Atlantic Orient Corporation 15, 50 User manual

AOC 15/50 Wind Turbine Generator
User Manual
DOC012R02 Nov 2001
U.S. $55.00
Atlantic Orient Corporation Tel: [phone]
Farrell Farm Road, Rt 5 North Fax: [phone]
P.O. Box 1097 [e-mail]
Norwich, VT 05055 www.aocwind.net

NOTICE: Use of the material contained in this document is subject to the warning on page Iv and the disclaimer
on page v of this document.
DOC012R02 AOC 15/50 User Manual Nov 2001
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Table of Contents
WARNING...........................................................................................iv
DISCLAIMER...................................................................................... v
Part I.......................................................................................................1
1.0 Introduction........................................................................................ 3
1.1 Manual Use.................................................................................................................4
1.2 Cautionary Icons .........................................................................................................5
1.2.1 Warning Icon...........................................................................................................5
1.2.2 Caution Icon............................................................................................................5
1.3 Personnel Definitions..................................................................................................5
1.3.1 Installation Personnel ..............................................................................................5
1.3.2 Operational Personnel..............................................................................................5
1.3.3 Maintenance Personnel............................................................................................6
2.0 System Description..............................................................................7
2.1 General Description and Features of the Turbine.........................................................8
2.2 Control System Description.......................................................................................11
2.3 Operation Description ...............................................................................................11
3.0 Safety Guidelines...............................................................................13
3.1 Personnel Training ....................................................................................................14
3.2 Safety Equipment......................................................................................................14
3.3 Start-up and Shut-down Safety Procedures................................................................15
3.4 Securing Machine for Maintenance and Repair..........................................................15
3.5 Climbing Safety ........................................................................................................16
3.6 Electrical Safety........................................................................................................17
3.7 Weather Related Safety.............................................................................................17
3.8 Emergency Procedure................................................................................................18
Part II ...................................................................................................21
4.0 Planning and Installation Checklist.....................................................23
4.1 Siting Factors............................................................................................................24
4.2 Utility Factors ...........................................................................................................24
4.3 Permits and Approvals ..............................................................................................25
4.4 Plans and Drawings...................................................................................................25
4.5 Construction Planning Considerations.......................................................................26
4.6 Electrical Planning Considerations ............................................................................27
4.7 Installation Tools and Equipment ..............................................................................27
4.8 Installation Personnel Considerations........................................................................28
4.9 General Installation/Commissioning Timeline...........................................................28
5.0 Site Preparation................................................................................31
5.1 Site Access................................................................................................................32
5.2 Foundation Installation..............................................................................................32
5.3 Receiving the Wind Turbine at the Site .....................................................................33
6.0 Tower and Wind Turbine Generator Installation................................. 35

NOTICE: Use of the material contained in this document is subject to the warning on page Iv and the disclaimer
on page v of this document.
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6.1 Tower Assembly .......................................................................................................36
6.2 Tower Erection..........................................................................................................37
6.3 Wind Turbine Component Preparation ......................................................................38
6.3.1 Tip Brake Installation............................................................................................38
6.4 Blade Installation ......................................................................................................41
6.5 Lift Preparation.........................................................................................................46
6.6 Lifting and Securing the Wind Turbine......................................................................50
7.0 Electrical Installation.........................................................................53
7.1 Electrical Interface to Utility .....................................................................................54
7.2 Wiring and Cable Requirements................................................................................56
7.2.1 Power and Control Cable.......................................................................................56
7.3 Control Box Connections..........................................................................................59
7.4 Twist Cables and Junction Box..................................................................................60
8.0 Function Tests and Commissioning..................................................... 61
8.1 Function Tests and Commissioning...........................................................................62
8.2 Generator Test...........................................................................................................63
Part III..................................................................................................65
9.0 Wind Turbine Operation ................................................................... 67
9.1 Normal Operation......................................................................................................68
9.1.1 Turbine TEST/OFF/ON.........................................................................................69
9.1.2 Heater ON.............................................................................................................70
9.1.3 Parking Brake Release...........................................................................................70
9.1.4 Rotor Jog...............................................................................................................72
9.1.5 Dynamic Brake......................................................................................................72
9.1.6 Operator Interface Indicating Lights......................................................................72
9.1.7 PLC Description....................................................................................................72
9.1.7.1 PLC Inputs............................................................................................................76
9.1.7.2 PLC Outputs..........................................................................................................77
9.1.8 Control Systems Options.......................................................................................77
9.2 Emergency Operation................................................................................................77
9.3 Test Operation...........................................................................................................78
9.3.1 Power Up ..............................................................................................................78
9.3.2 Parking Brake Release Test...................................................................................78
9.3.3 Rotor Jog Test.......................................................................................................79
9.3.4 Dynamic Brake Test..............................................................................................79
9.3.5 Anemometer Signal Test .......................................................................................79
9.3.6 Speed Sensor Signal Test.......................................................................................80
9.3.7 Normal Start-up/Shut-down Test...........................................................................80
9.3.8 Emergency Shut down Test...................................................................................80
9.3.9 Low Wind Shut Down Test ...................................................................................80
9.4 Environmental Considerations...................................................................................80
9.4.1 Corrosion ..............................................................................................................80
9.4.2 Lightning...............................................................................................................81
9.4.3 Ice and Snow.........................................................................................................81

NOTICE: Use of the material contained in this document is subject to the warning on page Iv and the disclaimer
on page v of this document.
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9.4.4 Temperature and Elevation....................................................................................82
9.4.5 Acoustics...............................................................................................................83
10.0 System Monitoring ..........................................................................85
10.1 Kilowatt-Hour Meter Applications ............................................................................86
10.2 Anemometers............................................................................................................86
10.3 Output Analysis.........................................................................................................86
10.4 Output Analysis Worksheet.......................................................................................86
10.5 Wind Energy Data Sheet ...........................................................................................87
11.0 Maintenance ................................................................................... 89
11.1 Rotor Assembly.........................................................................................................90
11.2 Tower Assembly .......................................................................................................91
11.3 Drive Train Assembly ...............................................................................................91
11.4 Power Distribution System/Controls..........................................................................92
11.5 Maintenance Schedule...............................................................................................93
12.0 Troubleshooting .............................................................................. 95
12.1 Braking System.........................................................................................................96
12.2 Generator ................................................................................................................100
12.3 Gearbox ..................................................................................................................100
12.4 Blades.....................................................................................................................100
12.5 Twist Cable.............................................................................................................100
12.6 Yaw Bearing ...........................................................................................................102
12.7 Troubleshooting Summary ......................................................................................102
13.0 Spare Parts ................................................................................... 105
Appendix A: Specifications................................................................... 107
Appendix B: Turbine Assembly Drawings.............................................. 113
Appendix C: Assembly Drawings for 24.4 m (80 ft) Tower.......................119
Appendix D: Assembly Drawings for 30.5 m (100 ft) Tower.....................127
Appendix E: Crate Dimensions and Weights .......................................... 135
Appendix F: Foundation Loads and Details............................................ 139
Appendix G: Installation Records..........................................................149
Appendix H: Maintenance Records........................................................155
Appendix I: Tools and Equipment ......................................................... 161
Appendix J: Wire, Cable and Bolt Specifications ....................................165
Appendix K: Planning ..........................................................................171
Appendix L: 50Hz Electrical Schematics................................................ 175
Appendix M: 60 Hz Electrical Schematics .............................................. 203
Appendix N: Hand Signals for Crane Operators.....................................231

NOTICE: Use of the material contained in this document is subject to the warning on page Iv and the disclaimer
on page v of this document.
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WARNING
THE INSTALLATION OF A WIND TURBINE GENERATOR REQUIRES SPECIALIZED
SKILLS, EQUIPMENT AND EXPERIENCE. INFORMATION SUPPLIED BY ATLANTIC
ORIENT CORPORATION AND ITS SUPPLIERS, FOR THE PURPOSES OF INSTALLING,
OPERATING AND MAINTAINING ALL EQUIPMENT, ASSUMES THAT PERSONNEL HAVE
THE SKILLS, EXPERIENCE AND EQUIPMENT NEEDED. NO ONE SHOULD ATTEMPT TO
CLIMB TOWERS AND OPERATE OR MAINTAIN WIND TURBINES WITHOUT THE
NECESSARY SKILLS, EXPERIENCE, TOOLS AND SAFETY EQUIPMENT.
ATLANTIC ORIENT CORPORATION ASSUMES NO DIRECT OR CONSEQUENTIAL
LIABILITY IF FAULTY OR DANGEROUS INSTALLATION OR MAINTENANCE
PRACTICES ARE USED. TRAINED AND EXPERIENCED PERSONNEL ARE AVAILABLE
TO ASSIST IN INSTALLATION, OPERATION, MAINTENANCE AND TROUBLE
SHOOTING. CONTACT ATLANTIC ORIENT CORPORATION OR ITS AUTHORIZED
REPRESENTATIVE IF CONSULTATION OR ASSISTANCE IS REQUIRED.
ATLANTIC ORIENT CORPORATION AND ITS SUPPLIERS RECOMMEND RESTRICTING
ACCESS, WITH ANTI-CLIMB SECTIONS OR FENCES FOR ALL TOWERS, TO PREVENT
UNAUTHORIZED PERSONS FROM CLIMBING THEM. APPROPRIATE WARNING SIGNS
SHOULD ALSO BE PLACED ON EACH TOWER.
THE AOC 15/50 IS CONSIDERED A HEAVY DUTY INDUSTRIAL MACHINE AND SHOULD
BE SITED ACCORDINGLY. ATLANTIC ORIENT CORPORATION RECOMMENDS AN
EXCLUSION ZONE CONTROLLING PUBLIC ACCESS. ALL MOVING PARTS SHOULD BE
CONSIDERED DANGEROUS.
TOWERS SHOULD NOT BE INSTALLED NEAR UNPROTECTED POWER LINES. ALL
ELECTRIC WIRES AND CABLES SHOULD BE CONSIDERED DANGEROUS.
To ensure optimal performance, all wind turbine installations should be thoroughly inspected by
qualified personnel within 60 days of their completion, as well as at least biannually and after
any major windstorm, earthquake or other severe event. The inspection and service intervals
identified by Atlantic Orient Corporation must be followed for any Atlantic Orient Corporation
warranty to remain valid.
Atlantic Orient Corporation
P.O. Box 1097
Norwich, Vermont 05055 USA
Phone: [phone]
Fax: [phone]
e-mail: [email protected]

NOTICE: Use of the material contained in this document is subject to the warning on page Iv and the disclaimer
on page v of this document.
DOC012R02 AOC 15/50 User Manual Nov 2001
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DISCLAIMER
This manual is intended as a guide only. It should not be considered as a replacement for
professional services or as a definitive text for assembling and installing wind turbine
generating systems.
Atlantic Orient Corporation, its affiliates and representatives make no warranties either
expressed or implied that the information contained herein is accurate or complete.
Atlantic Orient Corporation makes no warranties of merchantability or fitness for a
particular purpose and/or site. Atlantic Orient Corporation will not be responsible for any
direct or consequential damages, or any incidental expense.
All instructions and diagrams are believed to be accurate at the time of publishing. Note
that success and safety in working with tools depend greatly on individual accuracy, skill
and caution. For this reason, Atlantic Orient Corporation or its affiliates are not able to
guarantee the result of any procedure contained herein, nor can they assume responsibility
for any damage to property or injury to persons resulting from the procedures contained in
this manual. Persons engaging in the procedures do so at their own risk.
Actual wind resources and site conditions impact on energy production, which will vary
with wind turbine maintenance, altitude, temperature, topography and the proximity to
other structures. Therefore, Atlantic Orient Corporation makes no representation or
warranties regarding energy production.
Atlantic Orient Corporation is constantly striving to improve its products and, therefore,
the information contained within this manual is subject to change without notice.

NOTICE: Use of the material contained in this document is subject to the warning on page Iv and the disclaimer
on page v of this document.
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Part I
NOTICE: Use of the material contained in this document is subject to the warning on page Iv and the disclaimer
on page v of this document.
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Part I

Part I
NOTICE: Use of the material contained in this document is subject to the warning on page Iv and the disclaimer
on page v of this document.
DOC012R02 AOC 15/50 User Manual Nov 2001
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NOTICE: Use of the material contained in this document is subject to the warning on page Iv and the disclaimer
on page v of this document.
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1.0 Introduction
KOTZEBUE ELECTRIC ASSOCIATION WIND FARM
Photo Courtesy of
KEA

1.0 Introduction
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on page v of this document.
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1.1 Manual Use
This manual has been developed for use by qualified technicians for the operation and
maintenance of the wind turbines manufactured by Atlantic Orient Corporation (AOC). The
information provided specifically applies to the AOC 15/50 wind turbine and is valid for both the
50 Hz and the 60 Hz versions, unless otherwise stated.
It is essential for the reader to become familiar with the manual prior to preparing the site,
installing equipment, operating the system or servicing any equipment. The site should be
prepared, maintained, operated and managed to allow work to be performed safely and
efficiently. Special consideration should be given to installing, operating and maintaining
the wind turbine system under unusual conditions such as lightning, high winds or icing
(where applicable). For any operation or service related questions, please contact AOC for
clarification.
Many of the safety guidelines in this manual are based on recommendations made in the
International Electro-technical Commission’s Wind Turbine Generator Systems Part I: Safety
Requirements, Second edition, 1999, 61400-1 or its latest edition. In case of questions or doubts
concerning a potentially hazardous or harmful situation, please contact AOC for assistance. The
following standards were considered in the design of the controller and selection of components:
US National Electrical Code 196 DFPA 70, Canadian Electrical Code, Part I, 1994,
International Electro-technical Commission IEC TC88 –Safety of Wind Turbine Generators
1400-1or the latest edition.
If there are any questions that are not adequately addressed in this manual, please contact AOC
at its corporate headquarters in NORWICH, VERMONT, USA or one of its authorized
representatives. Improvements or suggestions from field experience are always welcome.
The content of this document is the property of Atlantic Orient Corporation. Any
unauthorized use or reproduction by any means is strictly prohibited.

1.0 Introduction
NOTICE: Use of the material contained in this document is subject to the warning on page Iv and the disclaimer
on page v of this document.
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1.2 Cautionary Icons
1.2.1 Warning Icon
The warning icon denotes actions or procedures that may lead to
equipment failure or death to personnel, if not carried out correctly.
1.2.2 Caution Icon
The caution icon denotes actions or procedures that may lead to
severe equipment damage or injury to personnel, if not carried out
correctly.
1.3 Personnel Definitions
1.3.1 Installation Personnel
Installation personnel are defined as technical staff with training and/or experience in climbing
towers and the use of safety equipment, as well as rigging and lifting heavy industrial machinery.
ONLY TRAINED AND QUALIFIED TECHNICIANS SHOULD ATTEMPT TO CLIMB
A WIND TURBINE TOWER AND SHOULD USE OSHA/ANSI APPROVED PRACTICE
AND EQUIPMENT.
1.3.2 Operational Personnel
Operational personnel are defined as persons trained and qualified to operate a wind turbine’s
control panel. They are responsible for monitoring the wind turbine’s mechanical and
production performance, as well as for performing routine visual inspections of all equipment.
See Chapter 10 for the parameters to be monitored. The operation personnel should also ensure
that proper maintenance is routinely performed as described in Chapter 11.

1.0 Introduction
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on page v of this document.
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1.3.3 Maintenance Personnel
Maintenance personnel are defined as technical staff with training and/or experience in climbing
towers and the use of safety equipment, as well as a firm understanding of the wind turbine’s
mechanical and control system. Knowledge of rigging and lifting heavy industrial machinery
may also be necessary. ONLY TRAINED AND QUALIFIED TECHNICIANS SHOULD
ATTEMPT TO CLIMB A WIND TURBINE TOWER AND SHOULD USE OSHA/ANSI
APPROVED PRACTICE AND EQUIPMENT.

NOTICE: Use of the material contained in this document is subject to the warning on page Iv and the disclaimer
on page v of this document.
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2.0 System Description
ALASKA FIELD SERVICE
Photo Courtesy of
KEA

2.0 System Description
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on page v of this document.
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The following sections provide a general description of the AOC 15/50 and its control system.
2.1 General Description and Features of the Turbine
The designation 15/50 refers to the 15 m diameter wood/epoxy or fibreglass rotor and its
projected rated output of 50 kW. This rated output is achieved at 12 m/s (26.8 mph) by the 50 Hz
version and at 11.3 m/s (25.3 mph) by the 60 Hz one.
The AOC 15/50 includes the following design features:
•Advanced NREL thick series airfoils
•High strength to weight ratio wood/epoxy or fiberglass blades
•Electro-magnetically/actively controlled tip brakes
•Single piece hub casting
•Rotary transformer to power the tip brake magnets
•Integrated planetary gearbox
•Induction generator
•Single piece cast tower top with turn table yaw bearing
•Uniformly tapered lattice tower
•Dynamic brake
•PLC based controller with adaptive features
•Optional tilt-up lattice tower
Both turbine versions are designed to cut in at 4.6 m/s (10.2 mph). The 50 Hz version reaches its
peak continuous output of 55 kW at 15 m/s (34 mph); the 60 Hz one achieves its peak of 65 kW
(60 Hz) at 16 m/s (36 mph). Assuming 100% availability and average wind speeds of 8 m/s (18
mph), the 50 Hz wind turbine is calculated to produce approximately 190,000 kWh per year and
the 60 Hz one, 215,000 kWh. In average wind speeds of 6.7 m/s (15 mph), the 50 Hz version
produces approximately 145,000 kWh annually and the 60 Hz one, 153,000 kWh.
NOTE: Energy production is site specific and varies with altitude, temperature,
topography, climate and the wind turbine’s proximity to other structures, as well as its
maintenance condition.
The standard tower is a 24.4 m (80 ft) tall, self-supporting lattice structure. The gearbox is
integrated in the single piece cast housing. See Figure 2-2 for a more detailed view of the drive
train assembly. The generator is flange mounted to the planetary gearbox, with the parking
brake coupled directly to the generator.

2.0 System Description
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Figure 2-1 AOC 15/50 Wind turbine

2.0 System Description
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on page v of this document.
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Figure 2-2 AOC 15/50 Wind turbine assembly, drive train detail
Figure 2-3 AOC 15/50 Drive train assembly

2.0 System Description
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on page v of this document.
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2.2 Control System Description
The following parameters are monitored by the wind turbine’s control system. It initiates
shutdowns when faults have been detected to protect the wind turbine from mechanical and
electrical damage.
UTILITY NETWORK:
•Over/under voltage
•Phase loss
•Phase reversal
•Over/under frequency (optional)
TURBINE:
•Generator temperature
•Rotor speed
•Power (derived from rotor speed)
•Parking brake current
SYSTEM:
•Wind speed (redundant anemometers)
•Ambient temperature switch (optional)
2.3 Operation Description
The AOC 15/50 is a downwind turbine, i.e. its blades rotate downwind of the drive train
assembly. Furthermore, it has no active yaw control and depends on its blades to track the wind.
In winds outside of the required wind band, the PLC (Programmable Logic Controller)
disconnects the wind turbine from the grid and parks it; the wind turbine is brought to a complete
stop. The parking brake remains applied, thereby preventing the blades from rotating. However,
they will still track the wind and the wind turbine will pivot about its yaw bearing accordingly.
The AOC 15/50 has three main modes of operation: test, off and on. The setting of the
TEST/OFF/ON switch determines the parameters monitored by the PLC and which other
switches can be activated. When the turbine TEST/OFF/ON switch is set to OFF, the PLC only
monitors grid faults.
Once the turbine TEST/OFF/ON switch is set to ON, the PLC starts evaluating the wind speed
data which, together with the generator rotor speed, is the most important source of input data to
the PLC; grid related parameters and thermal relays play a secondary role.
The wind speed is measured using two cup anemometers. For the wind turbine operation the
wind speed has to fall within the specified speed band of 3.6-22.3 m/s (8-50 mph). The cut-in
speed of 4.9 m/s (11 mph) is slightly higher than its minimum operational speed because of the

2.0 System Description
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on page v of this document.
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inertia of the rotor and drive train that must be overcome initially. Once the wind speed
conditions are met, the parking brake is released and the generator starts rotating, at which point
PLC starts monitoring the generator rotor speed.
Once the parking brake has released and the rotor speed is in band,the wind turbine is connected
to the grid automatically. The wind turbine will then stay on-line until wind conditions fall
outside the operating band or until a fault or shutdown is registered. The generator shaft speed is
measured using two speed sensors from which the PLC can tell whether the shaft speed falls
within the required range. Since power produced is proportional to rotor speed, the rotor speed is
also used to check for excessive power generation.
Whenever the wind and/or shaft speeds deviate from the specified values the PLC initiates a
shutdown of the wind turbine system. In order to avoid unnecessary shutdowns, each fault is
monitored for a set period to confirm that it is not due to a temporary deviation but to a definite
change in the operating conditions. Since faults impact on the system with varying degrees of
severity, in terms of possible electrical or mechanical damage, the time delays after which a
shutdown is initiated differ.
Should the PLC register a fault that requires the wind turbine to be shut down, it does so in a set
sequence. The tip brakes and dynamic brake are deployed immediately. The parking brake is
then deployed after a variable time delay, generally set to 4 seconds. Following any deployment
of the brakes the wind turbine enters a cooling cycle, generally set to 15mins. The turbine will
not be available to comeback on line until the end of the cooling cycle to prevent overheating of
the brake components.
The dynamic and parking brakes can be tested individually when their test switches are set to ON
and the TEST/OFF/ON switch is set to TEST. See section 9.1 for a more detailed description of
the individual switches.