Southwest Windpower Whisper 200 User manual

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WIND GENERATOR SERIAL NUMBER ________________
Owners Manual
Installation, Operation and Maintenance
Southwest Windpower, Inc.
1801 W. Route 66
Flagstaff, Arizona 86001
Phone: [phone]
Fax: [phone]
Email: [e-mail]
Web page: http://www.windenergy.com
© 1 April 2000 Southwest Windpower , Inc
All Right Reserved
WHISPER WIND GENERATORS
MODEL Whisper 200
Tailored for Grundfos
SQFlex Water Pumping Systems
Southwest Windpower, Inc.
Renewable Energy Made Simple
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WELCOME TO YOUR RENEWABLE ENERGY SYSTEM!
BEFORE YOU BEGIN:
Read this entire manual. Following the instructions and recommendations in this manual will help assure safe and
enjoyable use of your new renewable energy system.
SAFETY INFORMATION: These systems present mechanical and electrical hazards that can be life
threatening. The tower could fall and cause injury or death and property destruction. A component of the
wind generator could come loose causing injury or death and property destruction. During installation, ensure
that the turbine wires are shorted to each other (twisted together) to prevent the turbine from spinning up in
unexpected gusts. Contact with the high speed propeller can result in severe injury or death. High voltage from
the wind generator or the breaker box can cause injury or electrocution. A burn injury can result from an
electrical short.
These conditions are addressed in the following safety messages:
STOP! DANGER! It is your responsibility to obtain all required permits and engineering certifications for your
tower and tower location. Soil and wind conditions vary and towers and tower foundations must be designed for your
specific location. Tower must not be able to fall on occupied buildings, neighbor's property or power lines. Tower
climbing is dangerous and should be attempted only by experienced personnel using proper safety equipment. A fold-
over tower can eliminate climbing. Locate your mounting mast (tower) well away from occupied buildings and power
lines; a minimum of 100m (300 ft) is recommended.
STOP! DANGER! If the generator appears or sounds loose in the tower or is making an unusual sound, the condition
must be corrected immediately. A loose generator or component will soon damage itself further and may fall from
the tower or lose parts that could be lethal. Never stand in line with an operating propeller.
STOP! DANGER! Provide climbing protection against all unauthorized persons or children. Never allow an
untrained person or someone without the proper safety equipment to climb the tower. Always stop the propeller
before climbing the tower. Both falling from the tower and contact with the operating propeller can be lethal.
STOP! DANGER! High voltage systems represent a dangerous shock hazard and could be lethal. All high voltage
systems should be wired and maintained by a qualified and licensed electrician.
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DESCRIPTION OF SYSTEMS
The illustrations below depicts typical installations. Whisper Wind Generators include the turbine system
and water pumping system only. For more information regarding specifications, please contact your
distributor or installer. Note that the illustrations below are for information purposes only. See the appropriate
section to properly wire your own wind system.
Wind System Only Wind System with Level Switch
Item Number Description
1 SQF Pump
2 Cable
3 Cable Clips
4 Straining Wire
5 Wire Clamps
8 Wind Turbine
9 IO 102 Breaker Box
11 CU 200 Control Unit
14 Water Reservoir
15 Level Switch
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Wind/Solar Combi System
Item Number Description
1 SQF Pump
2 Cable
3 Cable Clips
4 Straining Wire
5 Wire Clamps
6 Solar Panels
7 Support Structure
8 Wind Turbine
9 IO 102 Breaker Box
11 CU 200 Control Unit
14 Water Reservoir
15 Level Switch
FURTHER DESCRIPTION OF SYSTEMS
During windless periods, solar panels may supplement your usage of renewable energy. Solar PV
(photovoltaic) panels make electricity directly from the sunlight
Wind/Solar Combi System with Level
Switch and CU 200 Control Unit
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Overview of Wind Generator
Whisper 200 Shown
Introduction
Tail Stalk
Assembled Generator
Blade
Nose Cone
Tower Insert
Tail Fin
Tower
Blade Extender
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Introduction
WIRE SIZE FROM WIND
GENERATOR TO
BREAKER BOX
The following tables are used to
determine the wire size based on your
system voltage and the distance required
to connect your Whisper to the breaker
box. Distances are one way distances.
Use manufacturer’s recommended wire
sizing for pump and solar panel.
VOLTS 120 V 120 V
COPPER
WIRE SIZE Feet Meters
AWG 14 207 63
12 330100
10 525160
8831253
61293394
42066629
32598791
2 3277 998
141831274
052001584
2/0 66002011
3/0 83002529
AWG
SIZE 14 12 10 8 6 4 3210 2/0 3/0
Diam
inches 0.064 0.081 0.102 0.129 0.162 0.204 0.229 0.258 0.289 0.325 0.365 0.41
Diam
mm 1.628 2.057 2.591 3.277 4.115 5.182 5.817 6.553 7.341 8.255 9.271 10.414
Inch to Metric Conversion — AWG
Typical Renewable Energy System Wiring
You will need to make the electrical connections as shown below.
See Wire Size
Table Below.
IO 102 Breaker Box
Grundfos
SQFlex
Pump
Wind Solar
Optional Solar Panel
Ground
- +
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Tower
Tower height minimum: 7m (20 ft) above trees or obsta-
cles within 100m (300 ft).
100m (300 ft)
1. TOWER LOCATION/TYPE AND
HEIGHT. INSTALL TOWER
(Install tower following manufacturer’s instructions.)
Tower height minimum is 7 meters (20 feet) above trees
or obstacles within 100m (300ft). The lateral thrust rat-
ing at top must match wind generator model. The high-
est point on your property is generally best, but wind
generator distance to the pumping system determines the
correct wire size (Refer to wire size table on the previ-
ous page). A fold over design permits easy installation
and maintenance on the ground and eliminates the need
for climbing.
Whisper Models are suitable for roof or side-of-building
mounting on unoccupied buildings such as garage or
barn. Some vibration transmission will be noticeable
from mounts to structure. Foundations must be designed
and approved for local wind/soil conditions.
1. INSTALLATION
DO THE FOLLOWING STEPS IN ORDER AND CIRCLE WHEN COMPLETE
Roof Mount Side of Building Mount
Mounting
Bracket
Installation
Complete these tests before mounting blades to
rotor.
These tests confirm that the wind generator was
not damaged in shipment and is ready to install
on the tower.
GROUND TEST
Check
resistance to
ground on
any wire.
Resistance
must exceed
10,000 ohms.
SHORT CIRCUIT TEST
When the wires
are shorted to-
gether the
generator rotor
should turn hard
and smooth.
2. WIND GENERATOR ELECTRICAL
TESTS
When the wires are
unconnected the
wind generator
rotor should spin
freely.
OPEN CIRCUIT TEST
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Installation
Mounting Instructions
Check fit of insert by fitting it inside the tower.
A maximum of 1.5 mm (1/16 in) play is al-
lowed. You must be able to pull pipe or tube
tight against insert with mounting bolts.
Install insert on yaw shaft with slot facing
down. Slot used for tower wire support. Use
medium-strength thread locking compound on
all fasteners. M6 X 10 Allen head set-screws
must engage both holes in yaw shaft
Use plastic wire nuts or split bolts to make
electrical connections. Any wind generator
wire can go to any tower wire. Wrap split bolts
thoroughly with electrical tape to prevent
shorts to tower. Support wires to avoid weight
on slip ring wires.
Slide generator without propeller into tower
and install mounting hardware as shown. For a
more complete description of the tower instal-
lation, refer to the Whisper tower manual.
3. CONNECT WIRES AND MOUNT
WIND GENERATOR TO TOWER
Whisper 200 - Tower Mount
Wire Nut or
Split Bolt
Connector
Cable Sleeve
Tower
Wires to Whisper
Key Wire System
Blue Wires
From Turbine
Tower Insert Support Wires
by Attaching
to the Tower
Insert
Tower
Ite
m Description 2.5” QTY
1 Set Screw (M6 X
10) 2
2 Bolt M8X20 4
3 Lock Washer M8 4
2
2.5” Insert
1
3
Engagement
Holes
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Installation
4. INSTALL TAIL
Item Number Description Quantity
1 Assembled Generator 1
2 Tail Stalk 1
3 Tail Fin 1
4 Hex Bolts, M8 x 55 2
5 Nylon Washer, M8 x 31 2
6 SSTL Washer, M8 x 30 2
7 Nylock Nut, M8 4
8 Hex Bolt, M8 x 25 1
9 Hex Bolt, M8 x 70 1
2
1
5
4
3
6
7
9
8
7
Whisper 200 Tail Assembly
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Installation
5. INSTALL BLADE AND NOSE CONE. IO 102 ON/OFF SWITCH IN POSITION “OFF”
Installation instructions for Whisper 200
1. Bolt down Blade Extension (#1) to rotor using only the one bolt (#3) and lock washer (#2) nearest center of
rotor. Insure remaining Extension bolt-hole lines up with rotor by loosely inserting bolt in outer hole and tighten
inner bolt securely. Repeat for each Blade Extension.
2. Line up bolts (#3) through Nose Cone (#4) using Flat Washers (#5), and lock washers (#2). Tighten.
3. Install blade (#6), rounded edge advancing clock-wise, on Extension (#1) using cut washer (#10) on outside
mounting bolt. Using bolts (#11), Washers (#9 and #10), and Nuts (#7) Tighten all bolts to 18 Ft-lbs torque.
Repeat for remaining Blades. Note: Tapered ground end of extensions faces towards blades.
Item Description Quantity
1 SS Blade Extension 3
2 SS Lock Washer, M10 6
3 SS Hex Bolt M10 x 40 6
4 Nose Cone 1
5 SS Flat Washer M10 x 20
(Thin) 3
6 Blade 3
7 SS Nylock Nut M10 6
9 SS Flat Washer M10 x 30
(Thick) 3
10 SS Shaved Flat Washer
M10 x 30 3
11 SS Hex Bolt, M10 x 50 6
4
1
Ground Edge
2
3
3
5
2
6
9
11
10
Leading Edge
Rounded
Trailing Edge Sharp
7
WHISPER 200
Blade Installation
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Maintenance
3. INSPECT THE TOWER
Follow all inspection and maintenance requirements of
the tower manufacturer. Tighten all nuts and bolts,
especially wire clips. Check for cracks and bent or
broken parts at the anchors and base structure. Check
for broken strands and tighten guys.
2. CHECK MECHANICAL CONDITION
WATCH AND LISTEN FROM THE TOWER BASE.
Use binoculars. There should be no mechanical noise,
rattle or vibration. The propeller and tail must not
wobble. Lower or climb the tower for inspection, if
indicated. There should be no buzzing either heard or
felt with your hand on the tower mast. Go to Electrical
Problems, if indicated.
1. TEST BRAKE
(This checks electrical wiring.)
STOP THE WIND GENERATOR IN A MODERATE
WIND (CHARGING BUT NOT FURLING) No
unusual difficulty or noise should be experienced in
stopping the propeller. A noise during braking can
indicate a disconnected wire.
Breaker Panel
On/Off
Grundfos
Water Pump
MAINTENANCE - MONTHLY,
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LOWER TOWER AND GIVE WIND
GENERATOR A COMPLETE
MECHANICAL CHECK. FIX OR
REPLACE ANY WORN OR LOOSE
PARTS.
a) Check tightness of all tower, hub, tail mounting nuts
and bolts and propeller mounting bolts.
b) Check all bearings. Just perceptible play is acceptable.
c) Clean the propeller with mild scrubbing agent to
remove all dirt and debris. Replace blades if they are
cracked or damaged.
MAINTENANCE - ANNUAL
Whisper 200 Turbine
Tighten tower,
tail, hub and
blade mounting
bolts
Do not tighten
pivot pin nut.
Maintenance
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Troubleshooting and Repair
WIND GENERATOR SYSTEM
First, one must determine if the problem is mechanical or electrical. Refer to the two illustrations below and
then proceed to the appropriate section.
TROUBLESHOOTING AND REPAIR
Propeller turns slowly = Electrical Problem
Proceed to next page to diagnose the type of electrical
problem the turbine is experiencing.
Propeller does not turn = Mechanical Prob-
lem
Proceed directly to Table: Symptoms of Mechanical
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Troubleshooting and Repair
DETERMINING THE TYPE OF ELECTRICAL PROBLEM
Electrical problems can be in the generator or the breaker box. Determine which as follows:
1. Wind generator will not start (blades turn slowly as if the IO 102 on/off switch is off): On a day of moderate
wind, disconnect the three wires from the wind generator one at a time at the breaker box. If the wind generator
starts, the wire that allowed it to start leads to a bad diode in the breaker box. Call the factory or the distributor to
replace the breaker box.
2. Wind generator still does not start. On a day of moderate wind, disconnect any two wires. If the wind generator
starts, the problem is in the breaker box or in the pump. Call the factory or the distributor to replace the breaker
box or the pump. If the wind generator still does not start the problem is in the tower wiring or the wind generator.
Go to Table, Symptoms of Electrical Problems.
3. Wind generator is running, but may have an electrical problem. Using a voltmeter, read the voltage across the
leads and see the list below as a guide to possible problems.
Voltmeter Test
1. Voltage increase and decreases slowly with wind speed equally across all wires = Everything ok.
2. No voltage across two wires = One wire from wind generator not carrying power. Check in order: Check the
tower wiring to insure it is properly wired. Check slip rings and brushes, stator connections and stator wind-
ings for obvious damage. Report damage to authorized distributor or factory.
3. Voltage significantly high across two wires than the others = Contact the distributor or the factory, possibly a
bad diode.
4. Voltage produced after IO 102 on/off switch OFF = Possibly a faulty brake switch or a wire shorted to the
other two or an internal fault has occurred in the breaker box.
5. Voltage significantly lower across two wires than the others = Bad connection at wind turbine voltage con-
nections or faulty stator winding. Report this failure to your distributor or the factory.
6. Should these results appear inconclusive in determining the problem proceed directly to Table: Symptoms
of Electrical Problems.
From Wind
Generator
To Breaker Box Terminals
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Troubleshooting and Repair
Table: Symptoms of Mechanical Problems
a. Ice in generator, or uneven ice on
propeller
b. Debris between rotor and stator
c. Loose magnet
d. Bad bearing, worn bearing
a. Wait for warm weather
b. Turn propeller gently by hand and
blow or use piece of paper to
dislodge debris
c. Contact distributor
d. Contact distributor
a. Bad bearing, worn bearing
b. Swelled wire keepers due to high
moisture
a. Contact distributor.
b. Contact distributor.
a. Ice on blade
b. Dirty blade
c. Split, warped or damaged blade
d. One or more blades on backwards
a. Blades on backwards.
(See blade installation)
a. Blade out of balance
b. Blade not tracking
a. Wait for warm weather. Prop will
eventually shed ice, leave running
unless there is substantial vibration
b. Clean with soap or bug cleaner
c. Contact factory or distributor to
replace broken or damaged blade
d. See blade installation
a. Turn blades over. Leading edge
advances clockwise from upwind
view.
a. Retighten mounting hardware, use
Loctite or equivalent thread-locking
compound
b. Repair as required
c. Contact distributor
d. Contact distributor
a. Generator loose in tower
b. Loose rotor (magnet can) on shaft
loose tail, missing rubber bumper,
wires slapping inside of mast,
governor pivot bolt loose
c. Worn bearings
d. Shaft broken
a. Contact distributor
b. Contact distributor
1. Propeller is stationary, even in
high winds
2. Propeller will not turn at all ex-
cept in high wind, scraping or
rubbing sound at low rpm, al-
ways stops at same propeller po-
sition
3. Propeller is harder starting, out
put is lower & there is more pro-
peller noise than usual. Seems out
of balance.
4. Propeller turns a little, never
starts
5. Tail, generator and tower vibrate
or shake at all or some wind
speeds
6. Rattle or clunking from generator
Symptom Possible Cause Correction
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Troubleshooting and Repair
Table: Symptoms of Electrical Problems
1. Check to see if the IO 102 on/off
switch is ON (in the normal run
position)
2. On a day of moderate wind, dis-
connect the pump.
3. If the generator still does not turn
in moderate winds.
When the on/off switch is ON, the
turbine should begin spinning. If not
proceed to step 2.
The generator starts to turn.
Check Observation Possible Cause
Symptom—Generator will not start (blades spin slowly as if IO 102 switch is set to OFF)
The pump may have a problem or
the motor cable can have a short
circuit or the generator is
producing too little energy.
Connect the pump again.
If the pump still does not start:
-check the voltage to the pump
-check the cable and
connections
-check the pump
Consult the Grundfos Service
Instructions.
Note: The wind speed must be
moderate to insure that the wind
energy is powerful enough to
start to pump.
Disconnect the three wires from the
generator one at a time at the
breaker box. If the generator
starts, the rectifier in the breaker
box is defective.
Call the installer or distributor to
replace the breaker box.
NOTE: ALWAYS BE AWARE OF THE DANGER OF HIGH
VOLTAGE. DO NOT DIRECTLY TOUCH THE WIRES.
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Troubleshooting and Repair
Table: Symptoms of Electrical Problems
1. Set IO 102 on/off switch to OFF
(in stopped position).
2. If the generator does not slow
down
The generator slows down and turns
slowly or stops. If the generator
does not slow down, proceed to
step 2.
Turbine blades running fast and not
slowing when IO 102 on/off switch
in OFF position.
Check Observation Possible Cause
Symptom—Generator spins up and pump does not operate
No connection to the pump.
Check to see that the pump is
connected
Check the motor cable for
disconnections.
One or more of the three wires may
be disconnected. Check the
wires.
Note: Be aware of high voltage.
Danger exists if the wires are
touch or short against each
other.
If all steps have been followed to this point and the
pump or generator does not function as described. Ei-
ther the pump or generator may defective. Please con-
tact the installer or distributor to replace the defective
units.
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Troubleshooting and Repair
Do not attempt these repairs on top of the tower. Perform repairs only after tower has been
lowered.
BLADE UNMOUNTING
Remove blade, see Installation step #8. Remove rotor bolts and blade mounting plate. See exploded view
Reassemble in reverse order.
MECHANICAL REPAIRS AND PARTS REPLACEMENT
(Refer to exploded view)
Typical Blade Assembly Whisper 200
Nose Cone
Blade Extender
Rotor
Blade Extender Bolt
Turbine Generator Housing
Blade Bolts
Blade
Blade Extender Bolt
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Troubleshooting and Repair
Exploded View Parts List-Whisper 200
Item No. Description Quantity Southwest Windpower Part # - H80
1 Casting Top 1 IAA07
2 Nylock Nut, M8 1 IAR17
3 Hex Head Cap Screw M8 x20 1 IAR07
4 Stator 1 IAR019
5 Snap Ring (20 mm) 2 IAR18
6 Bearing 3 IAJ01
7 Spindle 1 IAP06
8 Snap Ring (47 mm) 1 IAR22
9 Rotor 3 IAE20
10 Washer M6, SS 3 IAR05
11 Socket Head M6 x 16 3 IAR06
12 Stop Head, Rubber Pad 1 IAL03
13 Stop Head, Rubber Pad 1 IAL04
14 Pan Head Screw, M5 x 60 4 IAR02
15 Bronze Bushing 1 IAJ04A
16 Pivot Shaft 1 IAG06
17 Brush Cover 1 IAF09
18 Brush Holder 3 IAF06
19 Spring 4 IAF03
20 Brush with wire 3 IAF02
21 Brush, wire with terminal 1 IAF02, IAF01
22 Ground Screw M6 x 10 1 IAR03
23 Casting Bottom 1 IAB07
24 Washer, M8 x 16 1 IAR48
25 Nylock Nut, M8 1 IAR17
26 Yaw Shaft 1 IAD03
27 Snap Ring (62mm), 1 IAR21
28 Seal 1 IAR22
29 Light Assembly (Not Available) 1 IAK06
30 Bronze Thrust Washer 1 IAJ12
31 Hex Bolt, M8 x 25 SS 1 IAR09
32 Hex Bolt, M8 x 70 SS 1 IAR13
33 Tail Stock 1 IAQ07
34 Nylock Nut, M8 3 IAR17
35 Nylon Washer, M8 x 31 3 IAR16
36 SS Washer, M8 x 24 3 IAR15
37 Hex Bolts M8 x 55 SS 2 IAR12
38 Tail Fin 1 IAS04
39 Yaw Bearing 2 IAJ02
40 Yaw Shaft Snap Ring 1 IAR19
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Troubleshooting and Repair
1
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7
8 9
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16
17
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25
39
29
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Whisper 200 Exploded View
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