EST 2KW WIND TURBINE Operation Manual

2KW WIND TURBINE

Operation Manual

GRADE AAA

**Please read carefully before using**

EST energy saving technology

ESPECIALLY DESIGNED FOR EST LEBANON

1. Application

A wind power generator is a piece of equipment that converts wind energy into electric power
which is used to charge a storage battery group. It can be widely used in windy areas without
electrical grid access. It is capable of providing power for lighting, TV, telecommunication
equipment and other equipment.

2. Structure and Main performance

The unit is mainly composed of wind rotor, permanent magnet generator, tail vane, stand,
electronic controller, storage batteries, electric inverter, electric cable, and diversion load
(Fig1)

Main technical performances

Rotor Diameter (m)

3.2

Material and number of the blades

Reinforced fiberglass *3

Rated power/maximum power

2000/3000

Rated wind speed (m/s)

10

Startup wind speed (m/s)

3

Working wind speed (m/s)

3–30

Survived wind speed

40

Working voltage

DC48v

Generator style

Three phase, permanent magnet

Charging method

Constant voltage current saving

Speed regulation method

Yawing + Electromagnetic brake

Stop method

Manual brake

Tower height (m)

6

Weight (kg)(not including batteries
or inverter)

Main unit 95 / Total 155

3. Preparation

3.1 Prepare batteries according to manufacturers specifications.

3.2 Unpack and check the turbine parts and verify all parts are included.

3.3 Choose an open and flat place with no barriers around for wind turbine installation.
To avoid losses due to voltage drop over the cable run, the distance between wind turbine

and batteries should be made as short as possible. For best results, it should be less than
30m.

3.4 Install Foundation pylon and anchor points.

3.41 Dig a hole where you want the center pylon for the turbine base. The size of the pylon

should be 50X30X36cm. Next dig four triangular (each side is 80cm) pits with the depth of
60cm symmetrical 4.5 meters from the central hole in four directions. One point of each

triangle pit points to the center hole. (Fig 2)

3.42 Start with the center pylon. Attach the 4 foundation bolts onto the base plate. Screw on the
M16 nuts respectively until the top of bolt is 15mm out of nut. Align the axis of the pivot pin
with anchor points BD or AC. The Base plate should be 4-5cm above the ground. Adjust the
base plate to make it level and fill the hole with concrete. The mixture ratio of concrete is
cement: sand: gravel= 1:2:3.

3.43 Hold the top of the anchor chain and put the anchor horizontally into the base of pit along
the outside edge. Lay crushed stone (about 2~5kg) into the pits, then cover them in
concrete. Lay crushed stone into the pits and add more concrete. Repeat until the triangular
pit is full. Finally adjust the guy wire anchors toward the center with an angle of 60-degree
from the ground. Hold the chain and fill the pit with concrete until the middle part of the top
link, leaving the other half out of the concrete. (Fig 3)

3.44 The curing period of the concrete pylons and anchors is 100 hours. During this period, do
not install the wind turbine.

4. Installation procedure

4.1 Select a sunny day without wind (wind speed less than 3m/s)

4.2 Adjust the Base plate level, then put the washer onto the foundation bolt and fasten the nuts.

Put together the upper, middle and lower mast. Lay the mast on the “A” pit. Link the mast
bottom to the base plate with Φ16 pin, then put on the washer and connect them with the
pivot pin.

4.3 Draw out the guy wires in all four directions. Bend the tip of the steel wire to a loop, the

length of which should be approximately 20cm. Put the loop for guy wire through the loop
welded to the tower section. Close the loop with two wire-clamps. Repeat for each of the
remaining cables.

4.4 Put the heart ringer for steel wire across the “o” loop of turnbuckle, and then rip the steel wire

into the heart ringer. Bend for a loop; no less than 30cm long, fasten with wire-clamps. Hook
the turnbuckles of A, B and D pits to the chain of anchor. Draw back the mast, and then hook
the turnbuckle and anchor chain. Adjust the length of steel wire through turnbuckles to plumb
the mast. Install the stay bar to the lower mast，fix up it with M12 bolts. Untie “U” shape
screw between anchor and turnbuckle of pit C. Connect the steel wire of C pit and the top of
stay bar and fasten it. Then adjust until the steel wire between stay bar and mast in strain
state.

4.5 Put a 1m bracket into pit A. Loose the “U” shape screw buckle in pit B and pit D (About 5cm

length). Untie the link of the “U” shape screw and the ground anchor chain in pit C. Fall

down the mast slowly; support the steel wire pothook with20cm height stow-wood.

4.6 Insert the cable through the bottom to the top of the mast with a steel wire(2~3mm) and
extend out about 20 to 50cm. Connect the 3 ends of the cables (which start from the slip
ring) with the terminal block. Connect the 3 ends of the cables which come from the slip ring
with the terminal block.

4.7 Install the generator onto the mast top through the sleeve. Fasten the screw.

4.8 Assemble the tail rod to the rotating body, aligning the M12 holes correctly, insert the lock
washer; screw the four M12X25 inner six angle nuts tightly. (FIG5)

4.9 There are two holes that can be chosen on the trough shape clamp of the tail rod and two
holes distributing on the two sides of the tail vane tie-in’s axes, whose diameter is 11mm.

Insert the tie-in of tail vane into the trough shape clamp of the tail rod, insert M12X70 bolt
into the ø13 holes correctly, put on washer 12, lock washer 12 and M12 self-locking nuts,
Adjust the tail rod angle against the level plane according to the local wind resources and
electricity consumptions (it can be adjusted to four angles). Decrease the angle can
increase the rotating speed of the rotor. Then insert the screw shaft into ø13, screw the
adjusting bolt and nut (M12). After adjusting, tighten the two self-locking nuts. (See fig.6).

4.10 Before leaving the factory, every rotor has been assembled and balanced. For easy
transportation, the rotor had been disassembled. When reassembling the rotor, please
check the marks on the blades, to return them to the proper positions, then fit the M12×80
screws, washers, and M12 self-locking nuts one by one. Tighten the nuts finger tight first,
then measuring the distances between the center point to the tip end of blades a, b and c,
the difference in distance between the 3 blades should less than 5mm. If it is not, adjust the
blade before tightening the bolts. Tighten the nuts firmly to a torque of between 40 – 45 N.m
(see fig.7).

4.11 Assemble the blade-rotor on the axes of generator, put on the flat washer and lock washer
one by one, and then screw the self-locking nut tightly.

4.12 Assemble the nose cone to the rotor hub with M6 screws, lock washers and flat washers.

4.13 Draw backs the mast through chain jack; connect the screw buckle of pit C to the anchor.
Adjust the length of the screw buckle in four directions. Strain the steel wires to make the
mast in its vertical position. Strain the steel wire until it can rebound lightly when gives a
transverse force.

4.14 Check the wire block, screw buckle and all connecting point. Make sure it is safe. Then

wrap and blocked them with galvanized wire. Put anti-corrosive grease on wire block,
screw buckle and all links where necessary.

4.15 Connect the batteries in series to be a group, two ends connectors are “+” pole and “- ” pole

respectively. Connecting wire between batteries and the input & out put wires of the battery
group should be 6mm², “+”pole is marked by red color; and “-”pole is marked by black(or
yellow, or blue). All connections should use wire connecting clips to ensure every
connection is secure and electricity conducts well. In order to prevent corrosion of the
connecting clips caused by acid vapor from the batteries, put a layer of protective grease
on them.

4.16 Connect the red wire “+” pole of the batteries to the “+” pole connector of the controller &

Inverter; then, connect the black wire of “-” pole of the batteries to the “-” pole connector of

the controller & Inverter. Connectors must be tightened firmly to ensure good electrical
conductivity.

4.17 Connect the 3 phase output wires of the generator to the connectors of the controller

respectively.

4.18 According to the different requirement, there are two kinds of arrangements for
electric box: a) DC output; b) DC/AC output. Please follow the marks on the box to connect
with the appliances. Please take care for safe operation when using the AC220 output!

5. Application notice

5.1 Application principles

5.1.1 Please read the specification carefully before using. Do not install or uninstall on a windy

day.

5.1.2 The off-grid wind turbine charges the batteries through a controller or a control-inverter.