Navitron Renewable Energy and Sustainability Forum

WIND TURBINES => Wind Turbines and associated systems => Topic started by: merkland on November 16, 2011, 08:49:11 PM



Title: 200w wind turbine packed up
Post by: merkland on November 16, 2011, 08:49:11 PM
Disaster!! My 200w x 24v wind turbine has stopped generating, I noticed it did not seem to be producing anything and on checking discovered there was no output. I have taken it down in the faint hope that it might be repairable.
Dismantled it as far as I could this afternoon and tested the three output wires with the continuity setting on my little meter. I get a reading between two of the wires but can get nothing from the third.
The attached pictures show the main windings section of the turbine.
I assume that each wire represents a winding and that my continuity test indicates that two windings are sound and the third is faulty.
I cannot see how to dismantle any further and am probably at the limit of my capability.
Has anyone any suggestions how I might proceed as, if at all possible, I would like to get the turbine working again.
I have had a look for a possible replacement but Navitron does not appear to stock them any more and so far have found no one else.

merkland.


Title: Re: 200w wind turbine packed up
Post by: guydewdney on November 16, 2011, 08:50:48 PM
last pic - is that a crack in the magnet at the 7 o clock position?


Title: Re: 200w wind turbine packed up
Post by: clockmanFR on November 16, 2011, 09:11:10 PM
3 wires, looks like 3 phase, normally you should get the same reading between any of the wires if its a star connection, 36 coils? therefore 12 per phase.

Do the coil enameled copper look damaged or burnt? . Sometimes the enamelled copper windings joints to the output wires can be suspect.

Sorry i can not be more helpfull, if it was here then i could possibly find the faulty coil or joint by tracing the wire that has no reading back as far as possible.


Title: Re: 200w wind turbine packed up
Post by: merkland on November 16, 2011, 10:24:20 PM
Guy,

I don't think that the crack is in the magnet but I will check.

Clockman,

It is three phase and I can see no obvious signs of burning or damage. I cannot see any way of stripping down anymore to allow a proper examination.

Merkland.


Title: Re: 200w wind turbine packed up
Post by: biff on November 17, 2011, 01:43:46 AM
hi merkland,
             that particular turbine is one of the most reliable ones and not given to any kind of bother.i suggest you check the wiring back to what you consider to be the faulty winding  and its possible you will find a break under the plastic insulation,these were made by the million and have turned up all over the globe,they are much loved because they are quite basic ,exellent performers and easy to fix,it might be an idea to check the slip rings as well.
                                                                                                           biff


Title: Re: 200w wind turbine packed up
Post by: agrarian on November 17, 2011, 04:01:57 PM
Hello Merkland,

You could always have the stator rewound, but it can be quite expensive, and a new alternator, especially a Chinese one can often be cheaper if you can identify the manufacturer.

Ag


Title: Re: 200w wind turbine packed up
Post by: ecogeorge on December 04, 2011, 09:49:42 PM
Any news here ? or has she gone to the graveyard? .


Title: Re: 200w wind turbine packed up
Post by: merkland on December 04, 2011, 10:32:14 PM
Don't like throwing anything away if there is any hope of a possible repair. Still hoping to work out how to strip down further which may allow a repair. Will report further when I get a chance

Merkland.


Title: Re: 200w wind turbine packed up
Post by: merkland on December 16, 2011, 05:42:21 PM
Well I have finally got back to this and worked out how to remove the stator from the casing.
With stator removed I checked between pairs of output wires for continuity and now found I was getting a reading on each pairing but no two the same. Thinking it might be moisture related I stuck the stator in the drying oven of the Aga overnight. On retesting between pairs I could get no reading at all !
I decided to take some pictures to post and while doing this I think I have found the fault.
Picture 1 shows removed stator.
Picture 2 shows where the three output wires are connected to windings
Picture 3 shows what appears to be connections in the windings on opposite side to output wires.
Pictures 4 & 5 shows what appears to be the fault. There seems to be a fourth connection immediately below those of the three output wires and this connection has got hot to the point that it has burnt out. If I poke one connector from the test meter into this burnt mess I can get an equal reading to each output wire in turn.
I am going to attempt to remake this burnt out connection, do a general tidy up, then see if everything now works as it should.
Keeping fingers crossed, will report progress, if any, in due course.

Merkland.


Title: Re: 200w wind turbine packed up
Post by: clockmanFR on December 16, 2011, 07:39:47 PM
merkland,

The fourth connector 'as you put it' should be where all the first 3 coils enameled copper wires are joined together, and hence when you put a meter on the 4th connector and to each of the 3 other wires you get the same reading.

When i wire up my 12 coils coil the inside wire on 1 , 2 and 3 are joined together then the outer coil wire of 1 joins to the inner wire of coil 4 then to 7 then 10, and 2 goes to 5, 8 and 11. coil 3 goes to 6, 9, and 12, this then gives you 3 phase series/star connection.

So that fourth connector, desolder it and test each of the 3 phase's to find the faulty connection.

My money is on these connections to the enamelled coated  copper winding wire. I normally solder them to Triphase rated wire, (very multi stranded very flexible) along side each other for a minimum of 20mm then i use  Glue lined heat shrink, twice, to insure insulation and none movement, then i encase the joint and a good distance of the Triphase cable in Vinyester resin.

 So me thinks its your joints.   

Ps, I use a sharp knife to scrape the enamell coating of the wire then a bit of fine wet and dry paper to get a good solder joint.


Title: Re: 200w wind turbine packed up
Post by: Eleanor on December 17, 2011, 12:31:13 AM
Can't offer any help but it's good to see that the Ladies Curling Team excelled themselves  8)


Title: Re: 200w wind turbine packed up
Post by: ecogeorge on December 17, 2011, 07:28:53 PM
Can't offer any help but it's good to see that the Ladies Curling Team excelled themselves  8)
Are you sure your monitor is the right way up ?  ;D


Title: Re: 200w wind turbine packed up
Post by: Eleanor on December 17, 2011, 08:25:39 PM
It's all in the Training Manual George and this runs to several thousand pages. The trick is to look like a blundering idiot and avoid suspicion  ralph:


Title: Re: 200w wind turbine packed up
Post by: Mladen on December 17, 2011, 08:48:29 PM
there is one smaller version of wind generator, as DIY project. It can be used as small electric device charger, or LED power supply.
here is building manual: http://solar.freeonplate.com/floppy_windmill.htm


Title: Re: 200w wind turbine packed up
Post by: clockmanFR on December 17, 2011, 08:56:34 PM
I say chaps, Ecogeorge and Eleanor, thou is certainly on the ball.

There's me looking at the coils and windings, never even saw the Australian Hockey lot.

Mladen, err wot, looked at site link, noticed it picked me up as a stranger from France, 'so you have a cunning plan'?

Look out!, Mart (Innuendo Kid) will be here next, me i love coils, just the thought of the magnet passing by gets them all excited.  exhappy:


Title: Re: 200w wind turbine packed up
Post by: Eleanor on December 17, 2011, 09:10:56 PM
Steady on Clockman, you'll attract the attention of the Ladies Curling Team and we shouldn't forget how long it took to calm things down last time that happened  facepalm


Title: Re: 200w wind turbine packed up
Post by: clockmanFR on December 17, 2011, 09:39:30 PM
Roger !


Title: Re: 200w wind turbine packed up
Post by: M on December 18, 2011, 05:12:33 PM
I say chaps, Ecogeorge and Eleanor, thou is certainly on the ball.

There's me looking at the coils and windings, never even saw the Australian Hockey lot.

Mladen, err wot, looked at site link, noticed it picked me up as a stranger from France, 'so you have a cunning plan'?

Look out!, Mart (Innuendo Kid) will be here next, me i love coils, just the thought of the magnet passing by gets them all excited.  exhappy:

Sorry clockman, I wasn't paying attention, and I feel I let you down badly.

I promise next time you ask for a double entendre I'll be much quicker to give you one.

As for innuendo and wind, I simply don't know enough about the equipment to comment. But personally, I feel what you choose to strap on and wave in the air in the privacy of your own garden, is your business, and yours alone. So long as it doesn't offer a distraction to any given flight path, I say live and let live.

Mart.


Title: Re: 200w wind turbine packed up
Post by: clockmanFR on December 18, 2011, 06:59:32 PM
Unfortunately, are garden is 8 1/2 acres on the side of the river Touque valley with fantastic views all round.

Excellent for wind.

People come to see my antics. They park at the side of the one track lanes and have their lunch watching the Windturbines going round, (very French). Watch me chasing the sheep and the next door neighbours cattle about with a English teacloth.  :hysteria

Messy farmer at the bottom of the valley, "The English man has got his trailer stuck in the field" (translation) "the English man is mad, he is putting a ships anchor on the ground and winching the trailer up the field, damn i can not charge him for getting my tractor out!".

As regards the Planes that fly in the air, (never can tell), the french Air force use our place as a way point and fly Hercules at 500ft and fast jets at 1000ft. I am told that our good old English Scaffolding shows up really well on their radar, and our Turbine Dump loads on PWM mode give off interference. If they get any lower i will toss them a couple of those handgrenades i keep digging up.  :D


Title: Re: 200w wind turbine packed up
Post by: merkland on March 03, 2012, 06:31:48 PM
I eventually got the burnt joint remade and everything tested O.K.
While the turbine was in pieces I decided to follow Biff's excellent advice and build in a swivelling connection to finally solve my twisting cable problem, which has to be unwound about once a week.
The commutator unit I found on ebay was just the job but unfortunately just a tad too big to get the casing back on so had to cut a hole to accommodate it then fit a small dome to make it watertight. 
Now back up churning away and producing!

merkland.


Title: Re: 200w wind turbine packed up
Post by: Heinz on March 03, 2012, 07:56:37 PM
I like your telegraph pole tower, very neat  ;D

H


Title: Re: 200w wind turbine packed up
Post by: camillitech on March 03, 2012, 09:37:53 PM
I like your telegraph pole tower, very neat  ;D

H

Yes me too, I have a telegraph pole already set up and this seems like a perfect way of giving it some height. I was considering a similar set up but foolishly would have put the hinge at the base  ::)


(http://i224.photobucket.com/albums/dd170/camillitech/oldmastSmall.jpg)

It's been up for ten or twelve years and had a Rutland 910 on top until it disintegrated  sh*tfan: after the second winter. I never replaced it as the Proven went up but this mast is right next to the new house site so I'm looking at options and following Biff and Ag's  exploits with interest  ;)

Cheers, Paul


Title: Re: 200w wind turbine packed up
Post by: merkland on March 03, 2012, 10:49:44 PM
Credit where it is due,it was Billy(the barge) that gave me the idea in the first place.
It is not perfect but it works reasonably well and the hand winch allows me to raise and lower it on my own. Before it was a two man job to raise or lower it safely.

Merkland.


Title: Re: 200w wind turbine packed up
Post by: clockmanFR on March 04, 2012, 09:04:46 AM
merkland,

That's a very smart way of doing it. Your Gin pole is permanent.

The only comment i have is that you might consider putting a temp cable /rope at the top of your wooden telegraph/ Gin Pole that goes to a ground anchor when lowering/raising, then there's no worry that the whole lot toppling over.

Off course depends on the weight of your turbine assembly, each one of mine weighs about 45-50kgs. 


Title: Re: 200w wind turbine packed up
Post by: clockmanFR on March 04, 2012, 09:07:02 AM
paul,

I love your shooting hide.