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SP SOLAR WIND SOLUTIONS

SITE INSTALLATION AND SPECIFICATIONDOCUMENT: PART 10

DC BACK UP GENERATOR

D0273 48V 70A HYBRID POWER SUPPLY

BROCHURE REV3


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SP SOLAR WIND SOLUTIONS LM01/V08: PART 10

Issued by

SP Solar Wind Solutions (Pty) Ltd

309 Derdepoort Road / Silvereike Tannery Industrial Park Unit 32 Sinoville

Pretoria

Copyright SP Solar Wind Solutions (Pty) Ltd All Rights Reserved.


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Table of Content

Table of Content5

part 18

Document Information8

Introductions10

1. Aim10

2. Copyright10

3. Issue Control10

4. History10

5. Glossary and Abbreviations10

6. Keyword / Descriptor11

Tool List13

7. General13

8. Safety13

9. Special Tool14

10. Instruments List14

part 1015

DC Back up Generator D0273 48V 70A HYBRID POWER SUPPLY BROCHURE REV317

11. DESIGN PHILOSOPHY18

12. Present Solution18

13. Future Solution20

14. Proposed Layout of Hybrid Solution21

15. General21


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16. Generator Specification22

17. Operation Threshold Settings22

18. System Specification24

a. The Base Frame24

b. The Unit Specifications24

c. The Diesel Fuel Tank24

d. Anti Vibration Mounting Rubbers24

e. Engine25

f. Noise Levels25

g. Maintenance25

h. Alternative Information Specification25

i. Control25

j. Canopy26

k. Engine Operation as well as Engine Protection26

i. Emergency Stop Pushbutton Alarm26

ii. Engine Low Oil Pressure Alarm26

iii. Start Failure Alarm26

iv. Faulty Switch Position Alarm27

v. Exhaust27

vi. Alternator Abnormal Voltage.27

l. Manual Operation27

m. Alternator27

n. Load Battery28


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o. Documentation and Training28

19. Photographs Of 48v 70a Hybrid Power Supply Prototype29


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part 1

Document Information

Document SITE INSTALLATION AND SPECIFICATION DOCUMENT:

Document number SP SOLAR WIND SOLUTIONS LM01/V08: PART 10

Date created 05/10/2006

Author G.B. Posthumus

Technical writer G.B. Posthumus

Last modified (date) 22/11/2006

Last modified (by) Gerhard Posthumus


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Introductions

1. Aim

a. The aim of the document is define all equipment and civil used to produce this site.

b. Ensure that safety is applied in all actions performed in the installation of thisequipment.

c. State the technical specifications of this equipment regarding to the installation of the

equipment.

d. Indicate the wiring of the equipment.

e. Supply technical drawings were applicable.

f. Stipulated the step by step installation processes.

g. To be applied as a training Document.

2. Copyright

a. All rights reserved. No part of this publication may be reproduced, transmitted, stored

in retrieval system, or translated into any language in any form by any means, optical,electronic, recording, or otherwise, without the written permission of our company.

b. We reserve the right to revise this manual and make changes to any or all parts at any

time, without obligation to notify any person or entity of such revision and changes.

3. Issue Control

See Paragraph 4 History.

4. History

Issue Date Reason for Changes

01 05/10/2006 New Specification

02 21/10/2006 Add Astrabase mast and HCM information to specification

5. Glossary and Abbreviations


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a. BTS - Base Transceiver Station

b. GSM - Global System Mobile

c. Regulator Charge Controller Blue Sky

d. LM Last Mile

6. Keyword / Descriptor

a. Container, BTS, Base Station


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Tool List

7. General

a. Spanners ring and open end, 8mm to 32mm.

b. Shifter 28mm

c. Pliers Combination.

d. Screw driver set flat and star. (Full Set)

e. Battery Drill/Screwdriver.

f. Tech Screw 6 and 8mm by 25mm.

g. Spirit Level.

h. Ratchet set, 8mm to 32 mm.

i. Ladder 6 foot x2.

j. Balancing Rope x4.

k. Pulley Times 2.

l. Rope rigging.

m. Side cutters small and big.

n. Crimpers big and small.

o. Heat Gun.

p. Concrete Drill.

q. Pop rivet gun.

r. Torch.

s. Rigging Spanners for mast.

8. Safety


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a. Safety Gloves.

b. Grip Poles.

c. Safety shoes.

d. Safety harness.

e. Hard hat.

f. Fall Arrestor Equipment.

g. Rigging Equipment.

9. Special Tool

a. Block and Tackle 7 meter chain.

b. Solar Frame lifting tool.

c. Rigging rope.

d. Rigging Harness.

10. Instruments List

a. Multi Meter.

b. Clamp meter.

c. Heat detector.

d. Wind Measurement.

t. Digital camera.

e. Label instrumentation.


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part 10


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DC Back up Generator


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D0273 48V 70A HYBRID POWER SUPPLY BROCHURE REV3

11. DESIGN PHILOSOPHY

a. For remote Base Transceiver Station (BTS) sites, where solar power is utilized tocharge a bank of 48V Batteries to power transmission equipment, the followingscenario usually applies:

b. The BTS Radio Transmission equipment requires a 48V DC Power Source. As mains

or grid power is usually not available on these remote sites, the power source utilizedis a battery bank. The battery bank uses solar power to recharge by utilizing a solar

panel. Should the weather be overcast, the solar panel will be unable to recharge thebattery. For this reason, the typical battery is sized to store five days of energy.

Depending on the site requirements, the typical battery bank is 48V, 2000Ah.

c. A problem arises however, when the weather is overcast for more than five days, or if

the window period for adequate sunlight is shortened due to seasonal rainfall. On theisolated occasions (probably 5 or 6 times per year) when this does occur, an alternate

means of charging the batteries is required.

12. Present Solutiona. The standard solution to this problem is relatively expensive and complex. One would

usually use a standard Genset.


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b. Then add to that a set of rectifiers to convert three phase 400V AC into a 55V DCFloat voltage. Then a special controller would be needed to monitor the state of the

battery bank.

c. By the time you have added all of these components, the end result is relatively

expensive.


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13. Future Solution

We propose to do it a different way:

a. The heart of the solution incorporates a standard 48Vdc wind turbine generatorsupplied by Kestrel Wind Turbines (Pty) Ltd that supplies battery charging energy.

b. The generator being directly connected to the battery system is powered by a reliable

air-cooled single cylinder diesel engine from a 750rpm half speed output shaft.

c. The genset is designed in such a way that the fuel tank acts as a shelter for the genset,and no extra expensive housing is required.

d. A Siemens LOGO! PLC controls the Genset, and monitors the state of the battery

bank. If it is necessary to supplement the solar power recharging by using the

generator, the controller will signal the generator to run for a pre-determined periodand charge the battery bank.

e. The unit is designed for this purpose, and we anticipate it will only run a few times

per year, when there has been a climatic reason for the Solar panels to be unable tocharge the batteries.


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14. Proposed Layout of Hybrid Solution

15. General

a. A specially designed 48V DC Generator, that was specially designed by Kestrel Wind

Turbines c.c. in South Africa, for use on Wind Turbines will be used.

b. A modified version of this DC Generator to recharge the battery bank.

c. A reliable air-cooled single cylinder engine with a half speed shaft that rotates at

750RPM, to drive the DC generator will be used.

d. At 650 Rpm the wind turbine is producing 3400 Watt.

e. The output of this generator couples to the battery bank directly.

f. The genset is designed in such a way that the fuel tank acts as a shelter for the genset,and no extra expensive housing is required.

g. A Siemens LOGO! PLC controls the Genset, and monitors the state of the batterybank. If it is necessary to supplement the solar power recharging by using the

generator, the controller will signal the generator to run for a pre-determined periodand charge the battery bank.


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16. Generator Specification

Engine:Kirloskar DA10, 7kW Single Cylinder Air Cooled Diesel

Engine

Alternator: Kestrel Wind Turbines c.c. DC Generator. 3.3kW, 70A 48VController: Siemens LOGO! PLC

Control V: 12V DC

Fuel Tank: 200 litres capacity

Load Battery: 48V DC Typically 2000Ah

Weight: 450Kg

Size: 1.500 x 1.000 x 1.200m

Fuel Consumption: 1.1l/hour

a. Hybrid Genset dimensions:(H)1350mm x (D)1100 x (W) 1700.

b. Canopy provider to provide canopy with at least the following dimensions, with at

least 600mm access at the front and back for maintenance etc. That is (H) 1500 x (D)2300 x (W) 1700

17. Operation Threshold Settings


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Unit will start when battery voltage

reaches this threshold:46V for 30 seconds

Time unit will run for after start

command is given:6 hours (programmable)

Unit will stop on fault condition below

this threshold:42V

Unit will stop on fault condition above

this threshold:60V for 2 seconds

Unit will stop on fault condition above

this threshold:58V for 15 minutes


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18. System Specification

a. The Base Frame

i. The Base Frame for the Hybrid System is manufactured out of mild steel

channel, and painted black.

ii. The base frame includes lifting eyes at all 4 corners for ease of rigging andinstallation.

iii. Anti corrosive base coat: A Raw metal primer is applied to aid in corrosion,and in correct paint application.

b.

The Unit Specificationsi. The unit is supplied without a canopy.

ii. The unit is to be installed in the Tower's canopy/room/enclosure.

iii. The genset dimensions are (H)1350mm x (D)1100 x (W) 1700.

iv. The unit has access at the front and back - at least 600 mm either side for easy

access for maintenance etc. Louvres must be provided to allow enough airflowacross the engine. (Louvres not supplied by Diesel Electric Services).

v. You need a louvre 600x800 for air intake, and another louvre 600x800 for air

removal.

c. The Diesel Fuel Tank

i. The diesel fuel tank has a 200 litre capacity, and is manufactured out of mildsteel plate.

ii. A spill tray can be provided by customer request, however its not necessary on

such a small set with such a small tank.

d. Anti Vibration Mounting Rubbers

i. The Engine has Anti Vibration Mounting Rubbers installed to dampen

vibration transfer from the Engine to the base frame when the engine is running.


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ii. The Anti Vibration Mounting Rubbers have a warrantee it for 1 year, but theyare designed to work for the life of the engine - 10 years.

e. Engine

The engine used is a Kirloskar DA10, 7kW Single Cylinder Air Cooled Diesel Engine.

The engine has a warrantee of 2800 hours or one year, witch ever comes 1st.

f. Noise Levels

i. Noise Levels of Engine at 1 Meter on open Set are 90dBA.

ii. Noise level on open set at 7 metres is 84dBA. the db of a closed canopy willdepend on the canopy design by the canopy manufacturer.

g. Maintenance

i. Engine Maintenance in very dirty environments, clean the air filter and oilfilter sieve. Every 50 hours.

ii. Service every 500 hours, replace the oil, oil filters, fuel filters, and air filters.

Check injectors etc.

h. Alternative Information Specification

i. This engine has a rotating shaft available running at half the engine speed.

ii. The engine is coupled to the alternator via this half speed shaft.

iii. The option to use a Lister Engine is not available.

i. Control

i. The Engine Control utilizes a Siemens LOGO! PLC.

ii. The control utilizes 12V DC from the engine starting battery.

iii. The unit is designed in such a way that the starting battery is charged from theload batteries by using a DC to DC converter, to ensure that the engine starting

battery remains fully charged at all times. The LOGO! PLC controls Load BatteryMonitoring.


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j. Canopy

i. Canopy needs to be such that it provides protection to minimum if IP53

ii. The engine supplier approved the configuration engine/canopy in terms of

accessibility, air intake and exhaust location?

iii. The unit is supplied without a canopy.

iv. The unit is to be installed in the Tower's canopy/room/enclosure. T

v. he genset dimensions are (H)1350mm x (D)1100 x (W) 1700. T

vi. he unit has access at the front and back - at least 600 mm either side for easy

access for maintenance etc. Louvres must be provided to allow enough airflowacross the engine. (Louvres not supplied by Diesel Electric Services).

vii. You need a louvre 600x800 for air intake, and another louvre 600x800 for air

removal.

k. Engine Operation as well as Engine Protection

Engine Operation as well as engine protection for the following conditions:

i. Emergency Stop Pushbutton Alarm

If the Emergency Stop Pushbutton is pressed, the engine will immediately stop, avisual LED on the control panel will indicate the particular alarm and the Potentialfree Common Alarm Contact will activate.

ii. Engine Low Oil Pressure Alarm

If a low oil pressure is detected while the engine is running, the engine willimmediately stop, a visual LED on the control panel will indicate the particular

alarm, and the Potential free Common Alarm Contact will activate.

iii. Start Failure Alarm

Three start attempts are allowed once the engine is instructed to run. If the engine

hasnt started after the third start attempt, a visual LED on the control panel willindicate the particular alarm and the Potential free Common Alarm Contact will

activate.


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iv. Faulty Switch Position Alarm

If the control Switches on the control panel are not selected for Automaticoperation, a visual LED on the control panel will indicate the particular alarm, and

the Potential free Common Alarm Contact will activate

v. Exhaust

(1) The engine is supplied without an exhaust. A new exhaust is fit

(2) The manufacturer measurements on the carbon monoxide: TBA

vi. Alternator Abnormal Voltage.

(3) Should the voltage of the batteries exceed a pre-determined threshold, the

unit will be instructed to stop charging, thus preventing any damage to thebatteries due to overcharging, and preventing any damage to the DC

Generator due to an open circuit occurring.

(4) The Load Batteries are at a nominal voltage of 48V. Please see section onOperation Threshold Settings.

(5) These settings are the recommended settings, but can be changed by theoperator on site if so required.

l.

Manual OperationManual Operation of the System is available as an option if required.

m. Alternator

i. The alternator is a Kestrel 0404 48Vdc nominal 3kWdc (60A at 55Vdc) 70A

maximum.

ii. 12 Stage rectification DC, unregulated.

iii. The Kestrel 0404 alternator is mounted directly onto the base frame.

iv. A Special coupling between this and the engine is utilizes to minimise the

vibration perceived by the alternator.

v. The windings are coated to suite all weather conditions and the warrantee of

the wind generator covers this as well. This includes Tropical conditions.


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vi. 2 Year Warrantee

n. Load Battery

i. Load Battery: 48V DC Typically 2000Ah.

ii. This is not part of our scope of supply, however the system is designed for abattery bank of this capacity, and if this capacity is reduced significantly, the

operation of the system may not be optimal.

o. Documentation and Training

i. A full set of documentation including operation and maintenance manuals are

provided with each hybrid system.

ii. Although the documentation is comprehensive, training can be provided at our

premises in at no charge if required.

iii. To be provided within 2 weeks of placement of order.


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19. Photographs Of 48v 70a Hybrid Power

Supply Prototype

Kestrel Wind Turbines 70 48V DC Generator Coupling between Engine and DC Generator


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1 Cylinder Kirloskar Engine with half speed shaft

Coupling between Engine and DC Generator


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Back view of our Hybrid Prototype

Front view of our Hybrid Prototype

Documents

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