ista Breeze i-1500 Windsafe User manual

SAVE
SAVE
ENERGY
PLANET
TRANSLATION OF THE
ORIGINAL INSTRUCTIONS
- Keep handy at the place of use -
Wind turbine system
i-1500 Windsafe, i-2000 Windsafe

EarthSafe
7.1 Shipping ...................................................................................................... 13
7.1.2 Scope of supply .......................................................................................... 13
1 - Contents -
1 Contents ................................................................................................. 2
2 General.................................................................................................... 4
2.1 About this translation of the original instructions ....................................... 4
2.1.1 Revision status of the original instructions .................................................. 4
2.1.2 Conditions for installing and operating the wind turbine system ................ 4
2.1.3 Availability of the instructions....................................................................... 4
2.2 Conventions used in this translation of the original instructions.................. 4
2.2.1 Other symbols used ...................................................................................... 5
2.2.2 Information ................................................................................................... 5
2.3 Name and address of the manufacturer and his authorised representative 5
2.4 Warranty and liability ................................................................................. 6
2.5 Product feedback ........................................................................................ 6
3 Technical Description.............................................................................. 6
3.1 Intended use .............................................................................................. 6
3.2 Reasonably foreseeable misuse.................................................................. 6
3.3 Main components........................................................................................ 7
3.4 Main components of the wind turbine ....................................................... 8
4 Technical Data........................................................................................ 9
5 Charge Controller and Specifications...................................................... 10
5.1 Permissible operating and storage conditions............................................. 12
5.1.1 Storage ........................................................................................................ 12
5.1.2 Operation .................................................................................................... 12
6 Safety Information ................................................................................. 12
6.1 Modifications or changes by the user ......................................................... 12
6.2 Residual risks.............................................................................................. 12
6.3 Personnel requirements.............................................................................. 12
7Preparing to use the System.................................................................... 13
7.1.1 As-delivered condition ............................................................................... 13
2 of 28Translation of the original instructions iSTA wind turbine system 24.07.2018I00

EarthSafe
7.2 Requirements at the place of use ............................................................... 13
8.1 Switching on the wind turbine system......................................................... 18
9.1 Emergency shut-down ............................................................................... 18
9.2 Temporary shut-down................................................................................ 18
9.3 Prolonged shut-down................................................................................. 18
7.6 Erecting the wind turbine ............................................................................ 17
8Normal Operation .................................................................................. 18
8.2 Restart after an emergency ........................................................................ 18
9Shutting down the Wind Turbine System ............................................... 18
7.2.1 Permissible wind class, footprint and minimum clearances ...................... . 13
7.2.2 Tower foundation ...................................................................................... 14
7.3 Unpacking the components ........................................................................ 15
7.4 Assembling the wind turbine....................................................................... 15
7.5 Electrical connections ................................................................................. 16
Translation of the original instructions iSTA wind turbine system 24.07.2018I00 3 of 28
10 Maintenance ......................................................................................... 19
10.1 Safety precautions during maintenance work............................................. 19
10.2 Inspection and maintenance schedule ....................................................... 19
10.3 Maintenance and cleaning by the user ....................................................... 19
11 Troubleshooting and Diagnostics ........................................................... 20
11.1 Errors with LED........................................................................................... 20
11.2 Errors without LED...................................................................................... 20
12 Removal from Service and Disposal ....................................................... 21
12.1 Final decommissioning of the wind turbine system .................................... 21
12.2 Disposal of the wind turbine system and components ............................... 21
13 Declaration of Conformity ..................................................................... 22
14 Index...................................................................................................... 23
15 Notes .................................................................................................... 24
16 Performance Charts……………………………………………………………………………… 25
17 Certificates............................................................................................. 26
18 Suitable Battery Capacities ..................................................................... 27
19 Technical Drawing of Flange.................................................................... 28

EarthSafe
2.1 About this translation of the original instructions
2.1.1 Revision status of the original instructions
2.1.2 Conditions for installing and operating the wind turbine system
Please make sure that
•The wind turbine system has been erected correctly by a suitably trained
person.
•All operating personnel have read and fully understood this translation of the
original instructions
•The wind turbine system is properly maintained and repaired.
2.1.3 Availability of the instructions
Keep this translation of the original instructions handy at all times, so that it can be
referred to by all persons working on or with the wind turbine system.
2.2 Conventions usedin this translation of the original instructions
Safety information is always identified by a signal word and in some cases also by
a hazard-specific symbol.
DANGER!
Immediate danger!
Non-observance of the safety instructions will result in serious or fatal injury!
WARNING!
Potentially dangerous situation!
Non-observance of the safety instructions can result in serious or fatal injury!
CAUTION!
Potentially dangerous situation!
Non-observance of the safety instructions can result in minor or moderate injuries!
IMPORTANT!
Potentially dangerous situation!
Non-observance of the safety instructions can result in damage to property or
pollution of the environment!
Revision date: ..........................................................................................24.07.2018
Revision index: .......................................................................................... 00
2 - General -
4 of 28Translation of the original instructions iSTA wind turbine system 24.07.2018I00

EarthSafe
2.2.1 Other symbols used
The following symbols are used in this translation of the original instructions as well
as on the wind turbine system itself:
Warning signs
General warning!
Danger: High voltage!
May start without warning!
Environmental hazard!
Table 1 Warning signs
Mandatory signs
Read manual before operating!
Isolate before opening!
Table 2 Mandatory signs
2.2.2 Information
Note
Indicates general information and recommendations.
2.3 Name and address of the manufacturer and his authorised
representative
Table 3 Manufacturer
Table 4 Authorised representative
Translation of the original instructions iSTA wind turbine system 24.07.2018I00 5 of 28
Name FastTrading Ltd
Address Ul.Stancıonna No. 64 Et.2 · BG-8500 Aytos / BULGARIA
Phone [phone]
Internet www.istabreeze.com
Name ALTINEL ENERJI DIS TIC. ELEK. ELEKTRONIK SAN.VE TIC.
LTD. STI
Phone [phone]
Internet www.altinelenerji.com
Address Gökevler Mah, 2331 Sk. No: 2/d -Esenyurt / Istanbul / TURKEY

EarthSafe
2.4 Warranty and liability
The “General Terms of Sale and Delivery” of the manufacturer or his authorised
representative apply.
2.5 Product feedback
Please notify the manufacturer or his authorised representative about any of the
following
•Accidents
•Potential safety hazards associated with the wind turbine system
•Ambiguities in this translation of the original instructions
•Description of the wind turbine system
3.1 Intended use
•The wind turbine system may only be used as a “small wind turbine system”
(SWTS) to generate power in accordance with EN 61400-2.
•The wind turbine system may only be operated in accordance with the ratings
and in the approved wind class (refer tothe technical data).
•Observance of the original instructions and compliance with the maintenance
and repair instructions are essential preconditions of use for the intended
purpose.
3.2 Reasonably foreseeable misuse
All forms of use which deviate from or exceed the limits of use described above are
considered to be contrary tothe intended purpose. The manufacturer is not liable
for any damage resulting from such use.
No liability will be accepted by the manufacturer if the equipment has been altered
as well as in the event of improper assembly, installation, start-up, operation,
maintenance or repair.
Only original parts supplied by the manufacturer are approved as spare parts or
accessories. Any spare parts or accessories not supplied by the manufacturer
have not been tested for operation and could be detrimental to reliability. No
liability will be accepted by the manufacturer for any damages which result from the
use of non-approved spare parts or accessories.
Reasonably foreseeable misuse includes:
•Operation outside the manufacturer’s specification
•All modifications or changes tothe wind turbine system without the
manufacturer’s written approval!
•Use of parts other than iSTA Breeze original parts.
•Operation in non-approved SWTS classes.
•Operation in strong winds or hurricanes.
3 - Technical Description -
6 of 28Translation of the original instructions iSTA wind turbine system 24.07.2018I00

EarthSafe
3.3 Main components
Fig. 1: Main components of the wind turbine system
No. Component Function
Emergency shut-down.
When pressed, the wind turbine must be short-
circuited.
5Solar panels
(optional) Convert solar energy into electrical energy
6To converter
Table 5 Main components and their functions

Wind turbine
1 Converts wind energy into electrical energy
2
Charge controller
3
4 Battery (optional) Stores electrical energy (Acid, Gel)
Recommendation:
Several batteries can be connected in series or series. Depending
on which system voltage is used.
(optional)
Type : i/HCC 2000
Generates electrical voltage (24 / 48 VDC
Optionally).The iSTA Breeze charge controller.
Converts 24/48 VDC into 110/220 VAC
(optional)
Switch switch AC
Emergency Stop Button
(optional)
Translation of the original instructions iSTA wind turbine system 24.07.2018I00 7 of 28

EarthSafe
3.4 Main components of the wind turbine
Fig. 2: Main components of the wind turbine
No. Component Quantity
7 1
Table 6 Main components of the wind turbine and their functions
5
1
4
1Nose 1
2 Rotor blade 3
3 Hub for holding the blades 1
4 Generator for producing electricity 1
5Boom for wind direction flag 1
6 Tail vane for turning the blades into the wind 1
8 of 28Translation of the original instructions iSTA wind turbine system 24.07.2018I00
2
3
6
7
Adapter stud for attaching the wind turbine to the tower
81
Main Body
8

EarthSafe
Generator
EN 61000-6-3 (electromagnetic compatibility – emissions)
Rotor blades
Noise emissions
[dB(A)]
Table 7 Technical data
Designation
Housing material
Permanent magnet rotor, brushless, gearless, maintenance-
Type free
Aluminium
Direction of rotation Any
Approx. weight per
Rotor Blades 3 pieces of plastic with glass fiber mixture
Direction of Rotation from the front in a clockwise direction
60
Max. power
48V 40A
Current 3-phase-AC
Start of charging Approx. 3 m/s (wind speed)
Hub flange Cast Steel
690 720
Max. Speed [rpm] 1000
EN 61000-6-1 (electromagnetic compatibility – susceptibility)
Test standard
rotor blade [g]
Blade Color
Black or White
4 - Technical Data -
Translation of the original instructions iSTA wind turbine system 24.07.2018I00 9 of 28
Diameter, approx. [m] 2.20
i-1500 Windsafe i-2000 Windsafe
24V 55A
Open circuit voltage [VAC]
[48V] 0 - 200
[24V] 0 - 100
Weight [kg] 31 32

EarthSafe
With its discreet appearance, simple operation, with integrated protection functions, this device has
high efficiency and low no-load losses. This version of the controller will significantly increase the life
and stability of the whole system, especially the batteries.
The special features and product information are listed below:
Microprocessor controlled charge with integrated voltage and current limiting. Electromagnetic
brake control.Integrated 3-phase short circuit breakers (brake switch)
Protection against lightning strikes. Protection against overcharging, deep discharge, short
circuit, overload and against incorrect reverse polarity.
Integrated display.
In addition, the control electronics in the control cabinet monitors the system voltage and brakes the
wind turbine when a max. Overvoltage.
Use of external and high quality (Triacs & Hyper Mosfet), solid state components. Increasing the
life of the controller.
The Wind / Solar Hybrid Charge Controller from IstaBreeze® is an intelligent controller of the wind
turbine and solar cells that controls you at the same time. The high-end device can also be used
as a monitoring system. It is used to safely and efficiently charge and control your battery with the
Wind Generator / Solar Module combination.
The generator is automatically braked gently when the battery is full, modern braking
system with external load resistance (Dump Load) to avoid the immediate blocking of the
turbine. Increasing the life of the stator.
5 - Charge Controller -
10 of 28Translation of the original instructions iSTA wind turbine system 24.07.2018I00

EarthSafe
5 - Specifications of Charge Controller -
Translation of the original instructions iSTA wind turbine system 24.07.2018I00 11 of 28

EarthSafe
•Ambient temperature: -25 to +40°C
•Place of use: Max. SWTS Class III acc. to EN 61400-2
The wind turbine system is in conformity with the European Machinery Directive
2006/42/EC provided only original iSTA Breeze components are used and subject
to proper erection. The use of components from other manufacturers as well as
modifications or changes tothe wind turbine system by the user are prohibited and
could render the declaration of conformity invalid!
Any residual risks which arise as a result of operation or maintenance are
described in the relevant sections of these instructions.
All work on the wind turbine system must be carried out by authorised persons!
Such persons must be familiar with the safety devices and regulations prior to
carrying out the work.
Authorised persons are defined as follows:
Operating mode Necessary qualifications
Erection Suitably trained persons
Normal operation Trained personnel
Cleaning Trained personnel
Maintenance Suitably trained persons
Repair Manufacturer
Table 8 Personnel requirements
•Ambient temperature: -15 to +40°C
•Storage location: Dry, frost-free
5.1 Permissible operating and storage conditions
5.1.1 Storage
5.1.2 Operation
6.1 Modifications or changes by the user
6.2 Residual risks
6.3 Personnel requirements
6 - Safety Information -
12of 28Translation of the original instructions iSTA wind turbine system 24.07.2018I00

EarthSafe
WARNING!
Danger to life due to operation in non-approved wind classes!
The wind turbine system may only be operated at Class III wind sites.
For information on local wind classes, please contact the responsible authorities or
your nearest meteorological office.
Fig. 3: Footprint and minimum clearances
The place of use must be free of obstacles; alternatively, the wind turbine must be
erected with a sufficient height (refer to Fig. 3:). Obstacles are defined as houses,
hedges, trees, hills, etc.
When choosing the place of use, make sure adequate room is
available totilt the tower and blades if necessary.
H
20 H
2 H
2 H
7.1 Shipping
7.1.1 As-delivered condition
The wind turbine system is shipped disassembled.
7.1.2 Scope of supply
Refer tothe contract documentation for the scope of supply.
7.2 Requirements at the place of use
7.2.1 Permissible wind class, footprint and minimum clearances
7 - Preparing to use the System -
Translation of the original instructions iSTA wind turbine system 24.07.2018I00 13of 28

EarthSafe
Fig. 4: Design of the foundation for erecting the tower
The soil must have a sufficient load-bearing capacity. The size and structure of the
foundation depend on the soil characteristics.
Recommendation:
Ask a qualified structural engineer for advice regarding the optimal
design of the foundation.
Fig. 5: Suitable guying system
7.2.2 Tower foundation
14of 28Translation of the original instructions iSTA wind turbine system 24.07.2018I00

EarthSafe
Carefully open the packaging.
Check the shipment for completeness (refer tothe shipping documents).
Separate the packaging material and dispose of it in an environmentally
responsible way.
Danger due to rotor imbalance!
Always replace the complete set of rotor blades.
Risk of injury in case of assembly at windy sites!
Choose an assembly site which is sheltered from the wind.
The assembly process requires calm weather conditions.
Fig. 6: Assembling the wind turbine
7.3 Unpacking the components
7.4 Assembling the wind turbine
WARNING!
5
1
4
23
6
3
Translation of the original instructions iSTA wind turbine system 24.07.2018I00 15of 28
5
3
2
1
4
6
For installation, select sheltered place.
Hold propeller blade (1) with flat side to hub (2).
Fasten with a M8x45 bolt, nut and one.
Screw on further M8x45 screws and tighten by hand.
Attach boom rod (3) with M8x60 bolt to alternator housing.
Screw nose (4) to hub with M8x75 screw.
Screw wind vane (5) to boom with M8x60 bolt.
Plug - in pin 138,5 mm outer diameter mm as mast connection (technical
drawing , you can find it in Page 28.

EarthSafe
Fig. 7: Balancing the rotor (Y position)
Danger: High voltage!
All work on electrical equipment must be carried out by a qualified
electrician with the power switched off!
Note: To ensure proper operation, you must use an original iSTA
Breeze charge controller.
Connect athree-wire cable with a suitable cross-section (refer to Table 9 /
Table 10) and the required length tothe generator.
Make the electrical connections as shown in Fig. 1:.
Connect the charge controller and the transformer as shown in the
connection diagram (refer to the relevant documentation).
Distance between
generator and charge
controller [m]
< 11 11 – 18 18 – 29 20 – 44 44 – 68 68 – 110
Cable cross-section [mm²] 2.5 4 6 10 16 25
Distance between
generator and charge
controller [m]
< 11 11 – 18 18 – 29 20 – 44 44 – 70 68 – 113
Cable cross-section [mm²] 2.5 4 6 10 16 25
Move rotor to Y position (see Fig. 7)
Carefully release rotor blade.

Observe in which direction the rotor turns (the heavier rotor blade pushes downwards).
Repeat the process for all three positions to determine which rotor blade is in imbalance.
Check repeller for balance
Tighten all screws to 25 Nm.
 Check balance again.
 Secure all screws with locking varnish.
Note: The repellers have already been tested for equal weight
by the manufacturer.
7.5 Electrical connections
DANGER!
Table 9 Cable cross-section with 24 V generator voltage
Table 10Cable cross-section with 48 V generator voltage
16of 28Translation of the original instructions iSTA wind turbine system 24.07.2018I00

EarthSafe
Feed the three-wire cable through the tower right up to the top.
Provide suitable strain relief.
Connect the wires tothe generator.
Fig. 8: Connecting the three-wire cable tothe generato
Pull heat shrink tubing over the solder joint and shrink.
Wrap each wire with textile insulating tape.
Danger due to unsuitable tower constructions!
Only use tested mast constructions or original iSTA Breeze masts.
7.6 Erecting the wind turbine
WARNING!
 Pull a suitable shrink tube over each wire of the cable.
 Twist and solder each wire of the cable to the wire from the generator
Short circuit all 3 phases to activate the generator brake.1
1When using the iSTA Breeze charge controller, press the brake button
Choose a mast diameter <70 mm, so that the rotor blades are
not pressed against the mast during a storm.
Attach the wind turbine tothe tower. Be careful not to damage the cable.
Screw wind generator to mast.
Erect the mast.
Align the mast vertically in all directions.
Brace the vertical mast (see Fig. 5)
Kurzschluss aufheben.
Translation of the original instructions iSTA wind turbine system 24.07.2018I00 17of 28

EarthSafe
For information on operating the iSTA Breeze charge controller, refer to
the separate instructions.
Unlock the emergency stop button or release the brake button on the iSTA
Breeze charge controller.
The brake is released.
The fast-blinking red LED on the iSTA Breeze charge controller goes out.
The wind turbine system supplies power.
Make sure the risk has been removed.
Switch on the wind turbine system (section 7.1)
Press the emergency stop button between the wind turbine and the charge
controller.
The wind turbine is short-circuited via the iSTA Breeze charge controller.
The wind turbine is braked.
Press the “Charge controller OFF” button on the iSTA Breeze charge
controller.
Operation is interrupted.
Press the “Charge controller brake OFF” button on the iSTA Breeze charge
controller.
The wind turbine is short-circuited via the iSTA Breeze charge controller.
The wind turbine is braked.
Carefully tilt the wind turbine.
Clean the wind turbine (section 9.3)
8.1 Switching on the wind turbine system
8.2 Restart after an emergency
9.1 Emergency shut-down
9.2 Temporary shut-down
9.3 Prolonged shut-down
8 - Normal Operation -
9- Shutting down the Wind Turbine System -
18of 28Translation of the original instructions iSTA wind turbine system 24.07.2018I00

EarthSafe
Risk of injury when carrying out maintenance work!
Shut down the wind turbine system prior to all maintenance work.
Take steps to prevent the wind turbine system from being switched on again
by unauthorised persons.
Shut down the wind turbine system (section 8.2).
Carefully tilt the tower.
Interval Part / component Activity
Daily
Wind turbine Check for abnormal noises
Rotor blades Check that the blades turn freely
Tower Inspect for damage
Yearly2/ at
end of winter
or after
extreme
weather
events
Rotor blades

Inspect for cracks / damage and
if necessary replace
Treat with underbody protection
wax

Are the rotor blades balanced?
Tower

Check for vibration
Check the guy wires
Is the tower still aligned
vertically?

Inspect for damage
Wind turbine Check the bolts
Electrical wiring Inspect the cables for damage
Table 11Inspection and maintenance schedule
WARNING!
Danger due to damaged parts!
Shut down the wind turbine system immediately if the rotor blades or the
electrical wiring are damaged.
Refer tothe supplementary documents for information on maintaining supplier
components.
Coat the wind turbine and the rotor blades regularly with commercially
available underbody protection wax using a soft cloth.
A wax film protects the surfaces of the wind turbine and the rotor blades
from the weather and increases the efficiency of the blades.
2Or every 6 months if situated close to sea
10.1 Safety precautions during maintenance work
WARNING!
10.2 Inspection and maintenance schedule
10.3 Maintenance and cleaning by the user
10 - Maintenance -
Translation of the original instructions iSTA wind turbine system 24.07.2018I00 19of 28

EarthSafe
Error messages are displayed on the iSTA Breeze charge controller.
Refer tothe separate instructions.
Error Possible cause Possible actions
Wind turbine
does not start up
Not enough wind None
“Stop” switch pressed Release the “Stop” switch
Rotor turns too
slowly
Rotor blades incorrectly
attached
Attach the rotor blades
correctly
Rotor blades not balanced Balance the rotor blades
Bearing for wind alignment
is stiff Replace the bearing
Generator makes contact
as it turns
Send the generator in to
the manufacturer
Unfavourable location or
tower too low

Check and move to
another location if
necessary
Increase the height of the
tower
Wind turbine
vibrates on tower
Rotor not balanced Balance the rotor
Tower not aligned vertically Align the tower vertically
Tower bends in the wind 
Design a more robust
tower
Tower foundation has too
much clearance
Reduce the clearance to a
minimum
Wind turbine
system produces
too little power
Wind turbine or charge
controller defective
Contact the manufacturer
or a specialist dealer
Battery defective Replace the battery
Battery too small 
Use a larger battery (at
least 100 Ah)
Battery fuse tripped

Replace the fuse
Check the electrical
connections
Cable cross-section does
not match installed cable
length
Match the cable cross-
section correctly
Table 12Errors without an LED
Recommendation:
Make a note of the relevant parameters at the site and have them handy
when you contact the manufacturer / specialist dealer.
1. What is the average / typical wind speed?
2. How high is the tower?
11.1 Errors with LED
20 of 28Translation of the original instructions iSTA wind turbine system 24.07.2018I00
11.2 Errors without LED
11 - Troubleshooting and Diagnostics -
3. What are the characteristics of the countryside / built-up area in the vicinity of
the wind turbine?
4. What is the voltage between phases (measured by a qualified electrician – this
voltage should be roughly identical in identical wind conditions)?
5. What is the battery voltage? How old is the battery or batteries?
6. Which loads are connected tothe battery?
7. Are solar panels also connected tothe charge controller? If so:
a. What is the no-load voltage3[VDC]?
b. What is the power [Wp]?