Kestrel e300i User Manual

e300i User Manual Document #: 0503M01A REV : 1.3
Approval: Date: March ‘08 Page 1 of 25

Registration Number 2006/005438/07

VAT Registration Number 4870231406

Tel: [phone]

Website: www.kestrelwind.co.za

User Manual Revision 1.3 (03-08)

Revision 1.2 (12-07)
Revision 1.1 (08-07)

Revision 1.0 (06-07)

e300i User Manual Document #: 0503M01A

REV : 1.3

Approval: Date: March ’08 Page 2 of 25

CONTENTS

CONTENTSCONTENTS

CONTENTS

1

11

1 Safety Considerations

Safety ConsiderationsSafety Considerations

Safety Considerations

1.1

1.11.1

1.1 Mechanical Safety

Mechanical SafetyMechanical Safety

Mechanical Safety 3

3 3

3

1.2

1.21.2

1.2 Electrical Safety

Electrical SafetyElectrical Safety

Electrical Safety 3

3 3

3

1.3

1.31.3

1.3 Installation Hazards

Installation HazardsInstallation Hazards

Installation Hazards 3

3 3

3

1.4

1.41.4

1.4 Operational Safety

Operational SafetyOperational Safety

Operational Safety 3

3 3

3

2

22

2 Wind Turbine Overview

Wind Turbine OverviewWind Turbine Overview

Wind Turbine Overview

2.1

2.12.1

2.1 Turbine Description

Turbine DescriptionTurbine Description

Turbine Description 4

4 4

4

2.2

2.22.2

2.2 Identification and Markings

Identification and MarkingsIdentification and Markings

Identification and Markings 4

4 4

4

2.3

2.32.3

2.3 Applications and uses

Applications and usesApplications and uses

Applications and uses

2.4

2.42.4

2.4 Charge Controllers and Inverters

Charge Controllers and InvertersCharge Controllers and Inverters

Charge Controllers and Inverters

2.5

2.52.5

2.5 Grid Tied Applications

Grid Tied ApplicationsGrid Tied Applications

Grid Tied Applications

2.6

2.62.6

2.6 Voltage Limiter

Voltage LimiterVoltage Limiter

Voltage Limiter 5

5 5

5

3

33

3 Unpacking and

Unpacking and Unpacking and

Unpacking and Turbine Assembly

Turbine AssemblyTurbine Assembly

Turbine Assembly

3.1

3.13.1

3.1 Components Supplied

Components SuppliedComponents Supplied

Components Supplied 6

6 6

6

3.2

3.23.2

3.2 Tools Required

Tools RequiredTools Required

Tools Required 6

6 6

6

3.3

3.33.3

3.3 Unpacking

UnpackingUnpacking

Unpacking 7

7 7

7

3.4

3.43.4

3.4 Technical Requirements for

Technical Requirements forTechnical Requirements for

Technical Requirements for Assembly

Assembly Assembly

Assembly

8

8 8

8

3.5

3.53.5

3.5 Generator

GeneratorGenerator

Generator Assembly

AssemblyAssembly

Assembly

8888

3.6

3.63.6

3.6 Pitch control Assembly

Pitch control AssemblyPitch control Assembly

Pitch control Assembly 8

8 8

8

3.7

3.73.7

3.7 Tail Assembly

Tail AssemblyTail Assembly

Tail Assembly

9999

3.8

3.83.8

3.8 Fitting the Pitch Control

Fitting the Pitch ControlFitting the Pitch Control

Fitting the Pitch Control

10

1010

10

3.9

3.93.9

3.9 B

BB

Blade Assembly

lade Assemblylade Assembly

lade Assembly

11111111

4

44

4 Site Considerations and Mountings

Site Considerations and MountingsSite Considerations and Mountings

Site Considerations and Mountings

4.1

4.14.1

4.1 Mounting Flange Detail

Mounting Flange DetailMounting Flange Detail

Mounting Flange Detail 1

1 1

12222

4.2

4.24.2

4.2 Roof Mounting

Roof MountingRoof Mounting

Roof Mounting 1

1 1

12222

4.3

4.34.3

4.3 Towers

TowersTowers

Towers 1

1 1

12222

5

55

5 Wiring and

Wiring and Wiring and

Wiring and Cable Sizing

Cable SizingCable Sizing

Cable Sizing

5.1

5.15.1

5.1 Turbine Wiring

Turbine WiringTurbine Wiring

Turbine Wiring 1

1 1

13333

5.2

5.25.2

5.2 Lightning Protection

Lightning ProtectionLightning Protection

Lightning Protection 1

1 1

13333

5.3

5.35.3

5.3 Wire

WireWire

Wire and Cable Sizes

and Cable Sizes and Cable Sizes

and Cable Sizes 1

1 1

14444

6

66

6 Battery Considerations

Battery ConsiderationsBattery Considerations

Battery Considerations

6.1

6.16.1

6.1 Lead Acid Batteries

Lead Acid BatteriesLead Acid Batteries

Lead Acid Batteries 1

1 1

15555

6.2

6.26.2

6.2 Sealed Gel Batteries

Sealed Gel BatteriesSealed Gel Batteries

Sealed Gel Batteries 1

1 1

15555

6.3

6.36.3

6.3 Ni

NiNi

Ni----Cad Batteries

Cad BatteriesCad Batteries

Cad Batteries 1

1 1

15555

6.4

6.46.4

6.4 Temperature Compensation

Temperature CompensationTemperature Compensation

Temperature Compensation 1

1 1

15555

7

77

7 Technical

Technical Technical

Technical Details

DetailsDetails

Details

7.1

7.17.1

7.1 Technical Specification

Technical SpecificationTechnical Specification

Technical Specification 1

1 1

16666

7.2

7.27.2

7.2 Declaration of Conformity

Declaration of ConformityDeclaration of Conformity

Declaration of Conformity 1

1 1

17777

8

88

8 Trouble shooting

Trouble shootingTrouble shooting

Trouble shooting 1

1 1

18888

9

99

9 Maintenance

MaintenanceMaintenance

Maintenance 1

1 1

19999

10

1010

10 Warranty Conditions

Warranty ConditionsWarranty Conditions

Warranty Conditions 21

2121

21

11

1111

11 Customer Feedback

Customer FeedbackCustomer Feedback

Customer Feedback 2

2 2

25555

e300i User Manual Document #: 0503M01A

REV : 1.3

Approval: Date: March ’08 Page 3 of 25

11 SSaaffeettyy CCoonnssiiddeerraattiioonnss

11..11 MMeecchhaanniiccaall SSaaffeettyy

11..22 EElleeccttrriiccaall SSaaffeettyy

11..33 IInnssttaallllaattiioonn HHaazzaarrddss

11..44 OOppeerraattiioonnaall SSaaffeettyy

Disclaimer

Kestrel Wind Turbines makes every effort to give accurate information in this manual and is in no way

liable for any error or omission. The user of this manual assumes full responsibility and risk.

We appeal to your common sense to read and apply the safety notes. Consult professional engineers

and take advice if you are unsure.

1 SAFETY FIRST

1 SAFETY FIRST1 SAFETY FIRST

1 SAFETY FIRST

Although Kestrel’s wind turbines are designed with your safety in mind, accidents can easily occur
and there are always inherent dangers associated with any type of machine. Consult installation

professionals if you lack experience or confidence.

1.1 Mechanical Safety

1.1 Mechanical Safety1.1 Mechanical Safety

1.1 Mechanical Safety

Use good handling methods and take precautions to avoid physical injury during installation and
maintenance/repair procedures. The rotating blades of any wind turbine are a main hazard. The
e300

iiii

blades are extremely tough and will cause serious injury to the body. Never install the e300

iiii

such that any person or animal could come into accidental contact with any part of the machine. Never
approach the machine if the blades are rotating.

1.2 Electrical Safety

1.2 Electrical Safety1.2 Electrical Safety

1.2 Electrical Safety

The e300

iiii

output voltage can become dangerous and even lethal when running on open circuit.

Maintain a healthy respect for this wind turbine. Always short the output wires together when the

e300

iiii

is disconnected. Do not work on the system when the turbine is running or when lightning is

possible. Disconnecting a running e300

iiii

may cause a spark and the presence of explosive
hydrogen from battery charging is always a possibility. Adequate ventilation must be provided for

battery installations. The wire size used for connections must be correct for the powers supplied. The

smaller the wire diameter, the higher the wire losses and therefore the heat generated in the wire.

Use correct wire sizes throughout the installation. The amount of energy stored in a battery is

considerable and fire can result from shorts. Fit a suitable fuse or circuit breaker in the battery cable.

In general, respect the system and use common sense. Consult a qualified electrician if you are unsure.

1.3 Installation Hazards

1.3 Installation Hazards1.3 Installation Hazards

1.3 Installation Hazards

All installation work should be completed at ground level wherever possible. Be very aware of the

blades during installation. Contact with the blades will only injure you, not the blades. The
installations of poles or towers pose their own dangers. Always work carefully and have an
assistant wherever possible. Short the generator output wires (Red and Black) throughout any

installation procedure. Consult a civil engineer or reputable builder if you are not sure about

installing structures. Always re-check the work as you progress. Slack bolts, poor workmanship and
loose electrical connections must be avoided.

1.4 Operational Safety

1.4 Operational Safety1.4 Operational Safety

1.4 Operational Safety

The turbine blades are dangerous. Respect a rotating turbine. Always shut the turbine down before
approaching. This may be achieved by shorting the generator output. Preventative maintenance is

always the best.

Checks are best carried out in calm weather conditions. Avoid any maintenance or

inspection during windy weather.

3

e300i User Manual Document #: 0503M01A

REV : 1.3

Approval: Date: March ’08 Page 4 of 25

22 WWiinndd TTuurrbbiinnee OOvveerrvviieeww

22..11 TTuurrbbiinnee DDeessccrriippttiioonn

22..22 IIddeennttiiffiiccaattiioonn aanndd MMaarrkkiinnggss

22..33 AApppplliiccaattiioonn aanndd UUsseess

22..44 CChhaarrggee CCoonnttrroolllleerrss aanndd IInnvveerrtteerrss

22..55 GGrriidd TTiieedd IInnvveerrtteerr AApppplliiccaattiioonnss

22..66 VVoollttaaggee LLiimmiitteerr

2 WIND TURBINE OVERVIEW

2 WIND TURBINE OVERVIEW2 WIND TURBINE OVERVIEW

2 WIND TURBINE OVERVIEW

2.1 Turbine Description

2.1 Turbine Description2.1 Turbine Description

2.1 Turbine Description

The e300

iiii

is a unique wind turbine that incorporates superior technology. The heart of the machine

comprises of a unique twin axial flux permanent magnet brushless alternator. The alternator

contains no less than 96 poles and 52 magnets. The polyphase high frequency output is internally

rectified to give a dc output with extremely low ripple content. The generated power is

transferred to the output cables via heavy duty bronze slip rings and twin copper composite

electrical brushes. The prime mover on the e300

iiii

is a 3.0m (9.85’) diameter three blade wind

rotor fitted with quiet running high efficiency blades. The blade hub incorporates passive pitch

control. The e300

iiii

pitch control changes the operating angle of the blades to achieve speed

control in high wind. The tail vane assembly is static and simply aligns the machine with the

prevailing wind.

All steel components are electro-galvanised and passivated for extra protection. The standard

finish consists of the application of an etching marine primer and an intermediate protective coat

followed by polyurethane two pack finishing coats.

2.2 Identification and Markings

2.2 Identification and Markings2.2 Identification and Markings

2.2 Identification and Markings

The turbine generator body carries a stamped unique serial number and a rating plate. Both the

stamped serial number and rating plate are visible on the bottom yaw shaft housing. If this e300

iiii

does not carry this stamp it does not carry a Kestrel warranty and may not be authentic.

4

e300i User Manual Document #: 0503M01A

REV : 1.3

Approval: Date: March ’08 Page 5 of 25

2.3

2.3 2.3

2.3 Applications

ApplicationsApplications

Applications and Uses

and Uses and Uses

and Uses

The e300

iiii

is suitable for electrical power generation on various installations that include battery

charging, water delivery and grid tie applications. Each application requires specific additional

electrical equipment. Consult the manuals supplied with this equipment.

2.

2.2.

2.4444 Charge Contr

Charge Contr Charge Contr

Charge Controllers

ollersollers

ollers and Inverters

and Inverters and Inverters

and Inverters

Any wind turbine produces uncontrolled power that varies with incident wind speed. The open

circuit generator voltage is directly proportional to generator speed (rpm). Some form of

regulator must control this “raw power”. A battery charging regulator is often referred to as a

charge controller.

A charge controller is required for the Kestrel to charge a battery. Kestrel can supply a standard

charge controller for the e300

iiii

. A suitable diversion resistor is available from Kestrel.

An inverter can be connected to the battery and is used to convert the battery dc power to ac

power. An inverter therefore allows the use of standard electrical equipment that works on ac

voltage.

2.

2.2.

2.5555 Grid Tied Inverter

Grid Tied InverterGrid Tied Inverter

Grid Tied Inverter Applications

Applications Applications

Applications

The 200Vdc version of the e300

iiii

is suitable for connection to an approved Grid Tie Inverter. Grid

Tied installation is subject to local electrical codes of practice and is usually carried out by

qualified personnel. Prior approval from the local utility company must be obtained before

connection to the mains.

2.

2.2.

2.6666 Voltage Limiter

Voltage Limiter Voltage Limiter

Voltage Limiter

Grid tied applications require a Voltage Limiter to be connected between the e300

iiii

(200Vdc

version) and the Grid Tie Inverter. Certain operating modes of the inverter allow the Kestrel output

voltage to rise beyond the limit of the inverter. The Kestrel Voltage Limiter will restrict the rise in

voltage as the inverter performs various functions. Refer to the manual provided with the Kestrel

Voltage Limiter.

5

e300i User Manual Document #: 0503M01A

REV : 1.3

Approval: Date: March ’08 Page 6 of 25

33 UUnnppaacckkiinngg aanndd TTuurrbbiinnee AAsssseemmbbllyy

33..11 CCoommppoonneennttss SSuupppplliieedd

33..22 TToooollss RReeqquuiirreedd

33..33 UUnnppaacckkiinngg

33..44 TTeecchhnniiccaall RReeqquuiirreemmeennttss ffoorr AAsssseemmbbllyy

33..55 GGeenneerraattoorr AAsssseemmbbllyy

33..66 TTaaiill AAsssseemmbbllyy

33..77 FFiittttiinngg tthhee PPiittcchh CCoonnttrrooll

33..88 BBllaaddee AAsssseemmbbllyy

3 UNPACKING AND TURBINE ASSEMBLY

3 UNPACKING AND TURBINE ASSEMBLY3 UNPACKING AND TURBINE ASSEMBLY

3 UNPACKING AND TURBINE ASSEMBLY

3.1 Com

3.1 Com3.1 Com

3.1 Components Supplied

ponents Suppliedponents Supplied

ponents Supplied

The following components are supplied.

 Pitch hub assembly
 Shaft drive key
 Propeller blade set
 Generator assembly
 Tail boom (two pieces)
 Tail (two pieces)
 Tail Stabiliser (two pieces)
 Nacelle cover
 Nosecone
 All fasteners and bolts
 Assembly grease
 Locktite

3.

3.3.

3.2222 Tools Required

Tools Required Tools Required

Tools Required

The following hand tools are required for turbine assembly and installation.

 10mm metric ring spanner or socket wrench (two required)
 13mm metric ring spanner or socket wrench
 19mm metric ring spanner or socket wrench (two required)
 Small size electrical screwdriver
 Medium size electrical screwdriver
 10mm Allen key wrench
 Wire strippers for electrical connections



Tape measure to adjust the blades

 Torque wrench

6

e300i User Manual Document #: 0503M01A

REV : 1.3

Approval: Date: March ’08 Page 7 of 25

3.3 Unpacking

3.3 Unpacking3.3 Unpacking

3.3 Unpacking

Open the packaging container and check for any transit damage. The parts contained are listed
in section 3.1 and on the included packing slip. Lay out the parts and identify them with the
assembly drawing provided.

3.

3.3.

3.

30053

Spring Washer 10mm S/Steel 1 031

30094

Hex Bolt M6x1x16L S/Steel

4 030

30834

Front Stiffner

2 029

30153

Bottom Tail Plate

1 028

30836

Rubber Strip

2 027

30819

Hex Bolt M6x1x70L S/Steel

2 026

30831

Rear Stiffner

2 025

30835

Clampi

ng strip

2 024

30957

Hex Bolt M6x1x80L S/Steel

5 023

30830

Top Tail Plate

1 022

30091

Hex Nut Nylock M6x1 S/Steel

13 021

30925

Nacelle

1 020

30769

Tail Boom

1 019

30925

Nacelle Cover Plate

1 018

30149

Screw M5x16 C/Head S/Steel

4 017

30088

Bolt Hex M8x30L S/Steel

4 016

30095

Nut Hex M8 Nylock S/Steel

7 015

30096

Washer Plain Metric 8mm S/Steel

7 014

30022

e300i Generator Assembly

1 013

30173

Nut-Hex M12x1.75 Nylock

6 012

30029

e300i Blade Set

3 011

3

0768

Compression Plate

3 010

Hex Bolt M12x65L S/Steel

6 009

30899

Hub to Bearing Collar

1 008

30054

Shaft Key (8mmx7mm)

1 007

30990

Pith Control

1 006

30689

Hub Clamping Spacer 1 005

30660

H/Tensile Cap Screw M10x40L ZP

1 004

30

092

Washer Plain Metric 6mm SlSteel

16 003

30152

Screw C/Head M6x16 S/Steel

3 002

30924

Nose Cone

1 001

Item

#

Description

Qty Part

e300i User Manual Document #: 0503M01A

REV : 1.3

Approval: Date: March ’08 Page 8 of 25

4

4 4

4 Technical Requirements for Assem

Technical Requirements for AssemTechnical Requirements for Assem

Technical Requirements for Assembly

blybly

bly

Torque Settings

Torque SettingsTorque Settings

Torque Settings

DESCRIPTION BOLT TYPE

TORQUE

(Metric)

TORQUE

(Imperial)

NOSE CONE SCREWS M6 x 16, S/S 5Nm 3,7 ft·lb
FRONT BOLT 12.9 HI-TENSIL + LOCTITE M10 X 35 60Nm 44,3 ft·lb
BLADE BOLT M12 x 80, S/S WITH M12 NYLOCK NUT 35Nm 25,8 ft·lb
TAIL BOOM M8 BOLTS, S/S 30Nm 22,1 ft·lb
M8 NYLOCKS 25Nm 18,4 ft·lb
NACELLE SCREWS M6 x 16, S/S 3Nm 2,2 ft·lb
M5 x 15, S/S 3Nm 2,2 ft·lb

TAIL BOLTS M6 x 60, S/S WITH M6 NYLOCK NUT 10Nm 7,4 ft·lb

MOUNTING BOLTS M8 x 25, 8.8 HI-TENSIL PLATED 35Nm 25,8 ft·lb

3.5 G

3.5 G3.5 G

3.5 Generator Assembly

enerator Assemblyenerator Assembly

enerator Assembly

The alternator (01) is factory assembled.

3.6 Pitch control Assembly

3.6 Pitch control Assembly3.6 Pitch control Assembly

3.6 Pitch control Assembly

The pitch control boss (03) is factory assembled.

8