Owner’s Manual

Bergey EXCEL 10
Grid-Intertie
Wind Turbine &
Powersync II Inverter

Bergey Windpower Co.

2200 Industrial Blvd.
Norman, OK 73069
TEL: 405-364-4212
Fax: 405-364-2078
E-mail: [email protected]
Rev. 1 March, 2011 Web Site: www.bergey.com
 BERGEY EXCEL 10 SPECIFICATIONS

PERFORMANCE
START-UP WIND SPEED……………………………………………. 5 mph (2.2 m/s)
CUT-IN WIND SPEED………………………………………………... 5 mph (2.2 m/s)
RATED WIND SPEED……………………………………………...… 26 mph (11.6 m/s)
AWEA RATED POWER (at 11 m/s or 25 mph) ……….…. 8.9 kW
AWEA ANNUAL ENERGY (at 5 m/s average) ……………. 13,600 kWh
CUT-OUT WIND SPEED………………………………………..…… none
FURLING WIND SPEED……………………………………………… 36-40 mph (16-18 m/s)
MAXIMUM DESIGN WIND SPEED………………………….…. 134 mph (60m/s)
RATED POWER………………………………………………………... 10 kW
ROTOR SPEED……………………………………………………….... 0-400 RPM

MECHANICAL
TYPE………………………………………………………………………… 3-Blade Upwind, Horizontal-Axis
ROTOR DIAMETER……………………………………………………. 23 ft (7.0m)
WEIGHT……….…………………………………………………….……. 1020 lbs (460 kgs)
GEARBOX …………………………………………………………….…. none
BLADE PITCH CONTROL……………………………………..….... none
OVERSPEED PROTECTION………………………………….….... AUTOFURL®
TEMPERATURE RANGE…………………………………………… -40 to 140 deg. F (-40 to 60deg. C)

ELECTRICAL
OUTPUT FORM………………………………………………..…….. 240VAC, 1-Phase, 60Hz
or 220VAC, 1-Phase, 50Hz
GENERATOR ………………………………………………………….. Permanent Magnet Alternator
POWER PROCESSOR …………………………………………..…. Powersync II Inverter

Bergey Excel 10 Power Curve (Sea Level)

USDA Data per IEC 61400-12
14
13
12
11
10
Power 9
Output 8
(AC kW) 7
6
5
4
3
2
1 m/s = 2.237 mph
1
0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Wind Speed (m/s) at Hub Height

Owner’s Manual Bergey EXCEL 10 Turbine

INTRODUCTION

This manual contains important information concerning your Bergey EXCEL 10 wind turbine
system and its operational characteristics. We strongly recommend that you read and
familiarize yourself with its contents.

At several points in this manual items of special interest or significant impact are highlighted by
one of the following symbols:

DANGER Hazards or unsafe practices that could cause

personal injury or death.

WARNING Hazards or unsafe practices which could cause

product damage.

NOTE Significant points of interest.

Serial Numbers

Each Bergey EXCEL 10 wind turbine has a serial number located on the tower adapter. The
turbine serial number can also be found on the outside of the shipping carton and on the
warranty registration card. We recommend that the serial number be copied to this manual for
possible future reference.

Bergey EXCEL 10 Serial No.: ________________________

The Powersync II inverter has a serial number label on its right side. We recommend that this
serial number also be copied to this manual.

Powersync II Serial No.: __________________________

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Owner’s Manual Bergey EXCEL 10 Turbine

Table of Contents
Section Title Page No.

1 System Description 4
A. Rotor System 5
B. Alternator 5
C. Mainframe 5
D. Slip-Rings and Brushes 5
E. Tail Assemble and AutoFurl® Operation 6
F. Spinner and Nacelle 6
G. Powersync II Inverter 6

2 System Operation 7
A. Normal Operation 7
B. High Winds - AutoFurl® 8
C. Unloaded Operation 8
D. Manual Furling 9
E. Furling Procedure 9
F. Powersync II Inverter 10

3 Installation 14
A. Bergey EXCEL 10 Wind Turbine and Tower 14
B. Fused Disconnect Switch 14
C. Wire Sizes 14
D. Powersync II Inverter 14

4 Inspections and Maintenance 16

5 Trouble-Shooting Problems 19

6 Appendix 22
A. Warranty 23
B. Warranty Registration 24
C. Vendors Manual for Powersync II inverter 25

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Owner’s Manual Bergey EXCEL 10 Turbine

1. SYSTEM DESCRIPTION
The Bergey EXCEL 10 is an upwind horizontal-axis wind turbine designed for distributed
generation applications, connected to the power grid on the customer’s side of the utility
meter. The complete unit consists of the following major components, as shown in the figure
below:

1. Spinner 6. Slip-ring and Brushes

2. PowerFlex® Blades 7. Tail Assembly
3. Alternator 8. Nacelle Assembly
4. Mainframe 9. Furling Winch
5. Yaw Bearing 10. Powersync II Inverter

Alternator
Spinner Nacelle

Tail
Rotor Mainframe Assembly Powersync II
Blades Assembly Inverter

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Owner’s Manual Bergey EXCEL 10 Turbine

A. ROTOR SYSTEM

The rotor system consists of three PowerFlex® fiberglass blades. Acting like aircraft wings, the
blades convert the energy of the wind into rotational forces that drive the alternator. The
PowerFlex® blades are rigidly attached to the alternator and they are fixed pitch. The Excel 10
rotor blades have a proprietary airfoil, the BWC-7, which was custom designed to provide high
efficiency and low noise.

The blades for the EXCEL 10 are extremely strong because they are made in a “pultrusion”
process that puts more high-strength glass fibers in the structure than any other molding
technique. This contributes to their long life and toughness. Blade sets are carefully matched
for balance at the factory to ensure smooth operation of the wind turbine. Each blade has a
serial number inscribed on its root pad at the inboard end.

B. ALTERNATOR

The alternator converts the rotational energy of the rotor into electricity. The alternator
utilizes permanent magnets and has an inverted configuration in that the outside housing
rotates, while the internal windings are stationary. It was specifically designed for the Bergey
EXCEL 10 and produces power at low speeds, eliminating the need for a speed-increasing
gearbox. Since it uses permanent magnets, the alternator is generating voltage whenever the
rotor is turning.

DANGER The output wiring of the BWC EXCEL presents

shock hazard whenever the rotor is turning.
Caution must be exercised at all times to avoid
electrical shock.

C. MAINFRAME

The mainframe is the structural backbone of the wind turbine. It serves as the attachment
point for the yaw bearing and the housing for the yaw-axis slip-ring brushes. The yaw-axis is
the full 360 degree pivot that allows the turbine to freely align itself to the wind direction.

D. SLIP-RINGS AND BRUSHES

The slip-rings and brushes conduct the electricity generated in the alternator from the moving
(as it orients with the direction) wind turbine to the fixed tower wiring. The slip-rings are

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Owner’s Manual Bergey EXCEL 10 Turbine

enclosed in a metallic housing to help protect them from lightning.

E. TAIL ASSEMBLY AND AUTOFURL OPERATION

The tail assembly keeps the rotor aligned into the wind at wind speeds below approximately 35
miles per hour (16 m/s). At about 35 mph the AutoFurl® action turns the rotor away from the
wind to limit the rotor speed in high winds. The tail appears to fold, but in reality the tail stays
stationary as the rotor turns sideways to the wind. The rotor furls to a maximum angle of 75
degrees (limited by rubber tail stops), so that the unit continues to produce power in high
winds. When the high winds subside, the AutoFurl® system automatically restores the turbine
into the normal straight position.

The rotor continues to spin even in very high winds and this actually makes the blades stiffer.
The AutoFurl® system works whether or not the Powersync II inverter is on or not. Unlike many
other turbines designs, the Bergey EXCEL 10 can operate safely without an electrical load
connected to the turbine.

F. SPINNER AND NACELLE

The spinner (nose cone) and nacelle provide additional weather protection for the bearings and
the slip-ring assembly. The nacelle also improves lightning protection.

G. Powersync II Inverter

The UL-approved Powersync II inverter converts the “variable AC” from the Bergey EXCEL 10
turbine into utility grade electricity so that it can be connected to the wiring in your home. This
conversion requires sophisticated electronics and is designed to operate automatically. The
Powersync II has a digital display that provides information on the status of the system, its
current output power, and its cumulative energy production.

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Owner’s Manual Bergey EXCEL 10 Turbine

2. SYSTEM OPERATION

A. NORMAL OPERATION

The Bergey EXCEL 10 produces utility compatible power in the form of 240VAC, 60 Hz, single
phase electricity (208 VAC/60Hz and 220 VAC/50 Hz options are available). It is connected
through the Powersync II inverter to the utility distribution network in the same manner as
household appliances. When the wind speed is too low to operate the wind turbine, all of the
electrical power needed for the home will be supplied by the utility company. During these idle
periods the Powersync II will consume approximately 0.3 kilowatt-hours of electricity per day.

When the system begins producing power, the amount of power which must be purchased
from the utility is reduced by an amount equal to the output of the wind system. From the
perspective of the utility company the wind system output reduces the electrical load they have
to supply, just as if you turned off lights and appliances. The output of the wind system
fluctuates with the speed of the wind so the instantaneous amount of electricity being saved
will be constantly changing. Quite often your home will be served simultaneously by the utility
and your Bergey wind turbine.

When the output of the wind system exceeds the power requirements of the house the excess
electricity is sold back to the utility. Both the consumer’s right to interconnect a wind system
and the utilities obligation to purchase excess power are prescribed by federal law (PURPA,
Section 210). The amount you will be credited or paid for this excess production varies state-
to-state and sometimes utility-to-utility. If your utility company offers “net metering” then
your meter is allowed to turn backwards so that you essentially bank energy, at full value, for
less windy periods. This banking can be done over a month or over a year depending on the
policy of your state or your utility. If you do not get “net metering” then you will have a second
utility meter to register excess production and your utility will pay or credit you for this,
typically at less than full value.

If your utility experiences an outage (blackout) the wind system will cease to produce power so
that it does not present an electrical safety hazard to utility repair crews. Although the wind
turbine will continue to operate, no power will be transferred from the Powersync II inverter to
your circuit breaker panel. When utility power is restored, the Powersync II will automatically
return the wind system to full working status following a five minute delay and then a two
minute countdown. These time delays are dictated in the UL standards required by the utilities.

The rotor of the EXCEL 10 should begin to rotate when the wind speed reaches approximately 8
mph (3.6 m/s). Once started, the rotor may continue to turn in winds below 5 mph (2.2 m/s),
but the system will not be producing power below this wind speed.

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Owner’s Manual Bergey EXCEL 10 Turbine

NOTE All operational wind speeds given assume steady winds, sea-
level conditions and moderate temperatures. Hot weather,
high altitude, turbulence and gusting winds will reduce system
performance.

The rotor speed will increase with increasing wind speed and the system will produce a higher
output. This output increases rapidly because the energy available in the wind varies as the
third power (cube) of the wind speed. For example, if the wind speed increased form 5 mph to
10 mph, a factor of two, the energy in the wind would increase from one unit to eight units, a
factor of eight (2 to the 3rd power). One result of this relationship is that there is very little
energy available in light winds. For the average site, winds in the range of 12-20 mph (5.5 – 9
m/s) will provide most of the system’s energy production on an annual basis.

B. HIGH WINDS - AUTOFURL®

During periods of high wind speeds the AutoFurl® system will automatically protect the wind
turbine. Furling means that the rotor is turned away from the wind. When furled, the power
output of the turbine will be reduced. In winds between 33 mph (15 m/s) and 45 mph (20 m/s)
it is normal for the turbine to repeatedly furl and then unfurl and then furl again. During
intermittent cycling the turbine may produce output surges up to 13,000 watts.

C. UNLOADED OPERATION

If an abnormal condition occurs on the utility line, such as a voltage fluctuation or a complete
interruption, the Powersync II inverter will automatically disconnect the wind turbine from the
power grid. If sufficient wind is present, the rotor will continue to operate. Since it is unloaded
it will spin at a higher speed and some increase in blade sound is to be expected. This is a
perfectly safe and permissible condition as the AutoFurl system will continue to protect the
turbine.

DANGER During unloaded operation the alternator can still generate

high voltages, so the EXCEL 10 electrical system should be
handled with the same caution used during normal operation.

In order to enhance the systems reliability, the power output of the Excel is limited to
approximately 12.5 kilowatts. Since this output is reached at 31 mph (14 m/s), the rotor will
become progressively unloaded as wind speeds increase up to the furling point at

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Owner’s Manual Bergey EXCEL 10 Turbine

approximately 35 mph (15.6 m/s).

D. MANUAL FURLING

The Bergey EXCEL 10 is designed for unattended operation over an extended period of time.
Exceptional situations may occur, however, in which the wind turbine should be manually
furled. These situations include:

1. EXCESSIVE VIBRATION - Uneven ice build-up, ice shedding, or blade damage may cause the wind
turbine to experience excessive vibration. Always furl the turbine as soon as an increase in vibration
is detected. Any new or excessive vibration in the turbine when ice is not present should be
investigated immediately.

2. UNUSUAL SOUND - If the turbine begins making clinking, growling, or other unusual sound it should
be furled and fully inspected as soon as possible.

3. INSPECTION AND MAINTENANCE - Whenever someone has to climb the tower the wind turbine must
be manually furled, and the alternator dynamically braked (ie. electrically shorted), even if the wind
speed is very low.

Manual furling of the EXCEL 10 is accomplished by operating the furling winch located at the
base of the tower. The winch cable is connected to the tail boom such that as the cable is
tightened the tail “folds” and the rotor is pulled away form the wind. Furling the wind turbine
will not stop the rotor completely and it may take some time for the rotor to be pulled around
away from the wind. Fully furled the rotor will still be partly facing into the wind and will
normally turn at a reduced rate. The rotor can only be brought to a complete stop by shorting
the output leads of the turbine.

DANGER Do not attempt to furl the wind turbine or approach any part
of the tower when there is lightning in the area.

E. FURLING PROCEDURE

The furling winch is located at the base of the wind turbine tower. To furl the wind turbine,
first make sure that the winch ratchet is engaged (a strong clicking sound should be heard as
the handle is turned). The winch handle may then be turned until the tail comes to rest against
its rubber stop. When the stop is reached the tail will stop rotating towards the blades and the
force required to turn the handle will greatly increase. When fully furled, the tail will have
come around approximately 70 degrees: it does not come around parallel to the blades.

The turbine may not come out of the wind immediately because the rotor forces will
sometimes resist the sideways force acting of the tail. This situation will correct itself after a

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Owner’s Manual Bergey EXCEL 10 Turbine

short time.

CAUTION Do not over tension the furling cable. Tightening the cable
beyond the amount required to furl the wind turbine will reduce
its ability to track the wind and may damage the furling system.

To return the turbine to the straight, normal operation, position, grasp the winch handle firmly
and then release the ratchet mechanism. The cable can now be slowly unwound until the
turbine has fully straightened out and the cable is slightly slack. It is a good idea to then
reengage the ratchet.

DANGER Hold the winch handle firmly before the ratchet is released
and until all tension is removed from the cable. The winch
handle could whirl dangerously if it is released before the
cable tension is reduced.

F. POWERSYNC II INVERTER

The Powersync II inverter is connected to the household circuit through a dedicated 70 amp
breaker. Before opening the Powersync II enclosure, the breaker must be turned off and the
tower disconnect switch must be switched OFF, to avoid electrical shock.

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Owner’s Manual Bergey EXCEL 10 Turbine

DANGER Always remember that the system operates at 240 volts,

so electrical shocks can be fatal!

Using the utility grid as a reference, the Powersync II inverter converts the output of the wind
turbine into utility-compatible alternating current (AC). The Powersync II inverter has been
designed for automatic, unattended operation and it is programmed to provide maximum
performance from your Bergey EXCEL 10 wind turbine. It is also programmed to safely
disconnect the wind turbine in the event of a problem with the utility power and to
automatically reconnect the turbine after the problem is remedied.

The LCD digital display on the front of the Powersync II provides information on the status of
your Bergey EXCEL 10 wind turbine. The contrast can be adjusted UP or DOWN using hidden
buttons on the right side of the display.

In normal operation the Powersync II will show the status as “Running” and will display the
instantaneous Output Power in Watts. Other operating modes that may be indicated are as
follows:

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Owner’s Manual Bergey EXCEL 10 Turbine

Using the Up and DOWN arrows you can scroll through the additional Powersync II information
available, as shown below.

When the Powersync II is starting up after initialization, or after the RESET button has been
pushed, or after a power outage, it will go through a 300 second (5 minute) countdown that is
required by UL 1741. This UL standard also dictates high and low limits for utility voltage and
frequency, outside of which the inverter is required to shut down until they return to the
acceptable range. This is called a FAULT condition.

There are a number of possible FAULT conditions during which the Powersync II will be
protecting itself or the power grid. When a FAULT occurs the Powersync II will shut down (no
power production) and a Fault Code will be displayed on the digital display. A list of the Fault
Codes can be found in the detailed instructions for the Powersync II inverter provided in the

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Owner’s Manual Bergey EXCEL 10 Turbine

Appendix. FAULTS will reset themselves automatically; assuming the underlying cause of the
fault has been cleared, unless the inverter experiences three (3) FAULTS of any type in a one
hour period. In this case a manual RESET is required on the digital display.

CAUTION If a manual reset is required we highly recommend that

you check the FAULT CODE list for indications that there is
an equipment or wiring problem that needs addressing.

One unique feature of the Powersync II inverter is its Soft Grid power limiting capability that
can reduce the number of nuisance FAULTS on weak power lines during periods of high turbine
power output. On a weak power line the EXCEL 10 wind turbine can, on a windy day, raise the
local utility voltage above the UL 1741 threshold, causing a FAULT. The Soft Grid feature tries
to prevent these FAULTS by reducing power output from the wind turbine. When the
Powersync II is in this mode the digital display will show “Soft Grid”.

The STOP pad on the digital display will shut down the Powersync II inverter. Press the RESET
pad to restart (which will start the 300 sec. countdown).

If the circuit breaker in your home or business load center (circuit breaker panel) trips, it should
be reset by first switching it to the OFF position and then to the ON position. If the breaker
trips again immediately, or if it continues to trip after brief periods of normal operation, switch
the breaker OFF and contact your Bergey dealer for assistance.

The following recommendations will help ensure the safe operation of the Powersync II
inverter:

1. Keep all sources of moisture away from the Powersync II enclosure.

2. Do not work near the Powersync II with gasoline, paint thinner, or any material
which produces flammable vapor. Do not store flammable materials near the
Powersynce II enclosure.

3. Do not open the Powersync II enclosure unless the circuit breaker and Accessible
Disconnect Switch (ADC) at the base of the tower have been switched OFF. Note
that even with the circuit breaker and ADC switched OFF, a shock hazard will still
be present inside the Powersync II enclosure for approximately 15 minutes (as the
capacitor voltage drains down).

4. Do not block airflow around the Powersync II enclosure in any way. A six-inch
clearance must be maintained around the sides, top, and bottom of the enclosure
for adequate air circulation.

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Owner’s Manual Bergey EXCEL 10 Turbine

3. INSTALLATION
Please use the following instructions in assembling and commissioning your system. If you
need any additional information, please contact us.

A. BWC EXCEL WIND TURBINE and TOWER

Please refer to the BWC EXCEL Installation Manual, and any addendum for the specific tower
design, for instructions on installing the wind turbine and tower.

B. FUSED DISCONNECT SWITCH

The electrical output of the wind turbine is a three-phase alternating current (AC). We strongly
recommend the installation of a fused three-phase AC disconnect switch between the wind
turbine and the Powersync II, as shown in the drawing on Page 16. This switch is commonly
referred to as an Accessible Disconnect Switch (ADC) and most utilities will require one to be
installed. A 60A weather-tight switch box with 45A fuses for the 240 VAC, 60Hz or 220VAC,
50Hz system is recommended. The fuses will help protect the alternator in the event of a
wiring, controller, or load short circuit. The fused disconnect switch is normally installed at the
base of the tower.

CAUTION Do not install a “short circuiting switch” that will provide

dynamic braking of the alternator. These switches can be
easily misused, leading to serious damage to the alternator.
Such damage is not covered by the BWC warranty.

C. WIRE RUN AND WIRE SIZES

Please refer to the BWC EXCEL Installation Manual for recommended wire and conduit sizes for
the tower-to-Powersync II wire run. Refer to the row labeled “BWC Excel-S” for appropriate
wire sizes.

D. POWERSYNC II INVERTER

The Powersync II inverter should be installed indoors, near the main breaker enclosure if
possible. The Powersync II is designed to operate in a clean environment and should never be

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Owner’s Manual Bergey EXCEL 10 Turbine

installed outdoors as it is not weatherproof and will be damaged by rain. A minimum of six
inches of clearance is required on the top, bottom and sides of the Powersync II to ensure
adequate air flow through the enclosure.

The Powersync II should be connected to a dedicated 70A breaker installed in the main breaker
box. System grounding is accomplished by attaching a wire, # 8 AWG minimum, from the
grounding lug inside the Powersync II enclosure to the panel ground inside the main breaker
box. Additionally, the tower “bond” ground wire should be connected to the grounding lug
inside the Powersync II enclosure. A typical system wiring schematic for the Bergey EXCEL 10 is
shown below. The three AC connections from the wind turbine can be connected to the
Powersync II terminals in any order; there is no required phase orientation.

DANGER Do not attempt to make the Powersync II connections with

energized leads. Always have the wind turbine fully
disconnected and the circuit breaker switched to “off” before
making the Powersync II connections.

All wiring should conform to the National Electric Code or other governing local electrical code.
The use of electrical conduit for wiring between components is highly recommended. All
terminations should be coated with an anti-oxidation compound to prevent corrosion.

CAUTION All loads should be equipped with fuses or circuit breakers to

avoid hazards from accidental short circuits.

10 kW Wind Turbine

24 m (80 ft)
GuyedTower

Safety Cummulative
Switch Production
Meter
Power
Processing AC Load
Unit (Inverter) Center

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Owner’s Manual Bergey EXCEL 10 Turbine

4. INSPECTIONS AND MAINTENANCE

The Bergey EXCEL 10 turbine and tower should be inspected 30 days after installation, and then
again 180 days after installation.

Following these two inspections the installation should be inspected every two years and after
any particularly severe weather. Inspections should be done on days when the wind is below
16 mph (7 m/s).

Check List for Inspections

1. Inspect each of the anchor points. Ensure that all hardware is secure and the guy wires are
properly tensioned. Check to ensure that no strands are broken and the turnbuckle safety
cables are in place.

2. Furl the wind turbine and check that the damper restricts the tail's unfurling to a period of
at least three seconds when the winch cable is rapidly unwound.

3. Disconnect the inverter, furl the turbine and short the alternator using the procedure given
in the installation manuals. Climb the tower. Always use proper safety climbing gear and
safe climbing practices.

4. Inspect the blades for:

A. Cracks outboard of the hub pad, in the blade pultrusion itself. Cracks in the
molded hub pad are normal after a few weeks of operation and will not affect the strength
or reliability of the blade.
B. Condition of the leading edge protection tape. Torn or peeling tape will need
replacing.
C. Leading or trailing edge damage.
D. Condition of the paint.

5. Remove the spinner and hang it from the machine. Check the torque on the blade nuts;
the recommended value is 150 ft-lbs. Check the front bearing for seal integrity and grease
loss. Reattach the spinner and check that it is secure.

6. Open the hatch on the nacelle. Use a small rope to lash the hatch open.

7. At the 180 day inspection only: Inspect the flanged connection between the mainframe
and alternator. Check the torque on each of the bolts; the recommended value is 80 ft-lbs.

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Owner’s Manual Bergey EXCEL 10 Turbine

8. Check the rear alternator bearing for seal integrity and grease loss.

9. Inspect the mainframe for cracks.

10. Remove the slip-ring cover plate. Make the following inspections:
A. Check brushes for ease or movement in the brush holder.
B. Check slip rings for signs of arcing damage.
C. Check that no grease from the yaw bearings has leaked on to the slip-rings.

11. Inspect damper. Some leakage around the front seal is okay.

12. Inspect the furling cable (particularly at the ball end/fork attachment to the tail boom) and
furling cable conduit.

13. Check for cracks or loose hardware on the tail boom and fin.

14. Check the tail pivot pin and particularly its fasteners.

15. Close the nacelle and check that all of its fasteners are secure.

16. While descending the tower, inspect the following:

A. Check that the tower wiring is properly secure.
B. Check all fasteners.
C. Look for any cracks in the tower structure.
D. Check the condition of the guy wire attachment.
E. Check the furling cable.

17. Check the furling winch and make sure that the furling cable is not twisted up. If the cable
is twisted up, check the swivel.

18. Check the connection on all ground rods and hardware.

19. Remove the alternator shorting connection. Check the disconnect switch.

20. Switch the disconnect switch to "OFF" and unfurl the wind turbine. Listen to the sound of
the machine as it speeds up. No mechanical sounds, such as a "clunking" or "banging,"
should be heard. Also watch for any new or significant vibration. The turbine operation
should be smooth.

21. Inspect the wire run, particularly all electrical connections.

22. Use a Meggar to check the three-phase wiring from the turbine to the controller (the
procedure is the same as used for commissioning).

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Owner’s Manual Bergey EXCEL 10 Turbine

23. Use a VOM to check that the three legs of the AC output of the wind turbine are balanced.

24. Check condition of all wiring connections into and out of the Powersync II.

25. Check the fan filters on the Powersync II.

At the second annual inspection, and at each alternate inspection thereafter, the right nacelle
half should be opened and the slip-ring cover removed. This will allow the condition of the
brushes and slip-rings, and internal fasteners to be checked.

DANGER Only qualified personnel with proper safety equipment should

climb the tower. Never climb the tower when the rotor is
turning.

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Owner’s Manual Bergey EXCEL 10 Turbine

5. Trouble-Shooting Problems
The following guide can help to pin-point the cause of operational problems with the Bergey
EXCEL 10 wind turbine and the Powersync II inverter For problems or symptoms not found in
the following listing please contact the Service Department at Bergey Windpower Co. at Tel.
No. 1-405-364-4212, Telefax No. 1-405-364-2078, or E-mail: [email protected]

Problem Cause(s) Diagnosis Remedy

Broken furling cable 1. Over-tightening of When replacing cable Replace cable and conduit
furling cable check for free play inside as indicated.
2. Jammed cable furling furling cable conduit.
cable conduit Check swivel.
3. Leaving turbine furled
for long periods
4. Swivel not installed or
not working
Oil stain at rear of nacelle Tail damper failure Check for damper If damper fails the test,
effectiveness by furling the turbine should be
the turbine and then furled during high winds
rapidly unwinding the until the damper is
furling cable. It should replaced.
take at least three (3)
seconds for the tail to
return to the straight
position.
Turbine makes an unusual 1. Damaged blade leading 1. Have leading edge tape 1. Replace tape as
blade sound, such as edge tape inspected necessary
whistling or buzzing
2. Blade (pultrusion) 2. Have blades inspected. 2. If blade damage is
structural damage Cracks outboard of the suspected, the turbine
molded hub can lead to should be furled until it is
blade failure. inspected. Contact your
dealer.
Rotor is unbalanced, 1. Uneven ice build-up on 1. Ice on turbine and 1. Do nothing – ice will
causing the turbine to blades tower. Turbine ran dislodge in a few days. No
move slightly back and smoothly before ice need to furl the turbine.
forth as it spins storm. Slow rotor speed.

2. Blade damage 2. No ice. Turbine ran 2. If blade damage is

smoothly before suspected, the turbine
should be furled until it is
inspected. Contact your
dealer.

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Owner’s Manual Bergey EXCEL 10 Turbine

Problem Cause(s) Diagnosis Remedy

Turbine makes a banging 1. Loose spinner 1. More likely on pre- 1. Have spinner inspected
or rattling sound once per 2004 turbines (when
revolution, particularly at design was changed)
low speeds
2. Alternator rear bearing 2. Requires inspection 2. Have alternator
ring fasteners loose or inspected
missing

3. Alternator bearings 3. Excessive grease 3. Have alternator

leakage. Squeaking inspected
sounds at low speed.
Turbine makes a “fog Electro-mechanical Sound comes and goes, This is normal, but contact
horn” sound at certain, interaction between but occurs at the same your dealer or the Bergey
typically low, wind speeds alternator and inverter wind speed(s) Service Department if the
that causes transient noise is excessive
vibrations in the turbine
Turbine makes a Switch fused disconnect
continuous growling or on tower to OFF. If
rumbling sound, which growling disappears an
reduces at higher wind electrical problem is
speeds indicated. If growling
continues a mechanical
problem is indicated

1. Wiring fault 1. Check fuses. Check 1. Repair or replace as

wiring for continuity, needed
phase-to-phase fault, or
short to ground.

2. Inverter fault 2. After completing the 2. Contact your dealer

wiring check, disconnect
the inverter and
reconnect wiring to the
turbine. If the noise
disappears an inverter
problem is indicated.

3. Alternator bearings 3. Check for excessive 3. Have the alternator

grease loss inspected

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Owner’s Manual Bergey EXCEL 10 Turbine

Problem Cause(s) Diagnosis Remedy

Rotor turns slowly and 1. Ice build-up on blades 1. Check for ice 1. Do nothing – ice will
does not speed up in dislodge in a few days. No
higher winds need to furl the turbine.

2. Short circuit in wiring 2. Open tower 2. Contact your dealer

or inverter disconnect. If turbine
spins freely an electrical
system problem is
indicated

3. Short circuit in tower 3. The most likely 3. Contact your dealer

wiring, slip-rings, or problem is a shorted
alternator alternator. Diagnosis
requires tower climbing
Rotor does not turn at all Mechanical failure inside Rotor does not turn even Contact your dealer
alternator when winds exceed 15
mph (6.7 m/s)
Powersync II display not 1. No power to inverter 1. Turn off utility power
functioning to inverter, using the
2. Display or other dedicated breaker in your
inverter component not breaker panel, for a
functioning properly minimum of 20 seconds.
Then turn power back on
using the breaker. Wait
300 seconds (5 minutes).

If inverter does not

resume operation, with
full display functionality,
contact your dealer

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Owner’s Manual Bergey EXCEL 10 Turbine

Appendix

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Owner’s Manual Bergey EXCEL 10 Turbine

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Owner’s Manual Bergey EXCEL 10 Turbine

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Owner’s Manual Bergey EXCEL 10 Turbine

Powersync II - 240 VAC (AMFA-27)

and
Powersync II - 208 VAC (AMFA-29)

Operator's Manual
&
Installation Instructions
Rev. 2.6

Date: 22 November, 2010

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AMFA-27/AMFA-29 Operators Manual

Permanently-connected, utility Interactive, single-phase, inverters

Model AMFA-27 WIND TURBINE INVERTER (240 VAC nominal output)

The phase angle between L1 and L2 is 180°. Line to Neutral is 120 VAC nominal.

Model AMFA-29 WIND TURBINE INVERTER (208 VAC nominal output)

The phase angle between L1 and L2 is 120°. Line to Neutral is 120 VAC nominal.

USL - Evaluated to the requirements of the Standard for Safety for Inverters,
Converters, Controllers and Interconnection System Equipment for Use with Distributed
Energy Resources, UL 1741, 2nd Edition, dated January 28, 2010.

CNL - Additionally evaluated to CAN/CSA C22.2 No. 107.1-1, "General Use Power
Supplies." 3rd Edition, Dated September 1st, 2001 with revision through 2006.

The Diversified Technology Inc. Model AMFA-27 and AMFA-29 inverters are intended
for variable frequency un-rectified 3-phase AC input from Wind Powered Turbines.

Table of Contents

1. Ratings

2. Important Safety Instructions

3. Installation
a. Mounting
b. Electrical Connections

4. Markings

5. Operation

6. Touch Screen Display

a. Stop / Reset
b. Status
c. Faults
d. Parameters

7. Equipment Maintenance

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AMFA-27/AMFA-29 Operators Manual

Ratings

Turbine Input

Input Voltage Maximum (3 Phase Input) 400 VAC

Input Start Voltage Minimum 30 VAC
Input Operating Voltage Range 200 to 400 VAC
Input Frequency Maximum 400 Hz
Input Current Maximum 40 Amps
Input Short Circuit Current Maximum 462 Amps
AC Backfeed Current to Input Source N/A

Utility Interactive Output

AMFA-27 AMFA-29
Continuous Output Power Maximum 12000 KW 10400 KW
Continuous Output Power Tolerance +/-10%
Continuous Output Current Maximum 50 Amps
Continuous Output Current Tolerance +/- 10%
Output Voltage Nominal (Single Phase) Line-Line 240 VAC 208 VAC
Operating Voltage Range Line-Line 212-264 184-228
Output Voltage Nominal (Single Phase) Line-Neutral 120 VAC
Operating Voltage Range Line-Neutral 106-132 VAC
Voltage Measurement Tolerance +/- 10 VAC
Operating Frequency Nominal 60 Hz
Operating Frequency Range 59.3 to 60.5 Hz
Operating Frequency Measurement Tolerance +/- 0.5 Hz
Output Power Factor 0.95 +/- 0.05
Temperature Range Normal Operation -20ºC to 45ºC
Output Over-Current Protection Maximum 80 Amps
Output Fault Current Maximum 1030 Amps
Synchronization In-Rush Current Maximum 6.3 Amps
Utility Interconnection Trip Time 100 msec
Time Measurement Tolerance +/- 85 msec

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 AMFA-27/AMFA-29 Operators Manual

Important Safety Instructions

SAVE THESE INSTRUCTIONS

This manual contains important instructions for Model
AMFA-27 and AMFA-29
that shall be followed during installation and maintenance of the inverter.
The output field wiring terminal can be used for connection of a maximum of:
One 1/0 AWG wire per terminal (1 wire for each line)
The input field wiring terminal can be used for connection of a maximum of:
One 2 AWG wire per terminal (1 wire per phase per terminal provided).
The field-wiring terminals shall be connected using the following wire types:

Copper Conductors Only (Input connection)

Use No. 6 - 2 AWG, 90 °C copper wire only

Copper, Aluminum or Copper-Clad Aluminum Conductors Only (Output connection)

Use No. 6 – 1/0 AWG, 90 °C Copper Conductors
Use No. 4 – 1/0 AWG, 90 °C Copper Clad Aluminum, or Aluminum Conductors.
The following symbols are used as markings on this product with the following meanings:

Equipment grounding conductor –

This inverter is intended for operation in an indoor NEMA 1 compatible environment having
a maximum ambient temperature of 45 degrees C.
This unit or system is provided with fixed trip limits and shall
not be aggregated above 30 kW on a single Point of Common Connection

CAUTION
To reduce the risk of fire, connect only to a circuit provided with 80 amperes maximum
branch-circuit over-current protection in accordance with the National Electrical Code,
ANSI/NFPA 70.
Note that the input and output circuits are isolated from the enclosure. In accordance with
Clause 15.2.1.1 of CAN/CSA-C22.2 No. 107.1, system grounding, when required by the
Canadian Electrical Code, Part I, is the responsibility of the installer.

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AMFA-27/AMFA-29 Operators Manual

2. Installation
a. Mounting
i. The enclosure, having a NEMA 1 rating, is designed for indoor installation.
ii. The enclosure is provided with four mounting feet with 0.281” dia. mounting holes.
iii. For mounting to a 0.10” thick metal surface, use M6, ¼-20 or ¼-28 bolts grade 3 or
higher with nuts and flat washers.
iv. For mounting to concrete, use M6 or ¼” bolts using concrete anchors with an 800
pound or greater tension rating.
v. The required bolt length is such that the internal threads need to be 100% engaged.
vi. The enclosure is to be oriented with the conduit openings facing toward the floor.
vii. Enclosure ventilation is to be provided such that the following guidelines are satisfied.
1. Provide a minimum of 12 inches clearance to the air inlet filters.
2. Provide a minimum of 6 inches clearance to the outlet side vents.
3. Use in a well ventilated area within the maximum ambient temperature rating.

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AMFA-27/AMFA-29 Operators Manual

b. Electrical Connections are made to the unit via the holes in the bottom of the enclosure.
Holes are sized for 1.5’’ rated conduit. Wiring methods in accordance with the National
Electrical Code, ANSI/NFPA 70 are to be used.

c. The input and output circuits are isolated from the enclosure. System grounding when
required by the Canadian Electrical Code, Part I, is the responsibility of the installer.

d. AC Output Connection (Utility)

i. The AC output is single phase and not bonded to ground.
ii. Connect the two single phase 240VAC wires to the dual fuse block located on the
lower left side of the enclosure.
iii. Tightening torque, allowable wire size, and type, for the Field-Wiring Terminals:
1. 100 lbf-in tightening torque maximum
2. 6 AWG to a maximum of 1/0 AWG for Copper Conductors Only
3. 4 AWG to a maximum of 1/0 AWG for Aluminum Or Copper-Clad Aluminum
Conductors Only
4. Wire type – rated 90C minimum
iv. The inverter’s earth ground connection must be bonded directly to the service
entrance’s earth ground which in turn is bonded to neutral.

e. AC Input Connection (Turbine)

i. Connect the three phase turbine wires to the DIN rail terminal block located on the
lower right side of the enclosure.
ii. The inverter’s wind turbine input must be connected to a 3-phase “delta” or “wye”
connection with the neutral not connected to earth ground (left floating).
iii. The inverter must be provided with 3, UL listed fuses rated, 400 VAC minimum, 50
Amp maximum for proper protection from the wind turbine input to the unit as well as
an appropriate UL listed fuse holder to accommodate the fuses.
iv. Tightening torque, allowable wire size, and type, for the Field-Wiring Terminals:
1. 22 lbf-in tightening torque
2. 6 AWG - to a maximum of 2 AWG for Copper Conductors Only
3. Wire type – rated 90C minimum
v. An input ground connection must be made between the inverter and the ground
terminal of the tower disconnect, wire size minimum of 8 AWG."

f. Earth Ground Connection

i. Earth ground is to be connected to the two terminals provided inside the enclosure as
indicated by the earth ground equipment marking.
ii. Allowable wire size range is 8 AWG – 4 AWG.
iii. 50 lbf-in tightening torque

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AMFA-27/AMFA-29 Operators Manual

g. Connection Example
i. Surge arrestors are not required but are recommended for a minimum amount of
lightning and surge protection. No lightning protection system provides complete
protection. Lightning damage is not covered under your warranty.

3. Markings
a. Enclosure: Type 1 – for INDOOR USE ONLY
b. Earth ground is indicated by the following marking:

4. Operation

This equipment is a UL 1741 certified Utility Interactive Inverter and complies with the requirements of
IEEE1547 which is the standard for interconnecting distributed resources with electric power systems.

The Normal Operation of the inverter is as follows: When single phase 240VAC is applied to the inverter,
the display will power up and a message stating that the unit is initializing is shown. A countdown timer
set for 5 minutes (300 seconds) starts before the inverter is ready to transfer power to the utility grid. The
inverter will automatically transfer power to the utility when AC voltages in the range of 30VAC to 400VAC
are present at the Turbine input.

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AMFA-27/AMFA-29 Operators Manual

5. Touch Screen Display

a. The touch screen display located on the front panel of the enclosure provides manual over-
ride and status of the inverter’s operation. The touch screen display also provides a Stop and
a Reset button. The Stop button is used when it is desired to disconnect the inverter from the
power grid and the wind turbine. After Stop is pressed the inverter will remain in a powered-
up stand-by mode until Reset is pressed or Grid voltage is removed. When Reset is pressed
the inverter will resume normal operation.

b. Status
i. Status of the inverters operation is shown on the lines one and two of the display.
The following table lists the status messages that may appear.

Status Message Description

Waiting The inverter has been reset or that the 5 minute countdown delay is
Initializing in progress
Waiting The voltage from the turbine is lower than the factory set auto-start
For Wind voltage threshold
AC Running The active rectifier is regulating the internal DC Boost voltage
Running The inverter is transferring power to the utility grid
Fault A fault has occurred. See fault messages
Manual Stop
The manual stop button has been pressed
Press Reset
Fault Limit
Three faults have occurred in an hours time
Press Reset
Indicates that a communication problem exists between the display
Disconnected
and the inverter. Check for bad cable connection.
The inverter has detected that the output voltage is approaching the
Soft Grid over voltage limit and is reducing its output to compensate for the
less than ideal current carrying ability of grid connection.

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AMFA-27/AMFA-29 Operators Manual

c. Fault Messages

i. Fault messages are displayed when a fault occurs and when the last fault parameter
is selected. The following table is a list of possible faults that may be displayed.

Fault
Fault Message Description
Code
IGBT Desat or control logic fault. An occurrence of this
INTERNAL ERROR 10 fault requires that the unit be completely powered down to
reset it.
DC OVER VOLT 1 1000 The DC Bus voltage has exceeded its maximum threshold
DC OVER VOLT 2 1500 The DC Input voltage has exceeded its maximum threshold
The internal DC Boost voltage has dropped below its
DC UNDER VOLT 1250
minimum threshold
AC OVER VOLT 2030 The AC line voltage has exceeded its maximum threshold
The AC line voltage has dropped below its minimum
AC UNDER VOLT 2280
threshold
Indicates that there is a problem with one or more of the
TURBINE PHASE 2500
turbine input phases. Bad connection, missing phase.
Phase A line current sensed by the converter module has
OVER CURRENT 3000
exceeded its maximum current threshold
Phase C line current sensed by the converter module has
OVER CURRENT 3020
exceeded its maximum current threshold
The DC Boost phase of the converter module has
OVER CURRENT 3050
exceeded its maximum current threshold
The internal high temperature threshold has been
OVER TEMP 4000
exceeded
UNDER TEMP 4250 The internal low temperature threshold has been exceeded
GROUND FAULT 7000 An input phase appears to be shorted to chassis ground
The frequency of the utility grid voltage went out of range.
AC UNDER FREQ 8000
The upper range threshold was crossed
The frequency of the utility grid voltage went out of range.
AC OVER FREQ 8100
The lower range threshold was crossed

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AMFA-27/AMFA-29 Operators Manual

d. Parameters

i. The Up and Down arrow that is visible on the left side of the touch screen display* is
used to scroll through a list of parameters. The list of viewable parameters is as
follows:

Parameter Description
Grid Voltage Magnitude of the connected single phase grid voltage
Grid Frequency Frequency of the connected single phase grid voltage
Bus Voltage Magnitude of the actively rectified DC bus voltage
DC Current Averaged value of the DC current
Turbine Volts Averaged value of the rectified AC voltage from the Input
Output Power Output power displayed in watts
Accum. Energy Output Power accumulated over time of operation. Accuracy within 10%.
VRef Used for factory setup**
IRef Used for factory setup**
Displays the last fault that occurred since the inverter was powered up along
Last Fault
with a fault code that may be useful when troubleshooting.

*A hidden feature of the display is the contrast adjustment. The right side of the display has invisible up
and down arrows that can be used to increase and decrease the contrast of the display.

**Vref is used as an index look-up into a virtual table used for a customizable power curve, the graph of
which is configured by parameters 81 through 93, called Iref request values. The virtual size of the table
is 768 points. The table parameters configure every 64th value of the look-up curve for Iref. Iref is the
current request in counts for a given DC input voltage tracked by Vref. Using this configuration the
inverter can be adjusted to provide any power curve required.

6. Equipment Maintenance

a. Periodically check the ventilation screen for the cooling fans. When necessary, use a
vacuum to clean the screen from the outside of the enclosure. Do not force air or spray water
into the enclosure.

b. The touch screen display may become dirty over time. To clean the display use clean water
applied to a soft non-abrasive cloth. Water sprayed directly onto the display could possibly
leak inside and cause damage. Dirt and fingerprints do not affect the operation of the touch
screen display.

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