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Related Manuals for Bergey XL-15
Summary of Contents for Bergey XL-15
- Page 1 BERGEY XL-15 INSTALLATION QUICK GUIDE Page 1 of 28 REV 0.1...
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Page 2: Table Of Contents
TABLE OF CONTENTS RECOMMEND TOOL LIST………………………………………………………………………………………4 TORQUE VALUES……………………………………………………………………………………………….…5 TURBINE HARDWARE……………………………………………………………………………………………6 ELECTRICAL STANDARD 240VAC…………………………………………………………………………..7 ELECRICAL TRANSFORMER REQUIRED………………………………………………………………….8 WIRE SIZE CHART…………………………………………………………………………………………………9 GETTING STARTED………………………………………………………………………………………………10 POSITIONING THE UNIT FOR TAIL ASSEMBLY…………………………………………………….11 TAIL INSTALLATION………………………………………………………………………………………12-13 TAIL FIN INSTALLATION………………………………………………………………………………………14 RIGGING THE TURBINE FOR THE LIFT…………………………………………………………………15 BLADE INSTALLATION…………………………………………………………………………………………16 ... - Page 3 SYSTEM COMMISSIONING ……………….………………………………………………………………..24 MEGGER TEST……………………………………………………………………………………….….24 INVERTER/DUMPLOAD …………………………………………………………………………...25 ALTERNATOR OUTPUT……………………………………………………………………………..26 SYSTEM COMMISSIONING CHECKLIST………………………………………………………27 ADDITIONAL INFORMATION……………………………………………………………………………….28 ***BEFORE PERFORMING ANY LIFTING OPERATION ENSURE ALL PARTS ARE FREE AND CLEAR FROM OBSTRUCTIONS AND ARMORED CABLE WILL NOT BE CRUSHED OR DEFORMED IN ANY WAY*** Page 3 of 28 REV 0.1...
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Page 4: Recommend Tool List
RECOMMENDED TOOL LIST Please note the below list is to serve as a general reference of what tools you should have available. However in no way is it meant to be a comprehensive list of tools required to complete the installation. ... -
Page 5: Torque Values
TORQUE VALUES TASK TOOL HARDWARE TORQUE Attach tailboom to mainframe 17 MM 10 MM ft⋅lb Attach tailfin to tailboom 17 MM 10 MM ft⋅lb Torque bracket to alternator 24 MM 16 MM ft⋅lb Blades/clamp plate to alternator 24 MM 16 MM *SEE PG 20 Spinner mounting 17 MM... -
Page 6: Turbine Hardware
TURBINE HARDWARE Page 6 of 28 REV 0.1... -
Page 7: Electrical Standard 240Vac
ELECTRICAL –STANDARD 240VAC 60Hz This is how a typical 240 VAC grid tied installation will look once installed. For deviation to the one line follow all local codes. Page 7 of 28 REV 0.1... -
Page 8: Elecrical Transformer Required
ELECTRICAL TRANSFORMER REQUIRED This configuration is typical for a grid tied system that is not a standard 240VAC. A 25KVA transformer is sized appropriately. A number of manufactures make transformers that are suitable for installation. For this example we will use the single phase transformer from Maddox. -
Page 9: Wire Size Chart
WIRE SIZING Recommended Wire Size for BWC EXCEL 15 Installations Note that wire run lengths correspond to performance values estimated by WindCAD. Annual Energy Output losses of 4.5% were factored into the WindCAD model to account for energy losses due to wire sizing. Page 9 of 28 REV 0.1... -
Page 10: Getting Started
GETTING STARTED The unit will come in three packages. Below is the power head crate that has been open and stripped down to begin turbine assembly. Note the alternator is bolted to the pallet. Tower adapter Brake resistors Rigid armor cable Mainframe The mainframe WARNING: The... -
Page 11: Positioning The Unit For Tail Assembly
POSITIONING THE UNIT FOR TAIL ASSEMBLY A mechanical advantage will be required to lower the powerhead on its side as it weights over 1,000 lbs. Careful attention must be given to the armored cable and brake resistors to ensure this is not crushed in the process. Damage to the armored cable could result in a non-operational turbine. -
Page 12: Tail Installation
TAIL INSTALLATION Take caution to ensure the tail is not installed upside down, note it will bolt on incorrectly. Leave all bolts finger tight until all bolts are started. Ensure extreme caution is taken to avoid damaging the brake resistors protruding from the rear of the mainframe when joining mainframe and tail together. - Page 13 TAIL INSTALLATION CONTINUED A quick check to ensure you are installing the tailboom correctly: While looking down the turbine, from the alternator to the tailboom the tail fin should be located on the right side of the machine. Tailboom installed correctly Page 13 of 28 REV 0.1...
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Page 14: Tail Fin Installation
TAIL FIN INSTALLTION Shown below are images of how it will look after proper installation. Page 14 of 28 REV 0.1... -
Page 15: Rigging The Turbine For The Lift
RIGGING THE TURBINE FOR THE LIFT The turbine has two eye bolts atop the mainframe. Ideally a separate strap is attached to each eye bolt. It has been reported when picked in this manner the tower adapter does not “sit” parallel with the tower top. A chain hoist can provide for fine adjustments. -
Page 16: Blade Installation
BLADE INSTALLATION Torque brackets Blade clamp plate Blade Page 16 of 28 REV 0.1... -
Page 17: Clamp Plate Spacers
TORQUE BRACKETS Install the blade clamp plate and the torque brackets. Notice the bolt goes through the clamp plate then through the plate spacers into the alternator. Leave all hardware loose. NOTE: The clamp plate spacers are from a previous revision. -
Page 18: Blade Orientation
BLADE ORIENTATION The blades can bolt onto the alternator backwards. It is import to ensure this does not happen. Although the blades come with stickers that indicate which side of blade root should face the alternator, close scrutiny should be applied to ensure they are correct. -
Page 19: Fitting Blades
FITTING BLADES Now that the blade clamp plate and clamp plate spacers are installed loosely. We can install the first blade. Fit the blade between the alternator and clamp plate as documented below. Install first blade Install second blade Two blades can be installed before the turbine is lifted. While the turbine is being lifted they can be rotated around for the easiest installation of the third blade. -
Page 20: Blade Torque
BLADE TORQUE While lifting the turbine pay attention to the armored cable and ensure that it is not crushed at any point in the process. The blades have a procedure for being torqued. Start with 50 ft⋅lb. then back off a ¼ turn, 75 ft⋅lb. then back off a ¼ turn, 100 ft⋅lb. -
Page 21: Nose Cone Installation
The nose cone will line up with the rubber mounts factory installed on the torque brackets. One bolt and fender washer are used per torque bracket to install the nose cone. Page 21 of 28 REV 0.1... -
Page 22: Applying A Phase To Phase Short
APPLYING A PHASE TO PHASE SHORT At this time a phase to phase short should be applied in the down tower disconnect box. Use two 10 gauge solid strand wires to jump between the bottoms of the fuses as shown below. This short should be left in place until the system is commissioned. -
Page 23: Raising The Turbine
RAISING THE TURBINE The top blade should be tied off to the lifting eye bolt to physically stop the alternator rotation. Once the electrical connections are made the phase to phase short applied in the disconnect will electrically stop the alternator rotation and the blade should be untied. -
Page 24: Megger Test
SYSTEM COMMISSIONING Megger Test The installation of the wiring must be checked to ensure adequate insulation. This will require a megger (insulation breakdown tester) with a 1000V scale. The test should show any damage to the wire run from the turbine to the inverter. While performing these tests the underground wire run must be disconnected from the inverter, the tower wire run disconnected from the turbine and adequate measures taken to ensure the turbine does not free spin while the test... -
Page 25: Inverter/Dumpload
SYSTEM COMMISSIONING Inverter / Dump load Perform a visual inspection of the inside of the inverter; look for any damage that might have occurred in shipping. Double check all inverter and grid connections are tight and in good repair. Open the dump load and locate the two copper bus bars. Take an OHM reading between the two buss bars and ensure that you have 10 OHMS. -
Page 26: Alternator Output
SYSTEM COMMISSIONING Alternator output With the inverter fully powered up and having completed its initialization process of five minutes, remove the phase to phase short in the down tower disconnect. With enough wind, the blades should begin to rotate and the alternator output variable voltage variable frequency alternator current. -
Page 27: System Commissioning Checklist
SYSTEM COMMISSIONING Checklist Ensure all turbine wiring has proper insulation by performing 1000 volt megger testing. Do not test wiring with turbine or inverter in the circuit. (see page 23) Check all inverter and dump load connections. Test the resistors in the dump load, a correct reading should be 10 ohms between the buss bars ... -
Page 28: Additional Information
A junction box is required to install the down tower cable with the armored cable that is protruding from the 15KW tower adapter. This will also require a source for connecting the wires, Bergey WindPower recommend Polaris IT-4 connections.