Kestrel e300i User manual

e300i User Manual Document #: 0503M01A REV : 1.3
Approval: Date: March ‘08 Page 1 of 25
Registration Number 2006/005438/07
VAT Registration Number 4870231406
Tel: [phone]
Website: www.kestrelwind.co.za
User Manual Revision 1.3 (03-08)
Revision 1.2 (12-07)
Revision 1.1 (08-07)
Revision 1.0 (06-07)

e300i User Manual Document #: 0503M01A REV : 1.3
Approval: Date: March ’08 Page 2 of 25
CONTENTS
CONTENTSCONTENTS
CONTENTS
1
11
1Safety Considerations
Safety ConsiderationsSafety Considerations
Safety Considerations
1.1
1.11.1
1.1 Mechanical Safety
Mechanical SafetyMechanical Safety
Mechanical Safety 3
3 3
3
1.2
1.21.2
1.2 Electrical Safety
Electrical SafetyElectrical Safety
Electrical Safety 3
3 3
3
1.3
1.31.3
1.3 Installation Hazards
Installation HazardsInstallation Hazards
Installation Hazards 3
3 3
3
1.4
1.41.4
1.4 Operational Safety
Operational SafetyOperational Safety
Operational Safety 3
3 3
3
2
22
2Wind T rbine Overview
Wind T rbine OverviewWind T rbine Overview
Wind T rbine Overview
2.1
2.12.1
2.1 T rbine Description
T rbine DescriptionT rbine Description
T rbine Description 4
4 4
4
2.2
2.22.2
2.2 Identification and Markings
Identification and MarkingsIdentification and Markings
Identification and Markings 4
4 4
4
2.3
2.32.3
2.3 Applications and ses
Applications and sesApplications and ses
Applications and ses
2.4
2.42.4
2.4 Charge Controllers and Inverters
Charge Controllers and InvertersCharge Controllers and Inverters
Charge Controllers and Inverters
2.5
2.52.5
2.5 Grid Tied Applications
Grid Tied ApplicationsGrid Tied Applications
Grid Tied Applications
2.6
2.62.6
2.6 Voltage Limiter
Voltage LimiterVoltage Limiter
Voltage Limiter 5
5 5
5
3
33
3Unpacking and
Unpacking and Unpacking and
Unpacking and T rbine Assembly
T rbine AssemblyT rbine Assembly
T rbine Assembly
3.1
3.13.1
3.1 Components S pplied
Components S ppliedComponents S pplied
Components S pplied 6
6 6
6
3.2
3.23.2
3.2 Tools Req ired
Tools Req iredTools Req ired
Tools Req ired 6
6 6
6
3.3
3.33.3
3.3 Unpacking
UnpackingUnpacking
Unpacking 7
7 7
7
3.4
3.43.4
3.4 Technical Req irements for
Technical Req irements forTechnical Req irements for
Technical Req irements for Assembly
Assembly Assembly
Assembly 8
8 8
8
3.5
3.53.5
3.5 Generator
GeneratorGenerator
Generator Assembly
AssemblyAssembly
Assembly 8
88
8
3.6
3.63.6
3.6 Pitch control Assembly
Pitch control AssemblyPitch control Assembly
Pitch control Assembly 8
8 8
8
3.7
3.73.7
3.7 Tail Assembly
Tail AssemblyTail Assembly
Tail Assembly 9
99
9
3.8
3.83.8
3.8 Fitting the Pitch Control
Fitting the Pitch ControlFitting the Pitch Control
Fitting the Pitch Control 10
1010
10
3.9
3.93.9
3.9 B
BB
Blade Assembly
lade Assemblylade Assembly
lade Assembly 1
11
11
11
1
4
44
4Site Considerations and Mo ntings
Site Considerations and Mo ntingsSite Considerations and Mo ntings
Site Considerations and Mo ntings
4.1
4.14.1
4.1 Mo nting Flange Detail
Mo nting Flange DetailMo nting Flange Detail
Mo nting Flange Detail 1
1 1
12
22
2
4.2
4.24.2
4.2 Roof Mo nting
Roof Mo ntingRoof Mo nting
Roof Mo nting 1
1 1
12
22
2
4.3
4.34.3
4.3 Towers
TowersTowers
Towers 1
1 1
12
22
2
5
55
5Wiring and
Wiring and Wiring and
Wiring and Cable Sizing
Cable SizingCable Sizing
Cable Sizing
5.1
5.15.1
5.1 T rbine Wiring
T rbine WiringT rbine Wiring
T rbine Wiring 1
1 1
13
33
3
5.2
5.25.2
5.2 Lightning Protection
Lightning ProtectionLightning Protection
Lightning Protection 1
1 1
13
33
3
5.3
5.35.3
5.3 Wire
WireWire
Wire and Cable Sizes
and Cable Sizes and Cable Sizes
and Cable Sizes 1
1 1
14
44
4
6
66
6Battery Considerations
Battery ConsiderationsBattery Considerations
Battery Considerations
6.1
6.16.1
6.1 Lead Acid Batteries
Lead Acid BatteriesLead Acid Batteries
Lead Acid Batteries 1
1 1
15
55
5
6.2
6.26.2
6.2 Sealed Gel Batteries
Sealed Gel BatteriesSealed Gel Batteries
Sealed Gel Batteries 1
1 1
15
55
5
6.3
6.36.3
6.3 Ni
NiNi
Ni-
--
-Cad Batteries
Cad BatteriesCad Batteries
Cad Batteries 1
1 1
15
55
5
6.4
6.46.4
6.4 Temperat re Compensation
Temperat re CompensationTemperat re Compensation
Temperat re Compensation 1
1 1
15
55
5
7
77
7Technical
Technical Technical
Technical Details
DetailsDetails
Details
7.1
7.17.1
7.1 Technical Specification
Technical SpecificationTechnical Specification
Technical Specification 1
1 1
16
66
6
7.2
7.27.2
7.2 Declaration of Conformity
Declaration of ConformityDeclaration of Conformity
Declaration of Conformity 1
1 1
17
77
7
8
88
8Tro ble shooting
Tro ble shootingTro ble shooting
Tro ble shooting 1
1 1
18
88
8
9
99
9Maintenance
MaintenanceMaintenance
Maintenance 1
1 1
19
99
9
10
1010
10 Warranty Conditions
Warranty ConditionsWarranty Conditions
Warranty Conditions 21
2121
21
11
1111
11 C stomer Feedback
C stomer FeedbackC stomer Feedback
C stomer Feedback 2
2 2
25
55
5

e300i User Manual Document #: 0503M01A REV : 1.3
Approval: Date: March ’08 Page 3 of 25
1
1 S Sa af fe et ty y C Co on ns si id de er ra at ti io on ns s
1 1. .1 1 M Me ec ch ha an ni ic ca al l S Sa af fe et ty y
1 1. .2 2 E El le ec ct tr ri ic ca al l S Sa af fe et ty y
1 1. .3 3 I In ns st ta al ll la at ti io on n H Ha az za ar rd ds s
1 1. .4 4 O Op pe er ra at ti io on na al l S Sa af fe et ty y
Disclaimer
Kestrel Wind Turbines makes every e ort to give accurate in ormation in this manual and is in no way
liable or any error or omission. The user o this manual assumes ull responsibility and risk.
We appeal to your common sense to read and apply the sa ety notes. Consult pro essional engineers
and take advice i you are unsure.
1 SAFETY FIRST
1 SAFETY FIRST1 SAFETY FIRST
1 SAFETY FIRST
Although Kestrel’s wind turbines are designed with your safety in mind, accidents can easily occur
and there are always inherent dangers associated with any type of machine. Consult installation
pro essionals i you lack experience or con idence.
1.1 Mechanical Safety
1.1 Mechanical Safety1.1 Mechanical Safety
1.1 Mechanical Safety
Use good handling methods and take precautions to avoid physical injury during installation and
maintenance/repair procedures. The rotating blades of any wind turbine are a main hazard. The
e300
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ii
i
blades are extremely tough and will cause serious injury to the body. Never install the e300
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ii
i
such that any person or animal could come into accidental contact with any part o the machine. Never
approach the machine i the blades are rotating.
1.2 Electrical Safety
1.2 Electrical Safety1.2 Electrical Safety
1.2 Electrical Safety
The e300
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output voltage can become dangerous and even lethal when running on open circuit.
Maintain a healthy respect for this wind turbine. Always short the output wires together when the
e300
i
ii
i
is disconnected. Do not work on the system when the turbine is running or when lightning is
possible. Disconnecting a running e300
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ii
i
may cause a spark and the presence of explosive
hydrogen from battery charging is always a possibility. Adequate ventilation must be provided or
battery installations. The wire size used for connections must be correct for the powers supplied. The
smaller the wire diameter, the higher the wire losses and therefore the heat generated in the wire.
Use correct wire sizes throughout the installation. The amount of energy stored in a battery is
considerable and fire can result from shorts. Fit a suitable use or circuit breaker in the battery cable.
In general, respect the system and use common sense. Consult a quali ied electrician i you are unsure.
1.3 Installation Hazards
1.3 Installation Hazards1.3 Installation Hazards
1.3 Installation Hazards
All installation work should be completed at ground level wherever possible. Be very aware of the
blades during installation. Contact with the blades will only injure you, not the blades. The
installations of poles or towers pose their own dangers. Always work carefully and have an
assistant wherever possible. Short the generator output wires (Red and Black) throughout any
installation procedure. Consult a civil engineer or reputable builder if you are not sure about
installing structures. Always re-check the work as you progress. Slack bolts, poor workmanship and
loose electrical connections must be avoided.
1.4 Operational Safety
1.4 Operational Safety1.4 Operational Safety
1.4 Operational Safety
The turbine blades are dangerous. Respect a rotating turbine. Always shut the turbine down before
approaching. This may be achieved by shorting the generator output. Preventative maintenance is
always the best. Checks are best carried out in calm weather conditions. Avoid any maintenance or
inspection during windy weather.
3

e300i User Manual Document #: 0503M01A REV : 1.3
Approval: Date: March ’08 Page 4 of 25
2
2 W Wi in nd d T T r rb bi in ne e O Ov ve er rv vi ie ew w
2 2. .1 1 T T r rb bi in ne e D De es sc cr ri ip pt ti io on n
2 2. .2 2 I Id de en nt ti if fi ic ca at ti io on n a an nd d M Ma ar rk ki in ng gs s
2 2. .3 3 A Ap pp pl li ic ca at ti io on n a an nd d U Us se es s
2 2. .4 4 C Ch ha ar rg ge e C Co on nt tr ro ol ll le er rs s a an nd d I In nv ve er rt te er rs s
2 2. .5 5 G Gr ri id d T Ti ie ed d I In nv ve er rt te er r A Ap pp pl li ic ca at ti io on ns s
2 2. .6 6 V Vo ol lt ta ag ge e L Li im mi it te er r
2 WIND TURBINE OVERVIEW
2 WIND TURBINE OVERVIEW2 WIND TURBINE OVERVIEW
2 WIND TURBINE OVERVIEW
2.1 T rbine Description
2.1 T rbine Description2.1 T rbine Description
2.1 T rbine Description
The e300
i
ii
i
is a unique wind turbine that incorporates superior technology. The heart of the machine
comprises of a unique twin axial flux permanent magnet brushless alternator. The alternator
contains no less than 96 poles and 52 magnets. The polyphase high frequency output is internally
rectified to give a dc output with extremely low ripple content. The generated power is
transferred to the output cables via heavy duty bronze slip rings and twin copper composite
electrical brushes. The prime mover on the e300
i
ii
i
is a 3.0m 9.85’) diameter three blade wind
rotor fitted with quiet running high efficiency blades. The blade hub incorporates passive pitch
control. The e300
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ii
i
pitch control changes the operating angle of the blades to achieve speed
control in high wind. The tail vane assembly is static and simply aligns the machine with the
prevailing wind.
All steel components are electro-galvanised and passivated for extra protection. The standard
finish consists of the application of an etching marine primer and an intermediate protective coat
followed by polyurethane two pack finishing coats.
2.2 Identification and Markings
2.2 Identification and Markings2.2 Identification and Markings
2.2 Identification and Markings
The turbine generator body carries a stamped unique serial number and a rating plate. Both the
stamped serial number and rating plate are visible on the bottom yaw shaft housing. If this e300
i
ii
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does not carry this stamp it does not carry a Kestrel warranty and may not be authentic.
4

e300i User Manual Document #: 0503M01A REV : 1.3
Approval: Date: March ’08 Page 5 of 25
2.3
2.3 2.3
2.3 Applications
ApplicationsApplications
Applications and Uses
and Uses and Uses
and Uses
The e300
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ii
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is suitable for electrical power generation on various installations that include battery
charging, water delivery and grid tie applications. Each application requires specific additional
electrical equipment. Consult the manuals supplied with this equipment.
2.
2.2.
2.4
44
4 Charge Contr
Charge Contr Charge Contr
Charge Controllers
ollersollers
ollers and Inverters
and Inverters and Inverters
and Inverters
Any wind turbine produces uncontrolled power that varies with incident wind speed. The open
circuit generator voltage is directly proportional to generator speed rpm). Some form of
regulator must control this “raw power”. A battery charging regulator is often referred to as a
charge controller.
A charge controller is required for the Kestrel to charge a battery. Kestrel can supply a standard
charge controller for the e300
i
ii
i
. A suitable diversion resistor is available from Kestrel.
An inverter can be connected to the battery and is used to convert the battery dc power to ac
power. An inverter therefore allows the use of standard electrical equipment that works on ac
voltage.
2.
2.2.
2.5
55
5 Grid Tied Inverter
Grid Tied InverterGrid Tied Inverter
Grid Tied Inverter Applications
Applications Applications
Applications
The 200Vdc version of the e300
i
ii
i
is suitable for connection to an approved Grid Tie Inverter. Grid
Tied installation is subject to local electrical codes of practice and is usually carried out by
qualified personnel. Prior approval from the local utility company must be obtained before
connection to the mains.
2.
2.2.
2.6
66
6 Voltage Limiter
Voltage Limiter Voltage Limiter
Voltage Limiter
Grid tied applications require a Voltage Limiter to be connected between the e300
i
ii
i
200Vdc
version) and the Grid Tie Inverter. Certain operating modes of the inverter allow the Kestrel output
voltage to rise beyond the limit of the inverter. The Kestrel Voltage Limiter will restrict the rise in
voltage as the inverter performs various functions. Refer to the manual provided with the Kestrel
Voltage Limiter.
5

e300i User Manual Document #: 0503M01A REV : 1.3
Approval: Date: March ’08 Page 6 of 25
3
3 U Un np pa ac ck ki in ng g a an nd d T T r rb bi in ne e A As ss se em mb bl ly y
3 3. .1 1 C Co om mp po on ne en nt ts s S S p pp pl li ie ed d
3 3. .2 2 T To oo ol ls s R Re eq q i ir re ed d
3 3. .3 3 U Un np pa ac ck ki in ng g
3 3. .4 4 T Te ec ch hn ni ic ca al l R Re eq q i ir re em me en nt ts s f fo or r A As ss se em mb bl ly y
3
3. .5 5 G Ge en ne er ra at to or r A As ss se em mb bl ly y
3 3. .6 6 T Ta ai il l A As ss se em mb bl ly y
3 3. .7 7 F Fi it tt ti in ng g t th he e P Pi it tc ch h C Co on nt tr ro ol l
3
3. .8 8 B Bl la ad de e A As ss se em mb bl ly y
3 UNPACKING AND TURBINE ASSEMBLY
3 UNPACKING AND TURBINE ASSEMBLY3 UNPACKING AND TURBINE ASSEMBLY
3 UNPACKING AND TURBINE ASSEMBLY
3.1 Com
3.1 Com3.1 Com
3.1 Components S pplied
ponents S ppliedponents S pplied
ponents S pplied
The following components are supplied.
Pitch hub assembly
Shaft drive key
Propeller blade set
Generator assembly
Tail boom two pieces)
Tail two pieces)
Tail Stabiliser two pieces)
Nacelle cover
Nosecone
All fasteners and bolts
Assembly grease
Locktite
3.
3.3.
3.2
22
2 Tools Req ired
Tools Req ired Tools Req ired
Tools Req ired
The following hand tools are required for turbine assembly and installation.
10mm metric ring spanner or socket wrench two required)
13mm metric ring spanner or socket wrench
19mm metric ring spanner or socket wrench two required)
Small size electrical screwdriver
Medium size electrical screwdriver
10mm Allen key wrench
Wire strippers for electrical connections
Tape measure to adjust the blades
Torque wrench
6

e300i User Manual Document #: 0503M01A REV : 1.3
Approval: Date: March ’08 Page 7 of 25
3.3 Unpacking
3.3 Unpacking3.3 Unpacking
3.3 Unpacking
Open the packaging container and check for any transit damage. The parts contained are listed
in section 3.1 and on the included packing slip. Lay out the parts and identify them with the
assembly drawing provided.
3.
3.3.
3.
30053
Spring Washer 10mm S/Steel1031
30094
Hex Bolt M6x1x16L S/Steel
4
030
30834
Front Stiffner
2
029
30153
Bottom Tail Plate
1
028
30836
Rubber Strip
2
027
30819
Hex Bolt M6x1x70L S/Steel
2
026
30831
Rear Stiffner
2
025
30835
Clampi
ng strip
2
024
30957
Hex Bolt M6x1x80L S/Steel
5
023
30830
Top Tail Plate
1
022
30091
Hex Nut Nylock M6x1 S/Steel
13
021
30925
Nacelle
1
020
30769
Tail Boom
1
019
30925
Nacelle Cover Plate
1
018
30149
Screw M5x16 C/Head S/Steel
4
017
30088
Bolt Hex M8x30L S/Steel
4
016
30095
Nut Hex M8 Nylock S/Steel
7
015
30096
Washer Plain Metric 8mm S/Steel
7
014
30022
e300i Generator Assembly
1
013
30173
Nut
-
Hex M12x1.75 Nylock
6
012
30029
e300i Blade Set
3
011
3
0768
Compression Plate
3
010
Hex Bolt M12x65L S/Steel
6
009
30899
Hub to Bearing Collar
1
008
30054
Shaft Key 8mmx7mm)
1
007
30990
Pith Control
1
006
30689
Hub Clamping Spacer1005
30660
H/Tensile Cap Screw M10x40L ZP
1
004
30
092
Washer Plain Metric 6mm SlSteel
16
003
30152
Screw C/Head M6x16 S/Steel
3
002
30924
Nose Cone
1
001
Item
#
Description
Qty
art

e300i User Manual Document #: 0503M01A REV : 1.3
Approval: Date: March ’08 Page 8 of 25
4
4 4
4 Technical Req irements for Assem
Technical Req irements for AssemTechnical Req irements for Assem
Technical Req irements for Assembly
blybly
bly
Torq e Settings
Torq e SettingsTorq e Settings
Torq e Settings
DESCRIPTION BOLT TYPE TORQUE
(Metric) TORQUE (Imperial)
NOSE CONE SCREWS M6 x 16, S/S 5Nm 3,7 ft·lb
FRONT BOLT 12.9 HI-TENSIL + LOCTITE M10 X 35 60Nm 44,3 ft·lb
BLADE BOLT M12 x 80, S/S WITH M12 NYLOCK NUT 35Nm 25,8 ft·lb
TAIL BOOM M8 BOLTS, S/S 30Nm 22,1 ft·lb
M8 NYLOCKS 25Nm 18,4 ft·lb
NACELLE SCREWS M6 x 16, S/S 3Nm 2,2 ft·lb
M5 x 15, S/S 3Nm 2,2 ft·lb
TAIL BOLTS M6 x 60, S/S WITH M6 NYLOCK NUT 10Nm 7,4 ft·lb
MOUNTING BOLTS M8 x 25, 8.8 HI-TENSIL PLATED 35Nm 25,8 ft·lb
3.5 G
3.5 G3.5 G
3.5 Generator Assembly
enerator Assemblyenerator Assembly
enerator Assembly
The alternator 01) is factory assembled.
3.6 Pitch control Assembly
3.6 Pitch control Assembly3.6 Pitch control Assembly
3.6 Pitch control Assembly
The pitch control boss 03) is factory assembled.
8

e300i User Manual Document #: 0503M01A REV : 1.3
Approval: Date: March ’08 Page 9 of 25
3.
3.3.
3.7
77
7 Tail Assembly
Tail Assembly Tail Assembly
Tail Assembly (if not factory assembled)
Offer the tail boom 05) to the rear of the generator and align the three inner fixing holes with
the inner studs. Fasten the boom to the rear of the generator with the three M8 Nylock nuts 18).
Now fit the four lower bolts 20), washers 19) and nuts 18) on to the
generator sides by means of the side bars. Level the boom with the
generator, secure the bolts through the rubber bushes so that the boom is
held in place and tighten all fastenings to the required torque setting see
3.4 Pg 7).
Slide the nacelle cover 0730) along the boom so that it is
covering the generator. Secure the nacelle cover to the rear of the
generator with the two M6 screws to the required torque setting
see 3.4 Pg 7). Slide the front closing plate between the underside
of the generator and the nacelle cover and secure with the four
M5 screws to the required torque setting see 3.4 Pg 7) through
the holes provided.
Fasten the tail 07) upper and lower halves to the boom with the ten
stainless bolts 23), stainless flat washers 24) and with the ten stainless
Nylock nuts 23) provided. Now fit the tail stabilisers, two on each side
of the tail using the one longer stabiliser bolts 27) through the tail
boom and the middle of each stabiliser on either side. The other two
stabiliser bolts 26) are fitted through the tail with the washers 28)
and nuts 29) at each end of each stabiliser.
Do not over-tighten such that the tail boom is crushed or distorted. Always adhere to the torque
settings provided. Check once again that all bolts are itted and tightened to torque settings (3.4).
9

e300i User Manual Document #: 0503M01A REV : 1.3
Approval: Date: March ’08 Page 10 of 25
3.
3.3.
3.8
88
8 Fitting the Pitch Control
Fitting the Pitch Control Fitting the Pitch Control
Fitting the Pitch Control
The generator is a complete unit. The shaft drive key is factory fitted
to the generator shaft with a cable-tie. Remove cable-tie, before
fitting pitch control.
Smear waterproof grease 30) over the shaft and insert a little
inside the front of the generator where the shaft projects out.
Offer the pitch control hub to the shaft and
slide it onto the shaft.
Using a hexagon key, fit the front shaft bolt 15) and washer 14) to
the spring locking washer provided into the generator shaft and
tighten the assembly.
It is important that the bolt is secured with Locktite.
10