User manual SOUTHWEST WINDPOWER WHISPER 200 REV C

[. . . ] Southwest Windpower, Inc. Renewable Energy Made Simple Owners Manual Installation, Operation and Maintenance WHISPER WIND GENERATORS MODEL Whisper 200 For the *NEW* Whisper Controller Southwest Windpower, Inc. 1801 West Route 66 Flagstaff, Arizona 86001 Phone: (928)-779-9463 Fax: (928)-779-1485 Email: info@windenergy. com Web page: http://www. windenergy. com © January 2005 Southwest Windpower , Inc All Right Reserved WIND GENERATOR SERIAL NUMBER ________________ Whisper 200 Owners Manual 3-CMLT-1033-02 REV C Southwest Windpower, Inc. Renewable Energy Made Simple Owners Manual Installation, Operation and Maintenance WHISPER WIND GENERATORS MODEL 200 For the *NEW* Whisper Controller Southwest Windpower, Inc. 1801 W Route 66 Flagstaff, Arizona 86001 Phone: (928)-779-9463 Fax: (928)-779-1485 Email: info@windenergy. com Web page: http://www. windenergy. com © January 2005 Southwest Windpower , Inc All Right Reserved WIND GENERATOR SERIAL NUMBER ________________ SOUTHWEST WINDPOWER 06/17/2010 1 Whisper 200 Owners Manual Table of Contents 3-CMLT-1033-02 REV C Table of Contents INTRODUCTION 1. MECHANICAL REPAIR AND REPLACEMENT 3 7 7 8 10 11 12 13 13 15 16 17 18 23 24 26 31 FOLLOW STEP-BY-STEP INSTALLATION LOOK FOR THE SHADED BOXES AND FOLLOW THE STEPS IN ORDER. CHECK THE PROVIDED BOX WHEN COMPLETE. SUGGESTED TOOLS AND EQUIPMENT YOU WILL NEED Round or Half Round File Carpenters Level (optional) Torque Wrench w/ 9/16" socket Blue Loctite 242 Sawhorse Electrical Wire (see p. 6) Wire Connectors (preferably copper split bolts) Pipe Insulation (to prevent wire "rattle" inside pole) 3/8" Drill Motor SOUTHWEST WINDPOWER Pliers Metric Wrenches and Sockets Large Adjustable Wrench Tubing or Pipe for Tower Hex Wrenches (metric and standard) Ground Rod and Clamp Soldering Iron and Solder Electrical tape 3/8" or 10mm Metal Cutting Drill Bit 6/17/2010 2 Whisper 200 Owners Manual Introduction 3-CMLT-1033-02 REV C WELCOME TO YOUR RENEWABLE ENERGY SYSTEM! ELECTRICITY FROM THE WIND AND SUN: Renewable electric power systems provide independent (no utility grid!) electric power for boats, homeowners, farms, villages and commercial applications such as telecommunications. [. . . ] If necessary, knock out one of the sheet metal plugs in the Whisper Controller base unit and route the ethernet cable inside the unit. Plug the ethernet cable into the jack in the lower right corner of the controller board. Display Function Verification Once the display is plugged into the controller base and the batteries are connected to the controller there should be text displayed on the LCD display. If the display is blank there is a contrast adjusting potentiometer that can be adjusted to brighten the display. Insert a bladed screwdriver into the hole on the display between the buttons and the LEDs. If a display is still not visible disconnect and reconnect the cable to the display to reset the display. Once display function is verified re-install the electronics cover on the controller base. The system wiring is now complete. Proceed to assembling the turbine and mounting blades to rotor. SOUTHWEST WINDPOWER 06/17/2010 15 15 Whisper 200 Operators Manual Installation 3-CMLT-1033-02 REV C 10. F or maximum i mpact, us e two or thr ee sentences. 5 4 6 9 8 Item Number 1 2 3 4 5 6 7 8 9 Description Assembled Generator Tail Stalk Tail Fin Hex Bolts, M8 x 55 Nylon Washer, M8 X 31 SSTL Washer, M8 x 24 Nylock Nut, M8 Hex Bolt, M8 x 25 Hex Bolt, M8 x 70 Quantity 1 1 1 2 2 2 4 1 1 SOUTHWEST WINDPOWER 06/17/2010 16 Whisper 200 Operator's Manual Installation 3-CMLT-1033-02 REV C 11. Apply Loctite 242 (provided) to one (M10 x 40 bolt, item #3) and along with a flat washer (item # 5) bolt a Blade Extension (#1) to the rotor using only the one bolt nearest the center of rotor . Insure the remaining Blade Extension bolt-hole lines up with the rotor by loosely inserting a bolt in the outer hole. Tighten the inner bolt to 18 Ft-lbs (24 Nm) torque and repeat the process for each Blade Extension. Apply Loctite 242 to an (M10 x 40 bolt, item #3) and along with a flat washer (item #5) install the bolt through the nose cone and into the "outer" bolt hole of the rotor. Tighten the bolt to 18 Ftlbs (24 Nm) torque and repeat for the other two bolts. Install blade (#6), rounded edge advancing clock-wise, on Extension (#1) using cut washer (#10) on outside mounting bolt. Using bolts (#11), Washers (#9 and #10), and Nuts (#7), tighten all bolts to 18 Ft-lbs (24Nm) torque. 10 6 11 7 9 1 3 WHISPER 200 Blade Installation 5 Apply Loctite 242 to these bolts (item #3) 4 3 Item 1 3 4 5 6 7 9 10 11 Description SS Blade Extension SS Hex Bolt M10 x 40 Nose Cone SS Flat Washer M10 x 20 (Thin) Blade SS Nylock Nut M10 SS Flat Washer M10 x 30 (Thick) SS Shaved Flat Washer M10 x 30 SS Hex Bolt, M10 x 50 Quantity 3 6 1 6 3 6 3 3 6 Important Assembly Note ! Each turbine blade has a dot of paint on the "front " of the blade between the blade mounting holes. The blades should be bolted to the "front" of the blade extensions (item 1) as shown in the above figure so that the paint dot is VISIBLE after the blades are mounted. SOUTHWEST WINDPOWER 06/17/2010 17 Whisper 200 Operators Manual Normal Operation--Whisper Controller 3-CMLT-1033-02 REV C 12. Normal Operation ­ Whisper Controller Overview The Whisper Controller is a one or two part system specifically designed to control the operation and convert the power of a Southwest Windpower Whisper 100 or 200. Its basic functions are rectification, regulation, and resistive power dumping. However, to best accommodate many individual customers, the Whisper Controller offers many features and adjustable operation parameters. The main Whisper Controller block (hereafter the "Controller") is a functionally autonomous unit. [. . . ] Check in order: Check the tower wiring and Whisper Controller connections to insure proper wiring. If the wiring is correct contact authorized distributor or factory for further assistance. Voltage significantly higher across two wires than the others = Contact the distributor or the factory, possibly a shorted diode. Voltage significantly lower across two wires than the others = Bad connection at wind turbine voltage connections or faulty stator winding. [. . . ]