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Superwind 1250 Operation Manual

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Operation Manual
Superwind 1250
March 2015

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Summary of Contents for Superwind 1250

  • Page 1 Operation Manual Superwind 1250 March 2015...

  • Page 2: Table Of Contents

    Table of Contents: Page General information and references Labelling Range of application Safety instructions Potential hazards 2.1.1 Mechanical hazards 2.1.2 Electrical hazards 2.1.3 Hazards when mounting the wind turbine Technical specifications Main dimensions Technical data Functional description / special features Preparations for assembly Packing list Tools...
  • Page 3 Spare parts list Warranty Notices: This information is believed to be correct and reliable. However, superwind GmbH assumes no responsibility for inaccuracies or omissions. The user of this information and product assumes full responsibility and risk. All specifications are subject to change without notice.

  • Page 4: General Information And References

    Internet: www.superwind.com The data tag listing the serial number and nominal voltage of your Superwind is located on the yaw shaft. Range of application The electric power generated by the Superwind 1250 can be used to charge batteries and/or directly power 24 VDC or 48 VDC appliances (depending on the system voltage).

  • Page 5: Safety Instructions

    The rotor blades are constructed of glass fibre and carbon fibre reinforced plastic. This material is extremely durable (which enables your Superwind 1250 to cope with heavy storms) however it can break if objects are introduced into the rotor at higher rotational speeds.

  • Page 6: Hazards When Mounting The Wind Turbine

    electrical switch for example). To reduce the possibility of explosion, always ensure battery installations are provided adequate ventilation and that all equipment used in the space is ignition protected. WARNING: Never install batteries in locations where the danger of sparks exists. Provide sufficient ventilation at all times.

  • Page 7: Technical Specifications

    Technical specifications Main dimensions Technical data Nominal power 1250 W Nominal wind speed 11.5 meters per second (22.35 Knots) Cut in wind speed 3.5 meters per second (6.8 knots) Cut off wind speed None Rotor diameter 2.40 m Number of blades...

  • Page 8: Functional Description / Special Features

    Functional description / special features The Superwind, like all other wind turbines, uses a part of the kinetic energy of the wind and converts it into electricity. The power generated is approximately proportional to the cube of the wind speed, i.e.

  • Page 9: Preparations For Assembly

    Preparations for assembly Packing list Please check your delivery for completeness and transport damage. Packing list: Generator unit item item Wind vane supporter item Wind vane item Rotor blade item DC-box item Plug 5-pole "Buccaneer" item Socket cap screw M12 x 120 item Hexagon head screw M8 x 50...

  • Page 10: Tools

    Tools The following tools are needed for the installation of the Superwind 1250: Allen key 6 mm Allen key 8 mm Allen key 10 mm Torque wrench with suitable sockets Set of screw drivers Set of wrenches (mm) Wire stripper...

  • Page 11: Wiring Diagrams

    Wiring diagrams 5.2.1 Wiring diagram with a charge regulator in diversion mode (for example Morning Star TS-60) System components 5.3.1 Wires A five wire cable is required to connect the wind generator to the DC-box: a) 3 output power lines b) 2 lines for electrical control of the disc brake The cross section (also known as diameter or gauge) of the wires to be used will depend on their length and the rated voltage of your wind generator.
  • Page 12 48 Volt system: distance from mast top up to 9,9 – 15,6 – 23,3 – 38,7 – 61,8 – to DC-box 9,8 m 15,5 m 23,2 m 38,6 m 61,7 m 96,4 m minimum cross section 2,5 mm² 4 mm² 6 mm²...

  • Page 13: Dc-Box

    5.3.2 DC-box The main function of the DC-box is to rectify the 3-phase AC current coming from the wind turbine into DC current for battery charging. The DC-box must be installed vertically and in a location where the heat sink (located on the top) is well ventilated.
  • Page 14 Internal view: To protect the battery against short-circuit a fuse is installed in the positive line between the rectifier set and the battery terminal. The fuse is either an 80 amp slow-blow type (24 V-system) or 40 amp slow-blow type (48 V-system). WARNING: Do not install other fuses in the three AC wires between the wind generator and DC-box as they will be blown when stopping the generator by shorting.

  • Page 15: Batteries

    When selecting batteries, always ensure their voltage matches the rated voltage of the system (24 V or 48 V). The rated voltage of your Superwind is specified on the unit’s data label (on the yaw shaft). Flooded Lead-acid batteries are the most commonly used battery type known world-wide, however we recommend the use of ‘deep cycle’...

  • Page 16: Grounding

    Never install the wind generator in a location where persons can accidentally come into contact with rotating blades. Mast mounting Before your Superwind is finally installed on the mast or support, the electric cables must be led through the mast tube and connected to the DC-box (see Section 5.3).

  • Page 17: Mast Recommendations

    6.2.1 Mast recommendations Refer to the drawing below for the recommended dimensions of the steel mast tube. The yaw shaft of your Superwind 1250 has a flange which must be attached with four M10 screws and nuts (not included).

  • Page 18: Mounting The Generator To The Mast

    6.2.2 Mounting the generator to the mast The following instructions refer to a tilt-able (tip-tower) mast system. 1. Lower the mast. 2. Insert the turbine output and electric brake power cables into the mast tube. 3. Install the "Buccaneer" plug onto the cable (refer to the below drawing for wiring terminations). The terminals of the plug are suitable for wires of cross section up to 6mm²...
  • Page 19 Position the generator unit close to the mast flange. Screw the plug onto the socket of the generator unit.
  • Page 20 Move the generator unit carefully towards the mast flange. Attach the yaw shaft flange to the mast flange with 4 screws M10 with washers and nuts. (The length of the screws required will depend on the thickness of your mast flange.) Tighten the screws to 50 Nm.

  • Page 21: Assembling The Wind Vane

    Assembling the wind vane 6.3.1 Mounting the wind vane to the wind vane supporter Insert the wind vane into the slot of the wind vane supporter and align the 4 holes. Insert the three M8 x 40 socket cap screws and the one M8 x 20 socket cap screw into the holes. Note: the single M8 x 20 socket cap screw fits in the hole at the end of the supporter.

  • Page 22: Mounting The Wind Vane Supporter To The Generator Unit

    6.3.2 Mounting the wind vane supporter to the generator unit Lubricate the O-ring seal of the wind vane supporter with supplied grease. Raise the tilted mast into a working position (approximately 1.2 m) place a temporary support structure beneath it and secure against movement. Rotate the housing so that the rear of the housing (the wind vane attachment point) is facing upwards as shown in the above picture.
  • Page 23 Place one each 8.5mm washer on the four M8 x 50 hexagon screws and inset into the four flange holes. Ensure each of the four screws are installed and hand tight prior to final torqueing. To ensure proper seating of the O-ring seal, tighten the screw alternately a half turn each until snug, the torque to 25 Nm (SAE 18.4 foot-pounds).

  • Page 24: Rotor Assembly

    Rotor assembly 6.4.1 Mounting the hub to the generator shaft NOTE: To prevent unintentional rotation of the rotor during the remainder of the installation, short circuit the three generator cables or turn the brake switch 1 into the STOP-position. Verify that the parallel key on the generator shaft is in the correct position (as shown below).
  • Page 25 Align the hub and carefully slide onto the generator shaft. NOTE: When sliding the hub onto the generator shaft ensure the parallel key slides into the corresponding keyway (groove) of the hub.
  • Page 26 Insert the M12 x 120 socket cap screw through the central hole of the hub and screw into the threaded generator shaft. Tighten and torque the screw to 50 Nm (SAE 36.9 foot-pounds).

  • Page 27: Attaching The Rotor Blades To The Hub

    Individual replacement blades can be ordered, but these must be properly matched to your existing set. Contact your Superwind dealer for additional information. Each rotor blade is attached using two M10 x 45 socket cap screws. Each screw is TUFLOK-coated to prevent loosening during operation.
  • Page 28 Do not use excessive force when installing the blades. Do not over torque the screws. Mount the remaining two rotor blades the same manner. Your Superwind 1250 is now assembled and ready to be raised into position by lifting the mast.

  • Page 29: Commissioning

    Commissioning Before initial operation of your new Superwind unit, verify the following installation checklist has been completed. Check List done also see Section:  Mast: Assembled and erected in accordance with all applicable manuals. Bolts, joints, anchors and braces checked. Mast vertically adjusted.

  • Page 30: Operation

    Operation Safety instructions Do not operate your Superwind until verifying that no persons can touch or come into contact with the spinning rotor blades. Do not operate your Superwind without an electrical load. RUN and STOP While your Superwind is designed for unattended, automatic operation in all weather conditions, it can be stopped if desired (routine inspections, etc.) by using the dual brake switches on the DC-box.

  • Page 31: Overspeed Protection

    Overspeed Protection The Superwind is additionally equipped with an automatic rotor control system, which includes an over- speed controller. The over-speed controller works at all wind speeds even without electrical loads. Although it is not a normal operation mode, load throw-off could occur under certain conditions, such as a blown fuse, malfunction of the charge regulator or electrical failures caused by overvoltage or a lightning strike.

  • Page 32: Maintenance

    Check the rotor blades for damage (e.g. cracks, broken edges, unusual discolouring etc.). If you see any damage, your Superwind must be put out of operation. Small gel coat defects can be repaired by using an off-the-shelf gel coat repair set. If structural damage exists, the blade will have to be replaced. When ordering a spare blade you will need to provide the blade number to your dealer.

  • Page 33: Bolted Connections

    9.1.2 Bolted connections Check all accessible bolted connections, ensuring they are tightened at the correct torque. This is particularly important with regards to the bolts for the rotor blades, hub and wind vane. Also check the bolts securing the yaw shaft. Refer to Section 6. 9.1.3 Bearings The generator bearings and the yaw shaft bearings are sealed and lifetime lubricated.

  • Page 34: Mast

    - worthy of tracking its use, output and other important data. Trouble shooting If problems occur after installation of your new Superwind you probably can solve most of them following the trouble shooting list below. Be aware of electrical and mechanical hazards at all time: WARNING: Do not approach a turning rotor.

  • Page 35: Wind Generator Does Not Start

    10.1 Wind generator does not start Possible source of errors Test Solution Not enough wind Measure wind speed Wait for more wind. Annotation: start-up wind speed 3,5 m/s (during running-in period slightly higher) Brake switches in STOP position Place switch in RUN position Debris between generator housing Inspect the unit for debris Remove the hub from the generator...

  • Page 36: Checking The Open Circuit Voltage

    10.5 Checking the open circuit voltage A simple test to detect an internal defect of the generator or the rectifiers in the DC-box is measuring the open circuit voltage. WARNING: Due to the danger of high voltage, the following tests must only be carried out by a skilled electrician.

  • Page 37: Repairs And Recommended Spare Parts

    11.1 Repairs If your Superwind should fail or be damaged all parts accessible from the outside are designed to be user replicable (e.g. rotor blades, carbon brushes, etc). In case of any other defects please consult your dealer, an authorized service partner or the manufacturer.

  • Page 38: Warranty

    Costs for disassembly and reassembly of the product to enable shipment for warranty reasons. Others superwind GmbH reserves the right to decide whether the product or parts of it shall be repaired or replaced instead. In case neither repair nor replacement could be performed by superwind GmbH the purchaser solely will be entitled to cancel the purchase.

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