AWS AWS2000 User manual
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AUSTRALIAN WIND AND SOLAR
AWS2000 WIND TURBINE
INSTRUCTION MANUAL
2
AWS2000 Wind Turbine Page
Table of Contents
1. Geng started
2. Safety instrucon
3. Installaon sing
4. Specicaons
5. Part name
6. Assembling module
6.1 Verify the following upon purchase
6.2 Assembly procedure
6.3 Aaching to pole
7. Connecng the system
7.1 Before connecng
7.2 Length of the extension cable that leads to the wind genera-
tor to the baery
7.3 D.P.D.T. (Double pole double throw) blade switch
7.4 Connecng the wind generator output cable extension
7.5 Connecon example
7.6 Connecng the system
8. Explanaon operaons
9. Consideraons when choosing peripheral materials/device
9.1 Baeries
9.2 Mounng tower
9.3 Cable diameter size
9.4 Inverters
9.5 Grounding
10. Site elevaon
11. Maintaining the generator system
12. Troubleshoong
13. Warranty informaon
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1.Geng Started
☼
2.Safety instrucon
4
Be aware that failure to use the product in the manner indicated by
may, depending on circumstances, also have severe consequences. All of the symbols
described above indicate important safety information. Obey all safety information when
using this product.
5
3.Installaon sing
6
Wind Turbine Type Horizontal axis, up-wind
UPC Code 839290007075
Rotor Diameter 1776mm (69.9”)
Weight 18kg (38lbs)
Mount Diameter 48.6mm (1-15/16”)
Number of Blades 3
Blade Material Carbon-bre
Blade Mass (per piece) 532g
Body Material Aluminum die cast
Product Finish Teon-based paint
Generator Synchronous-type, three phase power generator with neodymium iron boron mag-
nets
Controller Built-in
Yaw Control Free yaw (360 degrees)
Direcon Control Swing-tail
Over Wind Control Stall control (600rpm mode)
Start-up Wind Speed 3m/s (11KPH, 6.7MPH)
Cut-out Wind Speed 20m/s (72KPH, 45MPH)
Survival Wind Speed 49.2m/s (177KPH, 110MPH)
Rated Power 1KW (12.5m/s, 45KPH, 28MPH)
Rated Rotor Speed 1000rpm
Maximum Power 2kW (20m/s, 72KPH, 45MPH)
Maximum Rotor Speed 1000rpm, (20m/s, 72KPH, 45MPH)
Output Voltage DC25V or DC50V
Braking System Regenerave electromagnec braking system
Communicaon System Remote monitor (oponal accessory)
Recommended System O-grid: deep cycle lead acid baery, 420Ah or more
7
6. Assembling module
6.1 Verify the following upon purchase
Tail Unit
The body Unit and the tail is packed in
the same box.
Optional parts:
Remote Monitor System
8
9
10
7.Connecting the System
7.1 Before connecting
11
7.5 Connecon example
12
7-6 Connecng the System
13
Type: We recommend the use of deep cycle baeries (parcularly AGM) to handle the deep
charge/discharge cycles in the wind turbine system. The deep cycle baery has less instant
energy than the starng (cranking) ones used on cars, but greater long-term energy delivery.
A car baery will not last as long when used for repeated deep charged/discharged cycles.
Series/Parallel Connecons: You have to connect 4 x 12V baeries in series to get a 48V group
(24v system 2 x 12V baeries).
Mode Indicator Light Status Cause Next Operaon
Start/Restart No light Not generang power
(Wind speed range:
0—3m/s, 0—11KPH, 0—
6.7MPH)
The power is o, or the wind
is weak and the rotor is ro-
tang below 420rpm or the
DPDT Switch is on brake posi-
on.
Status in normal operang
mode
Normal Operaon Solid green Generang power, (Wind
speed range: 3—12m/s,
11—43KPH, 6.7—27MPH)
When the rotor is rotang at
0—999rpm
Normal Operaon Flashing green Generang power at con-
trolled rpm. (Wind speed
range: 12—20m/s, 43—
72KPH, 27—45MPH)
The rpm is limited to 1000
Normal Operaon Flashing red Generang power at con-
trolled 600rpm
Wind speed: over 20m/s,
72KPH, 45MPH
Recovers to normal operaon
when wind speed is below
20m/s, 72KPH, 45MPH
Voltage protecon Flashing red Generang power at con-
trolled rpm
When baery voltage is full
and exceeds 57.2V (24V SYS
28.6V)
Recovers to normal operaon
when the voltage drops below
53.2V (24V SYS 26.6V)
Voltage protecon Solid red Rotor stopped When baery voltage is full
and exceeds 57.2V (24V SYS
28.6V)
Recovers to normal operaon
when the voltage drops below
53.2V (24V SYS 26.6V)
Temperature protec-
on
Solid red Rotor stopped When the temperature of the
alternator cover exceeds
90oC, 194oF or the tempera-
ture sensor is damaged
Recovers to normal operaon
when the temperature drops
below 60oC, 140oF. If it is not
recovered over one hour, con-
tact us)
Other On and o Intermient brake Defecve or loose connecon
to the baery
Check baery connecons, the
turbine brushes and their
tracks
14
The baeries in series within a group have to be the same type, chemical, age and capacity (in Ah).
You can connect several 48V groups in parallel to increase the baery bank capacity in Ah. However
the capacity of a 48V group is the same of each single baery in series within the group (no Ah in-
crement). Each 48V group can have dierent capacies. When connected in parallel the total capaci-
ty is the sum of all individual 48V group capacies (24V sys need match 2V group).
Minimum Baery Bank Capacity in Ah: We recommend 500Ah (420 Ah minimum) when using
the 2000W wind turbine as the unique power source. If there are addional 48VDC sources
connected to the baery bank (ie. Solar panels, AC-baery chargers, addional wind turbines,
etc.) the capacity of the baeries should be increased to avoid exceeding their maximum
charging current. As an approximaon, the rao between Total-48VDC-Source-Power / 4 =
Minimum recommended baery capacity. For example if there are up to 500W of solar panel
power and up to 2000W of the wind turbine power connected to the baery bank, we get
(500 + 2000) / 4 = 2500/4 = 625 Ah = minimum recommended baery bank capacity (24V sys-
tem need match concern 24V baeries group). Please check your baeries specicaons.
Sizing: The size (capacity in Ah) of your baery bank depends on your applicaon. For a spe-
cic load, the bigger the baery capacity in Ah, the longer the run me and the charging me.
The charging me for the baery bank depends on its capacity in Ah, the average consumpon cur-
rent of the loads and the average power supplied by the turbine. This average power depends on
the average wind speed condion (in MPH) at your locaon. The higher the average power you get
from the turbine the shorter the charging me will be. As a result of that, for a specic charging
me, the faster the average wind speed the bigger (in Ah) the baery bank can be.
The wind turbine can supply a power from 0—2000W in a wind speed range from 7—45 MPH. You
can approximate the values in between the range. With this informaon and using standard baery
charging tables/ calculators (check the Web), you can get the average charging me. So you can play
with all the parameters in order to meet the requirements for your specic applicaon.
9.2 Mounng Tower
The mounng tower that supports the wind generator is an extremely important part with respect
to safety. The mast used to aach the turbine and its foundaon, must be strong enough to provide
adequate safety.
Locaon and height of the mounng tower: select a free and safe locaon where the ample
amount of wind ow is obtained. The height of the pole must be 11.5 (3.5m) or more to en-
sure safety from hazard to people.
The tower must have an upper poron of at least 3 (1m) in length and an outer diameter of
1.9 inches (48.6mm) (the 1 ½ inch schedule 80 steel pipe meets it). The total tower height
must be sucient to prevent accidents with body or structures.
The tower must withstand horizontal wind pressure of 231 lb (105kgf) (at a wind speed of
49.2m/s, 177KPH, 110MPH).
If unsure please consult with your local tower contractor for details.
15
9.3 Cable Diameter Sizes:
To select the appropriate cables gauge, measure the distance between the turbine and the baer-
ies. Make sure to include the height of the tower. Please refer to the following wire gauge chart.
NOTES:
For the connecon between the DPDT switch and the baery bank, you can use the same
double wiring per polarity as in the table. Alternavely you can use a single cable AWG #6. In
all the cases the cable between the DPDT and the baery bank has to be no more than 3
long.
The DPDT blade switch included in the kit allows cables up to AWG #4 easily. For the AWG #2,
perhaps you need to remove some of the wires at the end of the cable to reduce its diameter
or use a proper spade or pin crimp terminal.
9.4 Inverters
This device is used to convert the DC power from the baery to the standard AC power used at
home.
Verify the capacity and type of your inverter to ensure that it is appropriate for the load you are us-
ing.
Always use 48VDC inverters (24V system need to match 24V inverters).
Always use inverters equipped with baery (DC Input) overvoltage protecon circuit and
baer low voltage (under voltage) disconnect feature.
Distance between
the turbine and the
DPDT switch
Cross
Seconal Area
Diameter of
the cooper
core
AWG # Maximum
Total
resistance
(round & trip)
Up to 7m (23) 5.5mm22.64mm 10 0.022Ω
Up to 15m (49) 8.0mm23.19mm 80.03Ω
Up to 30.5m (100) 21mm25.19mm 40.024Ω
Up to 46m (150) 34mm26.6mm 20.023Ω
16
17
FEET METER OUTPUT POWER
1-500 0-150m 100%
500-1,000 150-300m 97%
1,000-2,000 300-600m 94%
2,000-3,000 600-900m 91%
3,000-4,000 900-1,200m 88%
4,000-5,000 1,200-1,500m 85%
5,000-6,000 1,500-1,800m 82%
6,000-7,000 1,800-2,100m 79%
7,000-8,000 2,100-2,400m 76%
8,000-9,000 2,400-2,700m 73%
9,000-10,000 2,700-3,000m 70%
If replacement is necessary, only use parts specied by Australian Wind and Solar. Use other parts
could cause accidents or malfuncon.
When strong winds blow, tree branches and other objects may make contact with and damage the
wind turbine, its support pole, or its wiring. Connued use of the wind turbine when it is damaged
may cause electric shock, a serious accident, or cause the turbine to cease funconing. Inspect all
parts of the wind turbine aer periods of strong wind.
Do not place the wind generator body upside down or inclined during installaon or maintenance.
Water (rain, snow) can leak inside from the joint gap of the body and may cause damage to the tur-
bine. When the body is upside down or inclined and have a possibility of geng wet, put a cover over
the body to avoid water.
18
Problem Symptom Soluon
Insucient charging current to the
baery bank when the rotor is run-
Insucient wind speed, below the
start-up speed (11KPH, 7MPH)
Wait for beer wind speed condi-
on
Insucient charging current to the
baery bank when the rotor is run-
ning
Rotor and/or yaw bearings within
the break-in period
This requires about 60-100 hours of
operaon in normal wind speed (18-
20MPH) before they are running at
peak eciency
Insucient charging current to the
baery bank when the rotor is run-
ning
Rotor sha gets stuck and rotates
with diculty
Rotor bearings damaged (rusted or
with dust). The bearings need to be
replaced
Insucient charging current to the
baery bank when the rotor is run-
ning
Rotor sha gets stuck and rotates
with diculty
Stator and rotor touching together
because of excessive bearing waste.
The bearings need to be replaced
Insucient charging current to the
baery bank when the rotor is run-
ning
Consistent air turbulence condion
(1)
Change the locaon and/or increase
the height of the tower/mast. Make
sure to install the turbine 25
(7.6m) on open ground or 20 (6m)
above nearby obstrucons
Insucient charging current to the
baery bank when the rotor is run-
The yaw is not moving 360o freely so
the turbine is not poinng toward
Rotor bearing damaged (rusted or
with dust). The bearing needs to be
Insucient charging current to the
baery bank when the rotor is run-
The yaw is not moving 360o freely so
the turbine is not poinng toward
The pole/mast is not standing
straight up. It needs to be in a per-
Insucient charging current to the
baery bank when the rotor is run-
ning
Generang power at controlled rpm This is normal when the wind speed
and/or the baery bank voltage are
close to their highest limits. For
more details see the Indicator Light
on the operang status table. The
unit will resume normal rpm opera-
on in an automac and unaended
way
19
The turbine (especially its tail) is
yawing connuously
Swirling air because of turbulence Change the locaon and/or in-
crease the height of the tower/
Every me the rotor sha begins to
spin, it stops suddenly with a strong
brake acon
Open circuit in the DC connecon
between the turbine and the
baery bank
Check for loose or open connec-
ons in the cables. Make sure the
DPDT blade switch is in the ON po-
sion (neither the open not the
brake [short circuit] one)
The rotor remains stopped even
with high wind speed condions
If the indicator light is solid red The baery bank voltage and/or
the internal temperature of the
turbine have reached their highest
(cut-out) limit and the turbine
stops. The turbine will resume nor-
mal operaon in an automac and
unaended way. Wait for the prop-
er cut-in threshold or reset the unit
disconnecng and reconnecng the
baery voltage with the DPDT
The rotor remains stopped even If the indicator light is o Make sure the DPDT switch is not in
The rotor remains stopped even
with high wind speed condions
If the indicator light is o There is some mechanical problem
(rotor sha bearings, hub, internal
stator and rotor contact, internal
damage). The unit has to be in-
spected
The turbine works at controlled
rpm oen, with the baery bank
voltage below the normal maxi-
mum of 57.2V (24V system 28.6V)
The indicator light status is ashing
red
Normal if within the + 7% of toler-
ance in the baery voltage thresh-
old values shown in the Operang
Status Table
The turbine works at controlled
rpm oen, with the baery bank
voltage below the normal maxi-
mum of 57.2V (24V system 28.6V)
The indicator light status is ashing
red
Excessive voltage drop through the
cables and/or related connectors.
Please check the proper cable
gauge vs length as per the cable
gauge chart, the related connectors
and the baeries’ posts
The turbine works at controlled
rpm oen, with the baery bank
voltage below the normal maxi-
mum of 57.2V (24V system 28.6V)
The indicator light status is ashing
red
High resistance or loose connecon
in the turbine’s brushes and/or
their tracks. They should be in-
spected and cleaned
20
The baery bank voltage increases
easily and fast, forcing the unit to
acvate the controlled rpm mode
and even the complete stop very
oen
The indicator light status is ashing
red (controlled rpm mode of opera-
on)
Normal if the baery bank is fully
charged and there is not/low power
consumpon from the loads con-
nected to the baery bank
The baery bank voltage increases
easily and fast, forcing the unit to
acvate the controlled rpm mode
and even the complete stop very
oen
The indicator light status is solid red
(rotor stopped because of over
voltage of 57.2V)
(24V system 28.6V)
Baery bank capacity in Ah lower
than the recommended absolute
minimum of 420Ah
The baery bank voltage increases
easily and fast, forcing the unit to
acvate the controlled rpm mode
and even the complete stop very
oen
The indicator light status is solid red
(rotor stopped because of over
voltage of 57.2V)
(24V system 28.6V)
Baery bank capacity in Ah ex-
tremely lower than the recom-
mended absolute minimum of
420Ah, or some damage in the
baeries (open cells)
Persistent over voltage in the
baery bank
(24V system match 24V baery
bank)
The indicator light status is solid red
(Rotor stopped)
Addional 48V source (solar panel,
baery charger, etc.) connected to
the baery bank without any volt-
age regulaon. Check it out and if
so, disconnect it to isolate the prob-
lem
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