Southwest Windpower Whisper 100 Owner'S Manual Download

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SOUTHWEST WINDPOWER

Whisper 100 Owners Manual

Document #0211 REV C

10/05/05

Troubleshooting and Repair

Summary of Contents for Whisper 100

Page 1: ...63 Fax 928 779 1485 Email info windenergy com Web page http www windenergy com January 2005 Southwest Windpower Inc All Right Reserved WIND GENERATOR SERIAL NUMBER ________________ WHISPER WIND GENERATORS MODEL Whisper 100 For the NEW Whisper Controller Southwest Windpower Inc Renewable Energy Made Simple Solarlink GmbH www solarlink de ...

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Page 3: ...West Route 66 Flagstaff Arizona 86001 Phone 928 779 9463 Fax 928 779 1485 Email info windenergy com Web page http www windenergy com January 2005 Southwest Windpower Inc All Right Reserved WIND GENERATOR SERIAL NUMBER ________________ WHISPER WIND GENERATORS MODEL Whisper 100 For the NEW Whisper Controller Southwest Windpower Inc Renewable Energy Made Simple ...

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Page 5: ...isper Controller 21 14 Maintenance Monthly 26 15 Maintenance Annual 27 16 Troubleshooting and Repair 29 17 Mechanical Repair and Replacement 34 10 Optional Display Installation 18 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 ...

Page 6: ...ttery explosion or contact with the sulfuric acid in a lead acid battery 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...

Page 7: ...ly wire your own wind system Whisper Wind Generators include the Whisper Controller System Center and the user supplies the battery tower inverter and wiring During windless periods solar panels may supplement your usage of renewable energy Solar PV photovoltaic panels make electricity directly from sunlight Batteries store electricity so you have power during windless and sunless periods as well ...

Page 8: ...e Tower Insert Kit Tail Fin Overview of Wind Generator Simplified Whisper 100 Shown Below 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 Controller if ordered with a controller 1 100 amp Fuse 1 Introduction 5 ...

Page 9: ...aluminum wire multiply the distances in the table by 0 65 WHISPER Controller See wire size table below 10 Feet or 3 Meters Maxi mum Distance See the Whisper Controller installation section for complete wiring de tails Fuse Included Battery Bank Ground Lug VOLTS 12 24 30 36 48 COPPER WIRE SIZE AWG 12 xx xx xx 66 10 xx xx 53 106 8 xx 42 84 168 6 xx 66 133 266 4 26 103 207 414 3 42 165 330 660 2 52 2...

Page 10: ...tance to battery and the battery voltage determine the correct wire size Refer to wire size table pg 6 A self supporting tower occupies less ground area than a guyed tower but is more expensive A tilt up design permits easy installation and maintenance on the ground and eliminates the need for climbing The Whisper 100 is suitable for side of building mount ing on unoccupied buildings such as garag...

Page 11: ...h grease or corrosion protector available at auto parts store Install Whisper Controller and Inverter fuse if used at battery positive To minimize the possibility of EMI electromagnetic interference the line from the battery to the Whisper Controller should be less than 10 feet 3 meters 12 Volt Configuration Inverter Inverter Whisper Controller Whisper Controller 24 Volt Configuration Inverter Inv...

Page 12: ...age configuration The three brush wires are interchangeable and are not labeled The brush wires are easily identifiable as they are larger multi strand wires and stator wires are solid wire 8 awg compared to 20 awg Stator wires are numbered and color coded with a wire sleeve For example stator wire Red 3 has a red sleeve with the number 3 printed on it Wire Red has a red sleeve with no number The ...

Page 13: ...or each connection WHISPER 100 200 MULTI VOLTAGE WIRING 12V Red Wire Nuts BRUSH WIRE BRUSH WIRE BRUSH WIRE WHITE 1 WHITE RED 1 WHITE 3 WHITE 2 RED 3 BLACK 2 RED 2 BLACK 1 BLACK RED BLACK 3 24V Red Wire Nuts Yellow Wire Nuts BRUSH WIRE BRUSH WIRE BRUSH WIRE WHITE WHITE 2 WHITE 1 RED 2 BLACK 1 RED 3 RED 1 WHITE 3 RED BLACK 3 BLACK BLACK 2 48V Red Wire Nuts Yellow Wire Nuts BRUSH WIRE BRUSH WIRE BRUS...

Page 14: ...nce 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 5 Wind Turbine Electrical Tests PHASE TO PHASE TEST When any two wires are shorted together the generator rotor should turn lumpy as thoug...

Page 15: ...nd 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 mou...

Page 16: ...he LEDs and Diversion Switch to the top Vertical mounting is required to provide good heat convection for the resistor bank dump load Since the dump load side of the controller may get very hot do not mount the unit near anything flammable or heat sensitive Conduit knockouts on the bottom of the controller unit accommodate 0 75 1 25 and 1 5 nominal size conduit An earth ground connection terminal ...

Page 17: ... position and observe the red LED to turn off When connecting the battery try not to allow the connection to bounce causing the microprocessor to power up and then power down quickly This kind of quick on off cycle can cause the microprocessor to latch up If the microprocessor locks up and depress ing the Reset button does not correct the problem contact Southwest Windpower for instructions Import...

Page 18: ...re connected For further opera tional information refer to Whisper Controller Operation on page 22 Optional Anemometer Connection The Whisper Controller has been designed to accommodate a Model 40 anemometer manufactured by NRG Other equivalent anemometers may work compare manufacturers specifications A terminal block on the circuit board is the connection point for the two anemometer signal wires...

Page 19: ...otentiometer set points Refer to sections on Reset Switch Adjusting the System Voltage and Optional Display for additional information 9 Whisper Controller Printed Circuit Board Switches and Reset Button Printed Circuit Board Switch Settings Switches 1 and 2 System Voltage Select the correct system voltage by setting the position of Switches 1 and 2 according to the following table After changing ...

Page 20: ...entiometer Enable Default Setting OFF Switch 5 in the ON position enables reading the potentiometer voltage on the Optional Display in real time The reso lution limits of the display are 0 2 0 4 and 0 8 volts for 12 24 and 48 volt systems respectively With the Switch set to ON voltage regulation points may not be set using the Optional Display They must set using the potentiometer With the Switch ...

Page 21: ...able will have to be purchased Install the display in the desired location and connect the ethernet cable to the display unit Remove the electronics cover on the Whisper Controller If necessary knock out one of the sheet metal plugs in the Whis per Controller base unit and route the ethernet cable inside the unit Plug the ethernet cable into the jack in the lower right corner of the controller boa...

Page 22: ...5 Installation 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 11 Tail Installation 19 ...

Page 23: ...2 Nose Cone Insure that Item 8 blade strap is contacting the top portion of the blade as shown below Note 6 bolts are slightly longer than 4 bolts and must go in a specific location 4 Start by installing outboard hardware 4 Bolt M8 x 50 3 Flat Washer M8 x 24 and 7 Nylock Nut M8 Install Items 4 Bolt M8 x 50 and 5 Lock Washer M8 on innermost rotor bolt circle This inner bolt circle will be cov ered ...

Page 24: ...easurements of which the Controller is capable It can be mounted at the Controller or in a remote location or with two Displays both places From the Display instant and easy access is gained to voltage current power energy charge peak power and wind speed with optional anemometer 2 Normal Operation Whisper Controller The Whisper Controller provides all of the necessary functions and displays for s...

Page 25: ...ation Off voltage If the control ler senses battery voltage below the Regulation On Voltage for approximately 30 40 second will stop diverting power and start charging the battery again Before adjusting the regulation setpoint understand that turning up the regulation voltage will not increase the turbine s output voltage or current This setpoint adjusts the regulation on voltage for battery charg...

Page 26: ...dis play lid and turn the potentiometer counter clockwise to increase the darkness of the LCD Display Operation Overview The basic navigational structure of the display pages are rings with the structure shown in the figure on page 20 Each of the menu pages in this main ring structure is an access point for various controller and display settings The A and B Function buttons scroll between the men...

Page 27: ...urn to reset menu 3 History Mph pow 00 0a 00 0a 00 0p 00 0p B go to reset menu A reset readings Reset Menu Reset Page A RESET B CANCEL B return to reset menu B Ring Mode On A batteries charging A OFF_REM B SKIP B go to regulation set menu Mode Off A batteries diverted 4 Mode A ON_REM B SKIP B go to regulation set menu REGULATION SET A change regulation point 5 Regulation Set A CHANGE B SKIP B retu...

Page 28: ...11 REV C 10 05 05 25 Normal Operation Whisper Controller Energy A History Main Display Mode Regulation Regulation On Regulation Off A A B B B A A A Reset B B Reset B B Charge On Off A A B B B B Increase Set Point Increase Set Point Display Menu Ring Structure ...

Page 29: ...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 DIVERSION CONTROL This checks electrical wiring DIVERT THE LOAD BY SETTING THE DIVERSION SWITCH TO STOP IN A MODERATE WIND CHARGING BUT NOT FURLING No unusual difficulty or noise should be experienced in ...

Page 30: ...tness of all tower mounting nuts and bolts and propeller mounting bolts b Check all bearings Just perceptible play is acceptable c Clean the propeller with a mild detergent solution 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 Do not tighten pivot pin nut 27 Maintenance 15 Maintenance Annual ...

Page 31: ... Manual Document 0211 REV C SOUTHWEST WINDPOWER 10 05 05 2828 Maintenance Log Observe Monthly and Annual Inspection Requirements Record ALL maintenance and repair work Date Problem Observation Action Taken 28 Maintenance ...

Page 32: ...ical Refer to the two illustrations below and then proceed to the appropriate section Propeller turns slowly Electrical Problem Proceed to ELECTRICAL DIAGNOSIS PAGE 31 to diagnose the type of electrical problem the turbine is experi encing Propeller does not turn Mechanical Problem Or turns slowly Proceed directly to Table Symptoms of Mechanical Problems 29 15 Troubleshooting and Repair ...

Page 33: ...ent i Contact factory or distributor to re place broken or damaged blade i See blade installation i Turn blades over Leading edge ad vances clockwise from upwind view i Inspect for damage Repair as required Retighten mounting hardware use Loctite or equivalent thread locking compound i Contact factory to replace bearings i Contact factory to replace shaft a Generator loose in tower Loose rotor mag...

Page 34: ...ge 32 OR 3 Wind generator is running but may have an electrical problem As directed below use a voltmeter to read the voltage across the leads and see the voltmeter test section below as a guide to possible problems Voltmeter Test 1 1 Voltage increases and decreases slowly relative to the wind speed across all combinations of paired wires Every thing ok 2 No voltage across two wires One wire from ...

Page 35: ...s open or wire is disconnected at diode terminal a Battery voltage over 50 high b 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 Controller b One open or disconnected diode c One slip ring or brush not making good connection a Battery voltage low or a dead battery b Incorrect turbine wiring i Turn DIVERSION ...

Page 36: ...ntact distributor or factory i Contact distributor or factory i Adjust setting Check battery with voltmeter i Contact distributor or factory a Brake Switch ON b Shorted diode c Dead or disconnected battery d Short in wiring to turbine a Battery volts below setting b Circuit Board bad a Dumpload burned out or discon nected or wired wrong b Bad connection from Circuit Board to power block a Wrong vo...

Page 37: ...heets provide a complete exploded view and parts list of the Whisper 100 It is included as a guide for replacement parts and troubleshooting It is however recommended that any internal repair of the turbine be performed by the factory or your authorized distributor Any unauthorized attempt to repair the turbine leading to damage is not covered by warranty 34 Troubleshooting and Repair 16 Mechanica...

Page 38: ...HDWA 200 07 M6 SPLIT LOCK WASHER 3 24 3 CMBP 1226 01 3 CMBP 1226 03 LOWER CASTING 1 25 3 CMBP 1228 BRUSH CARD SONIC WELDED 1 26 3 CMBP 1055 BRUSH CARD COVER 1 27 3 CMBP 1109 BRUSH CARD GASKET 2 28 HDBT 2001 027 SCREW M5 X 60 4 29 3 CAOT 1156 RUBBER GROMMET 1 30 3 CAOT 1177 CONVOLUTE TUBING 1 31 3 CAOT 1160 CABLE CLAMP 1 32 3 CMBP 1177 1 4 NEOPRENE BUMPER 2 33 3 HDWA 904 BRONZE WASHER 2 34 3 ELOT 1...

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Page 40: ...SOUTHWEST WINDPOWER Whisper 100 Owners Manual Document 0211 REV C 10 05 05 38 ...

Page 41: ...Whisper 100 Owners Manual Document 0211 REV C SOUTHWEST WINDPOWER 10 05 05 3838 39 ...

Page 42: ...SOUTHWEST WINDPOWER Whisper 100 Owners Manual Document 0211 REV C 10 05 05 40 ...

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