UNPACKING & ASSEMBLY INSTRUCTIONS AIRFORCE 1 1kW WIND TURBINE 12V, 24V, 48V & High-Voltage versions with AC Permanent Magnet Generator

Transcription

1 Issue: 3.2 UNPACKING & ASSEMBLY INSTRUCTIONS AIRFORCE 1 1kW WIND TURBINE 12V, 24V, 48V & High-Voltage versions with AC Permanent Magnet Generator For battery charge, off-grid and grid-tied installations Document Ref: 13108E Date: 20 th January 2017 Issue: 3.2 Ettington Park Business Centre Stratford Upon Avon Warwickshire CV37 8BT Tel:+44 (0) This document is issued to provide outline information only which (unless agreed by the Company in writing) may not be used, applied or reproduced for any purpose or form any part of any order or contract or be regarded as a representation relating to the techniques, processes, products or services concerned. The Company reserves the right to alter or cancel without notice the data in this document. copyright of FuturEnergy Ltd 2017 Title Page

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3 Issue: 3.2 REVISION HISTORY Issue Author Reason for issue Date 2.0 S. Harrison Incorporates AC PMG 20 th April S. Harrison Incorporates electrical connections 5 th May S. Harrison Routine Servicing detail included 24 th May S. Harrison Incorporates FE design PMG 20 th January 2017 Declaration of Conformity FuturEnergy declares that this product complies with: LV Directive EEC EMC Directive EEC Machinery Directive 98/37/EC Fully ROHS compliant Page 1 of 46

4 Issue: 3.2 REFERENCE DOCUMENTS No. Document No. Title K Power curve AIRFORCE 1 AC version with PMG M Noise Assessment AIRFORCE 1 AC with PMG C Turbine guide general information E AIRFORCE 1 Blade set assembly 5 6 Additional information on the equipment detailed within this document may be found by reference to the documents shown above. DEFINITIONS Terminology A AC DC HVGT LAeq m/s NM PMG RoHS V W Definition Amps Alternating Current Direct Current High- Voltage Grid-Tie Equivalent Continuous Level (noise) Meters per second Newton Meters Permanent Magnet Generator Restriction of Hazardous Substances Directive Volts Watts Icon conventions used in this document This is a warning This is a caution This is a hint This is a note Page 2 of 46

5 Issue: 3.2 Table of Contents SECTION 1: ASSEMBLING THE TURBINE INTRODUCTION AIRFORCE 1 KEY DESIGN CHARACTERISTICS AIRFORCE 1 TECHNICAL SPECIFICATIONS AIRFORCE 1 IDENTIFICATION PLATE INFORMATION UNPACKING AND CHECKING CONTENTS TAILFIN AND TURBINE FAIRING ASSEMBLY ROTOR ASSEMBLY INSTALLATION OF THE BLADES ROTOR STATIC BALANCING FITTING THE ROTOR TO THE TURBINE BODY SECTION 2: INSTALLING & CONNECTING THE TURBINE (BATTERY CHARGE AND OFF-GRID INSTALLATIONS) INTRODUCTION INSTALLATION EXAMPLES ELECTRICAL INSTALLATION OVERVIEW ELECTRICAL INSTALLATION KIT TURBINE INSTALLATION Turbine mounting pole Turbine power cable connections Turbine installation on the mounting pole STOP SWITCH AND BRIDGE RECTIFIER INSTALLATION Stop Switch fitting Stop Switch to Turbine cable connections Bridge Rectifier fitting Bridge Rectifier to Stop Switch cable connections Stop Switch completion Page 3 of 46

6 Issue: CHARGE CONTROLLER, BATTERY AND DUMPLOAD RESISTOR INSTALLATION Charge Controller Dip switch setting Dumpload resistor Dumpload resistor mounting Charge Controller, Battery and Dumpload Resistor connections overview Charge Controller to Dumpload Resistor cable connection Charge Controller to Battery cable connection Charge Controller to Battery, voltage sensing cable connection (optional installation) Battery to Bridge Rectifier cable connection ELECTRICAL CONNECTIONS COMPLETION TURBINE INSTALLATION - COMPLETION Final checks Stop Switch selection Turbine raising TURBINE OPERATION SECTION 3: INSTALLING AND CONNECTING THE TURBINE - HIGH-VOLTAGE GRID-TIED (HVGT) INSTALLATIONS INTRODUCTION INSTALLATION EXAMPLES ELECTRICAL INSTALLATION OVERVIEW ELECTRICAL INSTALLATION KIT TURBINE INSTALLATION Turbine mounting pole Turbine power cable connections Turbine installation on the mounting pole Page 4 of 46

7 Issue: STOP SWITCH AND BRIDGE RECTIFIER INSTALLATION Location Stop Switch fitting Stop Switch to Turbine cable connections Bridge Rectifier fitting Bridge Rectifier to Stop Switch cable connections Stop Switch completion BRIDGE RECTIFIER TO INVERTER INSTALLATION ELECTRICAL CONNECTIONS COMPLETION TURBINE INSTALLATION - COMPLETION Final checks Stop Switch selection Turbine raising TURBINE OPERATION SECTION 4: TURBINE MAINTENANCE SCHEDULE INTRODUCTION POST INSTALLATION INSPECTION ROUTINE (6 MONTHLY) INSPECTION SECTION 5: WARRANTY STATEMENT MONTH WARRANTY MONTH LIMITED WARRANTY ITEM REPLACEMENT WARRANTY EXCLUSIONS Accidental damage High winds Component disconnection Unauthorised modification Page 5 of 46

8 Issue: Operation under no-load Unbalanced rotor Servicing Painting the blades Blade erosion Failure to follow guidelines Other equipment Generation performance Structural damage Battery operation and maintenance Installation location Topple zone SECTION 6: FAULT REPORTING Reporting the fault Information required Fault assessment Replacement items Failure to correct fault Goods shipping address Failures other than for FuturEnergy cause Page 6 of 46

9 Section 1: Issue: 3.2 SECTION 1: ASSEMBLING THE TURBINE 1. INTRODUCTION This document provides information on the unpacking, assembling and installation of the AIRFORCE 1 wind turbine. These instructions refer to turbine systems incorporating the FUTURENERGY bespoke design and manufactured high performance Permanent Magnet Generator. AIRFORCE 1 wind turbine Page 7 of 46

10 Section 1: Issue: AIRFORCE 1 KEY DESIGN CHARACTERISTICS Designed & manufactured in the United Kingdom under a continuous product improvement management and support policy Bespoke high quality and performance Permanent Magnet Generator (PMG) Tough glass-reinforced-nylon turbine blades All bearings sealed for life with corrosion resistant materials throughout Fully compliant with RoHS Directive 60 Amp rated slip-ring to prevent cable twist Rugged and simple design throughout to prolong life-in-service Supplied complete with manual stop switch 3. AIRFORCE 1 TECHNICAL SPECIFICATIONS Nominal power output: Start-up wind speed: Rated wind speed: Survival wind speed: Total weight: All versions 1000W ~3.5 m/s 12.5m/s 52m/s 18kg Number of blades: 3 Rotor diameter: 1.8m Rotor speed (RPM): Generator type: Output type: Turbine mounting: Noise: 3-Phase Permanent Magnet 3-Phase AC (rectified DC available on request) 50mm tube to accept 48.3mm standard scaffold tube LAeq 5m/s wind speed measured behind rotor LAeq 7m/s wind speed measured behind rotor Page 8 of 46

11 Section 1: Issue: AIRFORCE 1 IDENTIFICATION PLATE INFORMATION Each PMG supplied with a turbine assembly is fitted with an identification plate providing information on the performance and operational characteristics of the generator. (The HVGT version is shown above). This information will be required should it be necessary to contact FUTURENERGY at any time for warranty or technical support. Users should ensure that they have this information available and ideally take and keep a copy. Page 9 of 46

12 Section 1: Issue: UNPACKING AND CHECKING CONTENTS The AIRFORCE 1 turbine is delivered in two boxes. Before unpacking, check the boxes are undamaged. Should damage be noticeable ensure no damage has occurred to the contents prior to assembling. Box 1 contents Turbine body and fin Box 2 contents Turbine blades and rotor Page 10 of 46

13 Option Document Ref E Section 1: Issue: 3.2 Box 1 contents (turbine body and fin) Item Description Qty Part No 1a Turbine complete with 12V PMG and hub adaptor 1 A0359 1b Turbine complete with 24V PMG and hub adaptor 1 A0344 1c Turbine complete with 48V PMG and hub adaptor 1 A0345 1d Turbine complete with HVGT PMG and hub adaptor 1 A Nose cone 1 P Turbine body cover 1 P Cable crimp connection with heat shrink 3 P M6 x 25mm bolts (rotor hub attachment) 5 PMG fix-kit 6 M6 washers (rotor hub attachment) 5 PMG fix-kit 7 M6 locknut (rotor hub attachment) 5 PMG fix-kit 8 M10 x 80mm SS screw (nose cone attachment) 1 SCR M10 washer (nose cone attachment) 1 WASHM10 10 Aluminium distance tube (nose cone attachment) 1 TUB01 11 M6 x 35mm stainless steel bolt (tail fin attachment) 2 P M6 stainless steel washer (tail fin attachment) 2 WASM6 13 M6 locknut (tail fin attachment) 2 NUT06 14 Rivet fixings (plastic) (housing cover to front plate) 5 P Tail bar 1 TAL02/S 16 Tail fin 1 P Stop Switch 1 A Assembly Instructions E Box 2 contents (turbine blades and rotor) Item Description Qty Part No 1 Rotor blade set (3 off) 1 set A Rotor Hub enclosures (2 off) 1 set HUB blade pitch locking pins 3 PITCH28 4 Blade static balancing discs & cable 1 A M6 x 20mm SS cap screws (hub halves attachments) 6 SCR620 6 M6 stainless steel washers (hub halves attachments) 6 WASM6 7 M6 stainless steel locknuts (hub halves attachments) 6 NUT06 8 Blade installation instructions 1 Page 11 of 46

14 Section 1: Issue: TAILFIN AND TURBINE FAIRING ASSEMBLY Tools required: 4mm hex key, 10mm socket and handle, calibrated torque wrench (10NM) Locate the turbine body, the turbine fairing, tailbar, tailfin and the M6 x35mm bolts, washers and locknuts, (2 off of each). Turbine body Turbine fairing Tailbar Tailfin Fairing rivets and tail bolts Page 12 of 46

15 Section 1: Issue: Fit the tailbar to the tailfin and secure using the M6 x35mm bolts, washers and locknuts (2-off each). Torque load to 10NM Pass tailbar through the turbine fairing. Page 13 of 46

16 Section 1: Issue: Insert the two clamps into the turbine body chassis and loose fit the two washers and nuts Align tailfin vertically with the turbine mounting shaft and insert tailbar under the clamps on the turbine chassis Secure the tailbar to the turbine chassis by equally tightening the two clamp M6 lock nuts. Ensure the two legs of the clamp are of equal length when fully tightened Slide the turbine fairing over the turbine body and mounting shaft, carefully prising apart where necessary, and push over the four location lugs Secure into position using the push-in plastic rivets. Proceed in the order top, bottom (2 rivets), left then right. Page 14 of 46

17 Section 1: Issue: ROTOR ASSEMBLY INSTALLATION OF THE BLADES Tools required: 5mm hex key, 10mm socket and handle or ring spanner. The working area should be clean and flat approximately 2m x 2m in area Locate the blades (x3), blade pitch locking pins (x3), rotor hub halves and the M6 cap-screws with washers and lock nuts (6-off of each). Rotor blades in transit box Blade pitch locking pins Rotor hub halves Hub halve attachments Page 15 of 46

18 Section 1: Issue: Insert a blade pitch locking pin into the root of each blade. Rotor hub halves 7.3. Place a rotor hub half on the work bench with the blade cups facing upwards. Page 16 of 46

19 Section 1: Issue: 3.2 ENSURE BLADES FACE THE SAME WAY 7.4. Each blade has a sticker attached to one face identifying the front (windward) face (adjacent to the blade embossed identification). Place the blades in the lower hub halve with the sticker facing upwards Check once more that all blades have the sticker facing upwards, (shown below with nose cover fitted indicating the forward face), and then place the other rotor hub half over the blade roots. Page 17 of 46

20 Section 1: Issue: Ensure the blades are correctly located in the hub and secure the hub halves using the M6 cap-screws, washers and lock nuts. Do not fully tighten the nuts at this time as it may be necessary to remove bolts during the static balancing procedure. 8. ROTOR STATIC BALANCING Tools required: 5mm hex key, 10mm socket and handle or ring spanner, calibrated torque wrench (8NM). A draft free area will be required with the ability to suspend the rotor assembly in free space at a comfortable working height. M6 washes may be required for use as balancing weights. Page 18 of 46

21 Section 1: Issue: Locate the rotor assembly static balancing disc. Rotor Assembly static balancing 8.2. Pass the cable of the disc through the centre of the rotor flange, ensuring it is centralised, and suspend from a secure overhead hook or other suitable location and allow the rotor to stabilise If the rotor hangs perfectly horizontally (shown below balanced rotor) the process is complete. Balanced rotor Un-balanced rotor 8.4. Add washers to the side that is high by resting them close to the heads of the cap-screws until the rotor is perfectly level. Page 19 of 46

22 Section 1: Issue: Transfer any additional washers under the nuts and torque load all nuts to 8NM. Temporarily placing washers to balance the rotor TO PREVENT DAMAGE CORRECTLY TORQUE BOLTS Balance washers moved under the nut and tightened When correctly tightened a very small gap will be visible between the hub halves as shown above. Tightening the halves in excess of the recommended torque loading can cause irreparable damage to the hub assembly. OVERTIGHTENING THE BOLTS CAN CRACK THE HUB Page 20 of 46

23 Section 1: Issue: FITTING THE ROTOR TO THE TURBINE BODY Tools required: 6mm hex key, 10mm socket and handle, calibrated torque wrench (10NM and 15NM) 9.1. Locate the M6 x 25mm stainless steel bolts, washers and locknuts (5-off each), nose cone and M10 x 80mm button head screw and distance piece With the stickers on the blades facing forwards, offer the rotor to the turbine rotor hub plate and secure using the 5 off M6 x 30mm bolts, washers and lock nuts. Torque load to 10NM. ENSURE BLADES ARE FACING FORWARDS Page 21 of 46

24 Section 1: Issue: Push the M10 x 80mm bolt though the nose cone and slide the distance piece on from the rear face Locate the nose cone evenly around the blades and secure the bolt. Torque load to 15NM. THE FUTURENERGY AIRFORCE 1 WIND TURBINE ASSEMBLY IS NOW READY FOR INSTALLATION ON THE TOWER Page 22 of 46

25 Section 2: Issue: 3.2 SECTION 2: INSTALLING & CONNECTING THE TURBINE (BATTERY CHARGE AND OFF-GRID INSTALLATIONS) 1. INTRODUCTION This section of the document provides information and instructions on installing the fully assembled turbine onto the mounting pole and making the electrical connections. 2. INSTALLATION EXAMPLES Examples of the various methods of installation and electrical connection may be found in document 11108C, available on request, or on the FUTURENERGY website. This shows examples of 12V, 24V and 48V battery charge installations, also with hybrid systems including solar panels and operation with inverters for domestic off-grid and High Voltage grid-tied connections. Go to for details. 3. ELECTRICAL INSTALLATION OVERVIEW The recommended installation method and equipment locations are shown here and may be adapted as required to meet the individual site requirements. For personnel and equipment safety, it is strongly recommended that the first course of action is install and connect the Stop Switch. When connected and switched to ON this will prevent the turbine from rotating and generating electrical energy. PREVENT THE ROTOR FROM ROTATING WHILE ELECTRICALLY UNLOADED Page 23 of 46

26 Section 2: Issue: 3.2 The preferred method of turbine installation is by using a lay-flat pole that is hinged at the base. This allows the turbine to be fitted to the pole at ground level and all electrical connections made before lifting the complete assembly into the operational position. These instructions assume that this method of installation is used. To increase the service life and reliability of the system all components should be fitted in areas that protect them from the environment. 4. ELECTRICAL INSTALLATION KIT The AIRFORCE 1 electrical installation kit is supplied as a series of loose items as follows. Item Description Voltage Qty Part No 1 Stop Switch (manual operation) All 1 A Bridge Rectifier All 1 REC02 3a Dumpload Resistor 12V 1 P1886 3b (i) Dumpload Resistor or 24V 1 RIS b (ii) Immersion heater 1kW 24V 1 P0803 3c (i) Dumpload Resistor or 48V 1 RIS c (ii) Immersion heater 1kW 48V 1 P0804 4a Charge Controller TS45 12V 2 P0822 4b Charge Controller TS60 24V 1 P0822 4c Charge Controller TS45 48V 1 P TURBINE INSTALLATION 5.1. Turbine mounting pole Lay the mounting pole down and rest on suitable firm support to provide easy working and installation conditions. Page 24 of 46

27 Section 2: Issue: Turbine power cable connections Pass three lengths of different colour flexible 10 2 mm insulated copper cable, (or a triple-core single cable), down the turbine mounting pole and secure and protect as required to prevent chafing. The cables must be long enough to reach from the top of the pole to the Stop Switch location. To prevent damage, it may be necessary to support the weight of the cable within the pole. Using suitable electrical connectors attach to the three cables projecting from the bottom of the turbine assembly Turbine installation on the mounting pole Feed the cables into the mounting pole and secure the turbine assembly to the top of the mounting pole and secure into position. Ensure the turbine is free to rotate in azimuth around the top of the pole. 6. STOP SWITCH AND BRIDGE RECTIFIER INSTALLATION 6.1. Stop Switch fitting Locate and identify the Stop Switch. Ensure the switch is set to the OFF position and remove the front cover. Page 25 of 46

28 Section 2: Issue: 3.2 Install the switch, with the UP arrow on the back of the body of the switch correctly orientated, in an easily accessible location using screws or bolts inserted through holes drilled in the switch back-plate onto a flat surface. Stop Switch and with cover removed Press out the two cable holes in the bottom of the Stop Switch Stop Switch to Turbine cable connections Pass the three cables routed from the turbine through a weather proofing grommet and into the bottom of the Stop Switch. Cut the cables to length, ensuring there is a natural curve of cable outside and below the Stop Switch to prevent water ingress, and strip back the insulation. Connect to the three TOP screw terminals of the Stop Switch (L1, L2 & L3) and secure. Set the Stop Switch to ON Completing these actions will prevent the turbine from rotating and presenting hazards to personnel and possible damage to the turbine assembly. Page 26 of 46

29 Section 2: Issue: Bridge Rectifier fitting Locate and identify the Bridge Rectifier and install in a suitable weather-proof enclosure that also provides sufficient air circulation for cooling. Bridge Rectifier 6.4. Bridge Rectifier to Stop Switch cable connections Use the same cable type as used previously and connect the Bridge Rectifier and Stop Switch. Pass through a weather proof grommet and into the Stop Switch, ensuring there is a natural curve of cable outside and below the Stop Switch to prevent water ingress, through the second of the two cable holes. Strip back the insulation and connect to the three top screw terminals of the Stop Switch (L1, L2 & L3) and secure. To avoid later confusion always match the input and output colours of the cables with the cable to the turbine. Connect the other end of the power cable to the three input connections of the Bridge Rectifier using insulated push-on spade connectors. These connections may be made in any order Stop Switch completion Ensure the cable grommets are secure in the base of the Stop Switch. Refit the Stop Switch cover. Page 27 of 46

30 Section 2: Issue: CHARGE CONTROLLER, BATTERY AND DUMPLOAD RESISTOR INSTALLATION Locate and identify the Charge Controller. Charge Controller Install in a suitably environmentally protected location using the template provided and screws/bolts inserted through the mounting face, with the cable connection glands oriented downwards. Fit the Charge Controller on a wall protected from direct sun, high temperatures, and water. Do not install in a confined area where battery gasses can accumulate. When mounting, ensure the air flow around the controller and the heat sink is not obstructed. Maintain an open space above and below the heat sink of at least 75mm (3 inches) to allow free air to circulate for cooling Remove the four screws securing the cover of the Charge Controller to reveal the cable connection terminals and Dip Switches. The black plastic reset button extension will be found secured by tape within this area. Locate it and push over the reset switch so that it clicks into place. Page 28 of 46

31 Section 2: Issue: Charge Controller Dip switch setting The DIP switches must be set to match the requirement of the desired operation. Refer to the manual supplied with the Charge Controller for further details Dumpload resistor Locate and identify the Dumpload Resistor unit. Dumpload Resistor 7.3. Dumpload resistor mounting Install using screws/bolts inserted through the mounting face, with the cable connection glands oriented downwards, and in a suitable location that must be: not in the same enclosure as the batteries on a non-combustible surface protected from the environment, especially moisture be at least 300mm from any other components be protected from accidental contact by personnel be freely ventilated to allow generated heat to escape Page 29 of 46

32 Section 2: Issue: Charge Controller, Battery and Dumpload Resistor connections overview Charge Controller, cover removed 7.5. Charge Controller to Dumpload Resistor cable connection Connect two suitable lengths of insulated 10 2 mm cable, one red, the other black, between connections shown as No. 2 (red +ve) and No. 3 (black -ve) on the Charge Controller connection diagram above and the Dumpload Resistor Charge Controller to Battery cable connection Connect two suitable lengths of insulated 10 2 mm cable, one red, the other black, between connections shown as No. 1 (red +ve) and No. 4 (black -ve) on the Charge Controller connection diagram above and the Battery. Ensure that the positive connection between the Battery and the Charge Controller is protected using a suitable fuse, normally approximately 5A above the maximum current rating of the charge controller. Page 30 of 46

33 Section 2: Issue: Charge Controller to Battery, voltage sensing cable connection (optional installation) If required by the user, connect two suitable lengths of insulated mm to mm cable, (max. length 30m), between the battery positive and negative terminals and the battery voltage sensing terminals on the Charge Controller. To prevent incorrect system operation, ensure that the Battery positive terminal is connected to A, and the Battery negative terminal is connected to B on the Charge Controller as shown on the diagram above. Refit the Charge Controller cover Battery to Bridge Rectifier cable connection Ensure the Stop Switch is fitted and selected to ON prior to making any connections between the Battery and Bridge Rectifier. Route and connect two suitable lengths of insulated 10 2 mm cable, one red (+ve), the other black (-ve), between the Battery and the Bridge Rectifier positive and negative output terminals. 8. ELECTRICAL CONNECTIONS COMPLETION Before continuing ensure that: all items are correctly installed in accordance with the recommendations all connections are fully tightened the polarity of all connections is correctly followed all cables are safely routed, secured and protected all covers, where removed, are correctly refitted Page 31 of 46

34 Section 2: Issue: TURBINE INSTALLATION - COMPLETION 9.1. Final checks Before continuing ensure that: the turbine is correctly secured to the mounting pole all cable connections and routings are secure the turbine is free to rotate around the top pf the pole 9.2. Stop Switch selection Ensure the Stop Switch is set to ON 9.3. Turbine raising The turbine system may now be raised to its operational position. For correct operation ensure the mounting pole is perpendicular. Secure the pole as required. THE FUTURENERGY AIRFORCE 1 WIND TURBINE INSTALLATION IS NOW COMPLETE 10. TURBINE OPERATION Set the Stop Switch to OFF to enable turbine operation. Page 32 of 46

35 Section 3: Issue: 3.2 SECTION 3: INSTALLING AND CONNECTING THE TURBINE - HIGH-VOLTAGE GRID-TIED (HVGT) INSTALLATIONS 1. INTRODUCTION This section of the document provides information and instructions on installing the fully assembled turbine onto the mounting pole and making the electrical connections for grid tied installations. 2. INSTALLATION EXAMPLES Examples of the various methods of installation and electrical connection may be found in document 11108C, available on request, or on the FUTURENERGY website. This shows examples of 12V, 24V and 48V battery charge installations, also with hybrid systems including solar panels and operation with inverters for domestic off-grid and High Voltage grid-tied connections. Go to for details. 3. ELECTRICAL INSTALLATION OVERVIEW The recommended installation method and equipment locations are shown here and may be adapted as required to meet the individual site requirements. For personnel and equipment safety, it is strongly recommended that the first course of action is install and connect the Stop Switch. When connected and switched to ON this will prevent the turbine from rotating and generating electrical energy. PREVENT THE ROTOR FROM ROTATING WHILE ELECTRICALLY UNLOADED 46 Page 33 of 46

36 Section 3: Issue: 3.2 The preferred method of turbine installation is by using a lay-flat pole that is hinged at the base. This allows the turbine to be fitted to the pole at ground level and all electrical connections made before lifting the complete assembly into the operational position. These instructions assume that this method of installation is used. To increase the service life and reliability of the system all components should be fitted in areas that protect them from the environment. 4. ELECTRICAL INSTALLATION KIT The AIRFORCE 1 electrical installation kit is supplied as a series of loose items as follows. Item Description Voltage Qty Part No 1 Stop Switch (manual operation) All 1 A Bridge Rectifier All 1 REC02 5. TURBINE INSTALLATION 5.1. Turbine mounting pole Lay the mounting pole down and rest on suitable firm support to provide easy working and installation conditions Turbine power cable connections Pass three lengths of different colour flexible 10 2 mm insulated copper cable, (or a triple-core single cable), down the turbine mounting pole and secure and protect as required to prevent chafing. The cables must be long enough to reach from the top of the pole to the Stop Switch location. Using suitable electrical connectors attach to the three cables projecting from the bottom of the turbine assembly. Page 34 of 46

37 Section 3: Issue: Turbine installation on the mounting pole Feed the cables into the mounting pole and secure the turbine assembly to the top of the mounting pole and secure into position. Ensure the turbine is free to rotate in azimuth around the top of the pole. 6. STOP SWITCH AND BRIDGE RECTIFIER INSTALLATION 6.1. Location All items should be located in a covered position that is easily accessible and close to the inverter and as far from the turbine as possible and practical Stop Switch fitting Locate and identify the Stop Switch. Ensure the switch is set to the OFF position and remove the front cover. Install the switch, with the UP arrow on the back of the body of the switch correctly orientated, in an easily accessible location using screws or bolts inserted through holes drilled in the switch back-plate onto a flat surface. Stop Switch and with cover removed Press out the two cable holes in the bottom of the Stop Switch Stop Switch to Turbine cable connections Pass the three cables routed from the turbine through a weather proofing grommet and into the bottom of the Stop Switch. 46 Page 35 of 46

38 Section 3: Issue: 3.2 Cut the cables to length, ensuring there is a natural curve of cable outside and below the Stop Switch to prevent water ingress, and strip back the insulation. Connect to the three TOP screw terminals of the Stop Switch (L1, L2 & L3) and secure. Set the Stop Switch to ON Completing these actions will prevent the turbine from rotating and presenting hazards to personnel and possible damage to the turbine assembly Bridge Rectifier fitting Locate and identify the Bridge Rectifier and install in a suitable weather-proof enclosure that also provides sufficient air circulation for cooling. Bridge Rectifier 6.5. Bridge Rectifier to Stop Switch cable connections Route suitable lengths of the same power cable as that used previously between the Bridge Rectifier and Stop Switch. Pass through a weather proof grommet and into the Stop Switch, ensuring there is a natural curve of cable outside and below the Stop Switch to prevent water ingress, through the second of the two cable holes. Page 36 of 46

39 Section 3: Issue: 3.2 Strip back the insulation and connect to the three top screw terminals of the Stop Switch (L1, L2 & L3) and secure. To avoid later confusion always match the input and output colours of the cables with the cable to the turbine. Connect the other end of the power cable to the three input connections of the Bridge Rectifier using insulated push-on spade connectors Stop Switch completion Ensure the cable grommets are secure in the base of the Stop Switch. Refit the Stop Switch cover. 7. BRIDGE RECTIFIER TO INVERTER INSTALLATION 7.1. Connect the positive and negative outputs from the bridge rectifier to the input of the inverter. It is recommended that the input to the inverter is protected with a suitable fuse, unless the inverter is already fitted with a replaceable fuse. 8. ELECTRICAL CONNECTIONS COMPLETION Before continuing ensure that: all items are correctly installed in accordance with the recommendations all connections are fully tightened the polarity of all connections is correctly followed all cables are safely routed, secured and protected all covers, where removed, are correctly refitted 46 Page 37 of 46

40 Section 3: Issue: TURBINE INSTALLATION - COMPLETION 9.1. Final checks Before continuing ensure that: the turbine is correctly secured to the mounting pole all cable connections and routings are secure the turbine is free to rotate around the top pf the pole 9.2. Stop Switch selection Ensure the Stop Switch is set to ON 9.3. Turbine raising The turbine system may now be raised to its operational position. For correct operation ensure the mounting pole is perpendicular. Secure the pole as required. THE FUTURENERGY AIRFORCE 1 WIND TURBINE INSTALLATION IS NOW COMPLETE 10. TURBINE OPERATION Set the Stop Switch to OFF to enable turbine operation. Page 38 of 46

41 Section 4: Issue: 3.2 SECTION 4: TURBINE MAINTENANCE SCHEDULE 1. INTRODUCTION The following schedule has been compiled to avoid premature turbine failure. Turbine life will be reduced if situated in coastal areas or on sites that exhibit high turbulence. To prevent damage to the turbine it should always remain under load as a free spinning turbine will burn out its generator very quickly. 2. POST INSTALLATION INSPECTION Approximately one month following installation check that: there are no abnormal noises or vibrations all bolts and fixings are secure all guy wires, foundations and ground anchors are secure no noticeable damage to blades or fairings damaged blades cause unbalance and premature bearing failure 3. ROUTINE (6 MONTHLY) INSPECTION Every 6 months check that: there are no abnormal noises or vibrations all bolts and fixings are secure check blades for damage, especially the leading edges check for play in slew and generator bearings check electrical connections for tightness, corrosion, wear or chafing to prevent short circuits check the tower, guy wires, foundations and ground anchors for security or signs of wear Rectify all faults identified as soon as practical Page 39 of 46

42 Section 5: Issue: 3.2 SECTION 5: WARRANTY STATEMENT MONTH WARRANTY Products are warrantied against defects in parts or workmanship, unless otherwise specified, for 12 calendar months dated from the date of purchase. The warranty covers replacement only of faulty parts MONTH LIMITED WARRANTY A 24 calendar month limited product warranty at no additional cost is provided to those customers who register their product with FuturEnergy. Registration must take place within one month of the original purchase date. This process extends the standard 12 months warranty by a further 12 months, Please complete the enclosed product registration card and mail to Futurenergy. Some products may (subject to contract) be warrantied for a longer period on a product-by-product basis. These are subject to placement of a valid maintenance contract with FuturEnergy Ltd or our nominated supplier. 3. ITEM REPLACEMENT In the event of a failure due to faulty parts or workmanship, the part will be replaced free of charge during the warranty period only. A replacement part assumes the remaining warranty of the original part or ninety (90) calendar days from the date of replacement, whichever provides the longer term. When a part is exchanged, the replacement item becomes the property of the client and the replaced item becomes the property of FuturEnergy. FuturEnergy shall not be held liable for damage due to alterations, modifications, usage or installation outside of the original product specification or recommended operation. Page 40 of 46

43 Section 5: Issue: 3.2 FuturEnergy may refund the shipping should the item(s) have failed due to faulty workmanship or materials. Alternatively, the customer may visit our premises by arrangement to exchange the faulty unit. If the item(s) has failed due to fair wear and tear, misuse or damage, no refund will be issued. No exchange will be given without the return of the original part. This does not affect your statutory rights. Faulty goods will not be exchanged until return authorization has been provided by the sales or product support team representative. Product serial numbers must be provided in all correspondence. 4. WARRANTY EXCLUSIONS The warranty provided is subject to the following exclusions: 4.1. Accidental damage Accidental damage, howsoever caused, or damage due to abuse, misuse or vandalism High winds Damage caused to wind turbines and electronics by exposure to high winds, or gusts exceeding the maximum design speed of the turbine. FuturEnergy turbines are specifically designed for highoutput at low-wind speed. In locations with high wind speeds customers are advised to monitor weather forecasts, and shut down the turbine in anticipation-of rather than in reaction-to the winds. Use of these wind turbines in coastal areas or use in other high-wind areas is at the customer's risk only Component disconnection Damage caused to electrical components by disconnecting any component during operation. Page 41 of 46

44 Section 5: Issue: 3.2 Disconnection of the inverter, batteries, charge controller or turbine whilst any component is powered/delivering power can cause irreversible damage Unauthorised modification The warranty is automatically invalidated if any part of a system is modified, (even if the modified part is not the component that has failed), unless prior agreement is obtained in writing from FuturEnergy Ltd Operation under no-load Damage may be caused to the wind turbine or blades by overspinning when running without suitable load or battery connected Unbalanced rotor Damage may be caused to the turbine by out-of-balance hub or blades. Assembly balancing must be carried out by the client in accordance with the instructions provided before attaching to the turbine body Servicing Failure to service and maintain the system in accordance with the recommended maintenance schedule shall invalidate the warranty Painting the blades Applying paint or other coatings to the blade surfaces constitutes an un-authorised modification as this weakens the structure of the blades and will cause failure / breakage Blade erosion Damage caused to wind turbine components due to abrasion by particles carried by the wind shall constitute fair wear and tear. Page 42 of 46

45 Section 5: Issue: Failure to follow guidelines No liability is accepted for any damage caused to persons or property as a result of a failure to follow product safety instructions, misuse, or as a result of use of installation methods, fixings or applications other than those recommended by FuturEnergy Other equipment FuturEnergy shall not be liable for damage to equipment not supplied by Futurenergy, that may be used by the client and connected to FuturEnergy products unless it can be demonstrated that the FuturEnergy equipment is at fault. Consult FuturEnergy with details of the intent prior to connecting equipment Generation performance Erecting the turbine on or close to buildings will result in inferior turbine power output which is the sole responsibility of the client Structural damage FuturEnergy does not recommend building-mounted installations other than for steel-framed and other industrial buildings. FuturEnergy shall not be liable for structural or any other consequential damage or losses due to building mounted turbines Battery operation and maintenance FuturEnergy shall not be liable for damage to batteries due to excessive deep discharge, short-circuiting, excessively high load, excessive charging, loss of electrolyte, failure to maintain electrolyte level, topping up using fluid other than distilled or deionised water or any weather condition outside of the manufacturer's specification for battery use. Page 43 of 46

46 Section 5: Issue: Installation location All machinery and equipment supplied by FuturEnergy, and wind turbines in particular, shall be installed and operated at a safe distance from individuals and property in accordance with guidelines provided. If doubt exists clients should consult FuturEnergy prior to installing the equipment Topple zone The turbine should not be erected where tower or turbine failure can cause the machinery to fall onto individuals or property. When the wind turbine is operating, no personnel should come within a distance equivalent to twice the tower height for safety reasons. FuturEnergy shall not be liable for any injury or damage, howsoever caused, by failing to heed these warnings. Page 44 of 46

47 Section 6: Issue: 3.2 SECTION 6: FAULT REPORTING Step by step procedure for reporting faulty goods 1. Reporting the fault Report the fault in writing to or by telephone to: +44 (0) Information required When contacting FuturEnergy to report a fault the following information is required: 2.1. Detailed description of the fault. Please provide photos where possible to assist with fault diagnosis Contact name 2.3. Address address 2.5. Contact telephone number 2.6. Date of purchase 2.7. Original sales invoice (a receipt or proof of purchase is needed for all returns) 2.8. Date of installation 2.9. Turbine site location digit serial number, available on the test certificate provided with the turbine or alternatively on the turbine body front plate, item 13 on the parts list. Page 45 of 46

48 Section 6: Issue: Fault assessment Once assessed FuturEnergy will determine the best way to resolve the fault. A unique RMA (Return Material Authorisation) number will be issued if the fault falls within the parameters of our returns policy. 4. Replacement items If a component is deemed faulty the company's liability shall be limited to, at the company's discretion, sending a spare part, replacing the goods, refunding the price of the goods or offering an exchange. 5. Failure to correct fault If the fault cannot be resolved by sending a spare part the goods will need to be returned to FuturEnergy for inspection and testing. If you are advised to return the faulty product for inspection where possible send the item back in its original packaging (or equivalent) to prevent further damage. FuturEnergy shall not be liable for additional damage to returned items if goods are not adequately packaged. 6. Goods shipping address Please arrange shipment of returned goods clearly showing the RMA number provided to: FuturEnergy Ltd, Ettington Park, Stratford-Upon-Avon, Warwickshire, CV37 8BT 7. Failures other than for FuturEnergy cause Should testing prove the fault occurred for any other reason other than faulty manufacturing the component will be returned to the client and outbound postage charges will apply. This will be carried out within 30 calendar days of receipt by Futurenergy of the subject goods. Page 46 of 46

49 Product Registration Card

50 FuturEnergy Ltd Ettington Park Business Centre Stratford-On-Avon Warwickshire CV37 8BT United Kingdom Postage Here