XZERES ARE442 & 442SR Battery Charger Wind Turbine ...

7305 Rev A

XZERES ARE442 & 442SR

Battery Charger Wind Turbine System

XZERES 442SR Battery Charger Wind Energy System Installation and Operation Manual

PN: 7305 Revision A, XCO 1159 ©2014 XZERES Corporation

Copyright 2014 by XZERES Corporation

The XZERES Corporation manufactures the XZERES ARE442 and 442SR wind energy system in

the United States.

XZERES ARE442 and 442SR are used interchangeably throughout the Battery Charger Wind

Energy System Installation and Operation Manual; both systems are installed and operated

identically.

The information contained in the XZERES ARE442 and 442SR Battery Charger Wind Energy

System Installation and Operation Manual is subject to change without notice.

XZERES Corporation makes no warranty of any kind with regard to this material. XZERES

Corporation shall not be liable for errors contained herein or for any incidental or consequential

damages in connection with the use of this material. The information contained herein is the

exclusive property of XZERES Corporation and/or its licensors and should not be distributed,

reproduced, or disclosed in whole or in part without the prior written consent of XZERES

Corporation.

The terms and conditions governing the sale and licensing of XZERES Corporation products are set

forth in the written contracts between XZERES and its customers. No representation or other

affirmation of fact contained in this publication shall be deemed to be a warranty or give rise to any

liability of XZERES Corporation whatsoever. This document is for informational and instructional

purposes. XZERES Corporation reserves the right to make changes in specifications and other

information contained in this publication without prior notice, and the reader should, in all cases,

consult XZERES to determine whether any changes have been made.

XZERES Corporation has made every effort to ensure that the information presented in this manual

is accurate. However, XZERES Corporation assumes no responsibility for any errors or omissions.

Users of this information and of other XZERES Corporation products assume full responsibility and

risk.

This document contains confidential information proprietary to XZERES Corporation. Do not

reproduce this document or any information contained within, in whole or in part, without express

written consent of XZERES Corporation.

Trademarks

XZERES Wind is a trademark of XZERES Corporation.

XZERES Corporation

9025 SW Hillman Court

Suite 3126

Wilsonville, OR 97070

www.XZERES.com

Phone: (503) 388-7350

Fax: (503) 212-0109

Support: 1-877-404-9438



This page intentially left blank.



TABLE OF CONTENTS

TABLE OF FIGURES ................................................................................................................... 6

TABLE OF TABLES ..................................................................................................................... 7

1.0 ABOUT THIS MANUAL ..................................................................................................... 8

1.1 Before You Begin: Basics ........................................................................................................................ 9 1.2 Notations Used in This Manual ............................................................................................................. 10 1.3 Who Should Use This Manual ............................................................................................................... 10 1.4 Customer Service and Technical Support ............................................................................................... 10 1.5 Safety Information ............................................................................................................................... 10 1.6 Shutdown and Lockout Procedure ........................................................................................................ 13

2.0 INTRODUCTION .............................................................................................................. 14

2.1 System Description ............................................................................................................................... 17 2.2 System Installation ............................................................................................................................... 18 2.3 Supplied Parts and Hardware ................................................................................................................ 18 2.4 Not Supplied Parts and Hardware ......................................................................................................... 19

3.0 TOWER ASSEMBLY AND FOUNDATION INSTALLATION .......................................... 21

3.1 Install the Foundation .......................................................................................................................... 21 3.2 Assemble the Tower ............................................................................................................................. 23

4.0 ELECTRICAL INSTALLATION ....................................................................................... 25

4.1 Uncrate Electrical Components ............................................................................................................. 25 4.2 Install the Electrical Components and Wiring ........................................................................................ 27 4.3 Electrical Connections........................................................................................................................... 33 4.4 Connect Electrical Components ............................................................................................................. 36 4.5 Tower Wiring ....................................................................................................................................... 39

5.0 TURBINE ASSEMBLY INSTALLATION ......................................................................... 39

5.1 Uncrate and Inspect the Yawhead/ Alternator Assembly ....................................................................... 40 5.2 Mount the Yawhead and Alternator to the Tower Top Plate .................................................................. 43 5.3 Connect the Yawhead Wiring to Tower ................................................................................................. 46 5.4 Uncrate and Inspect the Blades ............................................................................................................. 48 5.5 Install the Tail Boom ............................................................................................................................. 48 5.6 Install the Rotor Blades ........................................................................................................................ 51 5.7 Install the Nose Cone ............................................................................................................................ 54

6.0 RAISE THE TOWER ........................................................................................................ 55

7.0 CONNECT THE SYSTEM WIRING ................................................................................. 56

8.0 SYSTEM START-UP ....................................................................................................... 58

9.0 SYSTEM OPERATION ................................................................................................... 63

9.1 Operating Parameter Display ................................................................................................................ 64 9.2 Operating Fault Condition Display ......................................................................................................... 67 9.3 Regularly Scheduled Maintenance ........................................................................................................ 69



10.0 TROUBLESHOOTING .................................................................................................... 69

10.1 Power Failure: Troubleshooting when the Turbine does not spin ........................................................... 70 10.1.1 Down Tower Faults ............................................................................................................................... 70 10.1.2 Up Tower Faults ................................................................................................................................... 71 10.2 Power Failure: Troubleshooting with a Spinning Turbine ....................................................................... 72 10.3 Other Up Tower Checks ........................................................................................................................ 76

APPENDIX A: 442SR SYSTEM WIRING DIAGRAMS .............................................................. 77

Appendix A1 442SR Turbine Controller Schematic .......................................................................................... 78 Appendix A2 Battery to Turbine Controller Connections Diagram ................................................................... 79 Appendix A3 Yawhead Electrical Box Wiring Diagram ..................................................................................... 80 Appendix A4 Service Disconnect Box Wiring Diagram ..................................................................................... 81 Appendix A5 Wire Conversion Table .............................................................................................................. 82 Appendix A6 Length Conversion Table ........................................................................................................... 82

APPENDIX B: UPDATING FIRMWARE 83

APPENDIX C: WARNING LABEL PLACEMENT 86

APPENDIX D: SERVICE MAINTENANCE LOG ........................................................................ 88

DECOMMISSIONING AND DISPOSAL ..................................................................................... 90

INDEX......................................................................................................................................... 91



TABLE OF FIGURES

Figure 1 Consider Turbulence ..............................................................................................................................9

Figure 2 Typical Tower Warning Label ............................................................................................................... 12

Figure 3 Service Disconnect Box Lockout (Off Position Only) Service Disconnect Switch ...................................... 13

Figure 4 XZERES 442SR Wind Energy System ...................................................................................................... 14

Figure 5 442SR Wind Turbine ............................................................................................................................ 15

Figure 6 442SR Battery Charger One Line Drawing ............................................................................................ 15

Figure 7 XZERES 442SR Battery Charger Electrical System .................................................................................. 16

Figure 8 Typical Monopole Mat Foundation ...................................................................................................... 21

Figure 9 Typical Monopole Pad and Pedestal Foundation ................................................................................... 22

Figure 10 Typical SSL Tower Pad and Pier Foundation ......................................................................................... 22

Figure 11 Monopole and Self-Supporting Lattice Towers .................................................................................... 23

Figure 12 Self-Supporting Lattice Tower Construction ......................................................................................... 24

Figure 13 Electrical Components and Yawhead .................................................................................................. 25

Figure 14 442SR Diversion Load Clearance......................................................................................................... 28

Figure 15 Diversion Load Mounting ................................................................................................................... 29

Figure 16 442SR Diversion Load Dimensions ...................................................................................................... 30

Figure 17 Controller Dimensions ....................................................................................................................... 31

Figure 18 Terminals, Ground and View of Power Out Cover in Place .................................................................... 32

Figure 19 Securing the wires ............................................................................................................................. 32

Figure 20 Back Bracket and Service Disconnect Box ........................................................................................... 33

Figure 21 Board Connections ............................................................................................................................ 34

Figure 22 442SR Cable Schematic ....................................................................................................................... 35

Figure 23 Turbine Controllers to Distribution Panel ............................................................................................ 36

Figure 24 Tower Base to Service Disconnect Box ................................................................................................ 37

Figure 25 Turbine Controller to Service Disconnect Box ...................................................................................... 38

Figure 26 Service Disconnect Control Wiring Diagram ........................................................................................ 38

Figure 27 Exploded View XZERES 442SR Turbine ................................................................................................ 40

Figure 28 Yawhead Shipped with Cowling and Alternator ................................................................................... 41

Figure 29 View Down Top of Yawhead ............................................................................................................... 42

Figure 30 Yawhead Slip Rings ........................................................................................................................... 42

Figure 31 Yawhead/Alternator Liftstrap Rigging ................................................................................................ 44

Figure 32 Tower Top to the Yawhead Flange (illustration shown without alternator) .......................................... 45

Figure 33 Yawhead Bearing Bolts (illustration shown without alternator) .......................................................... 46

Figure 34 Cable Support (Kellems Grip) ............................................................................................................. 47

Figure 35 Blade Crate ....................................................................................................................................... 48

Figure 36 XZERES Turbine Blade ......................................................................................................................... 48

Figure 37 Yaw Lock ............................................................................................................................................ 49

Figure 38 Tail Vane and Boom Installation ........................................................................................................ 50

Figure 39 Mounting Blade Studs to Alternator ................................................................................................... 51

Figure 40 Blade Edges and Rotation Direction ................................................................................................... 52

Figure 41 Nose Cone Mounting Holes on Clamping Plates .................................................................................. 53

Figure 42 Rotor Locked with Nylon Strap ........................................................................................................... 53

Figure 43 Nose Cone Installation ....................................................................................................................... 54



Figure 44 SSL Tower Raising .............................................................................................................................. 55

Figure 45 Tower Grounding System ................................................................................................................... 57

Figure 46 Installer Link...................................................................................................................................... 58

Figure 47 Log in ................................................................................................................................................ 59

Figure 48 Turbine Configuration........................................................................................................................ 59

Figure 49 Battery Charger System Setup window .............................................................................................. 60

Figure 50 Turbine Controller Keypad ................................................................................................................. 61

Figure 51 Turbine Controller Warning Label ...................................................................................................... 63

Figure 52 System Group Location ...................................................................................................................... 73

Figure 53 Turbine Controller Fuses .................................................................................................................... 74

Figure 54 Access Service Disconnect Box Power ................................................................................................. 75

TABLE OF TABLES

Table 1 XZERES 442SR Safety Symbols ............................................................................................................... 12

Table 2 442SR System Specifications ................................................................................................................. 17

Table 3 Installation Tools .................................................................................................................................. 20

Table 4 Minimum Electrical Wire Requirements ................................................................................................ 26

Table 5 Wire Run Distance and Wire Size ........................................................................................................... 27

Table 6 Battery sensors to Turbine Controller Connections ................................................................................. 36

Table 7 Diversion Load to Turbine Controller Connections .................................................................................. 37

Table 8 Service Disconnect Box to Turbine Controller Connections ...................................................................... 37

Table 9 Flange Thickness and Bolt Length.......................................................................................................... 43

Table 10 Turbine Controller Parameters ............................................................................................................ 66

Table 11 Operating Fault .................................................................................................................................. 69

Table 12 Brake Troubleshooting ........................................................................................................................ 71

Table 13 Revision History .................................................................................................................................. 94



1.0 ABOUT THIS MANUAL

Note: Revision History is located at the end of the manual.

The XZERES 442SR Battery Charger Wind Energy System Installation and Operation Manual

describes how to assemble, install, and operate the XZERES 442SR Battery Charger

wind energy system. It includes instructions for installing the turbine on the tower, the

mechanical assembly, the electrical assembly and connection, and operating the

turbine.

This manual contains the following information. The location of each section is in

parentheses.

Before you begin: Basics to assemble and install (Section 1.1)

Who should use this manual (Section 1.3)

Customer service and technical support (Section 1.4)

Safety information (Section 1.5)

System description (Section 2.1)

System specifications (Table 2)

Parts and hardware (Section 2.3 and 2.4)

Required tools (Section 2.5)

Assemble and install the electrical components (Section 4)

Assemble and install the mechanical parts (Section 5)

Install the turbine on the tower (start at Section 5.4)

System operation (Section 9)

Turbine Controller operation and faults (Section 9.2)

Troubleshooting (Section 10)



1.1 Before You Begin: Basics

Many issues are beyond the scope of this manual and need addressing before you

assemble and install the system components. These include, but are not limited to,

the following:

Site assessment

Permits

Grading

Preparing the site in compliance with local codes and regulations

Constructing the tower foundation

Assembling the tower

Constructing or preparing a location for the electronic components

Setting up the utility connection

Figure 1 Consider Turbulence



1.2 Notations Used in This Manual

This manual uses the following types of messages to draw attention to important

information or safety issues.

NOTE: A NOTE is additional information of the subject matter; however, a note

is not a hazard.

CAUTION: A CAUTION is a possible hazard that could result in minor or moderate

injury, or could cause damage to equipment or property.

WARNING: A WARNING is a possible hazard that could result in severe injury or

death.

DANGER: A DANGER is a possible hazard that will result in severe injury or death

if not avoided.

1.3 Who Should Use This Manual

Professional installers, who have received training on the XZERES 442SR system,

should do the assembly and installation described in this manual. The installers

should be familiar with the tools and related hardware associated with these

procedures. The installers are ultimately responsible for their own work.

Owners of an XZERES 442SR system should refer to the following sections for

information about the 442SR and its operation:

Section 1.4 has Customer Service and Technical Support information.

Section 1.5 and Table 1 have safety information and notation for those assembling,

installing, operating, and maintaining the 442SR.

Section 9 has an overview of the basic operation.

1.4 Customer Service and Technical Support

XZERES Corporation can help dealers, installers, and owners with questions

concerning the XZERES 442SR wind energy system.

Customer Service and Technical Support is available from 8:00 a.m. to 5:00 p.m.

Pacific Standard Time. The toll-free number is 1-877-404-9438.

1.5 Safety Information

The XZERES 442SR system can cause serious injury or death if not correctly

assembled and installed. When in operation, the system can cause injury or death

and do damage to property if safety procedures are not followed.

This manual identifies possible hazards that can occur during the assembly, operation,

and maintenance of the system with the appropriate CAUTION, WARNING, or

DANGER note. The symbols in Table 1, and found throughout this manual and on the

XZERES equipment, represent hazards in installing and operating the 442SR system.



Hazard Symbols and Descriptions

Symbol Meaning Description

Electrical Electricity present, possible electric shock or burn hazard

Electrical Earth Ground

Earth ground required, to avoid shock or damage to

equipment connect to a low-resistance earth ground (PE:

protective earth)

Electrostatic Electrostatic sensitive equipment, to avoid damage to

equipment follow proper electrostatic handling practices

Fire Hazard Produces heat, keep clear to avoid fires

Attention Review information on proper procedures

Heavy Object Follow proper lifting methods to avoid possible injury or

equipment damage

Mechanical Pinch-point

Possible to crush or pinch body parts while moving

equipment or lifting objects

Hot Surface Surface hot or can get hot. Touch carefully. Do not place items on it. Keep flammables at a safe distance.

Strike Possible for a person to collide with or to be struck by

moving parts

Lift with Two

Persons

Heavy object, requires two persons to lift or move safely

(continued)



Hazard Symbols and Descriptions (continued)

Symbol Meaning Description

Read

Manuals

Read safety, operation, and service manuals before

beginning work

Lockout Lockout access to electric panels and work areas when

possible

Hard Hat

and Safety

Glasses

Everyone within the work area must wear a hard hat and

safety glasses

Safety

Harness

A safety harness is required for any work above ground

level

Table 1 XZERES 442SR Safety Symbols

Figure 2 Typical Tower Warning Label

NOTE: Installers are responsible to follow all safety and installation instructions in

this manual and ultimately for the quality of their own work.



1.6 Shutdown and Lockout Procedure

ELECTRICAL HAZARDS

WARNING

BEFORE SERVICING THIS TURBINE CONTROLLER ALWAYS:

1) Press the STOP button on the Turbine Controller and wait for the turbine to stop spinning.

2) Place the Controller disconnects located in the Main Power panel in the O position (OFF); Tag and Lockout the circuit breaker (s). Disconnect all wiring between the 48 V Battery bank and the Controller.

3) Place the Service Disconnect Box in the O position (OFF).

4) Open the Service Disconnect Box and place the Service Disconnect Switch in the SERVICE position.

5) Close, Tag and Lockout the Service Disconnect Box.

6) After all power is off, wait five minutes for voltages to dissipate.

7) Verify with a voltmeter that no live circuits exist.

Figure 3 Service Disconnect Box Lockout (Off Position Only) Service Disconnect Switch

NOTE: Only qualified professionals and XZERES trained personnel shall have access to

power and distribution panel.



2.0 INTRODUCTION

The XZERES 442SR is a reliable and efficient wind energy system. It requires little

maintenance because of its rugged design that uses a minimum of moving parts and

solid construction. The system has a large swept area with high-efficiency blades, a

purpose-built alternator, and optimized power electronics that ensure maximum energy

capture over a wide range of wind speeds. Also included in the system are a service

disconnect switch and surge suppressors to protect the system from lightning strikes on

the tower.

Figure 4 is a representation of the 442SR system connected to the Battery Bank.

Figure 4 XZERES 442SR Wind Energy System



Figure 5 is a rendering of the turbine assembly and rotor blades.

Figure 6 and 7 are general system layout schemes.

Figure 5 442SR Wind Turbine

Controller

Load 1

Load 2

Lightning ProtectionIn Yawhead

XZERES 442SR Turbine/Battery Charger Controller

XZERES 442SR Wind Turbine

Diversion Load

Existing Distribution Panel

DC BUS Tap w/ Square D Disconnect

400 Amp

XZERES 442SR Battery

Charger

One Line Drawing

Optional

Customer

Provided

Disconnect(s)

1x___ AWG, ___ ft (Green/Yellow)

Tower Top

Junction

Box

3x_____ AWG, _____ ft (Black)1x_____ AWG, _____ ft (Green/Yellow)

24 VAC Brake Contactor Power2x 14 AWG, _____ ft (Red)

Brake Sensor2x 14 AWG, _____ ft (Yellow)

4x 10 AWG, _______ ft for DL (Black)

1x 10 AWG, _______ ft for PE (Green / Yellow)

2x 14 AWG, _______ ft for TS (Blue / White and Blue)

2x 400 MCM, _____ ft

(Red and Black)Turbine Output3-Phase 0-400 VAC3x____ AWG____ ft (Black) Service

Disconnect Boxw/ Lightning ProtectionNEMA 4X

2x14 AWG, _______ ft (Red)

2x14 AWG, _______ ft (Yellow)

48 V Battery Bank

CustormerLoads

2x 400 MCM, _____ ft

(Red and Black)



Battery Sense Wires

2x 22 AWG, _______ ft (Red)

4x 22 AWG, _______ ft (Black, Red, Yellow and Brown)

2x 22 AWG, _______ ft (Black)

400 A

Figure 6 442SR Battery Charger One Line Drawing



Tower Top

Junction Box

Thermal

Switch

Ground Rod

At Tower

XZERES 442SR Wind Turbine

Resistive

Brake

Load

texN442SR Battery Charger

Electrical System

Yawhead Electrical Box

3–Phase YAlternator

Class H Insulation

Surge Supp

Yawhead

N. C Contactor

TOWER

Battery Sensor Inputs (voltage, current and temperature)

48V

Battery

LAN

Customer

Distribution

Panel

64 – 44 Vdc

275 A max

XZERES Turbine Controller

Control

Assembly

Power

Supply

Relay

Battery

Charger

Assembly

EMS

XZERES Service Disconnect Box

Junction Box

Optional

3 Ø Short SW

Surge Supp

CB60A

LCD

Up to 300'

conductors

AC – DC

Rectifier

Assembly

Contactor

Diversion

Load

Aux Con

3- Phase 0 – 45 Hz60 Amps max375 Vrms L-L217 Vrms L-N, (307 Vp) max

Diversion and Brake load applied at max voltage

CB

Lock Out

device

Figure 7 XZERES 442SR Battery Charger Electrical System



2.1 System Description

The 442SR system generates power by use of a tower-mounted turbine system, and

consists of the following parts:

Tower Foundation and Tower

Turbine Assembly installed on top of the tower

Customer supplied interconnection wiring, main power panel, and electrical

junction boxes (local codes may require disconnect switches instead of junction

boxes)

Electronic equipment usually installed in a weather protected enclosure near the

battery connection. The Turbine Controller can be installed in an outdoor area but

must not be exposed to direct water spray from hoses, sprinklers, etc.

Table 2 lists the system specifications.

Configuration Three-blade upwind

Over-Speed Control, Electrical Pulse-width modulated Diversion Loading

Rated Power at 25 mph (11 m/s) 10 kW (10,000 watts)

Duty Cycle Continuous

Power Factor 0.95

Maximum Amperage

(Short Circuit Amperage) 130 A

Ground Specification Bonded less than 0.2 ohm (verify during installation)

Rotor Diameter 7.2 m (23.6 ft)

Swept Area of Blades 41 m2 (442 sq ft)

Cut-in Wind Speed 2.2 m/s (5 mph)

Blade Quantity, Construction Three, fiber-reinforced composite

Blade Rotational Speed 0–150 rpm

Alternator Type/Construction Neodymium or samarium–cobalt permanent magnet

Alternator Electrical Output 3-phase, variable voltage (0 - 375 Vrms L-L)

Tower-Top Weight 1043 kg (2300 lb)

Maximum Lateral Thrust 7115 N (1600 lb)

Operating Temperature (Normal environmental conditions)

-10°C to +40°C

Operating Temperature (Extreme environmental conditions)

-20°C to +50°C

Storage/Transportation Temperature 60°C

Humidity 90% RH, non-condensing

Maximum Altitude 2000 m (6562 ft.)

Voltage Required

(Turbine Controller requires external power) 44 - 64 VDC

Table 2 442SR System Specifications



2.2 System Installation

For most installations, XZERES recommends assembling the turbine to the tower

top while the tower is horizontal and supported above the ground. Complete the

tower installation outlined in Section 3 before installing the system.

The installation steps are:

Uncrate and inspect the electronic parts

Mount the electronic parts

Wire the electronic parts

Uncrate and inspect the turbine equipment

Assemble the turbine at the tower top

Connect the wires at the Yawhead Electrical Box and Turbine Top junction box

Raise the tower

Connect the wires at the Tower Base junction box

2.3 Supplied Parts and Hardware

The XZERES 442SR ships to the installation site in two wooden packing crates:

2.3.1 The 442SR Yaw Head Controller crate contains:

Yawhead Assembly – with alternator attached

Diversion Load

Turbine Controller

Service Disconnect Box

Blade-mount Studs (9 studs)

Fastener Kit (Alternator Installation, Blade Installation, Tail Installation,

Yawhead Installation, and Loctite )

Inner and Outer Blade Mount Plates

2.3.2 The 442SR Blade crate contains:

Blade Set (3 blades)

Tail Boom

Tail Vane

NOTE: Some items may be shipped separately. See packing slip for more details.



2.4 Not Supplied Parts and Hardware

Items not supplied by XZERES will need purchasing from other suppliers before you

assemble and install the system. The items needed for a typical installation are

listed below. Local codes and regulations may require additional parts.

2.4.1 Customer supplied installation parts:

Properly sized wire, as described in Section 4.3: Wire lengths must accommodate

the distance from the top of the tower to the Turbine Controller. Wire runs must

connect the junction boxes and then connect to the Turbine Controller without

stress on the wires.

Material for mounting the electronic parts, for example 3/4″ (19 mm) plywood

boards

Electric distribution panel

Electrical connecting hardware (wire nuts, nylon tie-wraps, tape, and so forth)

DC circuit breakers and fuses (400 A breaker and fuses for the Turbine Controller

to Battery circuit).

Conduit for wiring - including underground conduit.

Cable support (Kellems grips or cable support wedges)

Junction boxes for the top and base of the tower, and wherever else needed

Wind Vane and Anemometers

One 5/8 x 11 Yaw Lock bolt at least two inches (50 mm) long

Mating RJ45 connector for Controller. CONEC part number 17-10001. See page 31.

NOTE: See Table 4 in Section 4.1.3 “Minimum Electrical Wire Requirements” and

Tables 5 and 6 in Section 4.1.4 “Power Wire Requirements,” page 27 for wire

sizes and power-wire run lengths. See Figure 26, page 36, and Appendixes A2

through A15, pages 81 to 87, for all wire size requirements.



2.5 Required Tools

The installers need the following tools and equipment.

Tool Description Size or Type

Ratchet for sockets 1/2 inch drive

Extension for ratchet 8 inch

Metric sockets/box wrenches 10, 13, 19, 21, 22, 24, 30 & 32 mm

English sockets/box wrenches 3/4 inch and 15/16 inch

Hex/Allen wrenches 3, 4, 5, 6, 10 mm & 1/8 inch, 3/16 inch

Adjustable wrench 8 inch (opens to 1.25 inch)

Screwdrivers Phillips #2 Blade, 3/16 in. max width blade, 6 inch overall length

Wire strippers 6 AWG (16 mm2) –

16 AWG (1.5 mm2)

Torque wrenches Range: 0.6-343 N-m (0.4-253 ft-lb)

Locking pliers (Vise-Grip)

Hole saw or stepped drill For 1/2 inch (12.7 mm) conduit

Multi-meter Ohmmeter, AC/DC Voltmeter

Mechanical lifting equipment (crane or similar machinery)

Lifting equipment: straps, shackles, cables, etc.

Table 3 Installation Tools

DANGER

The XZERES 442SR wind energy system can produce voltages that can result in serious injury or death.

— Do not touch wiring or electrical connections without verifying that the turbine has come to a complete stop.

— Verify the circuit breakers are turned off, tagged, and locked out.

— Verify the DC power to the Turbine Controller is turned off, tagged, and locked out at the Main Power panel .

— After powering down the system, allow five minutes for the voltage to dissipate.

— Verify with a voltmeter that no live circuits exist.



3.0 TOWER ASSEMBLY AND FOUNDATION INSTALLATION

3.1 Install the Foundation

Many possible foundation types and sizes exist depending on the tower height and

type, site-specific soil conditions, wind speed region, and other factors. The most

common foundation types are described below.

3.1.1 Foundations for Monopole Towers

XZERES Corporation has two standard foundation types for monopole towers. The

first type is a mat foundation, also known as “Type 1.” The second type is a pad

and pedestal foundation, also known as “Type 2.” The installer is responsible for

verifying the local requirements and determining which foundation is appropriate.

The following guidelines will help the foundation type selection.

The mat foundation uses more concrete but less labor, formwork, and

excavation. The mat foundation is often preferred by installers, but not always.

The mat foundation only works for mild climates.

The pad and pedestal foundation type works for mild or cold climates.

The mat foundation works better for the motorized tilt-up monopoles (less

additional concrete).

The largest surface of the foundation is on top and visible on a mat foundation,

but not on a pad and pedestal foundation.

Figure 8 Typical Monopole Mat Foundation



Figure 9 Typical Monopole Pad and Pedestal Foundation

3.1.2 Foundations for Self-supporting Lattice (SSL) Towers

SSL towers usually use a square “pad” type foundation with three individual

round piers that extend above the top of the footing to support each leg of the

tower. Figure 11 shows a typical configuration of this foundation type.

Figure 10 Typical SSL Tower Pad and Pier Foundation

3.1.3 General Foundation Installation Requirements

All foundation types require some excavation. The installer should have a

basic knowledge of the soil at the tower location before excavation, to avoid

unexpected problems. Rocky soil can make excavation difficult, while loose

sand may require formwork—even for the shallow, mat type foundation.

Specific concrete and rebar specifications are shown on the foundation

drawings. The installer must coordinate access to the foundation site, delivery

of the rebar and concrete, formwork, and all labor including subcontractors

necessary to perform the work.



Tower manufacturers recommend that templates for the tower anchor bolts be

installed and carefully braced during the concrete placement. Steel templates are

provided for the bolt circles for both monopole and SSL towers. As a

recommended option for SSL towers, tower manufacturers can provide large

triangular templates that ensure proper placement of the bolt circles for all three

tower legs in relation to each other.

Figure 11 Monopole and Self-Supporting Lattice Towers

3.2 Assemble the Tower

3.2.1 Assembly of Monopole Towers

A monopole tower provided by XZERES Corporation has an installation manual

from the tower manufacturer. The installer shall follow the instructions in the

tower manufacturer’s manual.

Crane-lifted sectional monopole towers are usually assembled on the ground.

After the turbine is installed, the tower is lifted into the vertical position with a

crane while the monopole tower sections are still rigged together. This allows the

pole to be picked with a crane only once. After the tower is vertical and the nuts

at the tower base are tightened, the rigging and crane hook are removed.

Tilt-up type monopole towers, such as a gin-pole system or a ground-controlled

motorized system, do not require a crane. These towers are assembled on the

ground with the turbine and are then raised according to the manual provided by

the manufacturer. Tilt-up towers require certain tools or parts that may be

detached from the tower and used for other similar tilt-up towers. A gin-pole

tower system requires a gin-pole and a winch, while a ground-controlled

motorized tower system requires a motor to operate the system.

3.2.2 Assembly of Self-supporting Lattice (SSL) Towers



An SSL tower provided by XZERES Corporation is delivered to the site

unassembled with the various legs, bolts, and plates. A packing list is

provided that lists all pieces. Each piece must be matched to the packing list

to determine where to place it in the structure.

- The SSL tower usually gets assembled on the ground in 20-ft (6.096 m)

segments.

- The SSL tower pieces are laid out on the ground in the appropriate

locations. The tower is assembled from the bottom to the top. The tower will

need to be supported above the ground in the upper sections since it tapers

to a thinner overall size at the top of the tower.

- A loader or some kind of machine is needed to lift the third tower leg off the

ground so all the bracing can be attached to it.

- Basic tools are required, the most important being a torque wrench for all

the bolts. The bolts may be tightened before or after the tower is lifted.

Figure 12 Self-Supporting Lattice Tower Construction

NOTE: See Section 7.7, page 58, for tower grounding instructions.



4.0 ELECTRICAL INSTALLATION

CAUTION

If defects or damage are found during inspection of any parts or hardware, notify XZERES of the problem. Do not assemble, install, or use any equipment that is damaged or defective.

4.1 Uncrate Electrical Components

XZERES ships the electronic components for the 442SR system to the construction site

in a crate labeled 442SR Yaw Head Controller.

The electronic parts are:

One Turbine Controller

Diversion Load


Figure 13 Electrical Components and Yawhead

4.1.1 Junction boxes (not supplied)

The 442SR electrical system requires that you install a minimum of two junction

boxes: one at the base of the tower and one at the top of the tower.

4.1.2 Anemometers and Wind Vane (optional, not supplied)

When running cable for the anemometers and the wind vane, use shielded twisted

wire cable (CAT5 or better) to cancel electromagnetic interference (EMI).

Maximum supported length is 1000 ft (305 m).

Mount the anemometer head 24 ft (7.32 m)—1.0 rotor diameter—below the

turbine rotor hub.

Locate the anemometer upwind of the tower, for the prevailing wind direction.

Locate the anemometer at least four tower diameters away from the tower for

monopole towers or two face widths away from the tower for self-supporting

lattice towers.

Ground one end of the shield around the twisted pair at the tower (but not

inside of the Controller) for lightning protection.



4.1.3 Minimum Electrical Wire Requirements

Install all wiring using the wire color system shown in Table 4.

Description Color Wire Specifications

Ground (SR4): Green/Yellow 2 AWG (35 mm2), 600V, 90°C

Diversion Load to Controller:

TS

TSJ

-DL and +DL

Blue/White

Blue

Black

14 AWG (2.5 mm2), 600V, 90°C, UL 1063 & UL 83

14 AWG (2.5 mm2), 600V, 90°C, UL 1063 & UL 83

10 AWG (6 mm2), 600V, 90°C, UL 1659

Tower Top to Tower Base to Building Junction Box to Service Disconnect to Controller:

SR1, SR2, and SR3

SR5 and SR6

SR7 and SR8

Black

Red

Yellow

Refer to Table 5 for wire sizes, 600V, 90°C

Refer to Table 6 for wire sizes, 600V, 90°C

16 AWG (1.5 mm2), 600V, 90°C, UL 1063 & UL 83

Turbine Controller and Distribution Panel:

DC-

DC+

Black

Red

400 MCM (203 mm2), 600V, 90°C, UL 1659

400 MCM (203 mm2), 600V, 90°C, UL 1659

Battery to Turbine Controller:

BAT- and BAT+

LEM V+, LEM V-, LEM OUT and LEM GND THERM- and THERM+

Red

—

Black

22 AWG (0.33 mm2), 600V, 90°C, UL 1063 & UL 83

22 AWG (0.33 mm2), 600V, 90°C, UL 1063 & UL 83

22 AWG (0.33 mm2), 600V, 90°C, UL 1063 & UL 83

Table 4 Minimum Electrical Wire Requirements

NOTE: All splices, wire supports, connections, electrical hardware, wire types, sizes and

colors must meet local codes and requirements.

4.1.4 Power Wire (SR1, SR2, SR3) Requirements

The following table lists the minimum wire gauge of the wire run from the turbine

to the system electronics based on a one-way distance (through the tower and the

junction boxes to the electronics in the building). Verify the wire insulation is

rated for outdoor use and for at least 600 volts. Underground portions must be in

conduit and maintain spacing per 4.1.6.



Distance Minimum Wire Size

United States Europe

0 - 445 feet 6 AWG (13.3 mm2) 33.6 mm2 (2 AWG)

446 - 700 feet 4 AWG (21.1 mm2) 33.6 mm2 (2 AWG)

701 - 1130 feet 2 AWG (33.6 mm2) 33.6 mm2 (2 AWG)

Table 5 Wire Run Distance and Wire Size

NOTE: See Appendix A20, page 92, for a wire conversion table.

4.1.6 Wire Spacing Requirements

When routing wires from the Turbine to the Controller, maintain at least 8

inches of separation between the power wires (SR #1, #2, #3), the brake

control wires (SR #5, #6, #7, #8) and the anemometer/wind vane cable. This is

especially important for long runs because the alternating current waveforms

on the power wires and brake control wires can interfere with proper

measurement of the anemometer and wind-vane signals. This 8-inch spacing

can be a vertical distance to limit the width of the wiring trench in the

ground.

CAUTION

Use only copper wire for electrical connections. The wire type and connections must conform to local codes.

(If desired, you may use aluminum wire from the tower base to the building entrance if you use proper splices at both ends and adjust wire sizes.)

4.2 Install the Electrical Components and Wiring

Install the Turbine Controller and Service Disconnect Box indoors or outdoors. In

either location, do not expose them to direct rain, water spray from hoses or water

sprinklers.

Install the Diversion Load in a sheltered space (or building) that protects it from the

weather (no direct exposure to dripping water, rain, or other moisture). The Diversion

Load may generate up to 18 kW of heat. Locate it in an area that will not overheat

under this condition. Carefully observe the minimum clearances specified later in this

section.

The wire run between the Diversion Load and the Turbine Controller can be up to

300 ft (91.44 m) long.

Mount the heavy wall mounted electrical components to a strong, properly supported

surface. Indoor installations typically use stud mounted plywood or strand board. The

installers must use proper mounting surfaces and fasteners.

NOTE: Mount the control gear between 1.0 m to 1.9 m (3′ 3" to 6′ 3″) above the surface

level. Mount the Main Disconnect handles between 1.0 m to 1.9 m (3′ 3" to 6′ 3″)

from the surface level—a 1.7 m (5′ 7″) upper limit is recommended.



DANGER

Before installing the electrical wiring, turn off the circuit breakers in the Main Power panel that you plan to use. After turning off the breakers, tag and lockout the panel in accordance with your local codes.

Disconnect all wiring between the Battery Bank and the Turbine Controller.

4.2.1 Install Diversion Load

4.2.1.1 Open the crate labeled 442SR Yaw Head/Controller.

CAUTION

The Diversion Load can dissipate as much as 18 kW of heat. The exterior surfaces get hot and the hot air emitted from the Diversion Load must not be restricted. Follow all clearance specifications (see Section 4.2.1.3 for clearances).

Never place objects on or near the Diversion Load.

4.2.1.2 Remove the Diversion Load from the crate and verify it has arrived without

damage. Figure 14 is a picture of the Diversion Load.

Figure 14 442SR Diversion Load Clearance

4.2.1.3 The Diversion Load needs space around it to ensure proper air flow during

operation. It must be mounted at least 60 inches (1.52 m) above the ground.

Verify the following clearances exist around the Diversion Load.

Top: 18 inches (457 mm)

Bottom: 12 inches (305 mm)

Sides: 3 inches (76 mm) to a wall or other surface



4.2.1.4 Orient the diversion load with the field wiring pigtail in the position shown in

Figure 15.

Mount the diversion load with .25" or 6 mm fasteners and washers. The

fastener and mounting surface material combination must achieve a 200 Lb.

minimum pull out strength, per fastener.

Place washers between the diversion load base and the mounting surface

attachment points to compensate for the gap caused by the pem nuts, see

Figure 17.

Connect the pigtail wires to the wires connected to the controller in a

junction box. Mount junction box 3" min to 12" max away from controller. If

pigtail wires are trimmed, re-attach wire identification.

NOTE: To achieve maximum corrosion protection, place a thin Kapton washer

between the base and the meal washers.

NOTE: The .75" EMT female conduit fitting is not grounded.

Figure 15 Diversion Load Mounting

NOTE: Do not mount the Diversion Load on a flammable surface.

Figure 16 shows the Diversion Load dimensions and hole locations.

CAUTION

Do not install the Diversion Load more than 300 ft (91.44 m) from the Turbine Controller.



Figure 16 442SR Diversion Load Dimensions

4.2.2 Install Turbine Controller

NOTE: Choose a location for the Controller and the Service Disconnect Box so you

have easy access to the red STOP button on the Controller and the

disconnect switch on the Service Disconnect Box.

NOTE: The Controller weighs approximately 155 lb. (70 kg). Verify the surface or

bracket that you mount it on and the screws are appropriate for this

weight. Mounting holes are .375 (9.53 mm) diameter. The minimum screw

size must be .312 (8 mm) diameter. Figure 17 shows the Controller’s

dimensions and required clearance area.

4.2.2.1 Remove the Controller from the crate and take it out of its box.

4.2.2.2 Inspect the Controller and verify it arrived without damage.

4.2.2.3 Use the following clearances in mounting the Controller:

Top: 12 inches (305 mm)

Bottom: 36 inches (914 mm)

Power Out Side: 12 inches (305 mm)

Door Open Side: 32 inches (813 mm)

WARNING

The Turbine Controller weighs approximately 155 lb. (56.8 kg). To avoid

injury, use two people to lift or move the Turbine Controller.



Figure 17 Controller Dimensions

4.2.2.4 Refer to Figure 18 bottom view for the name and location of I/O wiring ports.

Remove the rubber washers and fastener from the ports that will be used.

Install conduit and attach conduit connectors to the ports to seal them. Install

and secure wires as specified. Each port is sealed with a rubber washer and

fastener to ensure NEMA 4 enclosure environmental protection. Do not

remove the rubber washers if a port is not used. Leaving an open, unsealed,

port will void the controller warranty.

4.2.2.5 The RJ45 COM port is sealed with a connector. A mating connector should be

used if the controller is installed outdoors. Use CONEC plug kit part number

17-10001.

4.2.2.6 48 VDC Power Out and Ground Connection

These connections are made on the outside of the enclosure. Installing

2.50” (63.5 mm) conduit is optional. If the enclosure is installed outdoors

and conduit is not used, water proof cable must be incorporated.

Use a properly sized compression lug to attach the cable to the power

terminal. The power terminal has a .375” (9.53 mm) diameter threaded

post for compression lug attachment. A nut and washers are supplied with

the power terminal.

Remove the power out cover (four screws) to access the power terminals.

Apply antioxidant compound, Ideal NOALOX® or equivalent, on the power

terminal and compression lug mating surface. See Figure 19.

Insert the compression lug and washers over the power terminal. Apply

Loctite 243 to the nut, and torque to 180 in lbs (20 Nm).



Run properly size ground wire to the ground lug and secure with the set

screw. Torque to 275 in lbs (31 Nm). See Figure 18.

Reattach power out cover. Power out cover must be in place during

operation to avoid exposure to dangerous electrical shock.

Figure 18 Terminals, Ground and View of Power Out Cover in Place

DANGER

The 48 VDC power out cover on the side of the controller must be in place when power is applied to the controller. Dangerous electrical current is present, and poses a severe danger.

Figure 19 Securing the wires



4.2.3 Install Service Disconnect Box

Figure 20 Back Bracket and Service Disconnect Box

4.2.3.1 Mount the Service Disconnect Switch within direct eyesight of the Turbine

Controller. Refer to Figure 8, Page 19.

4.3 Electrical Connections

Wire sizes, colors, specifications, and Power Lead lengths are given in Sections

4.1.3 and 4.1.4, pages 26 and 27. Controller wire connection locations are

illustrated in Figure 21

Figure 23, page 36, shows the electric cable or wire runs. The Turbine Controller

bracket is intended for use with a gutter style conduit installation.



THERM–

THERM+

LEM GND

LEM OUT

LEM V‒

LEM V+

BAT ‒

BAT+ FUSES

F1

F2

Gro

un

d

Re

se

tB

utt

on

S4

Bu

tto

n

J8Pins

Negative

Positiv

e

SR

7

SR

8

2 12 1 V-

SIG V+

Div

ers

ion

L

oa

d 2

Div

ers

ion

L

oa

d 1

+D

L2

+D

L1

-DL

2-D

L1

SR

1

Po

we

r L

ea

d

IGB

T

Pin

s

4 3 2 1

SR

2S

R3

Po

we

r L

ea

dP

ow

er

Le

ad

+DL1TS

-DL1TS

+DL2TS

-DL2TS

SR5

SR6

Brake C

ontrol

Bra

ke S

enso

r

Win

d S

PD

2

Win

d S

PD

1

Fuses

Div

ers

ion

L

oa

d

Figure 21 Board Connections

C

on

tro

ller

Bo

ard

Dau

gh

ter

Bo

ard



Wire from turbine to tower top junction box (5 FT (1.52 M) Length) supplied by XZERES

SR5-SR8: 4x Wire (2 Red & 2 Yellow)

WIND

VANE

Wind Vane & Anemometers (Optional):

7x 24 AWG (0.205 mm2) Wire

(Use shielded twisted pair cable to cancel EMI—CAT5 or better. Ground shield OUTSIDE of controller.)

SR1-SR3: 3X Long AWG/mm2 Wire (Black)

(Refer To Manual For Wire Sizes, Table 5)

SR4: 1x Wire (Green/Yellow)

XZERES 442SR

Wind Turbine

BRAKE

RESISTORS

ANEMOMETER 1

AN

EM

OM

ET

ER

2

YAWHEAD

ELECTRICAL

BOX W/LPS

TOWER

TOP

JUNCTION

BOX

SLIP

RINGS

TOWER BASE

TOWER BASE

JUNCTION BOX

(OPTIONAL)

SR1-SR3:

3X Long AWG/mm2 Wire (Black)

(Refer To Manual For Wire Sizes, Table 5)

SR4: 1x Wire (Green/Yellow)

SR5-SR8: 4X Wire (2 Red & 2 Yellow)

BATTERY

BANK

Wind Vane & Anemometers:

7X 18 AWG (0.823 mm2) Wire

SR

1-S

R3

: 3

X _

L

on

g A

WG

/mm

2

Wire

(B

lack)

SR

5-S

R8

: 4

X 1

4 A

WG

(2

.08

mm

2)

Wire

(2

Re

d &

2 Y

ello

w)

4 X 22 AWG Wire

XZERES SERVICE

DISCONNECT BOX

W/LPS

CUSTOMER

DISTRIBUTION

PANEL

400 MCM Wire (Black)

Equipment supplied by XZERES: Turbine Diversion Load Turbine Controller Service Disconnect Box

All other equipment to be provided by the customer.

All wires to be rated for 600V, 90°C Minimum

Install conduit type:

___________________________________

30

0 F

T (

91

.44

M)

Ma

xim

um

4X Wire For DL (Black)

2X Wire For TS (Blue / White & Blue)

1X 10 AWG (5.26 mm2) Wire For PE

(Green/Yellow)1/0 AWG Minimum (Green Yellow)

DIVERSION LOAD ENCLOSURE

+DL1 –DL1 TS PETSJ+DL2 –DL2

XZERES TURBINE CONTROLLER

400 MCM Wire (Red)

Current Sensor

4 X 22 AWG Wire

Figure 22 442SR Cable Schematic



4.4 Connect Electrical Components

4.4.1 Connect the Distribution panel to the Turbine Controller. See Figure 23 below.

2 POLE 400A2 POLE 400A

48 V Battery48 V Battery

PEPE

XZERES

TURBINE

CONTROLLER

BUILDING PANEL OR SUBPANEL

400 MCM LINE CONDUCTOR (RED)

+

1/0 AWG MINIMUM LINE CONDUCTOR (GREEN/YELLOW)

-PE

400 MCM LINE CONDUCTOR (BLACK)

Customer loadCustomer load

Customer loadCustomer load

2X FUSE 400A2X FUSE 400A

+

-

Figure 23 Turbine Controllers to Distribution Panel

4.4.2 Connect the Battery bank to the Distribution panel.

4.4.2.1 Place the Controller disconnects in the Distribution panel in the O

position (OFF). Tag and lock-out the circuit breaker(s).

4.4.2.3 Connect the 48 V Battery bank to the Distribution panel at connections

shown in Appendix A2, page 79.

CAUTION

Make sure the Battery bank is wired with the correct polarity. Reverse polarity could damage the Turbine Controller.

4.4.3 Connect the Battery sensors outputs to the Turbine Controller. See Figures Appendix

A1-A2 and Table 6 below.

Turbine Controller

THERM- THERM+ LEM GND LEM OUT LEM V- LEM V+ BAT- BAT+

Battery

sensors

THERMISTOR -

THERMISTOR + LEM GND LEM OUT

LEM V- LEM V+ BATTERY- BATTERY +

Table 6 Battery sensors to Turbine Controller Connections



4.4.4 Connect the Diversion Load to the Turbine Controller. See Figure Appendix A1 and

Table 7 below. Turbine Controller

+DL 1 -DL 1 +DL2 -DL2 +DL1TS -DL2TS PE (Ground) SR4

Diversion Load

+DL1

-DL1 +DL2 -DL2 TS TSJ PE

Table 7 Diversion Load to Turbine Controller Connections

4.4.5 Connect the Service Disconnect Box to the Turbine Controller. See Figure Appendix

A4 and Table 8 below, and figures 24, 25, and 26.

Turbine Controller

Slip Ring 1

Slip Ring 2

Slip Ring 3 PE (Ground) SR4

SR5 SR6 SR7 SR8


SR1 Black

SR2 Black

SR3 Black

SR4 Green/Yellow

SR5 Red

SR6 Red

SR7 Yellow

SR8 Yellow

Table 8 Service Disconnect Box to Turbine Controller Connections

4.4.6 Connect the building junction box (if used) or the tower base junction box and the

Turbine Controller to the Service Disconnect Box.

4.4.6.1 Route the turbine wires from the building junction box to the Service

Disconnect Box.

4.4.6.2 Connect the SR1, SR2, and SR3 turbine wires to the terminal board TB1

(SR1, SR2, and SR3) inside the Service Disconnect Box. See Figures 24

and 26.

Figure 24 Tower Base to Service Disconnect Box

4.4.6.3 Connect the disconnect box to earth ground. See Figure 24.

4.4.6.4 Connect the wires from the Turbine Controller to the circuit breaker

(CB1) in the Service Disconnect Box (SR3, SR2, and SR1). See Figures 25

and 26.



Figure 25 Turbine Controller to Service Disconnect Box

4.4.6.5 Connect the ground (PE) from the Turbine Controller to the ground in

the Service Disconnect Box. See Figure 25.

4.4.6.6 Connect the SR5 and SR6 (Red) wires from the Turbine to the Service

Disconnect Box terminal board TB3. See Figure 26.

4.4.6.7 Connect the corresponding Turbine Controller SR5 and SR6 (Red)

wires to the Service Disconnect Box terminal board TB3. See Figure

26.

Figure 26 Service Disconnect Control Wiring Diagram

4.4.6.8 Connect the SR7 and SR8 (Yellow) wires from the Turbine to the

Service Disconnect Box terminal board TB3. See Figure 26.

4.4.6.9 Connect the corresponding Controller SR7 and SR8 (Yellow) wires to

the Service Disconnect Box terminal board TB3. See Figure 26.



4.4.7 Connect wind-vane and anemometer sensor wires from the shielded twisted-pair

cable (optional components). See Figure 21.

4.4.7.1 Use one twisted pair for anemometer 1, if present.

4.4.7.2 Use one twisted pair for anemometer 2, if present.

4.4.7.3 If a wind-vane is present: on one twisted pair, connect “V+” and “SIG.” On

the other twisted pair, connect “V-“ and “SIG.” This will ensure that the

“SIG” wire has the least resistance and the best balance from positive to

negative.

4.4.8 Route the wires from the building junction box to the tower base. The wires must

be long enough to reach the Tower Base junction box. Coil the extra wire near the

tower foundation. Connect the wires at the building junction box.

NOTE: Your local codes may require installation of disconnect switches in place of the

junction boxes. If you install disconnect switches for the turbine power wires you

must also install an auxiliary contact to disconnect the SR5 wire (Brake Control)

running from the turbine assembly to the Controller.

4.5 Tower Wiring

Complete the following installations on the tower:

4.5.1 Install the junction boxes at the top and the base of the tower.

NOTE: Your local codes may require a disconnect switch at the tower base. If you install

a disconnect switch on the turbine power wires you MUST also install auxiliary

contacts that disconnect the four 14 AWG (2.5 mm2) brake control wires.

NOTE: The wires from the Slip Rings are 5 feet long. Place the Tower Top junction box

where the Slip Ring wires can reach it.

4.5.2 Route the wire from the Tower Base junction box up the tower to the Tower Top

junction box. See Steps 4.1.3 and 4.1.4, pages 26 and 27, for wire size

specifications. Use Kellems grips (or equivalent) as required by wire size, tower

height, and local codes.

5.0 TURBINE ASSEMBLY INSTALLATION

This section describes how to install the 442SR Turbine Assembly in the following order:

1. Install the Yawhead on the Tower.

2. Connect drop wires at Tower Top junction box.

3. Mount Tail Vane on Tail Boom.

4. Install Tail Boom on Yawhead.

5. Install Blades on Alternator.



Yawhead

T

Alternator

uter C

Olamping

P late

Blades

InnerClamping

Plate

Nose

Cone

OuterClamping

Plate

Blade

Studs

TailVane

Outer Tail Boom

Yawhead

Alternator

Figure 27 Exploded View XZERES 442SR Turbine

NOTE: The installers are ultimately responsible for the quality of their own work.

5.1 Uncrate and Inspect the Yawhead/ Alternator Assembly

Uncrate and Inspect the Yawhead/Alternator Assembly. The Yawhead is in the

crate labeled 442SR Yaw Head Controller.

The Yawhead is shipped with the Cowling attached. You will need to remove the

Cowling before you can start working with the Yawhead.

5.1.1 Place the crate on firm level ground. Remove the top and sides of the crate with

the large side that the Yawhead/Alternator Assembly is lag bolted to last. Unload

everything except the Yawhead/Alternator Assembly. Remove the 2 x 4, which is

bolted to the yaw bearing.

5.1.2 Remove both sides of the Cowling from the Yawhead before assembling the

Turbine.

5.1.2.1 Each half of the Cowling is held in place with four M6 x 16 hex cap head

screws (tool: 10 mm socket).



Figure 28 Yawhead Shipped with Cowling and Alternator

5.1.2.2 The Cowlings also attach by a Lanyard (wire rope rig that secures the

Cowling to the Yawhead). To remove the Cowling Lanyard, unscrew the

M6 nut on the M6 hex cap head screw that holds the Lanyard to the

Cowling (tool: 10 mm wrench).

5.1.3 Set the Cowlings in a safe place until after assembling the Turbine to the Tower.

5.1.4 To reattach the Cowling before lifting or tilting up tower and turbine assembly:

5.1.4.1 Looking at the front of the Turbine, attach the left-side Cowling first.

5.1.4.1.1 Attach the Lanyard first (tool: 10 mm wrench).

5.1.4.1.2 Line the Cowling up with the eight screw holes on the Yawhead

brackets.

5.1.4.1.3 Start all of the four M6 x 16 hex cap head screws before tightening (tool:

10 mm socket).

Torque to 17 in. lb. (1.92 N-m).

5.1.4.2 Looking at the front of the Turbine, attach the right-side (with logo) of the

Cowling.

5.1.4.2.1 Attach the Lanyard first (tool: 10 mm wrench).

5.1.4.2.2 Line the Cowling up with the four screw holes on the Yawhead bracket.

5.1.4.2.3 Start all of the four M6 x 16 hex cap head screws before tightening (tool:

10 mm socket).

Torque to 17 in. lb. (1.92 N-m).

5.1.5 Remove the Yawhead top access cover.

5.1.6 Inspect the Brake Resistors.

5.1.6.1 Inspect resistors and wiring to ensure resistors and wiring have not

inadvertently loosened during transit and handling. See Figure 29.

Examine the resistors for damage. If damaged, disconnected, or loose

wires are discovered, contact customer service.



NOTE: DO NOT attempt field repair without prior approval.

Figure 29 View Down Top of Yawhead

5.1.7 Put the Yawhead top access cover back on.

5.1.8 Place three M20-2.5 lifting rings (included in the hardware kit) on the Yawhead

top flange.

5.1.9 Remove the Slip Ring access cover. Inspect slip rings to ensure each brush is

aligned in the proper grooves. Inspect the Slip Rings for damage. See Figure 30.

NOTE: Each ring has a total of four brushes. All 32 brushes should be checked.

5.1.10 Inspect the drop wires for damage to the wire insulation.

5.1.11 Put the Slip Ring access cover back on.

Figure 30 Yawhead Slip Rings



5.1.12 Remove door to access the electrical box. Check all wires with pull test to

ensure all wires remained sufficiently secure during transit and handling.

Ensure all screws are tightened properly. Review wiring diagram (Reference

Appendix A16) inside door panel to ensure all is wired correctly and have not

been tampered with since leaving the factory. Reattach access door.

5.1.13 Check electrical connections from wires below yaw bearing.

5.1.13.1 Measure resistance on the two red wires - SR5-SR6 to ensure the correct

resistance (6-10 ohms).

5.1.13.2 Measure resistance on the two yellow wires – SR7-SR8 to ensure they are

showing OL (Open circuit).

5.1.13.3 Connect 24VAC power supply to SR5-SR6. With 24VAC on SR5-SR6,

measure resistance on the two yellow wires – SR7-SR8 to ensure the correct

resistance (0-10 ohms). Remove power supply from SR5-SR6.

5.1.13.4 Measure resistance between phase wires (SR1-SR2, SR2-SR3, SR1-SR3) to

ensure the correct resistance (1.5-1.8 ohms between each pair of phase wires).

CAUTION

The Yawhead and Alternator weigh approximately 1325 lb (601 kg). Use lifting equipment and exercise extreme caution when lifting and moving the Yawhead and aligning it to the Tower Top Interface Plate.

5.2 Mount the Yawhead and Alternator to the Tower Top Plate

NOTE: XZERES supplies bolts for the standard tower top interface plate thickness of

3/4-inch (19.05 mm). Measure the thickness of your tower top plate. If more than

3/4-inch (19.05 mm) thick, you will need longer bolts per the Table 9. Use only

ASTM F593 Grade B bolts. If you have difficulty locating the proper bolt, please

contact XZERES for help.

Tower Top Flange Thickness

5/8″-11 Mounting Bolt Length

0.75″ (19.05 mm) 2.0″ (50.8 mm)

1.0″ (25.4 mm) 2.5″ (63.5 mm)

1.25″ (31.75 mm) 2.5″ (63.5 mm)

1.5″ (38.1 mm) 2.75″ (69.85 mm)

Table 9 Flange Thickness and Bolt Length



5.2.1 Rig nylon straps and lift the Yawhead (with Alternator attached) to the

approximate height of the Tower Top Interface Plate. See Figure 31.

Figure 31 Yawhead/Alternator Liftstrap Rigging

5.2.2 Apply 1 thread-locking compound, (Loctite 243*) to the threaded ends of the two

5/8″ diameter tapered pins. Install the pins in the inner race of the yaw bearing on

opposite sides of the bolt circle (180° apart). *New models are supplied with

Loctite 243.

5.2.3 Screw the pins in approximately 11 turns. These two pins will serve as guide bolts

when you set the Yawhead to the Tower Top Interface.

5.2.4 Verify the mounting surfaces (yaw bearing inner race and Tower Top Interface

Plate) are clean and nothing can get pinched between the Tower Top Interface

Plate and the Yawhead mounting flange.

NOTE: XZERES supplies bolts for the standard tower top interface plate thickness of

3/4-inch (19.05 mm). Measure the thickness of your tower top plate. If more

than 3/4-inch (19.05 mm) thick, you will need longer bolts per the Table 10. Use

only ASTM F593 C / F593 G bolts. If you have difficulty locating the proper bolt,

please contact XZERES for help.

5.2.5 Using the tapered pins as a guide; align the Yawhead bolt holes to mount to the

Tower Top Interface Plate. See Figure 32.



Figure 32 Tower Top to the Yawhead Flange (illustration shown without alternator)

5.2.6 Apply Loctite 243 to the threaded ends of the 5/8″-11 x (flange thickness length)

bolts with structural washers. Attach the Yawhead to the Tower Top Interface

Plate with these bolts and the washers (Tool: 15/16″ wrench).

NOTE: Leave the tapered pins in place.

5.2.7 Torque the bolts to 156 N-m (115 ft-lb).

5.2.8 Locate the two 5/8″-11 x 2″ bolts and washers. Apply 1 inch

(25 mm) of thread-locking compound, Loctite 243, to the threaded ends of the

bolts. Install the bolts on the top side of the lower yawhead flange (into the holes

where the lag screws were removed).



5.2.9 Torque to 156 N-m (115 ft-lb) (Tool: 15/16″ or 24 mm wrench). See Figure 33.

Figure 33 Yawhead Bearing Bolts (illustration shown without alternator)

5.3 Connect the Yawhead Wiring to Tower

NOTE: Eight wires come off of the slip rings and drop down from the Yawhead: Four

6 AWG (16 mm2) wires and four 14 AWG (2.5 mm2) wires. The wires extend

five feet below the Yawhead and are for connecting to the wires that run

down the tower.

5.3.1 Run the eight wires from the Slip Rings and connect to the Tower Top junction box.

5.3.2 In the Tower Top junction box:

Connect the 6 AWG (16 mm2) power leads from the Slip Rings SR1, SR2, and

SR3 to the Black power leads in the tower cable. Phase sequence is not

important.

Connect the 6 AWG (16 mm2) SR4 wire from the Slip Rings to the Green/Yellow

ground wire in the tower cable.

Connect the 14 AWG (2.5 mm2) wires SR5 and SR6 from the Slip Rings to the

Red SR5 and SR6 wires from the Turbine Controller panel in either order.

Connect the 14 AWG (2.5 mm2) wires SR7 and SR8 from the Slip Rings to the

Yellow SR7 and SR8 wires from the Turbine Controller panel in either order.

5.3.3 Secure and support all cables to the Tower Top junction box according to your local

codes.



CAUTION

During the installation, connect and support all wires in accordance with local codes. Use a junction box near the tower top and cable support grips (Kellems grips). The number of Kellems grips needed is determined by the wire run length and local code requirements.

DANGER

Make sure all wiring and connections are insulated for 600 volts. Inadequate insulation can result in injury or death, and damage to equipment.

5.3.4 Use cable supports to bear the cable weight and to remove tension from the cable.

If the tower is a Monopole, use a Kellems grip or equivalent for each cable running

down the tower.

WARNING

Do not hang cables without support. This can cause wire damage and compromise the splices. Support each cable individually.

Figure 34 Cable Support (Kellems Grip)

5.3.5 Confirm proper electrical connections at base of tower

5.3.5.1 Measure resistance on SR5-SR6 to ensure the correct resistance (6-10 ohms).

5.3.5.2 Measure resistance on SR7-SR8 to ensure they are showing OL (Open circuit).

5.3.5.3 Connect 24VAC power supply to SR5-SR6. With 24VAC on SR5-SR6, measure

resistance on SR7-SR8 to ensure the correct resistance (0-10 ohms). Remove

power supply from SR5-SR6.



5.3.5.4 Measure resistance between phase wires (SR1-SR2, SR2-SR3, SR1-SR3) to

ensure the correct resistance (1.5-1.8 ohms between each pair of phase

wires).

5.3.5.5 Repeat steps 5.3.5.1 through 5.3.5.4 at additional junction boxes as

necessary to validate proper electrical connections.

5.4 Uncrate and Inspect the Blades

5.4.1 Remove the top of the Blade crate.

CAUTION

The Tail Vane weighs approximately 145 lb (65.8 kg), and the Blades weigh approximately 93 lb (42 kg) each. To avoid damage always use two people, one on either end, to lift and move the Tail Vane and the Blades.

Figure 35 Blade Crate

5.4.2 With a person holding each end, remove the Tail Vane and each Blade from the

crate.

5.4.3 Inspect the Blades for any damage. Inspect the Leading Edge, Trailing Edge, the

Blade Root, and the Blade Tip. See Figure 36.

5.4.4 Set the Blades in a safe place until ready to install.

Figure 36 XZERES Turbine Blade

5.5 Install the Tail Boom

NOTE: The Tail Boom (see Figure 35) is shipped underneath the Blades in the blade crate.

Use straps and lifting equipment to remove the assembly from the crate and to

install it on the Yawhead.



CAUTION

The Tail Boom weighs approximately 205 lb (92.5 kg). Do not attempt to move it by hand.

5.5.1 Place a lifting strap around the Tail Boom just forward of the Tail Vane mounting

plates and lift it out of the crate.

5.5.2 Lay the Tail Boom flat on the ground with a 4″ x 4″ (101.6 mm x 101.6 mm) timber

supporting the Tail Vane end of the boom above the ground.

5.5.3 Move the Tail Vane into position with a person lifting each end.

5.5.4 Apply Loctite 243 to the threaded ends of the M20 x 80 mm bolts. Install bolts,

washers, and nuts. Tighten as shown on Figure 38.

5.5.5 Torque to 122 N-m (90 ft-lb).

5.5.6 Install one of the eyebolts off of the top of the yawhead in the front of the alternator

(it only fits one hole). Rotate the eye bolt out to one side and attach a rope or strap.

Use a lifting device to rotate the yawhead and raise the alternator until the

alternator face is vertical.

5.5.7 Insert a 5/8 x 11 Yaw Lock bolt at least two inches (50 mm) long thru the clearance

hole in the tower top flange and into the outer race of the Yawhead Bearing. (The

Yaw Lock bolt is not supplied; however, a Tower Top Plate to Yaw Bearing bolt can

be used.)

WARNING

The weight of the alternator will have a tendency to roll the tower. Make sure the tower is secure. If necessary, support the alternator by blocking.

5.5.8 Torque Yaw Lock bolt to 54 N-m (40 ft-lb). See Figure 37.

Figure 37 Yaw Lock

5.5.8 Lift the Tail Boom assembly with the strap installed around the boom just forward

of the Tail Vane.



5.5.9 Attach the tail vane to the tail boom as shown in Figure 38.

5.5.10 Apply thread-locking compound, Loctite 243 to the threaded ends of the M16 mm

screws. Install screws with washers and tighten as shown on Figure 38.

5.5.11 Torque 16 mm screws to 102 N-m (75 ft-lb) and 20 mm screws to 122 N-m

(90 ft-lb).

Figure 38 Tail Vane and Boom Installation



5.6 Install the Rotor Blades

CAUTION

The Blades for the 442SR are 3.6 meters (11.81 feet) long. Raise the tower high enough to allow for clearance between the Blade tips and the ground. On level ground you will need a minimum three feet (one meter) clearance between the blade mounting face on the Alternator and the ground.

5.6.1 Apply Loctite 243 to the threaded ends of the Blade Studs.

5.6.2 Screw the M24 male threaded side of the nine M24 Blade Studs into the set of

threaded holes on the front (rotor side) of the Alternator rotor. See Figure 39.

5.6.3 Torque the Blade Studs to 339 N-m (250 ft-lb) (Tool: 30 mm wrench).

Hole for M20 lifting eyebolt

Torque all Blade Studs

to 339 N-m (250 ft-lb)

(30 mm wrench)

Figure 39 Mounting Blade Studs to Alternator

CAUTION

Once a Blade is installed on the rotor, the rotor can spin (however, very slowly). Use caution when mounting the Blades to the Alternator. Restrain Blade motion by hand or by using a rope until the Blade installation is complete.



5.6.4 Install each Blade onto the Blade Studs so that the leading edges will rotate

clockwise when viewed from the front of the Alternator. See Figure 40. Raise the

turbine and tower to install three blades; this can be done first or after the first two

blades are installed.

Figure 40 Blade Edges and Rotation Direction

5.6.5 Temporarily install the two outermost M22 x 60 mm bolts on each Blade to hold

them in place.

5.6.6 Apply Loctite 243 to the ends of the three innermost M22 x 60 mm bolts.

5.6.7 Position the Inner Blade Clamping Plate over the three inner Blade Studs.

5.6.8 Secure the Inner Blade Clamping Plate with the M22 bolts and flat washers (Tool:

32 mm wrench).

5.6.9 Torque to 252 N-m (186 ft-lb).

5.6.10 Remove the six outermost bolts and apply Loctite 243.

5.6.11 Position the Outer Blade Clamping Plate over the six outer Blade Studs, use a

strap or leash on outer clamping plate until it is secured with a couple of bolts. See

Figure 41.

5.6.12 Secure the Outer Blade Clamping Plate with the M22 bolts and flat washers (Tool:

32 mm wrench).

5.6.13 Torque to 252 N-m (186 ft-lb).

DANGER

DO NOT allow the turbine to rotate freely with disconnected power

wires. This will cause very high voltages that can result in injury or

death, and can destroy equipment.

5.6.14 Rotate the Blades slightly around the Alternator’s axis to verify the rotor turns

freely.



Figure 41 Nose Cone Mounting Holes on Clamping Plates

5.6.15 The rotor locks electrically when the Service Disconnect Box is in the SERVICE

mode or by shorting phase wires manually if building turbine before electronics are

mounted and wired. However if necessary, mechanically lock the rotor with a rope

or nylon strap tied to a Blade and anchored at the Yawhead.

Figure 42 Rotor Locked with Nylon Strap



NOTE: Mechanically lock the Rotor whenever working on the Brake Resistors, Yawhead

Electrical Box, or disconnecting the Alternator from the Yawhead Electrical Box.

DANGER

Whenever the Brake Resistors or the Alternator is offline, a spinning Rotor can produce dangerous voltage across the Alternator leads.

Avoid this by mechanically locking the Rotor with a rope or nylon strap.

The Rotor also locks and neutralizes electrically by shorting the Alternator leads together. (Put the three Alternator leads—U, V, and W—together with a large wire nut.) Preferably, short the leads at the tower top box. If possible, do not disconnect alternator leads from the Yawhead Electrical Box. If the alternator leads are disconnected from the Yawhead Electrical Box, they must be shorted at that location.

5.7 Install the Nose Cone

5.7.1 Remove the Nose Cone from the Yawhead crate.

5.7.2 Apply Loctite 243 to the threaded ends of the M8 X 16 mm bolts. Install the Nose

Cone and secure with three M8-1.25 x 16 mm bolts, washers and lock washers.

Refer to Figure 47 (Tool: 13 mm wrench).

5.7.3 Torque to 16 N-m (12 ft-lb).

Figure 43 Nose Cone Installation



6.0 RAISE THE TOWER

Check all of the wiring and verify the wires are not pinched or strained, and that the

wires have sufficient slack to raise the tower.

Raise the Tower per the manufacturer’s instructions.

WARNING

Do not climb to release crane and yaw lock until tower is properly secured to foundation.

Remove the Yaw Lock bolt.

WARNING

Do not attach lifting straps or other lifting means to any part of the turbine assembly. Lift the tower/turbine assembly by straps or other lifting means attached to the tower only.

Lifting the tower/turbine assembly from the turbine can damage the Yaw Bearing.

Figure 44 SSL Tower Raising

CAUTION

When raising a Self-supporting Lattice

tower, set your lifting strap or cable about 20

feet (6.1 m) down the tower from the base of

the Yawhead. This will allow clearance to

avoid damaging the Tail or Cowling.



7.0 CONNECT THE SYSTEM WIRING

7.1 Verify the STOP button on the Turbine Controller is in the stopped position.

7.2 Verify all the circuit breakers for the Turbine Controller are turned off and locked out.

7.3 Place the Service Disconnect Box in the O position (OFF).

7.4 Open the Service Disconnect Box and place the Service Disconnect Switch in the

SERVICE mode.

7.5 Close the Service Disconnect Box, tag, and lock the switch in place.

DANGER

DO NOT allow the turbine to rotate with disconnected power wires.

This will cause very high voltages that can result in injury or death,

and can destroy equipment.

7.6 In the Tower Base junction box:

NOTE: The wire nut that shunts the turbine lead wires can be safely removed as long

as the control wires (SR5 and SR6) are not connected or do not have voltage on

them. Without power to the Yawhead Electric Box contactor, the brake is

engaged as long as the alternator remains connected to the Yawhead

Electrical Box.

WARNING

Alternator leads should never be disconnected from yaw box and brake; wire nut should be at tower top box.

Connect the Black power leads from the turbine controller to the Black power

leads (SR1, SR2, and SR3) from the turbine in any order.

Connect the Green/Yellow ground wire (SR4) from the turbine controller and the

Green/Yellow ground wire from the turbine to the ground lug in the terminal

box.

Connect the Red wires (SR5 and SR6) wires from the Turbine to the Red wires

from the Turbine Controller in either order.

Connect the Yellow wires (SR7 and SR8) from the Turbine to the Yellow wires

from the Turbine Controller panel in either order.

NOTE: Your local codes may require a disconnect switch on the turbine power wires

at the tower base. If you install a disconnect switch on the turbine power wires

you MUST also install auxiliary contacts that disconnect the four 14 AWG

(2.5 mm2) brake control wires: SR5, SR6, SR7 and SR8.



7.7 Install a Tower grounding system.

7.7.1 Grounding (Earthing) serves a number of important safety and functional

purposes in a wind turbine installation, including lightning protection, ground

fault protection, proper operation of turbine controller, and proper operation of

household equipment.

Xzeres requires users to install a tower grounding system. The system shall

meet local codes and regulations and be approved by local authorities. Many

factors contribute to good ground system design, the following should be used as

a minimum requirement:

Ground resistivity of 10 Ohms or less

All grounds shall be bonded together with minimum 2 AWG bare copper,

tinned copper, or other approved wire, buried approximately 30" deep

(including tower and existing and new building ground systems).

Minimum of 4 ground rods around the tower base, installed not less than 2

feet from the tower.

Rods shall be spaced a minimum of twice the rod length apart (20 feet for 10

foot ground rods).

Ground rods shall be completely buried, preferable such that the top of the rod

is 30" below the surface of the soil.

Guy wires shall be grounded as well as the tower structure itself, if a guyed

tower is present, each leg of the tower shall be bonded to the ground system in

the case SSL and guyed lattice type towers.

Material list for recommended tower grounding system

2 AWG or 50mm^2 bare copper wire, long enough to circle the footing and

reach the tower.

Minimum of four 5/8" 10.0" long copper clad ground rods.

Six ground rod clamps for monopole towers and 8 for 3 legged towers.

One terminal lug for monopole towers; three terminal lugs for 3 legged towers.

NOTE: This is the minimum requirements for grounding.

Figure 45 Tower Grounding System



8.0 SYSTEM START-UP

WARNING

DO NOT start the turbine until properly installed by a licensed or

trained electrician and approved by the local jurisdictional authority.

XZERES Turbine Controller Operating Instructions

Before starting the system:

Verify all wiring and connections are complete.

Remove any shunts on the power leads.

Open the Service Disconnect Box and place the Service Disconnect Switch in the

OPERATE position.

Close the Service Disconnect Box and place the handle in the position (ON).

Press in the Emergency Stop Button on the controller.

Place the Controller disconnects located in the Main Power panel

in the position (ON).

Refer to Set the Controller Configuration instruction before

proceeding to the next step.

8.1 Set the Controller Configuration

8.1.1. Locate the IP address of the Turbine Controller. (Section 9.1 display IP_ADDRESS

variable on controller display).

8.1.2. Enter the IP address into the URL address bar of a web browser on a computer

connected to the network accessible to the controller.

8.1.3. Click on the INSTALLER link. (Figure 46).

Figure 46 Installer Link

ON

OFF



8.1.4. Log in with username: MyTurbine, Password: m442+SRt (Figure 47).

Figure 47 Log in

8.1.5. Select Turbine Configuration.

Figure 48 Turbine Configuration



8.1.6. The Battery Charger System Setup window will appear (Figure 49).

Figure 49 Battery Charger System Setup window

a. Set the number of anemometers.

b. Set the number of wind vanes.

c. Set Wind Vane Correction (if necessary) so that pointing the wind vane due north

results in a wind direction of 0 degrees.

d. Set the Diversion resistance. All systems should now have 4.4 Ohm diversion

loads. If you received the diversion load that is 6.6 Ohm (13.2 Ohm), please

contact XZERES for upgrade instructions.

e. Click Apply.

f. To start the wind turbine:

1.) Rotate the red STOP button on the Turbine Controller clockwise so it pops

out.

2.) Press the green checkmark next to the display to enable the turbine.

3.) Wait 5 minutes. If there is sufficient wind, the turbine should start on its

own.



4.) If the turbine fails to start, and the wind speed exceeds 8 m/s please see the

troubleshooting section, or contact XZERES technical support at

1-877-404-9438.

The XZERES Turbine Controller has a liquid crystal display (LCD) and buttons for the user

to monitor and control the operation of the turbine. The default display mode is “parameter”

view. You can cycle through the list of viewable parameters by using the left and right

arrow buttons. (See Figure 50.)

When an operating fault occurs, the LCD display switches to the “fault” view and displays

the current fault. While in the “fault” view, you can cycle through the list of previous faults

by using the left and right arrow buttons.

You can toggle between the “fault” view and the “parameter” view by pressing the red “X”

button.

Figure 50 Turbine Controller Keypad

Startup

When the 48 V DC voltage from the Battery bank is applied to the Turbine Controller, the

Controller software version will display for ten seconds:

Once the Controller startup sequence completes, the LCD should display the following

turbine state:

NOTE: If you forget to release the red STOP button, the display will show the following:

Rotate the red STOP button clockwise to release it to get to the Disabled state above.

Press the green “” button in the center of the keypad to get past the Disabled state to the

Stopped state:

NOTE: The display will also jump right to this “Stopped” state if you forgot to have the

red STOP button pressed when applying the 48 V DC voltage.

Turbine_State:

Disabled

BATTERY CHARGER

Revision: nnn NOTE: nnn will be replaced with the actual revision number.

Turbine_State:

ESTOP

Turbine_State:

Stopped



The turbine will then cycle through a 5-minute delay and go to the Enabled state. This

delay helps the unit recover from a prior Hard Fault condition. At this point, the turbine

control is enabled and, if the wind is blowing, the turbine will begin spinning:

NOTE: Pressing the S4 button (see Figure 21, page 34) while in the “Stopped” state will

bypass the 5-minute wait.

As the wind turns the turbine and the DC Bus exceeds 90 volts, the Controller will run a

brief test. During the test, the display will show:

Once the test has completed, the Controller will begin a soft-start operation as the DC

Bus voltage increases to a normal operating level. The LCD should show:

Once the Controller begins delivering power to the battery or any connected load, the

controller will indicate normal operation by showing:

When the winds decrease to a level insufficient to charge the battery, then the Controller

will re-enter the soft-start state and show:

If the DC Bus drops below 90 volts for more than ten minutes, the Controller will re-enter

the Enabled state. The display will then show:

Pressing the STOP button at any time will cause the controller to apply the up-tower

brake, and apply 100% diversion load, to stop and hold the turbine from spinning. When

the STOP button is pressed the Controller will display:

Rotating the STOP button clockwise to release it will go back to the Disabled state shown

at the beginning of this sequence. Pressing the green “” button in the center of the

keypad will re-enable the system.

Turbine State:

ESTOP

Turbine_State:

Enabled

Turbine_State:

Soft Start

Turbine_State:

Running

Turbine_State:

Soft Start

Turbine_State:

Testing

Turbine_State:

Enabled



9.0 SYSTEM OPERATION

Once operating, the 442SR should run without monitoring or other action, except for

routine maintenance.

However, under the following abnormal conditions you must manually shut the turbine

down. Follow the shutdown procedure at the Turbine Controller, Section 1.6 page 13:

If you see or hear any excessive vibration, noise, abnormal operation, or

accidental damage to any system parts.

Extreme wind conditions, wind speeds of 112 kph (70 mph) or greater.

Weather conditions such that ice could be thrown from the blades.

Possible fault conditions that can be cleared with a manual reset are listed in Table 11,

Operating Fault.

ELECTRICAL HAZARDS

WARNING

BEFORE SERVICING THIS TURBINE CONTROLLER ALWAYS:

1) Press the STOP button on the Turbine Controller and wait for the turbine to stop spinning.

2) Place the Controller disconnects located in the Main Power panel in the O position (OFF); Tag and Lockout the circuit breaker (s). Disconnect all wiring between the 48 V Battery bank and the Controller.

3) Place the Service Disconnect Box in the O position (OFF).

4) Open the Service Disconnect Box and place the Service Disconnect Switch in the SERVICE position.

5) Close, Tag and Lockout the Service Disconnect Box.

6) After all power is off, wait five minutes for voltages to dissipate.

7) Verify with a voltmeter that no live circuits exist.

Figure 51 Turbine Controller Warning Label



9.1 Operating Parameter Display

Once the Controller completes its startup sequence, it begins displaying the turbine-

state operating parameter by default:

View other operating parameters by scrolling using the left and right arrow keys.

For example, total hours of turbine operation:

The following parameters are available for display:

Label Description Units

TURBINE_RPM Turbine revolution speed RPM

TURBINE_HOURS Total Turbine Operating Time Hrs

TOTAL_EXP_ENERGY Cumulative Energy Delivered to

Inverters

kWh

TURBINE_STATE Operating State of Turbine Text

FAULT_NUMBER Count of Operating Faults Count of Faults

PDL Power delivered to Diversion Load W

WIND_SPD_1 Wind Speed on Anemometer #1 m/s

WIND_SPD_2 Wind Speed on Anemometer #2 m/s

WIND_DIRECTION Bearing of Wind Vane °

CHARGER_POWER Power delivered to Output Watts

CHARGER_STATE State of Charging Machine Number

IP_ADDRESS Internet Protocol Address Assigned x.x.x.x

BRAKE_ENABLE Up-Tower Brake Enabled on/off

TOTAL_POWER Total Delivered DC Power W

TOTAL_ENERGY Cumulative Energy Production kWh

AC_FREQ Frequency of AC from Alternator Hz

ESTOP STOP Button State on/off

IDC_BUS DC Bus Current A

(continued)

TURBINE_HOURS

84.9 hrs

Turbine_State:

Stopped




VDC_BUS DC Bus Voltage V

IDC_MAX Maximum DC Current Recorded A

VDC_MAX Maximum DC Bus Voltage Recorded V

HS_TEMP Heat-Sink Temperature C

HS2_TEMP Heat-Sink #2 Temperature C

TOTAL_HS_TEMPSW Count of how many times the Heat Sink

Temp Switch has been opened.

Count

CONTROLLER_HOURS Total operating hours Hrs

DL_TEMP_SWTCH Diversion Load Temperature Switch on/off

DL_HOURS Total Diversion-Load Hours Hrs

IDIVERSION_LOAD Current to Diversion Load A

WS1_MINUTE One-Minute Average of Wind Speed #1 m/s

WS1_STDDEV Standard Deviation of Wind Speed #1 m/s

WS2_MINUTE One-Minute Average of Wind Speed #2 m/s

WS2_STDDEV Standard Deviation of Wind Speed #2 m/s

WS_MAX Maximum Wind Speed Recorded m/s

WIND_DIR_STDDEV Standard Deviation of Wind-Vane

Bearing

°

BATTERY_CURRENT Current going into Battery Amps

BATTERY_VOLTAGE Battery Voltage measured at

Controller

Volts

TERMINAL_VOLTAGE Battery Voltage at Battery itself Volts

AMP_HRS_CHARGE Ampacity of Battery AmpHrs

KWH_CHARGED Number of Kilowatt-Hours sent out kWhrs

BATTERY_TEMP Temperature at battery sensor C

BULK_PHASE_HRS Time spent in bulk charge phase Hrs

ABSORP_PHASE_HRS Time spent in absorption charge phase Hrs

FLOAT_PHASE_HRS Time spent in float charge phase Hrs

OUTPUT_CURRENT Current going out of Charger to

Battery/Load

Amps

PROG_CURRENT Boost Converter Current Setpoint A

(continued)




PWM_RATIO Diversion Load PWM ratio %

FAN_PWM Heat-Sink Fan PWM Ratio %

TICKS Ticks since controller startup 977Hz Tick

count

V12_RLY 12 Volt Relay Supply V

BRKEN_SENSE Up-Tower Brake Enable Sense on/off

UPTOWER_CONTACTS State of Up-Tower Contactor on/off

DL_FAN Diversion Load Fan Enable on/off

HS_FAN Heat-Sink Fan Enable on/off

HS_TEMP_SWTCH Heat-Sink Temperature Switch on/off

HW_OVLT Hardware Overvoltage Sense State on/off

IAC_PHASE1 AC Phase #1 Current Arms



VAC_PHASE1 AC Phase #1 Voltage Vrms



TOTAL_DL_TEMPSW Count of how many times the Diversion

Load Temp Switch has been opened.

Count

FAC_MAX Maximum Alternator AC Frequency

Recorded

Hz

PROG_POWER Power Setpoint for inverters based on

alternator frequency

W

SPEED_LIMIT Target frequency for AC during

absorption

Hz

CHG_PWR_ONE_MIN Average Charging Power averaged over

one minute

Watts

Table 10 Turbine Controller Parameters



9.2 Operating Fault Condition Display

Operating Faults are divided into two categories: Soft and Hard Faults.

Soft Faults result from transient system conditions that can be remedied by stopping

the turbine for a cool-down period. At the end of a cool-down period the turbine will

automatically re-enable.

Hard Faults are conditions that indicate a fault with the system caused by a failed

component or improper configuration of the system. Hard Faults may require the

attention of a technician to diagnose and correct the underlying problem.

Fault Class

Fault Text Description Procedure

Soft

Soft Overvolt The DC Bus has exceeded the factory set voltage limit.

Turbine is stopped for a 5-minute cool-down period.

(continued)

HSINK OVERTEMP (or) Soft HS Overtemp

The heat-sink for power electronics has exceeded the factory-set temperature limit.

DL OVERTEMP The Diversion Load temperature switch has opened indicating high temperature condition.

F-Max Exceeded The turbine AC frequency has exceeded the factory-set limit indicating a turbine over-speed condition.

I-Max Exceeded DC Bus current has exceeded the factory-set limit.



Fault Class


Hard

UPTOWER FAULT The contactor set in the yawhead electric box has failed to close.

Turbine is stopped and will not restart automatically. A Manual Reset is required. To reset:

1.) Press the STOP button.

2.) Rotate the STOP button clockwise (CW) and the button will pop out.

3.) Press the

button. The system is operational.

(continued)

AC Phase Lost One or more of the AC lines from the alternator is not properly connected

Brake Failure Functional tests of the up-tower brake have failed during the startup of the turbine

HW_OVERVOLTAGE DC Bus voltage has exceeded the limit determined by independent hardware protection circuits.

DLOAD Failure Functional tests of the Diversion Load have failed during the startup of the turbine.

Charger Overvolt The charger boost voltage has exceeded the limit determined by independent hardware protection circuits.



Fault Class


Charger Overcurr The charger input current has exceeded the limit determined by the independent hardware protection circuits.

Charger Fault The battery voltage is too low or the battery sense inputs are not connected.

Table 11 Operating Fault

Manual Reset:

To shut down the turbine, press the STOP button.

To reset the turbine:

1.) Rotate the STOP button clockwise (CW) and the button will pop out.

2.) Press the button. The system is operational.

9.3 Regularly Scheduled Maintenance

XZERES recommends regular maintenance of the 442SR system for optimum

performance. The recommended maintenance interval is three years. Use qualified

technicians to perform the majority of this maintenance. Owners should contact

their XZERES dealer for questions or requests regarding maintenance, inspection,

or adjustments to the system. XZERES recommends that owners maintain a log or

record of all maintenance and service performed on the system. This manual has a

Service Maintenance Log on page 98.

Refer to 7306 Battery Charger Service and Maintenance Manual for specific

scheduled maintenance information.

10.0 TROUBLESHOOTING

XZERES designed, built, and tested your wind turbine system to give years of

trouble free operation. If you have problems, the following section gives some

general troubleshooting suggestions.

Follow all safety requirements.

Feel free to contact XZERES toll free at 1-877-404-9438 for technical support.

If you are not comfortable working on your particular problem, please contact a

qualified professional.



10.1 Power Failure: Troubleshooting when the Turbine does not spin

10.1.1 Down Tower Faults

Check the Diversion Load (an engaged Diversion Load serves as a break on

the Turbine).

1.) Push the Emergency STOP button on the Controller. You may hear the

Controller relay engage (clunk).

2.) If you did not hear the Diversion Load contactor engage, then that may

mean the Diversion Load is engaged.

3.) Rotate Emergency STOP button clockwise so it pops out, and press the

Controller’s CHECK () button on the LCD, wait 5 minutes. You should

hear the Controller relay release (clunk, disengaging the Diversion

Load).

4.) If this cleared the Diversion Load, then the Turbine should return to

spinning, if the wind is sufficient.

Check that the Turbine State is ENABLED.

1.) Put the probes of a voltmeter across the brake wires at SR5 and SR6. See

Figure 24 and Table 12. The voltage should measure between 24 and

28 VAC.

2.) If not, the Controller is bad and you will need to send it to XZERES for

repair.

3.) If the voltage is between 24 and 28 VAC and no indication of an UP

TOWER FAULT on the LCD, then put the probes of a voltmeter at SR7 and

SR8. See Figure 21 and Table 12. The voltage should be 0 VAC.

4.) If not, then the Controller is not working. In that case, try to upgrade the

firmware. See Appendix B. If a firmware upgrade does not help, you will

need to send the Controller to XZERES for repair.

5.) If the voltage at SR7 and SR8 is 0 VAC, then no problem exists with the

Brake Control or the Brake Control wiring.

Turbine state ENABLED:

Uptower Fault

SR5 to SR6 SR7 to SR8

Working Controller 24 VAC 0 VAC

Sense wires are open 24 VAC 24 VAC

Indicate that no power

to Brake

0 VAC 0 VAC Sense wires shorted or Bad LPS

0 VAC 24 VAC



Turbine State STOPPED:

Uptower Fault

SR5 to SR6 SR7 to SR8

Danger! Controller

Broken

24 VAC 24 VAC Brake Sense Wires Open or

Controller not operating

24 VAC 0 VAC Expected

Normal 0 VAC 24 VAC

should generate 0 VAC 0 VAC Sense wires shorted

Bad LPS

Stuck contactor

Table 12 Brake Troubleshooting

10.1.2 Up Tower Faults

WARNING

ELECTRICAL AND MECHANICAL HAZARDS ON

THE TOWER CAN CAUSE INJURY OR DEATH

BEFORE CLIMBING A TOWER ALWAYS:

1) Read the Service and Safety instructions.

2) Follow electrical lockout and tag out procedures.

3) Wear Personal Protection Equipment.

Before Locking the Rotor

1.) Verify that you cannot spin the Turbine by hand.

2.) Examine the Alternator for any obvious signs of damage (foreign

objects stuck between the Rotor and the Alternator, loose magnets,

etc.).

Lock the Rotor and access the Yawhead Electrical Box

Open the Yawhead Top Cover and examine the Brake Resistors.

1.) Verify the wires to the Brake Resistors are not shorted together or

broken (open). Repair as necessary.

2.) Verify the Brake Resistors are not damaged.

3.) Look for signs of sparking between the Brake Resistors and the

Yawhead, the Heat Shield, wires, etc. Repair as necessary.

4.) Look for signs of the Brake Resistors shorting together (foreign

material in the resistors). Repair as necessary.



5.) Look for blown sections of the Brake Resistors. Repair as necessary.

6.) If no damage is found, return the Yawhead Top Cover.

Examine the Slip Rings and Brushes.

1.) Remove the Left Cowling and the Yawhead Slip Ring Cover.

2.) Verify the brushes make good contact with the Slip Rings and haven’t

worn down excessively. Replace brushes that have worn to their plastic

holder.

3.) Verify the brush shunts are secure to both the brushes and the Slip

Rings.

4.) Look for any signs of arching, broken or damaged wires, signs of

damage to the brushholders, Slip Rings, etc.

Examine the wiring between the Slip Rings, Tower Top junction box, and

the Service Disconnect Box.

1.) You can check the wiring between the Slip Rings and the Tower Top

junction box by isolating the brushes from the Slip Rings (either pull

the brushes free of the Slip Rings or slide a piece of paper between the

brushes and the Slip Rings) and disconnecting the wires in the Tower

Top junction box.

2.) Check for shorts or grounds in the wires between the Slip Rings and

the Tower Top junction box.

3.) With the wires isolated in the Tower Top junction box isolate the wires

at the Service Disconnect Box (set the Service switch to OPERATE).

4.) Check the Tower Top to Service Disconnect Box wires for shorts or

grounds.

10.2 Power Failure: Troubleshooting with a Spinning Turbine

With the Turbine spinning, does the system produce power at the Controller inputs?

(Use a voltmeter to check the input voltage from the Service Disconnect Box.)

DANGER

When turbine is spinning, lethal voltages may be present. Only qualified personnel should troubleshoot a running turbine and only if no other option is available.

High Voltage Equipment is required, including fire rated clothes, high voltage gloves, face shield, and insulated sole shoes. Make sure test probes are rated for voltages over 1,000 volts.

NO, Is power coming into the Service Disconnect Box? (Use a voltmeter to check the

input voltage from the Tower.)

YES, Contact Xzeres Support.

.

2



Main

Power

Panel

Turbine

Controller

Service

Disconnect

BoxAlternator

Yawhead

Slip

Rings

Yawhead

Electrical

Box

Brake

Resistors

Tower Top

Junction

Box

DOWN

TOWER

UP

TOWER

Diversion

Load

Figure 52 System Group Location

Check the Turbine Controller

To check the Controller for input voltage from the Service Disconnect Box:

1.) Use an AC voltmeter at SR1, SR2, and SR3 of the Controller to Ground.

See Figure 24, page 34.

2.) Touch one of the AC voltmeter probes to SR1 and the other probe to

Ground.

3.) Then move the SR1 probe to SR2 and leave the other probe on the

Ground.

4.) For the third phase, move the SR2 probe to SR3 leaving the other probe

on the Ground.

The voltages should balance (read about the same).

To do a phase to phase check:

1.) Use an AC voltmeter touching a probe to SR1 and the other probe to SR2

2.) Next leave the probe on SR1 and move the SR2 probe to SR3

3.) Last leave a probe on SR3 and move the SR1 probe to SR2

The voltages should balance.

If you find a phase imbalance, no reading on one phase, or no power at all,

Check your power lead wires back to the Service Disconnect Box and, if

necessary, back to the Turbine.

If power at the Turbine Controller is present and balanced at SR1, SR2, and

SR3,

Check the Controller connections. Verify all connections to the Turbine

Controller. (Give every wire a mild tug to verify they are securely connected).

See Figure 21, page 34.

1



Controller Check

Is the Controller Keypad lit with no output power to the Main Panel?

No, check the Controller output with a voltmeter. Read across +

(positive output terminal) and – (negative output terminal) of the

Controller, see Figure 21, page 32.

Is the Controller input voltage between 44 – 66 V?

No, check the voltage output of the Main Power panel.

Is the Main Power panel output 44 – 66 V?

No, fix Controller input power.

Yes, the Controller fuse is blown, verify the power switch is set

to the proper input voltage before replacing. If the fuses are all

good, then the Controller will need returning to XZERES for

repair or replacement.

Yes, check the fuses (see Fuses on Figure 21 or Figure 53). If the

fuses are good, then return the Controller to XZERES for repair or

replacement.

Yes, check the Controller Board fuses (see Fuses on Figure 21 or Figure

53). If the fuses are good, then return the Controller to XZERES for

repair or replacement.

Figure 53 Turbine Controller Fuses

If no power is present at the Turbine Controller,

Check the Service Disconnect Box

Fuse locations, sizes and types: F3B Fuse, 5x20 mm, 400 mA, 250V, Type T

F2A Fuse, 5x20 mm, 2A, 250V, Type T

F1B Fuse, 5x20 mm, 6.3A, 250V, Type T



Figure 54 Access Service Disconnect Box Power

Verify the Turbine is spinning, service switch is in operate position CB1 is in

the “ON” position.

1.) Use an AC voltmeter with probes at terminal board 1 (TB1) to check

Service Disconnect input voltage.

The voltage from SR1 to Ground, SR2 to Ground, and SR3 to Ground

should be balanced (about the same).

2.) If you do not detect voltage and the turbine is spinning, then:

Both the Brake Resistors and Slip Rings are disengaged (this situation is best

left for a qualified professional).

Other up tower parts has failed and will need repair or replacing.

3.) If proper voltage is present at TB1,

Use AC voltmeter probes at circuit breaker 1 (CB1) to check Service

Disconnect output voltage.

The voltage from SR1 to Ground, SR2 to Ground, and SR3 to Ground should

be balanced.

If you still have no output power, then the circuit breaker (CB1) is bad.

Contact XZERES support.

WARNING ELECTRICAL AND MECHANICAL HAZARDS ON

THE TOWER CAN CAUSE INJURY OR DEATH



10.3 Other Up Tower Checks

Check the Brake Resistors (see Figure 33, page 43):

Verify all the wires are connected and show no damage.

Inspect for points of contact or arcing to the Yawhead, to wires, to the heat

shield and all other locations within the Yawhead.

Check the Brake Resistors for correct mounting:

Look for expansion room below the resistor (it should not bind tight at the

bottom connection pin, but should move up and down easily).

Check that the Alternator spins freely:

If the Alternator is frozen or only spins slowly with effort, send the Alternator to

XZERES for repair or replacement.

Check for foreign substances or loose magnets in the turbine.

Remove foreign substances; however, if you find loose magnets, send the

Alternator to XZERES for repair or replacement.

Does the Turbine vibrate excessively?

Check the Blades for damage.

Check the Blades for water intrusions.

Check the bearings for damage or damage to their machine fits. (With the

turbine stopped, see if you can detect any unusual up-and-down or side-

to-side motion of the rotor.)

Do the Blades show signs of cracking?

Replace the Blades.

Does the Nose Cone show signs of cracking?

Replace the Nose Cone.

Disconnect the up tower LPS and verify that the Alternator spins freely. See also

the LPS instructions.

Check that the brake contactors switch state.

This will require Down Tower support and may require disassembling the

sealed contactor box to verify both contactors function. (When engaged, the

BEFORE CLIMBING TOWER ALWAYS:

1) Read the Service and Safety instructions.

2) Follow electrical lockout and tag out procedures.

3) Wear Personal Protection Equipment.



mechanical override will be at the bottom of the contactor; when disengaged,

the mechanical override will be at the top of the contactor.)

NOTE: Alternator winding, bearing, magnet and Turbine Controller problems are not

Field Serviceable.)

10.3.1 Complete the Commissioning Closeout Inspection Checklist, 442SR

(document #4037) and return a copy to Xzeres. The System owner should keep a

copy for their records.

APPENDIX A: 442SR SYSTEM WIRING DIAGRAMS

Appendix A1 442SR Turbine Controller Schematic ....................................... 78

Appendix A2 Battery to Turbine Controller connections diagram ................ 79

Appendix A3 Yawhead Electrical Box Wiring Diagram ................................ 80

Appendix A4 Service Disconnect Box Wiring Diagram ................................. 81

Appendix A5 Wire Conversion Table .............................................................. 82

Appendix A6 Length Conversion Table .......................................................... 82



Appendix A 442SR SYSTEM WIRING DIAGRAMS

XZ

ER

ES

Tu

rbin

e C

on

trolle

r – B

atte

ry

+DL1TS

‒ DL2TS

+DL2TS

‒ DL1TS

BLACK

BLUE

BLUE/WHITE

BLACK

BLACK

BLACK

DIVERSION

LOAD

+DL

‒ DL

+DL

‒ DL

DIVERSION LOAD 2

DIVERSION LOAD 1

SLIP RING 1

SLIP RING 2

SLIP RING 3

SR1

SR2

SR3

PE

XZERES

SERVICE

DISCONNECT

BOX W/LPS

BLACK

BLACK

BLACK

GREEN/YELLOW

GREEN/YELLOW

DIV FAN

DIV FAN

GREEN/YELLOW

GREEN/YELLOW

V‒

SIG

V+

WIND VANE

2211

BR

AK

E S

EN

SO

R

BR

AK

E S

EN

SO

RS

R7

SR

8

BRAKE CTL

BRAKE CTL

SR5

SR6

ANEMOMETER 1

ANEMOMETER 2

RED

RED

YELLOW

YELLOW

WIN

D S

PD

2

WIN

D S

PD

1

BATTERY

SENSE

INPUTS

THERM –

THERM +

LEM GND

LEM OUT

LEM V –

LEM V +

BAT –

BAT +

Appendix A1 442SR Turbine Controller Schematic



‒ +

48V Battery

NTCALUGO3A103G THERMISTOR

SECURED TO TERMINAL

LEM HAS 300-S CURRENT SENSOR

250 mA

BATTERY +BATTERY ‒LEM V +LEM V ‒LEM OUTLEM GNDTHERMISTOR +THERMISTOR ‒

8 CONDUCTOR #22 AWG CABLE

442SR Turbine Controller

Battery‒ +

Customer Distribution Panel

CUSTOMER LOADS

EQUIPMENT BOND CONDUCTOR 1/0 MINIMUM

SINGLE 400 MCM OR DUAL 250 MCM MINIMUM DUAL 400 MCM MAXIMUM

CUSTOMER LOADS

GROUND

PORT

BA

T +

BA

T ‒

LE

M V

+L

EM

V ‒

LE

M O

UT

LE

M G

ND

TH

ER

M +

TH

ER

M ‒

400 A

+

‒

Appendix A2 Battery to Turbine Controller connections diagram



Yawhead Electrical Box Wiring Diagram

BOTTOM OF RESISTORS

TO SR8 ON SLIP RING

1 2

R1

R2

R3

R4

3 4

A1

A2

1R

1R

33 4

R4

R2

2

13

NO

21

NC

A1

14

NO

22

NC

A2

1 2

R1

R2

R3

R4

3 4

A1

A2

1R

1R

33 4

R4

R2

2

13

NO

21

NC

A1

14

NO

22

NC

A2

Contactor 1

T2

TOP OF 1.54Ω RESISTOR



T2 FROM ALTERNATOR

V FROM ALTERNATOR

W FROM ALTERNATOR

N FROM ALTERNATOR

TO SR5 ON SLIP RING

LIGHTNINGPROTECTION

SYSTEM

TO GROUND INSIDE YAWHEAD

T1T1 FROM ALTERNATOR

U FROM ALTERNATOR

ALTERNATOR

ALT

ER

NA

TO

R

TH

ER

MA

L S

WIT

CH

6.5"

6.0"

Contactor 2

Black

Black

Black

White

TO SR3 ON SLIP RING

TO SR2 ON SLIP RING

TO SR2 ON SLIP RING

TO SR1 ON SLIP RING

TO SR1 ON SLIP RING

TO SR3 ON SLIP RING

SLIP

RINGS

TO SR6 ON SLIP RING

TO SR7 ON SLIP RING

U SR1

V SR2

W SR3

N N

SR6

Appendix A3 Yawhead Electrical Wiring Diagram



Service Disconnect Box Wiring Diagram

Appendix A4 Service Disconnect Box Wiring Diagram



Appendix A Metric Conversion Tables

INCHES METRIC

AWG Number Ø [Inch] Ø [mm] A [mm²] FRACTIONAL DECIMAL mm

6/0 = 000000 0.580 14.73 170.30 1/64 0.0156 0.3969

5/0 = 00000 0.517 13.12 135.10 1/32 0.0313 0.7938

4/0 = 0000 0.460 11.7 107 1/16 0.0625 1.5875

3/0 = 000 0.410 10.4 85.0 1/8 0.1250 3.1750

2/0 = 00 0.365 9.26 67.4 3/16 0.1875 4.7625

1/0 = 0 0.325 8.25 53.5 1/4 0.2500 6.3500

1 0.289 7.35 42.4 5/16 0.3125 7.9375

2 0.258 6.54 33.6 3/8 0.3750 9.5250

3 0.229 5.83 26.7 7/16 0.4375 11.1125

4 0.204 5.19 21.1 1/2 0.5000 12.7000

5 0.182 4.62 16.8 9/16 0.5625 14.2875

6 0.162 4.11 13.3 5/8 0.6250 15.8750

7 0.144 3.66 10.5 11/16 0.6875 17.4625

8 0.128 3.26 8.36 3/4 0.7500 19.0500

9 0.114 2.91 6.63 13/16 0.8125 20.6375

10 0.102 2.59 5.26 7/8 0.8750 22.2250

11 0.0907 2.30 4.17 15/16 0.9375 23.8125

12 0.0808 2.05 3.31 1 1.0000 25.4000

13 0.0720 1.83 2.62 1 1/4 1.2500 31.7500

14 0.0641 1.63 2.08 1 1/2 1.5000 38.1000

15 0.0571 1.45 1.65 1 3/4 1.7500 44.4500

16 0.0508 1.29 1.31 2 2.0000 50.8000

17 0.0453 1.15 1.04 2 1/4 2.2500 57.1500

18 0.0403 1.02 0.823 2 1/2 2.5000 63.5000

19 0.0359 0.912 0.653 2 3/4 2.7500 69.8500

20 0.0320 0.812 0.518 3 3.0000 76.2000

21 0.0285 0.723 0.410 3 1/2 3.5000 88.9000

22 0.0253 0.644 0.326 4 4.0000 101.6000

23 0.0226 0.573 0.258 4 1/2 4.5000 114.3000

24 0.0201 0.511 0.205 5 5.0000 127.0000

25 0.0179 0.455 0.162 10 10.0000 254.0000

Appendix A5 Wire Conversion Table

20 20.0000 508.0000

30 30.0000 762.0000

40 40.0000 1016.0000

100 100.0000 2540.0000

Appendix A6 Length Conversion Table



APPENDIX B: UPDATING FIRMWARE

To update the turbine firmware from the internet, the Turbine Controller and your computer

must connect to the internet through a DHCP enabled router. If your turbine is not

connected to the internet, contact Xzeres to receive a USB stick and instructions for updating.

Locate the IP address of the Turbine Controller:

1.) Log into the internet router (see the router manual) and search the options to find

the list of attached Ethernet devices. The IP address listed next to the “XZERES-

442SR” label is the Turbine Controller’s IP address. NOTE: the XZERES-442SR

label may not show up on your particular router. Try other IP addresses in your

browser until one works.

2.) You can also find all the IP addresses on your network tied to the router by

installing and running free software (search for “Advanced Port Scanner”) from the

internet.

3.) Type the IP address of the Turbine Controller into the URL address bar of a web

browser on the computer.

Appendix B1 Homepage

4.) Click on the INSTALLER button link.

Appendix B2 Installer Button



5.) Log in with username: MyTurbine, Password: m442+SRt

Appendix B3 Login Window

a.) Select NO or decline any offer by the browser to save the password.

6.) The installer links window will appear (if not, select INSTALLER again, this will refresh

the screen). Select IP CONFIG / FW UPDATE. Window will appear.

Appendix B4 Installer Links

7.) On the following webpage, click the Check for Software Updates button.



Appendix B5 Check for Software Updates

8.) Depending on the speed and quality of the connection, this may take a few minutes.

If the next screen displays “Controller Updates Available,” click the Update Now button.

Appendix B6 Update Page

If you wish to update later, click the Check Later button and you will return to the

Configuration page (as will clicking the HOME link).

The update could take up to 5 minutes or more. When done, the turbine controller will reboot

and go to the “Stopped” state for 5 minutes before enabling the turbine.



APPENDIX C: WARNING LABEL PLACEMENT

The XZERES 442SR Energy System consists of seven Warning labels. These labels must

always be prominent in their given location. If they ever become damaged or lost, they will

need immediate replacing. Purchase replacement labels from XZERES Corporation or have

them manufactured at your convenience. For the safe operation of this system, these labels

must always occupy a prominent, visible place in the area where they relate.

The Diversion Load Warning Label must always be visible on the Diversion Load to warn of fire or heat related damage.

The Turbine Controller Label must always be visible on the Turbine Controller to warn of potential injury and damage to the energy system. The Danger Label must always be visible on the Turbine Controller Side Cover to warn of the Lethal Current.

The Service Disconnect Box Label must always be on the front cover of the Service Disconnect Box to warn of potential injury and damage to the energy system.

The Yawhead Electrical Box Label must always be on the front cover of the Yawhead Electrical Box to warn of potential injury and damage to the energy system.



Attach the Tower Warning Label at the base of the tower where it will be seen before the tower is climbed.

Attach the Yawhead Warning Label at the base of the Yawhead where it will be seen before work on the Yawhead can be started. If the label cannot be mounted directly to the tower, then mount it on a metal plate and attach the plate to the tower below the Yawhead where it will be seen.

The Rotor Lock Warning Label must always be displayed on the access door of the Yawhead where it will be seen before starting work on the Yawhead Electric Box.

The Turbine Controller Nameplate should be viewable on the side of the Turbine Controller.



APPENDIX D: SERVICE MAINTENANCE LOG

Service and Maintenance Log

Date Reason for Service/ Service Performed

Technician or Service Company

Contact Information

(continued)



Service and Maintenance Log (continued)

Date Reason for Service/ Service Performed

Technician or Service Company

Contact Information



DECOMMISSIONING AND DISPOSAL

With proper care, maintenance, and rebuilding with quality parts, the XZERES Wind

Turbine System could easily surpass the life cycle of a human. Industrial machinery, electric

motors, and generators from 100 years ago are still in use today. Much of the technology in

the XZERES Wind Turbine System follows along these same time proven designs. However,

the XZERES design incorporates all of the advancements of the last 100 years!

For example, the iron lamination that makes up the core of the alternator’s winding uses the

most recent advancements in iron lamination insulation (C-5 coreplate coating). If it had to,

the iron core could endure numerous trips through a burnout oven with negligible core loss.

The magnet wire in the alternator has the most advanced insulation coating possible

(polyurethane). XZERES winds the alternator to meet Class H insulation standards. This

gives the winding a life expectancy in the tens of thousands of hours worth of use at 180°C!

Abuse a wind turbine on this planet would never see. In addition, like standard industrial

machinery, almost all of the components of the turbine can be disposed of by your local

recycling center.

However, in some cases the rotor magnets may require some special disposal handling.

Neodymium Iron Boron (NdFeB) magnets are extremely powerful and can easily injure

someone if not handled correctly. If the magnets are magnetized, and you have the means of

thermally demagnetizing (by taking the magnet to its curie temperature), then you should do

this. Once the magnets are demagnetized, your local recycling center can handle their

disposal. If this is not an option, use some sort of shielding (galvanized steel sheets work

great) to line the boxes or containers used for disposal. A shield will prevent the magnets

from sticking to any trash container.

The Nose Cone, Tail Vane, and Blades are made of fiberglass and designed to an expected life

of 20 years and should far exceed that. Fiberglass is recycled all around the world. Check

with your local recycle center with any questions or concerns. They may require that you chop

or breakup the fiberglass.

The XZERES Turbine Controller, Service Disconnect Box, and Diversion Load likewise carry

a 10-year warranty and a 20-year life expectancy. All decommissioned electronics should

follow local recycling procedures. For information in your area, check with your local recycling

center.

All other materials in your Wind Turbine System should include standard disposal

information or be of a common nature that your local recycling center can assist in their

disposal.



INDEX

A

abnormal conditions 63

alternator 52, 54, 68, 71, 76, 90

electrical output 17

type/construction 17

altitude, maximum 17

amperage, maximum amperage 17

anemometer 19, 25

arrow button 60

arrow key 64

B

battery 17

bearings 76

blade 39, 48, 53, 76, 90

construction 17

edge 52

edge 48

inner and outer blade mount plates 18

inner clamping plate 52

outer clamping plate 52

root 48

rotational speed 17

set 18

studs 18, 51, 52

swept area 17

tip 48

brake control 70

brake resistor 41, 71, 75

brake resistors 54, 76

brushes 72

button 61, 62, 69, 70

check for software updates 84

check later 85

installer 83

S4 61

STOP 61, 62, 69, 70

update now 85

C

cable schematic 35

cable support 19

caution 10

circuit breaker 19, 20, 56

conduit 19

configuration 17

controller 17, 18, 19, 20, 25, 26, 27, 29, 30, 33, 37, 38, 46,

56, 61, 62, 70, 73, 74, 77, 83

cowling 40, 55, 72

D

danger 10

DC bus 62, 67, 68

dealer 10

demagnetizing 90

disabled state 62

diversion load 18, 25, 26, 27, 67, 68, 70, 90

clearance 28

warning label 86

duty cycle 17

E

electrical 11, 25, 27, 33, 36

distribution panel 19

hardware 19

over-speed control 17

electromagnetic interference 25

electrostatic 11

enabled state 62

F

fastener kit 18

fiberglass 90

fire hazard 11

foundation mat 21

pad and pedestal 21, 22

frequency 67

fuse 74

G

ground 11, 26, 38, 46, 56, 73, 75

PE 11

specification 17

guide bolt 44

H

hard faults 67

hard hat 12

hazard symbols 11

heat-sink 67

hole saw 20

homepage 83

humidity 17

I

ice 63

installer 10, 12, 21, 22, 27, 40

IP address 83

J

junction box 19, 25, 26, 37, 39, 46

tower base 18, 56

tower top 72

turbine top 18



K

Kellems grips 19, 39, 47

L

lanyard 41

laptop 83

lightning 14, 25

liquid crystal display 60

local codes 17, 26, 39, 46, 56

lockout 12

Loctite

243 44, 45, 49, 50, 51, 52, 54

Loctite 18

LPS 76

M

magnets 76, 90

main power panel 20, 58, 74

manual reset 63, 68, 69

multi-meter 20

N

neodymium iron boron 90

nose cone 54, 76, 90

note 10

O

ohmmeter 20

operating faults 67

owner 10

P

pinch-point 11

plywood 19, 27

polyurethane 90

power

factor 17

rated 17

R

ratchet 20

recycling 90

revision table 94

rotation direction 52

rotor 51

diameter 17

rotor lock 53

warning label 87

router 83

S

safety 10, 69

glasses 12

harness 12

screwdriver

flat-head 20

Phillips 20

service disconnect 13, 18, 25, 26, 27, 33, 37, 38, 56, 58,

72, 73, 74, 75, 90

switch 33, 56, 58, 72, 86

service disconnect box See service disconnect

service maintenance log 88

shunt 56, 58

shutdown 13

slip rings 39, 42, 46, 72, 75

socket 20

soft faults 67

surge suppressors 14

T

tail

boom 18, 39, 48, 49

boom weight 49

vane 18, 39, 48, 49

Tail 55

tail vane 90

tapered pin 44

technical support 69

temperature 17

thrust, maximum lateral 17

toll-free number 10

tower 39, 55

anchor bolts 23

gin-pole system 23

grounding 24

grounding system 57

monopole 21, 23, 25, 47

self-supporting lattice 22, 23, 25, 55

template 23

tilt-up monopole 23

top weight 17

warning label 12, 87

wiring 39

tower top interface plate 43, 45

turbine 71, 72, 75

turbine controller See controller

turbine-state 64

turbulence 9, 12

U

URL address bar 83

V

vise-grip 20

voltage

required 17

voltmeter 20, 70, 73, 74, 75



W

warning 10

wind vane 19, 25

wire 19, 26

aluminum 27

brake 70

brake control 56

color system 26

conversion table 82

insulation 26

magnet 90

run 19, 26, 27

shielded twisted 25

strippers 20

wrench 20

adjustable 20

hex/Allen 20

torque 20, 24

Y

yaw lock 19, 49, 55

yawhead 40, 53

assembly 18

bearing 49

electric box 56, 68

electrical box 18, 54, 71

electrical box warning label 86

mounting flange 44

sleeve 50

warning label 87



Rev XCO Release

Date Major / Minor

Description

A 1159 3/25/2014 --- Initial release

Table 13 Revision History



This page is left intentionally blank.

XZERES ARE442 & 442SR Battery Charger Wind Turbine ...

Documents

Transcript of XZERES ARE442 & 442SR Battery Charger Wind Turbine ...