Bergey XL-15 User guide

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BERGEY XL-15 INSTALLATION QUICK GUIDE

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TABLE OF CONTENTS
RECOMMEND TOOL LIST………………………………………………………………………………………4
TORQUE VALUES……………………………………………………………………………………………….…5
TURBINE HARDWARE……………………………………………………………………………………………6
ELECTRICAL STANDARD 240VAC…………………………………………………………………………..7
ELECRICAL TRANSFORMER REQUIRED………………………………………………………………….8
WIRE SIZE CHART…………………………………………………………………………………………………9
GETTING STARTED………………………………………………………………………………………………10
POSITIONING THE UNIT FOR TAIL ASSEMBLY…………………………………………………….11
TAIL INSTALLATION………………………………………………………………………………………12-13
TAIL FIN INSTALLATION………………………………………………………………………………………14
RIGGING THE TURBINE FOR THE LIFT…………………………………………………………………15
BLADE INSTALLATION…………………………………………………………………………………………16
 CLAMP PLATE SPACERS…………………………………………………………………………….17
 BLADE ORIENTATION………………………………………………………………………………..18
 FITTING BLADES………………………………………………………………………………………..19
 BLADE TORQUE…………………………………………………………………………………………20
NOSE CONE INSTALLATION…………………………………………………………………………………21
APPLYING A PHASE TO PHASE SHORT…………………………………………………………………22
RAISING THE TURBINE………………………………………………………………………………………..23

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SYSTEM COMMISSIONING ……………….………………………………………………………………..24
 MEGGER TEST……………………………………………………………………………………….….24
 INVERTER/DUMPLOAD …………………………………………………………………………...25
 ALTERNATOR OUTPUT……………………………………………………………………………..26
 SYSTEM COMMISSIONING CHECKLIST………………………………………………………27
ADDITIONAL INFORMATION……………………………………………………………………………….28
***BEFORE PERFORMING ANY LIFTING OPERATION ENSURE ALL PARTS
ARE FREE AND CLEAR FROM OBSTRUCTIONS AND ARMORED CABLE
WILL NOT BE CRUSHED OR DEFORMED IN ANY WAY***

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RECOMMENDED TOOL LIST
Please note the below list is to serve as a general reference of what tools you
should have available. However in no way is it meant to be a comprehensive list
of tools required to complete the installation.
 Torque wrench -150 FT LBS
 1-1/16 deep socket
 17 MM socket and wrench
 24 MM socket
 22 MM socket
 5/32 or 4MM allen key
 Screw drivers
 Wire strippers
 Wire crimpers
 Diagonal cutters
 Razor blade knife
 Drill bits
 Volt meter/megger
 Spud wrench
 Tag line
 Chain hoist

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TORQUE VALUES
TASK
TOOL
HARDWARE
TORQUE
Attach tailboom to mainframe
17 MM
10
MM
35
ft⋅lb
Attach tailfin to tailboom
17 MM
10 MM
35
ft⋅lb
Torque bracket to alternator
24
MM
16
MM
100
ft⋅lb
Blades/clamp plate to alternator
24 MM
16 MM
*SEE PG
20
Spinner mounting
17 MM
10 MM
20
ft⋅lb
Turbine to tower
1
-
1/16”
5/8 (UNC)
120
ft⋅lb (wax)
198-240 ft⋅lb
Inverter grid side connections
5/32 or 4mm
allen key
90 inch lbs
Inverter Turbine side connections
#2 flathead
screwdriver
40 inch lbs
Dumpload +/- connections
3/16” or
5MM
90 inch lbs
Dumpload fan connections
Wire
crimpers
Butt splice

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TURBINE HARDWARE

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ELECTRICAL –STANDARD 240VAC 60Hz
This is how a typical 240 VAC grid tied installation will look once installed. For
deviation to the one line follow all local codes.

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ELECTRICAL TRANSFORMER REQUIRED
This configuration is typical for a grid tied system that is not a standard 240VAC. A
25KVA transformer is sized appropriately. A number of manufactures make
transformers that are suitable for installation. For this example we will use the
single phase transformer from Maddox.
208 – 120/240: MIT-DRY-224 (25 KVA)
240 / 480 – 120/240: MIT-DRY – 120 (25 KVA)
NOTE: The 120A fused disconnect is not mandatory but could be required by local
code.

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WIRE SIZING
Recommended Wire Size for BWC EXCEL 15 Installations
Note that wire run lengths correspond to performance values estimated by
WindCAD. Annual Energy Output losses of 4.5% were factored into the WindCAD
model to account for energy losses due to wire sizing.

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GETTING STARTED
The unit will come in three packages. Below is the power head crate that has
been open and stripped down to begin turbine assembly. Note the alternator is
bolted to the pallet.
Mainframe
The mainframe
and alternator
combined is a
powerhead
Alternator
Brake resistors
Tower adapter
Rigid armor cable
WARNING: The
alternator louvers
must be covered if
any moisture could
accumulate on the
back of the alternator
while stored in this
position.