EVEREADY Kestrel 1112-3500-048, Manual

Page 1: ...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 w...

Page 2: ..._____________________________ Installation Site Address GPS co ordinates are appreciated ________________________________________________________________________ ______________________________________...

Page 3: ...al Installation e400nb 48Vdc and MPPT Charge Control 28 5 6 Electrical Installation e400nb 110Vdc limiter and MPPT 30 6 0 Installation Commissioning 31 7 0 Maintenance Schedule 32 7 1 Wind Power Class...

Page 4: ...n working with this wind turbine Use good handling methods and take precautions to avoid physical injury The Kestrel e400nb output voltage can become dangerous and even lethal when running on open cir...

Page 5: ...ols 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 sp...

Page 6: ...starting and activation ii Procedures during normal running iii Procedure for stopping and de activation iv Procedure for routine maintenance Procedure for Starting Assumption The turbine is braked an...

Page 7: ...mption The turbine is to be stopped and electrically isolated Procure the brake T bar and approach the tower base Verify that the brake ratchet mechanism is engaged Insert the T bar into the brake and...

Page 8: ...s also the easiest to assemble and install due to its simple design and optional hydraulic or electro mechanical lifting pack Monopole towers are usually available in 12m 40 and 18m 60 versions Consul...

Page 9: ...The dimensions are shown below The following specification is recommended for the top pipe section of the tower Mild steel pipe grade 350WA Nom Dia 125mm 5 5 SCH 40 by 1 8m long A standard adapter pi...

Page 10: ...rate for any transit damage and then carefully remove the top of the crate to reveal the contents Check that everything is intact Pay special attention to the blade package Carefully remove all the pa...

Page 11: ...ins a set of fasteners for different parts of the turbine The enclosed grease is used on all nuts that are M10 or larger Note One additional fastener pack contains one spare unit of every fastener use...

Page 12: ...rd screwdrivers plain and Philips Torque wrench suitable for torques of 0 180Nm 132ft lb Electrical pliers cutters crimping tool Refer to the diagrams and follow the instructions to assemble the compl...

Page 13: ...ets 6 Nuts and washers on the bottom Two rear stiffeners 4 to boom 1 with one stainless bolt set 6 Two front stiffeners 5 to boom 1 with one stainless bolt set 6 Bolt all stiffeners 4 and 5 to top and...

Page 14: ...M16 x 90 H T 8 8 ZP 15 1 Rubber flange 16 8 Rubber sleeve 17 1 Steel Flange for welding to tower 18 8 Fender washer 19 8 16mm standard washer 20 8 M16 Hex Nut 21 8 Compression sleeve Take note that th...

Page 15: ...red and ve black generator output cables correctly Reverse polarity will damage the generator and any connected equipment Remove the short across the generator wires Make and complete the electrical...

Page 16: ...NG THE BOOM ASSEMBLY TO THE GENERATOR FIT ALL THE FASTENERS BEFORE TIGHTENING AND ASSEMBLE EXACTLY AS SHOWN IN THE DIAGRAM Take note of the this way up orientation indicators on each component You nee...

Page 17: ...w 4 5 Tail Assembly to the Boom PARTS LIST ITEM QTY DESCRIPTION 22 2 Hex Bolt M10 x 90 washer and nut 23 1 e400nb Nacelle 24 1 Complete tail assembly You need the fastener pack marked Tail Boom weld A...

Page 18: ...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 su...

Page 19: ...e Each blade is fitted with 2 steel positioning sleeves The protruding end of each sleeve must locate in the recessed hole on the blade mount Insert the two bolts 28 from the rear through the blade mo...

Page 20: ...cedure 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...

Page 21: ...brake fork using the shackle provided Tighten to 6Nm and lock by the preferred method Either apply a little Locktite to the shackle pin or use a small piece of stainless wire to secure the shackle pi...

Page 22: ...nd operates the ratchet Engage the ratchet at the brake winch and only wind up the slack in the cable Note that only a small force is required to operate the brake Do not over tension the brake cable...

Page 23: ...lle at the front with four M5 screws and washers 35 Torque to 3Nm 3ft lb Fit the nosecone 31 over the stiffener ring Fit the nosecone over the three support posts Secure the nosecone to the stiffener...

Page 24: ...ltage 48Vdc 110Vdc 250Vdc Operating Range 0 140Vdc 0 290Vdc 0 580Vdc SPD Voltage 200Vdc 350Vdc 650Vdc The turbine output power form is two wire dc Many authorities require GFD Ground Fault Detection a...

Page 25: ...l storm can create a potential difference across two ground points even in underground cable It may not be practical to have one single ground point if the turbine and tower is distant from the instal...

Page 26: ...m 11 120m 400ft 7 0mm 8 5 3mm 10 4 2mm 11 48Vdc battery charging Wire Size Table for Kestrel e400nb 3 5kW 48Vdc 65A One Way Distance 3 Power loss 4 Power loss 5 Power loss 20m 66ft 30mm 2 23mm 3 18mm...

Page 27: ...local electrical codes and practices The installation must comply with the local electrical codes that are in force in the country of installation Please consult your area dealer or a local qualified...

Page 28: ...ng the correct operation of the inverter When such a disconnection takes place the output voltage of the then unloaded turbine can rise to 550Vdc The inverter must be rated to accept up to 600Vdc on t...

Page 29: ...el recommends the Midnite Classic 200 charge controller The Kestrel Interface module includes a turbine brake switch and isolating battery circuit breaker The e400nb is selectively wound to provide th...

Page 30: ...nds the Midnite Solar Classic 200 charge controller All charging installations use the same e400nb 110Vdc turbine Whenever there is an increase in turbine voltage the limiter restricts the voltage to...

Page 31: ...Check all three blades thoroughly for any damage during installation Edge damage will increase noise and change the sound signature of the turbine Verify that the electrical installation is complete V...

Page 32: ...d is not user serviceable Specialist tools and knowledge is required to carry out any maintenance or repair procedures Do not make any unauthorised adjustments or modifications to any part of this ass...

Page 33: ...intervals Dismount the machine and check for transfer brush wear Check for wear on pitch control parts Replace as required Treat any corrosion and touch up paint Every 5 years Every 3 years Dismount t...

Page 34: ...balance The tower is resonating with natural vibration 8 The turbine sounds different from when it was installed See 3 A blade is damaged The blade leading edge tape is defective 9 Should I lower the...

Page 35: ...Speed 11m s 24 6mph Maximum Design W Speed Survival 70m s 157mph Generator Type Axial flux PMG Overspeed Protection Blade pitch control Rotor Diameter 4m 13 1ft Number of Blades 3 Blade Material Epox...

Page 36: ...Document No 1112M001 Revision 1 8 Date June 2013 36 10 0 Compliance...

Page 37: ...lies 2 4 Repaired or replaced product may be new upgraded re manufactured or refurbished at the sole discretion of Kestrel 2 5 Kestrel will provide return shipping to customers within South Africa or...

Page 38: ...ions There should be virtually no movement or slackness Push and pull the blade along it s length There should be no movement of the blade If any wear or defect is detected consult your dealer or the...

Page 39: ...ted rpm the centrifugal force generated by the blades and blade mounts begin to compress the springs As the blades move outward they are rotated This blade rotation alters the blade angle to the wind...

Page 40: ...od Unlike many generators the Kestrel e400nb produces dc power There are therefore no inductive affects in cabling and radiated emission is absolutely minimal The power output has a much lower ripple...

Page 41: ...r fetch at least in the prevailing wind direction The wind speeds up significantly near the top of the hill and the airflow should be reasonably smooth and free from excessive turbulence Excessive tur...

Page 42: ...e for professionals to use although such predictions should be applied with care a Get a reliable estimate of the wind speed at the proposed site b Mount the turbine on as high a tower as possible and...

Page 43: ...he Power One Aurora 3 6 inverter must be installed with the Kestrel e400nb 3 5kW 250V The main requirements for a suitable inverter are given below Continuous power rating 3 6kW Input dc voltage range...

Page 44: ...nly a small force is required Insert the brake T bar into the hole on the tower Slide the small lever to engage the ratchet Slowly wind the T bar clockwise to tension the brake until the machine start...

Page 45: ...taking this task If you feel uncomfortable carrying out this procedure please contact your sales agent for assistance Fitment instructions are as follows You will need the following hand tools in addi...

Page 46: ......

Page 47: ...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 Smear white grease onto the shaft brake key 39 before inserting it...

Page 48: ...ont 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 Fit 2 x Cable pulley pins 8 with thread glue Fi...

Page 49: ...hor block using a 4mm Allen key Ensure anchor block is against the shoulder of the anchor pin Fit band guide pulley 3 in position and insert M8x55 Cap screw 4 with thread glue tighten by hand using a...

Page 50: ...is clean Before inserting the bottom yoke please insert 4 off M16 x 100 bolts G through the bottom flange at the back of the yaw shaft After fitment of the yokes access to these holes will no longer...

Page 51: ...of thread glue onto the thread portion of the yoke screw pins 13 before fitting the 2 off screw pins through the yoke 14 into the bottom slip ring 43 Take care not to leave any thread glue on the bear...

Page 52: ...ately 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 Secure shackle thread with thread...

Page 53: ...ontrol back to the generator smear white grease over shaft and hub clamping spacer before assembly If you have removed the shaft main key in the process of fitting the brake return it to position afte...

Page 54: ...rter The Power One Aurora 3 6 is the preferred inverter The wind table configuration for the Aurora inverter is given in the table and in the screenshot of the Aurora software The version of Aurora in...