Manual for FD5KW Wind Turbine Generator

• Overview

Model FD5KW provide independent electric power for homeowners, farms, villages and commercial applications such as telecommunications. FD5KW consists of a 6.4 meter , 200 kilogram wind turbine rated at 5,000 watts, a tilt-up tower of 12 meter high, a multi-function turbine and system controller and a sine wave inverter. The user supplies the battery.

Model FD5KW wind turbine features superior low wind-speed performance, very high system efficiency, and low noise.

Model FD5KW provides high wind protection and batteries overcharge protection. During periods of high wind speeds, the anemometer detects it and send a message to the micro processor inside the controller which instruct the dogvane on the turbine and a DC motor against the turbine yawing. The rotor will turn over to the side, away from the wind , thus reducing the power output significantly. When batteries bank is full and there is little load, the micro processor will instruct the rotor to turn away from the wind too and stop the output of the turbine.

• System Description

Wind Turbine Components

The major components of the FD5KW wind turbine are shown in Figure 1.

Blades/Rotor System

The rotor system consists of three fiberglass blades. Acting like aircraft wings, the blades convert the energy of the wind into rotation forces that can drive a generator. The rotor has three blades because three blades will run much smoother than rotors with two blades. The dogvane on the turbine can, together with the micro processor in the controller, push the rotor over to the side, away from the wind.

• Alternator

The alternator converts the rotational energy of the rotor into electricity. The alternator utilized permanent magnets and produce three phase AC electric power. The internal windings and central shaft rotate, while the outside housing are stationary. The alternator was specially designed for the FD5KW and produces power at low speeds of 2m/second only., eliminating the need for a speed increasing gearbox.

The output from the alternator is three-phase alternating current(AC), but it is rectified to direct current by the charge controller. Since it uses permanent magnets, the alternator is generating voltage whenever the rotor is turning.

• Nacelle

The nacelle is the steel housing around the main body of the machine. It contains the main structural backbone of the turbine(called the mainframe), the slip-ring assembly, the yaw bearings and the tower mount. The yaw bearings allow the wind turbine to freely pivot around the top of the tower so that the rotor will face into the wind.

The slip-ring assembly is the electrical connection between the moving(as it orients with the wind direction) wind turbine and the fixed tower wiring. The slip-rings and yaw bearings are located just above the tower mount. The tower mount attaches the FD5KW to the top of the tower.

• High wind protection system

The high wind protection system, composed of a dogvane, anemometer and a micro processor which is inside the controller box. The dogvane is mounted on the nacelle(Figure 25), while the anemometer can be mounted on the building roof or anywhere high above the ground ( Figure 33 ) . During periods of high wind speeds(wind speed over 25 m/s), the anemometer detects it and send a message to the micro processor inside the controller which instruct the dogvane on the turbine and a DC motor against the turbine yawing. The rotor will turn over to the side, away from the wind , thus reducing the power output significantly. The rotor is kept facing into the wind at speeds up to 25 m/s, therefore the rotor will rotate again once the wind speed falls down 25 m/s.

• Charge Controller

The charge controller, shown in Figure 3 and Figure 4, has a rectifier module which rectify the three phase AC power from the turbine into DC power, proving power for batteries bank and house applications. The built-in micro processor is a important part of the high wind protection system and batteries bank protection system.

Figure 3

Figure 4

• Batteries overcharge protection system

The FD5KW provides a batteries bank protection. When batteries are full and there is no load, the micro processor will take in the information and instruct the rotor to turn away from the wind and stop the output of the turbine, thus prevents the wind turbine from operating without load once the batteries are full.

D. Tower kit

The FD5KW wind turbine generator system includes a 12 meter high guyed lattice towers.

• SYSTEM OPERATION
• Normal Operation

The rotor of the FD5KW should begin to rotate when the wind speed reaches approximately 2.5 m/s. Battery charging should commence shortly after the rotor spins up to speed. Once turning, the rotor will continue to turn in lower wind speeds, down to approximately 2 m/s. The rotor speed will increase with increasing wind speed and the system will provide a higher output. This output increases rapidly because the energy available in the wind varies as the third power(cube) of the wind speed. For example, if the wind speed doubles from 5 m/s to 10 m/s, the energy in the wind increases by a factor of eight(2 3=2 x 2 x 2 = 8). One result of this relationship is that there is very little energy available in light winds. For the average site, winds in the range of 5.5 – 9 m/s will provide most of the system annual energy production.

• Charge Controller

The basic electrical schematic for the FD5KW is shown in Figure 5.

The controller contains all of the wind turbine’s power electronics including rectification. Additionally, it continuously monitors voltage, current, energy production, and wind speed.

The alternator produces three-phase alternating currency(AC) that varies in voltage and frequency with the rotor speed. The AC power is rectified to direct current(DC) power by a rectifier module inside the controller.

The internal regulator inside the controller will monitor the batteries charging. When the batteries are full, the regulator will instruct the DC motor to turn the wind turbine off the wind. There will be not power output from the turbine and thus stopping charging.

The rotor can be stopped under most wind conditions using the electrical stopping function in the controller. You might use this function, for example, before lowering or climbing the tower. To initiate stopping simply turn to “OFF” position. The turbine shall stop gradually.

4. Tower Installation

Tower Kit Part List

Part name Quantity

------------------------------- -------------

Assembled Generator      1 set

Blade                              3 pc

Blade fasten plate            3 pc

Blade bolts and nuts      18 set

Hub                               1 pc

Nose Cone                    1 pc

Dogvane                         1pc

Anemometer                   1 pc

Anemometer supporting bar 1 pc

Charger controller with micro processor 1 set

Power inverter                 1 set

Tower base                    1 piece

Guy wires                         7 sets

Wire clamp                    24 pieces

Turnbuckle                      4 pieces

Long steel rod                  4 pieces

Forged anchor                 4 pieces

Guide anchor                    4pieces

Tower pipe                       3 x 4 meters

Bolts and nuts for tower pipe 24 set

Gin pole                            2 x 3 meters

Step 3: Tower, Base and Anchor Layout

This tower kit must only be erected on a calm day(no wind). The tower base and anchors should be laid out as described in Figure 6 and Figure 18. The tower will be assembled laying on the ground and then tilted up into position.

CAUTION!

NEVER INSTALL A TOWER WHERE IT COULD CONTACT POWER LINES IN ANY DIRECTION. DANGER OF LETHAL SHOCK! CONTACT WITH OVERHEAD POWER LINES WILL CAUSE INSTANT ELECTROCUTION

Determine Location for Tower Base

Select a location for the tower base, and determine the direction in which the tower will lower and raise. If you will be using a vehicle to raise the tower, clear a path for the lift line from the lift anchor to the vehicle. A swivel pulley will be installed at the lift anchor, between the tower base and the vehicle. Mark the ground locations for the base and anchors.

This tower kit is designed for installation on a flat surface. If you have a location that is on an incline or side of a hill you will need to have a local certified engineer review your installation. The design of this tower requires the gin pole(lift pipe) to rest on the eyebolt/anchor. If the gin pole was not supported from the ground it would cause unnecessary stressed and could force the tower to buckle. In addition, on an incline, your upper anchor should be installed on a dugout in order to make sure enough dirt is actually supporting the stresses of the anchor. If you are unsure of your design, and before you begin your project on a hill, we recommend you contact us.

When your tower is being installed on an incline you must make sure that the side anchors and base anchor are level. The front and back anchors must be directly up and down slope with the gin pole on the downhill section. This will help raise the tower since the turbine will be resting uphill. Make sure the anchor points and base anchor are in line when sighted from anchor to anchor. This will ensure the forces on the guy wires are balanced properly.

Step 4: Tower Base & Guy Anchor Assembly

1. Dig a hole for the base anchor. The hole should be at least 150cm in diameter and 150 cm in deep.

2. Fasten the 4 long steel rods (included in this kit) to the base (see Figure 7) to form a base anchor unit.

3. Put the base anchor unit to the hole and pour in concrete around it(Figure 8,9,10,11).

4. Make sure the base is at the center of the hole and let concrete cure for 28 days.

5. Dig four holes for guy wire anchors. The hole should be 70cm in diameter and 100cm in depth. Insert a forged anchor through the end of each anchor (see Figure 12). Cast it into hole and pour concrete around it. Let the concrete set for 28 days.

Note: The base anchor should be 6 inches above ground level. The four guy wire anchors should be 4 inches above ground level.

Step 5: Assembly of Pipe sections

Assemble the 4 sections of tower pipes by flange.

Assemble the two sections of gin pole by flange

Bolt tower to tower base. Figure 13, 14.

Insert the gin pole into the hole at the bottom of the tower Figure 15

Raise the turbine end of the tower pipe and set it on a saw horse or other supporting object.

Step 5: Attaching Guy Wires

Now that the pipe sections are assembled you are ready to install the guy wires.

Install a shackle to each of the two side anchor eyebolts and to the backside anchor eyebolt.

Install one turnbuckle to each of these shackles. Install one turnbuckles to the gin pole tab. Figure 21.

Cut the steel cable into the proper lengths for the guy cables. The following table indicates the individual cable lengths that are necessary for this tower.

Note: You should have 20 feet of cable left over after cutting the guy cables. This last piece of cable should be cut into four 5’ sections. These cable lengths will be used as backup security loops after the tower is erected and the guy cables are properly tensioned.

Attach the side anchor guy wires to the gin pole as shown .

Attach a thimble to the tab on the gin pole and also to the side anchor eyebolt. Note that the left and right guy wire for the gin pole are connected directly to the eyebolts and do not connect to the turnbuckles.

Attach guy cables to the two side anchors.

You should have around five feet of cable on each end to make the connections with the cable clamps. Be sure that the forged side of the cable clamp is used on the cable that is under load.

Attach backside guy cable from the tower pipe to the backside anchor. This guy cable will prevent the tower from rotating past vertical when the tower is erected. It is very important that this cable is secured to the tower pipe before you try to raise the tower.

Attach guy cable from the tower pipe to the gin pole. One end of the cable should attach to the turnbuckle attached to the gin pole (see Figure 15)

Attach one end of the tower lift line to the gin pole and attach the other end to the bumper on the vehicle or a winch.

Step 6: Turbine Installation

• Run the turbine wires and the dogvane wire through the tower pipe.
• Install the turbine to the tower pipe by flanges (figure 22 and Figure 32)
• Install the hub and fasten it with nut and washer(Figure 24).
• Install the dogvane. WARNING! All 5 screws must be fastened to avoid wrong mounting. Figure 25.
• Install the blade and then nose cone(Figure 23).
• Install the anemometer on the roof, vertical to the ground. Connect it by a wire with the controller(Figure 33). WARNING! The anemometer must be amounted high on the roof, otherwise the wind turbine can not work and would probably be damaged after some time

Step 7: Raising the Tower

Important Note - Since you are about to lift the complete tower, we want to double check the procedure to make sure it is safe to continue. The following must be completed before proceeding with the following section:

• Tower pipe and gin pole must be connected to the tower base. Figure 20.
• All sections of tower pipe and gin pole must be fitted together
• All side guy cables for the tower and gin pole are connected to the side anchors. The cables should be properly tensioned so only minor modifications with the turnbuckles will be required after the tower is raised. Figure 20.
• The guy cables on the backside of the tower are connected to the anchor. The cable length should be similar to the cable lengths for the side anchors so that the tower pipe does not tilt past vertical during the tower erection.
• The tower lift line is connected to the winch or the vehicle. Figure 29.
• All guy connections and bolts must be re-checked.

• Pull on the tower lift line until the tension in the guy cables just begins to lift the tower pipe off the ground.
• Stop the vehicle and check that the gin pole and tower pipe are at a 90 0 angle.

The tension in the upper and lower cables should be equal. If the two pipes are not at a 90 0 angle or if the cables do not have equalized tension, then lower the gin pole just enough to be able to make adjustments in the cable length on the tower pipe.

• Now you should be ready to erect the tower pipe for the first time. Do not raise the tower with a turbine on top until you have raised and lowered the tower several times without a turbine. It will be easier to make adjustments to the tower if there is not a turbine on the tower pipe. Also, it is important to learn how to smoothly raise and lower the tower before you try to do this with your new wind turbine.

CAUTION: NEVER STAND NEAR OR UNDER TOWER, GUYS, OR GIN POLE WHEN RAISING OR LOWERING TOWER

Raise tower slowly – carefully observing the tension in the side guys. Figure 29

If the Side guys become taut, stop lifting and lower the tower and loosen the side guys

that are too tight. Raise tower until nearly vertical but with tension still on lift

cable. A second person or the driver can now catch the lift pole and lower it gently

to the ground. Allowing the lift pole to crash to the ground puts a serious strain on

the back guys and other tower components. At the end of this step, the tower should

be vertical.

• Check that the length of cable on the backside guy cables is not too slack or too taut. Minor adjustments can be made with the turnbuckles, but major adjustments should be made by lowering the tower and adjusting the length of cable through the cable clamps. Also, check that the cable length on the side guys is correct. Be sure to lower the tower if any adjustments need to be made.
• Fasten the lift pole to the anchor. Guy wires should be just tight enough to eliminate sag
• After the tower pipe is vertical and the guy cables are properly tensioned, practice lowering and raising the tower several times without the turbine installed.
• Once you are comfortable lowering and raising your tower, it is time to install the turbine. Lower the tower pipe so the end is resting on a support stand near the top guy cables (see figure 14). This stand should hold the end of the tower pipe approximately 3 to 4 feet off the ground. You may need several wood blocks of different heights to support the tower.

Install the turbine to the top of the tower by following the instructions in STEP 6. The electrical wires for the wind turbine should be installed inside the tower pipe. Double check the rotor blades. The ends of the electrical wires from the wind turbine should be shorted to prevent the turbine from spinning while raising the tower.

• Connect the tower to ground. You need to install a ground rod and using a AWG # 10 solid copper wire or bigger connecting the tower to the rod. Consult your local building code for proper grounding of metal structures.
• After the turbine is installed, raise the tower following the same procedure as above.
• Secure the gin pole to the anchor and make any final adjustments to the tension in the guy cables with the turnbuckles..
• Congratulations! –You are now ready to begin harnessing power from the wind.

• Charge Controller Installation

The general electrical configuration for FD5KW is shown in Figure 33. In most cases the loads will be AC(alternating current) and they will be supplied through a DC-to-AC inverter.

The charge controller must be installed indoors and should be located relatively close the battery bank. Do not install the charge controller outdoors; it is not waterproof.

Step 1.

Connect battery leads. First run wire from the battery negative(-) to the controller panel battery terminal marked (-). Touch the positive terminal (red color) with battery positive wire and withdraw quickly. If a big spark takes place, the connections are reversed. Double check everything to find the cause. Run the battery positive wire to the terminal of red color on the panel after checking.

The maximum current to the batteries will be ~25 amps. Wiring to the batteries must be sized accordingly(minimum 10mm 2). The connection wire between the batteries and the controller should be short than 3 meters. WARNING! The user must connect batteries to the wind generator system. Without batteries, the wind turbine will not turn and may be damaged after some time! Minimum batteries required:

20 pieces of 12V/200AH normal batteries.

Step 2.

Connect the three wind turbine leads to the three terminals on the controller panel. The three wires are interchangeable and are not labeled. Any leads can go to any terminal. The turbine leads should still be shorted from the turbine installation. In order to make the connections to the controller a small wire can connected to allow the turbine wires to remain shorted until the wires are fully connected to the controller.

Once all turbine leads are connected, remove the shorting wire. If there is sufficient wind then the turbine will begin turning and the turbine LED will begin blinking, indicating that the turbine is charging the battery.

Connect the dogvane leads to the terminal marked ‘wind direction”. Connect the anemometer leads to the terminal marked ‘wind speed’.

Step 3.

Connect inverter. If the system includes a DC to AC inverter, connect the inverter input leads to the battery terminals, not to the charge controller. The controller circuit board is not designed to handle the high currents that are possible with inverters. Make sure that there is a fuse between the batteries and the inverter.

Step 4.

Press on the button “ON” and “AUTO” (both lights on) and the FD5KW begin working merrily. When the wind speed exceeds the limit(set up by user beforehand), the rotor will turn off the wind direction and stop automatically. When the batteries are full and there is little load the wind rotor turn off the wind direction and stop running.

If you want to stop the wind turbine, press button “OFF”(“AUTO” and “OFF” light on). The turbine will stop gradually.

The LCD will show the batteries voltage, battery charging current and wind speed.

• Batteries Bank

You should buy 20 pieces of 12V/150AH batteries to connect to the FD5KW wind turbine generator system.

Specification: