Always leading the pack

WIND ENERGY MODULAR

MOTORIZED KIT

DESCRIPTION

TRAINER

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Sommario

Components identification .................................................................................................................. 3

Wind Turbine assembly ....................................................................................................................... 4

Base Assembly ...................................................................................................................................... 5

Motor driver kit assembly .................................................................................................................... 6

Operating the aero generator using the motor driver kit ................................................................... 8

Aero generator Operation ................................................................................................................... 9

7-1 Operational Summary ................................................................................................................ 9

7-2 Operating Modes ....................................................................................................................... 9

Charging ....................................................................................................................................... 9

Regulation .................................................................................................................................. 10

Stall Mode .................................................................................................................................. 10

Braking Mode ............................................................................................................................. 10

No Load Operation /Open Circuit /Free Spinning...................................................................... 10

Aero generator Trouble Shooting ...................................................................................................... 11

TEST 1 ............................................................................................................................................. 11

TEST 2 ............................................................................................................................................. 11

TEST 3 ............................................................................................................................................. 11

Aero generator Exploded Views & Parts List ..................................................................................... 12

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Components identification Aero generator is made up by several parts (Figure 1); the main body contains both the electric generator and the control unit. Externally the wind turbine is installed on the alternator shaft; also the wind turbine is composed by different components and can be assembled as shown in Figure 3.

Figure 1: Aero generator components: detailed

Figure 2: Aero generator components

CAUTION: THE EDGES OF THE ROTOR BLADES ARE SHARP. PLEASE HANDLE WITH CARE.

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Wind Turbine assembly In case of installation of the aero generator with the wind turbine (for external use), be sure to avoid human interaction with the equipment while working.

Blade can be installed on blade hub as shown in the Figure 3. The ensemble can be installed on the alternator shaft using the related Nut (see Figure 1 for all type of things).

Figure 3: turbine assembly details

1- Blade Hub 2- Blade 3- ¼ -20 Socket Head Cap Screw (2) 4- ¼-Nylock Nut (2)

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Base Assembly The tripod pole must be fixed to a solid base to allow the system working correctly. To allow a portable installation, a 5 feet base is provided; the pole can be mounted on it having a stable and portable installation. Figure 4 and Figure 5 show in detail the connection.

Figure 4: 5 feet base

Figure 5: detail of connection between pole and base

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Motor driver kit assembly Because of the didactic purpose and the indoor usage of the trainer, the wind turbine can be substituted with a motor kit, allowing the aero generator working without wind and indoor in safety condition.

The motor kit is composed by a 24VDC motor and related power supply (DL 2555ALW). Through mechanical kit it is possible install the motor to drive directly the rotor of the aero generator.

Following is shown the sequence to easy install the motor kit on the aero generator:

Figure 6: main body pole mounting

Figure 7: shaft and coupling protection mounting

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Figure 8: motor installation

Figure 9: assembled motor kit

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Operating the aero generator using the motor driver kit Once the kit is ready, the motor can be electrically connected to the power supply (DL 2555ALW), following the color convention.

To operate the system, follow the instruction foreseen for the Operating Guide.

In any case different behavior of the system can be depicted:

- leaving disconnected the aero generator from the battery, it will work in “No Load Operation /Open Circuit /Free Spinning” mode (see later in this document). Increasing the speed of the motor acting on the power supply, will take the system in the cycle of rapid blade speed followed by rapid braking. - short circuit the aero generator cables, cause the rotor shaft to be blocked (Braking Mode); in this condition, the motor is not able to turn the shaft; the absorbed current will grow up to the maximum value and an overheat of the motor can occur. Do not insist with this kind of trial to avoid damage. - aero generator cables connected to the battery: in this condition, the system will work according to the battery charge status and the motor power applied through the potentiometer of the DL 2555ALW. The working mode will be one of “Charging” “Regulation” or “Stall Mode” accordingly to battery status, load applied and motor power.

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Aero generator Operation

7-1 Operational Summary Wind turbines operate by capturing the kinetic energy of moving air: the wind. They convert it to rotational motion to turn an alternator that produces electrical power. The electrical power must be regulated to a voltage to charge the system batteries, and there must be a system to prevent overcharging the batteries and resume charging as the battery voltage drops. A means to protect the wind turbine from extreme wind damage must also be provided.

The Aero generator accomplishes all these goals by incorporating a three phase brushless permanent magnet alternator and microprocessor controlled electronics to optimize its power production capability. The microprocessor continuously adjusts the loading of the alternator to keep the blades operating at their optimal angle of attack. The result:

• high power production;

• high blade efficiency; and

• lower blade noise.

7-2 Operating Modes

Charging With Aero generator connected to batteries with the voltage below the voltage regulation set point, the blades will spin in response to the wind. With an available wind, the blades will continue to spin until the battery voltage matches the regulation set point.

Note that Aero generator requires a minimum battery bank voltage (approximately 10.5 volts on a 12-volt system) or the controller will behave as if an open circuit condition exists. Refer to Open Circuit/Free Spinning section.

When charging the batteries, the Aero generator LED will be continuously illuminated.

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Regulation As Aero generator produces power and the battery voltage rises to the regulation set point voltage, Aero generator will go into “regulation.” At that point it stops producing power and the blade rpm will lower dramatically (almost stopping). Aero generator will remain in regulation until the battery voltage drops slightly below the regulation set point – this is often referred to as the cut-in voltage. When the cut-in voltage is reached, the blades will resume spinning in response to the available wind. Regulation mode is indicated by the Aero generator LED blinking at a rate of approximately twice a second.

Stall Mode Stall mode is marked by a dramatic reduction in turbine speed to approximately 500 – 700 rpm. Aero generator will enter stall mode when a wind speed of 35 mph (15.6 m/s) is sensed, and it will remain in stall mode until the speed drops to 32 mph (14 m/s). If a wind speed of 50 mph (22 m/s) is detected, the turbine will completely shut down for 5 minutes.

When in stall mode the Aero generator LED will blink quickly – approximately 10 times per second.

Braking Mode Aero generator may be placed in braking mode by directly shorting the turbine positive and negative wires together or by the use of a stop switch. The stop switch first disconnects the turbine from the battery and then shorts the positive and negative wires. In very strong winds the blades may rotate slowly even with the switch activated.

No Load Operation /Open Circuit /Free Spinning Aero generator will spin freely if disconnected from an electrical load. This results in a cycle of rapid blade speed followed by rapid braking – this mode of operation may accelerate wear of the turbine and is also non-productive. To turn Aero generator off for short periods of time manufacturer recommends using a properly installed switch. If your Aero generator will be shut down for an extended period of time manufacturer recommends lowering the turbine completely or securing the blades to prevent rotation.

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Aero generator Trouble Shooting Three quick bench tests can verify if your Aero generator is working correctly. Test 1 does not require any equipment. For tests 2 and 3 you will need a battery bank and a power drill.

TEST 1 1) Remove the blade/hub assembly from the turbine and place in a safe location. Replace the rotor hub nut on the rotor shaft.

2) Attempt to quickly spin the rotor shaft with your fingers while connecting and disconnecting the red and black wires (turbine must not be connected to batteries). A second person may be helpful to perform this test.

3) With the red and black wires connected to each other, the shaft should be more difficult to turn. Replace the rotor hub nut on the rotor shaft. With the yaw wires disconnected it should spin freely. Spinning the shaft quickly makes difference easier to detect. If these conditions do not exist, you should contact your turbine dealer.

TEST 2 1) Remove blade/hub assembly from turbine and place in a safe location.

2) Connect the turbine power wires to the appropriate terminals on your battery: RED= Positive, BLACK = Negative.

3) Each time the Aero generator is connected to a battery, the LED will blink two times to indicate that the controller is running properly. You may need to wait 10 seconds between iterations of this test in order to let the microprocessor reset. If the LED does not blink when the Aero generator is connected to a battery, you should contact your turbine dealer.

TEST 3 1) With Aero generator connected to your battery bank, use an electric drill to spin the rotor shaft (ore use the motor driver kit) while observing the LED. A short length cut from the 5/16 inch hex key wrench can serve as a drive if necessary.

2) Below 500 RPM, the rotor should spin freely and the LED should remain off.

3) At 500 RPM and above, the Aero generator should be charging the battery. There should be resistance on the rotor shaft and the LED should turn on. If the shaft is cogging (difficult to rotate), contact your turbine dealer or Southwest Windpower. Be sure your battery voltage is not high enough to activate the regulation mode during this test.

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Aero generator Exploded Views & Parts List

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