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The
orientation of the blades is important. If one or more of the
blades are installed backwards the wind turbine will not
function properly. Correct blade rotation is clockwise when
viewed from in front of the wind turbine looking toward the
tail. The blades are marked in an obvious way, if you are not
sure examine the blade root to ensure that the thick leading
edge of the blade is forward (toward the wind) and the thin
training edge of the blade is aft(toward the alternator).
Check the tip to tip measurements between blades, they should be
equal. After the blades have been accurately adjusted, tighten
each of the six inner lock nuts in sequence to a final torque to
12 Nm (9 ft lbs). Be careful not to disturb the radial
positioning of the blades. Do not tighten the apex nuts as they
will have to be removed to install the spinner in a later step,
but be sure they are inserted before torquing the innerbolts or
you may not be able to insert them later. |
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Mount the turbine on a bench and drop the
blades over the hub making sure that the metal torque key is
properly inserted in the locating slot in the drive shaft.
Rotate the blades to ensure that the blade assembly is properly
seated on the drive shaft.
Torque the drive shaft lock nut to 19 Nm (14 ft lbs).
When tightened properly, two to three complete shaft
threads should protrude past the drive shaft lock nut.
Spare torque key, nuts, bolts and washers are included in the
fixing kit in case you loose some. |
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To install the spinner, remove the three lock
nuts that were loosely threaded onto the bolts in the apex holes
of the triangular hub plate. Place the spinner over the three
bolts and secure with the M6 flat washer and M6 lock nut.
Gradually tighten the three nuts in sequence to a final torque
of less than 8 Nm (6 ft lbs). |
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The furling system of the ULTRA is preset to
assure proper operation of the furling mechanism. The springs
are coated with a natural sheep lanolin that should not be
handled or removed. Remove the white plastic shipping covers on
the lower stabilization bar and tighten the lock nuts on either
end. |
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| CONTROLLER |
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The ULTRA'S
all-in one control panel
combines
all the
necessary
power management, conversion and diversion load safety circuits
in one panel.
Simply mount the
controller on a wall,
preferably vertically in a well ventilated area, to support the
best cooling. Connect the turbine and batteries to their
terminal blocks on the Commander, the
phase wires to the blue terminals and POS NEG to the battery
terminals. Ensure the circuit breaker on the controller
is OFF before making the positive connection. Keep the battery
leads as short as practical to minimize power losses and use
wire sizes appropriate to the voltage and circuit breaker
selections. An electrician can help you with selecting that
right wire.
Prior to final installation and erection of
the ULTRA X900 Wind Turbine, the
other components of the system (controller, batteries,
diversion loads, inverters etc.) must be installed and
wired in accordance with the overall
system design and component manufacturer’s
guidance. As a minimum, the
ULTRA controller
must be installed to ensure that there
is a means of preventing the wind turbine from starting when
it is first erected. |
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| SITE SELECTION AND PREPARATION |
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The two primary requirements for optimum
performance are relatively high average windspeed and relatively
low wind turbulence. The power available in the wind is
proportionate to the speed of the wind cubed. Therefore a
comparatively small increase in average windspeed can make a
dramatic difference in power production.
If a site has high turbulence it will deliver less energy than a
site with relatively the same wind speed but lower turbulence. A
turbine located in a turbulent wind regime will also incur
higher levels of stress and fatigue.
When selecting a site for a wind turbine try and find the
highest point available with the smoothest uninterrupted wind
flow. Wind turbines mounted on taller towers encounter
less turbulence, harvest substantially more energy annually, and
require less maintenance than units that have harvested the same
energy values from turbulent flows. |
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The first step in installing this
kit is to locate the tower’s center or base pad location. From
the center, you will need to confirm that there is adequate
space, free from any obstacles, for the anchors that will be
located in four equidistant locations from this point. From
tower center measure 6.4 meters (21 feet) out to locate the
center of the forward (fore) anchor pad. It is also referred to
as the tow anchor because this pad will be used for the tow
cable that comes from the tower mast, up over the gin pole and
down through the anchor on its way to the tow vehicle or winch
prior to erection. The end of the gin pole will also drop down
to this point. This tow cable will become the forward guy
wire(s) after final erection.
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ANCHOR FOUNDATIONS
All excavated anchor holes must be at least 45cm (18 inches) in
diameter and a total of 76cm (30 inches) deep. If the holes are
not taken to at least this depth and width, it is very likely
that the anchors could be pulled from the ground in high wind
and result in catastrophic tower failure. |
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If the port and
starboard anchors are not level, you may need to raise the
concrete forms above the ground or recess them into the earth.
These drawings illustrate this method.
Please contact us for technical layout data if you are
installing on a heavily sloping site.
Always remember to allow at least two weeks for the concrete to
harden. |
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Never compromise on the amount of concrete
used to pour the anchors. Each anchor must weigh at least 700
lbs. In high wind sites such as with gusts up to 120 miles per
hour, the vertical lift on the anchor pad will exceed 550 lbs in
the vertical direction and 300 lbs in the horizontal direction.
These foundation details are intended as a guide only. Soil and
ground conditions vary from site to site, always seek
professional local advice for appropriate foundation
specifications |
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The mast base plate must be aligned with the
tow path. It is helpful to make a ply wood template of the
fixing positions so that the J bolts can be embedded in the
poured concrete base in the correct position. Remember that you
may need to allow a conduit for cable runs out of the base
plate. Remember to allow a provision for a lightning earthing
rod or similar protection at the mast base. |
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| TOWER ASSEMBLY |
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Using the compression couplings
provided with the ULTRA X900 tower fixing kit, layout the tower
sections on the ground in position, inline with the tow route.
Feed the electrical supply cable through each section of the
tower. Bolt the base plate to the central foundation, insert and
fix the lower section of tube. Join the second (or third if you
have selected a taller tower) tower section and add the
additional cable support clamp. Be sure that the top cable
attach point leaves sufficient clearance for the blades to turn.
With the assembled tower lying flat on the ground arrange the
two side cables so that they can be clamped in position.
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Attach the two side cables to the anchor points and leave the
tensioners loose. Attach the aft (rear) cable leaving about 50cm
slack. Using the rest of the cable make up the last (front)
cable and attach it to the tower. This cable will be the tow
cable. Before mounting the ULTRA turbine head carry out a test
raise of the tower.
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The wire rope clamp must be
mounted to the tension wire, not the short end! we recommend
that you use a one-inch distance between clamps.
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| RAISING THE TOWER |
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The gin pole is a
further section of tower pipe (not supplied with the kit) and
should be kept for lowering the tower at a later date for
servicing. It is advisable to cut a slot in the end of the gin
pole to secure the cables in position during lift.
Insert the gin pole in the tower kit tilt base and pass the
front cable through the slotted end. Secure the end to the tow
vehicle or winch. |
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Test raise the tower into a near
vertical position. Tension the horizontal (left and right hand)
cables to the final position so that they hold the tower
vertical in the side axis. Adjust the rear cable as required to
prevent the tower going past the vertical position. Prepare the
front cable to the required length for fixing to the front
anchor after the final lift. Lower the tower onto a suitable
stand to allow room to fix the turbine head.
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Make the electrical connections between the
turbine and the cable inserted into the tower tube. Carefully
fit the turbine assembly to the tower tube and tighten the
compression joint bolts.
Before raising the turbine connect the controller and batteries
and set the electromagnetic brake to ON. This will prevent the
ULTRA X900 from turning until you are ready. |
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 ULTRA
X900 wind turbines output in 3 phase, connect the turbine power
supply to the connections 'leg' 1,2 and 3. It does not matter
which of the wires goes to which of the three input terminals.
Connect the battery bank to the positive and negative terminals
on the battery charging block. |
When ready, proceed with the final tower lift. While you are
installing the turbine and power components, make sure the
ginpole is either removed or fully secured. If left unattended,
the gin pole could start falling sideways, and may seriously
damage the mast base.
The towline must now be carefully disconnected from the tow
vehicle or the winch. Keeping plenty of tension on the cable,
bring it back to the front anchor and fix it to the anchor. DO
NOT CUT THE TOW CABLE. The full length of wire will be needed in
the future for tower lowering and lifting. The cable can be
coiled up at the base of the for anchor or strapped to the guy
wire.
Check and adjust the tensioners of each guy cable to finally
position the tower in the vertical position. |
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