1. Manuals
  2. Brands
  3. EVEREADY Manuals
  4. Wind Turbines
  5. Kestrel e400nb
  6. Manual

EVEREADY Kestrel e400nb Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
250Vdc,
110Vdc,
048Vdc,
With Conditional Two Year Warranty
Important Note: Only the e400nb 3.5kW 250V grid tie version when installed with the Power
One Aurora 3.6 Inverter is MCS and SWCC certified.
Document No. 1112M001
Kestrel e400nb
Type 1112-3500-250 (3.5kW 250Vdc)
Type 1112-3500-110 (3.5kW 110Vdc)
Type 1112-3500-048 (3.5kW 048Vdc)
Revision 1.8
Date: June 2013
1

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the Kestrel e400nb and is the answer not in the manual?

Questions and answers

Summary of Contents for EVEREADY Kestrel e400nb

  • Page 1 Kestrel e400nb 250Vdc, Type 1112-3500-250 (3.5kW 250Vdc) 110Vdc, Type 1112-3500-110 (3.5kW 110Vdc) 048Vdc, Type 1112-3500-048 (3.5kW 048Vdc) With Conditional Two Year Warranty Important Note: Only the e400nb 3.5kW 250V grid tie version when installed with the Power One Aurora 3.6 Inverter is MCS and SWCC certified.
  • Page 2 Comissioned Date GENERAL COMMENTS: ……………………………………………………………………………………………………………… ……………………………………………………………………………………………………………… Send to: Kestrel Wind Turbines, P.O. Box 3191, North End, Port Elizabeth, 6056, Eastern Cape, South Africa Or email to: kestrel.admin@eveready.co.za OR Fax: +27 41 394 8183 Document No. 1112M001 Revision 1.8 Date: June 2013...
  • Page 3 Index 1.0 Safety Warnings and Notes 1.1 Safety Symbols 1.2 Turbine Operating Procedures 2.0 The Tower 2.1 Mounting Flange and Tower Top 3.0 Unpacking the Wind Turbine 4.0 Turbine assembly and Installation 4.1 Identification Marking 4.2 Tail Assembly 4.3 Generator to the Tower with Damper Kit 4.4 Tail Boom Weld assembly to the Generator 4.5 Tail Assembly to the Boom 4.6 Blades and Nosecone Stiffener Ring...

  • Page 4: Safety And Warning Notes

    Please carefully read and apply the safety notes. Consult a professional engineer and take advice if you are unsure. Note: The Kestrel e400nb has a mechanical brake and the Kestrel e400n is supplied without this mechanical brake. 1.0 Safety and Warning Notes Accidents can easily occur and there are always inherent dangers associated with any type of machine.

  • Page 5: Safety Symbols

    1.1 Safety Symbols The symbols shown are used throughout this manual to highlight safety points General caution warning Danger of hand injury Danger of electrical shock Injury from blades Work Instructions Asterisk denotes a special instruction or reminder. ► Arrow head denotes an assembly/build instruction. Document No.

  • Page 6: Standard Operating Procedure

    1.2 Turbine Operating Procedures A standard start and stop procedure is included in this product manual (Annexure 4). It is recommended that a label showing this procedure be visible adjacent to the wind turbine tower. A “T” bar is supplied to operate the tower brake. This “T” bar should be stored in a safe but accessible location and never left in position on the tower.
  • Page 7 Procedures During Normal Running (Assumption: The turbine is running normally) • No operating procedures are required. Take every opportunity to visually observe the system in operation and to listen for any unusual noise. This is always a good practice. Procedures for Stopping and De-activation IMPORTANT NOTE: A stopped turbine will still yaw and align to follow the wind.
  • Page 8 2.0 The Tower A monopole free standing tower is preferred for the Kestrel e400nb. The tower sections can be taper formed or parallel tubular. These towers use larger diameter sections to increase rigidity and strength but optimise the total tower weight. This tower type is also the easiest to assemble and install due to its simple design and optional hydraulic or electro-mechanical lifting pack.
  • Page 9 2.1 Mounting Flange and Tower Top The tower for the Kestrel e400nb is fitted with a circular flange made from 20mm 300WA mild steel. The dimensions are shown below. The following specification is recommended for the top pipe section of the tower. Mild steel pipe grade 350WA Nom.
  • Page 10 3.0 Unpacking the Wind Turbine A Packing list is packed with the product. Ensure that all parts are present. Notify your dealer of any shortages. The e400nb is contained in one shipping crate. Check the crate for any transit damage and then carefully remove the top of the crate to reveal the contents.
  • Page 11 The bare generator and pitch control is factory assembled. This complete sub-assembly weighs approximately 170kg (375lb). Unpack and check the following parts. Inform your supplier of any defects or shortages. ► Remove the blade package and store safely. ► Remove the nacelle and nosecone with ring and store safely.
  • Page 12 4.0 Turbine Assembly and Installation You will need the following hand tools. ► Trestle, table or other support to support the turbine that is safe for 250kg (550lbs). ► Plastic or rubber mallet, brass mallet/ hammer & 8mm pin punch. ►...

  • Page 13: Tail Assembly

    4.2 Tail Assembly PARTS LIST ITEM DESCRIPTION Tail Boom Extension Top Tail Plate Bottom Tail Plate Rear Stiffener Front Stiffener Hex Bolt M6 x 80 long, washer and nut Hex Bolt M6 x 16, washer and nut ASSEMBLE EXACTLY AS SHOWN IN THE DIAGRAM. FIT ALL THE FASTENERS BEFORE TIGHTENING.
  • Page 14 4.3 Generator to the Tower with damper kit The steel flange (17) is fitted and welded to the tower top to adapt non-Kestrel towers. Kestrel accepts no responsibility for any third party tower design or application. Each e400nb turbine is supplied with a standard rubber mounted resilient kit.
  • Page 15 Avoid damage to any paint finishes by protecting with suitable sundry material (HD foam, carpet tiles, cloth rags etc). Make all power cables ends safe by insulation before installing the generator. ► Support the lowered tower at a suitable height to receive the generator.
  • Page 16 4.4 Tail Boom Weld Assembly to the Generator PARTS LIST ITEM DESCRIPTION Tail Boom Weld Assembly M12 Tail Boom Bolt, washer and nut M12 Allen cap bolts and washers Tail Boom Flange Generator Pitch Control THE GENERATOR SHOULD BE FITTED ON THE TOWER BEFORE FITTING THE BOOM ASSEMBLY TO THE GENERATOR.
  • Page 17 The finished generator installation is shown below 4.5 Tail Assembly to the Boom PARTS LIST ITEM DESCRIPTION Hex Bolt M10 x 90, washer and nut e400nb Nacelle Complete tail assembly You need the fastener pack marked “Tail Boom weld Assembly” for this work.
  • Page 18 ► Slide the tail assembly (24) to the boom as shown. Place a little grease inside the two nut threads. Fit the two stainless M10 bolt sets (22). Torque to 35Nm (25ft lb). ► Raise the tower and generator to a suitable height from the ground for blade fitment.
  • Page 19 4.6 Blades and Nosecone Stiffener Ring PARTS LIST ITEM DESCRIPTION Blade Hex Nut M16 Nylock Compression plate Hex Bolt M16 x 100 Nose Cone stiffener ring You need the fastener pack marked “Blade Fasteners” for this work. Fit the Nosecone stiffener ring (29) over the pitch control before fitting the blades (25) and leave it loose in place !! The ring is tapered and the smaller diameter must face forward to match the shape of the nosecone.
  • Page 20 Note that no balancing procedure of the turbine blades is required. 4.7 Mechanical Brake Assembly (e400nb only) The Kestrel e400nb is fitted with a mechanical band brake. This brake is activated by a manual cable winch and a drop cable that are shipped with the turbine.
  • Page 21 Assembly of the brake winch: The tower is in the lowered position to assemble the brake winch. ► Remove the single brake pulley at the tower top so that the cable can exit. ► Thread the operating cable into the tower. The cable end with the fitted eye is connected to the turbine brake lever using the supplied shackle.
  • Page 22 ► Install the winch assembly inside the tower and fit by using the three provided nuts and bolts. Ensure that the operating handle freely enters the tower side and turns the winch. Ensure that the ratchet lever exits the tower freely and operates the ratchet. ►...
  • Page 23 4.8 Nacelle and Nosecone PARTS LIST ITEM DESCRIPTION Nose Cone M6 Nylock nuts and washers M8 Nylock Nuts and washers M6 Nylock Nuts and washers M5 CH screws and washers Nacelle Check all previous work before fitting the “covers”. You need the fastener pack marked “Nacelle and Nosecone” for this work ►...
  • Page 24 nut sets (33) and torque to 10Nm (7.5ft lb). 5.0 Electrical Installation 5.1 Lightning Protection (No responsibility is accepted) The tower must be properly grounded to local codes. Suitable SPD’s (Surge Protection Device) should be fitted at the power input connections to the electronics.
  • Page 25 5.2 Earthing (Grounding) (No responsibility is accepted) Induced surges cannot be stopped; they can only be directed away from equipment. The objective is to create the same zero potential and minimum impedance to ground on all equipment. The tower and all fitted equipment must be properly earthed. Note that the positive and negative power lines from the turbine are isolated and must not be connected to ground.
  • Page 26 250Vdc Grid Tie Wire Size Table for Kestrel e400nb 3.5kW 250Vdc 14A One Way 3% Power loss 4% Power loss 5% Power loss Distance 20m (66ft) 1.0mm² (17) 1.0mm² (17) 1.0mm² (17) 40m (130ft) 2.5mm² (13) 1.8mm² (14) 1.5mm² (15) 60m (200ft) 3.5mm²...
  • Page 27 5.4 Electrical Installation (e400nb 250Vdc and Grid Tie) Under no circumstances shall the Kestrel e400nb be directly connected to any grid tie inverter. The turbine must be connected via the Kestrel interface module (575V). A grid tie installation supplies electrical energy from the wind turbine to the utility electrical grid.
  • Page 28 Detailed information can be found in the grid-tie inverter manual. The following information highlights points relevant to the turbine. The Kestrel e400nb wind turbine is rated at 250Vdc. The power range from 0 – 3.5kW is developed between 220Vdc and 250Vdc. This is the normal working voltage range.
  • Page 29 This method makes it possible to charge 12, 24, 36, and 48Vdc batteries. In general, certain applications allow the use of alternative charge controllers with the e400nb 48V as shown . These controllers often disconnect to perform measurements and other functions. The turbine voltage is restricted (capped) by the blade pitch control.
  • Page 30 MPPT controller. The same charge controller type is used on both wind and solar in hybrid installations. The Kestrel e400nb 110Vdc power range from 0 – 3.5kW is developed between 90Vdc and 120Vdc. This is the normal working voltage range.

  • Page 31: Installation & Commissioning

    6.0 Installation Commissioning The turbine installation on the tower is complete. The electrical installation is also complete and approved. Safety precautions are in place ready for the tower to be raised. The electric brake is standard on the e400n and e400nb. The additional mechanical brake is only fitted to the e400nb.

  • Page 32: Maintenance Schedule

    7.0 Maintenance Schedule The Kestrel e400nb operates with minimum maintenance. The frequency of visual inspections and integrity checks depends on the wind class of the installation site. Wind Power Class definition for wind power density and average wind speed at a hub height of 10m is given below.

  • Page 33: Planned Maintenance Schedule

    Inspection of the tower including all bolts/fasteners ground anchors and guy wires. b) Inspection of the Kestrel e400nb tower securing bolts. c) Check all electrical connections for tightness and corrosion. d) Functionality and general checks on all other electrical equipment.

  • Page 34: Questions And Answers

    8.0 Questions and Answers The tail is swinging from side The blade rotor is unbalanced. There to side or moving up and is blade damage. down. The turbine fails to track light The tower is not vertical and so the winds / always comes to rest turbine is not horizontal.

  • Page 35: Technical Specification

    9.0 Technical Specification NOTE: Performance may vary due to site conditions and local weather pattern Parameter Battery Charging MCS/BWEA SWCC/AWEA Rating Reference Version e400nb 3.5kW 48/110V e400nb 3.5kW 250V Maximum Power 3500W (Peak turbine) 2990W 3.03kW Rated Power at 11m/s 2500W 2550W 2.5kW...
  • Page 36 10.0 Compliance Document No. 1112M001 Revision 1.8 Date: June 2013...

  • Page 37: Warranty

    11.0 Warranty Kestrel e400nb Two Year Limited Warranty 1. General Terms and Conditions 1.1) The user must complete and return the Warranty Form within one month from the date of installation or within three months after receipt of the Kestrel product.
  • Page 38 Annexure 1: General Information The Kestrel e400nb is a high quality wind turbine that often becomes a local landmark. It is a serious machine with a remarkable performance being designed to give the owner many long years of trouble free service.
  • Page 39 allow water to enter. This will cause the blade set to become unbalanced which will cause other mechanical failures and shortened bearing life. Water inside a blade can freeze and cause cracks. Pitch Control The Kestrel Pitch control consists of a patented design that after a long development phase was thoroughly tested.
  • Page 40 The Generator The Kestrel e400nb generator is a completely sealed unit and requires no regular maintenance. The generator carries two single deep groove bearings and one double bearing assembly. All bearings are of a high quality and are sealed for life.
  • Page 41 Annexure 2: Choosing a Site (Courtesy of BWEA) The output from a wind turbine is highly sensitive to wind speed. It is essential that turbines should be sited away from obstructions, with a clear exposure or fetch for the prevailing wind. Wind speed also increases with height so it is best to have the turbine high up, and...
  • Page 42 and in many cases the user may already have a good feel for the winds in the locality. However impressions can be deceptive. A more reliable way to evaluate the wind resource, which is strongly recommended when there is doubt over whether the wind is strong enough, is to take regular measurements over a period of several months, preferably a year.
  • Page 43 Your Kestrel dealer or the factory can comment on the characteristic of any control algorithm. No input rectifier is necessary. The Kestrel e400nb turbine outputs dc voltage and current. Images are for illustration only. Kestrel does not endorse any grid tie inverter.
  • Page 44 Annexure 4: Manual Brake Operation It is recommended to display a label that describes the stop and start procedure. An example is given below. Kestrel e400nb Manual Brake Operation You need the brake “T” bar ! DO NOT OVER_TENSION THE BRAKE.
  • Page 45 Annexure 5: Brake Fitment Instructions (For e400n only) The model e400n turbine is supplied without a factory fitted brake. The brake unit may be purchased as a standard accessory. The correct fitment of the brake unit is extremely important for the safe operation of the turbine.
  • Page 47 ► Remove white plugs (x3) (A) at the front of the generator using a thin flat screw driver ► Remove bolt (B) at the front of the pitch control using a 24mm wrench. Pull off the pitch control unit (C). ►...
  • Page 48 ► Offer the brake drum (2) onto the main shaft. Slide brake drum over main shaft with the flat face against the generator. Tap the front of the drum while inserting to slide over shaft. ► Fit anchor pin (D) on the left side of the generator with thread glue and tighten using a 16mm spanner.
  • Page 49 ► Fit brake band assembly (16) over anchor pin (D) and insert split pin (21). Secure the pin by bending one of the legs over. Tighten the bottom 2 bolts (F) of the anchor block using a 4mm Allen key. Ensure anchor block is against the shoulder of the anchor pin ►...
  • Page 50 ► Fit top slip ring 2 halves (44) to generator swivel shaft and secure with 2 M8x50 SS Allen Cap screws. (46) ► Fit top yoke bracket (10) onto generator drum and secure with M8x16 cap screws SS (20). Secure with thread glue.
  • Page 51 ► Lubricate all bushes in bottom yoke with a thin film of oil or grease before fitment. ► Fit bottom yoke (11) to slip ring with cut-out facing downwards, slip yoke into bottom yoke bracket and insert yoke anchor pin (12) and 2-off split pins (19).
  • Page 52 ► Fit brake band cable assembly (40) by screwing the cable bolt into the tension block by approximately 10mm. ► Fit the shackle-end of the brake band cable assembly (40) to the hole on the arm of the top yoke (11) after routing it over the pulleys as per the figure below.
  • Page 53 Test for up and down movement of yokes Test for free rotation of the brake drum. The brake mechanism must be able to be operated by hand and be free and functional. The bottom yoke should fall freely to its original position if raised.
  • Page 54 MCS and SWCC certification is given in the technical data on page 35 of this manual. Consult the inverter manual for full details. To report errors or omissions or to suggest improvements please write to: kestrel.technical@eveready.co.za kestrel.admin@eveready.co.za Document No. 1112M001 Revision 1.6...

This manual is also suitable for:

Kestrel 1112-3500-250Kestrel 1112-3500-110Kestrel 1112-3500-048

Table of Contents