are110-48v owners manual mechanical ver5.0

© 2008 Abundant Renewable Energy, LLC

ARE110-48V (2.5kW) Wind Generator Battery Charging Model

Owners Manual Mechanical

Installation, Operation, & Maintenance Version 5.0

Manufactured in the USA by:

ABUNDANT RENEWABLE ENERGY 22700 NE Mountain Top Road

Newberg, OR 97132

www.AbundantRE.com

(503) 538-8298 (Telephone) (503) 538-8782 (Fax)


Table of Contents

1. Safety Warning 3 2. Introduction 4 3. Wind Generator Specifications 5 4. Equipment Supplied 6 5. Required Installation Tools 7 6. Choosing Sites for Wind Generators 7 7. Towers & Rigging 8 8. Wire Size Requirements 8 9. Turbine Assembly Instructions 9

A. Position the Tower 9 B. Check the Yaw Head Axle 9 C. Electrical Connection: Yaw Head to Tower 10 D. Mount Yaw Head to Tower 10 E. Mount Alternator to Yaw Head 11 F. Wire the Yaw Head Terminal Strip 11 G. Test the Electrical Connections 13 H. Install Tail Boom to Yaw Head 14 I. Install Blades & Nose Cone 16

10. Inspection & Maintenance 19 11. Component List & Drawing 20 Warranty 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:

ABUNDANT RENEWABLE ENERGY 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 ARE products assume full responsibility and risk.


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, purpose-built 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).

Figure 1. ARE110 wind generator


3. Wind Generator Specifications

Configuration Three-blade upwind Over-Speed Control, Mechanical Side furling with gravity return Over-Speed Control, Electrical Pulse-width modulated resistor loading Rated Power 2.5 kW (2500 watts) Rotor Diameter 3.6 m (11.8 ft) Swept Area of Blades 10.2 m2 (110 sq. ft.) Cut-in Wind Speed 2.5 m/s (6 mph) Start-up Wind Speed 3 m/s (7 mph) Rated Wind Speed 12 m/s (25 mph) Blade Quantity, Construction Three (3), molded fiberglass Blade Rotational Speed 0–340 rpm Alternator Type/Construction Neodymium permanent magnet Alternator Electrical Output 3-phase, variable voltage (0 - 100 VAC) Tower-Top Weight 143 kg (315 lbs.) Maximum Lateral Thrust 160 Kg (350 lbs.)

Table 1. ARE110 specifications

ARE110 Wind Generator

Power Curve

0

1000

2000

3000

0 5 10 15 20 25 30 35 40

Wind Speed (mph)

Pow

er (

wat

ts)

ARE110 gen power curve based on measured data; power data above 25 mph based on a

small number of data points

Figure 2. ARE110 power curve


A R E 1 1 0 W in d G e n e ra to rsM o n th ly E n e rg y E s tim a te s

0

2 0 0

4 0 0

6 0 0

8 0 0

8 1 0 1 2 1 4A v e ra g e L o c a l W in d S p e e d (m p h )

Ener

gy P

rodu

ctio

n (

kWh)

Figure 3. ARE110 monthly energy estimates graph

4. Equipment Supplied

Qty. Item Description 1 Alternator 3 Bolts (alternator-mount) with star washer – M16-2.0 x 30mm 1 Yaw head with slip rings 4 Bolts (tower-mount) with self-locking nut - M16-2.0 x 70mm 3 Blades 6 Studs, hex (blade-mount) with self-locking nut - M12-1.75 1 Plate (blade-clamping) 1 Nose cone 3 Bolts (nose-cone mount) with washers & lock washers - M6-1.0 x 16mm 1 Tail boom, inner (gusset) with tail hinge pin, tail pin latch, & E-clip retainer 1 Tail boom, outer (sq. tube 1.5" x 92") 1 Bolt (tail boom) - M16-2.0 x 70mm 1 Tail fin (with ARE logo) 3 Bolts (tail fin mount) with (2) washers and self-locking nuts – M14-2.0 x 60mm 1 Tail weight (approx. 3 lbs.)

Table 2. Equipment Supplied with ARE110 wind generators

To Be Purchased from Other Suppliers: • Appropriately sized wiring, as described in Section 8 (“Wire Size

Requirements”) • Cable support grips for wires (see Section 9, Part C)


5. Required Installation Tools

Ratchet for sockets 8” extension for ratchet Sockets: 10, 13, 17, 19, 22, & 24mm Wrench, Allen – 4 mm Wrench, adjustable – 8” Screwdrivers – Phillips (#2) & flat-head (3/16” max width blade 6” over all length) Wire Strippers Torque wrench – range: 10–170 N-m (7–120 lb-ft) Locking pliers (Vise-Grips) Thread-locking compound (e.g. Loctite® 242® Threadlocker, Med-Strength/Removable) Hole saw or stepped drill bit for ½” conduit (suggested size)

6. Choosing Sites for Wind Generators

To attain optimal performance from your wind generator, an appropriate site must be chosen for the installation. Buildings, trees, rocky outcrops and other obstructions can disrupt the smooth flow of wind and increase “wind shear”. This creates significantly lower wind speeds and more turbulence close to the ground. Turbulence is swirling air that causes the turbine to yaw continually; this greatly increases wear and tear on mechanical components, and reduces the useful life of this equipment.

Figure 4. Turbulence illustrations (courtesy of P. Gipe)

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 α v3 and v α 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 turbine’s blades.

H 2 H

20 H2 H

Turbulent airflow

Smooth, laminar airflow

Sharp edges create turbulence Turbulent air flow created by obstructions


7. Towers & Rigging

An appropriate wind turbine tower should be chosen and prepared very carefully; this can be the most difficult and most crucial aspect of a wind energy equipment installation. Guyed, tilt-up pipe tower kits manufactured by ARE are specifically designed for the ARE110 and are recommended. ARE assumes no responsible for assuring the suitability of towers provided by other suppliers. ARE tilt-up towers can be easily lowered for servicing and do not require climbing. Consult with ARE for assistance with alternative tower selection and qualification.

8. Wire Size Requirements

The following table lists the required wire gauge, based on the one-way wire run distance from the tower top to the building entrance (where it connects to system electronics). These requirements result in a voltage loss to less than 2% at rated power. Ensure that the wire insulation is rated for outdoor use and for at least 300 volts. Please contact the factory if you have wire runs longer than those listed in the table below. It is important to use the proper wire size for the number of feet of wire run. The turbine controls rely on a specific wire size for a given distance. Do not use a larger or smaller wire than specified in the table. One-Way Distance between turbine and Voltage Clamp

8 AWG 6 AWG 4 AWG 2 AWG 1 AWG 1/0 AWG 2/0 AWG

140-220 feet

220-350 feet

350-550 feet

550-870 feet

870-1100 feet

1100-1390 feet

1390-1770 feet

Table 3. Wire size recommendations NOTE: The Voltage Clamp’s 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.


9. Turbine Assembly Instructions

If using an ARE tilt-up tower kit, the tower should first be assembled, raised, and all rigging adjusted so that the tower stands vertically and can be raised and lowered properly. See the tower installation manual for details. Assemble the wind turbine onto the lowered tilt-up tower. Although one person can assemble the machine with mechanical aids, it is advisable to have an assistant, as many parts are heavy and cumbersome to maneuver into position. Keep the alternator covered as long as possible to prevent dirt or metal objects from entering the alternator and becoming lodged between the magnets and rotor. 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.

B. Check the Yaw Head Axle

Ensure that the yaw head axle rotates freely within the outer housing (see Figure 9 below).

Figure 9. Yaw head axle

NOTE: DO NOT TIGHTEN THIS NUT. It is intended to be loose in order to allow yaw head rotation.

Yaw head axle


C. Electrical Connection: Yaw Head to Tower

Splice the three power wires and the ground wire with suitable splices. Ensure they are insulated for 300 volts. Use wire support devices such as cable support grips (see Figure 10 below) to bear the wire weight and remove tension from wire splices. On ARE tilt-up towers, the bolt which holds the tower top flange may be used to carry wire support devices (see Figure 11). Four (4) wire connections are made at the yaw head – three (3) for the power from the generator leads (white) and one (1) for the ground (green).

Figure 10. Cable support grip (a.k.a. “Kellem’s grip”)

D. Mount Yaw Head to Tower

Attach the yaw head to the tower top flange using M16-2.0 x 70mm bolts and self-locking nuts (provided). Fasteners should be tightened to 163 N-m (120 lb-ft) torque. Ensure that the wires are not pinched between the top flange and the yaw head mounting flange (see Figure 11 below).

Figure 11. Mating the tower top to the yaw head flange

NOTE: Each wire should be supported individually.

Install M14 bolts so that bolt heads face the generator (i.e. bolt heads face upward on the erect tower).

Ensure wires are not pinched during assembly.

This bolt may be used to bear the weight of cable support grips.


E. Mount Alternator to Yaw Head

Line up the alternator mount holes with the yaw mount. CAUTION: The alternator weighs approximately 84 kg (185 lbs.) and is very awkward to hold, so plan this step carefully. The tail gate of a pick up truck works well; alternatively, a wheelbarrow or large storage drum could be used. The tower may need to be raise or lowered slightly to facilitate aligning the yaw head and alternator holes.

Line up the bolt holes and pass the alternator lead wires through the hole provided, taking care not to pinch the lead wires between mating surfaces. Apply thread-locking compound and tighten the three (3) M16-2.0 x 30mm bolts (with star washers) to a 163 N-m (120 lb-ft) torque (see Figure 12 below).

Figure 12. Bolting the yaw head to the alternator

F. Wire the Yaw Head Terminal Strip Connect the alternator lead wires to the terminal strip mounted on the yaw head access door. Match the label of each wire to labels on the terminal strip (see Figure 13 below). Alternator power output leads are labeled ‘A’, ‘B’, and ‘C’; lead ‘Z’ is used with ARE’s optional Lightning Protection System and must also be attached to the terminal strip. The ground stud is used for the Lightning Protection System. Do not attach any of the generator wires to the ground stud.

Figure 13. Yaw head terminal block wire connections

Attach alternator lead wires to the

terminal block on the yaw head

access door and secure wire with

screw and clamping plate.

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.


Figure 14. Yaw head ground stud location

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.

Figure 15. Close-up view of yaw head slip rings

Slip Ring

Slip Ring Brush

Adjustment Nut

Spacer

Ground Stud – Do NOT attach generator wires here

Bottom slip ring to be used only for ground connection


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).

Figure 16. Access door lock

G. Test the Electrical Connections Manually rotate the turbine rotor at a steady rate while another person (at the tower base junction box) uses a voltmeter to verify consistent AC voltage readings across the three wires lead wires. This verification will require three voltage readings: A-B, B-C, A-C). During this step, the lead wires should not be connected to electronic equipment (i.e. Voltage ClampTM). If the measured voltages between lead wires are approximately equivalent, the turbine’s lead wires can be connected to the lines that run to the Voltage ClampTM and subsequent electronic equipment.

If the measured voltages are not approximately equivalent, check all connections in the yaw head and tower to ensure there are no short-circuits or open connections. Verify that the slip ring brushes are making positive, firm contact with their respective slip rings. Also check to ensure that the wires that are attached to the brushes are clamped to the correct terminals.

Use this bolt to hold the door in the closed position. Tighten bolt fully to ensure that it does not back out.

Yaw head access door.


H. Install Tail onto Yaw Head

Figure 17. Tail pin latch plate 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).

Figure 18. Tail pin installation onto yaw head

Pin latch plate on inner tail boom section

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.

Figure 20. Mounting the tail fin Figure 21. Inserting the tail weight

E-clip: Install in groove.

Install these two bolts first

Install tail weight into tail boom

The bolt in this hole acts as a “stop” for the tail weight [Bolt & tail fin omitted for clarity]

Latch plate: Install in notch

Use these holes to mount tail fin to tail boom [All round holes – no slots]


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.

Figure 22. Assembling the outer & inner tail booms I. Install Blades & Nose Cone

Apply thread-locking compound and screw the six (6) blade stud bolts into the threaded holes on the front of the alternator drum. IMPORTANT: The shorter threaded section of the stud must screw into the alternator drum (see Figure 23 below). Tighten the blade studs to 80 N-m (60 lb-ft) torque.

Figure 23. Mounting blades to alternator

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).

Outer tail boom

Inner tail boom

Blade stud for mounting blades

M16-2.0 x 60mm bolt with self-locking nut


Figure 24. Blade edges & rotation direction 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.

Figure 25. Close-up view of nose cone mounting bracket

Install the nose cone and secure with three (3) M6-1.0 x 16mm bolts, washers and lock washers (see Figure 26 below).

Leading edge of blade

Nose cone mounting brackets: locate between blades and orient pointing toward the alternator.

Trailing edge of blade


Figure 26. Nose cone installation

Rotate the blades slightly about the alternator’s 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.

M6-1.0 x 16mm bolts, washers, and lock washers


10. Inspection & Maintenance

Frequency Category Task Comments

Continually Turbine

Listen for unusual alternator or blade noise, and look for excessive vibration.

If detected, such warning signs should prompt a detailed inspection.

Tower Verify that tower guy cables, saddle clamps, and shackles are tight. Every 6

months Tower Check all cables for

excess fraying or rust

These tasks apply only to ARE guyed tilt-up towers. For other towers, please reference manufacturer's documentation for maintenance schedules

Turbine Inspect the blades for leading edge wear.

This should be done by close visual inspection: by lowering the tower (if tilt-up) or by climbing it (if free-standing).

Tower Check the upper guy joints for wear and/or rust

Every 12 months

Tower

Verify (with torque wrench) that all cable clamps continue to firmly grip guy cables

These tasks apply only to ARE guyed tilt-up towers. For other towers, please reference manufacturer's documentation for maintenance schedules

Table 5. Inspection & Maintenance Schedule


11. Component List & Drawing NOTE: Exploded drawing and component list to be added in an addendum.

Item Description Qty Item Description Qty Item Description Qty

Table 7. Component list


Five-Year Warranty for ABUNDANT RENEWABLE ENERGY

Wind Generators WARRANTY AGREEMENT

In order to validate this Warranty Agreement, the Customer must detach, complete, and return the ARE Mail-in Warranty Form (page 2 of this Agreement) within one (1) month of installation or seven (7) months of receipt of warranted ARE products, whichever occurs first.

Abundant Renewable Energy (ARE) warrants that the wind turbines it manufactures will be in good working order, in accordance with ARE standard specifications, upon delivery to its customers and for a period of 66 months from the date of delivery or 60 months from the date of installation, whichever occurs first. During the warranty period ARE will, at its sole discretion, repair, replace, or refund the purchase price of defective components and assemblies. Repair parts or replacement product may be new, remanufactured, or refurbished, at the sole discretion of ARE. ARE is not responsible for any costs associated with the installation, removal, reinstallation, or transportation to ARE (or to an ARE dealer) of defective ARE products. Return freight to the customer will be provided by ARE. Product or components returned to ARE, which are not defective or which sustained damage not covered under this warranty, will be tested and/or repaired at ARE’s standard labor rates. Only warranty claims submitted to ARE in writing within 15 days of problem origin will be honored. GOVERNING LAW AND DISPUTE RESOLUTION

This Agreement will be interpreted and enforced according to Oregon state laws or U.S. federal laws, whichever has jurisdiction. Oregon law, without reference to conflicts of laws principles, shall control the interpretation and enforcement of this Agreement. In the event that any dispute, controversy, or claim between the Parties arising out of or relating to this Agreement cannot be settled by negotiation or mediation, the parties agree to have the dispute, controversy, or claim settled by Arbitration Service of Portland, Inc. Any arbitration is to be conducted in Portland, Oregon. The Parties agree that any determination by the arbitrator(s) shall be final and binding and that judgment upon the award may be entered in any court having competent jurisdiction. The arbitrators shall have no authority to award punitive damages. 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. Turbine Warranty, Rev. 02/06/06


ARE Wind Generator Warranty Agreement Form

Customer / End User Name ________________________________________________

Customer Address _______________________________________________________

____________________________________________________________________

____________________________________________________________________ Customer Phone ________________________ Email __________________________

ARE Dealer / Installer Name & State (if applicable) ____________________________

____________________________________________________________________

Product Part Number (e.g. ARE110) _______________________________________

Alternator Serial # _______________________________________________________ Mainframe / Yaw Head Serial # _____________________________________________ Controller / Voltage ClampTM Serial # _______________________________________ Inverter Serial # (grid-tie systems only) _____________________________________ Resistor Load Serial # ___________________________________________________ Date Product Received _________________ Installation Date __________________

Dealer Signature (if applicable) ____________________________________________ End User Signature ______________________________________________________

Send Completed Form to:

ABUNDANT RENEWABLE ENERGY 22700 NE Mountain Top Road

Newberg, OR 97132 Phone: (503) 538-8298

Fax: (503) 538-8782 Email: [email protected]

Website: www.AbundantRE.com

Turbine Warranty, Rev. 02/06/06

are110-48v owners manual mechanical ver5.0

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