Huaya 5 kw wind turbine

[Will vargo]

I have huaya 5 kwwind turbine thought to be faulty,I replaced the stator and stood back up. The power one inverter shows power coming into it then slowly stalls the turbine to 45 volts. the turbine company is off the hook they replaced the stator under warranty (reluctantly) the power curve has been checked and power one says it's not them the controller volts shows a rapid climb in volts till the inverter turns on I'm in total loss on what this could be no error code comes up on inverter any idea's out there

[Rob Beckers]

Will, did the turbine (and inverter) work properly before? Or has this been a problem since you installed the turbine?

-RoB-

[Will vargo]

This has been a problem since install. I've checked everything three to four times used both the factory turbine controller and switched to aurora interface box and the voltage climbed on the dc side till the inverter turns on the rapidly drops to 43 volts every time power one tech support had me run load test using a dump load and told me it was the stator bad copper winding so 4 months later I was shipped a new one and replaced it everything checked out on the turbine stood it back up the the exact same results. Could a short on the ac side cause a problem like this the inverter reads no codes shows the wind arrows moving starts out duplicating the volts input just to rapidly drop

[Rob Beckers]

Assuming the turbine is OK, it sounds like the MPPT curve inside the inverter is the wrong one for this machine. Seems the inverter ramps up its load much too fast and stalls the rotor. Who programmed the inverter, and who provided the MPPT curve for it?

Another popular one I've seen go wrong is people mounting the blades "backward". Don't know if that's possible with your turbine (many now have keyed slots that only accept the blades when they face the right way), but something to check if it can be done wrong.

My money would be on the MPPT curve though...

-RoB-

[Cor van Houtum]

you wrote then slowly stalls the turbine to 45 volts

does it realy almost stop turning or does only the voltage lower

because the inverter will not pull any power on 45 volts
most power-one inverters need to have about 90 volts and up to bring power to the grid

[Will vargo]

It will almost stop turning as if you pushed the emergency stop in a high wind .the turbine just stalls out to a slow spin and the interface drops to 46 volts were it was reading high voltage till the inverter turns on I just bought a ginlong 5 kw wind inverter but won't receive it for about 4 weeks I was told aurora inverters were designed for solar and converted to wind and can't take a variety of voltage were ginlong is specifically designed with variables of wind in mind and has a broader range

[Cor van Houtum]

put the pout ramp on 540
with aurora installer

[Cor van Houtum]

and post your curve setting so we can look at them

[Will vargo]

This is the photo off the inverter also the blades are installed correctly it spins clockwise when facing the turbine this is either the power curve done incorrectly or a crossbar in the inverter is my guess I've also tested all wiring in and out of inverter everything is good

[Cor van Houtum]

for testing make the table like this
first empty everything

50 volts 2 watt
100 volts 3 watt
150 volts 5 watt
200 volts 300 watts
250 volts 500 watts
300 volts 1500 watts
350 volts 2000 watts
360 volts 3000
370 4000
380 4500
390 6000
400 6001
410 6002
420 6003
430 6004
440 6005

the last seem not to do anything
but they are handy for future trimming the numbers

the turbine will spin up
the inverter gets on line
between 150 and 200 volts it starts feeding in

try this setting and let me know

I know that it is to discuss
but just try it first

[Cor van Houtum]

and put your protection time to 600
otherwise the inverter goes out every minute when it stoppes turning

[Will vargo]

I've entered the power curve only to have the same results before the inverter turned on the controller was reading 1185 volts with 11mph wind and turbine slowed down to 46 volts in about 50 sec

[Will vargo]

Also I noticed the red limiting square in the wind configuration is lighting up

[Cor van Houtum]

impossible voltage
what is your controller controlling ?
if you disconnect the inverter and let the turbine
run free
then it should never exceed 600 volt dc
the controller and dumpload must take care of this
if the inverter gets more then 600 volts on its input
it Will frie up and is defect
no warranty this is overvoltage
remember even when the inverter is not
connected to the grid cable it Will Be defect
when overvoltage is put on the input bus

the inverter is not a controller

[Will vargo]

I'm sorry I should have checked my reply first it was 185 volts with about a 9 - 10 mile an hour winds

[Will vargo]

I thought it might be a good idea to show my set up the controller works and tops voltage out at 585 I will post a couple more photos to show controller and inverter wiring

[Will vargo]

This is the wiring in the inverter I've triple checked all seems to b good

[Will vargo]

This would be the controller obviously there is no wind here at the moment

[Cor van Houtum]

Hello Will,

I have found or created a similar problem this week.
after a complete factory reset and erasing all the inverter data
of a pvi 6000 windinverter.
and then i programmed a new wind table and stored it.
at that time there was no wind enough to test the installation.
now after a few days it seems that the windgenerator stalls when
the inverter goes on line.
when the grid power is taken off then the turbine spins up.

what is going on ?
I do not know at this moment.
but it looks like your problem.

tomorrow i will drive up to customer site and find out.
but one thing is for sure , the problem is caused by the inverter.
this inverter was working fine untill the curve was reprogrammed
but i suspect the complete erase and factory reset.

these actions can only be done with the second level password
Sometimes installers erase data because the inverter is used for testing for a while
and then there is a higher counter then it was brand new.
to get no ugly questions from the new customer ,it is simple to reset counters
to zero so the unit seems new out of the box.
but now i suspect that there are more settings return to a non wind setting.

wait a day and i will find out and post it.

[Cor van Houtum]

Now it runs
I changed the start-up to 180 volts
also the table starts now with

180 volts 0 watts on line 1

the dc input voltage was also constant on 73 volts
this is a earth leak
I connected the earth point of the inverter to the earth of the controller with
a separate earth cable
now the dc input is 1 volt when the turbine stands stil and the inverter is on.

see the difference after 15:00 PM

http://www.solarmanpv.com/portal/Terminal/TerminalMain.aspx?come=Public&pid=14259


this is a normal working windspot
http://www.solarmanpv.com/portal/Terminal/TerminalMain.aspx?come=Public&pid=7723

in public you can put in the site name windspot
then there are more to see

[Will vargo]

I would like to thank you I've been working on this problem with abb and huaya for months with no answer and you figured it out so again thank you it is now up and running I've had a few days with no wind here but today the turbine is pushing 3000 watts the power curve need work but other than that she is a spinning and what a sight

[Cor van Houtum]

you are welcome
have fun
:bigsmile:

[Rob Beckers]

Cor, just so I can wrap my head around the issue: The problem was that the inverter was loading up the turbine too much just by switching on, and upping the startup Voltage took care of that?

-RoB-

[Cor van Houtum]

yep,

there seems to be a difference in start up when

in setting 1 from 16 you put in

180volts 200 watts
with a start up on DC Vin 180 volts on both mppt or even lower

or you put in
with a start up on DC Vin 180 volts on both mppt

180 volts 0 watts
190 volts 200 or something watts
the start up voltage should not be lower then the first entry on the table that ask's for power and not lower then 180.

I think this is a PVI6000 software thing because a 3.6 does not have this issue
atleast it seems to look like it

but reading the manual it says also the mppt range starts at 180 on a pvi6000 wind

[Cor van Houtum]

by the way rob we should update our foto's because we are allready 10 years older now
then the photograph suggests :wacko:

[Rob Beckers]

by the way rob we should update our foto's because we are allready 10 years older now
then the photograph suggests :wacko:

That's the beauty of the Internet Cor! :cheesy:
Besides, I look exactly the same. :D

Thanks for the inverter explanation. I had never run into that, but then again, I've always put a zero-output point as the first entry in the MPPT table. In fact, I like to set the inverter startup Voltage a little under the first point on the table, for example:

Vstart = 160 Volt
MPPT1 = 175 Volt, 0 Watt
MPPT2 = 190 Volt, 200 Watt

etc...

That seems to work well. When the inverter switches on it'll start drawing somewhere around 40 Watt from the turbine, so that's at Vstart. If the rotor didn't spin up properly that could immediately drive it to stall.

-RoB-

[Cor van Houtum]

@Rob,
reverse engineering brings sometimes ideas,
till now we always have programmed in a sort of liniar upwards
just keep on pushing to the max.
but this means that backwards is true also then.
by studie the behaviour of the inverter in real live with a liniare program
it seems to stall the turbine far down when the wind gusts.
why not program in steps ?
like a big stairs has rest places.
for instance ,
volt watts
200 0
210 100
220 200 rest place
240 201
250 300
260 350 rest place
280 351
290 550
300 1000

these numbers are just to make a sample

By looking at the logging data of a working turbine it seems to me
that most of the time when the turbine is slowing down it is pulled unnessesairy to far down
by the liniar program.
making a bigger voltage gap this could be seen as a step with almost no force
and the turbine could stay in this place as stepping down and then attack the next step. up again

what do you think ?
have you ever looked at it this way