ROPATEC Prelim Info Book.pdf

8/20/2019 ROPATEC Prelim Info Book.pdf

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ecentralized Wind Energy Systems

Information on the Ropatec WindRotor


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MARKET I NG & TECHN I CA L HANDBOOK

Seite 2 – Version 15.03.2004

THE ROPATEC AG COMPANY .................................................................................................. 3

1. WIND POWER! WHERE AND HOW? ................................................................................... 4

2. THE PRODUCT ......................................................................................................... 8

I. WindRotor............................................................................................................. 8

II. Classes of Performance................................................................................................ 9

III. Strong or Weak Wind.................................................................................................10

IV. Construction..........................................................................................................10

V. Certificates of Quality ................................................................................................11

VI.

Technical Specifications ..............................................................................................12

3. APPLICATIONS ........................................................................................................13

I. Battery Charging .....................................................................................................13

II. Network Power Supply ...............................................................................................13

III. Combination Network + Battery .....................................................................................13

IV. Hybrid Combinations .................................................................................................14

V. Areas of Use ..........................................................................................................14

4. POWER COMPONENTS................................................................................................15

I. Batteries..............................................................................................................15

II.

Inverters..............................................................................................................16

III. Generator.............................................................................................................17

5. Reference Installations ............................................. Fehler! Textmarke nicht definiert.


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THE ROPATEC AG COMPANY

One-shop solutions for decentralized energy supply, worldwide

This principle forms the foundation of our company vision.

The Ropatec AG company was founded in order to transform the knowledge from the patent of the wind rotor

into a company concept, to produce the product at an industrial level, and to market it on a worldwide scale.

The company has its headquarters in Bolzano, Italy in the province of South Tyrol. The main focus of the

activities of Ropatec AG lies in research and product development, quality management, marketing, and sales.

Production is outsourced. This arrangement was selected intentionally in order to manufacture in the most cost-

effective manner possible and to be able to build up production that is independent of location.


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1. WIND POWER WHERE AND HOW?

Before the concrete design of a wind power installation, several fundamental questions should be

clarified:

• Average Wind Velocity

The most important factor for the design of a wind power installation is the average wind velocity. General

information on the average wind velocity can be obtained, for example, from the nearest airport and from local

weather stations. Attention must be paid, however, to the fact that conditions at the planned location may vary

from this general information.

It would therefore be ideal to measure the wind velocity at the precise planned location of installation

for several months, and specifically at the planned elevation and height. It is very often the case that the wind

velocity measured in this manner is higher than the general information which the weather service assumed.

In rural areas, the information provided by longtime residents is for the most part also useful, since

people who are occupied with agriculture generally observe the weather very precisely. According to location,

the use of a WindRotor can in fact be very worthwhile.

The wind table listed on the following pages can be used for a primary orientation.

• Extreme Wind Velocities

In contrast to traditional horizontal wind power installations, the Ropatec WindRotor is absolutely suitable for

storms and delivers energy even at extreme wind velocities well over 200 km/h.

At high wind velocities, traditional systems are twisted or slowed by the wind and therefore deliver less

power or none at all.

The Ropatec WindRotor, on the other hand, is aerodynamically self-regulating; that is, as a result of its

special construction, it maintains a constant rotational speed even at high wind velocities.

The Ropatec WindRotor is therefore very well suited to locations with extreme wind velocities.

• Immediate Vicinity

The nature of the concrete location, the so-called "roughness", can have a strong influence upon the

wind velocity. Buildings, trees, and large installations of any kind located in the vicinity can produce turbulence

and wind breaks and thus change the wind velocity both negatively and positively.

Traditional horizontal systems are not suitable with such wind conditions, while the WindRotor, on the

other hand, delivers very good results even with turbulence.

In general, however, a high location, such as a hilltop or a tall mast, is an advantage.

• Elevation of the Location

At sea level, the density of the air is greater than at higher locations, and thus the same wind velocity will

contain more energy at sea level. This information is therefore important for the possible energy yield at the

location.


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• Average Electricity Usage

The selection of the dimensions of the installation depends upon the type of use, the average electricity usage,

and the peak usage. If additional electrical equipment and appliances are to be connected in the near future, this

ought to have an influence upon the design.

• Stand-Alone and/or Network Power Supply

It must be established whether the installation is to run in stand-alone operation or whether there is the

possibility for a network power supply. Since there are different possibilities for using the Ropatec WindRotor

(battery charging, network power supply, water heating, and so on, as well as combinations thereof), all

possibilities of use should be thought through and examined.

• Legal Basis

The installation of a Ropatec WindRotor will require different legal authorizations, depending upon the relative

national and local authorities. The legal requirements for the planned location should be known before

beginning the concrete design. With a planned network power supply with the energy that is not needed within

the installation, the technical and legal conditions, as well as the compensation for the energy supplied, should

be discussed with the local network operator.

Special attention must be paid to the construction regulations with regard to the erecting of a mast.

Aside from all of the legal regulations, the erecting of an installation of this type in densely inhabited areas

should be agreed upon whenever possible with the immediate neighbors.

• Energy Management

One point which is not to be neglected for the economical use of a Ropatec WindRotor, especially within stand-

alone operation, is the carefully thought-through energy management of the user. Through the use of

electricity-saving devices and lighting fixtures, such as modern household appliances and energy-saving lights,

the average electricity usage can be substantially reduced. The necessary peak usage can be reduced through a

division in the usage period of machines and household appliances with a large energy requirement (such as

washing machines, compressors, electrical heating, etc.)

These simple measures have a great influence upon the selection of the dimensions of the installation

and the necessary storage systems, and therefore naturally also upon the cost.

• Available Systems

If systems for an autonomous energy supply are already available, the possibility of a combination of these

existing systems should be examined. By means of the innovative MultiSourcePower-Controller (a CPU

controlled inverter with "Multi Point Power Tracking" technology and an integrated charge regulator), the

Ropatec WindRotor can be operated together with photovoltaic systems and/or with diesel generators.


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• Costs

Aside from the direct costs of the wind turbine, the following costs must also be included when planning the

total costs of an installation: legal authorizations, transportation, the foundation, the mast, the electrical

installation, batteries and any other necessary devices, and additional technical equipment and services.

• Decision-Making

The answers to the following questions ought to clarify whether and in which power class the erection of a

decentralized wind power installation is sensible.

Average Wind Velocity:

Is the average wind velocity at the planned location sufficient to cover the energy needs with the energy

produced?

Extreme Wind Velocities:

What are the peak wind velocities that are to be expected?

Elevation and Immediate Vicinity

Where exactly is the planned location situated?

Electricity Usage:

How high are the current and the future planned daily usage and peak usage?

Electrical Network:

Is there currently a network connection, or will one be established in the near future?

Legal Basis:

What legal regulations are there for the erection of a decentralized wind power installation and the network

power supply of surplus unused energy?

Energy Management:

Can the energy usage be reduced by means of conscious energy management?

Costs:

What is the budget that is available for the erection of a wind power installation?

Subsidies:

Will the installation of a wind power installation be financially supported by public funds?


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• Wind Table

Beaufort m/s km/h Indication Effects Observed on the Sea Effects Observed on Land0 0-0.2 117 Hurricane Air filled with foam; sea completely white withdriving spray; visibility greatly reduced

Heaviest damage


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2. THE PRODUCT

Ropatec AG currently offers the following product lines:

• The Ropatec WindRotor with integrated charge regulator (MultiSourcePower-Controller)

• The mechanical water pumping system, Ropatec WindWater.

This handbook deals exclusively with the WindRotor. (For information on the WindWater, please contact

Ropatec AG.)

I.

WindRotor

The Ropatec WindRotor is a vertically driven wind rotor which demonstrates special product characteristics as a

result of its unique construction. The system could be described as a hybrid solution, building upon the Savonius

and Darrieus principles.

• Innovative as a result of the following properties:

Independent of the wind direction

Low maintenance

High longevity

Independent operation at wind velocities of 2-3 m/s.

Nominal output at wind velocities of 14 m/s and higher

Nearly silent, even at high wind velocities

Self-regulated rotational velocity

Does not require any mechanical/electronic adjustment (pitch regulation)

Does not require any cut-out mechanism

Does not create an electromagnetic field outside of the turbine

Modular construction ensures easy transport and simple installation

Problem-free operation as a hybrid system

Air current from the WindRotor


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II. Classes of Performance

WRE.007

Nominal output of the shaft at 14 m/s

750 W

WRE.015


1500 W

WRE.030


3000 W

WRE.060


6000 W

The output figures refer to the nominal output of the shaft. Because of the loss of power through the generator,

wiring, and charge regulator, the effective output is lower depending upon the concrete application.

What should be of interest, however, is not the nominal output of the shaft but rather the daily or

yearly energy production. This amount is given in kilowatt-hours (kWh) and is calculated from the output curve

and the expected average wind velocity (see the section on the Weibull Calculation).


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III. Strong or Weak Wind

Because of its product properties, the WindRotor is suitable for use in areas with both strong winds and weak

winds. Even with an average wind of 7 m/s, the equipment (such as the WRE.030) delivers an output potential

that is of interest: with this expected average wind, the installation (hub height of 12 m. / 39 ft.) at 250 m. (820

ft.) above sea level produces an electrical output of approximately 4,000 kWh according to the Weibull

Calculation. This output would be sufficient to supply an average European home (3,500 kWh/year according to

IG Windkraft of Austria).

If a wind power installation is installed in areas with frequent storms or very high wind velocities, then

the Ropatec WindRotor is clearly the ideal alternative. WindRotors can withstand the highest loads without

having to be taken out of operation. Because of the aerodynamic auto-adjustment of the rotational velocity, the

WindRotor permanently supplies the full nominal output, even with such conditions.

IV.

Construction

The WindRotor consists of the following components: turbine, generator, shaft, and charge regulator (all

components refer to the WRE series). The generator is located in the core of the turbine. The installation finishes

at the assembly plate or assembly cone. The plate can be mounted on a mast or on similar constructions.

Because of the permanently produced generation, the build-up of an electromagnetic field is prevented

and therefore no disruptions are created for cellular telephone transmission. The WindRotor can therefore also

be mounted directly on GSM or UMTS masts.

The system is delivered in separate assemblies. These consist of:

2 blades (1)

2 consoles (2)

1 internal tube and generator (3)

2 housings for the core (4)

1 MultiSourcePower-Controller

1 mast (optional)

1 set of batteries (optional)

In addition, every installation is delivered with a technical handbook, assembly instructions, and a guarantee

certificate.


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V. Certificates of Quality

The WindRotors from Ropatec AG are reliable suppliers of energy. The quality of the products guarantees a

lengthy period of use. In our analyses, we reckon on an investment period of fifteen years. The selection of the

materials used and the construction method make it possible for us fulfill these requirements.

All WindRotors are produced in accordance with CE regulations. The systems are currently being

certified for quality testing according to the UL/CSA standard (North America). Furthermore, we are planning to

have the measurement of the performance curve and the noise level carried out by an independent and

recognized institute.

The MultiSourcePower-Controller has been inspected and certified according to all common

international standards.


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VI. Technical Specifications

Model WRE.007 WRE.015 WRE.030 WRE.060

Hub height 3 -- 12 m. 3 -- 12 m. 3 -- 12 m. 3 -- 12 m.

Nominal output 750W 1500W 3000W 6000W

Rotor weight 140 kg. 180 Kg 300 kg. 500 kg.

Starting velocity 3 m/s* 3 m/s* 2 m/s* 2 m/s*

Nominal velocity 14 m/s * 14 m/s * 14 m/s * 14 m/s *

Cut-out velocity none none none none

Rotor diameter 1.5 m. 1.5 m. 3.3 m. 3.3 m.

Rotor area 2,25 m² (1.5 m. x 1,5 m.) 2 x 2,25 m² (1.5 m. x 1,5 m.) 7.26 m² (3.3 m. x 2.2 m.) 14.52 m² (3.3 m. x4.4 m.)

Rotor rotational velocity 300-350 rpm at 14 m/s* 300-350 rpm at 14 m/s* 90/100 rpm at 14 m/s* 90/100 rpm at 14 m/s*

Rotational velocity controlAerodynamic auto-

adjustingAerodynamic auto-adjusting Aerodynamic auto-adjusting Aerodynamic auto-adjusting

Generator designPermanent production

-- multipolePermanent production --

multipolePermanent production --

multipolePermanent production --

multipole

Power output Charge regulator Charge regulator Inverter with integrated charge

regulator

Inverter with integrated charge

regulator

Output voltageCharge regulator 24V C Charge regulator 24V DC Charge regulator 48 DC

Inverter 230V AC-50/60 HzCharge regulator 48 DC

Inverter 230V AC-50/60 Hz

Gearing type Gear-free Gear-free Gear-free Gear-free

Brakes Not necessary Not necessary Not necessary Not necessary

Secondary brakesShort circuit brake forsafety at installation

Short circuit brake for safetyat installation

Short circuit brake for safety atinstallation

Short circuit brake for safety atinstallation

Control charge regulator charge regulator Multi-source power converter Multi-source power converter

* Figures refer to installations at sea level with constant temperature and air pressure.


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3. APPLICATIONS

I.

Battery Charging

The WindRotors are designed for battery charging and network power supply.

According to the application purpose, the customer can determine whether he or she wants to make use of the

constant direct current of the batteries (24V with the WRE.007 and WRE.015, or 48VDC with the WRE.030 and

WRE.060) or to obtain the energy through an integrated inverter (up to 2500 VA and 4500 VA, respectively)

which will convert the direct current to alternating current at 230 V/50-60 Hz (or 2 x 115V/50Hz for NorthAmerica).

For the stand-alone supply, the specifications of the batteries and the inverter must be adapted to the daily total

energy requirements and for the peak requirements. There are physical and economic limits to the selection of

the batteries. With the WindRotors (WRE.060 - 6000 W), batteries up to a capacity of 4,500 Ah can be charged.

Since the investment sums for the batteries represent a considerable portion of the total sum, batteries larger

than this would not prove to be a profitable investment.

II. Network Power Supply

For the network power supply, the MultiSourcePower-Controller (multi-source power controller) is connected to

the public electrical network and the electricity produced is fed into the network. The innovative

MultiSourcePower-Controller can consequently be used as both a stand-alone and grid connection.

With this solution, all applications can be controlled by means of a control unit. Costs can thus be substantially

reduced (the other products known to us are delivered for the most part with separate units for the charge

regulator and the inverter).

III.

Combination Network + Battery

The innovative MultiSourcePower-Controller charge regulator controls the energy transformation and the usage,

charges batteries, and at the same time feeds the energy not required by the user into the public electricity

network by means of a ‘‘clean’’ sine curve as required by regulations in force.


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IV. Hybrid Combinations

The innovative MultiSourcePower-Controller electronic control makes it possible to combine a Ropatec

WindRotor installation with other energy sources. This would typically be, for example, a photovoltaic system

and/or a backup system (diesel generator). The entire combined system is controlled without any problems by the

MultiSourcePower-Controller. Through this, a high degree of operation security and reliable availability of

electrical energy is achieved. It is no problem to later extend the WindRotor into a hybrid total solution, or to

integrate existing systems.

V.

Areas of Use

In general, the WindRotor can sensibly be used in any area with sufficient wind, either as a stand-alone system to

supply individual households and works with electricity and heat, or for the operation of freestanding technical

installations. If a network connection is available, the energy can be fed in, thereby contributing to a reduction

in electricity costs. In order to maximize the security of the energy supply, the WindRotor can sensibly be

supplemented by a photovoltaic system or a diesel generator in a quick and uncomplicated fashion. Through the

combination of several WindRotors with other renewable energy sources and a backup system, local electrical

networks can be created for the energy supply of small settlements and remote locations.

Urban Areas

Because of the extremely low noise level (the wind is always louder than the turbine) and the simple network

power supply, the WindRotor can be used without problems in urban areas because of the MultiSourcePower-

Controller. For that reason, our long term strategy includes higher output classes in order to fulfill the energy

requirements of the user.

Lower Mountain Areas

It is possible to make use of the WindRotor in lower mountain areas in which -- because of various reasons, the

most prominent of which are the visual appearance and the noise production -- the use of large installations is

not justified. Hilltops and mountain ridges are especially suitable locations.

Alpine Areas

Because of the enormous operational security and resistance even to extreme wind velocities, the WindRotor is

extremely suitable for use in high alpine areas, for example, for the decentralized power supply for alpine refuges

and lodges and for communications equipment.

Coastal Areas

Ideal for the power supply of remote coastal locations, lighthouses, buoys, for the operation of small-scale water

treatment plants, pumps, and so forth.


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4. POWER COMPONENTS

I. Batteries

If no electrical network is available, then the energy produced by the wind power installation must be stored in

batteries if a reliable power supply is desired. The batteries may be obtained through Ropatec AG but can also be

procured on the local market. We recommend normal stationery lead batteries with elements for every 2V.

After the calculation of the expected daily or yearly energy production (see WindCalc on the Ropatec AG

homepage at www.ropatec.com), the daily energy requirement must be determined (important: the daily average

energy requirement must be less than the expected daily energy production).

Example: average wind of 7 m/s, mounting height of 12 m. (39 ft.) at an elevation of 200 m. (656 ft.), the

WRE.030 (3 kW) installation produces about 10 kWh/day.

Step 1)

Because of the daily output required, the daily energy requirement amounts to an average of 7 kWh (washing

machine, lighting, etc.)

Step 2)In order to maximize the life of the batteries, we recommend discharging them only to 60%. Consequently, the

batteries must have a daily capacity of 7 kWh/0.60 = 11.6 kWh. Because the performance of the batteries is

reduced over time, we calculate with an efficiency coefficient of 85%. The result is: 11.6kWh/0.85 = 13.65 kWh

Step 3)

The customer must establish the battery time frame for the energy usage. If it regularly occurs that there is little

or no wind for 2 days, then the battery time frame should be established at 2 days. It is important to note that a

compromise must be reached between the dimensions of the batteries and the battery time frame, since the cost

of too generous of a battery time frame does not justify the expenditure.

With our example, we calculate as follows: 1 x daily requirement plus 2 x battery time frame requirement yields

3 x 13.65 kWh = 41 kWh

Step 4)

In order to cover the energy requirement, we need batteries with a capacity of 41 kW = 41,000 W = 41,000 VA

(W=VA). Dividing this figure by the nominal voltage of the batteries (in our case, 48V) yields the following:

41,000 W/48 V = 850 Ah. A battery with a capacity of 850 Ah with 24 x 2V elements is sufficient to fulfill the

requirement.


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II. Inverters

The Ropatec inverters are electronic components that make it possible to transform the 48V or 110V direct

current of the batteries into 115V or 230V alternating current. For our Windrotor, we use a microprocessor-

controlled inverter with a high level of efficiency and a low stand-by consumption (0.5-1.0 Wh).

The output rating of the inverters, for example, the MSP-CONTROLLER with 2500 VA/peak 6,000 VA, is read as

follows: the 2500 VA (= 2500 W) is the constant power input that the inverter handles. For short bursts, the

inverter also manages up to 6,000 VA. In our example, with a daily energy requirement of 7 kWh, it must be

defined in advance in what chronological sequence the power is required.

If the consumption is distributed equally over the entire day, then an inverter with 2500 VA of constant output is

sufficient (7 kWh/day = 7,000 Wh = 7,000 VAh/2,500 VA = 2.8 h). That is, that the energy consumption can be

required within 2.8 hours. If the user requires this energy in a short period of time or if the current energy

requirement is higher (simultaneous use of washing mashing, dishwasher, and television), then the output

capacity of 2,500 VA could be exceeded. An inverter with a higher output would have to be installed.

MultiSourcePower-Controller -- Functional Diagram


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III. Generator

In most wind power installations, the generators are connected to the system by means of gears. In thegenerator itself, the energy produced is transferred from the moving part (rotor) to the stationary part (stator)with carbon brushes, and only then is it conducted.This method of construction is unfortunately associated with a great deal of wear and tear and regularexpenditures for maintenance.

Ropatec uses a gear-free, permanent producing, low-rev generator which is located in the central tube of theWindRotor as an external rotor type construction and is directly driven.

Since there were no suitable standard products on the market, this generator was specially developedfor Ropatec.

The advantages of this permanent producing generator are:

- External rotors do not require any slip rings- Weather resistance- Low maintenance

Technical Specifications (Generator of the WRE.007 and WRE.015)

Nominal output 0.75 kw / 1,5 KwRevolutions 300-350 rpmPoles 24Resistance 0.5 Ω

Efficiency 85%-90%

Technical Specifications (Generator of the WRE.030)

Nominal output 3 kwRevolutions 90-100 rpmPoles 48Resistance 0,5 Ω Efficiency 85%-90%

Technical Specifications (Generator of the WRE.060)

Nominal output 6 kw

Revolutions 90-100 rpmPoles 48Resistance 0,5 Ω Efficiency 85%-90%

The information in this document is not guaranteed. Subject to change without notice. The provision of this information to third partiesand/or its reproduction requires the expressed written consent of Ropatec AG.© ROPATEC AG -- 2003

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ROPATEC Prelim Info Book.pdf