimensions 2. Locating The inverter must be installed in a weather protected environment. The inverter emits audible noise when operating. Do not locate the inverter in living spaces or on walls directly connected to living spaces. ... -
Page 17: Mounting
Owner’s Manual BWC EXCEL 10 Turbine The inverter will automatically shut down if the temperature is below -20ºC (-4ºF). Protect from extreme cold exposure if this is undesirable. Enclosure ventilation is to be provided such that the following guidelines are satisfied. -
Page 18: Ac Output Connection
Owner’s Manual BWC EXCEL 10 Turbine 5. AC Output Connection The AC output is single phase and not bonded to ground. Connect the two single phase 240VAC or 208VAC wires from the distribution panel to the dual fuse block located on the lower left side of the enclosure. ... -
Page 19: Fuse Replacement
Owner’s Manual BWC EXCEL 10 Turbine connection must be bonded directly to the tower disconnect ground lug which in turn is bonded to the tower’s ground rod. The input and output circuits are isolated from the enclosure. System grounding when required by the Canadian Electrical Code, Part I, is the responsibility of the installer. -
Page 20: Inverter Operation
Owner’s Manual BWC EXCEL 10 Turbine withstanding input line to ground surges of about 6kV at 3kA. Contact your distributor or BWC for application specific lightning surge suppression solutions. Inverter Operation This equipment is a UL 1741 certified Utility Interactive Inverter and complies with the requirements of IEEE1547 which is the standard for interconnecting distributed resources with electric power systems. - Page 21 Using the Up and DOWN arrows you can scroll through the additional Powersync II information available, as shown below.
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Page 22: Inverter Fault Codes
Owner’s Manual BWC EXCEL 10 Turbine DC Current This is the input current measured after the 3-phase AC input has been rectified to DC. Idc = IREF / 9 This current should not exceed 58A. Turbine Volts This is the DC voltage of the input measured after the 3-phase AC input is rectified. The inverter will begin exporting power when this voltage exceeds 85Vdc. - Page 23 Owner’s Manual BWC EXCEL 10 Turbine The DC Bus voltage has exceeded its maximum threshold. This occurs if the input power exceeds DC OVER VOLT 1 1000 the output power. This may occur in exceptionally high winds especially if the OV Power limit is active or temperature throttling is occurring.
- Page 24 (no power production) and a Fault Code will be displayed on the digital display. A list of the Fault Codes can be found in the detailed instructions for the Powersync II inverter provided in the Appendix. FAULTS will reset themselves automatically;...
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Page 25: Installation
AC disconnect switch between the wind turbine and the Powersync II, as shown in the drawing on Page XXX. This switch is commonly referred to as an Accessible Disconnect Switch (ADC) and most utilities will require one to be installed. -
Page 26: Wire Run And Wire Sizes
The Powersync II inverter should be installed indoors, near the main breaker enclosure if possible. The Powersync II is designed to operate in a clean environment and should never be installed outdoors as it is not weatherproof and will be damaged by rain. A minimum of six inches of clearance is required on the top, bottom and sides of the Powersync II to ensure adequate air flow through the enclosure. - Page 27 Owner’s Manual BWC EXCEL 10 Turbine CAUTION All loads should be equipped with fuses or circuit breakers to avoid hazards from accidental short circuits. 10 kW Wind Turbine 24 m (80 ft) GuyedTower Safety Cummulative Switch Production Meter Power AC Load Processing Center Unit (Inverter)
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Page 28: Inspections And Maintenance
VII. INSPECTIONS AND MAINTENANCE The Bergey EXCEL 10 turbine and tower should be inspected 30 days after installation, and then again 180 days after installation. Following these two inspections the installation should be inspected every two years and after any particularly severe weather. Inspections should be done on days when the wind is below 16 mph (7 m/s). - Page 29 23. Use a VOM to check that the three legs of the AC output of the wind turbine are balanced. 24. Check condition of all wiring connections into and out of the Powersync II. Page 29...
- Page 30 Owner’s Manual BWC EXCEL 10 Turbine 25. Check the fan filters on the Powersync II. At the second annual inspection, and at each alternate inspection thereafter, the right nacelle half should be opened and the slip-ring cover removed. This will allow the condition of the brushes and slip-rings, and internal fasteners to be checked.
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Page 31: Trouble-Shooting Problems
The following guide can help to pin-point the cause of operational problems with the Bergey EXCEL 10 wind turbine and the Powersync II inverter For problems or symptoms not found in the following listing please contact the Service Department at Bergey Windpower Co. - Page 32 Bergey Service speeds that causes transient Department if the noise vibrations in the turbine is excessive Turbine makes a...
- Page 33 Rotor does not turn Contact your dealer inside alternator even when winds exceed 15 mph (6.7 m/s) Powersync II display not 1. No power to inverter 1. Turn off utility power functioning to inverter, using the 2. Display or other...
- Page 34 Owner’s Manual BWC EXCEL 10 Turbine Appendix Page 34...
- Page 35 Owner’s Manual BWC EXCEL 10 Turbine Page 35...
- Page 36 Owner’s Manual BWC EXCEL 10 Turbine Page 36...
- Page 37 Owner’s Manual BWC EXCEL 10 Turbine Powersync II - 240 VAC (AMFA-27) Powersync II - 208 VAC (AMFA-29) Operator's Manual & Installation Instructions Rev. 2.6 Date: 22 November, 2010 Page 37...