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Owners Manual
Mechanical
Installation, Operation, & Maintenance
Version 5.0
Table of Contents
1. 2. 3. 4. 5. 6. 7. 8. 9. Safety Warning Introduction Wind Generator Specifications Equipment Supplied Required Installation Tools Choosing Sites for Wind Generators Towers & Rigging Wire Size Requirements Turbine Assembly Instructions
A. B. C. D. E. F. G. H. I. Position the Tower Check the Yaw Head Axle Electrical Connection: Yaw Head to Tower Mount Yaw Head to Tower Mount Alternator to Yaw Head Wire the Yaw Head Terminal Strip Test the Electrical Connections Install Tail Boom to Yaw Head Install Blades & Nose Cone
10. Inspection & Maintenance 11. Component List & Drawing Warranty
3 4 5 6 7 7 8 8 9 9 9 10 10 11 11 13 14 16 19 20 21
1. SAFETY WARNING!
Electrical shock hazard: The wind generator can produce high voltages sometimes more than 200 volts. These voltage levels can cause serious injury or death. No wires or electrical connections should be touched or handled without ensuring that the wind generator has been braked to a complete stop and the DC power to the Voltage Clamp (turbine controller) is off. After these steps are taken, approximately five (5) minutes is required for system voltage to decay to safe levels. The ARE110 is a powerful machine and can cause injury if not assembled and erected properly (according to the instructions and using appropriate equipment). Do not approach the machine while the blades are spinning they can cause serious injury!
Please Note:
2. Introduction
This manual provides the information needed to assemble, operate, and maintain the ARE110 (2.5 kW) wind generator with a direct grid connection. Please read it thoroughly and keep for future reference. The ARE110 provides a very long life with very little maintenance due to its relatively low rotational speeds (low RPM), its rigorous design utilizing a minimum number of moving parts, and its rugged construction. Its large swept area, high-efficiency blades, purposebuilt alternator, and optimized power electronics ensure maximum energy capture from a wide range of wind speeds. The simple, upwind side furling system (with gravity return) protects the wind turbine by reliably swinging the rotor out of winds higher than 11 m/sec (25 mph).
Three-blade upwind Side furling with gravity return Pulse-width modulated resistor loading 2.5 kW (2500 watts) 3.6 m (11.8 ft) 10.2 m2 (110 sq. ft.) 2.5 m/s (6 mph) 3 m/s (7 mph) 12 m/s (25 mph) Three (3), molded fiberglass 0340 rpm Neodymium permanent magnet 3-phase, variable voltage (0 - 100 VAC) 143 kg (315 lbs.) 160 Kg (350 lbs.)
1000
A R E 1 1 0 W in d G e n e r a to r s
M o n th ly E n e r g y E s tim a te s
800
600
400
200
0 8 10 12 A v e r a g e L o c a l W in d S p e e d (m p h ) 14
4. Equipment Supplied
Qty. Item Description
1 3 1 4 3 6 1 1 3 1 1 1 1 3 1 Alternator Bolts (alternator-mount) with star washer M16-2.0 x 30mm Yaw head with slip rings Bolts (tower-mount) with self-locking nut - M16-2.0 x 70mm Blades Studs, hex (blade-mount) with self-locking nut - M12-1.75 Plate (blade-clamping) Nose cone Bolts (nose-cone mount) with washers & lock washers - M6-1.0 x 16mm Tail boom, inner (gusset) with tail hinge pin, tail pin latch, & E-clip retainer Tail boom, outer (sq. tube 1.5" x 92") Bolt (tail boom) - M16-2.0 x 70mm Tail fin (with ARE logo) Bolts (tail fin mount) with (2) washers and self-locking nuts M14-2.0 x 60mm Tail weight (approx. 3 lbs.)
2H H 2H
Sharp edges create turbulence
Turbulent airflow
20 H
As a general rule, wind turbines should be mounted at twice the height of any sudden upwind obstructions. Alternatively, turbines may be located at least 10 meters (30 feet) plus the blade length above the tallest trees, buildings, or other such obstructions within 150 meters (500 feet). The power (P) obtainable from the wind is proportional the cube of the wind speed (v3), and wind speed increases with height (H) from the ground. [P v3 and v H]. According to this principle, a 26% increase in wind speed from a higher tower will yield a 100% increase in power from the turbine. A little more money spent on a taller tower harvests the same power as two (2) machines! Preference should be given to the prevailing wind direction, but please note that tall features downwind of the generator can also slow wind flow passing through the turbines blades.
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6 AWG
220-350 feet
4 AWG
350-550 feet
2 AWG
550-870 feet
1 AWG
870-1100 feet
1/0 AWG
1100-1390 feet
2/0 AWG
1390-1770 feet
NOTE: The Voltage Clamps terminal block does not accept wire sizes larger than 6 AWG. If a larger wire size is used, the wire size must be stepped down prior to insertion into this terminal block.
Assembly Procedure:
A. Position the Tower
If using an ARE tilt-up tower kit, the top of the lowered tower should be supported at approximately 1 meter (3 feet) above the ground.
NOTE: DO NOT TIGHTEN THIS NUT. It is intended to be loose in order to allow yaw head rotation.
Figure 11. Mating the tower top to the yaw head flange
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Three (3) M16 bolts attach the alternator to the yaw head. It may be necessary to remove the yaw head access door in order to fasten all bolts.
F.
Attach alternator lead wires to the terminal block on the yaw head access door and secure wire with screw and clamping plate.
Examine all the slip ring brushes to verify firm contact with the slip rings (see Figure 15 below). Check to see that brushes can be pulled back from the rings and return freely. If a brush sticks: Loosen the top nut in quarter-turn increments until the brush springs back. CAUTION: Do not loosen the top nut excessively, as this may result in improperly seated brushes.
Adjustment Nut
Slip Ring
Spacer
Reattach and close the yaw head access door (if removed in prior step). While closing the access door, make certain that wires are not pinched and do not interfere with the slip ring mechanisms. Use the M6 bolt to hold the door in place (as shown in Figure 16 below).
Use this bolt to hold the door in the closed position. Tighten bolt fully to ensure that it does not back out.
Remove the pin latch plate from the inner tail boom section (see Figure 17 above). Align the two (2) hinge eyes of the inner tail boom section with the two (2) bronze bushings (inserted in holders on the rear of the yaw head). Install the tail pivot pin to join the tail to the yaw head (see Figure 18 below).
Notch
Tail Pin
Groove
Align the notch in the hinge pin with the pin latch plate and secure in place. Apply thread-locking compound and tighten the two M6-1.0 x 16mm bolts to 10 N-m (7 lb-ft) torque. Install the E-clip retainer into the groove at the bottom of the hinge pin. Vise grips are a useful tool for the E-clip retainer installation (see Figure 19 below).
Figure 19. Close-up views of tail pin latch plate & E-clip retainer installation
Note Figure 20 below for the correct holes to use when mounting the tail fin to the tail boom. Mount the tail fin to the outer tail boom section (square tube) with the two (2) inner bolt holes. Use M14-2.0 x 60mm bolts with washers and self-locking nuts.
The bolt in this hole acts as a stop for the tail weight [Bolt & tail fin omitted for clarity]
Install the tail weight in the end of the outer tail boom, as shown in Figure 21 (above). Install the last (outermost) bolt to secure the tail fin. The tail weight will be captured between the two (2) outer bolts (see Figure 21 above). Tighten the M14 fasteners to 60 N-m (45 lb-ft) torque. Install the outer tail boom into the inner tail boom, and secure with an M16-2.0 x 60mm bolt and self-locking nut (see Figure 22 below). Tighten the M16 fastener to 80 N-m (60 lb-ft) torque.
Inner tail boom
I.
Install the three blades onto the blade studs. The studs are equally spaced, so you may start with any two studs. Orient the blades so that the blue leading edges will rotate clockwise (CW see Figure 24 below).
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After placing the three (3) blades, install the blade clamping plate over the six (6) blade studs with the nose cone mounting brackets between the blades and pointing toward the alternator (see Figure 25 below). Secure the plate with M12-1.75 self-locking nuts, tightened to 20 N-m (15 lb-ft) of torque.
Nose cone mounting brackets: locate between blades and orient pointing toward the alternator.
Install the nose cone and secure with three (3) M6-1.0 x 16mm bolts, washers and lock washers (see Figure 26 below).
Rotate the blades slightly about the alternators axis to verify that the rotor can turn freely. Double check all fasteners and electrical connections are secure. Ensure that the turbine will not encounter any physical interference prior to beginning the tower-raising. You may install the wind turbine before the electronic equipment. If this option is chosen the three (3) turbine power wires at the base of the tower should be connected together, thus shorting the alternator preventing the system from running unloaded. A shorting switch at a tower base junction box is the best way to a ccomplish this task. Use a switch that is rated for 30 Amps or more. Contact the ARE factory if you need assistance with a shorting switch.
Warning: The turbine must never be installed with out a load or being shorted.
Category
Turbine
Task
Listen for unusual alternator or blade noise, and look for excessive vibration. Verify that tower guy cables, saddle clamps, and shackles are tight. Check all cables for excess fraying or rust Inspect the blades for leading edge wear. Check the upper guy joints for wear and/or rust Verify (with torque wrench) that all cable clamps continue to firmly grip guy cables
Comments
If detected, such warning signs should prompt a detailed inspection. These tasks apply only to ARE guyed tilt-up towers. For other towers, please reference manufacturer's documentation for maintenance schedules This should be done by close visual inspection: by lowering the tower (if tilt-up) or by climbing it (if freestanding). These tasks apply only to ARE guyed tilt-up towers. For other towers, please reference manufacturer's documentation for maintenance schedules
Every 6 months
Tower Tower
Tower
Tower
Item
Description
Qty
Item
Description
Qty
Item
Description
Qty
EXCLUSIONS
This warranty does not cover the following: Towers, equipment, materials, or supplies not manufactured or supplied by ARE (Towers manufactured or sold by ARE are covered by their own separate warranty.) ARE equipment which has been improperly installed or modified without approval from ARE Damage or loss from winds in excess of 45 m/s (100 mph) Lightning damage or other acts of God. (The ARE lightning protection package provides its own individual warranty related to lightning damage to wind generators and related controls) Incidental or consequential damages Damage to product incurred during shipping
PRODUCT CHANGES
ARE reserves the right to make design changes, improvements, or additions to its products without obligation to install such changes or improvements in existing products.