AWP3.6 Wind Generator
Owners Manual
Version 2.0
Distributed in North America by:
Abundant Renewable Energy
22700 NE Mountain Top Rd.
Newberg, OR 97132
www.AbundantRE.com
(503)538-8298 Fax (503)538-8782
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AWP_Owner's Manual-May 2004
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Contents
1. Safety Warning
2. Introduction
3. Specifications
4. Equipment Supplied
5. Installation Tools Required
6. Siting the Wind Generator
7. Assembly Instructions
8. Towers and Rigging
9. Cables
10. Controllers
11 Inspection and Maintenance
12. Troubleshooting
13. Drawing and Spare Parts List
15. Warranty
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Safety Warning !
1. Electrical Shock hazard
The Wind generator can produce higher than nominal voltages
when running open circuit. This is especially dangerous in the
higher voltage machines. Keep the output wires shorted initially
and carefully follow the installation instructions.
2. The AWP3.6 is a heavily built machine and can cause injury if not
assembled and erected carefully, according to the instructions and
using the correct equipment.
3. Do not approach the machine while the blades are spinning-they
can cause serious injury!
Notice
African Windpower has made every effort to ensure that the
information presented in this manual is accurate but assumes no
responsibility for any errors or omissions. Users of this information
and AWP products assume full responsibility and risk.
2. Introduction
This manual contains all necessary information for assembling, operating and maintaining
the AWP36 Wind generator, please read it carefully and retain for future reference.
The manual covers all machines from 24v to 220v.
The AWP36 can be used for charging batteries, powering electric pumps and space heaters
and also for direct grid connection.
The AWP36 is built ruggedly, in the style of the “Heavy Metal School”. The 30 pole
machine operates at a relatively low RPM, which together with only 3 moving parts, ensures
very long life with little maintenance. Its large swept area ensures energy capture from low
wind speeds other machines ignore, but is also good in high winds. The simple gravity yaw
system protects the machine by reliably swinging the rotor out of winds faster than 12 m/sec
(27 mph).
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3. Specifications
Configuration
Over speed control
Rated power
Rotor diameter
Cut in wind speed
Start up wind speed
Rated wind speed
Blade construction
Number of blades
Alternator
Electrical output
Tower top weight
Maximum lateral thrust
Tower top mounting
3 blade upwind
Gravity yaw system
24v
850w
48v
1000w
110v (Grid Tie) 1500w
3.6m (11.8 ft)
2.5m/sec (6mph)
3m/sec (7mph)
12m/sec (25mph)
Fibre Glass
3
30 pole permanent magnet
3 phase, 0-380v, 0-70Hz
120 Kg (250lbs)
160 Kg (350 lbs)
3” Table D Flange (BS10)
AWP3.6 Power Curve
Power (Watts)
1200
1000
800
48 volt
600
24 volt
400
200
0
5
8
11 14 17 20 23 26 29 32 35
24v Daily Energy
Production
MPH
KWH
8
5.0
9
5.5
10
6.2
11
7.5
12
7.9
Wind Speed (mph)
4. Equipment Supplied
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
1 x Alternator
1 x Yaw head
3 x 16mm alternator mounting bolts with lock washers
4 x 12 mm bolts with nylock nuts and washers
2 x Tail fin pieces
2 x Tail boom pieces
8 x Tail fin mounting bolts
4 x Tail boom bolts
1 x Tail hinge pin & cotter pin
3 x Blades
6 x Blade mounting studs, washers & nylock nuts
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l.
m.
n.
o.
p.
1 x Blade clamping disk
3 x Blade clamping plates
1 x Nose cone & 3 x 8mm mounting bolts with washers
1 x cable clamping unit with 2 clamping studs, washers & nuts
1 x yaw mount top cap & 2 x 8mm bolts
And if ordered from Abundant Renewable Energy:
‰ Controller
‰ Dump Load
‰ Tower kit
From other suppliers :
Appropriately sized 3 phase wiring to power electronics
Kellems grip for wires (slip ring unit only)
Batteries, clamps and battery cable
Main battery fuse
Inverter and AC Wiring
5. Installation Tools Required
a.
b.
c.
d.
e.
f.
10, 13, 17, and 24mm combination wrench
8” adjustable wrench
Side cutters
Crimping tool
A socket set speeds up the assembly process
Grease gun
6. Siting the Wind Generator
To ensure good performance from the Wind Generator it is important that care is taken in
the siting of the machine.
Buildings, trees and rocky outcrops etc disrupt the smooth flow of wind creating a
Wind Shear with the wind velocity nearer the ground being slower than that higher up.
Turbulence is also created by these obstructions. Turbulence is detrimental as the
swirling air causes the turbine to yaw continually thus stressing the mechanical parts and
greatly increasing wear and tear.
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Smooth, laminar airflow
2H
H
2H
Turbulent airflow
20 H
Turbulent airflow created by obstructions (Ad. P.Gipe, 93)
Therefore, as a general rule the turbine should be mounted twice as high as any such
obstructions. The power obtained from the wind is proportional the cube of the wind
speed, and the wind speed increases with height from the ground. 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 higher tower will harvest the same power as 2 machines!
Preference should be given to the prevailing wind direction but it should be noted that tall
features behind the turbine can also slow down the wind flow through the turbine.
7. Assembly Instructions
•
•
•
•
When using an ARE tilt up tower kit, first assemble your tower, raise it and adjust all the
rigging so that the tower stands vertical and can be raised and lowered correctly. See
your tower installation manual for details.
Assemble the machine while on the ground, onto the lowered tilt-up tower, which can
then be raised.
Although one person can assemble the machine with mechanical aids, it is advisable to
have an assistant since many parts are heavy and cumbersome to maneuver into position.
At least two people are needed to raise the machine.
Keep the alternator wrapped in the plastic sheeting as long as possible to prevent dirt or
metal objects from entering the alternator and becoming lodged between the magnets and
the rotor.
Assembly Procedure:
a. The top of the lowered tower should be supported about 1 meter off the ground. (1)
b. Attach the yaw head to the top flange using the 12mm bolts, washers and nylock nuts
provided. (1)
c. Pull the cables through the tower pipe using a length of fish tape or other suitable device
(2) NOTE: (For slip ring equipped units, hang a Kellems grip from the bolt through the
top flange and tower. Hang the wire from the Kellems grip and connect to the yaw head
wires.)
d. Screw the 2 cable clamp stud bolts into the holes in the top surface of the yaw mount
(2). The shorter threaded section should be inserted into the top of the yaw mount.
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e. Fit the lower cable insulator over the stud bolts.
f. For the non-slip ring yaw head, feed the cables over the insulator and down the square
tube section into the terminal box with enough slack to reach the terminal bolts. (3).
g. Fit the top cable clamp section and tighten down with nuts and washers. Pump some
grease into the grease nipple in the top of the yaw mount, if provided. Fit top cap, and
secure by 6mm screws into lower cable clamp casting. (3).
1.
2.
3.
h. Line up the alternator to the yaw mount. The alternator weighs about 75 kgs and is very
awkward to hold, so plan this carefully. The tail gate of a pick up truck works well, or
you could use a wheel barrow or drum etc. (4)
i. Line up the bolt holes and pass the cables through the correct hole provided. Take care
not to crush the cable while doing this and tighten the 16mm bolts with the lock washers
(5). Locktite could be used on the bolt threads for extra security.
j. Connect the wires from the alternator to the drop cable wires by means of crimped lugs
and the terminal unit inside the yaw mount. Close the door and screw down the locking
screw.
k. Screw the blade stud bolts into the 6 threaded holes on the front of the alternator drum
(6). The shorter threaded section of the stud must screw into the alternator drum.
4.
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6.
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k. Fit the front tail section to the 2 hinge lugs on the rear of the yaw mount and insert the
hinge pin. Insert the cotter pin through the hole in the bottom of the hinge pin. (7)
l. Bolt rear tail boom section to front section. Bolt the two tail fin sections to the rear tail
boom. (8)
m. Fit the three blades onto the blade studs with flat side to the front. (9)
7.
8.
n. Fit the ply wood blade clamping disc over the studs with the nose cone mounting bolt
holes between the blades (10). Fit the clamping bars also between the blades and secure
with 12mm washers and nylock nuts. (10) Before final tightening check for even spacing
of the blades by measuring tip to tip. Tighten the nuts to 15 foot pounds. (10)
o. Fit nose cone and bolt on with 8mm bolts and washers. (11)
9.
10.
11.
p. Check that the rotor can turn freely and that the blades pass the tower at equal distances.
If there is more than 15mm difference loosen the blade bolts and fit small shims of thin
plastic (such as pieces of plastic bottles)between the blade and generator. While turning
the turbine at a steady rate check that there is a similar AC voltage measured across the
3 drop wires at the foot of the mast (3 measurements).
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q. Short (connect together) the drop wires at the foot of the tower, this acts as a brake on
the turbine, preventing it from turning while the tower is being raised. Check that there
is resistance to turning the rotor.
r.
Raise the tower and secure base and/or guy cables.
s.
Ensure that the tower is vertical so that the turbine can yaw (turn into the wind)
properly.
t.
Put the stop switch in the controller to the STOP position and connect the controller,
dump load and battery according to the Controller Instruction Manual. Remove the
shorting bridge wire from the drop cable and switch the Brake switch to RUN. If you
have some wind the turbine will soon start turning. Section 12 will help if you have
problems with the operation of the turbine.
8. Towers and Rigging
Great care should be taken in the selection and preparation of the wind turbine tower, as this
is the most difficult and crucial aspect of the entire installation. The tilt up pipe tower kits
manufactured by ARE are specifically designed for the AWP and are recommended. If you
select a tower from another source or build your own, you are responsible for assuring the
tower is suitable. The ARE tilt up towers can easily be lowered for servicing and climbing is
not required. Consult with ARE for assistance with alternative tower selection and
qualification.
9. Cables
The recommended minimum sized wire is listed in the following table. The distance listed is
one way wire run (not round trip).
Machine
150 Feet
300 Feet
600 feet
24 Volt
6
4
0
48 Volt
8
6
4
110 Volt
12
10
10
10. Controllers
I. AWP Battery Charge Controllers and Batteries:
The charge controller supplied by AWP contains a three phase rectifier, a DC meter, a PWM
(Pulse Width Modulated) Dump Load Controller, and a Turbine Brake switch.
The terminals are marked from left to right – Wind Generator U, Wind Generator V, Wind
Generator W, Dump Load, Dump Load, Battery Negative, Battery Positive.
CAUTION: Before removing the short on the alternator wires make sure all the controller
connections are correct and secure. If you allow the turbine to run and feed power to the
controller with no battery or dump load connected, the resulting high voltages will destroy
the PWM circuit and possibly the rectifiers.
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A. General Information
Controller
Voltage
Dimensions (mm)
Weight (Kgs)
Dump Load Volts
Dimensions (mm)
Weight (Kg)
24v
48v
400x220x120
6
24V
470x160x160
2
220x220x120
3
48V
470x160x160
2
B. Electrical schematics
i. 24V Version
1
2
3
ii. 48V Version
4
D
6
D3
7
OPTIONAL
FUSE
A
D1
C
5
1
8
LOAD
FUSE
LOAD
D
3
4
5
D
DB1
DB2
OPTIONAL
FUSE
DB3
DBATTERY
BATTERY
CA1797
CN1-2
T
H1
H1
CHARGE
CONTROL
CARD
CHARGE
CONTROL
CARD
H2
D4
D
C
S
CN1-2
D2
LOAD
C
D-
B
LOAD
FUSE
DUMP
LOAD
R
C
T
8
D+
DUMP
LOAD
S
7
B+
D+
D5
6
A
B+
R
B
H2
B
B
D6
RUN
RUN
B-
STOP
B-
STOP
A
A
1
2
2
3
4
5
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A
A
1
2
3
4
5
6
7
8
10
C. Ratings for cables and fuses
Controller
Voltage
Battery
Fuse
Battery
Cable Size
Dump Load
Cable Size
24
48
50 Amp
30 Amp
2
4
8
10
D. Installation Instructions
The AWP Charge controller should be mounted on a vertical surface in a dry well ventilated
area near to the battery.
After crimping suitable lugs to the three cables from the wind generator, connect them to the
terminals marked U, V ,W. These connections can be made in any order.
The dump load should be connected to the two terminal marked Dump Load + and – and can
be connected in any order.
The battery must be connected with the CORRECT polarity to the terminals market Battery +
and Battery-.
Reversal of these connections will destroy the rectifier diodes in the controller. It is advisable
to connect the controller to the battery via a suitable a fuse near to the battery.
Do not use only one fuse as the inverter could be left connected directly to the wind turbine
in the event of the fuse blowing and could be damaged if the dump load circuit was not
connected or functioning correctly.
Brake switch
Voltage set point
potentiometer
(adjacent to LED)
Hysteresis adjustment
potentiometer
Battery Negative
Wind Generator
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Dump Load
Battery Positive
11
II. ARE Grid Connect System:
ARE has developed a system for Grid Connect System utilizing a WindyBoy inverter from
SMA and custom controller. The system consists of a WindyBoy inverter, an ARE voltage
clamp, and a double diversion load.
Always have the AWP wind generator leads shorted until the entire system is connected and
ready to operate.
CAUTION: Allowing the wind generator to rotate unloaded can result in very high voltages
which can cause injury or death and can destroy equipment.
Hook up procedure:
• The three leads from the AWP are attached to the terminal block in the ARE voltage
clamp box.
• The ground conductor is attached to the connector in the back of the box.
• The diversion load leads are attached to R1 and R2 on the board. The resistors are
identical so it does not matter which is wired to R1 or R2. Also the polarity does not
matter to the resistors, either wire can be connected to plus and minus. Just be sure
that one resistor is wired to +R1 and –R1 and the other is wired to +R2 and –R2.
• Wire the WindyBoy to –Out and +Out. Polarity is important! Wiring the WindyBoy
with reverse polarity will damage the equipment and result in a several hundred dollar
repair bill. See your WindyBoy manual for instructions on the WindyBoy hook up
and operation.
11. Inspection and Maintenance
a. Wind Turbine- The turbine has been designed to operate with a minimum of
maintenance.
• Every 6 months check excessive twisting of the electrical cables inside the tower
and if necessary disconnect at tower base and untwist. At a site that does not
experience excessive turbulence, the average clockwise turns will be cancelled by
anti clockwise turns. (Not necessary for slipring equipped units)
• Listen for unusual alternator or blade noise and look for excessive vibration,
which would all call for close inspection.
• Inspect the blades for leading edge wear and apply grease to all lubricating
points. This should be done either by lowering the tower or by climbing it.
• Grease tail and yaw bushings in zerks provided.
b. Tower
Every 6 months
• Check that the guys are tight. Check that the guy cable clamps are tight by
ensuring that there is still a slack loop between the upper most clamp and the next
lower one.
• Check that the shackles are tight.
• Check all cables for excess fraying or rust.
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Every 12 months
• Check the upper guy joints for wear and rust
• Touch up paint if needed.
12. Troubleshooting
Symptoms
Turbine Fails to Turn
in good wind
Turbine turns slowly in
good wind
Turbine growls and
amps are low
Low output /
Batteries flat
Turbine vibrates
excessively
Turbine fails to swing
into the wind
Turbine running at
high speed no output
Possible Causes
Shorted cables
Shorted diodes
Failed bearings
Foreign body in
generator
Partial short in cables
1 diode short
1 phase open circuit
Faulty diodes
Insufficient wind
High power usage
Blades out of balance
Yaw bearing worn
Tower top not vertical
Yaw bearing worn
Cables disconnected
Battery Fuse blown
Controller Ammeter
open circuit
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Solutions
Remove short
Replace faulty diode(s)
Replace bearings
Remove obstruction
Remove short
Replace diode
Repair open circuit
Replace diodes
Improve tower siting/height
Economise on power use
Check blade
geometry/balance
Replace yaw bearing
Adjust guy cables
Replace yaw bearing
Fix cables
Replace fuse
Replace meter
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2-Year Limited Warranty
for
African Windpower (AWP) Equipment
Wind generators, controllers, and associated equipment manufactured by African Windpower
and distributed by Abundant Renewable Energy (ARE) are warranted against defects in
design, material, and workmanship for normal use for which intended. The warranty period
extends two years from installation or three years from the date of purchase by the user,
whichever comes first. During the warranty period AWP will repair or replace, at its option,
defective components and assemblies. In North America warranty service for AWP is
provided by ARE. Customers should ship defective components and assemblies to ARE at
their own expense for repair or replacement. Return shipping will be provided. Please call
ARE and make arrangements before shipping.
This limited warranty does not cover the following:
•
•
•
•
•
Towers, equipment, materials, or supplies not manufactured by AWP. Towers
manufactured or sold by ARE are covered by their own separate warranty.
AWP equipment that has been improperly installed or modified without approval
from AWP or ARE.
Damage or loss from winds in excess of 45 m/s (100 mph)
Lightning damage or other acts of God.
Incidental or consequential damages.
AWP reserves the right to make design changes, improvements, or additions to its products
without obligation to install such changes or improvements in existing products.
This warranty may be extended to five years by the purchase of an extended warranty. The
extended warranty shall have the same terms and conditions, except it shall be in force for 5
years from the date of installation.
Contact Information
Abundant Renewable Energy
22700 NE Mountain Top Road
Newberg, OR 97132
Phone: (503) 538-8298
Fax: (503) 538-8782
www.AbundantRE.com
[email protected]
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