NRG Systems Hybrid XT User manual
NRG Product Manual
Hybrid XT Anemometer
Authors:
Technical Services
HybridXT_Anemometer_Manual
Rev. 15
NRG Product Manual
Hybrid XT Anemometer
HybridXT_Anemometer_Manual
Rev. 15
02 January 2020
Specifications are subject to change without notice.
© NRG Systems
110 Riggs Road
Hinesburg VT 05461
Tel: 802-482-2255
email: [email protected]
NRG Product Manual
Hybrid XT Anemometer
HybridXT_Anemometer_Manual
Rev. 15
02 January 2020
CONTENTS
CUSTOMER SUPPORT .............................................................................................................. 4
INTRODUCTION ....................................................................................................................... 5
Using This Manual...........................................................................................................5
ANEMOMETER OPERATION AND CONSIDERATIONS................................................................ 6
Hybrid XT Anemometer Types ........................................................................................6
Heater Operation............................................................................................................8
ESD and Circuit Protection ..............................................................................................9
Cable Shielding - Important.............................................................................................9
Magnet Safety............................................................................................................... 10
Transport and Handling................................................................................................. 10
CABLE COMPATIBILITY TABLES .............................................................................................. 11
HXT SENSOR INSTALLATION .................................................................................................. 13
Mounting Mast Orientation ..........................................................................................13
Prepare Shield...............................................................................................................13
Mount Connector..........................................................................................................14
Connect Cable to Controller .......................................................................................... 16
Mount Sensor ............................................................................................................... 17
GROUNDING AND BONDING FOR OVER-VOLTAGE PROTECTION ........................................... 18
Introduction..................................................................................................................18
Recommended Practices............................................................................................... 18
Sensor Wiring Diagram .................................................................................................20
WARRANTY ........................................................................................................................... 21
REPAIR .................................................................................................................................. 21
DECLARATION OF CONFORMITY............................................................................................ 22
APPENDIX A | TECHNICAL DRAWING..................................................................................... 24
NRG Product Manual
Hybrid XT Anemometer
HybridXT_Anemometer_Manual
Rev. 15
02 January 2020
CUSTOMER SUPPORT
NRG Systems offers a variety of support options to help you get the most from your NRG products. If
you have questions about your NRG Systems product, first look in the product documentation, FAQs and
instructional tools contained in the Product Support section of the NRG Systems website. Customer
support is available 8:30 AM to 5:00 PM EST, Monday through Friday.
NRG Systems
110 Riggs Road
Hinesburg, Vermont
05461 U.S.A.
Telephone: 802-482-2255
When you call or email, you should have the appropriate product documentation at hand and be
prepared to give the following information:
Customer name
Who purchased equipment
Item number or description
Serial number
When equipment was purchased
Where equipment is installed - terrain conditions
Description of the problem with some detail
What events took place leading up to the problem
What you have tried while attempting to solve the problem
NRG Systems maintains an extensive website which includes an in-depth customer support area for NRG
Systems customers. If you need assistance at times other than our regular business hours, we suggest
visiting our website, www.nrgsystems.com.
All instruments, sensors, software and towers manufactured by NRG Systems are designed to be reliable
and easy to use. We welcome your comments and appreciate your help in making NRG products the
best available.
NRG Product Manual
Hybrid XT Anemometer
HybridXT_Anemometer_Manual
Rev. 15
02 January 2020
INTRODUCTION
The NRG Systems Hybrid XT (HXT) anemometer is an electrically heated wind speed sensor designed for
wind turbine control and wind resource assessment. The sensor is mounted to the turbine nacelle or
meteorological mast and provides an electrical output signal with frequency proportional to wind speed.
Although the Hybrid XT sensors can be used for meteorological work, this manual is specific to turbine
control applications. However, there should be little difficulty in adapting these sensors for
meteorological applications.
The Hybrid XT is rugged enough to accurately measure wind speed in excess of 70m/s (156 mph), yet its
relatively low moment of inertia permits it to respond rapidly to gusts and lulls. It is built with corrosion
resistant materials and finishes, and is sealed against wind-driven rain and dust.
The Hybrid XT sensor line has a captive mounting system with integral connector that allows quick and
easy changing of the sensor. There are only three internal components (electronics module, heater
assembly and bearing assembly) for ease of maintenance. The Hybrid XT also has a spare label pocket
for a customer-supplied identification label.
Using This Manual
Read this manual completely before installing and operating the Hybrid XT anemometer. Follow all
instructions and recommendations closely.
This document and the sensor may use the following symbols:
Earth (Ground)
Chassis Ground
AC Voltage
AC or DC Voltage
DC Voltage
Hot Surface
This typeface within the body of the manual is used for general descriptions and instructions to the user.
This typeface is used to warn users of a potential danger, either to themselves or to the sensor.
NRG Product Manual
Hybrid XT Anemometer
HybridXT_Anemometer_Manual
Rev. 15
02 January 2020
ANEMOMETER OPERATION AND CONSIDERATIONS
The HXT anemometer is available with a variety of output signal types including variable frequency and
4-20mA, among others.
Hybrid XT Anemometer Types
Sensor
Part #
Output
Signal
Meas.
Range
Scaling
Notes
#4718
Frequency
(Hz)
0-50 m/s
1-101 Hz
m/s = 0.5(Hz) –0.5
0 Hz = sensor fault
High-level square wave output
Amplitude equals supply voltage
Compatible with Personality Module
(NRG Part #3798)
Recommended load resistance
1200 Ωminimum
#5763
mA
0-50 m/s
4-20 mA
Linear mA scaling
<4 mA = sensor fault
Standard 4-20 mA current loop
0.1 m/s resolution
Recommended load resistance
50 Ω–1000 Ω
#7901
Frequency
(Hz)
0-60 m/s
0-117 Hz
m/s = 0.509(Hz) +
0.4
High-level square wave output
Compatible with PNP & NPN inputs
Amplitude equals supply voltage
Output scaling matches NRG IceFree3
anemometer
Recommended load resistance
1200 Ωminimum
#9365
mA
0-60 m/s
4-20 mA
Linear mA scaling
<4 mA = sensor fault
Standard 4-20 mA current loop
0.1 m/s resolution
Recommended load resistance
50 Ω–1000 Ω
#9387
Frequency
(Hz)
0-60 m/s
0-105 Hz
m/s = 0.566(Hz) +
0.4
High-level square wave output
Compatible with PNP & NPN inputs
Amplitude equals supply voltage
Output scaling is 90% of #7901 HXT
Recommended load resistance
1200 Ωminimum
NRG Product Manual
Hybrid XT Anemometer
HybridXT_Anemometer_Manual
Rev. 15
02 January 2020
Frequency/Push-Pull Output | HXT Anemometer Models #4718 | #7901 | #9387
This output type provides a square wave output signal with a frequency proportional to the head
rotation rate (wind speed). The square wave amplitude is determined by the power supply voltage.
The anemometer output signal can be timed on either the rising or the falling edges. For best accuracy,
time and count many cycles then divide the count by the time for an average frequency. This technique
also effectively filters out short-term wind speed variations.
4-20 mA Output | HXT Anemometer Models #5763 | #9365
The HXT 4-20 mA Turbine Control Anemometer provides an industry standard 4 to 20 mA output signal
sourced by the sensor. The output range of 4 to 20 mA corresponds to a specific wind speed range,
depending on the model of anemometer.
Under normal operation, the output signal current varies from 4 to 20 mA. A signal outside this range
indicates a fault condition. The most likely causes would be a loss of power, a wiring problem, or a failed
sensor.
The HXT 4-20 mA signal output has been engineered to adapt to most common 4-20 mA current loop
inputs. The range of compatible loads for the current loop signal does depend on the power supply
voltage provided to the sensor. At the lowest specified power supply voltage of 11 V DC, the output loop
load (or “burden”) may be 350 Ohms maximum (a 7 volt maximum voltage drop). When provided with
its maximum 24 V DC power supply voltage, the sensor can drive up to a 1000 Ohm loop load (a 20 V
maximum voltage drop).
Power Supply Common
Power Supply Voltage
Anemometer Output Waveform
Output frequency proportional to wind speed
NRG Product Manual
Hybrid XT Anemometer
HybridXT_Anemometer_Manual
Rev. 15
02 January 2020
Heater Operation
The heat source for the HXT is a self-regulating, constant-temperature heater. Constant heating
prevents condensation and corrosion and maintains proper bearing temperature for consistent
performance and transfer function. In severe wind and icing conditions, the HXT draws more power to
help remain clear of ice. As conditions improve, the HXT draws less power. The HXT’s self-regulating
feature increases reliability, insuring that the head does not reach excessive temperatures. Excessive
temperatures can stress bearing lubricants, wiring, and present a hazard in the presence of combustible
materials. The HXT’s heater is powered by 24 volt power, AC or DC, making it compatible with a wide
range of turbine controller power supplies and remote site equipment. An optional 120 / 240 V to 24 V
AC transformer is also available.
Following a brief inrush current, after approximately 30 seconds, the heater settles into its
temperature controlled mode.
Use a 15A slow-blow fuse be placed in-line with the heater.
Always power the heater on your HXT sensor! Failure to maintain constant
heating may lead to corrosion or inferior sensor performance. Constant heating
prevents condensation from forming on the bearings, enabling the sensor to
achieve a 10 year service cycle. If the sensor is used without the heater, the
warranty will be void.
Sensor surfaces (particularly the head and the upper body) can become quite hot
and may burn you; especially in warm ambient conditions.
Use caution when the heater power is on.
NRG Product Manual
Hybrid XT Anemometer
HybridXT_Anemometer_Manual
Rev. 15
02 January 2020
ESD and Circuit Protection
The HXT sensor has been designed to withstand most common wiring errors and electrostatic discharge.
These include reversed polarity on the power supply inputs, applying power to or shorting the signal
output lines, and electrostatic discharge on any line.
However, the sensor is not indestructible. Avoid applying more than the rated power supply to any pin.
While extremely rugged, nearby or direct lightning strikes may damage the sensor.
Cable Shielding - Important
The user must decide how to connect the shield of the signal cabling for their application. This is an
important part of the overall design of the lightning protection and grounding system for each turbine
design.
We recommend that the shield always be connected at the controller end of the cable. This provides
shielding against capacitively (electrostatically) coupled interference to the sensor signal.
If the shield can be connected to ground at the sensor boom as well, the shield can also provide
protection against inductive (magnetically) coupled noise sources, such as generator noise and lightning
electromagnetic pulses. However, you should connect the shield at both ends ONLY if the turbine
grounding system provides sufficient bonding and grounding to prevent ground loop currents in the
shield wire.
On the cable assembly for the HXT sensor, the shield is available for connection at both ends. If the
sensor end is not to be connected, cut off the shield wire at the sensor end before installation to
prevent accidental contact to the sensor mount.
NRG Product Manual
Hybrid XT Anemometer
HybridXT_Anemometer_Manual
Rev. 15
02 January 2020
Magnet Safety
The HXT sensors, particularly the vane version, contain small, but powerful neodymium iron boron
magnets. These magnets are strong enough to magnetize tools, erase magnetic media (floppy disks and
credit cards), damage CRT’s (computer monitors and TV’s), pinch fingers, etc. They can also shatter if
allowed to snap together, causing eye damage. If they are ingested, they can cause serious injury, or
even death.
Do not allow unskilled persons to disassemble these sensors. Do not remove the
magnets from their respective assemblies (Head Assembly and Shaft Assembly).
Keep small magnets and small pieces containing magnets away from young
children who might mistakenly or intentionally swallow them. Seek immediate medical attention if you
suspect a child may have swallowed a magnet.
Transport and Handling
This sensor is a precision instrument. Please use care in its handling to protect the bearings and shaft. It
is recommended that the sensor be carefully placed on its side instead of standing up.
If the sensor tips over onto a hard surface, bearing or shaft damage may occur. Physical damage to the
sensor is not covered by warranty.
NRG Product Manual
Hybrid XT Anemometer
HybridXT_Anemometer_Manual
Rev. 15
02 January 2020
CABLE COMPATIBILITY TABLES
There have been several different versions of the Hybrid cable assembly since inception to
accommodate various sensor and turbine configurations. Please see the tables below to verify cable
compatibility.
Hybrid/HXT Sensor Cables
Item
Number
Description
Notes
4716
Assembly-Cable,600V, 10m, Connector,
Power, Signal, WithMountingBolt, Hybrid
TCS
10 m length, 5 pin cable, Green Tag
4717
Assembly-Cable,600V,20m,
Connector,Power,Signal,
WithMountingBolt,Hybrid TCS
20 m length, 5 pin cable, Green Tag
8797
Assembly-Cable,600V,12m,6 Pin
Connector,Power,Signal,
WithMountingBolt,Hybrid TCS
12 m length, 6 pin cable, Red Tag
9234
Assembly-Cable,300V,10m,
Connector,Power,Signal,WithMountingBolt,
Hybrid TCS
10 m length, 6-pin cable Orange Tag
9319
Assembly-Cable,300V,20m,
Connector,Power,Signal,WithMountingBolt,
Hybrid TCS
20 m length, 6-pin cable Chartreuse Tag
NRG Product Manual
Hybrid XT Anemometer
HybridXT_Anemometer_Manual
Rev. 15
02 January 2020
HXT Sensor-to-Cable Compatibility
Sensor Part
Number
Sensor Type |
Output Type
Compatible Cable
Part Numbers
Notes
4715
HXT Vane |
Digital Frequency
4716, 4717, 8797,
9234, 9319
Any cable may be used
Yellow (Output 2) is not used and
should be left disconnected
4718
HXT Anemometer |
Digital Frequency
4716, 4717, 8797,
9234, 9319
Any cable may be used
Yellow (Output 2) is not used and
should be left disconnected
6624
HXT Anemometer,
Calibrated |
Digital Frequency
4716, 4717, 8797,
9234, 9319
Any cable may be used
Yellow (Output 2) is not used and
should be left disconnected
5762
HXT Vane |
4-20 mA, Clockwise
4716, 4717, 8797,
9234, 9319
Any cable may be used
Yellow (Output 2) is not used and
should be left disconnected
5763
HXT Anemometer |
4-20 mA, 0-50 m/s
scaled
4716, 4717, 8797,
9234, 9319
Any cable may be used
Yellow (Output 2) is not used and
should be left disconnected
7894
HXT Vane |
Push-Pull, Active
Low
8797, 9234, 9319
(Red, Orange or
Chartreuse tag) only
Only newer 6-pin cables can be used
All six wires are required to provide
both Vane signals.
7901
HXT Anemometer |
Push-Pull
4716, 4717, 8797,
9234, 9319
Any cable may be used
Yellow (Output 2) is not used and
should be left disconnected
9362
HXT Vane |
4-20 mA, Counter-
Clockwise
4716, 4717, 8797,
9234, 9319
Any cable may be used
Yellow (Output 2) is not used and
should be left disconnected
9363
HXT Vane | Push-
Pull, Active High
8797, 9234, 9319
(Red, Orange or
Chartreuse tag) only
Only newer 6-pin cables can be used
All six wires are required to provide
both Vane signals.
9365
HXT Anemometer |
4-20 mA, 0-60 m/s
scaled
4716, 4717, 8797,
9234, 9319
Any cable may be used
Yellow (Output 2) is not used and
should be left disconnected
NRG Product Manual
Hybrid XT Anemometer
HybridXT_Anemometer_Manual
Rev. 15
02 January 2020
HXT SENSOR INSTALLATION
Mounting Mast Orientation
Refer to the technical drawing for details on mounting mast design. Orient the cross-holes in the top of
the mounting mast such that they are lined up parallel to the turbine nacelle centerline.
Prepare Shield
Based on your decision about the cable shield connection scheme, cut off or attach the shield to the
mounting mast. If you choose to cut the shield wire, make sure to cut it off short enough to avoid
touching the mounting mast or bolt.
Cross-holes
Typical
mounting
mast
Nacelle centerline
Align cross-holes parallel to nacelle centerline.
If cutting shield wire, cut close to
connector base as shown.
NRG Product Manual
Hybrid XT Anemometer
HybridXT_Anemometer_Manual
Rev. 15
02 January 2020
Shield wire to be cut or
attached to mast
Feed cable through mast.
Shield wire to be cut or
attached to mast
Mount Connector
Remove the nut, washer, and bolt from the connector. Feed the cable through the mounting mast until
the connector reaches the mast. Align the bolt hole in the connecter with the holes in the mounting
mast such that the “TOWARD ROTOR” text molded onto the connector leg is oriented toward the
turbine rotor. If you are connecting the shield to the mounting mast, do so now.
nut
washer &
bolt
Remove the nut, washer, & bolt.
Install connector with “TOWARD ROTOR”
text pointing to the rotor.
rubber
washer
“TOWARD
ROTOR” text on
connector leg
NRG Product Manual
Hybrid XT Anemometer
HybridXT_Anemometer_Manual
Rev. 15
02 January 2020
Be sure that the connector is snug against the top of the mounting mast and that the washer is on the
bolt (compression of the rubber washer may be necessary) then pass the bolt though the mast and
connector. Now attach the nut to the bolt a few turns until the nylon patch is in contact with the nut.
The nylon patch prevents the nut from backing off the bolt threads. Note that the washer is between
the mounting mast and the bolt head.
The HXT sensors have four ridges running vertically
inside the body's lower end as shown in the picture
below. These ensure that the sensor mounts securely
on the mounting mast.
If attaching the shield to the ground screw,
make sure that it does not interfere with the
mounting ridges by running it straight down the
mast from the connector to the ground screw.
Do not wrap the wire around the mast. The
picture below shows the ground screw
attachment option.
Secure connector to mast with bolt,
washer, and nut.
SS washer away
from mast to
allow sensor to
slide in place
Connector and
rubber washer
snug to mast
Suggested method for attaching shield to mast.
NRG Product Manual
Hybrid XT Anemometer
HybridXT_Anemometer_Manual
Rev. 15
02 January 2020
Connect Cable to Controller
Route the sensor cable into the nacelle and to its connection point. It may be helpful to label the end of
each wire before pulling the cable to its connection point. Following the color code, connect the sensor
wires and shield wire to the turbine controller and heater power supply.
Sensor Common
Black, 22 AWG
Sensor Power
Red, 22 AWG
Sensor Signal
White, 22 AWG
N/A –not used
Yellow, 22 AWG (on all cables shipped since January, 2016)
Heater –*
Orange/White, 20 AWG
Heater + *
Orange/Black, 20 AWG
When powering the sensor heater with DC power, Orange/White MUST be connected
to DC Ground (-) and Orange/Black to 24V DC (+).
When using AC power, the wiring order does not matter.
NRG Product Manual
Hybrid XT Anemometer
HybridXT_Anemometer_Manual
Rev. 15
02 January 2020
Mount Sensor
To attach the sensor to the mounting mast,
slide the clamp bolt and washer away from the
mounting mast until the nut is against the
mounting mast and is hanging vertically.
Rotate the HXT sensor body so that the “THIS
SIDE TOWARD ROTOR” label is facing the
turbine rotor. This aligns the internal key with
the alignment slot in the connector. Now, slide
the sensor down over the boom carefully
making sure that the key drops into the slot.
Continue to slide the senor down until it is
firmly seated on the nut. There will be some
drag as the o-ring seal and the connector pins
engage. Tighten the bolt using a 10 mm wrench
to 7 N-m (5 ft-lbs).
Replacement washers, nuts and bolts can be ordered from NRG Systems (part #4422).
Nut against mast
and hanging
vertically.
Bolt & washer away
from mast
Slide sensor down over mast.
“THIS SIDE TOWARD
ROTOR”
NRG Product Manual
Hybrid XT Anemometer
HybridXT_Anemometer_Manual
Rev. 15
02 January 2020
GROUNDING AND BONDING FOR OVER-VOLTAGE PROTECTION
Introduction
The purpose of this section is to outline the recommended practices for wiring, grounding, and bonding
of HXT turbine control sensors. The goal is to provide the best possible protection against direct and
indirect lightning damage for both the sensor and the interconnected turbine systems.
This section also details the internal construction of the sensor’s bonding and over-voltage protection.
This allows the wind turbine designer to coordinate the sensor grounding and Over Voltage Protection
(OVP) with the rest of the turbine’s Lightning Protection System (LPS).
Recommended Practices
The long-term reliability and the Electromagnetic Compatibility (EMC) performance of the sensor are
dependent on proper installation and connections. These recommendations could apply to any control
electronics or sensors, but are particularly critical for wind sensors because they are exposed on the top
of the nacelle.
The purpose of recommendations 1 through 5 is to provide shielding of the internal sensor electronics,
heater, and cabling so that they are protected to LPZ 1, per IEC 61400-24.
1
IEC 61400-24 classifies several Lightning Protection Zones (LPZ). LPZ 0A is exposed on the surface
of the turbine and is subject to direct lightning attachment. The turbine must provide air
terminals such as lightning rods to protect the sensors from direct lightning attachment. This
creates an area in LPZ 0B to mount the sensors.
2
Careful routing of the lightning down-conductor and coordination of the grounding and bonding
of the down-conductor(s) to the turbine’s LPS is required to minimize the energy coupled into
other systems such as the sensors. Provide maximum possible spacing between lightning down-
conductors and any control cabling or raceway. Do not route any other cabling or raceway
alongside the lightning down-conductors. These measures will minimize the coupling of lightning
electromagnetic pulse (LEMP) energy into other turbine systems.
3
The Sensor body is metal, and bonds to the sensor mounting mast. The mounting mast must be
metal. Take particular care to bond the sensor mounting mast to the turbine’s LPS in coordination
with the placement and bonding of the lightning air terminals and bonding of the turbine frame
and nacelle.
NRG Product Manual
Hybrid XT Anemometer
HybridXT_Anemometer_Manual
Rev. 15
02 January 2020
4
Use shielded or “screened” cable with high shield coverage for sensor cabling. We recommend
bonding the cable shield to the grounding system at both ends- at the sensor, and at the
connection to the turbine control system- to provide maximum protection from LEMP. However,
see note 6 about preventing ground loops. NRG Systems supplied cables provide a shield at the
sensor end. If your LPS design does not use this shield drain, trim it off to prevent short circuits.
5
Run the sensor cabling in metallic raceway or conduit. Bond the raceway or conduit to the LPS at
both ends. This provides protection for the sensor and cabling against EMI and LEMP.
Recommendations 6 and 7 relate to ground loops and over-voltage protection.
6
Provide sufficient bonding to prevent ground loop currents in the shields and raceways.
Whenever possible, it is better to resolve the underlying grounding problems, rather than leaving
the shield unconnected to prevent ground loop current flow.
7
Since the sensor's electronics and cabling are in LPZ 1, isolation and or over-voltage protection
should be provided at the interface between the sensor cabling and turbine control system to
provide LPZ 2 or better protection for the controller.
Reference:
1. IEC TR 61400-24: 2002: Wind Turbine Generator Systems- Part 24: Lightning Protection.
2. IEC 61312-1: 1995: Protection against Lightning Electromagnetic Impulse- Part 1: General Principles
NRG Product Manual
Hybrid XT Anemometer
HybridXT_Anemometer_Manual
Rev. 15
02 January 2020
Sensor Wiring Diagram
The HXT turbine control sensor’s enclosure is metal, which provides an overall EMI shield for the internal
components of the sensor. The sensor includes internal over-voltage protection (OVP) components. For
these features to be effective, the sensor must be installed and connected properly. The figure below
shows the internal connection details of the sensor bonding and OVP.
Internal bonding and OVP of the HXT turbine control sensor
When powering the sensor heater with DC power, Orange/White MUST be connected
to DC Ground (-) and Orange/Black to 24V DC (+).
When using AC power, the wiring order does not matter.
This manual suits for next models
1
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