Southwest Windpower Whisper 200 HV User manual

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
© 15 October 2004 Southwest Windpower , Inc
All Right Reserved
WIND GENERATOR SERIAL NUMBER ________________
Southwest Windpower, Inc.
Renewable Energy Made Simple
WHISPER WIND GENERATORS
MODEL Whisper 200 HV
For the *NEW* Whisper Link
Utility-Tie System

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Whisper 200 HV Whisper Link Manual Document #0229 REV B
SOUTHWEST WINDPOWER
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
© 15 October 2004 Southwest Windpower , Inc
All Right Reserved
WIND GENERATOR SERIAL NUMBER ________________
WHISPER WIND GENERATORS
MODEL Whisper 200 HV
For the *NEW* Whisper Link
Utility-Tie System
Southwest Windpower, Inc.
Renewable Energy Made Simple

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SOUTHWEST WINDPOWER
WELCOME TO YOUR RENEWABLE ENERGY SYSTEM!
ELECTRICITY FROM THE WIND AND SUN:
Renewable electric power systems provide independent electric power for boats, homeowners, farms, villages and
commercial applications such as telecommunications. If utility power is available, your renewable energy system can reduce
the electric bill and provide back up electricity during storms or line failure. The most common sources of renewable electric
power in these systems are small wind powered generators and solar photovoltaic (pv) modules that convert sunlight directly
to electricity. Renewable means power sources that do not deplete the world's finite fossil fuel resources, do not pollute or
warm the atmosphere and do not generate hazardous waste. Electricity means your children can study at night for a better
future and you can benefit from appliances, power tools and communication technologies that make life easier and more
rewarding. Nearly three billion people in the world do not have electricity and by necessity most will ultimately get their
electricity from renewable resources to the benefit of everybody. You are a pioneer and part of the solution!
BEFORE YOU BEGIN:
Read this entire manual. Identify and note your model wind generator where it appears in this 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 or support structure 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. Contact with the high speed
propeller can result in severe injury or death. High voltage from the wind generator or the inverter can cause injury
or electrocution. A burn injury can result from an electrical short.
These conditions are addressed in the following safety messages:
WARNING: HIGH VOLTAGE SYSTEM
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 any spinning 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 spinning propeller can be lethal.
STOP! DANGER! NEVER place objects on top or near the Whisper Link enclosure. These devices must dissipate heat as
part of normal operation. FIRE AND FAILURE can result if airflow is blocked.
Introduction
SYSTEMS WITH VOLTAGES OF 64V AND ABOVE OR ON THE PRIMARY SIDE
OF ANY SYSTEM WITH A TRANSFORMER REPRESENT A DANGEROUS SHOCK
HAZARD AND COULD BE LETHAL. ALL HIGH VOLTAGE SYSTEMS SHOULD
BE WIRED AND MAINTAINED BY A QUALIFIED, LICENSED ELECTRICIAN.

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Table of Contents
INTRODUCTION 3
- DESCRIPTION OF SYSTEMS 4
- OVERVIEW OF WIND GENERATOR 5
- TYPICAL GRID INTERCONNECT SYSTEM WIRING 6
- WIRE SIZING 6
1. TOWER INSTALLATION 7
2. WIND GENERATOR ELECTRICAL PRE-TESTS 8
3. CONNECT WIRES AND MOUNT WIND GENERATOR TO TOWER 9
4. INSTALL TAIL 10
5. INSTALL BLADES AND NOSE CONE 11
6. WHISPER LINK 12
- MOUNTING 12
- WIRING 12
- NORMAL OPERATION 13
7. MAINTENANCE - MONTHLY 14
8. MAINTENANCE - ANNUAL 15
9. TROUBLESHOOTING AND REPAIR 17
10. MECHANICAL REPAIR AND REPLACEMENT 23
Table of Contents
FOLLOW STEP-BY-STEP INSTALLATION
LOOK FOR THE SHADED BOXES AND FOLLOW THE STEPS IN ORDER. CHECK THE
PROVIDED BOX WHEN COMPLETE.
SUGGESTED TOOLS AND EQUIPMENT YOU WILL NEED
Round or Half Round File Pliers
Carpenters Level (optional) (2) 9/16” or 15mm Wrenches/Sockets
Torque Wrench w/ 9/16” socket Large Adjustable Wrench
5/16” Wrench Tubing or Pipe for Tower
Sawhorse Hex Wrenches, Phillips and bladed screwdriver
Electrical Wire (see p. 6) Ground Rod and Clamp
Wire Connectors (preferably copper split bolts) Soldering Iron and Solder
Pipe Insulation (to prevent wire “rattle” inside pole) Electrical tape
3/8” Drill Motor 3/8” or 10mm Metal Cutting Drill Bit
Blue Loctite Long T-handle 3/16” allen wrench
INTRODUCTION

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DESCRIPTION OF SYSTEMS
The illustration below depicts a typical installation. For more information regarding specifications of wind, wind/solar and
inverter systems, contact Southwest Windpower. Note that the illustration below is for information purposes only. See the
appropriate section to properly wire your own wind system.
Whisper Wind Generators (Whisper 200 HV with Whisper Link) include the turbine, Whisper Link, SMA Windy Boy
inverter, and the user supplies the tower, and wiring.
Introduction

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Overview of Wind Generator
Whisper 200 HV Shown
Tail Stalk
Assembled Generator
Blade
Nose Cone
Tower Insert
Tail Fin
Tower
Blade Extender
What you should have with your Whisper wind generator
Assembled Generator 1
Blades 3
Tail Fin 1
Tail Stalk 1
Nose Cone 1
Tower Insert Kit 1
Hardware Kit 1
Whisper Link 1
100 amp Fuse 1
Introduction

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Introduction
Typical Grid Interconnect Renewable Energy System Wiring
You will need to make the electrical connections as shown below.
WIRE SIZE FROM WIND GENERATOR TO
WHISPER LINK
The following tables are used to determine the wire size based on
your system voltage and the distance required to connect your
Whisper 200 HV to the Whisper Link. Distances are maximum one
way distances from the turbine connection to Whisper Link
AWG
SIZE 20 18 16 14 12 10 8 6 4 3 2 1
Diam
inches 0.032 0.04 0.051 0.064 0.081 0.102 0.129 0.162 0.204 0.229 0.258 0.289
A
rea
mm20.516 0.821 1.310 2.500 4.000 6.000 10.000 16.000 25.000 25.000 35.000 35.000
*If using aluminum wire, multiply the distances in the table by 0.65.
COPPER
WIRE SIZE FEET METERS
AWG 20 115 20
AWG 18 180 35
AWG 16 295 55
AWG 14 476 90
AWG 12 771 145
AWG 10 1230 235
Inch to Metric Conversion — AWG vs European
See wire size
table below.
See the Whisper Link
installation section for
complete wiring details
Between Whisper Link and Inverter:
Locate the SMA inverter no more than 50 feet of wire length from the Whisper Link. Use nothing larger than
12AWG wire. 14AWG, or smaller is recommended for ease of wiring. Losses here are insignificant.
TO SMA INVERTER
TURBINE - +
INVERTER
WHISPER LINK CONTROL CIRCUIT

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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 highest point on
your property is generally best, but this and wind genera-
tor distance to the Whisper Link determines the correct
wire size (Refer to wire size table pg. 6). A self support-
ing tower occupies less ground area than a guyed tower
but is more expensive. The recommended tilt-up design
permits easy installation and maintenance on the ground
and eliminates the need for climbing.
Seek consultation with a professional engineer to de-
termine proper type and location of tower installation.
1. TOWER INSTALLATION
Installation

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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.
When the wires
are uncon-
nected the wind
generator rotor
should spin
freely.
OPEN CIRCUIT TEST
SHORT CIRCUIT TEST
When all the wires
are shorted together
the
generator rotor
should turn hard and
smooth.
2. WIND GENERATOR ELECTRICAL PRE-TESTS
PHASE TO PHASE TEST
When two wires are
shorted together the
generator rotor
should turn lumpy
as though there are
smooth and bumpy
portions of the rotor
Installation

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Mounting Instructions
The Whisper 200 HV turbine is designed to be mounted on
2.5” schedule 40 pipe (2.875” OD x .20” Wall). Check fit of insert
by placing it inside the tower. A maximum of 1.5 mm (1/16 in) play is allowed. You must be able to pull pipe or tube tight
against insert with mounting bolts. Next, using the template supplied on the last page of this manual, drill holes in the
tower tube. Check to see that the holes in the tower line up with the threaded holes in the insert. Install insert on yaw
shaft with slot facing down. The slot is used for tower cable grip strain relief. Use medium-strength thread locking com-
pound on all fasteners. M6 X 20 Allen head set-screws must engage both engagement holes in yaw shaft.
Solder or use split bolts to make electrical connections. A good wire connection is crucial. Any wind generator wire can
go to any tower wire. Wrap connections thoroughly with electrical tape to prevent shorts to tower. Support wires to avoid
weight on slip ring wires and wire connections. Slide generator without propeller into tower and install mounting hard-
ware as shown. Make sure the top flange of the tower insert is resting on the top end of the tower pipe. Insert and torque
all four insert mounting bolts (M8 x 35mm) to 10-11 ft-lb. (12-14 N-m) repeating any tightening sequence used at least
four times. As an option, the tower tube may be insulated with pipe insulation to prevent the wires from rattling.
Tower Insert Kit
For
2.5 Schedule 40 Pipe (2.875 O.D. x .20Wall)
Item Description 2.5”
QTY
1 Set Screw (M6 X 20) 2
2 Bolt M8 X 35 4
3 M8 SS Nylock Nut 4
2
2.5” Insert
1
3
Engagement Hole
Solder or
Split Bolt
Connector
Cable Grip
Strain Relief
Tower
Wires to Whisper
Controller Wire
System
Wires From
Turbine
Tower Insert Support Wires
by Attaching
to the Tower
Insert
3. CONNECT WIRES AND MOUNT WIND GENERATOR TO
TOWER
Installation

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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 24 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
4. INSTALL TAIL
Installation

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INSTALL BLADE AND NOSE CONE. DIVERSION SWITCH IN “STOP” POSITION.
1. Bolt down Blade Extension (#1) to rotor using only the one bolt (#3) and lock washer (#2) nearest center of rotor. In-
sure 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 to 18 Ft-lbs
(24Nm) torque.
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 (24Nm) 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 HV
Blade Installation
5. INSTALL BLADES AND NOSE CONE.
Installation

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Mounting
The Whisper Link should be mounted against a vertical wall with the ON/OFF Switch to the top. The object is that
the heat sink fins on the back of the unit be mounted vertically for good heat convection. The dump load side of the
unit may in some situations get very hot. Do not mount the unit near anything flammable or heat sensitive. Conduit
connections are only necessary if required by local codes. The knockouts on the bottom of the controller unit are de-
signed to accommodate 0.75”, 1.25”, and 1.5” nominal size conduit. An earth ground connection terminal is provided
inside the Whisper Link on the left-most terminal of the Inverter Output block.
6. WHISPER LINK - MOUNTING
Connecting
All connections should be made and the Whisper Link enclosure closed before the turbine is lifted into the wind.
HIGH VOLTAGE IS PRESENT ANY TIME THE TURBINE IS SPINNING, EVEN SLOWLY. If the turbine has
already been erected, choose a windless day for installation. If there is a light wind, keep all three phases in short-circuit
at all times to prevent startup. This can be easily accomplished with an alligator clip jumper.
Refer to the silkscreen labels on the circuit board. The three phases of the turbine are connected to the three connector
mounts labeled “Turbine.” They may be connected in any order. The (+) and (–) connections should be connected to the
positive and negative inputs of the SMA inverter. The ground on the Whisper Link circuit connects to any earth ground,
but the inverter’s own earth ground is the recommended location. Earth grounding is very important and must be con-
nected.
WHISPER LINK - WIRING
Knockouts (on back and
bottom of controller)
Inverter Outputs
and earth ground
connection
Turbine Inputs
Turbine Stop Switch
Dump Load Side/Hot Side
Suggested Mounting Configuration
+
-
Whisper Link

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1. Normal Operation –
In normal operation the Whisper Link rectifies the 3-phase AC out of the turbine, and provides the inverter with a DC out-
put voltage. If the utility grid should fail the inverter will no longer have a load. This will result in an open circuit condi-
tion. To prevent over-voltage damage to the inverter the Whisper Link automatically diverts power to its resistive heater.
2. Stop Switch
The switch on the top of the Whisper Link enclosure is designed to keep the turbine from spinning. It simply diverts the
turbine output to the dump load. The switch can be turned OFF at any time. IT IS NOT SAFE TO OPEND THE EN-
CLOSURE UNLESS THE TURBINE IS STOPPED. Under light wind conditions, selecting the OFF position should
stop the turbine and keep it stopped. In strong winds, the slowing action may be delayed, but once stalled, the turbine will
not return to operation until the switch is returned to the ON position.
WHISPER LINK - NORMAL OPERATION
Whisper Link
Turbine
Inverter
3. Windy Boy Inverter
Refer to the Windy Boy manual for operation of the inverter.
Whisper Link

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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 should appear
steady in consistent wind conditions. Lower the tower
for inspection when necessary. There should be no
buzzing either heard or felt with your hand on the tower
mast. See the section Electrical Problems for further
instructions.
Whisper Link
1. TEST STOP CONTROL
(This checks electrical wiring.)
STOP THE WIND GENERATOR BY SETTING THE
STOP SWITCH TO OFF 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.
7. MAINTENANCE- MONTHLY
Maintenance

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LOWER TOWER AND GIVE WIND
GENERATOR A COMPLETE
MECHANICAL CHECK. FIX OR
REPLACE ANY WORN OR LOOSE
PARTS. (See p. 24 and 25 for part descriptions.)
In wind sites with greater than a 12 mph average
wind speed, this maintenance should be
performed at least twice annually.
1. Check tightness of ALL tower mounting, tail and fin
mounting, and propeller mounting bolts.
2. Check all bearings. Just-perceptible play is
acceptable.
3. Check the pivot assembly for play. Just-perceptible
play is acceptable. Contact the distributor or factory
for instructions on resetting the pivot.
4. Clean the propeller with mild detergent to remove all
dirt and debris. Avoid scratching the surface. Replace
blades if they are cracked or damaged.
Tighten tower and blade mount-
ing bolts. See p. 9 and p. 11 for
torque specifications.
8. MAINTENANCE - ANNUAL
Maintenance

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Maintenance Log
Observe Monthly and Annual Inspection Requirements! Record ALL maintenance and repair work!
Date
Problem/Observation Action Taken
Maintenance

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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.
9. TROUBLESHOOTING AND REPAIR
Propeller turns slowly = Electrical Problem
Proceed to ELECTRICAL DIAGNOSIS PAGE, Page 18,
to diagnose the type of electrical problem the turbine is ex-
periencing.
Propeller does not turn = Mechanical Problem
(or turns slowly)
Proceed directly to Table: Symptoms of Mechanical
Problems, p. 22
Troubleshooting and Repair

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Table: Symptoms of Electrical Problems
1. Propeller turns slowly even in
strong wind, but will not start
2. Propeller runs too fast, may
whistle, no output, no unusual
mechanical noise
3. Propeller runs too fast, may
whistle, low output, no unusual
mechanical noise
4. Propeller runs too fast, may
whistle, output less than 50% for
wind speed, growling, buzzing,
or vibration felt by hand on tower
mast
a. Stop switch is in OFF position
b. Incorrect turbine wiring
c. Short circuit in wiring from generator to
Whisper Link
d. failed component in Whisper Link
e. Short circuit in brush card, or yaw shaft
f. Short in turbine
g. Inverter disconnected
a. Two or three wires open between
turbine and Whisper Link.
b. Whisper Link diodes open, or wire is
disconnected at diode terminal
a. Turbine may be in regulation, but the
wind may be too high for the turbine to
stop
a. Disconnected wire between the turbine
and the Whisper Link
b. One open, or disconnected diode
c. One slip ring, or brush not making good
connection.
i. Turn Stop switch to ON position.
i. Rewire, see p. 20, Condition I.
i. Check wiring from tower, see p. 21,
Condition I.
i. See p. 20, Condition I.
i. See p. 20, Condition I.
i. See p. 20, Condition I.
i. Check all connections
i. See p. 21, Condition II.
i. See p. 21, Condition II.
i. Wait for calmer conditions and
engage stop switch to determine
proper operation
i. See p. 21, Condition II.
i. See p. 21, Condition II.
i. See p. 21, Condition II.
Symptom Possible Cause Correction
Troubleshooting and Repair

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Table: Symptoms of Whisper Link Problems
Symptom Possible Cause Correction
i. Move switch to ON.
i. See p. 20, Condition I.
i. See p. 20, Condition I.
i. See p. 21, Condition II.
i. Wait for calmer conditions, retry.
i. Move switch to ON.
i. See p. 20, Condition I.
a. Stop Switch in OFF position
b. Shorted diode
c. Short in wiring to turbine
a. Bad switch
b. Runaway condition, wind speed is
too high
b. Switch set to OFF or disconnected.
a. Circuit board bad
1.Propeller turns slowly, even in
strong wind
2. Will not stall with stop switch.
4. Resistive heater always on
Troubleshooting and Repair