installation manual 6ac

Conergy EasyWind 6 AC

Installation manual

Table of Contents

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Conergy EasyWind 6 AC Installation manual 1

Table of Contents

1 Introduction 31.1 Short description 3

1.2 Safety systems 3

1.3 About this manual 4

1.4 Product liability 4

1.5 Standards and technical directives 4

1.6 Responsibilities of the operator 4

2 Safety 52.1 General safety instructions 5

2.2 Instructions on electrical safety 5

2.3 Warning symbols 5

3 System overview 63.1 Mobile steel foundation 6

3.2 Concrete foundation 6

3.3 Components and assembly elements 7

3.4 Interfaces and connections 8

3.5 System variants 8

4 Installation 94.1 Preparation for installation 9

4.2 Sequence of assembly 9

4.3 Foundations 10

4.4 Assembling the steel foundation 11

4.5 Shackling the turnbuckles 11

4.6 Pre-assembling the lower tower segment 11

4.7 Securing the lower tower segment 12

4.8 Completing the tower 12

4.9 Attaching the stay cables 12

4.10 Attaching the lateral braces 13

4.11 Attaching the wire cable clamp 13

4.12 Attaching the jin pole to the foundation 14

4.13 Completing the jin pole 14

4.14 Completing and attaching the cable winch 14

4.15 Correctly threading the lifting cable 15

4.16 Erecting and securing the jin pole 16

4.17 Connecting the upper stay cable 17

4.18 Trial tower lifting 17

4.19 Readjusting the stay cables 17

4.20 Adjusting and securing the stay cables 18

4.21 Lowering and securing the tower 18

4.22 Inserting the cable into the tower 18

4.23 Attaching the nacelle and securing the cable 19

4.24 Preparing the machine unit 19

4.25 Preparing the nacelle for installation 19

4.26 Attaching the machine unit to the nacelle 20

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4.27 Installing the brake activation module 20

4.28 Attaching the wind vane 21

4.29 Attaching the adjustment axis 21

4.30 Attaching the rotor blades 21

4.31 Fitting the cover 22

4.32 Attaching the stay poles 22

4.33 Installing the spinner 23

4.34 Lifting and securing the tower 23

5 Commissioning 245.1 Installing the AC box 24

5.2 Attaching the earth connection 24

5.3 Switching on 25

5.4 System messages 25

6 Maintenance 276.1 Safety check 27

6.2 Maintenance intervals 27

6.3 Maintenance work 27

7 Appendix 287.1 Check list: Safe installation 28

7.2 Check list: electrical safety 28

7.3 High voltage 28

7.4 Specifications 29

7.5 Included in delivery 30

7.6 Circuit diagram 32

8 Index 33

1 Introduction

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1 Introduction

1.1 Short description

The Conergy EasyWind 6 AC is a robust, durable wind power system with optimised energy yield. With an out-put of 6 kW it generates alternating current from kinetic wind energy. The AC box either supplies the operator's load current circuit or feeds the generated alternating current into the public grid.

If the Conergy EasyWind 6 AC wind power system is integrated into a Conergy ISA series 3-phase hybrid sys-tem with a standalone inverter, the energy generated can be used to supply the connected consumers directly or to charge a battery in the case of insufficient solar irradi-ation. In this case, to charge a battery using alternating current, a Conergy ISA series standalone inverter auto-matically switches to reverse charging mode (rectifier function).

Optimised energy production

The extremely changeable nature of the wind speed is compensated for using a patented and tested passive rotor blade adjustment mechanism (pitch control) for wind speeds exceeding 10 m/s. This technology allows the speed, and thus the energy generated, to be almost constantly maintained above the nominal capacity (> 6 kW) in all wind speeds.

Regulated speed switching

The dual-speed generator works in two speed ranges and determines the optimum speed fully automatically according to the wind conditions. Even at wind speeds as low as 3.5 m/s, the rotor starts up and generates elec-trical energy at speed 1. The generator upholds power

production at speed 1, as long as a wind speed of 7 m/s is not exceeded for longer than 20 seconds. If the wind speed exceeds 7 m/s, speed 1 is disconnected from the grid after 20 seconds. The speed of the rotor accelerates freely and at 126 rpm, speed 2 switches on.

Under certain conditions, the wind power system switches directly to speed 2 after startup. This occurs:

| when sudden gusts follow a period of calm or

| when the system is switched on in high winds.

If the speed falls below the threshold of 126 rpm for more than 20 seconds, the Conergy EasyWind 6 AC switches back to speed 1.

Automatic shutdown

If the wind speed is no longer sufficient for power pro-duction, the wind power system will be disconnected from the grid following a delay of 20 seconds. Discon-nection prevents the generator from using the mains power to act as a motor and drive the rotor, thus con-suming energy.

Mobile lifting device

A lifting device with a jin pole and a cable winch is sup-plied to lift the tower. After lifting is complete, the lifting device can be dismantled and used for other systems.

1.2 Safety systems

Rotor blade adjustment

A passive, self-regulating rotor blade adjustment mech-

anism (pitch control) limits output to the gearbox and asynchronous generator in normal mode. This means that, even during a storm, the system is never allowed to overload, nor the generator to overheat.

Passive pitch control fulfils the function of a torque lim-iter. When the wind speed increases, it independently turns the rotor blades into a "flag position", offering a smaller attack surface to the wind. The rotor speed is maintained almost constantly below the limit of 178 rpm. This means the wind power system cannot be damaged.

Brake system

The Conergy EasyWind 6 AC wind power system comes equipped with a compression-spring-loaded disc brake. As an independent safety system, the disc brake is not active in the course of normal operation.

While a supply voltage is present at the generator con-troller, the brake is held open by a retaining electromag-net. In unusual operating conditions, the power supply is interrupted, and the brake falls shut immediately.

Brake activation is caused by the following conditions:

| Manual disconnection of the generator from the grid

| Overloading of the asynchronous generator

| Unacceptable levels of vibration in the tower, caused by:

| Imbalance in the rotor due to ice formation| Severe, hurricane-strength gusts with sudden

changes in wind direction

| Irregularities in the public power grid, power fluctua-tions or disconnection by the energy provider

1 Introduction

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Following a shutdown caused by tower vibration, the system starts up again after a delay of 15 minutes. This delay is doubled after each subsequent vibration-induced shutdown.

If the generator controller is disconnected from the grid, system operation only recommences when the power supply returns and the wind power system is switched on.

1.3 About this manual

Subject of this manual

This manual is concerned with the assembly, lifting and electrical installation of the Conergy EasyWind 6 AC wind power system.

User group

The manual is intended for a group of people with tech-nical skills and basic mechanical knowledge to be briefed by the owner.

The electrical installation instructions are written for an audience with specialist knowledge of electrical engi-neering (qualified electrical specialists).

Signposts

The following aids will help with orientation when using this manual:

Headers

The headers display the heading of the current chapter.

Footers

The footers display the product name, the name of the document and the page number.

Text markups

Headings appear in the text in bold, brand and company names (except Conergy) in italics, item numbers in fig-ures are displayed in a text box in the format (1), (2), etc.

Symbols

1.4 Product liability

This technical documentation is part of the product. Conergy shall not be held liable for damages arising from a failure to observe and follow the operating manual, particularly the safety instructions, or from any improper use of the product.

1.5 Standards and technical directives

The product described complies with regulations con-tained in the following European directives:

| 73/23/EEC Council Directive on the approximation of the laws of Member States relating to electrical equipment for use within certain voltage limits (amended by Council Directive 91/263/EEC).

| 89/336/EEC Council Directive on the approximation of the laws of Member States relating to electromag-netic compatibility (amended by Council Directive 91/263/EEC and 93/68/EEC).

Compliance with regulations contained in these direc-tives is proven by complete adherence to the following standards:

| EN 50081-1/EN 60034-1/EN 60034-5/EN 60034-6/EN 60204-1/EN 50082-2

1.6 Responsibilities of the operator

Modifications should only be made to Conergy AG sys-tems by authorised personnel.

The system operator has the following safety-related responsibilities:

| To perform regular maintenance work in accordance with the maintenance plan (s. chapter 6, page 27).

| To make sure that the electrical installation is only carried out by individuals with specialist knowledge of electrical engineering (qualified electrical special-ists).

| To ensure that the designated persons are capable of the work assigned to them and can recognise any possible risks.

| To make sure that the installation manual is available during installation. The installation manual is a part of the product.

| To ensure that the installation manual, and in partic-ular the safety instructions, are read and understood by the relevant personnel before installation.

| Before installation, make sure that the correct foun-dation type is used for the subsoil properties and static requirements.

| To ensure the durability of the fitted connections, the foundations and the fixing of the tower to the foun-dations.

| To make sure that suitable lifting gears and ladders are used for installation; do not use ladders leaned against the structure.

Denotes background and additional informa-tion for operational procedures

Tips & tricks

Facilitates operational procedures and individ-ual steps, contributing to the success of the installation

2 Safety

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2 Safety

2.1 General safety instructions

The following general safety instructions and warning symbols form an essential part of this manual and are of fundamental importance when handling this product.

In addition, follow the following general safety instruc-tions:

| Do not remove or disable any safety devices.

| Wear work clothes in accordance with the regula-tions of the Employer's Liability Insurance Associa-tion and comply with the relevant safety regulations.

| The presence of a second party who can provide help in the event of an accident is obligatory during the entire sequence of assembly.

| No-one should stand underneath the tower while it is being raised or lowered.

| Always secure the crank handle on the cable winch with the locking bolt before releasing it.

| You must immediately replace any warning symbols fitted on the system which have become illegible. If necessary, contact Conergy's service hotline.

2.2 Instructions on electrical safety

Before starting any work on electrical systems, the fol-

lowing safety rules in accordance with VDE 0100 must always be followed:

| Disconnect from the mains

| Secure against being switched back on

| Make sure power is disconnected

| Earth and short-circuit

| Cover nearby live parts.

When working on any live device components or wires, a second person must always be present. In the event of an unforeseen electrical accident, that person must be able to switch off the power supply and provide aid.

In addition, observe the following general safety instruc-tions:

| Electrical work on the device should only be carried out by authorised and appropriately qualified per-sonnel (qualified electrical specialists).

| Never open the AC box during operation.

| Observe the warning symbols on the device and the safety instructions in this manual.

2.3 Warning symbols

The warning symbols used in this installation manual indicate information important for safety. They consist of the following:

| Warning symbol

| Indicator word showing the level of risk

| Details of the nature and source of the risk

| Information on the possible consequences of disre-garding the risk

| Instructions on what to do to avert the risk and pre-vent injuries or damage to property

The indicator word in the warning symbols denotes one of the following risk levels:Extremely heavy

The foundation beam for the steel foundation and the tower segments can cause considera-ble injury if transported incorrectly.

| Observe the relevant regulations from the Employer's Liability Insurance Association.

Denotes an extraordinarily high danger level. Not observing the notice will lead to serious injury or death.

WARNING

Denotes a potentially dangerous situation. Not observing this note may lead to serious or moderate injury and damage to property.

CAUTION

Denotes a potential danger, which may causedamage to property.

3 System overview

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3 System overview

The system overview on the following pages shows all the components included in the delivery of a mobile or permanently installed wind power system.Conergy EasyWind 6 AC

(1) Steel foundation, adjustable(1a) Cable winch beam(1b) Foundation beam(1c) Foot of the tower*(1d) Stay anchor*(1e) Foundation anchor*(2) Cable winch(3) Jin pole(4) Tower segments* Anchor for a concrete foundation

3.1 Mobile steel foundation

The transportable cruciform foundation, made from gal-vanised steel, is completed by large square-cut steel profiles, which are inserted into the sides of the cruci-form foundation. The weight of the completed steel cru-ciform foundation gives the wind power system tower enough weight to remain stable in all wind conditions. Mobile foundations are only used when the installation location is not final.

3.2 Concrete foundation

With its cast-in foundation anchor, a concrete cruciform foundation is used for continuous operation at the final installation location. All systems with a 19 m tower need a concrete foundation (see Chapter 4.3, page 10).

(1)

(2)

(3)

(4)

(1c)

(1d)

(1e)

(1a)

(1b)

3 System overview

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3.3 Components and assembly elements

The figures to the right provide an overview of all the important components of the Conergy EasyWind 6 AC wind power system. Reference will be made in the course of the installation manual (Chapter 4) to the item numbers and descriptions introduced here.

(1) Cruciform foundation

(1a) Cable winch beam

(1b) Foundation beam

(Z5) Bolt with split pins and rubber tube

(2) Cable winch

(2a) Locking pin

(2b) Pulley

(3) Jin pole

(3a) Connection piece

(3c) Turnbuckle

(4a) Lower tower segment

(4b) Lateral braces

(4c) Thimble connection

(5) Brake activation module

(7) Stay cables

(9a) Generator

(10) Hub

(12) Rotor blade

(14) Adjustment axis(16) Tower cable(17) AC box

(3c)

(3)

(4c)

(4b)

(4a)

(2)

(1)(1a)

(1b)

(Z5)

(12)

(3a)

(3c)

(2)

(10)(5)

(9a)

(14)

(2a)

(8)

(3)

(2b)

(17)

(7)

(16)

3 System overview

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(6) Nacelle(6a) Wind vane(8) Ventilating screen(9) Machine unit with machine carrier unit(11) Cover(12) Rotor blades(13) Stay poles(14) Adjustment axis(15) Spinner

3.4 Interfaces and connections

The three-phase AC connection is integrated in the sep-arate AC box. The AC box is affixed to the tower and connected to the generator connection cable which runs inside the tower and to the load connector or the utility's generator junction box. The instructions on electrical installation can be found in (s. chapter 5, page 24).

3.5 System variants

Conergy Small Wind Turbines are available in the follow-ing variants:

| System with a 19 m tower (standard, only with concrete foundation)

| System with a 13 m tower (concrete or mobile steel foundation)

| System with a 7 m tower (on-roof construction, steel foundation only)

(9)

(13)

(12)

(14)

(11)

(15)

(8)

(6)

)

(6a)

(11) (12)

(12)

(12)

(13)

(13)

(13)

4 Installation

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4 Installation

4.1 Preparation for installation

Choosing a location

The Conergy EasyWind 6 AC wind power system is designed to be set up on a dry, level surface. In excep-tional cases, the system can also be installed on hill-sides with a gradient (slope) of up to 10 % without the need for additional stabilisation. The space requirement for the installation is obtained from the height of the tower:

| For a 7 m tower - 10.6 × 15.3 m| For a 13 m tower - 10.6 × 21.3 m| For a 19 m tower - 15.2 × 29.6 m

On completion, the system should, if at all possible, be significantly taller than all other objects in the vicinity. When raising and lowering the tower, there must be no obstructions at the same height as the stay cables.

Tools

The following tools are required for assembly:

| Range of wrench sockets: 10, 13, 17, 19, 24. 30| Hexagon wrench sockets: 4, 5, 6| 2 torque wrenches: 10 – 110 Nm| Ratchet wrench with universal joint and extension| Range of open-end spanners: 10, 13, 17, 19, 24. 30| Allen keys: 3, 4, 5, 6, | Range of Phillips screwdrivers| Combination pliers| Rubber mallet | Spirit gauge| 10 m measuring tape| Grease| Jacking equipment| Stepladder: Minimum height 1.80 m

Assembly aids

Assembly of the Conergy EasyWind 6 AC must be per-formed by at least two people. If no lifting gear is availa-ble, assembly must be carried out by four people. We recommend using the following assembly aids:

| Wooden base or pallet: 800 × 500 × 500 mm

| Square wooden blocks*

If the wind power system is to be installed on a steel foundation, square wooden blocks (Z1) with a side dimension of 16 cm are required if the ground is soft.

| Assembly support(Z2)*

* included in delivery

To securely support the tower during assembly, you will need an assembly support (Z2) with a loading capacity of at least 500 kp.

| Installation aid for the generator

The installation aid (Z3) for the machine unit con-sists of a square steel profile, which is screwed onto the rotor hub. It facilitates the lifting of the pre-assembled machine unit.

Fig. 4-1: Assembly aids

4.2 Sequence of assembly

All assembly steps must be carried out in the correct order and the instructions on attaching and adjusting must be observed without fail. Installation is divided into five phases:

1. Build or assemble foundation

2. Assemble tower and erect for trial purposes

3. Complete and install cable, nacelle and machine unit

4. Install wind vane, rotor blades, adjustment axes and stay poles

5. Raise and secure the wind power system

(Z3)(Z2)

(Z1)

4 Installation

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4.3 Foundations

Construct concrete foundation

Concrete foundation checklist

Check the accuracy, dimensioning and completeness of the concrete foundation according to the following checklist:

| Cable winch anchor (A) with jin pole and fixing bit cast in and positioned

| Align foundation anchors (B), (D) and foot of tower (E)

| Right-angled position maintained in relation to the jin pole (3)

| Space requirement in the direction of tilt considered (approx. 30 m)

| The distance between the lower holes of the founda-tion anchor (B), (C) and (D) and cable winch anchor (A) and the upper edge of the foundation is 25 mm

| On hillside sites, foundation anchors (B), (E) and (D) are aligned parallel to the hillside and the upper edge of the foundation is positioned level: Point (A) should be lower down, facing the valley, point (C) should be higher up, facing the hill top

| Concrete quality B25, steel reinforcement according to reinforcement plan 05.02.4.01K (see appendix)

These instructions assume that a concrete foundation has already been prepared at the installation location. The adjacent diagrams should be used for project planning, verifica-tion of the completeness and dimensional accuracy of the foundation and to determine the amount of space required for installation. Detailed information and additional construc-tion diagrams and plans for building a concrete foundation can be found in the appendix of this installation manual.

(A)

(B)

(C)

(D)

(E)

(A) (E)

(3)

29,6

m

12,5 m

4 Installation 4.4 Assembling the steel foundation

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4.4 Assembling the steel foundation

1. Position a wooden block (Z1) at the intended inter-sect point of the cruciform foundation (1).

2. Centre the steel cruciform foundation (1) on the wooden block (Z1) using suitable lifting gear. Note the lowering direction of the tower (opposite to that of the notch (1c))

3. Insert the cable winch beam (1a) into the side of the cruciform foundation (1), pointing towards the notch (1c).

4. Insert the three remaining foundation beams (1b) into the cruciform foundation (1) up to the stop.

5. Place a prepared wooden block under the end of each foundation beam (1b) and under the cable winch beam (1a) (Z1) and centrally align.

6. Lift the cruciform foundation (1c) using the jacking equipment and remove the middle wooden block (Z1).

4.5 Shackling the turnbuckles

1. For the 13 m tower, attach three short turnbuckles (1d) to the middle hole in each of the three founda-tion anchors (1e) using shackles, and use M 20 x 60 mm screws to secure them.

Install turnbuckles only on the foundation beams, not on the cable winch beam.

2. Loosen the turnbuckles(1d) by a third.do not insert the split pins in the turnbuckles yet.

3. Insert a split pin into the shackle and bend it approx. 30°.

4.6 Pre-assembling the lower tower segment

1. Position the lower tower segment (4a) on the foun-dation beam opposite the cable winch beam (1a).

2. Place suitable wooden blocks between the tower and the foundation beam.

3. Insert the rubber hose (Z4) in the lateral pipe at the foot of the tower.

The wooden blocks are intended for use in soft ground. Roof installation requires massive anchoring points at the ends

being prepared

(1)

(1a)

160 mm

(Z1)

(1b)

(1c)

For the 19 m tower, additional turnbuckles must be attached to the lower holes of the foundation anchor in accordance with steps 1 and 2.

At each turnbuckle, the upper eye screw must be equipped with a pre-assembled thimble (3d).

(1d)

(1e)

(3d)

Note the position of the opening (4e) on the lower tower segment. The electric cable will be fed from here at a later stage. In addition, the switching unit (AC box) is attached at this loca-tion.

If possible, the opening (4e) should be located on the side of the tower facing away from the weather (east).

(1a)

(4e)

(Z4)

(4a)

4 Installation 4.7 Securing the lower tower segment

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4.7 Securing the lower tower segment

1. Slide the lower tower segment (4a) to the centre of the cruciform foundation (1) until the hole on the foot of the tower is located directly over the opening for the pin (Z5) on the cruciform foundation.

2. Align the holes and the rubber hose.

3. Insert the pin (Z5).

4. Align the pin symmetrically so that it protrudes prac-tically the same distance on both sides.

5. Insert two split pins (Z6) into the bolts from above and bend to an angle of at least 30°.

4.8 Completing the tower

1. Slide the middle tower segment (for a 19 m tower) or the upper tower segment (for a 13 m tower) (4c) into the lower tower segment, so that the prepared holes line up.

2. Screw 8 (or 12) hexagonal-headed bolts (M12 x 16 mm) into the face of the tower and tighten to a torque of 35 Nm.

3. Raise the top of the tower to a height of approx. 1.20 m using the adjustable support (Z2) (s. chapter , page 9).

4.9 Attaching the stay cables

1. Shackle three long stay cables (19 m tower) to the lower and both side thimble connections (4d) using a shackle (4f) and screw.

2. For a 19 m tower - also shackle a short stay cable to each thimble connection on the middle tower seg-ment.

3. Secure each shackle with a split pin.

4. After shackling, unravel each stay cable in the direc-tion of the corresponding foundation anchor.

CAUTION

Damage to property by knocking in the pin

Do not, under any circumstances, use force when inserting the pin. It should be possible to insert the pin without applying any particular force.

| Grease the bolts.

(Z5)

(1)

(4a)

(Z6)

(Z6)

(4c)

Leave the upper thimble connection (4g) free. This is where the stay cable from the jin pole connection piece is attached after the jin pole has been erected.

(4d)

(4f)

(4g)

4 Installation 4.10 Attaching the lateral braces

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4.10 Attaching the lateral braces

1. Attach all four lateral braces (4b) to the ring using Allen bolts. Insert the bolts from above.

2. Align the lateral braces (4b) at right angles to each other and tighten to a torque of 46 Nm.

4.11 Attaching the wire cable clamp

1. Route each of the three long stay cables, which have been shackled to the upper tower segment, via the associated lateral brace(4b) and attach a wire cable clamp (Z7) to each on the lateral brace above the cable,

2. Pretension the upper cable section of each stay cable by hand and secure the wire cable clamp on the lateral brace with self-locking nuts (9 Nm).

3. For a 13 m tower: thread three stay cables through the eyes (1d) on the turnbuckles attached to the foundation anchors.

4. For a 19 m tower: Thread six stay cables (3+3) through the eyes (1d) on the turnbuckles attached to the foundation anchors.

5. Double up each of the two opposite lying stay cables through the eye (1d), pretension slightly and secure each with two wire cable clamps (Z7).

6. Measure the doubled-up length of the attached stay cables and use on the 3rd doubled-up cable (13 m tower) and on the 6th doubled-up cable (19 n tower)– again attach with two wire cable clamps (9 Nm).

7. Secure each of the doubled-up wire cables to the eye screws with four wire cable clamps (Z7) (9 Nm).

The fourth lateral brace will guide and hold the stay cable which is attached to the jin pole con-nection piece (3a) and connected to the tower with the upper thimble connection.

The wire cable clamp is only connected to the fourth lateral brace when the jin pole is erected and the fourth stay cable is shackled to the upper thimble connection (see Chapter 4.17, page 17).

(4b)

WARNING

Incorrect wire cable clamp usage

If the wire cable clamps on the doubled-up stay cables are not fitted in the right location, this may lead to damage to property, as the cable will be weakened.

| Always fit the wide cast plate to the loaded cable section, then immediately attach a wire cable clamp.

(Z7)

When threading the cables, ensure that they are located in their respective thimbles.

The first wire cable clamp (Z7) must be attached as close as possible to the eye.

(Z7)

(1d)

4 Installation 4.12 Attaching the jin pole to the foundation

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4.12 Attaching the jin pole to the foundation

1. Attach the jin pole (3) to the bolts on the cruciform foundation using the fork at the end.

2. Screw the retaining plate (3d) on to the fork.

3. Insert two split pins (Z6) into the two holes in the bolt.

4. Support the jin pole at the other end, so that the tip hangs approx. 70 cm above the cable winch founda-tion anchor.

4.13 Completing the jin pole

1. Attach the connection piece on the upper hole of the jin pole to the system with a prefitted screw.

2. Loosen the turnbuckle (3c) by a third.

3. Temporarily secure the turnbuckle (3c) with two split pins.

4. Thread the stay cable through the free eye (1d) on the turnbuckle (3c) and secure with five (!) wire cable clamps at the doubled-up length of the other stay cables plus 0.7 m.

4.14 Completing and attaching the cable winch

1. Attach the pulley (2b) to the cable winch foundation anchor (1e) with a screw.

2. Attach the cable winch (2) to the cable winch foun-dation anchor (1e) with a screw.

(3)

(3d)

(Z6)

There are one or two prefitted turnbuckles on the upper hole(Z9) of the connection piece (3a) depending on the height of the tower. All turn-buckles are pre-assembled with thimbles (3d).

Screw in the screw for connecting the connec-tion piece and jin pole to the system – do not tighten.

(Z8)(3a)

(1d)

(3c)

(3d)

(Z9)

WARNING

Cable winch prefitted incorrectly.

If the plate(2c) on the cable winch is not fitted correctly, there may be serious damage to property and personal injury when the tower is lifted.

| Secure the plate (2c) to the cable winch so that the fork (2d) forms an angle of approx. 170°, which opens in the direction of the tower (see figure)

The screw (2a) can be pulled in and out and serves as a locking pin for the cable winch crank handle.

We recommend that you dismantle the cable winch after the installation is complete and to store it in a dry place.

(2)

(2c)

(2d)

(2a)

(1e) (2b)

4 Installation 4.14 Completing and attaching the cable winch

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4.15 Correctly threading the lifting cable

1. Lead the lifting cable attached to the connection piece towards the pulley (2b) on the cable winch foundation anchor (1e), pass it under the pulley in the direction of the tower and lead it up and around the pulley (3b) on the jin pole connection piece (3a).

2. Lead the cable from the pulley on the connection piece back to the cable winch (2) and thread it under the cable drum inside.

3. Slide the sharpened cable end into the location hole on the cable drum and carefully secure with Allen set screws.

4. On the floor, lay out the remaining loops of cable straight, along the length of the jin pole.

(3b)

(2)

(2b)

(1e)

(3a)

4 Installation 4.14 Completing and attaching the cable winch

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4.16 Erecting and securing the jin pole

1. Pull the free cable end of the stay cable attached to the jin pole towards the tower; this will raise the jin pole.

2. Raise the jin pole all the way up by pulling on the stay cable.

3. Shackle the pre-assembled stay cable eye to the upper thimble connection (4g) using the thimble.

4. Secure the shackle with a self-locking nut or with a split pin.

WARNING

Lifting cable may jump off the pulley

| Ensure when lifting the jin pole that the lift-ing cable does not jump off the pulley.

(4g)

4 Installation 4.19 Readjusting the stay cables

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4.17 Connecting the upper stay cable

1. Attach the wire cable clamp and the stay cable to the upper lateral brace (4h).

2. Loosely attach the wire cable clamp to the upper lat-eral brace (4h) using self-locking nuts (M10).

3. Pretension the upper cable section and tighten the self-locking nuts on the upper wire cable clamps (4h) (to a torque of 9 Nm).

4.18 Trial tower lifting

1. Slowly lift the tower using the cable winch

4.19 Readjusting the stay cables

1. Fully lower the tower again and properly support it at approx. 1 m.

2. Undo the cable clamps (Z7) on the doubled-up stay cable.

3. Slowly slide the cable back through the thimble, so that the supporting length increases and the cable is detensioned.

4. Retighten all cable clamps.

5. If necessary, repeat steps 1 to 4 for the other stay cables.

6. Lift tower.

(4h)

WARNING

Unsecured anchoring points

Before lifting the tower for the first time, make sure that

| all screws and shackles are correctly seated and tightened and

| the extended turnbuckles are secured with split pins as a precautionary measure,

| all cable clamps are tightened to a torque of 9 Nm.

Cable winch crank handle not secured

In the event that you need to interrupt the tower lifting procedure, always firmly hold the crank handle, until you have engaged the locking pin (2a) with your other hand and slowly turned the crank handle up to the stop at the locking pin (2a).

If, during lifting, excessive tension builds up on the side stay cables (i.e. a cable is too short, hindering lifting), the tower must be fully low-ered again.

In the event of excess tension occurring on one or more stay cables, proceed as follows:

(Z7)

4 Installation 4.20 Adjusting and securing the stay cables

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4.20 Adjusting and securing the stay cables

1. Attach the jin pole connection piece (3a) to the cable winch anchor (1e).

2. Check the vertical orientation of the tower with a spirit gauge in two directions.

3. Adjust the cable tension on all long and short stay cables using the turnbuckles (3c). At the same time, ensure that the opposite lying stay cables are evenly adjusted

4. Set the stay cable into a self-oscillating motion and count the number of self-oscillations in a 10 second period. Divide the result by 10.

5. Secure the turnbuckles with split pins.

4.21 Lowering and securing the tower

1. Undo the connection piece (3a) on the cable winch anchor (1e).

2. Pretension the opposite stay cable in the lowering direction and slowly lower the tower using the cable winch (2) until the cable on the lifting device is well tensioned.

3. Secure the tower at a height of approx. 1 m using a support (Z9) ;

The lifting cable must remain at its initial tension even after the tower has been supported. At least two revolu-tions of the cable should remain on the cable winch.

4.22 Inserting the cable into the tower

1. Insert the pre-assembled cable (16) into the opening in the lower tower segment – with the end covered by the plastic plug (16a) first.

2. Slide the cable through until it comes within reach from the end of the upper tower segment – no fur-ther.

With the 19 m tower, first align the lower tower segment with a spirit gauge. Afterwards, align the upper tower segment by sighting along the lower segment.

The natural frequency of the stay cables should be approximately 3 Hz for a 7 m or a 13 m tower and approximately 2 Hz for a 19 m tower. This corresponds to approx. 3 or 2 oscillations per second.

(3a)

(1e)

(3c)

(2a)


If the threaded crank handle is released without being secured, the tower may fall in an uncon-trolled manner, causing considerable personal injury and damage to property.

| Do not let go of the crank handle.

| Engage the locking pin (2a) with free hand.

| Turn the crank handle slowly up to the stop at the locking pin.

(3a)

(1e)

(Z9)

(16)

(16a)

4 Installation 4.23 Attaching the nacelle and securing the cable

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4.23 Attaching the nacelle and securing the cable

1. Grease the white plastic ring on the upper azimuth bearing (on the upper tower segment opening) and attach the nacelle (6).

2. Remove safety washers and attach cable plug (16) to the retaining plate (6c).

3. Attach the retaining plate (6c) to the nacelle – recess should point to the rear (towards the wind vane arm) – and secure with Allen bolts

4. Check the firm seating of the PE pipe (16) by pulling on the bottom of the cable (at the opening in the bot-tom tower segment).

5. Fit the air deflector (6d) and attach onto the lower transverse beam of the nacelle with two hexagonal-headed bolts, two washers and two self-locking nuts.

4.24 Preparing the machine unit

1. Remove the split pin from the connection plug (5c) for the brake lever (5b) and release the brake lever.

2. Unscrew the baseplate (5a) for the brake activation module and remove the module.

3. Unscrew and remove the plug on the control box from the brake activation module.

4. Place the machine unit on two wooden blocks in front of the nacelle oriented for installation.

5. Attach the installation aid bar (see Fig. 4-1, page 9, item (Z3)) to the rotor hub.

6. Pull the brake lever back slightly, just releasing the brake; turn the installation aid bar horizontally.

4.25 Preparing the nacelle for installation

1. Route the cable and plug behind the nacelle frame in such a way that the installation of the generator is not obstructed.

2. Insert four rubber tubes into the holes on the gear-box base.

3. Insert four hexagonal-headed bolts (Z11) (M12 x 110 mm) through the holes in the nacelle from under-neath; grease the threads.

4. Pull the bolts back out until the thread protrudes by approx. 10 mm.

On newer systems, a teflon ring is used instead of the while plastic ring. This ring does not require greasing.

(6c)

(16)

(6d)

CAUTION

Sensitive brake activation lever

When placing the machine unit on the wooden blocks, ensure that the brake lever is not dis-turbed and does not have any weight placed on it. To guarantee automatic brake activation, the brake lever need only be pulled just enough to make the disc brake move.

(5)

(5a)

(5b)(5c)

(Z11)

4 Installation 4.26 Attaching the machine unit to the nacelle

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4.26 Attaching the machine unit to the nacelle

1. Lift the machine unit - one man at the installation aid bar and one at the opposite end of the machine unit.

2. Four fitters - slide the two screws located on the top through rubber tubes on the gearbox base.

3. Insert the pre-assembled screw (Z14) on the rear cross member of the nacelle frame into the machine unit (9).

4. Secure the screws located on the top (Z11) on the cross member to the system with self-locking nuts (M12) and washers.

5. Slide the two screws located on the bottom (Z11) through rubber tubes on the gearbox base.

6. Secure the screws to the system with self-locking nuts (M12) and washers.

7. Screw on the third nut (Z14) with washer and tighten to a torque of 72 Nm.

4.27 Installing the brake activation module

1. Attach the brake activation module using four self-locking nuts (M6).

2. Plug the brake lever (5b) from above onto the plugs of the connection bars.

3. Secure the plugs (5c) between the brake lever and the connection bars with a split pin.

4. Plug into the activation module control box.

5. Plug into the generator and close the plug locking mechanism.

6. Attach the excess cable to the machine carrier unit with the cable splice.

Raised loads

Installing the machine unit (9) brings with it the risk of serious injury and considerable damage to property.

| Pay precise attention to the following notes and instructions and observe the relevant operational safety regulations.

| If the machine unit is to be installed by hand, four fitters are required.

(Z14)

(Z11)

(9)

(5b)(5c)

(5a)

4 Installation 4.28 Attaching the wind vane

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4.28 Attaching the wind vane

1. Plug the pre-assembled wind vane (6a) into the wind vane arm (6b).

2. Secure the wind vane to the stop with two Allen screws (M10 x 70 mm).

3. Screw in until a slight bulge appears on the under-side of the wind vane arm (6b).

4.29 Attaching the adjustment axis

1. Cover four Allen screws (M10 x 25 mm) with Loctite 243 and screw the adjustment axis into the desired position on the rotor hub.

2. Tighten the Allen screws in a crosswise pattern to a torque of 46 Nm.

4.30 Attaching the rotor blades

1. Thoroughly clean any dirt on the attachment sur-faces on the flange and hub.

2. Position the rotor blade flange in such a way that the pegs and the holes fit together – do not confuse the holes for threads.

3. Coat an Allen screw (M10 x 25 mm) with Loctite 243, screw in as far as possible, tighten and screw back out by ½ a rotation.

(6a)

(6b)

Affix the adjustment axis at the top first. Then screw in the three remaining Allen screws to the stop.

Always tighten the Allen screws in a crosswise pattern (always tighten screws diagonally opposite one another).

The rotor blades are balanced in pairs. To aid differentiation, the opposite sides of the rotor are drilled with either one or two additional holes (Z13). The pegs fit into the holes on the flange of the corresponding rotor blades.

In addition, make sure that the Allen screws on the flange of the rotor blade point in the direction of the adjustment axis.

(Z13)

4 Installation 4.31 Fitting the cover

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4. Coat the remaining screws with Loctite 243, screw in up to the stop and then tighten in a crosswise pat-tern to a torque of 46 Nm.

5. Attach the second and third rotor blades as per steps 1 to 4.

6. Attach the stay poles for the three rotor blades(s. chapter 4.32, page 22).

7. To attach the fourth rotor blade, raise the tower using the cable winch until the hub is at a height of approx. 2 m.

8. Then stabilise the tower again using an appropriate support.

9. Carefully vent the brake manually until the blade is able to turn through an additional 45°.

10. 4. Fit the rotor blade underneath at an angle, as per steps 1 to 4.

11. Attach the fourth stay pole.

4.31 Fitting the cover

1. Remove the rubber packing (ventilation) on the gear-box.

2. Make a note of the rated current value displayed on the generator type plate and the serial number.

3. Insert the two screws (M6 x 90 mm) for securing the cover from below into the holes provided for this purpose on the nacelle frame.

4. Place a non-threaded spacer sleeve on each screw.

5. Screw on a threaded spacer sleeve and tighten with a size 10 open-ended spanner.

6. Screw the rear ventilation grille (8) to the nacelle (holes provided).

7. Fit the upper half of the cover, attach to the spacer sleeve using an Allen screw and a washer and tighten the screw.

8. Secure the rear portion of the cover half over the prefitted round screw on the ventilation grille (8).

9. Install the lower half of the cover as per steps 3 to 8.

4.32 Attaching the stay poles

1. Coat four Allen screws (M10 x 25 mm) with Loctite 243 and place ready to hand.

2. Coat the thread on the stay bearing with Loctite.

3. Carefully fit the flat end of the stay pole (13) to the rotor blade and firmly tighten the stay bearing (13a) using a spanner, until the washer no longer moves..

4. Using an open-ended spanner, slowly unscrew the stay pole by approx. 1/8 of a rotation until there is no more friction between the stay pole and the stay bearing.

5. Using an Allen screw, attach the stay pole in this position to the controller head (13b) (46 Nm)

(8)

The following instructions on installing the stay poles must be precisely observed to ensure fault-free and reliable operation of the pitch controller.

CAUTION

Defective stay bearing

Ensure that the stay bearing (13a) is not twisted or bent during the sequence of assembly.

(13) (13a) (13b)

4 Installation 4.33 Installing the spinner

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4.33 Installing the spinner

1. Fit the two spinner shells (15).

2. Screw in two self-tapping screws per shell.

4.34 Lifting and securing the tower

1. Before lifting the tower, go through the check list "Safe installation" (s. chapter 6.1, page 27).

2. Slowly lift the tower using the cable winch.

3. Secure the jin pole connection piece to the cable winch anchor on the foundation.

4. Detension the cable winch.

(15)

WARNING


If the threaded crank handle is released without being secured, the tower may fall in an uncon-trolled manner, causing considerable personal injury and damage to property. Should you wish to interrupt the lifting process, proceed as follows:

| Secure the cable winch crank handle (2c) with the locking pin (2a).

| Slowly turn the cable winch crank handle up to the locking pin and then release the handle.

(2a)

(2c)

5 Commissioning

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5 Commissioning

5.1 Installing the AC box

1. Attach the cable cover (16b) with four Allen screws (M6 x 16)

2. Hang the AC box (17) using the slotted holes on the cable cover (16a) which is fitted to the tower.

3. Plug in the tower cable (16) and secure with a clip.

5.2 Attaching the earth connection

1. Connect the cable lug to the prepared earth cable (green and yellow) between the tower and the foun-dation.

2. Screw the cable lug of the earth cable to the earth connection (Z15) of the lower tower segment.

3. Tighten the screw (Z15) (35 Nm).The house or load connector must be equipped with a 3-phase 16-A-CE plug (round) and be connected to 3-phase asynchronous AC.

(16a)

(16)(17)

(16)

(Z12)

(Z15)

5 Commissioning

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5.3 Switching on

Switching on for the first time

Check that the AC box is wired up correctly and switch the power supply on using the external AC connection device.

The rotational direction of the asynchronous 3-phase AC generator is correct if the rotor is turning clockwise.

5.4 System messages

The operating status, system messages and current wind power system performance values Conergy EasyWind 6 AC are shown on the AC box display (17a). If the wind speed reaches 3.5 m/s, the rotor starts up independently. The display shows the frequency for the generator while idling.

Speed 1

If the rotor speed reaches a value of 83 rpm, speed 1 is automatically selected. The wind power system now works on the grid. The display shows the speed and the current in the generator.

The wind power system will remain at speed 1, as long

as a wind speed of 7 m/s is not exceeded for longer than 20 seconds.

Speed 2

If the wind speed remains consistently above 7 m/s for longer than 20 seconds, the generator will disconnect from the grid at speed 1. The rotor can now accelerate freely and at 126 rpm or at a generator frequency of < 75 Hz, speed 2 is selected. The display shows the speed and the current value.

The nominal capacity of 6 kW is achieved at 10.5 m/s and, thanks to the active pitch controller, can even be maintained at any wind speed in excess of this.

If wind speed falls below a value of 7 m/s for longer than 20 seconds, the system switches back to speed 1.

Shutdown during a period of calm

If the wind speed is insufficient to produce a constant output (less than 4 m/s), the generator will disconnect from the grid after a delay of 20 seconds. The display shows the message "Wind low".

Shutdown stops the generator from being driven using power from the grid and becoming a consumer in its own right.

Switching on after a fault

Manually switching on the system after a fault without knowing the cause risks considerable personal injury and damage to property.

| After an interruption caused by ice buildup, only manually switch the system on when the ice has fully melted.

| Following an automatic shutdown, only manually switch the system on after the cause of shutdown is determined and has been rectified.

| Only switch the wind power system on manually when the system has not switched back on automatically after more than 30 minutes.

If the rotational direction of the asynchronous generator is incorrect, disconnect the system from the public grid and reverse the two phases 2 and 3.

(17a)

Frequency 45.1 Hz

Speed 1 00

Current 04.3 A

Speed 2 00

Current 14.7 A

Wind low 00

5 Commissioning

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Vibration shutdown

If the system is forced to shut down due to heavy vibra-tions (from gale force winds, imbalance owing to ice buildup, etc.), the display shows the Vibrations mes-sage. After a delay of 15 minutes, the system starts up again and the counter in the top right corner of the dis-play increases from "00" to "01".

If the conditions which led to the vibration shutdown are still present, the system will shut down again. This time, the delay before the system starts up again is doubled and the index (top right) is increased by 1.

This process is repeated, as long as there is no change to the initial conditions. The only way to fully reset the system and reset the index to 00 is to disconnect it from the grid.

Overcurrent shutdown

In the event of an emergency shutdown caused by too high a current, the system does not switch back on auto-matically, as such a malfunction is likely caused by a fault in the generator. The display shows the "Overcur-rent/reset" message.

Shutdown in the case of grid or generator faults

In the case of generator faults, the generator controller puts the wind power system out of operation.

If symmetry, frequency or voltage faults occur in the grid, the wind power system is shut down automatically via the house connection box controller.

Manual system shutdown

Vibrations 01

Vibrations 02

CAUTION

CAUTION

Resetting in the event of an overcurrent

Attempting to restart the system using reset after an overcurrent-induced shutdown can cause damage to the generator.

| Notify Conergy after a shutdown caused by overcurrent.

WARNING

Imbalance or high noise emissions

In the event of an imbalance - which may be caused by ice buildup or rotor blade damage - or unusual noise emissions, the system must be shut down immediately.

| Shut down the system using the main switch on the house or load connector.

| Never disconnect the plug at the foot of the tower in such a case.

The automatic brake immediately senses when the power supply is interrupted, and brings the rotor to a stop.

| Notify Conergy Service in the event of an imbalance or of noise emissions.

Overcurrent/reset 00

6 Maintenance

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6 Maintenance

6.1 Safety check

Every two months, or following an automatic emergency shutdown, a reset of the system may be performed to check the function of the brake. During "Reset", the gen-erator in the Conergy EasyWind 6 AC wind power system is automatically braked.

6.2 Maintenance intervals

Maintenance of the EasyWind 6 AC wind power system is limited to carrying out a visual inspection, which should be performed for the first time after six months, and then every two years.

6.3 Maintenance work

To carry out maintenance work, switch the system off and lower the tower. Observe the procedures and safety instructions in this manual.

The following tasks must be carried out during mainte-nance:

| Check stay cables for rust and damage

| Check lateral braces for firm seating

| Cable clamps: visual inspection only (do not retighten)

| Check gearbox for oil leaks

| Check welds on the tower and the machine unit and nacelle for cracks

| Check wind vane for firm seating

| Check the shaft seals on the rotor blade flanges for leak-tightness

| Check the axial play of the stay poles

| Check the screw connections for firm seating

| Check rotor blades and blade edges for damage and spalling

| Check rotor blade tips for permeability of the venti-lation

| Check screws on the gearbox base

| Check ventilation grille for dirt, parasites, bird nests and insects

| With PA rings lubricate the azimuth bearing on the nacelle (do not use more than four stokes with a grease gun) Do not grease teflon ring.

Maintenance without shutdown

Carrying out maintenance work on the system without first switching it off involves a high risk of accident.

| Before performing any maintenance work, switch off the system manually and observe the effect of the automatic brake until the rotor has come to a stop.

| Ensure that the system remains powered down during maintenance and that it can-not be switched back on.

7 Appendix

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7 Appendix

7.1 Check list: Safe installation

Tower assembly

| Screw connection on the face of the tower: 35 Nm

| All shackles secured with split pins

| Correct seating of all shackles on the thimble con-nections and foundation anchors checked, and for a 19 m tower, correct seating on the intermediate stays also checked

| Four lateral brace screws: 46 Nm

| Eight lateral brace wire cable clamp screws: 9 Nm

| Jin pole secured on both sides with retaining plates and split pins

| All self-locking nuts (M16) at the other end of the jin pole (connection piece) tightened up to the stop

| All self-locking nuts (M20) on the foundation anchors tightened up to the stop

| 13 m tower vertically aligned

| For a 19 m tower, lower tower segment raised upright first using the intermediate stays

| For a 19 m tower, upper tower segment then raised upright using the upper stay

| Cable tension adjusted:

For a 19 m tower - 2 Hz; For a 7/13 m tower - 3 Hz

| All turnbuckles secured using split pins

| All wire cable clamps on the foundation and the jin pole tightened (9 Nm)

Installing the cable, nacelle and machine unit

| Cable inserted from below; cable grommet tightened from below

| White plastic ring on the upper azimuth bearing (upper tower segment) greased and nacelle fitted

| Cable tube with cable plugs and a plate attached to the nacelle

| Wind vane attached according to requirements

| Brake activation module screwed on

| Brake activation module connected to the brake lever using plugs and secured with a split pin

| Five self-locking nuts for the connection between the machine unit, the generator and the nacelle tightened (72 Nm)

| Ventilation hole free (rubber packing) on the gearbox

| Machine cover fitted and screwed tight

| Ventilation grille on the nacelle frame fitted

| Spinner fitted

| Freedom of movement of the brakes checked

Rotor assembly

| Adjustment axis attached with four Allen screws(DIN 912 M 10 x 25 mm 8.8 Zn)

| Rotor blade flanges fitted with Allen screws (DIN 912 M6 x 25 mm 8.8 Zn) (46 Nm, Loctite 243)

| Stay poles fitted in accordance with Chapter 4.32 of the installation manual: washer firmly seated on the plastic bearing

7.2 Check list: electrical safety

Before starting any work on electrical systems, the fol-lowing safety rules in accordance with VDE 0100 must always be followed:

| Disconnect from the mains

| Secure against being switched back on

| Make sure power is disconnected

| Earth and short-circuit

| Cover nearby live parts.

In addition, observe the following general safety instruc-tions:

| Electrical work on the device should only be carried out by authorised and appropriately qualified per-sonnel (qualified electrical specialists).

| Never open the AC box during operation.

| Do not remove or disable any safety devices.

| Observe the warning symbols posted on the device itself.

WARNING

7.3 High voltage

When working on any live device components or wires, a second person must always be present. In the event of an unforeseen electrical accident, that person must be able to switch off the power supply and provide aid.

7 Appendix 7.4 Specifications

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7.4 Specifications

Description/characteristic Value

Nominal capacity 1.5/6 kW

Max. output 6 kW

Hub height 13 m/19 m

Overall height 16 m/22 m

Rotor diameter 6 m

Rotor speed 86/128 rpm

Number of blades 4

Blade profile NACA 4415

Blade tilt angle 5 °

Cone angle 5.5 °

Axle angle 0 ± 1.4 °

Startup speed 4.0 m/s

Wind speed for nominal capacity 11 m/s

Generator speed at full load 1,078/1,566 rpm

Max. rotor speed during load shedding 179 rpm

Rotor speed for max. short-term overload 131 rpm

Output for short-term overload (precedes disconnection from the grid) 8.1 kW

Control (grid connection) Electronic

Rotor type Wind-facing, high-speed rotor

Wind tracking system Wind vane

Safety system Blade adjustment, disc brake

Total weight 583 kg

| Tower (13 m) 220 kg

| Nacelle (without rotor) 303 kg

| Rotor blade 15 kg

Gearbox Two-speed helical gearbox

Generator Asynchronous generator, pole-changing 1.5/6 kW at 1,000/1,500 rpm, 400 V

Rotor blades Steel/fibreglass composite

Blade adjustment Mechanical using aerodynamic and centrifugal forces

Tower 4-stayed steel tube tower, hot-dip galvanised

7 Appendix 7.5 Included in delivery

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7.5 Included in delivery

19 m system Number 7/13 m system Number

Foot of tower 1 pc. Cruciform foundation 1 pc.

Lifting anchor 1 pc. Cable winch beam 1 pc.

Anchor 3 pcs. Foundation beam 3 pcs.

Jin pole (two parts) with fixing bit 1 pc. Jin pole 7/13 1 pc.

Cable winch with holder 1 pc. cable winch with holder 1 pc.

Lifting cable 13/19 1 pc. Lifting cable 1 pc.

Stay cable 4 pc. Stay cable 4 pc.

Stay cable 19 4 pc. Stay bolts, long 1 pc.

Stay bolt, long 1 pc. Stay bolt, short 3 pcs.

Stay bolt, short 3 pcs. Connection piece 1 pc.

Stay bolt, long 19 1 pc. Pulley 1 pc.

Stay bolt, short 19 3 pcs. Lateral brace 4 pc.

Connection piece 1 pc. Tower 7/13 lower part 1 pc.

Pulley 1 pc. Tower 13 upper part 1 pc.

Lateral brace 4 pc. Pin with hose 1 pc.

Tower lower part 1 pc. Nacelle 1 pc.

Tower middle part 1 pc. Wind vane 1 pc.

Tower upper part 1 pc. Machine unit 1 pc.

Pin with hose 1 pc. Brake activation module 1 pc.

Nacelle 1 pc. Tower cable 7/13 1 pc.

Wind vane 1 pc. AC box 1 pc.

Machine unit 1 pc. Rotor blade form A 2 pc.

Brake activation module 1 pc. Rotor blade form B 2 pc.

Tower cable 13/19 1 pc. Adjustment axis 1 pc.

AC box 1 pc. Stay poles 4 pc.

Rotor blade form A 2 pc. Spinner 1 pc.

Rotor blade form B 2 pc. Cover 1 pc.

Adjustment axis 1 pc. Rear grille 1 pc.


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Stay poles 4 pc. Misc. screws & mounting elements 1 Box

Spinner 1 pc. Support 1 pc.

Cover 1 pc. Supporting bar 1 pc.

Rear grille 1 pc. Wooden blocks 4 pc.

Air deflector 1 pc. Air deflector 1 pc.

Misc. screws & mounting elements 1 Box

Support 1 pc.

Supporting bar 1 pc.

19 m system Number 7/13 m system Number


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7.6 Circuit diagram

The brake on the Conergy EasyWind 6 AC wind power system is spring-pretensioned and is held open by the electromagnet (H). The electromagnet is permanently supplied with mains current and only releases the brake lever when the mains current is interrupted. In such cases, the brake closes immediately and without delay.

Without mains voltage, the system can neither start up nor produce voltage. This means that the system remains completely safe, even during a grid failure.

The Conergy EasyWind 6 AC wind power system's elec-tronic control system consists of the following modules:

(A) Brake activation module

(B) AC box

(C) Controller for emergency shutdown from vibrations and overload capacity

(D) Lower cut-off point, accessible to the utility, lockable

(E) Lower tower cut-off point

(F) Upper tower cut-off point

1,5 kW 1000 U/Min. 6,0 kW 1500 U/Min. (H)

8 Index

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8 Index

AAC box 24, 28Assembly supports 9Automatic shutdown 3Axial play 27Azimuth bearing 19, 27, 28

BBird nests 27Bleeding 27Brake activation module 20, 28Brake lever 20Brake system 3

CCable 18Cable cover 24Cable grommet 28Cable lug 24Cable splice 20Cable winch 14, 23Cable winch crank handle 17, 23Cable winch foundation anchor 14CE plug 24Check lists 28Concrete foundation 6Concrete foundation checklist 10Connection piece 12, 15, 18, 23Connections 8

Cover fixing 22Cover half, lower 22Cracks 27

DDisplay 25, 26

EEarth cable 24Earthing 24Electrical safety 28

FFault 25Foundation 23, 28Foundation beam 11Frequency fault 26

GGearbox 22, 27Gearbox base 19, 27Generator fault 26Generator, installation aid 9Grease gun 27Grid supply fault 26

HHouse connection box 26

IIce buildup 25Imbalance 26Insects 27

JJin pole 12, 28

LLateral brace 13Lifting cable 16Lifting device 18Load connector 24Location 9Locking pin 17, 23Lower tower segment 12

MMachine cover 28Machine unit 19, 20Maintenance intervals 27Maintenance work 27Middle tower segment 12

NNacelle 19, 27, 28Nacelle frame 22Non-threaded spacer sleeve 22

8 Index

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OOil leaks 27Overcurrent 26

PParasites 27Period of calm 25Pitch controller 21Plug 20Pulley 15

QQualified electrical specialists 5, 28

RReset 27Responsibilities of the operator 4Rotor blade damage 26Rotor blade tips, ventilation 27Rotor blades 21Rubber packing 22

SSafe installation 28Safety check 27Safety equipment 28Safety instructions 5Self-tapping screws 23Set screws 15Shackle 17, 28Shaft seals 27Shutdown 25Speed 1 25Speed 2 25Speed switching 3Spinner 23

Spinner shells 23Spirit gauge 18Split pins 18Stay cable, frequency 18Stay cables 12Stay pole 22, 27Stay poles 27Steel foundation 6Support 22Switching on 25Switching on for the first time 25Symbols 4System variants 8

TThimble 17Thimble connections 16, 28Threaded spacer sleeve 22Tools 9Tower cable 24Tower segment, upper 18Turnbuckles 18Type plate 22

UUser group 4

VVDE 0100 5, 28Ventilation grille 22, 27Vibrations 26Visual inspection 27

WWarning symbols 5, 28Welds 27

Wind vane 21, 28Wind vane arm 19, 21Wire cable clamp 13Wire cable clamps 17Wooden blocks 9

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For further information: www.conergy.com Subject to technical changes without notice!2007 © Conergy AG

installation manual 6ac

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