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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blades are extremely tough and will cause serious injury to the body. Never install the e300
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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
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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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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
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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
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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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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
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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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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
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. 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
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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
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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.
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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).
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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

e300i User Manual Document #: 0503M01A REV : 1.3
Approval: Date: March ’08 Page 11 of 25
3.
3.3.
3.9
99
9 Blade Assembly
Blade Assembly Blade Assembly
Blade Assembly e300
e300 e300
e300
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IMPORTANT: The wheels o a car are balanced to allow smooth operation. In the same way, the
propeller rotor must be assembled such that it is balanced. Rotor imbalance will cause vibration,
unstable operation o the turbine and eventual damage. Please ollow the steps given below to
assemble a balanced rotor.
GENERAL
NOTE: The blades are fitted on the front of the pitch control hub. Refer to the assembly drawing
and fit all three blades on to the hub as shown. Each blade carries a serial number and a balance
mark on the front face of the blade. Be sure to fit the blades the correct way round. The blade
root is marked “FRONT” below the serial number on each. The rotation is clockwise viewed at the
front of the turbine. Each blade mount has two bolt holes. Fit
the bolts with the washers provided and through the blade
compression plate with the Nylock nuts behind the pitch
control.
The blades are factory balanced. Note that exact
balancing requires that the three blade tips be equally spaced when fitted.
lease follow the instructions given below.
a) Support the generator 02) such that the blades can be fitted to the
pitch hub 03).
b) Fit two blade bolts 11) through a blade compression plate 09) such
that they face toward the generator. Now fit the first blade 08) on to
the bolts and offer the blade from the front to one blade mount. Fit the
two Nylock nuts 13) on to the blade bolts from the rear. Do not tighten
the nuts.
c) Repeat b) such that all three blades are sandwiched between the
three compression plates 09) and the three blade mounts on the pitch
control hub. Now gently tighten all six blade bolts such that each blade
can still move sideways.
d) Using a tape measure, accurately measure the distance between each
of the three blade tips. Move each blade sideways until all three blade
tips have the same measured distance between them.
e) Now tighten all the blade bolts to the required torque setting see 3.4
Pg 7). Do not over-tighten the bolts such that any blade is damaged or
crushed.
f) Check the assembly for correctness. Check the blades are fitted
correctly, the bolts are all tightened and that the rotor spins freely and
evenly on the generator. Check the distance between the three blade
tips or balance marks) to be equal.
g) Now fit the nose cone 10) over the three spokes and fit the three Nylock nuts 16) and
washers 17).
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e300i User Manual Document #: 0503M01A REV : 1.3
Approval: Date: March ’08 Page 12 of 25
4 SITE CONSIDERATIONS AND MOUNTING
4 SITE CONSIDERATIONS AND MOUNTING4 SITE CONSIDERATIONS AND MOUNTING
4 SITE CONSIDERATIONS AND MOUNTING
The turbine is supplied with a “weld on” mounting flange for adaptation. Custom structures must
incorporate a 76mm 3”) - 100mm 4”) diameter pipe for machine mounting. Larger pipes may
interfere with the blades when pitch control operates.
There are infinite variations on sites and the information and suggestions may be adapted to suit
local conditions. Wind speed increases with height above the ground. An installation site should be
chosen which is free of obstructions like buildings, trees, mounds and hills. A "pure" airflow is
paramount for good performance. Naturally some compromise can be reached but there should
be a clear entry for the prevailing wind direction of the location. The absolute minimum height of
the structure should be 9m when placed clear of obstructions.
The general rule is that the e300
i
ii
i
should be 8m 25’) higher than any obstruction within a 150m
500’) radius of the tower. Otherwise mount the e300
i
ii
i
as high as possible. All obstructions add to
possible turbulence, which will cause undue stress on the unit and reduced performance. Wind
speed increases with height above the ground. The power in the wind is a cubic function of wind
speed. Doubling the wind speed increases the power by eight times.
4.1 Flange Mo nting Detail
4.1 Flange Mo nting Detail4.1 Flange Mo nting Detail
4.1 Flange Mo nting Detail
The e300
i
ii
i
is mounted using eight M8 Hi-Tensile bolts and spring washers fitted through the bottom
flange on the weather cocking swivel assembly.
4.2
4.24.2
4.2 Roof Mo nting
Roof Mo nting Roof Mo nting
Roof Mo nting
Roof mounting is possible but the turbine performance may suffer as a result of wind shift and
turbulence. Roof mounting structures are beyond the scope of this document and must comply with
the relevant structural standards that are in force.
4.
4.4.
4.3
33
3 Towers
Towers Towers
Towers
Towers are required to conform to relevant standards and must be designed to withstand the
loading regime of the wind turbine. Full details are included with any Kestrel tower kit supplied.
1
2
4
4 S Si it te e C Co on ns si id de er ra at ti io on ns s a an nd d M Mo o n nt ti in ng g
4 4. .1 1 F Fl la an ng ge e M Mo o n nt ti in ng g D De et ta ai il l
4 4. .2 2 R Ro oo of f M Mo o n nt ti in ng g
4 4. .3 3 T To ow we er rs s

e300i User Manual Document #: 0503M01A REV : 1.3
Approval: Date: March ’08 Page 13 of 25
5
5 W Wi ir ri in ng g a an nd d C Ca ab bl le e S Si iz ze es s
5 5. .1 1 T T r rb bi in ne e W Wi ir ri in ng g
5 5. .2 2 L Li ig gh ht tn ni in ng g P Pr ro ot te ec ct ti io on n
5 5. .3 3 W Wi ir re e a an nd d C Ca ab bl le e S Si iz ze es s
5
55
5 WIRE AND CABLE SIZES
WIRE AND CABLE SIZES WIRE AND CABLE SIZES
WIRE AND CABLE SIZES
5.1 T rbine Wiring
5.1 T rbine Wiring5.1 T rbine Wiring
5.1 T rbine Wiring
The e300
i
ii
i
wind turbine produces dc power and therefore has two double insulated output wires
tails). The RED wire is POSITIVE and the BLACK wire is NEGATIVE.
Observe the olarity at all times. Only connect +VE RED cables to +VE RED terminals and -VE
BLACK cables to -VE BLACK terminals. Otherwise, equipment damage may result and any
warranty will be invalidated.
The following suggestions are made as a guideline. If you are in doubt, consult an electrician.
The output wires must be extended as required for the installation. Good wire connections are
absolutely essential to avoid poor power delivery and high temperatures at the connection. All
electrical systems lose energy because cables have a resistance. The mounting structure must be
directly earthed for lightning. The power cable is usually brought down the inside of the mounting
structure to give some protection. Supply cables should never be spanned or suspended from the
turbine structure and should be buried at least one half metre deep in a suitable plastic or steel
conduit.
5.2
5.25.2
5.2 Lightning protection
Lightning protection Lightning protection
Lightning protection
Proper grounding is essential to protect the system from induced voltages and static. Local
requirements for electrical installations must be satisfied. Ensure that the generator is electrically
connected to the mounting structure and that the structure is earthed. This is usually done by
burying a 2 to 3m 6’ – 10’) length of water pipe steel or copper) horizontally, 1000mm 3.3’)
below the ground surface. A good connection is made between the middle of the pipe and the
structure. An improved method is to bury a cross of pipe, which requires a "X" shape to be
excavated. The connection is made in the centre of the cross.
The negative battery connection should also be grounded using a ground point close to the
battery. First, consult the Charge Controller Manual to avoid earth loops. The wire size for
grounding should be the same size as the power cables. Commercial lightning arrestors are
available at electrical stores and can be fitted at the bottom of the structure or pole or at the
regulator input.
1
3

e300i User Manual Document #: 0503M01A REV : 1.3
Approval: Date: March ’08 Page 14 of 25
5.3
5.35.3
5.3 Wire and Cable Sizes
Wire and Cable SizesWire and Cable Sizes
Wire and Cable Sizes
The copper wire sizes given in the tables are calculated for 3% power loss in wire resistance. This
is usually acceptable in low voltage installations. A larger wire size will increase the delivered
power but usually a compromise is reached as larger cables cost more. It is recommended that the
wire sizes given be taken as a minimum value.
Measure the distance from the top of your structure i.e. the e300
i
ii
i
) to the regulator. Select the
wire size for that distance from the table. The double run of +ve and -ve is already accounted
for.
The power cable should be run down the inside of the pole or structure and then buried in a
suitable underground conduit at least 500mm below the ground surface.
Wire Size for 12V e300
i
ii
i
(65A maximum current)
10m (33’) 20m (66’)
50sq mm (0) 85sq mm (000)
Wire Size for 24V e300
i
ii
i
(35A maximum current)
10m (33’) 20m (66’) 30m (96’) 40m (130’) 50m (165’)
16sq mm (5) 35sq mm (2) 40sq mm (1) 70 sq mm (00) 85 sq mm(000)
Wire Size for 48V e300
i
ii
i
(19A maximum current)
10m (33’) 20m (66’) 30m (96’) 40m (130’) 50m (165’) 80m(260’) 100m (330’)
6sq mm (9) 10sq mm (7) 16sq mm (5) 20sq mm (4) 25sq mm (3) 40sq mm (1) 50sq mm (0)
Wire Size for 110V e300
i
(12A maximum current)
10m (33’) 20m (66’) 30m (96’) 40m (130’) 50m (165’) 80m(260’) 100m (330’)
10sq mm (7) 20sq mm (4) 35sq mm (2) 35sq mm (1) 50sq mm (0) 70sq mm (00) 100sqmm(0000)
Wire Size for 200V e300
i
ii
i
(6A maximum current)
20m (66’) 40m (130’) 60m (200’) 80m(260’) 100m (330’)
0,5sq mm (20) 1,5sq mm (15) 2,5sq mm (14) 2,5sq mm (14) 4sq mm(11)
14

e300i User Manual Document #: 0503M01A REV : 1.3
Approval: Date: March ’08 Page 15 of 25
6
6 B Ba at tt te er ry y C Co on ns si id de er ra at ti io on ns s
6 6. .1 1 L Le ea ad d A Ac ci id d B Ba at tt te er ri ie es s
6 6. .2 2 S Se ea al le ed d G Ge el l B Ba at tt te er ri ie es s
6 6. .3 3 N Ni i- -C Ca ad d B Ba at tt te er ri ie es s
6 6. .4 4 T Te em mp pe er ra at t r re e C Co om mp pe en ns sa at ti io on n
6
66
6 BATTERY CONSIDERATIONS
BATTERY CONSIDERATIONS BATTERY CONSIDERATIONS
BATTERY CONSIDERATIONS
Batteries are available in many shapes, sizes and chemistry. Battery dealers will be pleased to
assist. The most common ones are reviewed below. In general, only "Deep cycle" batteries and
cells should be used and automotive or vehicle batteries will have a short life as they are not
designed for cyclic charging and discharging. A cell is a single unit of 2V and a battery consists of
a number of cells joined in series. The usual installation consists of 12V batteries arranged in series
or parallel, or both. Batteries should not be exposed to temperature extremes and good
ventilation is required as batteries can emit hydrogen while being charged.
The stored energy in a battery is given in Ampere Hours Ah) or Watt hours Wh). The capacity is
often based on a 10 hour discharge rate. A 100Ah battery will therefore supply a current of 5A
for 20hrs or 10A for 10hrs or 20A of current for 5hrs. It will not however supply 100A of current
for 1hr. There is much literature available on this subject. It is recommended that the e300
i
ii
i
should
be charging at least 200Ah of battery capacity for a 12V system.
6
66
6.1 Lead Acid Batteries.
.1 Lead Acid Batteries..1 Lead Acid Batteries.
.1 Lead Acid Batteries.
These are the most popular choice of battery type and can be vented/flooded Water may be
added), or semi-sealed or low maintenance Water cannot be added). Charging voltage is
typically 13.8-14.0 / 27.6-28.0Vdc for these batteries.
6
66
6.2 Sealed Gel Batteries
.2 Sealed Gel Batteries.2 Sealed Gel Batteries
.2 Sealed Gel Batteries
Sealed gel batteries are more expensive but offer clean and safer operation as no acid can be
spilled. Since they are sealed, they must never be boosted and the charging voltage is important.
Charging voltage is typically 14.0 / 28.0Vdc. Consult your battery supplier.
6
66
6.3 Ni
.3 Ni.3 Ni
.3 Ni-
--
-Cad Batteries
Cad BatteriesCad Batteries
Cad Batteries
This type of battery is traditionally used where large currents must be delivered and where deep
cycling is required. They are however relatively expensive. Consult your battery supplier for
details.
6
66
6.4 Temperat re Compensation
.4 Temperat re Compensation.4 Temperat re Compensation
.4 Temperat re Compensation
Much has been documented on this subject and there are certain merits. Generally, lower and
higher ambient temperatures allow higher and lower charging voltages respectively. K1000
regulators do not have this facility. Batteries should be sited in a cool area and temperature
compensation is only useful in extreme temperature variations.
1
5

e300i User Manual Document #: 0503M01A REV : 1.3
Approval: Date: March ’08 Page 16 of 25
7
7 T Te ec ch hn ni ic ca al l D De et ta ai il ls s
7 7. .1 1 T Te ec ch hn ni ic ca al l S Sp pe ec ci if fi ic ca at ti io on ns s
7
7. .2 2 D De ec cl la ar ra at ti io on n o of f C Co on nf fo or rm mi it ty y
7
77
7 TECHNICAL SPECIFICATIONS
TECHNICAL SPECIFICATIONS TECHNICAL SPECIFICATIONS
TECHNICAL SPECIFICATIONS
7
77
7.1 TECHNICAL SPECIFICATIONS
.1 TECHNICAL SPECIFICATIONS.1 TECHNICAL SPECIFICATIONS
.1 TECHNICAL SPECIFICATIONS
e300
i
ii
i
Maximum ower 1150W
Rated power at 11m/s 200Vdc 1000W
Rated power at 11m/s 48Vdc 1000W
Rated power at 11m/s 24Vdc 900W
Rated power at 11m/s 12Vdc 850W
Annual energy capture at 5m/s average 200Vdc 2160kWh
Annual energy capture at 5m/s average 48Vdc 2060kWh
Annual energy capture at 5m/s average 24Vdc 1940kWh
Annual energy capture at 5m/s average 12Vdc 1790kWh
For average wind speed of 5ms
-1
and 12m tower at sea level)
Rated sound level <50dB
Cut-in wind speed 2,5ms
-1
Cut-out wind speed N/A
Maximum voltage 200Vdc 1000Vdc
Maximum voltage 48Vdc 250Vdc
Maximum voltage 24Vdc 150Vdc
Maximum voltage 12Vdc 70Vdc
Output power form Two wire DC
Rotor swept area 7,07 sq m
No. of blades 3
Tower top mass 75kg
Lateral Thrust at 12ms
-1
(27mph) and 40ms
-1
(90mph)* 800N and 8600N
*NOTE: Lateral Thrust at 40ms
-1
is theoretical for a failed pitch control. For normal operation, thrust at 40ms
-1
is <1000N
Speed Control assive pitch
rotection I 55
16

e300i User Manual Document #: 0503M01A REV : 1.3
Approval: Date: March ’08 Page 17 of 25
7.2
7.27.2
7.2 DECLARATION OF C
DECLARATION OF CDECLARATION OF C
DECLARATION OF CONFORMITY
ONFORMITYONFORMITY
ONFORMITY
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e300i User Manual Document #: 0503M01A REV : 1.3
Approval: Date: March ’08 Page 18 of 25
8
88
8 TROUBLE SHOOTING
TROUBLE SHOOTING TROUBLE SHOOTING
TROUBLE SHOOTING
REST ASSURED THAT THE KESTREL WILL BE SERIOUSLY DAMAGED FROM POLARITY REVERSAL.
OVERCHARGING OF THE BATTERY CAN OCCUR WITH NO FITTED CHARGE CONTROLLER. IT IS
UNWISE TO DISCONTINUE CHARGING BY DISCONNECTING THE e300
i
ii
i
FROM THE BATTERY.
THE TURBINE THEN HAS NO LOAD WHATSOEVER AND CAN REACH VERY HIGH ROTATIONAL
SPEEDS.
Uncontrolled output voltage can reach LETHAL values.
IF THE e300
i
ii
i
IS DISCONNECTED FOR ANY REASON, SHORT THE GENERATOR OUTPUT WIRES.
THIS WILL LOAD THE GENERATOR AND MINIMISE ROTATION.
DO NOT ALLOW THE e300
i
ii
i
TO O ERATE WITH DAMAGED BLADES OR TAIL. DAMAGE TO
THE BLADES WILL CAUSE VIBRATION THAT CAN INCREASE TO DESTRUCTIVE LEVELS.
DO NOT ALLOW THE e300
i
ii
i
TO O ERATE WITH ANY SIGN OF UNBALANCE. ANY RE ETITIVE
SWINGING OF THE TAIL INDICATES THAT THE MACHINE IS UNBALANCED.
Q There is wind but the e300
i
ii
i
does not rotate or only rotates very slowly.
A The e300
i
ii
i
output is shorted. There is an electrical short elsewhere in the system. The blades
are fitted the wrong way round. The e300
i
ii
i
is restricted from swinging 360 degrees into the
wind. The charge controller is defective. Other connected equipment is defective. Disconnect
the e300
i
ii
i
from the equipment and check that the blades rotate easily). There is a short
within the turbine generator. In very light wind, the e300
i
ii
i
may well not rotate. This is quite
normal as there is no useful power in such a light wind and bearing life is greatly extended.
On older machines, check the generator bearings.
Q The e300
i
ii
i
is rocking from one side to the other at low speed but appears to run smoothly at
higher speeds.
A The blade rotor assembly is unbalanced. Remove the rotor and check for damaged blades.
Rebalance the rotor if possible or fit a new blade set.
Q The e300
i
ii
i
is vibrating or noisy.
A Check all fasteners on the unit, in particular the blade assembly. Vibration or noise can only
be caused by the imbalance of damaged blades. Check for bearing wear on older
machines.
Q Can the e300
i
ii
i
be left running and disconnected?
A Theoretically yes, but high voltages may be produced. Always short the output wires when
the e300
i
ii
i
is disconnected from the regulator.
Q What should be done in storm conditions?
A Never approach the e300
i
ii
i
during strong wind conditions. The e300
i
ii
i
has been tested up to
winds of 160km/h and is designed to survive such conditions. It is acceptable to lower the
turbine for predicted extreme weather conditions simply for peace of mind.
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e300i User Manual Document #: 0503M01A REV : 1.3
Approval: Date: March ’08 Page 19 of 25
9
99
9 MAINTENANCE
MAINTENANCE MAINTENANCE
MAINTENANCE
The e300
i
ii
i
is designed for continuous operation on 100% duty cycle and requires no regular part
replacement.
NEVER A ROACH A ROTATING TURBINE
The e300
i
ii
i
is designed to operate with minimum maintenance. The frequency of visual inspections
and integrity checks depends on the wind class of the installation site. Wind Power Class definition
for wind power density and average wind speed at a hub height of 10m is given below. In
general, higher class wind sites require more frequent installation checks.
WARNING ( itch Control)
The pitch control mechanism is a factory assembly and is not user serviceable. Specialist tools and
knowledge is required to carry out any maintenance or repair procedures. Do not make any
unauthorized adjustments or modifications to any part of this assembly. Do not force or twist the
blades other than gently when checking for wear.
Wind Power
Class
Wind Power Density
(W/sq m)
Wind Speed
m/s
Wind Speed
mph (Imperial)
1 Up to 100 Up to 4,4
Up to 9,8
2 100 – 150 4,4 – 5,1
9,8 – 11,4
3
150 – 200 5,1 – 5,6
11,4 – 12,5
4
200 – 250 5,6 – 6,0
12,5 – 13,4
5
250 – 300 6,0 – 6,4
13,4 – 14,3
6
300 – 400 6,4 – 7,0
14,3 – 15,7
7
Above 400 Above 7,0
Above 15,7
NOTE: RODUCT S ECIFICATIONS MAY CHANGE DUE TO CONTINUOUS DEVELO MENT. CONSULT THE
FACTORY OR AN A OINTED DEALER.
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e300i User Manual Document #: 0503M01A REV : 1.3
Approval: Date: March ’08 Page 20 of 25
The following schedule is designed to avoid machine failure. Component life will be
reduced on sites that exhibit high turbulence.
Wind ower Class 1 2 3 4 5 6 7
First post installation visual check All sites 1 month after installation
Visual Inspection, listen for abnormal noise and
vibrations.
After extreme
weather and every
3 months
After extreme
weather and
every 2 months
Close inspection, check for any loose bolts, blade
damage. Check the integrity of the pitch control (see
tips below). Touch up paint.
12 monthly intervals Six monthly
intervals
Dismount the machine and check for transfer brush
wear. Check for wear on pitch control parts. Replace as
required. Treat any corrosion and touch up paint.
Every 5 years Every 3 years
Dismount the machine and replace all bearings
(generator, yaw shaft and pitch control) Every 8 – 10 years
Every 4 – 5
years
Other A xiliary Inspections
Other A xiliary InspectionsOther A xiliary Inspections
Other A xiliary Inspections
Inspections should also be done with regard to all other site equipment. Specific procedures
are contained within the relevant user manuals. The following list illustrates typical topics.
a) Inspection of the tower including all bolts/fasteners ground anchors and guy wires.
b) Inspection of the e300
i
ii
i
tower securing bolts.
c) Check all electrical connections for tightness and corrosion.
d) Functionality and general checks on all other electrical equipment.
Maintenance Tips
Maintenance TipsMaintenance Tips
Maintenance Tips
The pitch control hub should be checked in the following way. Visually inspect the unit. Check
for any stress cracks, broken or cracked springs and/or corrosion. Use gentle pressure to
twist the blade in both directions. There should be virtually no movement or slackness. Push
and pull the blade along its length. There should be no movement of the blade. If any wear
or defect is detected, consult your dealer or the Kestrel factory. Do not under any
circumstances strip the assembly down without the required knowledge.
The generator produces a slight humming sound. This is quite normal. Any other grinding,
clicking or scraping noises are abnormal and must be investigated.
Good rotor balance is very important for long and reliable operation. The wind turbine must
not be allowed to continue in operation if any unbalance is observed. The most common
symptom of imbalance is observed when the turbine swings slightly from side to side as it
speeds up. The swinging action will be worse at a particular rotor speed and may well
disappear at higher speeds.
The rotor blades can suffer chips and erosion, mainly on their leading edge. Small chips can
be repaired with glass fibre filling compound. All cracks must be carefully examined.
Surface cracks can be repaired but any structural cracks must render the blade inoperative.
If there is any doubt, the blade set must be replaced for safety. All blade damage can
allow water to enter. This will cause the blade set to become unbalanced which will cause
other mechanical failures and shortened bearing life.
20