PHX20 WIND TURBINE

OPERATION MANUAL

4.01

2

2

CONTENTS

QED PHX20 OPERATION MANUAL 4.01

IMPORTANT SAFETY INSTRUCTIONS!

OPERATING IN A SAFE ENVIRONMENT

MAIN SCREEN OVERVIEW

OPERATIONS SCREEN

LOGIN SCREEN

HELP SCREEN

STARTING THE WIND TURBINE SYSTEM

MANUAL YAW OPERATION

AUTO UNWIND FUNCTION

TROUBLESHOOTING FAULTS FR1

TROUBLESHOOTING FAULTS FR2

RESET FAULTS

PREVENTIVE MAINTENANCE

PREVENTIVE MAINTENANCE MATRIX

CABLE TWIST HELP

LOWERING TOWER

WARRANTY

_______________________________

_______________________________

_______________________________

_______________________________

_______________________________

_______________________________

_______________________________

_______________________________

_______________________________

_______________________________

_______________________________

_______________________________

_______________________________

_______________________________

_______________________________

_______________________________

_______________________________

_______________________________

_______________________________

_______________________________

_______________________________

_______________________________

_______________________________

_______________________________

3

4

5

6

7

8

9

10

11

12

13

14

15

17

18

19

20

3

3

IMPORTANT SAFETY INSTRUCTIONS

This manual contains important information for the operation of your PHX20 Wind Turbine Control

System. It is extremely important that you read and familiarize yourself with all of its contents.

Failure to follow the procedures outlined in this manual voids the warranty, and may cause damage

to the product, personal injury or death.

Inside this manual items of special interest may be shown with the following symbols:

DANGER OR WARNING

IMPORTANT

When any procedures outlined in this manual are not clear in their instructions or intent, it is the

responsibility of the operator to contact QED or the distributor for clarification.

Any discrepancies discovered in this manual should immediately be reported to QED Wind Power.

Your wind turbine system was designed to provide many years of simple operation, high reliability

and safety. We hope you enjoy it!

4

4

OPERATING IN A SAFE ENVIRONMENT

The PHX20 Wind Turbine has been designed to recognize most unsafe operational situations and to

react safely, but no amount of code can replace the eyes, ears and intelligence of a human. As the

operator/owner of a wind turbine, it is the ultimate responsibility of the local site personnel to

recognize dangerous situations that may occur, and to act accordingly.

THINK SAFETY FIRST!

If it appears that the wind turbine is operating in an unsafe manner it is important to shut down the

system to maintain safety. Some unsafe environments could include the following:

Loud or unexpected noises coming from the wind turbine

Blades spinning at a speed that appear to be out of control

Imbalance of the wind turbine blades (top of tower rocking back and forth)

Ice buildup on the blades

Large storm or other environment changes

In case of dangerous situations with the wind turbine, always decide on personal safety first.

Shutting down the wind turbine should only be accomplished if it is safe to enter the control

room.

In the case of fire or wild electrical connections NEVER approach the wind turbine. In those cases

shutting off power from the property’s main power switch is the safest step. With that in mind, make

note of the location of the property’s main power disconnect switch and be sure that all persons

know how to safely operate (turn off) that switch.

To Stop the wind turbine follow any of these steps.

1. Press the Emergency Stop RED Button on the door of the controller.

2. Press any SHUTDOWN software button on the wind turbine touch screen.

3. Contact QED Technical Support and request a Remote Shutdown (requires an active internet

connection.)

5

5

USER INTERFACE OVERVIEW

MAIN SCREEN

1

2

3

4

5

1. LOGIN Screen for accessing advanced functions.

2. HELP Opens the HELP screen. Use this screen in non-emergency situations to

contact QED Technical Support.

3. SHUT DOWN This button will shut down the wind turbine.

4. OUTPUT Graph shows Output in Power (kW) and Wind Speed (Meters/Second)

5. STATUS Status information is displayed

6

6

USER INTERFACE OVERVIEW

The operations screen can be accessed with a special QED Operator Name and Password

OPERATIONS SCREEN

1. QED LOGO Touch to return to the Main screen

2. WIND POSITION Represents the wind direction relative to the blade front

3. SHUT DOWN Shuts down the wind turbine

4. PARAM Access Parameter Setpoints

5. START Begins the wind turbine Start sequence

6. MANUAL Access Manual Control Functions

7. VIEW FAULT Opens the System Fault Screen

8. VFD STATUS Opens the VFD Fault Screen

1

2

3 4 5 6 7 8

7

7

USER INTERFACE OVERVIEW

In order to access advanced and control features of the wind turbine system, an Operator Name and

Password must be entered in the LOGIN Screen. Contact QED Technical Support for more

information.

Password Access is active for only 30 minutes at a time before requiring re-Login.

LOGIN SCREEN

1. Operator Name Touch to enter the Operator Name

2. Password Touch to enter the Password

A Keypad will appear after touching the text blank areas. After entering the data press ENT on the

keypad. If ON and PWD are correct, a confirmation window will appear.

Operator Name

Password

1

2

8

8

USER INTERFACE OVERVIEW

In order to access the HELP Functions, the wind turbine must be connected to the internet and

actively communicating with the QED Server.

HELP SCREEN

1. SHUT DOWN This button will shut down the wind turbine.

2. CONTACT SUPPORT This button sends an urgent support request to the QED Tech Team.

3. MAIN SCREEN Use this button to return to the Main Screen

4. RESET Use this button if directed by QED Technical Support.

5. CANCEL Cancels the urgent status of a technical support request.

6. STATUS Status information is displayed

6

1

2

3

4

5

9

9

STARTING THE WIND TURBINE

The operations screen can be accessed with a special QED Operator Name and Password

Before starting the wind turbine, make sure that conditions are safe.

1. Press the START Button

2. A confirmation window will appear. Press “START” to continue or “CANCEL” to abort.

After START is pressed, the system will begin the startup sequence. Startup can take several

minutes depending on atmospheric conditions and other variables. Only press START once.

1

2

10

10

MANUAL YAW OPERATIONS

The Manual Yaw Screen can be accessed from the Main Screen and requires an Operator Name

and Password. Use this screen to manually unwind the tower cable.

MANUAL YAW SCREEN 1

NEVER use the yaw controls with the wind turbine tower lowered. Do not attempt manual yaw moves

in weather that would normally cause the wind turbine to shut down automatically.

1. Press the Press to Confirm Safety Button. The system will run self checks to insure all parameters are

safe for a manual control yaw move. The button will turn green after several seconds if conditions are

safe.

2. To perform a short move, press and hold either CW or CCW button for the duration of the yaw move.

There can be a short delay in the start and stop of this function. Plan accordingly.

3. For TIMED MODE Press the TIMED MODE BUTTON.

4. Enter the number in seconds of the desired yaw move (max 600) Touch for a keypad.

5. Select the desired direction of the yaw move by pressing on the required direction.

6. Press INITIATE YAW to begin the sequence.

7. Press STOP at any time to stop the move. There may be a short delay in response.

8. Press MAIN to return to the Operations Screen. (This will also stop the yaw move.)

CW CCW 2

5

3

1 6 7

8 9

4

11

11

MANUAL YAW OPERATIONS

This Screen uses the computer’s recorded relative yaw values to manually unwind the tower cable.

This Screen also is used to change the TOTAL and RELATIVE yaw values if required.

MANUAL YAW SCREEN 2

NEVER use the yaw controls with the wind turbine tower lowered. Do not attempt manual yaw moves

in weather that would normally cause the wind turbine to shut down automatically.

1. To reset the TOTAL YAW Counter touch the area and change the number to “0”

2. To reset the RELATIVE YAW Counter touch the area and change the number to “0”

To AUTO Unwind the cable using the computer: (NOTE THIS FUNCTION SHOULD NOT BE USED TO

CORRECT CABLE TWIST FROM A FAULT)

3. PRESS TO CONFIRM SAFETY. Button will turn green once yaw system is ready.

4. Press and release INITIATE YAW to begin the automatic unwind. Computer will Yaw the nacelle

until the relative total reaches “0”

5. Press PAUSE at any time to pause the move. There may be a short delay in response.

6. Press MAIN to return to the Operations Screen (this will stop the yaw)

7. Press BACK to access the MANUAL 1 screen. (this will stop the yaw)

2

5

3

1

6 7

4

12

12

TROUBLESHOOTING From time to time the wind turbine may report a fault. This list of faults will help determine how to safely proceed. We recommend contacting technical support or pressing the “HELP” button on the touch screen before proceeding.

• ESTOP PRESSED ALARM

• The ESTOP Button has been pressed. The button must be physically reset before the system can be restored to operation

• STARTUP OVER VOLTAGE ALARM

• DC Bus voltage has exceeded maximum operating voltage during startup.

• PRODUCTION OVER VOLTAGE ALARM

• DC Bus voltage has exceeded maximum operating voltage during production.

• PHASE IMBALANCE ALARM

• The computer has detected a large variance between phases of the generator.

• STARTUP OVER FREQUENCY ALARM

• The rotational speed of the generator has exceeded maximum settings during startup.

• PRODUCTION OVER FREQUENCY ALARM

• The rotational speed of the generator has exceeded maximum settings during production.

• NCC FAILED TO ENGAGE ALARM

• The Main contactor has failed to power.

• NCC FAILED TO CLOSE ALARM

• The Main contactor has failed to power.

• AC OVER VOLTAGE STARTUP ALARM

• AC Bus voltage has exceeded maximum operating voltage during startup.

• AC OVER VOLTAGE PRODUCTION ALARM

• AC Bus voltage has exceeded maximum operating voltage during production.

• MODBUS COMM ERROR REGULATOR ALARM

• The Regulator has failed to communicate with the computer.

• MODBUS COMM ERROR INVERTER ALARM

• The Inverter has failed to communicate with the computer.

• REGULATOR MAJOR FAILURE

• The Regulator has reported a Major Fault to the computer.

• INVERTER FAULT ALARM

• The Inverter has reported an internal Fault to the computer

• NOAA WEATHER ALERT ALARM

• A Remote shutdown for significant weather or other alert hazard has been received. Do not restart system until conditions are determined to be safe. Observe the system operation for abnormalities following restart.

• REMOTE STOP FR1

• A Remote shutdown has been engaged by QED Technical Support. Do not reset without consent from QED.

• OVER WIND ALARM

• Wind speed has exceeded safe operating speed. The system will auto-restart when conditions are safe.

13

13

TROUBLESHOOTING

Faults on this page require a check of the tower cable for excess twist before restarting. If the tower cable is

twisted it must be straightened and the counters reset to zero before restarting.

SEE CABLE TWIST HELP PAGE FOR HELP

DETERMINING CABLE TWIST UNWIND DIRECTION

We recommend contacting technical support or pressing the “HELP” button on the touch screen before proceeding.

• OVER YAW UNWIND ALARM

• The Tower Cable has twisted too far in one direction.

• YAW SERVICE REQUIRED ALARM

• The yaw motor and cable service has reached a scheduled maintenance threshold.

• WIND VANE NO MOVEMENT ALARM

• The wind vane is not reporting movement to the computer. *This may be due to heavy Icing. In the case of

icing do not restart system until all ice has melted from the wind turbine, blades and generator.

• ANEMOMETER FAILURE ALARM

• The wind speed cups are not reporting enough movement to the computer. *This may be due to heavy

Icing. In the case of icing do not restart system until all ice has melted from the wind turbine, blades and

generator.

• YAW MOVE CALCULATION ALARM

• An internal calculation has failed

• YAW MOVE SENSOR ALARM

• The yaw motor sensor is not reporting expected movement.

• YAW MOVE UNEXPECTED ALARM

• The nacelle is moving in an unexpected fashion

• VFD FAULT

• The yaw VFD is reporting an internal fault

• YAW MOVE CONTINUOUS MOVE ALARM

• The yaw system has operated continuously for longer than expected

• MODBUS COMM ERROR VFD ALARM

• The yaw VFD has stopped communicating with the computer

• REMOTE STOP FR2

• A Remote shutdown has been engaged by QED Technical Support. Do not reset.

14

14

RESET FAULT CONDITIONS

System Faults can be viewed using the VIEW FAULT page.

ALWAYS CONTACT TECHNICAL SUPPORT BEFORE RESTARTING IF ANY QUESTIONS

ARISE. ALWAYS THINK SAFETY FIRST!

1. ACKNOWLEDGE the fault by pressing and releasing. If the fault is able to be reset, both

“Acknowledged and Restored” will auto time-stamp.

If the fault does not reset, contact QED Wind Power for information on how to proceed.

2. Press MAIN to return to the Operations menu.

3. This screen will show a time-stamp for the Acknowledge button.

4. Restored faults will be time-stamped. Only when both areas are time-stamped will the system

allow a restart.

2

3

1

4

15

15

PREVENTIVE MAINTENANCE

In order to maintain the wind turbine system, periodic scheduled system preventive maintenance is

required. All required Inspections should be reported to QED Wind Power for warranty purposes.

Failure to perform required preventive maintenance voids the manufacture’s warranty.

BLADE INSPECTION

1. Clean the blades using a gentle wash solution (such as a car wash solution).

2. Inspect Blades for damage. Report any fissures larger than 1” to QED Wind Power by emailing

a picture and documenting the location.

3. Inspect the leading edge of the blades for paint chipping. Report any findings to QED Wind

Power by emailing a picture and documenting the location.

4. Check torque on the blade plate locking nuts. Torque should be 65ft lbs. Refer to the current

blade installation manual for proper tools. If torque is found to be incorrect, retorque all nuts on

the blade to installation torque specs. This must be reported to QED Wind Power.

5. Inspect blade flange for weld cracks or abnormalities. Report any findings to QED Wind Power

by emailing a picture and documenting the crack’s location.

6. Wax the blades using a high quality car wax (such as Nu-Finish). Waxing significantly extends

the lifetime of blade paint and protective coating.

GREASING: USE ONLY Mobile SCH220 or equivalent grease product.

CHECK THE YAW SYSTEM AND GREASE

1. Pump 5 shots into each of the two yaw system grease zerks.

2. Pump 20 shots into the Tabletop Bearing grease zerk.

3. Inspect the set screw underneath the main pinion gear. Torque should be 15 ft lbs.

4. Apply grease to the circumference of the main tabletop bearing.

5. Check Torque on the main planetary 5/8” retaining bolts. Torque should be 160 ft lbs.

6. Check torque between yaw motor and planetary. Torque should be 35 ft lbs.

7. Confirm Yaw RPM Sensor assembly is not loose. Do not overtighten.

8. Confirm Yaw motor shaft top sensor mount is secure (press fit only)

GREASE THE GENERATOR

1. Pump 10 shots into the front bearing zerk, and 5 shots into the tail bearing zerk.

16

16

PREVENTIVE MAINTENANCE

CHECK THE SECURITY OF THE NACELLE JUNCTION BOX

1. Check that all wire assemblies are secure in the Roxtec Cable Hanger.

2. Check that all wires are secure in their terminal blocks. Check for any wire insulation wear.

3. Check that the nacelle junction box is securely fastened to the chassis of the nacelle.

INSPECT THE WIND SENSOR AND LIGHTNING ROD

1. Confirm the security of the wind sensor pole mounting hardware. Make sure all connections are

secure.

2. Confirm the wind sensor is secure in the mount by checking the mounting bolt.

3. Inspect the wind vane and anemometer cups for problems. Never overtighten.

4. Check the security of the wind sensor wire plug.

5. Insert the wind vane’s test set screw to lock the vane in place. View the reported vane “actual”

direction on the HMI.

• Vane position should be 180 (+/- 3degrees.) Report any discrepancies to QED before

raising tower.

• IMPORTANT Remove the vane’s test set screw before raising tower!

6. Confirm the security of the lightning rod.

7. Confirm the security of the lightning conductor wires and their connections.

REMOVE ANY CABLE TWIST FROM TOWER CABLE

1. While tower is lowered, note the condition of the tower cable and record (if there is cable twist)

the direction of the cable twist.

2. Inspect cable for any damage.

3. After tower is raised, unwind any cable twist. Use “CABLE TWIST UNWIND HELP” page for

assistance.

4. Report cable twist to QED once maintenance is complete.

17

17

18

18

CABLE TWIST UNWIND HELP

19

19

LOWERING THE TOWER

ONLY TRAINED PERSONS SHOULD ATTEMPT LOWERING THE WIND TURBINE TOWER

REFER TO THE TOWER INSTALLATION MANUAL FOR INSTRUCTIONS ON THE

MECHANICAL ACTIONS INVOLVED

BEFORE LOWERING THE TOWER IT IS IMPORTANT THAT THE YAW SYSTEM IS

DISENGAGED. THIS IS EXTREMELY IMPORTANT. BLADES CAN BREAK OFF IF THE

TOWER IS LOWERED AND THE SYSTEM MAKES A YAW MOVE.

TO SAFETY THE YAW SYSTEM POWER OFF THE CIRCUIT BREAKERS SENDING POWER TO

THE CONTROLLER. THESE TWO BREAKERS WILL USUALLY BE LABELED “WIND

TURBINE CONTROLLER” AND “WIND TURBINE YAW”

20

20

21

21