USER’S MANUAL tle Here D400 Wind Generator Serial Number:_______________ Voltage:_____________________
Safety Issues When installing the D400, exercise due care at all times. The turbine weighs 17.2 kilograms and is awkward in shape. It is best to plan the installation carefully in advance and enlist some help when erecting the machine in order to avoid accidents. Complete as much of the installation procedure as possible at ground level. Choose a calm, dry day for your installation if possible. D400 blades are quite sharp, particularly on their trailing edges. Handle with care.
Contents Safety issues 1 Introduction 2 Features of the D400 3 Dimensions 4 Output 4 Checklist (parts, tools etc) 5 Principles of wind energy 5 Installation - Boats 6 Terrestrial mounting 7 Guyed towers 7 Freestanding towers 8 Roof mounting 8 Assembling the D400 9/10 Electrical connections 11 Regulation 11 Stopping the D400 / Braking switch 12 Electrical installation/ Circuit diagrams 13/14 Performance and expectation 15 ‘Trouble-shooting’ 16/18 Routine maintenance 19
Features of the D400 The D400 has been developed specifically to operate in close proximity to people. The noise and vibration usually associated with small wind turbines has been designed out of the D400. This has been achieved by making the turbine run relatively slowly for a given electrical output. In a given wind speed and a given electrical output, the D400 rotates at less than one quarter the speed of some competitor units.
Dimensions, output 695mm Rated outputs 225 watts at 11 m/s, 400 watts at 16.
Checklist Check that you have received in your delivery two cartons containing: 1 x alternator body 5 x air blades 1 x tail 2 x hub plates 1 x air hub spacer Fasteners 1 x tower liner 1 x nose cone Required for installation: The principles of Wind Energy Wind is a function of solar energy unevenly heating the Earth’s surface. As warmer air rises at the equator, cooler air flows in to replace it, setting in train global convective currents.
Installation Marine Mountings When mounting on a yacht or boat, positioning the turbine will be influenced by the configuration of the boat and other equipment fitted. It is important to ensure that the blades are at sufficient height such that injury to the crew from rotating blades is unlikely. A minimum height of the lowest point of the airblades above a crewed area should be 2.4 metres. Also ensure that no part of the turbine can come into contact with any other part of the boat’s fittings or rigging.
Terrestrial Mounting The performance of your D400 will be influenced by the topography of your proposed mounting site. The golden rule with wind turbines is to mount them as high as is practically possible. The higher the turbine is mounted, the more productive it will be. This is because windspeeds reduce steadily as they approach the ground due to the effect of friction between the airstream and the earth’s surface.
Correct use of Stub Tower Freestanding Towers For small wind turbines such as the D400, free-standing towers can take the form of old telegraph poles, or a self-supporting steel latice tower. It is important to ensure the tower’s foundation is sufficient such that the tower will withstand a horizontal load of 70 kg at the height of the turbine. In order to ensure that an acceptable blade to tower clearance is maintained, a stub tower should be used between the D400 and the free-standing tower.
Assembling the D400 Your D400 is supplied in two cartons. Unpack these and check the parts against the list at the beginning of this manual. Assemble the air rotor by sliding together the keys and mortises at the hub of the five air blades. Take the white, powder-coated hub plate, pass two 5mm bolts and washers through the inner holes, and fit the rotor hub spacer over the 5mm bolt heads. With the body of the wind generator on its back, offer the hub assembly up, and slide it onto the alternator shaft.
Assembling the D400 (continued) Place the turbine face down on its rotor, and attach the tail using the three M6 nuts and bolts provided. Note that the tail should be fitted to the left-hand face of the casting flange when the D400 is viewed from the rear. The large stainless steel washers should also be fitted on the left-hand side. To fit the nose cone, offer up the axial splits in the moulding to the leading edges of the blades while holding the cone square and central over the hub.
Electrical Connections Connecting cables between D400 and the battery bank or inverter should be appropriately sized to minimise transmission losses. For low voltage machines transmission losses are always a consideration, so it is advisable to keep cable runs as short as possible and be prepared to use heavier gauge cable for longer runs.
Stopping the D400 The D400 is a robust machine and can safely be left operating in most windspeeds. However, where extreme storm force winds are forecast, it is prudent to stop the machine and secure the rotor blades with a rope lashing. The D400 can be stopped by gripping the tail and turning the machine out of the wind, securing the blades once they have stopped rotating. Braking Switch: A braking switch can be fitted which provides a convenient aid to stopping the D400.
Electrical Installation Single battery bank installation It is recommended that the D400 is hard wired to the battery system. In yacht installations, the cable should enter the yacht via a cable gland. Deck plugs and sockets should not be used as they represent a shock hazard if they accidentally become disconnected. The D400 should always be connected to a battery when in use, otherwise a dangerously high voltage can be generated at the output cable. *For fuse sizes, see note on page 11.
Electrical Installation Connect the output cable to the battery bank(s) using the suggested wiring diagrams for guidance. Remember to observe the correct polarity. RED to POSITIVE + and BLACK to NEGATIVE – Where a battery monitor is fitted Twin Battery Bank Installation If your electrical system is fitted with a digital battery monitor, it will be driven by a shunt which is typically installed close to the batteries. One side of the shunt is connected directly to a battery terminal.
Performance and expectations The D400 is extremely efficient by design, making it the most powerful and productive wind generator of its rotor size currently available. The D400 should perform in line with, or exceed, the values given in the output graph. When verifying system performance, it is important that wind speed measurements are taken at the same height as the turbine, and that the batteries are at least 40% discharged.
D400 Trouble-shooting – Points to check if you think there’s a problem Mechanical checks: Spin the air blades by hand - they should rotate smoothly and freely with no hard spots. Listen for any grinding, scraping or rumbling noises - these would indicate failed bearings or contact between rotating parts inside the alternator. Note: if the air rotor rotates smoothly and silently, but feels stiff (like turning something in glue), refer to the electrical section on short circuits.
Trouble-shooting continued - Poor Yaw Action: Stiffness in yaw; the D400 will not rotate to face the wind – check for any physical obstructions and the action of the yaw shaft. If the yaw shaft does not rotate freely, suspect damaged or corroded yaw bearings, damaged or corroded slip rings/brush assembly or possibly a bent yaw shaft. Erratic yaw action; the D400 turns off the wind and is unstable – the D400 is normally very stable in yaw.
Undue mechanically transmitted noise or vibration Noise or vibration transmitted down the shaft – suspect a loose air rotor. Grasp an air blade and rock the rotor to check if there is any relative movement between the air rotor and the alternator shaft. If play is felt, remove hub parts and re-build, fitting a new hub liner. Correct fit of nose cone – check that the nose cone is not catching on the alternator housing. Air blade damage – check that the blades are not damaged or chipped.
Routine Maintenance The D400 is robustly engineered and should give years of trouble-free service. Bearing life in normal windspeed conditions is expected to be in excess of 10 years. Shaft seals may benefit from replacement after five years. The yaw bearing brushes should not require replacement during the life of the machine. The alternator itself is hermetically sealed against moisture ingress. Routine maintenance would consist of periodically examining the air blades for signs of damage.
www.eclectic-energy.co.uk DECLARATION OF CONFORMITY We declare that this product complies with the following standards/directives: 89/336/EEC Product description: D400 Alternator Model number: EE400 Serial number: Signed: Eclectic Energy Limited Unit 22 Sherwood Networkcentre Sherwood Energy Village Ollerton Nottinghamshire NG22 9FD +44 (0) 1623 821535 United Kingdom sales@eclectic-energy.co.
D400 Wind Turbine Specifications Performance & Power outputs Turbine features Alternator features Rated power Maxiumum power Rotational speed Cut-in speed Cut-out wind speed Turbine type Number of blades Airfoil type Diameter of turbine Swept area Tip speed ratio Typical noise level Blade material Alternator type Design Voltages available Materials Yaw System EMI (electromagnetic emissons) MCS Accreditation Control system Brake system Passive Mounting Weight Finish Turning circle Typical stub tower
