XZERES Wind Skystream 3.7 Owner's Manual
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XZERES Wind Skystream 3.7 Owner's Manual

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SKYSTREAM 3.7
Owner 's Manual
(NORTH AMERICA and EUROPE) Edition
3-CMLT-1054 Rev O
Installation
Operation
Maintenance
(North America)
(Europe)
© 2013 XZERES Corp
All Rights Reserved

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  • Page 1 SKYSTREAM 3.7 Owner ’s Manual (NORTH AMERICA and EUROPE) Edition 3-CMLT-1054 Rev O Installation Operation Maintenance (North America) (Europe) © 2013 XZERES Corp All Rights Reserved...
  • Page 2 The CE marking is a mandatory compliance requirement in EMEA and the UK and although it is self- certified, testing and evidence to support the testing is preferred from an independent test house. All XZERES Wind turbines are third party tested and fulfill all the relevant provisions of the following directives: Machinery Directive 2006/42/EC, Low Voltage Directive 2006/95/EC, Electromagnetic Compatibility Directive 2004/108/EC.

  • Page 3: Important Safety Instructions

    Important Safety Instructions Read these instructions in their entirety before installing or operating. Professional Installation: XZERES Wind strongly recommends Skystream be installed by trained professionals. SAVE THESE INSTRUCTIONS. This manual contains important instructions for Skystream that must be followed during installation and maintenance of the Wind Turbine generating system. Read, understand and respect all warnings.

  • Page 4: Radio Interference

    Radio (RF) Interference (USA) Skystream 3.7 has been tested and found to comply with the limits for a class B digital device, pursuant to Part 15 of the FCC Rules (US Federal Communications Commission). These limits are designed to provide reasonable protection against harmful interference in a residential installation.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Important Safety Instructions ........................ 3 Radio Interference ..........................4 ® Skystream 3.7 Specifications ......................6 European Grid Standards ........................8 PRIOR TO INSTALLATION ......................... 9 Intended Use ............................9 Unintended Use ............................ 9 Shipment Content ..........................10 Typical Skystream Installation ......................

  • Page 6: Skystream 3.7 ® Specifications

    ® Skystream 3.7 Technical Specifications Model Skystream 3.7 Rated Power 2.1 kW at 11 m/s (24.6 mph) Nominal Power 2.4 kW at 13 m/s (29 mph) Weight 170 lbs. / 77 kg Rotor Diameter 12 feet / 3.72 metres Swept Area 115.7 ft...
  • Page 7 Refer to production test result printout included with shipment. Tower Data (Loads calculated at 145 mph - 65 m/s) Note: Loads do not include safety factor. XZERES Wind recommends minimum safety factor of 1.5 Shaft Thrust 630 lbs (2802 N)

  • Page 8: European Grid Standards

    European Grid Standards Skystream 3.7 complies with the relevant grid connection requirements taken from the following European Grid Codes: • Verband der Electrizitätswirtschaft – VDEW –e.V. “Eigenerzeugungsanlagen am Niederspannungsnetz” (generation units at low voltage level), 4th Edition, 2001, Germany • ENA Energy Networks Association “Engineering Recommendation G83/1 – Recommendations for the connection of small-scale embedded generators (up to 16 A per phase) in parallel with the public low voltage distribution networks”’...

  • Page 9: Prior To Installation

    A typical Skystream installation is depicted in Figure 1 of this manual. Skystream 3.7 is designed to operate at sites with average wind speeds less than 8.5 m/s - IEC (International Electrotechnical Commission) Class II wind conditions. The installation of Skystream at sites with higher average wind speeds will accelerate component wear and require more frequent inspections.

  • Page 10: Shipment Content

    TIP: See exploded view on page 23. Installation Personnel XZERES Wind recommends professional installation of Skystream. While Skystream is not difficult to install, and many homeowners have successfully installed their own Skystream, knowledge of local zoning and building code requirements, construction techniques, as well as residential electrical systems is required for a safe installation.

  • Page 11: Typical Skystream Installation

    Figure 1 Typical Skystream Installation (North American) Note: Refer to Appendix A for detailed wiring drawings. Skystream Owner’s Manual Pg. 11 3-CMLT-1054 Rev O XCO 1191...
  • Page 12 Figure 1 Typical Skystream Installation (Europe) Note: Refer to Appendix A for detailed wiring drawings. Skystream Owner’s Manual Pg. 12 3-CMLT-1054 Rev O XCO 1191...

  • Page 13: Siting - Finding The Best Location For Skystream

    Siting - Finding the Best Location for Skystream The best location to install a wind turbine is often a compromise. Local building restrictions, the height of surrounding structures, wire length, and available open space may require Skystream be installed in a less than optimum location.

  • Page 14: Installation

    The following sections of this manual assume a tower and foundation appropriate for use with a Skystream are in place and ready for Skystream to be installed. XZERES Wind designed Skystream for easy installation by minimizing the number of electrical connections. Note that National Electric Code, ANSI/NFPA 70 wiring methods are to be used throughout the Skystream installation.
  • Page 15 North America Table 1 - Wire Size 120/240 VAC, Split Phase 120/208 VAC, 3 Phase 4 AWG (25 mm2) See Table 2 See Table 2 6 AWG (16 mm2) See Table 2 See Table 2 8 AWG (10 mm2) 303 ft. (92 m) 264 ft.

  • Page 16: Grounding

    ANSI/ NFPA 70. CAUTION : Overcurrent protection for the AC output circuit is to be provided by others. The Maximum size output circuit protection acceptable for Skystream 3.7 is 20 A. Skystream Owner’s Manual Pg. 16 3-CMLT-1054 Rev O XCO 1191...

  • Page 17: Electrical Connections To Skystream

    LOCK it when making connections! The following section provides directions for completing the main power connections to the Skystream. Warning: XZERES Wind strongly recommends and many local electrical authorities require a lockable disconnect switch (Figure 3) installed between the Main Service Panel and Skystream.
  • Page 18 Caution: Make sure AC power is switched “OFF” before proceeding with installation. Lightning Protection The Skystream 3.7 turbine is designed to withstand over voltages and surge currents (6kV, 3kA, 8/20 μs) caused by INDIRECT lightning strikes or switching operations according to the Standard for Interconnecting Distributed Resources with Electric Power Systems (IEEE 1547) .

  • Page 19: Installing Skystream On A Tower

    Warning: Working on towers is dangerous and should be left to professionals with proper safety equipment and training. IMPORTANT: XZERES Wind’s Warranty is only extended to installations that are made on a properly engineered tower. XZERES Wind reserves the right...

  • Page 20: Bolting Skystream To The Tower

    Bolting Skystream to the Tower The following section provides directions for bolting Skystream to the tower. Before Skystream is bolted to the tower, complete the electrical connections as described in the “ELECTRICAL CONNECTIONS” section of this manual. Bolting Skystream to the tower is most easily accomplished at ground level as in the case with a tilt-up tower.
  • Page 21 • Install nuts on bolts to secure Skystream to the tower. • Connect the turbine ground wire as depicted in Figure 2. The turbine MUST be grounded to the tower as shown. • Torque the vibration isolator bolts to 60 lb-ft (80 N·m) in two steps. First torque all bolts to 40 lb-ft (55 N·m) then tighten all bolts to 60 lb-ft (80 N·m).

  • Page 22: Blades, Nosecone And Antenna Assembly

    Installing the Blades (Hub Not on Turbine) Proper installation of the blades is critical for safe operation. The blade nuts and bolts are a unique grade of steel and are specially coated to prevent corrosion. DO NOT substitute different nuts and bolts.
  • Page 23 Installing the Nosecone and Antenna • Install the nosecone with three M6-1.0 socket head bolts. • Install RF Antenna on matching fitting on top of Skystream. Fingertight is sufficient. Important: Do Not Forget to Install RF Antenna RF antenna is required for communication with Skystream by the Skyview. Even if you do not intend to use Skyview be sure to install antenna as it service personnel may be able to diagnose and upgrade your Skystream via Skyview without removing it from the tower.
  • Page 24 Figure 11 Blade and Nosecone Assembly Figure 12 Completed Assembly DESCRIPTION QTY. RF Antenna M12 x 1.75 x 90 mm Hex Bolt Grade 10.9 Snubbing Washer 4, 5 Vibration Isolation Ring (4) and Bushing (5) Strain Relief Cover Assembly Yaw Shield M5 x 12 mm Socket Head Screw M12 x 1.75 Nut grade 10.9 5”...

  • Page 25: Operation

    One area of Skystream that may experience damage is the blades, for example from flying debris during a high wind storm. For this reason XZERES wind recommends Skystream be shut down on an annual basis and an inspection of the blades performed. The inspection may be accomplished using binoculars or by close visual inspection.

  • Page 26: Service

    In the event you must gain access to Skystream, use the opportunity to perform the following inspections: • Remove yaw shield and verify yaw bearing snap ring is properly seated. Wipe any grease that may have seeped from yaw bearing. A small amount of lubricant is normal – consult technical support if there is large amount of leakage.

  • Page 27: Key Operating Characteristics

    Electronic Stall Regulation The Skystream 3.7 has the ability to adjust the rotational speed of its blades or even stop the blades if required by ambient conditions. This is referred to as Stall Control, and it is accomplished by adjusting the current draw from the alternator.

  • Page 28: Disposal Of Skystream

    Only then will it operate the DPDT Grid Relay RL_G to allow the inverter to export power to the grid. Refer to the Skystream Block Diagram in Appendix A. Should the inverter sense an abnormal condition, for example high current in the alternator windings by means of the current sensors on the relay board, it will close relays RL1, 2, and 3 thereby stopping the turbine.

  • Page 29: Frequently Asked Questions

    Yes, Skystream has lightning protection. Skystream can withstand 6000 volts as required by UL 1741, IEEE 1547 and appropriate European Regulations. However, if you live in a lightning prone area, XZERES Wind recommends an additional lightning arrestor at the base of the tower.” 3) When should I contact an authorized service technician? a) If “Growling”...

  • Page 30: Appendix A: Electrical Diagrams

    Skystream 3.7 APPENDIX A: ELECTRICAL DIAGRAMS North America Figure 1 Grid Connection Option A: 120/240 V, 60 Hz, Split Phase, Junction Box at Tower Base ............31 Figure 2 Grid Connection Option B: 120/240 V, 60 Hz, Split Phase, Without Junction Box at Tower Base ......... 32 Figure 3 Grid Connection Option C: 120/208 V, 60 Hz, 3 Phase, Junction Box at Tower Base ............

  • Page 31: Grid Connection Option B

    North America Appendix A Figure 1. Grid Connection Option A: 120/240 V, 60 Hz, Split Phase, Junction Box at Tower Base Skystream Owner’s Manual Pg. 31 3-CMLT-1054 Rev O XCO 1191...

  • Page 32: Grid Connection Option C

    North America Appendix A Figure 2. Grid Connection Option B: 120/240 V, 60 Hz, Split Phase, Without Junction Box at Tower Base Skystream Owner’s Manual Pg. 32 3-CMLT-1054 Rev O XCO 1191...

  • Page 33: Grid Connection Option D

    North America Appendix A Figure 3. Grid Connection Option C: 120/208 V, 60 Hz, 3 Phase, Junction Box at Tower Base Skystream Owner’s Manual Pg. 33 3-CMLT-1054 Rev O XCO 1191...
  • Page 34 North America Appendix A Figure 4. Grid Connection Option D: 120/208 V, 60 Hz, 3 Phase, Without Junction Box at Tower Base Skystream Owner’s Manual Pg. 34 3-CMLT-1054 Rev O XCO 1191...

  • Page 35: Skystream Block Diagram

    North America Appendix A Figure 5. Skystream Block Diagram Skystream Owner’s Manual Pg. 35 3-CMLT-1054 Rev O XCO 1191...

  • Page 36: Europe

    Europe Appendix A Figure 6. TYPICAL Grid Connection: 230 V, 50 Hz, 1 Phase, Junction Box at Tower Base Skystream Owner’s Manual Pg. 36 3-CMLT-1054 Rev O XCO 1191...

  • Page 37: Appendix B: Tower Grounding

    SKYSTREAM 3.7 Appendix B: Tower Grounding Skystream Owner’s Manual Pg. 37 3-CMLT-1054 Rev O XCO 1191...
  • Page 38 Appendix B: Tower Grounding Important Safety Instructions ..................... 39 1) Introduction ..........................39 2) Grounding Techniques ....................... 40 2-1 Copper Clad Electrodes Driven Into Soil ................40 2-1-1 Grounding Electrode Installation ..................40 2-1-2 Electrode Resistance to Ground ..................41 2-1-3 Grounding Electrode Conductor: Material, Size, Bonding to Electrode &...

  • Page 39: Introduction

    Important Safety Instructions Read these instructions in their entirety before installing. In this guide TIP: Helpful information to ease the installation Professional installation highly recommended Warning: Risk of injury or death - proceed with extreme caution Professional installation highly recommended 1) SAVE THESE INSTRUCTIONS.

  • Page 40: Grounding Techniques

    Two - Grounding Techniques There are several tower grounding techniques compliant with NEC and IEC standards; this document presents two of the most common approaches: • Copper clad electrodes driven into the soil • Electrodes encased in the concrete of the tower foundation 2-1 Copper Clad Electrodes Driven Into the Soil The figure 1 shows a typical tower grounded using an electrode driven into the soil.

  • Page 41: Electrode Resistance To Ground

    ground level unless the above ground end and grounding electrode conductor are protected against physical damage as specified below (quoted from 2005 NEC article 250.10): a) In installations where they are not likely to be damaged b) Where enclosed in metal, wood, or equivalent protective covering 2-1-2 Electrode Resistance to Ground The resistance to earth of a single ground rod can be calculated using Dwight’s equation: R = [r/(2ϖL)]x[ln(4...

  • Page 42: Bonding The Grounding Electrode Conductor To The Tower

    Pre-assemble the extra nut (supplied in the tower bolt kit) on one of the tower bolts containing nuts “A” or “B” as shown in Figure 9 of 3-CMLT-1326 Skystream 3.7 Foundation and Tower Installation Manual. Move the extra nut towards the bottom of the bolt so that it does not interfere with the nut to go on top of it.

  • Page 43: Using Exothermic Welding

    2-1-6-3 Using Exothermic Welding Bond the grounding conductor to the tower base flange by exothermic welding of the conductor to the base flange. Make exothermic welds strictly in accordance with the weld manufacturer’s written recommendations. Electrode conductor routing and placement / installation: Ensure that the grounding conductor has no sharp bends in it.
  • Page 44 Figure 4 Concrete Encased Electrode Skystream Owner’s Manual Pg. 44 3-CMLT-1054 Rev O XCO 1191...

  • Page 45: Appendix C: Lightning Protection

    SKYSTREAM 3.7 Appendix C: LIGHTNING PROTECTION Skystream Owner’s Manual Pg. 45 3-CMLT-1054 Rev O XCO 1191...

  • Page 46: Appendix C: Lightning Protection Important Safety Instructions

    Appendix C: Lightning Protection Important Safety Instructions ......................46 Introduction ............................ 47 Location of Lightning Current Arrestor(s) ..................47 Selecting Appropriate Lightning Protection System ................47 Determine Tower Height ........................48 Determine Flash Density (Ng) ......................48 Table 1 Lightning Protection Efficiency for 33 ft (10 m) Towers ............48 Determine the Topography ......................

  • Page 47: Introduction

    Introduction The Skystream 3.7 turbine is designed to withstand over voltages and surge currents (6kV, 3kA, 8/20 μs) caused by indirect lightning strikes or switching operations according to the Standard for Interconnecting Distributed Resources with Electric Power Systems (IEEE 1547). For this protection to be effective, it is necessary to ensure that over voltages at the connection terminals will not be higher than the above values of the surge test.

  • Page 48: Lightning Protection Data

    Determine Tower Height Determine your tower height and select Table 1, 2, 3 or 4 corresponding to a 33, 45, 60 or 70 ft. tower (10, 14, 18 or 21 m). Tables 1, 2, 3 and 4 are used to calculate the Lightning Protection System Efficiencies corresponding to the tower height.

  • Page 49: Determine The Topography

    Determine the Topography Inspect the topography of the area in which the turbine is installed and select the one category that best describes the topography: • Isolated Flat Land: No structures present within a circle of radius three times the height of the turbine (with the turbine at the center of the circle) •...

  • Page 50: Lightning Protection System Efficiency (E)

    Table 3 - Lightning Protection Efficiency for 60 ft (18 m) Towers Isolated Flat Land Hill or Knoll Non-Isolated Flat Land efficiency efficiency efficiency Nc = Nc = Nc = Nc = Nc = Nc = Nc = Nc = Nc = 1/100 1/1000...

  • Page 51: Lightning Protection Level

    Table 4 - Lightning Protection Efficiency for 70 ft (21 m) Towers Isolated Flat Land Hill or Knoll Non-Isolated Flat Land efficiency efficiency efficiency Nc = Nc = Nc = Nc = Nc = Nc = Nc = Nc = Nc = 1/100 1/1000...

  • Page 52: Technology)

    Select Model and Number of Lightning Current Arrestor(s) Select the appropriate model and quantity of the Type 1 lightning current arrestor(s) required from Table 6. The selection method is described below: The lightning arrestor peak current rating is the peak current carrying capability of each pole or contact of the arrestor.

  • Page 53: Appendix D: Compliance/Certification

    SKYSTREAM 3.7 Appendix D: CERTIFICATION/COMPLIANCE Skystream Owner’s Manual Pg. 53 3-CMLT-1054 Rev O XCO 1191...

  • Page 54: Ul Certificate Of Compliance (Us & Canada)

    SKYSTREAM 3.7 APPENDIX D UL Certificate of Compliance (US & Canada) Skystream Owner’s Manual Pg. 54 3-CMLT-1054 Rev O XCO 1191...

  • Page 55: Ce Declaration Of Conformity (Europe)

    2. CE Declaration of Conformity (Europe) Skystream Owner’s Manual Pg. 55 3-CMLT-1054 Rev O XCO 1191...
  • Page 56 XZERES Wind 9025 SW Hillman Court Suite 3126 Wilsonville, Oregon 97070 info@XZERES.com Tel: 503-388-7350 Toll Free:1-877-404-9438 Fax: 503-212-0109 www.xzeres.com XZERES Wind Europe Ltd Headquarters Tel: +44 (0)121 764 7036 info@XZERES.co.uk Suite 528, Equipoint, 1506 Coventry Road Birmingham B25 8AD www.xzeres.co.uk...

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