Tesup ZEUS3.0 User manual

ZEUS3.0 (MADE IN EUROPE)
TESUP
ZEUS3.0
Wind Turbine
USER MANUAL
Made in Europe
“POWER IS IN CREATING.”
Revision Index 00
Revision Date:
ENGLISH | EN

ZEUS 3.0 (MADE IN EUROPE)
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TESUP
A GLIMPSE OF ZEUS 3.0

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Sr. No. Description Page no.
1 Index 3
2 General 5
2.1 General Instructions 5
2.1.1 Operating and Installing Conditions 5
2.2 Symbols Used 6
2.3 Warranty Details 7
2.4 Product Feedback 7
3 Technical Description 8
3.1 Intended Use 8
3.2 Reasonably foreseeable misuse 8
3.3 System Components 9
3.4 Wind Turbine Components 10
4 Parameter and Dimensional Details 11
4.1 Parameter Details 11
4.1.1 Power Curve 12
4.2 General Arrangement Drawing 13
5 Controller 14
5.1 Technical Details 14
5.2 Wiring Diagram 15
5.3 Permissible Storage & Operation 16
6 Safety Information 17
6.1 Modifications or changes by the user 17
6.2 Residual Risks 17
6.3 Personnel Requirements 17
6.4 Important Safety Instructions 17
7 Pre-Use Preparation 18
7.1 Shipping Conditions 18
7.2 Prerequisites at the place of use 18
7.2.1 Permissible wind class, footprint, and minimum clearances 18
7.2.2 Mounting Details 19
7.3 Unpacking the components 20
7.4 Assembling the wind turbine 20
7.5 Electrical Connections 22
8 Regular Operation 24
8.1 Switching on the wind turbine system 24
1. INDEX

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8.2 Restart after an emergency 24
9 Shutting down the System 25
9.1 Emergency Shutdown 25
9.2 Temporary shut-down 25
9.3 Prolonged shut-down 25
10 Maintenance 26
10.1 Safety precautions during maintenance work 26
10.2 Inspection and maintenance schedule 26
10.3 Maintenance and cleaning by the user 27
11 Troubleshooting and diagnostics 28
12 Removal from service and disposal 29
12.1
Final decommissioning of the wind turbine system
29
12.2 Disposal of the wind turbine system and components 29
13
Declaration of Conformity
30
14 Appendix 31
15 Manufacturer Details & Customer Support 32
16 Notes 33

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▪Before you begin installing, read this entire owner’s manual. Identify and note your model
wind turbine where it appears in this manual. Following the instruction and
recommendations in this manual will help assure safe and enjoyable use of your new
renewable energy system.
▪Please take the time to read through this manual prior to assembly.
oPlace this instruction manual in a safe place for reference.
oWait until a calm day to install or perform maintenance on your Turbine with
activation of brake.
oListen to your Turbine, if you hear any mechanical noise, maintenance may be
required, please contact your Turbine dealer.
oAfter installation re-adjust and tighten the screws and bolts.
oAdhere to proper grounding techniques as established by the National Electrical
Code.
oYour Wind Turbine must be installed in accordance with this manual and local and
national building code. Incorrect installation may void your warranty.
oWind Turbine blades spin at a potentially dangerous speed, this must be respected.
Never approach a Turbine in motion.
oNote wire size prior to wiring. Any under sizing of wire can be potentially
dangerous.
oCheck the manual brake periodically.
oCheck the battery health periodically. The low battery voltage and improper
connection can cause over-spin issues.
2.1.1 Operating and Installing Conditions:
▪Please make sure that:
oThe wind turbine system has been erected correctly by a suitably trained
person.
oAll operating personnel have read and fully understood this translation of the
original instructions
oThe wind turbine system is properly maintained and repaired.
2. GENERAL
2.1 GENERAL INSTRUCTIONS:

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2.2 SYMBOLS USED:
▪In this Manual
IMPORTANT: Please take a note.
DANGER: Immediate danger can cause serious injury.
WARNING: Potential Danger can cause Serious injury.
CAUTION: Potential Danger can cause moderate injury.
NOTE: Useful Tips
▪OTHER SIGNS USED:
GENERAL WARNING.
HIGH VOLTAGE
MAY START WITHOUT WARNING.
ENVIORNMENTAL HAZARD
SAFETY SYMBOLS

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2.3 WARRANTY DETAILS:
▪The “General Terms of Sale and Delivery” of the manufacturer or his authorised
representative apply.
2.4 PRODUCT FEEDBACK:
▪Please notify the manufacturer or his authorised representative about any of the following:
oAccidents
oPotential safety hazards associated with the wind turbine system
oAmbiguities in this translation of the original instructions
oDescription of the wind turbine system

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3.1 INTENDED USE:
▪The wind turbine system may only be used as a “small wind turbine system” (SWTS) to
generate power in accordance with EN 61400-2.
▪The wind turbine system may only be operated in accordance with the ratings and in the
approved wind class (refer to the technical data).
▪Observance of the original instructions and compliance with the maintenance and repair
instructions are essential preconditions of use for the intended purpose.
3.2 REASONABLY FORESEEABLE MISUSE:
▪All forms of use which deviate from or exceed the limits of use described above are
contrary to the intended purpose. The manufacturer is not liable for any damage resulting
from such use.
▪No liability will be accepted by the manufacturer if the equipment has been altered as well
as in the event of improper assembly, installation, start-up, operation, maintenance, or
repair.
▪Only original parts supplied by the manufacturer are approved as spare parts or
accessories. Any spare parts or accessories not supplied by the manufacturer have not
been tested for operation and could be detrimental to reliability. No liability will be
accepted by the manufacturer for any damages which result from the use of non-approved
spare parts or accessories.
▪Reasonably foreseeable misuse includes:
oOperation outside the manufacturer’s specification.
oAll modifications or changes to the wind turbine system without the
manufacturer’s written approval!
oUse of parts other than ZEUS 3.0 original parts.
oOperation in non-approved SWTS classes.
oOperation in strong winds or hurricanes.
3. TECHNICAL DESCRIPTION

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3.3 SYSTEM COMPONENTS:
NOTE: Several Batteries can be connected in Parallel
Or series depending upon the system voltage.
ZEUS3.0 WIND TURBINE
INVERTER
BATTERY
CHARGE CONTROLLER

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3.4 WIND TURBINE COMPONENTS:
Item No. Description Quantity
1 Nose 1
2 Turbine Blades 3
3 Hub for holding the blades 1
4 Generator 1
5 Boom for wind direction flag 1
6 Tail vane 1
7 Adapter stud ∅37 mm
PART LIST TABLE
6
1
5
3
2
7
4

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4.1 PARAMETER DETAILS:
SPECIFICATIONS
DESIGNATION TESUP Zeus3.0
GENERATOR
TYPE
Permanent magnet rotor, brushless, gearless,
maintenance- free
WEIGHT 24 kg
MAX. POWER 3.1 kW
OPERATING CIRCUIT VOLTAGE 0-143
CURRENT 3-Phase-AC
START OF CHARGING
3m/s
HOUSING MATERIAL Aluminium
DIRECTION OF ROTATION Any
TEST STANDARDS EN 61000-6-1 (electromagnetic compatibility –immunity)
EN 61000-6-3 (electromagnetic compatibility –emissions)
ROTOR BLADES
MATERIAL Composites
HUB FLANGE Cast Steel
DIAMETER 2.25 m
WEIGHT PER ROTOR BLADES 720 g
DIRECTION OF ROTATION From the front in a clockwise direction
STARTING WIND SPEED 2 m/s
NO. OF BLADES 3
MAX RPM 1200
MAX SPEED Hurricane scale III
NOISE 60 dB
PARAMETER
4. PARAMETER & DIMENSIONAL DETAILS
WARNING: If a hurricane scale III (50–58 m/s) or above occurs, please
cover wind turbine blades.

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4.1.1 POWER CURVE:
POWER CURVE

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4.2 GENERAL ARRANGEMENT DRAWING:
31.5 cm
193.0 cm
108 cm

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5.1 TECHNICAL DETAILS:
▪The Wind Turbine Charge Controller from TESUP is an intelligent controller which
controls the wind turbine. It safely and efficiently charges and control your battery with
the wind generator combination.
▪With its discreet appearance and simple operation with integrated protection functions,
this device has high efficiency and no-load losses. The version of the controller will
significantly increase the life and sustainability of all the component of the system.
▪The special features and product information are listed below:
oUse of solid-state components.
oManual brake function.
oIncreasing the life of the controller. Microprocessor controlled charge with
integrated voltage and current limiting.
oDump-load is included. Modern Load dissipation system in three steps to avoid
immediate blockage of turbine.
oResistors might be used for heating.
5. CONTROLLER

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5.2 WIRING DIAGRAM:
WIRING DIAGRAM
Main components and their functions
No. Component Function
1 Wind turbine Converts wind energy into electrical energy
2
Switch AC Emergency
Stop Button
Emergency shutdown. When pressed, the wind turbine must be
short-circuited.
3 Charge controller
Generates electrical voltage (24 / 48 VDC Optionally). The TESUP
charge controller.
4 Battery Stores electrical energy (Acid, Gel)
5 Solar panels Convert solar energy into electrical energy
6 To converter Converts 24/48 VDC into 110/220 VAC

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5.3 STORAGE & OPERATION:
▪STORAGE:
oAmbient temperature: -15 to +40°C.
oStorage location: Dry, frost-free.
▪OPERATION:
oAmbient temperature: -25 to +40°C.
oPlace of use: Max. SWTS Class III acc. to EN 61400-2.

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6.1 MODIFICATIONS OR CHANGES BY THE USER:
▪The wind turbine system is in conformity with the European Machinery Directive
2006/42/EC provided only original ATLAS 2.0 components are used and subject to
proper erection. The use of components from other manufacturers as well as
modifications or changes to the wind turbine system by the user are prohibited and
could render the declaration of conformity invalid!
6.2 RESIDUAL RISKS:
▪Any residual risks which arise because of operation or maintenance are described in
the relevant sections of these instructions.
6.3 PERSONNEL REQUIREMENTS:
▪All work on the wind turbine system must be carried out by authorised persons! Such
persons must be familiar with the safety devices and regulations prior to carrying out
the work.
▪Authorised persons are defined as follows:
Operating mode Necessary qualifications
Erection Suitably trained persons
Normal operation Trained personnel
Cleaning Trained personnel
Maintenance Suitably trained persons
Repair Manufacturer
PERSONNEL REQUIREMENT TABLE
6.4 IMPORTANT SAFETY INSTRUCTIONS
▪Properly torque all fasteners.
▪Use grounding techniques as established by the NEC.
▪Install turbine in accordance with this manual and local and national building codes. Failure to
comply may affect and possibly void your warranty.
▪Properly complete the Warranty Registration Card
▪Observe wire size and fuse recommendations listed in the Wiring Section of this manual.
6. SAFETY INFORMATION
WARNING: Rotating blades are a serious mechanical hazard. Install wind turbines
so no one can come in contact with blades.

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7.1 SHIPPING CONDITIONS:
▪The wind turbine system is shipped disassembled.
▪Refer to the contract documentation for the scope of supply.
7.2 PRE-REQS AT THE PLACE OF USE:
7.2.1 Permissible wind class, footprint, and minimum clearances:
▪For information on local wind classes, please contact the responsible authorities or
your nearest meteorological office.
▪The place of use must be free of obstacles; alternatively, the wind turbine must be
erected with a sufficient height (refer to Fig.).
7. PRE-USE PREPARATION
WARNING: Danger to life due to operation in non-approved wind classes!
The wind turbine system may only be operated at Class III wind sites.
NOTE: When choosing the place of use, make sure
adequate room is available to tilt the tower and blades
if necessary.
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7.2.2 Mounting Details:
The soil must have a sufficient load-bearing capacity. The size and structure of the
foundation depend on the soil characteristics.
MOUNTING DETAILS
NOTE: Ask a qualified structural engineer for advice regarding the optimal
design of the foundation.
.

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7.3 UNPACKING THE COMPONENTS:
▪Carefully open the packaging.
▪Check the shipment for completeness (refer to the shipping documents).
▪Separate the packaging material and dispose of it in an environmentally responsible
way.
7.4 ASSEMBLING THE WIND TURBINE:
Turbine Assembly:
▪For installation, select sheltered place.
▪Hold propeller blade (1) with flat side to hub (2).
▪Fasten with a M8x45 bolt, nut and one.
▪Screw on further M8x45 screws and tighten by hand.
▪Attach boom rod (3) with M8x60 bolt to alternator housing.
▪Screw nose (4) to hub with M8x75 screw.
▪Screw wind vane (5) to boom with M8x60 bolt.
▪Plug - in pin 37 mm as mast connection
Balancing the rotor:
▪Move rotor to Y position (see Fig. 7)
▪Carefully release rotor blade.
▪Observe in which direction the rotor turns
(the heavier rotor blade pushes downwards).
▪Repeat the process for all three positions
to determine which rotor blade is in imbalance.
▪Check reveller for balance
▪Tighten all screws to 25 Nm.
▪Check balance again.
▪Secure all screws with locking varnish.
WARNING: Choose an assembly
site which is sheltered from the wind.
The assembly process requires calm
weather conditions.
Always replace the complete set of
rotor blades.
NOTE: Note: The repellers have already been
tested for equal weight by the manufacturer.