DS-300 Vertical Axis Wind Turbine User Manual - Hi-VAWT
Contents
1. 33 Figure 4 5 DS 300 Installation Procedures I 34 Figure 4 6 DS 300 Installation Procedures 2 35 Figure 4 7 DS 300 Installation Procedures 3 wmumunwanawananunununununwawanua 36 Figure 4 8 DS 300 Installation 4 37 Figure 5 1 Wiring Diagram for Wind Charge Controller WGO400 40 Figure 5 2 Wiring Diagram for Wind PV Hybrid Controller WGO400 RCTO II EET Fe WANGA MAINI 42 Table Index Table 2 1 DS 300 Technical 5 14 Table 2 2 DS 300 COMPONENTS wicisinsaiaiudaiiaie nis Gadiadiicaieneae babinaadeataenteaadanaazan tees 15 Table 5 1 Wire SIZING Refere NCE wi aa 39 Table 5 2 DS 300 Wiring Size Reference WGO4OO ccccccecescecesseseesuseesuseusess 4 WARNING THIS USER MANUAL PROVIDES INSTRUCTIONS AND GUIDELINES FOR ASSISTANCE WITH ASSEMBLY AND INSTALLATION OF THE HI VAWT S DS 300 VERTICAL AXIS WIND TURBINE ALTHOUGH THE DS 300 VAWT HAS BEEN DESIGNED AS EASY AS POSSIBLE FOR THE INSTALLATION IT STILL REQUIRES SPECIALIZED SKILLS TOOLS AND EXPERIENCE AS WELL FOR THE PURPOSES OF ASSEMBLING2. 29 4 2 DS 300 VAWT 556 30 4 3 DS 300 InstallatioN w w wamwamanwanwanwanwanwanwanzanwanzanuananwana 33 Se WI ea EE EEEE E EAA E E rd 38 si an NIA Ia 38 5 2 DS 300 Wire 5 6 38 53 SEA WA WI KAA 39 Dee PN Ee IIIA 43 GOUN eee 43 PO IAA E 43 Oe AN AA 45 Table of Figures Figure 2 1 General View of the DS 300 VAWT 5 13 Figure 2 2 DS 300 Standard Packing 16 Figure 2 3 System CONLI OW Kaa 17 Figure 3 1 Dimension OF MASI zinaa 21 Figure 3 2 Optional Mast D sSigh EE 23 Figure 3 3 Ground Foundation Construction 25 Figure 3 4 Foundation for Roof Installation 27 Figure 4 1 Required Tools for Assembly and Installation 29 Figure 4 2 DS 300 Assembly 30 Figure 4 3 DS 300 Assembly Procedures 2 cisscecceccececcececceceesuceeseceuseceeseeseseees 32 Figure 4 4 DS 300 Assembly Procedures 3
3. 300 Verrical Axis Wine wine User Manual Hi VAWT Technology Corporation www hi vawt com tw Table of Contents WARNING ee 5 DISC ALIMER eee 7 1 Sey P ON IAA 8 LL MOON NAZI 9 E2 aa AA AA AA AAA 9 AA AA ere 10 EA 11 OPO II 12 Ze UA 12 2 1 DS 300 14 2 2 5 300 Standard Packing 15 2 4 DS 300 Wind Power System 8 17 2 5 DS 300 Optional 18 3 Preparation of Assembly and 18 3 1 Selecting LOCATION Aaa 18 3 2 Mast Preparation ssssssssssununnnnnnnnnnnnnnnnnnnnnnnnnnnnnnununnuuunnnrrnrnnnnnnn 19 3 3 Foundation Guide for DS 300 w wamwamanwanunwanuawanwanuawanwanuza 23 3 3 1 24 3 3 2 ROOT FOUNGAUUON III 26 4 DS 300 Assembly and Installation 29 4 1 Tools Required for Assembly and
4. 16 2 4 DS 300 Wind Power System Controllers The standard DS 300 VAWT System is also alternatively packed with two types of wind power system controllers either WGO400 12V 24V Wind Charge Controller or WG0400 12V 24V w RC10 Il Wind Power PV Hybrid Controller at user s choice The descriptions and specifications of both WG0400 12V 24V and RC10 Il System Controllers are detailed in their user manuals respectively Figure 2 3 lists the standard packing for DS 300 Wind Power System Controllers Figure 2 3 System Controllers WG 0400 12V 24V Wind charge controller OR Photo diode Sensor WG 0400 12V 24V RC10 II Wind PV Hybrid Controller 3 2 5 DS 300 Optional Parts This DS 300 VAWT System is designed with simplicity in mind so there are just a few parts needed which all included in the standard package Concerning the shipping cost and different applications applied by customers the required mounting mast to setup the DS 300 Wind Turbine is not included in the standard package It would be an optional part based on customer s choice The detail description of the mounting mast will be explored in Chapter 3 Preparation of Assembly and Installation Before going through the DS 300 VAWT System installation procedures please double check parts included in the package Prepare all required tools and equipments accordingly and have them ready on hands More importantly all safety issues have been w
5. 140mm 6 28mmxP1 25 Tapped bolt holes on PCD 2115 mm 60 each Flange thickness 10mm Mast Dimension Prototype Design material 140mm x 5m m galvanized steel pipe Mast Outer Dia 2140mm Mast Inner Dial 120mm Standard Length of the Mast 3m Mounting flange welded on the top of the Mast Foundation Plate welded under the bottom of the Mast with 4 support ribs t 10 Drill al8 5mm diameter hole at 30mm above the bottom of the mast This hole is reserved for wiring cable exit If an underground conduit is applied in the concrete foundation then ignore this exit Foundation Plate Dimension e 320mm x 320mm e Thickness 20mm e 4 x 25mm bolt holes on 270mm x 270mm e 4x 10mm in thickness of support ribs Figure 3 2 shows an optional design of the mounting mast You may use hinge type mechanism at one side of the foundation plate to make an easy way to access the DS 300 by lowering down or lifting up the mast 22 Figure 3 2 Optional Mast Design 3 3 Foundation Guide for DS 300 Before constructing the foundation for the DS 300 VAWT System read these instructions carefully These instructions are only intended to be a guide for concrete foundations on solid soils or 23 suitable roof infrastructure Please contact your local civil or structure engineer for more information 3 3 1 Ground Foundation The foundation should be prepared as 1 cubic meter in dimension 1000m m x 1000
6. 3 meters Roof Mounting Min Height above roof 2 meters Bedplate Mounting Used where deep excavation cannot be Warranty Limited Warranty 1 year on components 14 2 2 DS 300 Standard Packing Please check all components you receive from the shipment with the packing list that comes with the purchase invoice or the enclosed parts list in the shipment Ensure that you receive all standard components or parts for the DS 300 accordingly If any missing parts from the original packing please contact Hi VAWT Technology Corporation for replacement Table 2 2 shows the standard packing of DS 300 VAWT System Please also refer to Figure 2 2 for part locations Detail assembly instructions will be discussed in the Chapter 4 Assembly and Installation Table 2 2 DS 300 Components Labels Description Ouantity Included A Anodized Aluminum Blade 3 Assembly Needed gt Pre assembled Components 1 Upper Blades Connecting Plate a 1 1 R S T Generator Wiring Cables 15 Wind Turbine Surge Wire Connected between Damper and Flange of the Mast Bolt Sets 9 AA M10 x 25mm Button Hex 18 Head Bolts and Nuts Set 1 1 2 3 M8 x 30mm Hex Head Bolts Washers 7 1 Set Screw M10 x 10mm Socket Countersunk Head Cap 2 Screw M5 x 16mm Head Bolt and Nut Set Figure 2 2 DS 300 Standard Packing Contents M8 x 25mm Button Hex ae Head Bolts and Nuts
7. D Assembly The DS 300 VAWT System is designed in All Most Ready to Use format and shipped with factory pre assembled packing The only assembly work required is Darrieus blades assembly This user s manual will guide you through the assembly procedures with detailed illustrations CP NOTE e Please carefully read the assembly instructions in this manual before proceeding is important to have a suitable working environment for performing the assembly tasks e Refer to the suggested list of tools required for the assembly and have all of them ready before proceeding A WARNING e PLEASE ALWAYS KEEP SAFETY IN MIND WHILE PERFORMING THE ASSEMBLY PROCEDURES e AWAYS WEAR SAFE HELMET AND GLOVES 10 1 4 Installation A fall from the height at which a wind turbine is ordinarily mounted will often result in death or serious injury Therefore whenever practicably carry out as much work as possible on the wind turbine at ground level If it is necessary to work on the installation at such height then use an appropriate access system such as a mast that is designed to carry the load of a person a man rated winch or rope access system a hydraulic lift or other safe working platform Wear appropriate safety equipment and make the general working area as tidy and safe as possible Work during the daylight on windless days Above all else think carefully about what you need to do and plan your work carefully have a
8. INSTALLING OPERATING AND MAINTAINING THE DS 300 VAWT WE ASSUME THAT PERSONNEL WHO INVOLVED IN THE WHOLE PROCESSES HAS THE SKILLS TOOLS REQUIRED TO DO SO NO ONE SHOULD ATTEMPT TO ASSEMBLE INSTALL OPERATE AND MAINTAIN THE DS 300 VAWT SYSTEM WITHOUT THE NECESSARY SKILLS EXPERIENCE TOOLS AND SAFETY EQUIPMENT DISASSEMBLING THE PARTS FROM ORIGIONAL IS RESTRICTED ALL PRE ASSEMBLED PARTS ARE FACTORY ADJUSTED BALANCED AND TESTED HI VAWT TECHNOLOGY CORPORATION ASSUMES NO WARRANTIES AND LIABILITIES OF DOING SO HI VAWT TECHNOLOGY CORPORATION Hi VAWT ASSUMES NO DIRECT OR CONSEQUENTIAL LIABILITY IF FAULTY OR DANGEROUS ASSEMBLING INSTALLATION OR MAINTENANCE PRACTICES ARE PERFORMED PLEASE CONTACT HI VAWT TECHNOLOGY CORPOATION IF CONSULTATION OR ASSISTANCE IS REQUIRED HI VAWT RECOMMENDS THE DS 300 VAWT SYSTEM SHOULD BE SITED ACCORDINGLY IN AN EXCLUSION ZONE WITH CONTROLLING PUBLIC ACCESS APPROPRIATE WARNING SIGNS SHOULD BE PLACED ON THE OPERATING SITE THE DS 300 SHOULD NOT BE INSTALLED NEAR UNPROTECTED POWER LINES TREES OR ANY OBJECTS THAT WOULD POSSIBLY CAUSE THE HAZARDS OF THE OPERATION Hi VAWT Technology Corporation 5 168 Jhu lin 13 Rd Lin kuo town 244 Taipei County Taiwan Tel 886 2 8601 4373 Fax 886 2 8601 1263 E Mail sales hi vawt com tw Website www hi vawt com tw DISCALIMER Although Hi VAWT recommends reading the entire manual thoroughly prior to assembly and installation to ensure proper performa
9. ION 2 Introduction The DS 300 is a hybrid Vertical Axis Wind Turbine VAWT system which combines drag based design and lift based design It incorporates an S type of Savonius rotor and three airfoil blades of egg beater shape Darrieus to maximize the output performance The following Figure 2 1 shows a general view and major components of the DS 300 VAWT System 12 Figure 2 1 General View of the DS 300 VAWT System Side View Description A Upper Darrieus Blades Connector S Type Savonius 3 Darrieus blades with built in airfoil 3 Phase Direct Drive Weather Sealed Mechanically Integrated Permanent Magnet Generator gt Lower Darrieus Blades Connector Damper 3 Phase R S T Generator Wires 13 2 1 DS 300 Specification The following table shows the technical specification of the DS 300 Wind Turbine Table 2 1 DS 300 Technical Specification General Dimension Rotor Diameter 1 245 mm Height 1 060 mm Weight 25 5 Blades Number of Blade 3 Blade Material Anodized Aluminum Operation Mode Cut In Wind Speed lt 3 m s Cut Out Wind Speed Survival Wind Speed 60 m s Safety Mechanism Over Speed Braking Yes Setup by Power Controller Manual Brake 3 phase short circuit Switch Generator Type AC Direct Drive Weather Sealed 3 Phase Synchronism PMG Rated Output 300 W 13 5 m s Mounting Foundation Mounting Min Height above ground
10. NTY AS TO THE ACCURACY SUFFICIENCY OR SUITABILITY OF ANY TECHNICAL OR OTHER INFORMATION PROVIDED IN MANUAL OR OTHER DOCUMENTATION PROVIDED BY IT IN CONNECTION WITH THE PRODUCT ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSSES DAMAGES COSTS OR EXPENSES WHETHER SPECIAL DIRECT INDIRECT 46 CONSEOUENTIAL OR INCIDENTAL WHICH MIGHT ARISE OUT OF THE USE OF SUCH INFORMATION THE USE OF ANY SUCH INFORMATION WILL BE ENTIRELY AT THE USER S RISK A warning Limitations on Use Please Note the Hi VAWT s DS 300 VAWT System is not intended for use as the power source of life support systems or other medical equipment or devices and Hi VAWT makes no representation or warranty in connection with any use of the product for such purposes 47 48 E Hi VAWT Technology C ti ALA Technology Corporation Ill www hi vawt com tw D 168 Jhulin 1st Road S N IIMA Taipei County 24443 Taiwan 201006101210
11. Turbine System please well prepare all reguired tools to complete the assembly and installation 4 1 Tools Required for Assembly and Installation As the DS 300 is factory pre assembled only a few tools required for finishing entire assembly and installation We are strongly recommend having a crane with suitable capacity to haul up the mounting mast to desired location and also lift up the DS 300 to the mounting flange Please refer to Figure 4 1 for your tool preparation Figure 4 1 Required Tools for Assembly and Installation Assembly and Installation Tools ArEnergy M5 M6 and M8 Hex Allen Wrenches Lifting Crane or Crane Truck 29 caution We strongly recommend you to prepare all suggested tools before proceeding the assembly and installation Please always keep safety in mind while working on the assembly and installation e Preparing any extra equipments or safety devices accordingly if instructed by your local authority 4 2 DS 300 VAWT Assembly There are only a couple of steps to assemble the DS 300 Please follow the Figure 4 2 4 3 and 4 4 DS 300 Assembly Procedures to complete the assembly Figure 4 2 DS 300 Assembly Procedures 1 Assembly Procedures Step 1 3 sets of M10 x 25mm Hex Head Bolts Lock Nuts and 1 set of M8 x 25mm Hex Bolt Lock Nut Upper Blade Connector Connect UP with the Upper Blade Connector 3 sets of M10 x 25mm Hex Head Bolts Lock Nuts and 1 set o
12. a local electrical contractor for details and regulations The information and all specifications contained within this manual are subject to change without notice 1 Safety Precautions The DS 300 is designed with user safety in mind However there are inherent dangers involved with any structural mechanical and electrical equipment the surrounding environment as well Safety must be the primary concern as you plan the location assembly installation and operation of the DS 300 VAWT At all times be aware of electrical mechanical and rotor blade hazards This Owner s Manual contains important instructions guidelines and safety notes that should be followed during the installation and maintenance of the Hi VAWT s DS 300 VAWT Please read thoroughly and follow the instructions in this USER S MANUAL before assembling and installing the DS 300 VAWT Please refer to the following symbols which are used throughout this manual to indicate potentially dangerous situations important safety instructions or important notes for you to know A This WARNING symbol indicates a possible WARNING dangerous condition Please use extreme caution when processing the procedure A This CAUTION symbol identifies an CAUTION improper operation that could result in critical safety issue or damage to the system controller or related devices gt The NOTE symbol describes an important 7 NOTE procedure or issue for you to know
13. aft should face the screw holes on the Connector Damper Make sure that all three blades have been securely locked on both upper blade connector and lower blade connector Next step is to assemble the DS 300 VAWT System with the Mast Connector Dumper Please use proper lifting device such as crane to lift the DS 300 up to the height that enough to put the Mast Connector Damper under the main shaft of the DS 300 then insert the main shaft into the Mast Connector Damper There are two indents on the lower main shaft and should be lined up with two lock screw holes on the Mast Connector Damper A WARNING 0 indents on the lower main shaft must be lined up with lock screw holes on the Mast Connector Damper and securely 32 locked Fail to do so will cause the generator cables broken during break applied Figure 4 4 DS 300 Assembly Procedures 3 Assembly Procedures Step 3 Set Screw M10 x 10mm with Loctite Sealant Socket Countersunk Head Cap Screw M5 x 160mm M10 x 20mm Hexagon Socket Head Bolt and Nut Surge Wire Use the M10 x 10mm Hexagon Socket Screw to lock the upper hole and M10 x 20mm Hexagon Socket Head Bolt and Nut to secure lower section with the surge wire 4 3 DS 300 Installation WARNING e Double check with assembly procedures and make sure all screws are securely locked Any loosen screw will cause serious vibration and parts damaged 33 If you are going t
14. ell thought and followed 3 1 Selecting Location The DS 300 Wind Turbine is designed with flexibility to fulfill user s applications It can be installed along the street sea shore on the mountain in the city urban area or just right on top of the roof of the building The major key factor of affecting the performance of DS 300 Wind Turbine for all proposed applications is the location of optimizing wind energy P NOTE We assume that the proposed site of installing the DS 300 VAWT System has been well evaluated by users themselves for optimizing the wind energy environment before any installing procedures performed 18 A warning e DO NOT install the DS 300 VAWT System at a site where anyone can easily approach the rotating blades e DO NOT install the DS 300 VAWT System at a site surrounded by obstructions For example Trees power lines etc e DO NOT install the DS 300 VAWT System at a site with improper structure to hold the DS 300 System A caution e Always follow your local regulations codes about restrictions applied to such system installation e Always have your DS 300 grounded to avoid the lightning Strike e Perform the installation of the DS 300 VAWT System in a calm and windless day e Perform all required assembly for the DS 300 VAWT System at ground level 3 2 Mast Preparation As mentioned before shipping charge of the mast made by Hi VAWT will be costly If you prefer ma
15. f M8 x 25mm Hex Bolt Lock Nut Lower Blade Connector 30 Insert 3 M10 x 25mm Hex Head Bolts Lock Nuts and 1 M8 x 25mm Hex Head Bolt Lock Nut for each one of the blades on the upper blade connector Do not lock these four bolts yet until another 3 sets of M10 x 25mm Hex Head Bolts Lock Nuts and 1 set of M8 x 25mm Hex Head Bolt Lock Nut inserted for Lower Blade Connector Now use Wrench to securely lock blade on upper blade connector and lower blade connector Repeat this step for second blade and third blade and lower section as well The alignment of both upper blade connector and lower blade connector has been factory pre lined up A caution e Each blade has a mark of UP on one side please connect the UP end with the upper blade connector Do not connect UP end with lower blade connector If you are not able to see the UP mark on the blade you may find three M10 holes and on M8 hole on both blade and connecting plate just matching up each hole so you won t assemble the blade with wrong direction WARNING e For safety concern please short circuit the RST Generator Wiring Cables temporarily to stop the rotor from rotation 31 Figure 4 3 DS 300 Assembly Procedures 2 Assembly Procedures Step 2 Inserting the main shaft into the Mast Connector Damper Lifting up the DS 300 with proper tool crane Note Spot face for Set Screws MO B Indents on the main sh
16. id Controller WGO400 RC10 Wiring Diagram WC 0400 RC10 I WG 0400 12V 24V RC10 IIl Hybrid Charger Wiring Diagram BATTERY BANK SOLAR PANEL 85W P NOTE Please refer to the WG0400 RC10 II Wind Charge Controller User s Manual for further information 42 5 4 PV Charging To charge 12V battery bank the PV charger is available for PV panel which the voltage reaching between 12V and 50V Please note that the charger will not be available if the voltage of solar panel is lower than 24V when charging for 24V battery bank 5 5 Grounding In order to protect the DS 300 Wind Turbine System against damage by lightning static or over voltage properly grounding the DS 300 Wind Turbine System is very important Grounding procedures must be followed along with any local electrical codes The design of the grounding system depends on the local conditions like the site of the installation type of soil or a grounding bus already existing If you are in doubt contact your local electrician for more information A WARNING SEVERE TURBINE DAMAGE CAN RESULT FROM IMPROPER GROUNDING e FAILURE TO PROPERLY GROUND WILL VOID THE WARRANTY 5 6 Fusing To protect the battery against short circuit fuse must be installed in the positive line between the Controller and Battery The recommended fuse type is 50amp DC Slow Blow fuse for 12V system or appropriate automatic circuit breaker The fuse must be placed as clo
17. imited warranty by its inspection troubleshooting and any possible mean to identify e Shipping cost from Hi VAWT to user for replacement or repaired parts Hi VAWT has the option to use new or reconditioned parts in performing repair or replacement Hi VAWT also reserves the right to use parts or improved design in the repair or replacement If you purchase the product from our dealer in your area contact the dealer for repair or replacement or you may contact us directly at the following numbers Telephone 886 2 8601 4373 Fax 886 2 8601 1263 Email Address sales hi vawt com tw Please provide the proof of purchase dated invoice for defective products repair or replacement 45 The limited warranty does not apply to any product or part thereof damaged by the following conditions e Any alteration to the product either internally or externally or disassembly of the product e Not been used in accordance with the User s Manual supplied with the product e Installed and used in an unsuitable environment e Operation or installation contrary to instructions pertaining to the product e Damaged during shipping mishandled neglected improperly installed e Repair or service provided ay an unauthorized repair facility Lightning strikes without proper grounding Hi VAWT does not warrant or guarantee the workmanship performed by any person or firm installing its products HI VAWT MAKES NO WARRA
18. king your own mast for DS 300 VAWT System rather than purchasing from Hi VAWT we will show you here how the mast can be made by your local supplier 19 In the Figure 3 1 the Mast Specification was originally designed and tested on the DS 300 VAWT System It has been approved and applied as the standard DS 300 VAWT System It is important to follow the diameters shown in Figure 3 1 for Mounting Flange and Mast of the DS 300 VAWT System A caution e Please carefully check the structure of the building if you are going to install DS 300 VAWT System on the roof Make sure the structure is strong enough to endure DS 300 VAWT System in terms of total weight impact from gusty wind or earthquake etc Hi VAWT Technology Corporation suggests the length of the mast is 2 meters for the roof installation and 3 meters for the ground e Carefully check the surrounding area when determines the length of the mast Avoid any existing objects that affect the performance of wind energy or cause hazards The following Figure 3 1 shows the diagram for making the mast 20 Figure 3 1 Dimension for Mast JA Mounting Flange t 10 6 M8xP1 25 Tapped 140 OD PCD 115 95 ID i 18 5 Foundation Plate Unit mm 4 20 320 mm 21 This portion shows the dimension of the mounting flange which should be welded on top of the mast for connection with the DS 300 VAWT System Flange Inner Dia 95mm Flange Outer Dia
19. ll the tools and equipment ready before your Start A caution e Installation procedures should be performed as much as possible at ground level e Use safety harnesses safe helmets gloves etc e Make sure that all batteries if applied are disconnected from the system throughout the installation process e The DS 300 generator should be short circuited to prevent unintended wind turbine rotating during the shipment Please install the extension cable on the ground level and keep it short circuited throughout the installation process e Please keep the rotor straight up or lie on the support stands at all time during the installation process to prevent the blades twisted or lost balance e Please perform the installation at a calm and windless day 11 1 5 Operation Please check the support structures blades and electrical system on regular basis Even though the rotor blades are very strong however if they come in contact with a solid object they can be damaged or even broken e When perform routine inspections or at anytime you must approach the path of the blades please disconnect the power leads from the batteries and short circuit the wind turbine output leads use the Stop Switch after installation or tie the output leads together to stop the rotor blades from rotating The DS 300 is designed to be shut down through the use of stop switch brake switch e NEVER APPROACH THE TURBINE DURING OPERAT
20. m m x 1000m m depth dug into the soil Please follow the diagram shown in the Figure 3 1 make a template of the mast bottom This template will be temporarily used for holding four Anchor Bolts vertically and electrical conduit if applied in the precise position while pouring concrete into the foundation hole later Insert rebar into the foundation hole and jack up to approximately the right height Prepare the electrical conduit in place before pouring the concrete if a hidden wiring method is applied Attach the M16 screwed rods with nuts provided to the template such that they will hang into the foundation hole from the template Make sure there have at least 100mm of thread above the concrete level Fix the conduit through the center of the template and push the other end of the conduit to the side of foundation If applied Add the concrete using a vibrating poker to remove air voids from the pour It is very important to make sure the all four rods are hooked under the rebar Once the concrete is all poured make sure that the template has no air voids directly underneath More importantly make sure the template is leveled off Next clear excess concrete from above the template and use a Suitable cover to prevent the foundation from rain Wait until the 24 concrete has set completely before removing the template It will take at least for one week Just remember a solid with perfect leveled foundation is one of
21. nal codes or special regulations to be followed before installation All works on the electrical system like installation maintenance and repair Should be carried out by gualified technicians and make sure that they read all technical information and instructions contained in related manuals The wiring diagram should be planned ahead and make sure all reguired wiring components are well prepared accordingly A caution Carefully plan all required electrical components and install electrical components first before any electrical connection e Make sure that batteries if applied should be disconnected all installation works are completed All electrical power cables should be physically protected Run the wires inside the mast of conduit for maximum protection 5 2 DS 300 Wire Size The cross section of the wire to be used depends on its length resistance and rated current All electrical systems lose energy from the resistance of the wire used Larger wire size has smaller losses but can be considerably more costly Closely look at the site that the DS 300 VAWT System is to be installed and measure the following distances 38 e Distance between DS 300 VAWT and the location of DS 300 Controller e Distance between the solar panel and the DS 300 Controller Distance between the photodiode and the DS 300 Controller e Distance between the DS 300 Controller and the Battery It is recommended that
22. nce and safety this manual is intended as a guide only It should not be considered as a replacement of professional services or as a definitive text for assembling and installing the DS 300 VAWT systems Hi VAWT makes no warranties by either expressed or implied that the information contained in the manual is accurate or complete Hi VAWT Technology Corporation makes no warranties of fitness for a particular purpose and or site Hi VAWT will not be responsible for any direct or consequential damages or an incidental expense All instructions figures and diagrams are believed to be accurate at the time of printing The success and safety in working with tools depend greatly on individual accuracy skill and caution For this reason Hi VAWT is not able to guarantee the result of any contained procedure in the manual nor can they assume responsibility for any damage to property or injury to persons resulting from procedures contained in this manual Persons who engage in the procedures take their own responsibility and risk Actual power resources and selected site conditions will highly affect the energy production which will vary with wind turbine maintenance Surrounding environment therefore Hi VAWT makes no representation or warranties regarding energy production Wind generators like other sources of electrical power Must be installed following the guidelines established by local and national regulations Please consult
23. o install the DS 300 VAWT System at certain height please have proper safety devices ready for proceeding installation Figure 4 5 DS 300 Installation Procedures 1 Installation Procedures Step 2 Insert 6 Hex Head Screws with Spring Washers In Figure 4 5 please insert 6 Hex Head Screws with Spring Washers and connect the Surge Wire under one of the washers 34 Figure 4 6 DS 300 Installation Procedures 2 Installation Procedures Step 2 Use proper lifting device Crane to lift up the DS 300 above the mast flange P NOTE e There are 3 proper size of wires should be pre installed inside the Mast e Securely connect the RST Generator Wires with these 3 pre installed wires 35 Figure 4 7 DS 300 Installation Procedures 3 Installation Procedures Step 3 Connecting RST Wires with the 3 proper size of wires the pre installed inside the Mast GP NOTE e Please refer to the Chapter 5 Wiring section for detail Figure 4 8 DS 300 Installation Procedures 4 Installation Procedures Step 3 Securely lock 6 Hex Cap Screws on the Mast Flange Vertically insert the DS 300 into the Mast and then securely lock Mast Connector Damper with the Mast Flange by 6 Hexagon Socket Screws After the completion of this step you have finish the DS 300 Wind Turbine System and ready for further wiring procedures 37 5 Wiring 5 1 General Information Please refer to all local and natio
24. plate then put the first template on top of the square 26 template to hold four rods temporarily before the concrete set completely and keep the surface leveled Figure 3 4 Foundation for Roof Installation Reference Roof Concrete Surface Rod and Electrical Conduit if applied Holding Template Plywood Square Holding Template A warning e Although the DS 300 VAWT System is designed to be installed on the roof alternatively but Hi VAWT does not recommend to 27 do so unless you are 100 percent sure that the structure of the building is capable of doing so Please consult your local structural engineer and carefully evaluate such implementation before taking any further actions It is user s responsibility to make sure that the structure of the building is able to sustain the force of operating DS 300 Wind Turbine System on the roof Hi VAWT is not responsible for any potential damage or dangerous factors caused by insufficiency of structural design of the building Please closely follow your local government s regulations regarding related issues if you are going to install DS 300 on the roof If you are going to install the DS 300 on the ground level please consult your local civil engineer and carefully evaluate the nature of the soil and design of the foundation accordingly 28 DS 300 Assembly and Installation Before starting the assembly and installation of the DS 300 Wind
25. se to the battery as possible however not in the same compartment Unsealed lead acid batteries have vent holes releasing hydrogen which forms 43 5 7 detonating gas with the ambient air A spark when blowing the fuse or releasing an automatic circuit breaker can detonate the explosive mixture Stop Switch A Stop Switch must be used with the DS 300 Wind Turbine System This Stop Switch is installed between the DS 300 Wind Turbine and the Controller to provide a convenient method for remotely and manually shutting down the DS 300 turbine This Stop Switch disconnects the Controller then short circuits the turbine causing the turbine to stop spinning A Triple Pole Double Throw TPDT or 3PDT should be used for a 3 phase wind turbine generator equipped with the DS 300 44 6 Warranty The Hi VAWT Technology Corporation Hi VAWT provides one 1 year limited warranty Warranty Period for products it manufactures and covers defects in materials workmanship and guality Defeats in the DS 300 VAWT System The warranty is valid from the date of invoice to the original user The limited warranty is also transferable and applied to subsequent owners only within the Warranty Period Hi VAWT will repair or replace the defective products for free under the following conditions e The user has notified Hi VAWT of the Defeat within the Warranty Period Hi VAWT verifies the existence of a Defeat that is covered within the l
26. the key factors to achieve the success of the installation Please refer to the Figure 3 3 for DS 300 foundation construction Figure 3 3 Ground Foundation Construction Reference BEER a HELER KA 100mm 25 List of Material Reguired 1 Cubic meter of concrete 35 Newton or better 4 M16 with length of 360m m galvanized Anchor Bolts One end is bent into a hook shape 4 M16 Nuts 4 galvanized washers Electrical conduit 100m m diameter pipe or similar maybe needed for underground wiring if applied 3 3 2 Roof Foundation Installation of the DS 300 VAWT System on the roof may be much easier than it is on the ground But special thought of the building structure has to be carefully taken into account before the installation We strongly suggest that the location on top roof surface should be above the concrete beam Any surface other than concrete the users should contact their own architect or Structure engineer for advice and take their own responsibility for any possible dangers The concrete roof should be thick enough to allow 100mm drilling down from the surface Please follow the template explained in Section 3 3 1 and use this template as a guide and drill four 220 holes 100mm deep down to the surface Insert and secure four threaded rod to each hole use 4mm plywood to make a square holding template with inner dimension T1 x T2 x T3 pour the concrete into this square tem
27. the length between DS 300 Controller and Battery is no longer than 5 meters Please follow the reference table below for wire sizing Table 5 1 Wire Sizing Reference Distance Between Generator and Controller 0 10m 10m 10 20m 20 30m 30 50m 200m 2050m y Som is nor Gauge 5 3 DS 300 Wiring Diagram The DS 300 VAWT System is designed in collaboration with WG0400 Wind Charge Controller and WG0400 RC10 II Wind PV Hybrid Controller Both wiring diagrams will be illustrated in Figure 5 1 and Figure 5 2 A WARNING e Hi VAWT Technology Co Ltd makes no warranty that DS 300 Wind Turbine System will work with power management devices other than WG0400 and WG0400 RC10 II in terms of performance and functionality 39 Figure 5 1 Wiring Diagram for Wind Charge Controller WGO400 WA WG0400 Wind 300W VASWT peas CDS For Day and Night Detection POWER LOADING Deep Cycle Battery Bank 40 Table 5 2 DS 300 Wiring Size Reference WG0400 Description Wire Size Stop Switch AWG 12 gt 125VAC 30A Connection C Wind Charge Controller WGO400 oO Photo Diode AWG 18 z Wind Charge Controller AWG 12 Ground Fuse or Circuit Breaker AWG 10 SOAmps DC Within 5 Meters hine o baa Battery DC12V 100Ah 250Ah P NOTE e Please refer to the WG0400 Wind Charge Controller User s Manual for further information 41 Figure 5 2 Wiring Diagram for Wind PV Hybr
28. to properly and safely operating the device 1 1 1 2 Mechanical Hazards Rotating blades present the most serious mechanical hazard The DS 300 s rotor blades are made of very strong anodized aluminum Some edge of the blades are sharp please do not touch those sharp blades Even though with the built in airfoil the edges of those blades are not as sharp they still will cause serious injury when they start rotating even at low speed A WARNING e NEVER TOUCH THE RUNNING ROTOR e NEVER TRY TO STOP THE RUNNING ROTOR BY HAND e DO NOT INSTALL THE DS 300 VAWT SYSTEM WHERE ANYONE CAN APPROACH THE PATH OF THE BLADES e AVOID ANY OBJECTS TOUCHING THE RUNNING ROTOR Electrical Hazards The DS 300 VAWT System is equipped with sophisticated generator and designed to provide protection from electrical dangers Heat in wiring systems is often a result of too much current flowing through and undersized wire or through a bad connection It is important to follow the suggested wire sizing chart to ensure a safe electrical system The battery if applied should never be short circuited as it will result a danger of setting the battery and cable on fire In order to 1 3 avoid the threat and protect the cabling fuses should be installed in the lines connecting to the battery A WARNING e WIRING CABLE WITH INSUFFICIENTLY DIMENTION CROSS SECTION CAN CAUSE ELECTRICAL FIRE e NEVER SHORT CIRCUIT THE BATTERY IF APPLIE
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