Ennera Windera S Instruction Manual

Code: I.H4.V10.3003
Installation and Maintenance Manual Version: 07
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Installation and Maintenance
Manual
Windera S wind turbine
Ennera Energy and Mobility S.L.

Code: I.H4.V10.3003
Installation and Maintenance Manual Version: 07
2 / 66
Ennera Energy and Mobility, S.L.
This document contains confidential information which is property of Ennera Energy and Mobility, S.L. The copy, transmission or use by other people, of the whole document or
part of its contents, is not allowed without written permission from Ennera Energy and Mobility S.L.
CONTENTS
1. INTRODUCTION...................................................................................................................4
1.1. Aim..............................................................................................................................4
2. PRIOR CONSIDERATIONS ....................................................................................................5
3. PACKING LIST......................................................................................................................5
4. LIST OF ASSEMBLY TOOLINGS.............................................................................................6
4.1. Foundation..................................................................................................................6
4.2. Elevation......................................................................................................................6
4.3. Towerassembly...........................................................................................................7
4.4. Windturbine assembly................................................................................................7
5. INSTALLATION.....................................................................................................................8
5.1. Foundation..................................................................................................................8
5.2. Enneradesignmulti-sectiontowerassembly.............................................................13
5.3. Enneradesign2-sectiontowerassembly....................................................................17
5.4. Ambordesign3sectiontowerassembly....................................................................17
5.5. Lifting mechanism......................................................................................................17
5.6. Anemometerinstallation...........................................................................................21
5.7. Small Wind Turbine assembly....................................................................................21
5.7.1. Windera S packaging........................................................................................................................21
5.7.2. Yaw..................................................................................................................................................22
5.7.3. Generator........................................................................................................................................23
5.7.4. Rotor................................................................................................................................................24
5.7.5. Tail ..................................................................................................................................................26
5.8. Electrical connections................................................................................................26
5.8.1. Converterset....................................................................................................................................26
5.8.2. Cableconnections.............................................................................................................................28
5.8.3. Electrical scheme..............................................................................................................................31
5.8.4. Anemometer....................................................................................................................................31
5.9. Windturbine erection................................................................................................32
6. SCREW KITS.......................................................................................................................35
6.1. Tower assembly kit....................................................................................................35
6.2. Windturbine assembly kit .........................................................................................35
6.3. Anemometer assembly kit .........................................................................................36
6.4. Converter assembly kit...............................................................................................36
7. COMMISSIONING..............................................................................................................36
7.1. Load new firmware....................................................................................................36
7.2. Change parameters....................................................................................................37

Code: I.H4.V10.3003
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part of its contents, is not allowed without written permission from Ennera Energy and Mobility S.L.
8. MAINTENANCE..................................................................................................................41
8.1. Safety procedures......................................................................................................41
8.2. Routine inspections ...................................................................................................41
8.3. Maintenance plan......................................................................................................42
9. TROUBLESHOOTING..........................................................................................................43
10. FREQUENTLY ASKED QUESTIONS ..................................................................................43
11. RECYCLING ....................................................................................................................44
12. LOGBOOK......................................................................................................................45
13. ANNEX 1: GENERAL DIMENSIONS DRAWING................................................................46
14. ANNEX 2: SINGLE LINE DIAGRAM..................................................................................47
15. ANNEX 3: ELECTRICAL SCHEME .....................................................................................48
16. ANNEX 4: INSTALLATION CONTROL FORM....................................................................49
17. ANNEX 5: MAINTENANCE CONTROL FORM...................................................................52
18. ANNEX 6: INSTALLATION DRAWINGS............................................................................54
19. ANNEX 7: LIST OF ALARMS............................................................................................63

Code: I.H4.V10.3003
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Ennera Energy and Mobility, S.L.
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part of its contents, is not allowed without written permission from Ennera Energy and Mobility S.L.
1. INTRODUCTION
1.1.Aim
This Installation and Maintenance Manual describes the procedures to be carried out in order to
satisfy the requirements of the installation and maintenance process of the Windera S small wind
turbine (SWT).

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2. PRIOR CONSIDERATIONS
ONLY TRAINED PERSONNEL SHOULD INSTALL A WINDERA S WIND TURBINE.
A wrong installation of the turbine could lead to a serious damage.
Read this procedure carefully before starting any installation.
The Windera S wind turbine must not be installed with a wind speed average greater
than 10m/s. The loads at this wind speed could cause damage in the tower base and
pivoting point.
During wind turbine installation, the area surrounding the wind turbine should be free of people
not related with the installation.
FAILURE TO FOLLOW THE PROCEDURES DESCRIBED IN THIS MANUAL CAN CAUSE
SERIOUS INJURY.
3. PACKING LIST
The Windera S small wind turbine is supplied in 2 packages: One with the tower and one with
the wind turbine.

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Inside the wind turbine package there are the following components:
COMPONENT CODE UNITS
W1 Generator JI.H4.G5.4000.00 1
W2 Brake JI.H4.K5.4000.00 1
W3 3 blade set JI.H4.B5.4000.01 1
W4 Converter JI.H4.P5.4000.01 1
W5 Tail JI.H4.N5.4000.01 1
W6 Yaw JI.H4.Y5.4000.00 1
W7 Tower cable (3x6mm2) JI.H4.P5.4000.05 1
W8 Cone JI.H4.B5.4000.05 1
W9 Hub JI.H4.B5.4000.04 1
W10 Hub bushing JI.H4.B5.4000.06 1
W11 Blade fixing plate JI.H4.B5.4000.07 3
W12 Yaw cover JI.H4.Y5.4000.50 1
W13 Converter housing JI.H4.P5.4000.04 1
W14 Converter structure JI.H4.P5.4000.02 1
W15 Screw kits (4 ref.)
JI.H4.V5.4000.03
JI.H4.P5.4000.07
JI.H4.T5.4000.05
JI.H4.T5.4000.13
1
1
1
1
W16 Earthing cable JI.H4.P5.4000.06 1
W17 Elevation cable 8.3m JI.H4.T5.4000.06 1
W18 Shackle 3.25Tn JI.H4.T5.4000.10 1
W19 Anemometer JI.H4.T5.4000.11 1
W20 Anemometer structure JI.H4.T5.4000.12 1
W21 Nameplate JI.H4.V5.4000.06 1
4. LIST OF ASSEMBLY TOOLINGS
4.1.Foundation
Reference Tooling Nº units Drawing
FD-1 Tower bolts 8 JI.H4.T5.4000.04
FD-2 Bolts position tooling 1 JI.H4.V10.4000.51
4.2.Elevation
Reference Tooling Nº units
EL-1 Tractel ground fixing point 1
EL-2 Fixing point tooling 1
EL-3 Tractel 1600 kg 1
EL-4 Shackle 3.25Tn 2
EL-5 Tractel cable 15m 1
EL-6 GinPole Ø114.3mm, L=4m 1
EL-7 Hydraulic jack 2
EL-8 Hexagon bolt M20x180 1
EL-9 Spanner 46 1

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4.3.Tower assembly
Reference Tooling Nº units
TW-1 Ratchet tensioner 15m 2
TW-2 Metallic mallet 1
TW-3 Molykote spray (grease) 1
TW-4 Cable guide 1
TW-5 Galvanizing spray 1
TW-6 Level 2
TW-7 Trestle 1
4.4.Wind turbine assembly
Reference Tooling Nº units
WT-1 Allen keys 1
WT-2 Torque wrench 30-200Nm 1
WT-3 Spanner nº 17 1
WT-4 Spanner nº 19 1
WT-5 Spanner nº 50 1
WT-6 Loctite 243 Threadlocker 1
WT-7 Rotor extraction M20 screw 1
WT-8 Ratchet set with sockets 1
WT-9 Round file Ø10mm 1
WT-10 Screwdriver set 1
WT-11 RAL 9003 matt colouring spray 1
WT-12 Galvanizing spray 1
WT-13 Set of steel inserts for aluminium (Helicoil type-M5, M6, M8, M10) 1

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5. INSTALLATION
5.1.Foundation
See drawing JI.H4.V10.4000(Annex 4)
for foundation construction details.
The foundation must be
done at least 3 weeks
before wind turbine
installation.
1. Make ahole of 2x2m and 1m depth.
2. If the soil is not consistent, make a
box of wood to sustain the walls of the
hole.

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3. Add a 75mm of thick plain cement
concrete layer.
4. Place the foundation reinforcement
steel bars inside the hole, fixing the bars
between them with metallic wire (up
and bottom).
Lower reinforcement at a
distance of 100mm from
plain cement concrete.
5. Attach an earthing cable of 6mm2to
the bottom partof the reinforcement
bars.
(Foundation earthing
cable not supplied.
Length = 2m)
6. Place the 8xM30fixing steel bolts
(FD-1) with the template (FD-2), so that
the 8 bars are perfectly vertical and
concentrically to tower axis.
Follow dimension of the
drawing “Bolts position
tooling” in Annex 4.
2 bolts must be aligned
with the lifting direction.
After placing the template, level it.
lifting direction
FD-1 FD-2

Code: I.H4.V10.3003
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Ennera Energy and Mobility, S.L.
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part of its contents, is not allowed without written permission from Ennera Energy and Mobility S.L.
7. Place the Ø32mm corrugated tube.
One from the tower axis to the
converter and the other from the
converter to the grid connection point.
Avoid sharp corners in the
corrugated tube.
8. The other part of the earthing
conductor must be out of the
foundation at least 1m, from the middle
point of the fixing bolts.
9. Review the levelling of the template
with the bolts and the lifting direction.