iSTA i-1500 Wind Turbine System Instruction Manual

iSTA i-1500 Wind Turbine System Instruction Manual

General

About this translation of the original instructions
Revision status of the original instructions

Revision date: 24.07.2018
Revision index: 00

Conditions for installing and operating the wind turbine system Please make sure that

Please make sure that

• The wind turbine system has been erected correctly by a suitably trained person.
• All operating personnel have read and fully understood this translation of the original instructions
• The wind turbine system is properly maintained and repaired.

Availability of the instructions
Keep this translation of the original instructions handy at all times, so that it can be referred to by all persons working on or with the wind turbine system.

Conventions used in this translation of the original instructions
Safety information is always identified by a signal word and in some cases also by a hazard-specific symbol.

DANGER!
Immediate danger!
Non-observance of the safety instructions will result in serious or fatal injury!’

WARNING!
Potentially dangerous situation!
Non-observance of the safety instructions can result in serious or fatal injury!

CAUTION!
Potentially dangerous situation!
Non-observance of the safety instructions can result in minor or moderate injuries!

IMPORTANT!
Potentially dangerous situation!
Non-observance of the safety instructions can result in damage to property or pollution of the environment

Other symbols used
The following symbols are used in this translation of the original instructions as wellc as on the wind turbine system itself:

Warning signs

__| Environmental hazard!

Table 1 Warning sign

Mandatory signs

Table 2 Mandatory signs
Information
Note
Indicates general information and recommendations.

Name and address of the manufacturer and his authorised representative

Table 3 Manufacturer

Table 4 Authorised representative

Warranty and liability
The “General Terms of Sale and Delivery” of the manufacturer or his authorised representative apply.

Product feedback
Please notify the manufacturer or his authorised representative about any of the following

• Accidents
• Potential safety hazards associated with the wind turbine system
• Ambiguities in this translation of the original instructions
• Description of the wind turbine system

 Technical Description

Intended use

• The wind turbine system may only be used as a “small wind turbine system” (SWTS) to generate power in accordance with EN 61400-2.
• The wind turbine system may only be operated in accordance with the ratings and in the approved wind class (refer to the technical data).
• Observance of the original instructions and compliance with the maintenance nd repair instructions are essential preconditions of use for the intended purpose.

Reasonably foreseeable misuse
All forms of use which deviate from or exceed the limits of use described above are  considered to be contrary to the intended purpose. The manufacturer is not liablefor any damage resulting from such use. No liability will be accepted by the manufacturer if the equipment has been altered as well as in the event of improper assembly, installation, start-up, operation, maintenance or repair.

Only original parts supplied by the manufacturer are approved as spare parts or  accessories. Any spare parts or accessories not supplied by the manufacturerhave not been tested for operation and could be detrimental to reliability. No liability will be accepted by the manufacturer for any damages which result from the use of non-approved spare parts or accessories. Reasonably foreseeable misuse includes:

• Operation outside the manufacturer’s specification
• All modifications or changes to the wind turbine system without the manufacturer’s written approval!
• Use of parts other than iSTA Breeze original parts.
• Operation in non-approved SWTS classes.
• Operation in strong winds or hurricanes.\

Main components

Fig. 1: Main components of the wind turbine system

pressed, the wind turbine must be short- circuited.
3| Charge controller(optional)Type : i/HCC 2000| Generates electrical voltage (24 / 48 VDCOptionally). The iSTA Breeze charge controller.
4| Battery (optional)| Stores electrical energy (Acid, Gel)
5| Solar panels (optional)| Convert solar energy into electrical energy
6| To converter (optional)| Converts 24/48 VDC into 110/220       VAC

Recommendation :
Several batteries can be connected in series or series. Depending on which system voltage is used.

Main components of the wind turbine

Fig. 2: Main components of the wind turbine

Technical Data

Generator
Type| Permanent magnet rotor, brushless, gearless, maintenance- free
Weight [kg]| 25| 28
Max. power| 24V 55A48V 25A| 48V 40A
Open circuit voltage [VAC]| [24V] 0 – 80[48V] 0 – 148| [48V] 0 – 143
Current| 3-phase-AC
Start of charging| Approx. 3 m/s (wind speed)
Housing material| Aluminium
Direction of rotation| Any
Test standard| EN 61000-6-1 (electromagnetic compatibility – susceptibility)
EN 61000-6-3 (electromagnetic compatibility – emissions)
Rotor blades
Hub flange| Cast Steel
Diameter, approx. [m]| 2.20
Rotor Blades| 3 pieces of plastic with glass fiber mixture
Approx. weight perrotor blade [g]| 690| 720
Blade Color| Black or White
Direction of Rotation| from the front in a clockwise direction
Max. Speed [rpm]| 1000
Noise emissions [dB(A)]| 60

Table 7 Technical dat

Charge Controller

The Wind / Solar Hybrid Charge Controller from IstaBreeze® is an intelligent controller of the wind turbine and solar cells that controls you at the same time. The high-end device can also be used as a monitoring system. It is used to safely and efficiently charge and control your battery with the Wind Generator / Solar Module combination

With its discreet appearance, simple operation, with integrated protection functions, this device has high efficiency and low no-load losses. This version of the controller will significantly increase the life and stability of the whole system, especially the batteries. In addition, the control electronics in the control cabinet monitors the system voltage and brakes the wind turbine when a max. Overvoltage. The special features and product information are listed below:

Use of external and high quality (Triacs & Hyper Mosfet), solid state components. Increasing the life of the controller

Microprocessor controlled charge with integrated voltage and current limiting. Electromagnetic brake control. Integrated 3-phase short circuit breakers (brake switch)

Protection against lightning strikes. Protection against overcharging, deep discharge, short circuit, overload and against incorrect reverse polarity. Integrated display. The generator is automatically braked gently when the battery is full, modern braking system with external load resistance (Dump Load) to avoid the immediate blocking of the turbine. Increasing the life of the stator.

Specifications of Charge Controller

Charge Controller 1/HCC-1500/2000

Amper, Watt, RPM, Battery Voltage, Volt, Temperature
Charging Voltage| 52,8V| 25,2V
Charging current wind amperes max| 33A| 55A
Charging current PV Ampere max| 10A| 10A
Integrated manual stop switch| Maintenance| Maintenance
Battery voltage minimum| 42V| 17,5V
Brake function( electromagnetic short circuit, Wind Turbine| From 59,4V| From 29,6V
Cooling| External aluminum cooling fins| External aluminum cooling fins
Cable termination| likimm screw terminals| 10qmm screw terminals
Protection class| IP 20 (inside area)| IP 20 (inside area)
Dump load| 2 KW Braking resistor ( 4 Ohms)
The load resistance can deviate from the picture| 1,5 KW Braking resistor ( 2 Ohms)
The load resistance can deviate from the picture
Operating temperature| Normal:20″455°C/35″85%11H
Industrial: 30–+55°C/35″85%RH| Normal:20–455°05–85%M
Industrial: 3r+55.035–85%RH
Temperature compensation| 41m1PCPV, -35 °C– 480°C, Accuracy 4- 1°C| -4mV’CPV, -35°C– 480t, Accuracy 4- VC
Size| 300x400x200 mm| 300x400x200 mm
Weight| 6,5 kg| 7 kg
Recommended Battery Min.| Acid & Gel| Acid & Gel

Permissible operating and storage conditions

• Storage
• Ambient temperature: -15 to +40°C
• Storage location: Dry, frost-free
• Operation
• Ambient temperature: -25 to +40°C
• Place of use: Max. SWTS Class III acc. to EN 61400-2

Safety Information

Modifications or changes by the user
The wind turbine system is in conformity with the European Machinery Directive 2006/42/EC provided only original iSTA Breeze components are used and subjectto proper erection. The use of components from other manufacturers as well as modifications or changes to the wind turbine system by the user are prohibited and could render the declaration of conformity invalid!

Residual risks
Any residual risks which arise as a result of operation or maintenance are described in the relevant sections of these instructions.

Personnel requirements
All work on the wind turbine system must be carried out by authorised persons! Such persons must be familiar with the safety devices and regulations prior to carrying out the work.

Authorised persons are defined as follows:

Preparing to use the System

Shipping

As-delivered condition
The wind turbine system is shipped disassembled.

Scope of supply
Refer to the contract documentation for the scope of supply.

Requirements at the place of use
Permissible wind class, footprint and minimum clearances

WARNING!
Danger to life due to operation in non-approved wind classes!

• The wind turbine system may only be operated at Class III wind sites.

For information on local wind classes, please contact the responsible authorities or your nearest meteorological office.

Fig. 3: Footprint and minimum clearances

The place of use must be free of obstacles; alternatively, the wind turbine must be erected with a sufficient height (refer to Fig. 3:). Obstacles are defined as houses, hedges, trees, hills, etc.

**** When choosing the place of use, make sure adequate room is available to tilt the tower and blades if necessary.

Tower foundation

Unpacking the components

• Carefully open the packaging.
• Check the shipment for completeness (refer to the shipping documents).
• Separate the packaging material and dispose of it in an environmentally responsible way.

Assembling the wind turbine

WARNING!

Danger due to rotor imbalance!

• Always replace the complete set of rotor blades.

Risk of injury in case of assembly at windy sites!

• Choose an assembly site which is sheltered from the wind.
• The assembly process requires calm weather conditions

Fig. 6: Assembling the wind turbine

• For installation, select sheltered place.Hold propeller blade (1) with flat side to hub (2).
• Fasten with a M8x45 bolt, nut and one.
• Screw on further M8x45 screws and tighten by hand.
• Attach boom rod (3) with M8x60 bolt to alternator housing.
• Screw nose (4) to hub with M8x75 screw.
• Screw wind vane (5) to boom with M8x60 bolt. Plug – in pin 37 mm as mast connection

Fig. 7: Balancing the rotor (Y position)

• Move rotor to Y position (see Fig. 7)
• Carefully release rotor blade.
• Observe in which direction the rotor turns (the heavier rotor blade pushes downwards).
• Repeat the process for all three positions to determine which rotor blade is in imbalance.
• Check repeller for balance
• Tighten all screws to 25 Nm.
• Check balance again.
• Secure all screws with locking varnish

Note: The repellers have already been tested for equal weight by the manufacture

Electrical connection

DANGER!

Danger: High voltage!

• All work on electrical equipment must be carried out by a qualified electrician with the power switched off

Note: To ensure proper operation, you must use an original iSTA Breeze charge controller.

• Connect a three-wire cable with a suitable cross-section (refer to Table 9 / Table 10) and the required length to the generator.
• Make the electrical connections as shown in Fig. 1:.
• Connect the charge controller and the transformer as shown in the connection diagram (refer to the relevant documentation)

Distance betweengenerator and charge controller [m]| < 11| 11 – 18| 18 – 29| 20 – 44| 44 – 68| 68 – 110
---|---|---|---|---|---|---
Cable cross-section [mm²]| 2.5| 4| 6| 10| 16| 25

Table 9 Cable cross-section with 24 V generator voltage

Distance between generator and chargecontroller [m]| < 11| 11 – 18| 18 – 29| 20 – 44| 44 – 70| 68 – 113
---|---|---|---|---|---|---
Cable cross-section [mm²]| 2.5| 4| 6| 10| 16| 25

Table 10Cable cross-section with 48 V generator voltage

• Feed the three-wire cable through the tower right up to the top.

• Provide suitable strain relief.

• Connect the wires to the generator.
  
  Fig. 8 : Connecting the three-wire cable to the generato

• Short circuit all 3 phases to activate the generator brake.

• Pull a suitable shrink tube over each wire of the cable.

• Pull a suitable shrink tube over each wire of the cable.

• Pull heat shrink tubing over the solder joint and shrink.

• Wrap each wire with textile insulating tape

Erecting the wind turbine

WARNING!

Danger due to unsuitable tower constructions!

• Only use tested mast constructions or original iSTA Breeze masts.

• Choose a mast diameter <70 mm, so that the rotor blades are not pressed against the mast during a storm.

• Attach the wind turbine to the tower. Be careful not to damage the cable.

• Screw wind generator to mast.

• Erect the mast.

• Align the mast vertically in all directions.

• Brace the vertical mast (see Fig. 5)

• Kurzschluss aufheben.

Normal Operation

**** For information on operating the iSTA Breeze charge controller, refer to the separate instructions.

Switching on the wind turbine system

• Unlock the emergency stop button or release the brake button on the iSTA Breeze charge controller
• The brake is released.
• The fast-blinking red LED on the iSTA Breeze charge controller goes out.
• The wind turbine system supplies power.

Restart after an emergency

• Make sure the risk has been removed.
• Switch on the wind turbine system ( section 7.1)

Shutting down the Wind Turbine System –

Emergency shut-down

• Press the emergency stop button between the wind turbine and the charge controller.
• The wind turbine is short-circuited via the iSTA Breeze charge controller.
• The wind turbine is braked

Temporary shut-down

• Press the “Charge controller OFF” button on the iSTA Breeze charge controller.
• Operation is interrupted

Prolonged shut-down

• Press the “Charge controller brake OFF” button on the iSTA Breeze charge controller.
• The wind turbine is short-circuited via the iSTA Breeze charge controller.
• The wind turbine is braked.
• Carefully tilt the wind turbine.
• Clean the wind turbine ( section 9.3)

Maintenance

Safety precautions during maintenance work

WARNING!

Risk of injury when carrying out maintenance work!

• Shut down the wind turbine system prior to all maintenance work.
• Take steps to prevent the wind turbine system from being switched on again by unauthorised persons.
• Shut down the wind turbine system ( section 8.2).
• Carefully tilt the tower

Inspection and maintenance schedule

• Check for abnormal noises

Rotor blades|

• Check that the blades turn freely

Tower|

• Inspect for damage

Yearly2 / atend of winteror afterextremeweatherevents| **** Rotor blades|

• Inspect for cracks / damage and
• if necessary replace
• Treat with underbody protection wax
• Are the rotor blades balanced?

Tower|

• Check for vibration
• Check the guy wiresIs the tower still aligned vertically?
• Inspect for damage

Wind turbine|

• Check the bolts

Electrical wiring|

• Inspect the cables for damage

Table 11Inspection and maintenance schedule
WARNING!
Danger due to damaged parts!

•  Shut down the wind turbine system immediately if the rotor blades or the electrical wiring are damaged.

Refer to the supplementary documents for information on maintaining supplier components.

Maintenance and cleaning by the user

• Coat the wind turbine and the rotor blades regularly with commercially available underbody protection wax using a soft cloth

**** A wax film protects the surfaces of the wind turbine and the rotor blades from the weather and increases the efficiency of the blades

Troubleshooting and Diagnostics

Errors with LED

manufacturer
Unfavourable location or tower too low| ▶ ▶| Check and move to another location if necessaryIncrease the height of the tower
**** Wind turbine vibrates on tower| Rotor not balanced| ▶| Balance the rotor
Tower not aligned vertically| ▶| Align the tower vertically
Tower bends in the wind| ▶| Design a more robust tower
Tower foundation has too much clearance| ▶| Reduce the clearance to a minimum
**** Wind turbine system produces too little power| Wind turbine or charge controller defective| ▶| Contact the manufacturer or a specialist dealer
Battery defective| ▶| Replace the battery
Battery too small| ▶| Use a larger battery (at least 100 Ah)
**** Battery fuse tripped| ▶▶| Replace the fuse Check the electricalconnections
Cable cross-section does not match installed cable length| ▶| Match the cable cross- section correctly

Table 12Errors without an LED Recommendation:
Make a note of the relevant parameters at the site and have them handy   when you contact the manufacturer / specialist dealer.

1. What is the average / typical wind speed?
2. How high is the tower?
3. What are the characteristics of the countryside / built-up area in the vicinity of the wind turbine?
4. What is the voltage between phases (measured by a qualified electrician – this voltage should be roughly identical in identical wind conditions)?
5. What is the battery voltage? How old is the battery or batteries?
6. Which loads are connected to the battery?
7. Are solar panels also connected to the charge controller? If so:
   a. What is the no-load voltage3 [VDC]?
   b. What is the power [Wp]?

Removal from Service and Disposa

Final decommissioning of the wind turbine system

WARNING

Risk of injury due to unqualified dismantling, e.g.

• Persons without suitable training
• Stored energy
• Breakage during dismantling

Important note on dismantling and disposal:

• The system must be dismantled in the proper way by a suitably qualified person.
• Shut down the wind turbine system ( section 8).
• Have the electrical systems and equipment removed from service by a qualified electrician.
• Make sure all rotors are braked.
• Carefully tilt the tower.
• On the ground: Detach the rotor blades from the generator.
• Detach the generator from the tower and disconnect the electrical wiring.

Disposal of the wind turbine system and components

Where necessary, dispose of the individual components in consultation with the responsible local authorities.

Wind turbine system

Wiring, electrical components| Dispose of as electronic scrap
Mechanical components| Segregate prior to disposal

Table 13Disposal’

Declaration of Conformity –

Fig. 9. Declaration of conformity

A Adapter stud : 8
B Battery: 7, 10, 20, 21
C Cable cross-section : 16, 20 Charge controller :, 10, 11, 16, 17,18,20,21
F  Foundation: 14, 20
L Load : 10, 14, 21
M Main: components7, 8
P   Place of use: 12, 13
R Rotor blade: 8, 9, 15, 16, 17,19,20, 22
S Strain relief: 17
T Tail vane: 8 Transformer:16
W Wind: classes 13

Performance Charts

Certificates

Suitable Battery Capacities

SUITABLE BATTERY CAPACITIES

The minimum battery values in the table are suitable for Turbine uses only.
Maximum battery values are for hybrid (turbine + solar) systems.
Also, in hybrid systems, wind turbine and solar panel should be used at equal capacities.
Example: 1kw 24v turbine + 1kw 24v solar = 2 200 Ah battery
Example: 2kw 48v turbine + 2kw 48v solar = 4 200 Ah battery

References

• Altınel Enerji - IstaBreeze® Wind Turbines
• Istabreeze.store Versandhandel für Kleinwindkraftanlagen und Zubehör – Fast Trading LTD

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