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User Manual - Leading Edge Turbines

1. Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 16 of 18 Leading Edge Maintenance Please follow the preventive maintenance program listed below This will ensure that the Guyed Tower operates safely Always shut down the turbine before attempting to carry out maintenance on any part of the system Monthly Checks e Ensure that all foundations and earth anchors are sound and secure e Check that the tower pivot pin is secure and has not worked loose Adjust if required e Ensure that all guy wire rigging fixings are secure and have not worked loose e Check guy wire tension Adjust if necessary e Ensure that the tower is vertical Adjust if necessary Spares The following components may need to be replaced during the service life of your Guyed Tower Please contact your nearest Leading Edge Turbines Ltd Dealer and quote the part numbers listed below Guy Wire Rigging qty 1 DP TWKT 020 Guy Connection Plate qty 1 DP TWKT 019 Helical Earth Anchor qty 1 OS 042 Locking Collar OS 043 Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 17 of 18 K Leading Edge Warranty Your Guyed Tower Kit carries a two year warranty from the original purchase date During the warranty period any component found to be defective in material or workmanship will at the discretion of Leading Edge Turbines Ltd be replaced or repaired at
2. Bolt with Soft Solid Rock Long M12 Expansion Bolt Long M12 Expansion Bolt with Eye 400mm X 400mm x 200mm deep cast concrete with M12 J bolts or M12 Expansion Bolt 400mm X 400mm x 200mm deep cast concrete with M12 J bolts or M12 Expansion Bolt 400mm X 400mm x 200mm deep cast concrete with M12 J bolts or M12 Helical Earth Anchor supplied fixed into cast concrete Loose Sand Helical Earth Anchor supplied fixed into cast concrete Loose Gravel Helical Earth Anchor Rocky Soil supplied fixed into cast i te Expansion Bolt EE Grassy Soil Loam Tower Base Staple Helical Earth Anchor Y supplied direct into earth supplied direct into earth Note We recommend that a general purpose Rawlbolt part number 44 165 should be used for fixing the tower base into concrete rock There are many different kinds of expansion bolt available if in doubt seek the advice of a fixing hardware supplier Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 10 of 18 dd Leading Edge 4 Mark out the tower anchor positions Begin by selecting an appropriate position for the tower base Remember that the guy wires will radiate out from the centre of the tower so you will need to ensure that enough room is available A footprint of 4 meters diameter is required for the tower guy wires See fig 2 for the positions of the an
3. Duty Steel zinc plated powder coated Guy Wires 3mm Steel Catenary Wire Tower Foot Print 4000mm 4m Diameter Pitch Circle Tower Diameter 48 3mm Outer Diameter Tube 3mm or 4mm Wall Thickness _ CMAIN TOWER GUY CONNECTION a SECTION PLATE amp LOCKING COLLAR GUY WIRE RIGGING STAPLES WHERE APPROPRIATE CC HELICAL EARTH ANCHOR Fig 1 General Guyed Tower Kit Arrangement Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 6 of 18 K Leading Edge Package Contents Your tower kit will arrive containing the components shown below If any of the components are missing or damaged please contact your dealer immediately The main length of 48 3mm O D steel tubing is not included in the kit as it is difficult and expensive to transport Your dealer will be able to supply this length of steel from a local source such as a steel stockist or scaffolding supplier Tower Base Qty 1 Base Staple Qty 4 Locking Collar Qty 1 y Guy Connection Plate Guy Anchor Qty 3 Qty 1 Guy Wire Rigging User Manual Qty 1 Components Qty Various Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 7 of 18 K Leading Edge Tools Required For Assembly You will require the following tools to assemble your Guyed Tower Kit 19mm A F spanner or ratchet two required Power drill 6 5mm a
4. conditions 60mph Damage caused by flying debris e Aesthetic phenomena that do not affect performance If your Guyed Tower was not commissioned by Leading Edge Turbines Ltd the following are additional Warranty exclusions e Damage caused by unsatisfactory installation e Damage caused by unsatisfactory mount support structure e Damage caused by failure to observe current regulations concerning connection to external electrical networks equipment or any other devices If you should experience a problem with your Guyed Tower your first port of call should be the reseller or installer from whom you purchased the product They will be able to resolve the problem quickly and efficiently If you are unable to contact the original reseller then please contact us directly Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 18 of 18
5. firmly fixed in position mate the two items together Move the main tower section over to the tower base Insert the end of the tube with the 13mm hole into the base and secure it with the M12 X 120long bolt Use 19mm A F spanners to firmly tighten the bolt see fig 7 The main tower section can now be pivoted to rest upon the ground to carry out the remaining assembly stages It is recommended that the top end of the main tower section is lifted slightly above the ground by placing it on the tower kit packaging this will make the next assembly stages easier to complete MAIN TOWER SECTION Sg WV M12 X 120LG BOLT QTY 1 M12 PLAIN WASHER QTY 2 J M12 NYLOCK NUT QTY 1 TOWER A BASE i ff Fig 7 Attached the main tower section to the tower base Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 13 of 18 d Leading Edge 9 Attach the locking collar Slide the locking collar along the main tower section from the top end so that the top is 5300mm 5 3 meters from the tower base Secure the collar in position by using the correct Allen Key to tighten the grub screw see Fig 8 LOCKING COLLAR MAIN TOWER SECTION TIGHTEN GRUB _7 SCREW TO FIRMLY d GRIP THE MAIN TOWER wo SECTION 5300mm 5 3 METRES Fig 8 Attach the locking collar 10 Attach the Guy Wires to the connection plate Slide the connection plate down from the top of the to
6. ARTH My HELICAL EARTH 27 gt HELICAL EAP IE ANCHOR ANCHOR CONCRETE Fig 4 Guy Anchor Fixing 7 Drill the Main Tower Section The 48 3mm diameter steel tube requires a 6 5mm hole to be drilled in the top end to allow attachment of the LE300 and a 13mm hole to be drill at the lower end to act as the pivot point for the tower Fig 5 shows the position of the 6 5mm hole and fig 6 shows the position of the 13mm hole Using a power drill and suitable drill bit drill both of these holes in the 48 3mm diameter tube It is recommended that a pilot hole is drilled in both cases 48 3mm X 3mm or 4mm THK d 0 CIRULAR HOLLOW SECTION lt 7 4 OR EQUIVILANT i N H 1 HOLE DRILL 6 50 THRO ALL SIDE ce FRONT ELEVATION ELEVATION Fig 5 Mounting Hole for LE300 to be drilled at the top of the main tower section Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 12 of 18 dd Leading Edge 48 3mm X 3mm or 4mm THK DI G gt CIRULAR HOLLOW SECTION Ea OR EQUIVILANT 1 HOLE DRILL 013 00 THRO ALL SIDE aa lif FRONT ELEVATION LW ELEVATION Eo jil AD H H OM 35 0 Fig 6 Tower pivot hole to be drilled at the bottom end of the main tower section 8 Attach the Main Tower Section With the appropriate holes drilled in the main tower section and the tower base
7. CC esdine Edge LE300 Guyed Tower Kit Installation amp Operation Guide a eZ Sk ot S We i N ian oS ee a YO S Pa fs Pa pa Se P Ma F A SR ea oe p p ra a jt a j a 2 N a od N ee N r d N Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 1 of 18 K Leading Edge Contents TSE AUN saan aa a a Ie DE Da 3 DAVE OU ou el p sissies ee es ei ee de en ee ee ee ks De EN 4 Sarety PRECAUTIONS nah n GE Ge ee Ge Ee GE 5 Mechanical Safety Hazarde ss sis i Ed Ed es ee ee ee EG Ke Ge do 5 Electrical Safety H taf s uas sous ss os nn EKEN EDE EE ES EE AREA EE EE NEE EE ENS EE ERK RE 5 SPES iss ed eN Ee Ve N Ke ee RE de sa ee 6 Tools Required For Assembly sesse ss ee ee EE ER AR RE EE AR AA GE Ee Re GE RR ee GE ee ee 8 Pole SeleetiBn ss es Ge de EE ni 8 Turbine Site Selection ses in 9 Tower Kit Assembly Procedure ses sk na r s ke N eie eN KNEG EE ek Nee ND ER 10 MET Eie RE EE OR N RE E Eas 17 SPANOS ede Se ee N ee sa vida EEEE N Ge A sat Elna ei ee 17 Warranty N EE EE OE EE EE sais 18 Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 2 of 18 Leading Edge Disclaimer e All specifications are subject to change without prior notice e The information given in this user manual is believed to be accurate and reliable Leading Edge Turbines Ltd assumes no responsibility for omissions or
8. chors Measure and mark these positions starting from the position of the tower base One of the guy anchors must be in line with the tilting action of the tower to allow easy final erection TOWER BASE Oy N 120 EE IN DEGREES a 2000mm ZN d 2 METRES of POSITION 120 ae DEGREES Fig 2 Anchor positions 5 Fix the tower base Once you have selected the appropriate type of ground anchor technique from the table above begin by positioning and fixing the tower base see fig 3 If a cast concrete raft foundation is required dig and cast the raft according to the dimensions shown in the above table The concrete raft should be made from 80 Newton concrete Do not shutter or backfill TOWER BASE SUITABLE EXPANSION BOLT OR M12 J BOLT TOWER BASE N W ION N CONCRETE EARTH STAPLE FOUNDATION DRIVEN INTO i GROUND Fig 3 Tower Base Fixing Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 11 of 18 dd Leading Edge 6 Fix the guy anchors Using the positions marked out in step 4 secure the guy anchor bars into the ground Concrete the guy anchor into position if reguired If the guy anchor is being driven directly into the soil ensure that the guy anchor bar is driven into the earth vertically or at an angle pointing away from the tower see fig 4 DRIVE INTO THE EARTH EARTH Jb E
9. d depending on soil conditions Please read this manual carefully before continuing with the installation of your Guyed Tower Kit Please read the LE300 Installation and Operation Guide carefully before operating the turbine Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 4 of 18 Leading Edge Safety Precautions Safety must always be your primary concern during the assembly installation and operation of your Guyed Tower Kit Always be aware of the risks involved with mechanical and electrical installation work If in doubt about any issue regarding your tower kit or turbine please seek further assistance before proceeding Mechanical Safety Hazards e Ensure that the tower kit and turbine are installed in a suitable position where nobody can approach or interfere with the path of the turbine rotor blades e Ensure that the tower is located in a position where it cannot cause any damage to buildings neighbours property or utility lines should the tower fall for any reason e Never attempt to climb the tower It is not designed to handle this type of loading and may fail e If at any time a component of the tower or turbine works loose correct it immediately e Working with tools of any kind can be dangerous Your tower kit and LE300 turbine require some basic mechanical assembly with rudimentary hand tools If you are in any doubt about how to use these tools correctly please s
10. eek advice from a suitably experienced person e Always ensure that all personnel in the immediate vicinity are aware of any lifting hoisting operations that will be occurring Check there are no loose components or tools likely to fall and cause injury during the lifting operation Where possible all assembly work should be completed at ground level e Ensure that the batteries are disconnected during the installation procedure e Twist the turbine output cables together to create a short circuit during the mechanical installation process This will prevent the turbine from spinning up during the installation and erecting of the tower kit e Install your turbine and tower kit during a calm day e When performing routine inspection or maintenance always stop the turbine by activating a stop switch e Ensure protective gloves are worn when handling the guy wires e Tower sections can be heavy ensure protective footwear is used Electrical Safety Hazards e Always refer to the LE300 Installation and Operation Guide for advice and instructions on electrical aspects of the turbine installation Please use common sense when installing and operating your turbine Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 5 of 18 K Leading Edge Specifications Product Name Guyed Tower Kit for LE300 Turbine Part Number GA TWKT 002 Maximum Tower Height 7500mm 25 ft Materials Heavy
11. hness of the ground Long grass crops or bushes will have the effect of slowing the wind down even at the height of the tower Try to install your turbine where the ground is smooth to increase the overall power production of the system Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 9 of 18 d Leading Edge Tower Kit Assembly Procedure 1 Unpacking Inspect the contents of the box and ensure that all items are present and free from damage If any of the components are missing or damaged please contact your dealer immediately 2 Assess the installation area The tower kit must be installed on a reasonably level area of ground If the turbine is to be installed on ground that is slightly inclined ensure that the pivot action of the tower base is orientated so that the tower is raised in line with the hill This will allow the tower to be set vertical regardless of the hill angle 3 Assess the soil conditions Follow the table below to decide on the best anchoring system for your tower kit Your tower kit is supplied with 4 tower base staples and 3 guy anchors Different fixings may be required depending on the soil conditions These are readily available at most hardware stores For permanent installations it is recommended that all ground fixings are set into concrete Soil Condition Tower Base Fixing Guy Anchor Fixing Hard Solid Rock M12 Std Expansion Bolt Expansion
12. inaccuracies e The user of this information and product assumes full responsibility and risk e Wind Turbines are a source of electrical power They must be installed in accordance with local building and electrical regulations Consult your local planning zoning office for details e Wind turbines and associated equipment have moving parts that may cause injury due to poor installation and unsafe operation Leading Edge Turbines Ltd assumes no responsibility for problems caused by unsafe or unsatisfactory installation or operation Designed amp Manufactured in the UK By Leading Edge Turbines Ltd Skyrrid Farm Pontrilas Hereford HR2 OBW Tel 44 0 845 652 0396 www leturbines com CE Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 3 of 18 Leading Edge Introduction Please read this manual thoroughly before attempting to assemble and install your Guyed Tower Kit This will assure optimum performance and safety This Tower Kit has been designed for use with the LE300 Turbine from Leading Edge Turbines Ltd It is possible to use this kit with other turbines that require a 48 3mm diameter tower however under no circumstances should a turbine with a rotor diameter greater than 1 4m be installed using this Tower Kit It is possible to install the Guyed Tower Kit with two people in a very short time No winches or gin poles are necessary although concrete may be require
13. ired One person should pull the guy wire whilst the other lifts the tower from the other side Ensure that safety is your first priority during the hoisting operation Use the D shackle to attach the third guy wire to the guy anchor see fig 10 CONNECT 2 GUY 4 WIRES TO ANCHORS Fig 10 Connect two guy wires and hoist the tower Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 15 of 18 Leading Edge 13 Adjust the guy wire tension to ensure tower is vertical Use a spirit level to ensure that the tower is vertical Slowly tighten each turnbuckle to achieve a good tension on each guy wire The tower must be securely fixed in a vertical position with no movement from side to side Adjust individual turnbuckles to ensure the main tower section is vertical If required the position of the guy connection plate can be adjusted by moving the locking collar TURNBUCKLE Fig 11 Connect two guy wires and hoist the tower 14 Bring down the tower in order to install the turbine Reverse the procedure described in step 12 above to lower the tower to ground level The turbine can now be installed upon the tower Follow the installation instructions provided with the turbine Follow step 12 once again to re erect the tower complete with turbine Installation of the Guyed Tower Kit is complete Please now refer to the LE300 Installation and Operation Guide
14. mum of 4 0m s 9mph and low wind turbulence Wind turbulence is caused by obstructions to the wind such as trees and buildings Excessive turbulence will hamper the performance of your turbine Small wind turbines operate best in steady airflows Free flowing airstreams are more consistent in direction and wind speed which results in more overall power being generated by the wind turbine system Gusty conditions often result in a turbine hunting the wind reducing the amount of overall power generated Gusty and turbulent conditions also exert fluctuating forces upon the turbine that can reduce the reliability and lifespan of the system Wind shadowing and barriers Wind barriers are simply obstacles that impede the flow of the wind such as trees and buildings A large wake of turbulent airflow will occur for a long distance downwind of a barrier It is not desirable to locate a turbine in this zone WIND DIRECTION 2 AN TURBULENT AIRFLOW ZONE OBSTRUCTIONS 3 2 X HEIGHT 2 X HEIGHT 20 X HEIGHT Topography For areas of undulating ground the turbine should be installed in the highest possible position avoiding wind barriers and turbulence For areas that are generally flat the turbine can be installed in any position Remember that the LE300 has a low voltage output so it is important to keep the cable run to the batteries inverter as short as possible Surface roug
15. nd 13 00mm dia twist drill bit suitable for drilling through steel Long tape measure or steel rule Cement and mixing tools required for loose or sandy soil conditions Sledge hammer 10Kg Spirit level Gloves Pole Selection As mentioned above the main length of pole for mounting your turbine is not supplied with this kit as it is not economical to ship The pole required for theLE300 Turbine is a 48 3mm outer diameter x 4mm wall thickness circular hollow section This is commonly used as scaffolding tube or for fencing applications This pole is also known as 1 9 Schedule 20 or 40 pipe A galvanised pole should be used to prevent corrosion Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 8 of 18 K Leading Edge Turbine Site Selection The turbine location is a very important factor in the overall performance of your small wind turbine system Good site selection will maximise the power that your turbine will be able to deliver Installing a wind turbine in a bad position is similar to installing a solar panel system in the shade it will not maximise the performance of your investment The total amount of energy available in the wind increases drastically with small increases in wind speed Therefore it is very important that you site your turbine in the best possible location The proposed installation site for your wind turbine must have a good average wind speed of a mini
16. no charge For minor component failures replacements may be sent directly to the customer dealer for replacement For more serious defects we may suggest a return to base arrangement for replacement or repair In all cases Leading Edge Turbines will take reasonable action to ensure customer satisfaction You will always receive a warm courteous service in or out of your warranty period Your Guyed Tower Kit must be installed and operated in accordance with this guide and local codes Failure to do so will result in this warranty becoming null and void Any unauthorised modifications to the design will void the warranty and may compromise the safety of the mount What is not covered by your warranty If your Guyed Tower is commissioned by Leading Edge Turbines Ltd the following are excluded from the warranty e Damage caused by the neglect of periodic maintenance in the manner recommended e Damage caused by repair or maintenance performed using methods not specified by Leading Edge Turbines Ltd or by non authorised dealers of Leading Edge Turbines Ltd products e Damaged caused by the use of non genuine parts e Damage caused by operating in conditions outside of those specified in the Owners Guide e Damage caused by modifications to the mount not approved by Leading Edge Turbines Ltd e Damage caused to the mount by improper storage or transport e Damage caused by lightning strikes Damage due to extremely high winds and storm
17. wer until it meets the locking collar Measure out approximately 6100mm 6 1 meters of the steel catenary wire for each of the guy wires Arrange and fit the guy wires to the guy lugs Follow the fitting arrangement depicted in fig 9 Allow a 300mm overlap and always use two wire rope grips at each looped end of the wire Repeat this for all of the remaining guys 48 3mm O D CIRCULAR HOLLOW SECTION LUG COLLAR A 2 _WIRE ROPE Pd Em IN A N Pa lt N N N _ GUY WIRE Fig 8 Attach the guy wires to the lugs Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 14 of 18 K Leading Edge 11 Make ready the guy wire fixings for the earth anchors Prepare the fittings on the earth anchor side of the guy wires Follow the arrangement shown in Fig 9 Allow a 300mm overlap and always use two wire rope grips at each looped end of the wire _ GUY _ WIRE WIRE ROPE Sy eee GRIP X D SHACKLE sa HELICAL EARTH Ve ANCHOR Fig 9 Prepare the guy fittings on the ground end of the guy wires 12 Connect two of the guy wires to the guy wire anchors and hoist the tower Select two of the guy wires leaving the single guy wire that works in line with the tilt up direction Using the D shackles attach these two guy wires to a corresponding guy anchor The third guy wire is now used to hoist the tower Two people may be requ

User Manual - Leading Edge Turbines

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