NRG Systems Hybrid XT Vane Product Manual

NRG Product Manual

Hybrid XT Vane

Authors:

Technical Services

HybridXT_Vane_Manual
Rev 13.0

NRG Product Manual

Hybrid XT Vane

HybridXT_Vane_Manual
Rev 13.0

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Specifications are subject to change without notice.

e-mail: [e-mail]

© NRG Systems

110 Riggs Road

Hinesburg VT 05461

Tel: [phone]

Fax: [phone]

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TABLE OF CONTENTS

CUSTOMER SUPPORT ...................................................................................................................................... 4

INTRODUCTION .............................................................................................................................................. 5

USING THIS MANUAL ...................................................................................................................................... 5

VANE OPERATION AND CONSIDERATIONS ...................................................................................................... 6

Hybrid XT Vane Head Damping ........................................................................................ 6

CABLES COMPATIBILITY TABLES ...................................................................................................................... 9

INSTALLATION AND TECHNICAL DRAWINGS ................................................................................................. 11

GROUNDING AND BONDING HYBRID XT™ SENSORS FOR OVER-VOLTAGE PROTECTION ............................... 16

WARRANTY & REPAIR ................................................................................................................................... 19

SENDING ITEMS FOR REPAIR ......................................................................................................................... 20

DECLARATION OF CONFORMITY ................................................................................................................... 22

APPENDIX A: FG# 4715 – HYBRID XT TURBINE CONTROL VANE ..................................................................... 23

APPENDIX B: FG# 5762 – HYBRID XT 4-20 MA OUTPUT VANE ....................................................................... 24

APPENDIX C: FG# 7894 – HYBRID XT PUSH-PULL VANE ................................................................................. 25

APPENDIX D: FG# 9362 – HYBRID XT 4-20MA, COUNTER-CLOCKWISE VANE.................................................. 27

APPENDIX E: FG# 9363 – HYBRID XT PUSH-PULL, ACTIVE-HIGH VANE ........................................................... 28

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CUSTOMER SUPPORT

NRG Systems offers a variety of support options to help you get the most from your NRG Systems product. If you have
questions about your NRG Systems product, first look in the printed product documentation, the Knowledge Base and
the Technical Forum contained in the Tech Support section of the NRG Systems web site. If you cannot find the answer,
contact your salesperson or NRG Systems Technical Support for assistance using the information below. Customer
support is available 8:30 AM to 5:00 PM EST, Monday through Friday.

NRG Systems Telephone: [phone]
110 Riggs Road FAX: [phone]
Hinesburg, Vermont
05461 U.S.A. Email: [e-mail]

When you call or email, you should have the appropriate product documentation at hand and be prepared to give the
following information:

 Customer name
 Who purchased equipment
 Item number or description
 Serial number
 When equipment was purchased
 Where equipment is installed - terrain conditions
 Description of the problem with some detail
 What events took place leading up to the problem
 What you have tried while attempting to solve the problem

NRG Systems maintains an extensive website which includes an in-depth customer support area for NRG Systems
customers. If you need assistance at times other than our regular business hours, we suggest visiting our website,
www.nrgsystems.com.

All instruments, sensors, software and towers manufactured by NRG Systems are designed to be reliable and easy to
use. We welcome your comments and appreciate your help in making NRG Systems products the best available.

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INTRODUCTION

The NRG Systems Hybrid XT vane is an electrically heated wind direction sensor designed for wind turbine control and
wind resource assessment. The sensor is mounted to the turbine nacelle or meteorological mast and provides an
electrical output signal relative to wind direction. While the Hybrid XT sensors can be used for meteorological work, this
manual is specific to turbine control applications.

The Hybrid XT is rugged enough to accurately measure wind directions in excess of 70 m/s (156 mph), yet its relatively
low moment of inertia permits it to respond rapidly to gusts and lulls. It is built with corrosion resistant materials and
finishes, and is sealed against wind-driven rain and dust.

The Hybrid XT sensor line has a captive mounting system with integral connector that allows quick and easy changing of
the sensor. There are only three internal components (electronics module, heater assembly and bearing assembly) for
ease of maintenance. The Hybrid XT also has a spare label pocket for a customer-supplied identification label.

USING THIS MANUAL

Read this manual completely before installing and operating the Hybrid XT anemometer. Follow all instructions and
recommendations closely.

This document and the sensor may use the following symbols:

Earth (Ground) Chassis Ground AC Voltage

AC or DC Voltage DC Voltage Hot Surface

This typeface within the body of the manual is used for general descriptions and instructions to the user.

This typeface is used to warn users of a potential danger, either to themselves or to the sensor.

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Finished

good #

Vane type

Output

wires

Function

Signal

type

Description

4715

Hybrid XT Turbine

Control Vane

White

Pulsed

output

Frequency

100Hz - 460Hz square wave for 0 - 360 degrees

5762

Hybrid XT 4-20

mA Output Vane

White

Current

source

4-20 mA

4-20 mA output, clockwise, corresponds to 0 - 360

degrees

7894

Hybrid XT Push-

Pull Vane, ACTIVE

LOW

White

VL

2-channel

push/pull

Yaw right/left (VL), upwind/downwind (VR90); active

LOW

Yellow

VR90

9362

Hybrid XT 4-20

mA Output Vane,

CCW

White

Current

source

4-20 mA

4-20 mA output, counter-clockwise, corresponds to

0 - 360 degrees

9363

Hybrid XT Push-

Pull Vane, ACTIVE

HIGH

White

VL

2-channel

push/pull

Yaw right/left (VL), upwind/downwind (VR90); same

as FG #7894, but active HIGH

Yellow

VR90

VANE OPERATION AND CONSIDERATIONS

Output Circuit Operation

The Hybrid XT line of wind vanes are available with different output configurations to support a variety of turbine
control systems. See the appendices below for the output characteristics of the full suite of Hybrid XT vanes.

Hybrid XT Vane Head Damping

The Hybrid XT Vane has damping in the head to reduce overshoot and oscillation behind the turbine rotor. One result of
this is that the frequency response has been lowered slightly. This may, in some limited circumstances, require a slight
adjustment to the turbine controller settings when retrofitting a Hybrid XT in place of an IceFree 2, IceFree 3, or an
original Hybrid. Please contact Renewable NRG Systems for further information.

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Heater Operation

The heat source for the Hybrid XT is a self-regulating, constant-temperature heater. Constant heating prevents
condensation and corrosion and maintains proper bearing temperature for consistent performance and transfer
function. In severe wind and icing conditions, the Hybrid XT draws more power to help remain clear of ice. As conditions
improve, the Hybrid XT draws less power. The Hybrid XT’s self-regulating feature increases reliability, insuring that the
head does not reach excessive temperatures. Excessive temperatures can stress bearing lubricants, wiring, and present a

hazard in the presence of combustible materials. The Hybrid XT’s heater is powered by 24 volt power, AC or DC, making

it compatible with a wide range of turbine controller power supplies and remote site equipment. An optional 120 / 240
V to 24 V AC transformer is also available.

 Following a brief inrush current, after approximately 30 seconds, the heater settles into its temperature

controlled mode.

 It is recommended that a 15 A slow-blow fuse be placed in-line with the heater.

Always power the heater on your Hybrid XT sensor! Failure to maintain constant heating may lead
to corrosion or inferior sensor performance. Constant heating prevents condensation from
forming on the bearings, enabling the sensor to achieve a 10 year service cycle. If the sensor is

used without the heater, the warranty will be void.

Sensor surfaces (particularly the head and the upper body) can become quite hot and may burn

you; especially in warm ambient conditions. Use caution when the heater power is on.

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ESD and Circuit Protection

The Hybrid XT sensor has been designed to withstand most common wiring errors and electrostatic discharge. These
include reversed polarity on the power supply inputs, applying power to or shorting the signal output lines, and
electrostatic discharge on any line.

However, the sensor is not indestructible. Avoid applying more than the rated power supply to any pin. While extremely

rugged, nearby or direct lightning strikes may damage the sensor.

Cable Shield Decision - Important

The user must decide how to connect the shield of the signal cabling for their application. This is an important part of
the overall design of the lightning protection and grounding system for each turbine design. Reference information can
be found in Appendix A.

We recommend that the shield always be connected at the controller end of the cable. This provides shielding against
capacitively (electrostatically) coupled interference to the sensor signal.

If the shield can be connected to ground at the sensor boom as well, the shield can also provide protection against
inductive (magnetically) coupled noise sources, such as generator noise and lightning electromagnetic pulses. However,
you should connect the shield at both ends ONLY if the turbine grounding system provides sufficient bonding and
grounding to prevent ground loop currents in the shield wire.

On the NRG Systems -cable assembly for the Hybrid XT Turbine Control Sensor, the shield is available for connection at
both ends. If the sensor end is not to be connected, cut off the shield wire at the sensor end before installation to
prevent accidental contact to the sensor mount.

Magnet Safety

The Hybrid XT sensors, particularly the vane version, contain small, but powerful neodymium iron boron magnets. These

magnets are strong enough to magnetize tools, erase magnetic media (floppy disks and credit cards), damage CRT’s
(computer monitors and TV’s), pinch fingers, etc. They can also shatter if allowed to snap together, causing eye damage.

If they are ingested, they can cause serious injury, or even death.

Do not allow unskilled persons to disassemble these sensors. Do not remove the magnets from
their respective assemblies (Head Assembly and Shaft Assembly). Keep small magnets and small
pieces containing magnets away from young children who might mistakenly or intentionally

swallow them. Seek immediate medical attention if you suspect a child may have swallowed a magnet.

Transport and Handling

This sensor is a precision instrument. Please use care in its handling to protect the bearings and shaft. It is recommended
that the sensor be carefully placed on its side instead of standing up.

If the sensor should tip over onto a hard surface, bearing or shaft damage may occur. Use care!

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Item

Number

Description

Notes

4716

Assembly-Cable,600V, 10m, Connector, Power, Signal,
WithMountingBolt, Hybrid TCS

10 m length, 5 pin cable, Green Tag

4717

Assembly-Cable,600V,20m, Connector,Power,Signal,
WithMountingBolt,Hybrid TCS

20 m length, 5 pin cable, Green Tag

8797

Assembly-Cable,600V,12m,6 Pin
Connector,Power,Signal, WithMountingBolt,Hybrid TCS

12 m length, 6 pin cable, Red Tag

9234

Assembly-Cable,300V,10m,
Connector,Power,Signal,WithMountingBolt,Hybrid TCS

10 m length, 6-pin cable Orange Tag

9319

Assembly-Cable,300V,20m,
Connector,Power,Signal,WithMountingBolt,Hybrid TCS

20 m length, 6-pin cable Chartreuse Tag

4715

Hybrid XT Turbine Control
Sensor, Vane

4716, 4717, 8797,
9234, 9319

Any cable may be used; if present, Yellow (Out

2) is not used and may be left disconnected

4718

Hybrid XT Turbine Control
Sensor, Anemometer

4716, 4717, 8797,
9234, 9319

Any cable may be used; if present, Yellow (Out

2) is not used and may be left disconnected

6624

Sensor-Hybrid XT Turbine
Control Sensor, Anemometer
(calibrated)

4716, 4717, 8797,
9234, 9319

Any cable may be used; if present, Yellow (Out

2) is not used and may be left disconnected
5762

Hybrid XT 4-20mA Output
Turbine Control Sensor, Vane

4716, 4717, 8797,
9234, 9319

Any cable may be used; if present, Yellow (Out

2) is not used and may be left disconnected

5763

Hybrid XT 4-20mA Output
Turbine Control Sensor,
Anemometer

4716, 4717, 8797,
9234, 9319

Any cable may be used; if present, Yellow (Out

2) is not used and may be left disconnected

CABLES COMPATIBILITY TABLES

There have been several different versions of the Hybrid cable assembly since inception to accommodate various sensor
and turbine configurations. Please see the tables below to verify cable compatibility.

Hybrid Turbine Control Sensor Cables

HybridXT Turbine Control Sensor Cable Compatibility

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7894

Hybrid XT Push-Pull Output
Turbine Control Sensor, Vane

8797, 9234, 9319 (Red,

Orange or Chartreuse

tag) only

All six wires are required to provide both Vane
signals.

White == VL (yaw right/left)
Yellow == VR90 (upwind/downwind)

7901

Hybrid XT Push-Pull Output
Turbine Control Sensor, Anem

4716, 4717, 8797,
9234, 9319

Any cable may be used; if present, Yellow (Out

2) is not used and may be left disconnected

8115

Hybrid XT Coil Compatible
Output Turbine Control
Sensor, Anem

4716, 4717, 8797,
9234, 9319

Future Product.

8797 may be used, Yellow (Out 2) is not used
and may be left disconnected

9362

Hybrid XT Vane, 4-20mA
Output, Counter Clockwise

4716, 4717, 8797,
9234, 9319

Any cable may be used; if present, Yellow (Out

2) is not used and may be left disconnected
9363

Hybrid XT Vane,Push-Pull,
Active High

8797, 9234, 9319 (Red,

Orange or Chartreuse

tag) only

All six wires are required to provide both Vane
signals.

White == VL (yaw right/left)
Yellow == VR90 (upwind/downwind)

9365

Hybrid XT Anemometer, 4­20mA Output, 60 m/s

4716, 4717, 8797,
9234, 9319

Any cable may be used; if present, Yellow (Out

2) is not used and may be left disconnected

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Cross-holes

Typical
mounting
mast

Nacelle centerline

Align cross-holes parallel to nacelle centerline.

IF cutting shield wire, cut close to
connector base as shown.

INSTALLATION AND TECHNICAL DRAWINGS

Mounting Mast Orientation

Refer to the technical drawing for details on mounting mast design. Orient the cross-holes in the top of the mounting
mast such that they are lined up parallel to the turbine nacelle centerline.

Prepare Shield

Based on your decision about the cable shield connection scheme (see previous section and Appendix A), cut off or
attach the shield to the mounting mast. If you choose to cut the shield wire, make sure to cut it off short enough to
avoid touching the mounting mast or bolt.

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Shield wire to be cut or
attached to mast

Feed cable through mast.

Shield wire to be
cut or attached to
mast

nut

washer &
bolt

Remove the nut, washer, & bolt.

Install connector with “TOWARD ROTOR”

text pointing to the rotor.

rubber
washer

“TOWARD
ROTOR” text on

connector leg

Secure connector to mast with bolt,

washer, and nut.

SS washer away
from mast to
allow sensor to
slide in place

Connector and
rubber washer
snug to mast

Mount Connector

Remove the nut, washer, and bolt from the connector. Feed the cable through the mounting mast until the connector

reaches the mast. Align the bolt hole in the connecter with the holes in the mounting mast such that the “TOWARD
ROTOR” text molded onto the connector leg is oriented toward the turbine rotor. If you are connecting the shield to the

mounting mast, do so now.

Be sure that the connector is snug against the top of the mounting mast and that the washer is on the bolt (compression
of the rubber washer may be necessary) then pass the bolt though the mast and connector. Now attach the nut to the
bolt a few turns until the nylon patch is in contact with the nut. The nylon patch prevents the nut from backing off the
bolt threads. Note that the washer is between the mounting mast and the bolt head.

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Suggested method for attaching shield to mast.

The Hybrid XT sensors have four ridges running vertically inside the body's lower end as shown in the picture below.
These ensure that the sensor mounts securely on the mounting mast.

If attaching the shield to the ground screw, make sure that it does not interfere with the mounting ridges by running it
straight down the mast from the connector to the ground screw. Do not wrap the wire around the mast. The picture
below shows the ground screw attachment option.

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Sensor Common

Black, 22 AWG

Sensor Power

Red, 22 AWG

Sensor Signal

White, 22 AWG

N/A – not used

Yellow, 22 AWG (on all cables shipped since January, 2016)

Heater – *

Orange/White, 20 AWG

Heater + *

Orange/Black, 20 AWG

Slide sensor down over

mast.

Nut against mast
and hanging
vertically.

Bolt & washer away
from mast

“THIS SIDE

TOWARD
ROTOR”

Connect Cable to Controller

Route the sensor cable into the nacelle and to its connection point. It may be helpful to label the end of each wire
before pulling the cable to its connection point. Following the color code, connect the sensor wires and shield wire to
the turbine controller and heater power supply.

* When powering the sensor heater with DC power, Orange/White needs to be connected to DC
Ground (-) and Orange/Black to 24V DC (+). When using AC power, the wiring order does not
matter.

Mount Sensor

To attach the sensor to the mounting mast, slide the clamp bolt and washer away from the mounting mast until the nut
is against the mounting mast and is hanging vertically. Rotate the Hybrid XT sensor body so that the “THIS SIDE TOWARD

ROTOR” label is facing the turbine rotor. This aligns the internal key with the alignment slot in the connector. Now, slide

the sensor down over the boom carefully making sure that the key drops into the slot. Continue to slide the senor down
until it is firmly seated on the nut. There will be some drag as the o-ring seal and the connector pins engage. Tighten the
bolt using a 10 mm wrench to 7 N-m (5 ft-lbs). Replacement washers, nuts and bolts can be ordered from NRG Systems
(part #4422).

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Technical Drawing

GROUNDING AND BONDING HYBRID XT™ SENSORS FOR OVER-VOLTAGE
PROTECTION

Introduction

The purpose of this document is to outline NRG Systems’ recommended practices for wiring, grounding,
and bonding of Hybrid XT™ turbine control sensors. The goal is to provide the best possible protection

against direct and indirect lightning damage for both the sensor and the interconnected turbine
systems.

This document also details the internal construction of the sensor’s bonding and over-voltage
protection. This allows the wind turbine designer to coordinate the sensor grounding and Over Voltage
Protection (OVP) with the rest of the turbine’s Lightning Protection System (LPS).

Recommended Practices

The long-term reliability and the Electromagnetic Compatibility (EMC) performance of the sensor are
dependent on proper installation and connections. These recommendations could apply to any control
electronics or sensors, but are particularly critical for wind sensors because they are exposed on the top
of the nacelle.

1. IEC 61400-24 classifies several Lightning Protection Zones (LPZ). LPZ 0

the turbine and is subject to direct lightning attachment. The turbine must provide air terminals
such as lightning rods to protect the sensors from direct lightning attachment. This creates an area
in LPZ 0B to mount the sensors.

2. Careful routing of the lightning down-conductor and coordination of the grounding and bonding of

the down-conductor(s) to the turbine’s LPS is required to minimize the energy coupled into other
systems such as the sensors. Provide maximum possible spacing between lightning down­conductors and any control cabling or raceway. Do not route any other cabling or raceway alongside
the lightning down-conductors. These measures will minimize the coupling of lightning
electromagnetic pulse (LEMP) energy into other turbine systems.

is exposed on the surface of

A

3. The Sensor body is metal, and bonds to the sensor mounting mast. The mounting mast must be

metal. Take particular care to bond the sensor mounting mast to the turbine’s LPS in coordination
with the placement and bonding of the lightning air terminals and bonding of the turbine frame and
nacelle.

4. Use shielded or “screened” cable with high shield coverage for sensor cabling. We recommend

bonding the cable shield to the grounding system at both ends- at the sensor, and at the connection
to the turbine control system- to provide maximum protection from LEMP. However, see note 6

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about preventing ground loops. NRG Systems supplied cables provide a shield at the sensor end. If
your LPS design does not use this shield drain, trim it off to prevent short circuits.

5. Run the sensor cabling in metallic raceway or conduit. Bond the raceway or conduit to the LPS at

both ends. This provides protection for the sensor and cabling against EMI and LEMP.

The purpose of recommendations 1 through 5 is to provide shielding of the internal sensor electronics,
heater, and cabling so that they are protected to LPZ 1, per IEC 61400-24.

Recommendations 6 and 7 relate to ground loops and over-voltage protection.

6. Provide sufficient bonding to prevent ground loop currents in the shields and raceways. Whenever

possible, it is better to resolve the underlying grounding problems, rather than leaving the shield
unconnected to prevent ground loop current flow.

7. Since the sensor's electronics and cabling are in LPZ 1, isolation and or over-voltage protection

should be provided at the interface between the sensor cabling and turbine control system to
provide LPZ 2 or better protection for the controller.

Sensor Construction Notes

The Hybrid XT™ turbine control sensor’s enclosure is metal, which provides an overall EMI shield for the

internal components of the sensor. The sensor includes internal over-voltage protection (OVP)
components. For these features to be effective, the sensor must be installed and connected properly.
Figure 3 shows the internal connection details of the sensor bonding and OVP.

The direction vane is shown as an example; the anemometer uses the same construction.

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Pin 4: (white) Output Signal
Pin 6: (black) D.C. Ground

Pin 3: (red) D.C. Power to Sensor

Pin 2: (orange / black) Heater Power
Pin 5: (orange / white) Heater Power

Overvoltage protection of
D.C. Power and Output
returned to D.C. Ground

Cable Shield

Sensor Body is bonded to
mounting mast by mounting hardware

Mounting mast must be bonded to the
turbine lightning protection system

Reference:

1. IEC TR 61400-24: 2002: Wind Turbine Generator Systems- Part 24: Lightning Protection.

2. IEC 61312-1: 1995: Protection against Lightning Electromagnetic Impulse- Part 1: General

Principles

Internal bonding and OVP of the Hybrid XT™ turbine control sensor

*When powering the sensor heater with DC power, Orange/White needs to be connected to DC
Ground (-) and Orange/Black to 24V DC (+). When using AC power, the wiring order does not
matter.

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WARRANTY & REPAIR

NRG Systems (NRG) warrants its products for a period of two years from date of original purchase solely
for the benefit of the original consumer purchaser. If this product is determined to be defective in
materials or workmanship, NRG will, at NRG’s option, repair or replace this product without charge. This
warranty does not cover damage due to improper installation or use, accident or misuse, damages due
to any unauthorized service or lightning. This warranty also will not apply if any seal on any instrument
or sensor is broken, if any cable has been severed, or the equipment was not adequately grounded.

Always power the heater on your Hybrid XT sensor! Failure to maintain constant
heating may lead to corrosion or inferior sensor performance. Constant heating
prevents condensation from forming on the bearings, enabling the sensor to

achieve a 10 year service cycle. If the sensor is used without the heater, the warranty will be void

To return a defective product, request an RMA (return merchandise authorization) number by calling us
at the number below or by emailing [e-mail], or by submitting a request
through our website’s Technical Support area.

Please provide the serial number of the item as well as date of purchase. No products will be accepted
for warranty work without an RMA number. The product must be returned, postage prepaid, to NRG
with a brief description of the problem, RMA number and a return address with phone number.

The foregoing limited warranty is given in lieu of all other warranties, express or implied. NRG
specifically disclaims all implied warranties including, but not limited to, any implied warranties of
merchantability and fitness for a particular purpose.

The above limited warranty expressly excludes, and NRG shall not be liable for, any incidental or
consequential damages caused by or related to the selection, use of, inability to use or malfunction of
this product.

NRG will make a good faith effort to repair or replace promptly any product which proves to be
defective within the warranty period. First, contact NRG or the representative from whom the product
was purchased and ask for an RMA number. Inspect your shipments for damage to packages or missing
packages immediately upon receipt. Record any such exceptions on the freight receipt of the delivery
agent. If any contents are damaged or missing, report this in writing to the freight carrier and send NRG
a copy of the damage report. If you insured the shipment yourself, report any damages to your
insurance carrier.

Tel: [phone] Fax: [phone]
email: [e-mail]
website: https://www.nrgsystems.com/technical-support

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SENDING ITEMS FOR REPAIR

INTERNATIONAL CUSTOMERS

Contact NRG Systems by phone, email, or through our website to obtain an RMA number (Return

Material Authorization). Write the RMA number clearly on all shipping cartons.

Tel: [phone] Fax: [phone]

email: [e-mail]
website: https://www.nrgsystems.com/technical-support

2. Send your item to NRG Systems "Delivery Duty Paid" (see address below) using a door-to-door
courier service such as UPS, FedEx, or DHL. If the repair is not urgent, please send your package by
Airmail. (Courier services deliver the package directly to us, customs cleared.)

NRG Systems will not accept packages shipped Freight Collect or with Collect charges.

If NRG Systems refuses the shipment, the courier service will charge your account return freight charges.

DO NOT send return items by direct or consolidated air freight service with an airline.

The cost for air freight may seem lower than the courier service, but air freight costs do not include
customs clearance, airport handling, break bulk fees, and inland delivery to NRG Systems.

3. Attach a Commercial Invoice to the carton. The Commercial Invoice should include the following
information:

Name and address of the shipper.
NRG Systems' complete address and telephone number as the consignee.
Description of the items being returned.
Quantity of each item being returned.
Value for customs / insurance (purchase price or replacement cost).
Number of cartons with respective weights and dimensions.
Please include the following statement to avoid paying US import duties:

"These items are being returned to their U.S. manufacturer. Country of manufacture and origin is USA,
HTS CODE 9801.00.1012."

4. Pack your repair item in a sturdy packing carton. Tag each item with a brief description of the
problem.

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NRG Systems
Attn: RMA- __________
110 Riggs Road
Hinesburg VT 05461 USA

5. Insure your shipment against damage or loss in transit. Be sure to check the appropriate box and
enter a "Value for Carriage" (insurance) on your air waybill. The value is the purchase price of the
equipment or what it would cost to replace the equipment if the shipment were lost. Keep a record of
the tracking number.

Once your item arrives, we will assess the item and notify you of the repair cost. Any repair charges and
freight costs, if applicable, are payable before NRG Systems will return the repaired item to you via
door-to-door courier service. NRG Systems will send you a shipment advisement when the repaired item
is shipped.

International Customers:

Before sending the repair item to NRG Systems, check with your local customs authorities about
provisions in your country for exporting and re-importing repair items. Some countries treat repair
shipments like new shipments and charge import duties and taxes again upon re-importation. Other
countries have specific steps to follow or specific forms to complete which help reduce the import duties
upon re-import of the item.

US CUSTOMERS

Please see items 1, 4, and 5 above. Send your item(s) to NRG Systems “Freight Prepaid and Insured.”

Shipments sent freight collect will not be accepted by NRG Systems.

DECLARATION OF CONFORMITY

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Period

Power Supply Voltage

Power Supply Common

Output Frequency

Variable Period

APPENDIX A: FG# 4715 – HYBRID XT TURBINE CONTROL VANE

Output Circuit Operation

The Hybrid XT vane provides a square wave output signal with a frequency proportional to the head rotation position.
The square wave amplitude is determined by the power supply voltage.

Output frequency proportional to wind direction

The frequency varies between 100Hz and 459Hz. At 100 Hz, the direction is 0 degrees and at 459 Hz the direction is 359
degrees (1 degree per Hz). Note that the output signal will equal 280 Hz (180 degrees) when the vane is aligned with the
rotor. If the frequency output is 0 Hz, this indicates a fault condition. The most likely causes would be: no power, wiring
problem, or a failed sensor.

If you were to look at the signal on an oscilloscope, you would notice that the rising edges fluctuate back and forth from
cycle to cycle. This is normal and was designed this way for Renewable NRG Systems factory use. This will not affect your

frequency counter in any way. However, if you are using a “time per pulse” measurement method you will want to

trigger on the falling edges only. For best accuracy, time and count many cycles then divide the count by the time for an
average frequency. This technique also effectively filters out short-term wind direction variations.

Vane Output Waveform

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APPENDIX B: FG# 5762 – HYBRID XT 4-20 MA OUTPUT VANE

Output Circuit Operation

The Hybrid XT 4-20 mA Turbine Control Vane provides an industry standard 4 to 20 mA output signal sourced by the
sensor. The output range of 4 to 20 mA corresponds to 0 to 360 degrees.

For yaw control, the sensor should be mounted so that an indicated direction of 180 degrees corresponds to a turbine
direction oriented directly into the wind. In this configuration, the sensor output signal is 12 mA when the turbine is
aligned with the wind, and the transition from 4 mA output to 20 mA output is opposite the normal control direction.

Under normal operation, the output signal current varies from 4 to 20 mA. A signal outside this range indicates a fault
condition. The most likely causes would be a loss of power, a wiring problem, or a failed sensor.

The Hybrid 4-20 mA signal output has been engineered to adapt to most common 4-20 mA current loop inputs. The
range of compatible loads for the current loop signal does depend on the power supply voltage provided to the sensor.

At the lowest specified power supply voltage of 11 V DC, the output loop load (or “burden”) may be only up to 350

Ohms maximum (a 7 volt maximum voltage drop). When provided with its maximum 24 V DC power supply voltage, the
sensor can drive up to a 1000 Ohm loop load (a 20 V maximum voltage drop).

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APPENDIX C: FG# 7894 – HYBRID XT PUSH-PULL VANE

Output Circuit Operation

The Model 7894 Push-Pull Hybrid XT vane was designed as a direct replacement for 1- or 2-Channel NPN-type IceFree3™
wind vanes. It provides two output signals, in push-pull format. These outputs can source current when on and sink
current when off for compatibility with a wide range of controller inputs, including those designed for existing NPN or
PNP sensors.

The two signals are Yaw Right / Yaw Left, denoted VL, and the Upwind / Downwind signal, denoted VR90.

 White wire == VL (yaw right/left)
 Yellow wire == VR90 (upwind/downwind)

XT Vane Dithering

Most yaw vanes, including many OEM sensors, are under-damped. They move left and right continuously as the blades
pass the nacelle and other turbulence affects the sensor. Some turbine control systems depend on this motion, called
dithering, to allow them to estimate the average wind direction while observing only one digital signal. The wind vane
output is off when the vane is left of center, and on when the vane is right of center. In these systems, the controller
compares how much time the sensor indicates left and how much time the sensor indicates right. When the turbine is
correctly pointed into the wind, the vane will indicate left and right equally, and the on / off ratio is 50%.

The Hybrid XT turbine control vane head maintains a stable output position that tracks the wind direction more

accurately and
varies much less
than under­damped sensors.
For compatibility
with controllers
that are expecting a
dithered signal, the
electronics of the
Model 7894 Push­Pull Hybrid XT Vane
creates a
compatible
dithered signal.
When the XT
senses the wind
direction is
correctly pointed
into the wind, the

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dithered signal is switching on and off with a ratio of 50%. As the wind varies to the right or left, the sensor varies the
on/off ratio to simulate an under-damped vane’s mechanical dithering.

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APPENDIX D: FG# 9362 – HYBRID XT 4-20MA, COUNTER-CLOCKWISE VANE

Output Circuit Operation

The Hybrid XT 4-20 mA Turbine Control Vane provides an industry standard 4 to 20 mA output signal sourced by the
sensor. The output range of 4 to 20 mA corresponds to 0 to 360 degrees. The output of this Hybrid XT vane increases
from 4-20mA proportionally as the sensor swings in a counter-clockwise rotation, opposite the FG #5762 version.

For yaw control, the sensor should be mounted so that an indicated direction of 180 degrees corresponds to a turbine
direction oriented directly into the wind. In this configuration, the sensor output signal is 12 mA when the turbine is
aligned with the wind, and the transition from 4 mA output to 20 mA output is opposite the normal control direction.

Under normal operation, the output signal current varies from 4 to 20 mA. A signal outside this range indicates a fault
condition. The most likely causes would be a loss of power, a wiring problem, or a failed sensor.

This Hybrid XT 4-20 mA signal output has been engineered to adapt to the Mitsubishi controller 4-20 mA current loop
inputs. The range of compatible loads for the current loop signal does depend on the power supply voltage provided to

the sensor. At the lowest specified power supply voltage of 11 V DC, the output loop load (or “burden”) may be only up

to 350 Ohms maximum (a 7 volt maximum voltage drop). When provided with its maximum 24 V DC power supply
voltage, the sensor can drive up to a 1000 Ohm loop load (a 20 V maximum voltage drop).

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Rev 13.0

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7 February 2017

APPENDIX E: FG# 9363 – HYBRID XT PUSH-PULL, ACTIVE-HIGH VANE

Output Circuit Operation

The Model 9363 Push-Pull Hybrid XT vane was designed as a direct replacement for 1- or 2-Channel PNP-type IceFree3™
wind vanes. It provides two output signals, in push-pull format. These outputs can source current when on and sink
current when off for compatibility with a wide range of controller inputs, including those designed for existing NPN or
PNP sensors.

The two signals are Yaw Right / Yaw Left, denoted VL, and the Upwind / Downwind signal, denoted VR90. This type is
active HIGH, where the FG #7894 is active LOW.

 White wire == VL (yaw right/left)
 Yellow wire == VR90 (upwind/downwind)

XT Vane Dithering

Most yaw vanes, including many OEM sensors, are under-damped. They move left and right continuously as the blades
pass the nacelle and other turbulence affects the sensor. Some turbine control systems depend on this motion, called
dithering, to allow them to estimate the average wind direction while observing only one digital signal. The wind vane
output is off when the vane is left of center, and on when the vane is right of center. In these systems, the controller
compares how much time the sensor indicates left and how much time the sensor indicates right. When the turbine is
correctly pointed into the wind, the vane will indicate left and right equally, and the on / off ratio is 50%.

NRG Product Manual

Hybrid XT Vane

HybridXT_Vane_Manual
Rev 13.0

[e-mail] | Page 29

7 February 2017

The Hybrid XT turbine control vane head maintains a stable output position that tracks the wind direction more
accurately and varies much less than under-damped sensors. For compatibility with controllers that are expecting a
dithered signal, the electronics of the Model 7894 Push-Pull Hybrid XT Vane creates a compatible dithered signal. When

the XT senses the
wind direction is
correctly pointed
into the wind, the
dithered signal is
switching on and
off with a ratio of
50%. As the wind
varies to the right
or left, the sensor
varies the on/off
ratio to simulate an
under-damped

vane’s mechanical

dithering.