WindTronics AURORA PVI-3.0-OUTD-W User manual

AURORA INVERTER
for WindTronics™ Wind Turbine Model BTPS6500
This manual is intended for the use of a licensed contractor. If you are a licensed
and insured contractor who would like to become an Authorized Installer, please
download the application from our website www.windtronics.com.
Quick Start:
AURORA INVERTER
For Aurora wind inverter installations,
please also refer to and understand
the Aurora Installation and Operation
Manual that comes with the inverter.
It may also be downloaded from the
Power One website.
Model # PVI-3.0-OUTD-xx-W

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Quick Start
Safety Information
Important Safety Instructions
1. This Quick Start manual contains important instructions for the WindTronics™ Wind Turbine
installation and maintenance. Please save it.
2. Read the entire Quick Start manual prior to installation and follow all warnings and cautions included
in the Quick Start manual and/or attached to the WindTronics™ Wind Turbine.
3. Improper installation, adjustment, alteration, service maintenance, or use can cause re, electrical
shock, or other conditions which may cause death, personal injury or property damage.
4. Choose a very calm, nearly no wind, day for the installation.
5. Follow the installation procedures contained within this Guide and all safety codes. Follow your
National Electric Code and your local building zoning codes.
6. Only Authorized Installers or other licensed contractors may move and lift the WindTronics™ Wind
Turbine. The turbine should only be moved using standard hoists and hydraulic lifts such as a crane
or bucket truck.
7. Appropriate protective personal equipment such as hard hat, work gloves, safety glasses, and
closed-toe work shoes should be worn when installing the WindTronics™ Wind Turbine.
8. Only Authorized Installers or other licensed contractors may perform the following installation and
maintenance functions on the WindTronics™ Wind Turbine system:
• Open and work on the Aurora inverter
• Open and work on the junction box at the turbine
• Apply any torque to any of the turbine’s fasteners
9. The installation directions include recommendations of a variety of options. These must be approved
and certied by your local Professional Engineer (PE). The installer must acquire all the necessary
permits from the local authorities prior to installation.
The WindTronics™ Wind Turbine is manufactured by WindTronics. Please contact WindTronics at:
621 Sprucewood Avenue
Windsor, Ontario N9C 0B3
Canada
Customer Service and Technical Support:
877-946-3898
Manufacturer reserves the right, without notice or liability, to change design and specications at any
time.

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Quick Start: Aurora Inverter for WindTronics™ Wind Turbine BTPS6500 - Rev 1.0 - 16Sep11
Evaluation and Installation List
Permits
Permit#_________________________ Date_____________
Permit#_________________________ Date_____________
Permit#_________________________ Date_____________
Permit#_________________________ Date_____________
Site evaluation (go to page 5 for requirements)
Distance from Turbine to Aurora inverter (max 200 ft (60m))__________
Height to center of turbine______________________________
Draw all obstructions on site map
Draw site map (view from above - use space below for your drawing)
Prevailing wind direction
Location of:
Obstacles
Turbine
Aurora inverter
Tree
Turbine
LEGEND
T
A


N
Aurora
Prevailing
Wind
Compass

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Quick Start
* A run of conduit shall contain not
more than four quarter bends or
a combination of bends totaling
360 degrees between pull points.
Tubing shall not be threaded, and
ttings shall be listed for use with
EMT and shall be securely fas-
tened to the tubing.
Mounting Hardware (Choose one – see pages 7-9 for drawings - see
WindTronics™ Wind Turbine BTPS6500 Owner’s Manual for more details)
Pole: Height____________ Material_______________(Example on page 7)
Flat roof: QUADPOD Mount and Ballast (see page 8)
Pitched roof: QUADPOD Mount and ROOFBOX Mount (see page 9)
Accessories (Supplied by Installer)
DC Power Supply for Set Up: 45-48V, 10W (i.e. Astrodyne Switching Power Supply
# SPU50-9)
(1) Fused DC disconnect per turbine (see pages #13 and 18 for specs)
(1) Non-fused AC disconnect (see page #13 for specs)
¾” Conduit *
Wire (Power and Control):
#6 THWN - 2 (green)
#10 THWN - 2 (black)
#10 THWN - 2 (white)
#10 THWN - 2 (red)
#12 THWN - 2 (green)
#20 - two colours - OR stranded CAT5E or CAT6
Unpacking (Refer to instructions in turbine package)
Aurora: Serial #___________________ (record when unpacking)
Aurora Owner’s Manual
Turbine crate:
Unpackaging Instructions
Wind Turbine: Serial #____________________ (record when unpacking)
(2) Deectors and mounting hardware
Deector Installation Instructions (assemble before mounting)
Junction box with dump load and ON/OFF switch
Owner’s Manual
QA Inspection Sheet
Warranty Registration Card (scan or mail card or register online at www.
windtronics.com)
Mount and Level Turbine – Refer to lift point on page 12
Connect – Refer to page 13 for wiring diagram
Set Up – Follow menus on Aurora display (refer to pages 10-11)

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Site Survey
PERSONAL INJURY AND PROPERTY DAMAGE HAZARD
Improper installation, alteration, service or maintenance may result in death,
serious bodily injury or property damage. Installation or repairs made by
unqualied persons could result in hazards to you and others. Installation
must conform with all safety and other codes of all governmental authorities
having jurisdiction.
The information contained in this Quick Start Manual is intended for use by
Authorized Installers or other licensed contractors who are experienced in
installing and servicing the WindTronics™ Wind Turbine, are familiar with all
precautions and safety procedures required in such work, and are equipped
with the proper tools and machinery.
When selecting the best location for the wind turbine, consider the following:
1. Wind – Is the area windy enough to warrant the installation of a wind turbine?
2. Height – Install as high as possible. Ideally, it should be greater than 33’ from ground to turbine center
for best performance and safety of personnel.
3. Obstructions – Place the turbine in the location furthest away from all obstacles (buildings, trees,
parapets, HVAC units, rooftops, etc.)
4. Prevailing Wind – As a general guide, place the turbine in a location that can best take advantage of
prevailing winds (if you do not know, you can nd historical “wind rose” information on the Internet).
IMPORTANT: PLEASE TAKE NOTE
If the prevailing wind has to travel across a rooftop before passing through the turbine it will be less
effective than if the turbine was placed where the wind would come into contact with the turbine rst.
Mounting Options
PERSONAL INJURY AND PROPERTY DAMAGE HAZARD
Do not install the WindTronics™ Wind Turbine in a location that is
accessible to children or pets. Failure to follow this warning may result in
death, personal injury or property damage.
PERSONAL INJURY AND PROPERTY DAMAGE HAZARD
The WindTronics™ Wind Turbine must be mounted by Authorized Installers
or other licensed contractors only, with the use of all appropriate hardware.
Failure to follow this warning may result in death, personal injury or property
damage.

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Failure to follow proper installation practices for any of the
mounting options could result in death, serious injury and/or
property damage.
WHEN MOUNTING ON OR OVER A COMBUSTIBLE
SURFACE, A FOOT PLATE OF AT LEAST 1.43 mm
GALVANIZED OR 1.6 mm UNCOATED STEEL EXTENDED
AT LEAST 150 mm BEYOND THE EQUIPMENT ON ALL
SIDES MUST BE INSTALLED.
Power shall be disconnected from the equipment before the
junction box enclosure is opened and the enclosure shall be
closed before the power is restored. Failure to do so may
result in death, serious injury and/or property damage.
If any maintenance is to be done on the turbine, the turbine
must be put in STOP mode, the turbine switch on the
junction box must be in the “Turbine Off” position and the
wheel must be tie wrapped to prevent turning. Failure to
do so may result in death, serious injury and/or property
damage.
Use of WindTronics’ products for other than their intended
purpose may void warranty.
Whichever mounting option is chosen must be approved by a local Professional Engineer
(PE). All of the options listed have been rated by our Professional Engineer. Please refer to
the following designs and their included specications.

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Figure 1 Pole Mount
Pole Mount

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Figure 2 Pole Top Mount Assembly
Instructions for Pole Top Mount Assembly
Step 1:
• Position Leg Weldment
#WTM001 to bottom of
#WTM002 Coupler Weldment.
• Bolt together using fastener #’s:
70210, 70714, 71021, 71071 as
shown.
• Repeat pattern in three additional
locations.
Step 2:
• Position Mounting Bracket
#WTM003 to top of #WTM002
Coupler Weldment.
• Bolt together using fastener #’s:
70210, 70714, 71021, 71071 as
shown.
Pole Top Mount Assembly #WTMASSY001
Item Part No. Description Qty
1 WTM001 Mounting Leg Weldment 4
2 WTM002 Pole Mount Turbine Coupler Weldment 1
3 WTM003 Pole Mount Junction Box Mounting Bracket 1
5 Fastenal #70210 Hex Cap Screw, 1/2-13 x 1.75” lg Full Thread 18-8 S/S 9
6 Fastenal #70714 Hex Nut - 1/2-13 - 18-8 Stainless Steel 9
7 Fastenal #71021 Flat Washer - 1/2”, Small O.D., 18-8 Stainless Steel 9
8 Fastenal #71071 Flat Washer - 1/2”, Medium Split, 18-8 Stainless Steel 9
Note:
Be sure both pole and pole cou-
pler are installed level. Failure to
install them level will impact turbine
performance and may impact
warranty coverage.
Be sure the inner surface of the
Mounting Leg Weldment is ush
against the pole prior to bolting the
fasteners. Choose the bolt hole in the
base of the Pole Mount Turbine Cou-
pler Weldment that aligns with the
slot in the Mounting Leg Weldment.

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Figure 3 Ballast Mount
Ballast Mount with Extended QUADPOD Mount

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Figure 4 ROOFBOX with QUADPOD Mounting
ROOFBOX Mount with Extended QUADPOD Mount

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Set Up
The following is the proper procedure to set up the WindTronics™ Wind Turbine with an Aurora
inverter.
Before connecting the wind turbine, use any DC power supply set to a voltage between 45 to 48
Volts and capable of supplying about 10 watts of power to turn the inverter ON. Connect the positive
of the power supply to the “+IN” terminal of the Aurora inverter and the negative of the power supply to
the “-IN” terminal of the Aurora inverter.
Before turning ON the power supply, make sure that the +IN
is connected to the power supply’s positive and the -IN to the
negative of the power supply. Reversing the polarity will damage
the inverter.
IMPORTANT - First conrm the Aurora inverter has the WindTronics™ Wind Turbine conguration
le uploaded. If “Missing Table” message shows on the Aurora display on power up, please see
our website www.windtronics.com for the full Aurora Grid-Tie Installation Instructions which include
instructions for uploading the power curve. Note: the WindTronics™ Wind Turbine conguration le is
available from WindTronics. Please call Tech Support at 877-946-3898 or send an email request to
[email protected] if your Aurora is showing the “Missing Table” message.
1. When the Aurora inverter is ON, the default display will cycle through various values and parameters.
Press the Esc key, then scroll through the following menus:
2. Scroll down to “Settings” and press the Enter key. Enter the password “0000”.
Figure 5 DC Power Supply to Aurora

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Quick Start
3. After entering the password, the Settings Menu options can be scrolled through.
Scroll down to “Set Vgrid” and press the Enter key.
4. The following screens can now be scrolled through. The top line is the option
that is available and the bottom line is the option that is currently selected (in this case 208V is the option
currently selected):
Scroll down to the conguration that matches the grid. Press the Enter key.
5. Press ESC to go back to the “Settings Menu” to set up the communication/alarm trip point for the turbine
braking.
6. In the “Settings Menu”, scroll down to “Alarm” and press the Enter key.
7. The following screen will appear:
Scroll down to “Fault” and press the Enter key. Press the ESC key to go back to the “Settings Menu”.
8. Set up is now complete. Disconnect power supply from power source and then remove the leads from the
Aurora terminals.

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Quick Start: Aurora Inverter for WindTronics™ Wind Turbine BTPS6500 - Rev 1.0 - 16Sep11
Lift Point
Only Authorized Installers or other licensed contractors may move or lift the WindTronics™ Wind Turbine. The
turbine should only be moved using standard hoists and hydraulic lifts such as a crane or bucket truck. The
recommended lift point is shown in gure 5 below:
Figure 6 Proper Turbine Lift Point
Junction Box
Purpose: Interface between the turbine and the Aurora inverter which houses the safety braking circuitry
to limit the maximum turbine speed. Turbine will brake if voltage generated exceeds 165VDC. The structure
attached to the junction box houses the resistor used to brake the turbine and dissipate excess energy as heat.
Mounting: The junction box comes hard wired to the turbine. The junction box can be mounted through two
pre-drilled holes in the black bars on the back of the junction box. The QUADPOD Mount has pre-drilled holes
for mounting of the junction box. Mounting hardware is supplied by the Installer.
Figure 7 Junction box enclosure (outside and inside)

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Wiring
ELECTRIC SHOCK HAZARD
Before wiring the turbine, be sure the Turbine ON/OFF switch is in the OFF
position. Turn off all power before wiring. Failure to follow safety warning could
result in serious injury and/or death.
PROFESSIONAL INSTALLATION: REQUIRED
Installations must meet all local electrical codes. Installations for the equipment should only be
performed by an Authorized Installer or other licensed contractor.
The wiring connections between a mounted WindTronics™ Wind Turbine and the Aurora
inverter are relatively simple. The following diagram details and species the wire gauges
required in this installation. All electrical connections must be done by a licensed electrician.
All electrical systems must be grounded in accordance to your National Electric Code and
local standards.
The following wiring diagrams are for single turbine installations of one WindTronics™ Wind
Turbine with one Aurora inverter. For twin wind turbine installations of two WindTronics™ Wind
Turbines with one Aurora inverter, see Appendix for wiring diagrams.
Figure 8 Aurora (United States model) Grid-Tie Options
Grid Connection
The following are the grid connection options for the United States model of the Aurora inverter. For other models, see the
Appendix. Please also refer to the Grid Connection section of the Aurora Owner’s Manual that came with the inverter.

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Figure 9 Single WindTronics™ Wind Turbine with Aurora Inverter System Connections
Junction Box

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Figure 11 Turbine Brake Wiring to Aurora Alarm Contacts
Figure 10 Turbine DC Output to Aurora
Electrical Wiring Diagrams - Grid-Tie Junction Box to Aurora Inverter

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Spare Parts
Part Description Part Number #/Turbine Supplier
Finned Dump Load Enclosure Assembly RDLASSY6500 1 WindTronics
Replacement Grid-Tie Aurora Inverter PV130OUTDUSW 1 WindTronics
Replacement WindTronics™ Wind Turbine RBTPS6500 1 WindTronics
Replacement Grid-Tie Junction Box RJBGT6500 1 WindTronics
Pole Top Mount MPT6500 1 WindTronics
QUADPOD Mount MQP6500 1 WindTronics
QUADPOD Mount - Ballast (for at roof) MQP6500B 1 WindTronics
QUADPOD Mount - Feet (for pitched roof) MQP6500F 4 WindTronics

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Figure 12 Aurora 230V/50Hz Grid-Tie Power Wiring Diagram
Appendix
Aurora 230V/50Hz Model - Grid-Tie Connection
The following is the grid connection wiring for the 230V/50Hz model of the Aurora inverter. For the United States
Grid-Tie Connection options, please see gure 9 on page 15. Please also refer to the Grid Connection section of
the Aurora Owner’s Manual that came with the inverter.
Twin Turbine Wiring diagrams:
Figure 13 Twin Turbine Brake Wiring to Aurora Alarm Contacts
Turbine #1
Turbine #2

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Figure 14 Twin Honeywell Wind Turbines with Aurora Inverter System Connections

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Figure 15 Twin WindTronics™ Wind Turbines - DC Output to Aurora Inverter