OPERATION AND

MAINTENANCE
INSTRUCTIONS
ECOROTE 1500

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ECOROTE 1500

TABLE OF CONTENTS

1 General remarks .............................................................................................................. 6

2 Energy management forms ............................................................................................. 7

3 Location requirements .................................................................................................... 9

4 Work safety rules .......................................................................................................... 10

5 Technical Data ............................................................................................................... 11

6 ECOROTE 1500 turbine installation instructions........................................................... 13

7 Turbine installation on the support structure instructions .......................................... 25

8 ECOROTE 1500 Connection Instruction ........................................................................ 30

9 ECOROTE 1500 turbine supporting structures parameters .......................................... 34

10 Operating restrictions ................................................................................................... 37

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ECOROTE 1500

PRODUCTCHARACTERISTICS

The structure is based on Darrieus H rotor type, vertical wind axis turbine, using the
lift as in horizontal wind axis turbines.
It contains a rotor consisting of a shaft on which four pairs of laminar aerodynamic
profile arms are mounted, at equal angular intervals around the vertical axis of the turbine
and four blades are mounted at the ends of the arms. The effect of centrifugal force is
limited by crosspieces mounted near the ends at the top and bottom of the blades.
Aerodynamic and asymmetrical profile blades specially designed for work in a circle are
made entirely of aircraft aluminum, using extrusion method, while the surface is protected
by anodizing.
The high height-to-diameter ratio allows for higher speeds (circumferential speed is
2.5 times faster than wind speed - which significantly reduces generator costs). The
generator on permanent magnets, gearless coupled to the turbine with efficiency over 96%
does not have a coupling moment. Double protection was used against excessive RPM
increase and emergency stop. The most modern technical and technological solutions
based on research results conducted in the wind tunnel and our own experience have
allowed to create a wind turbine with high performance rarely achieved even in large
horizontal wind axis turbines.

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ECOROTE 1500

TURBINES ADVANTAGES

1 Uniform operation independent of wind direction - does not require a "wind

setting" mechanism, hence simplified mechanical structure and control.

2 Easy installation on facilities - no tall towers necessary (structure less expensive

than in case of horizontal wind axis power plants).

3 It can be mounted on roofs of buildings, pillars, existing tower structures, etc.

4 Aesthetic appearance.
5 Quiet operation - even at maximum speed (less arduous operation).
6 Resistance to strong winds - does not require stopping even at 40 m/s wind - the
rotor shape ensures aerodynamic speed limitation (greater use of high speed
wind).

7 Maintenance-free operation of the generating set - no sliding connections

(structure cheaper than in horizontal wind axis power plants).

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ECOROTE 1500

8 Relatively low cost compared to a classic windmill with a horizontal axis of

rotation.

9 Low start speed of approx. 1m/s - provides a low-speed coupling-less disc-type

generator

10 High efficiency of wind energy use Cp ~ 0.42 resulting from the innovative
structure and shape of the blades.

11 The horizontal force per tower in relation to the generated power is less than
in other turbines.

12 More power from a given area if a large number of turbines are installed.

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ECOROTE 1500

1 GENERAL REMARKS

Before starting installation work and starting up the device, all remarks and
recommendations must be followed.
HIPAR SP. Z O. O. is not responsible for their omissions.

The user is responsible for its own safety and the safety of others, it must know and
follow the following rules of use.
All specifications are subject to change without notice.
The wind turbine must be installed in accordance with the given country's standards.
Details and requirements for installation and connection should be consulted with
the power supplier or local spatial planning office.
The drawings contained in the instructions may differ from the actual state.
First read the instructions.
Any doubts should be resolved by contacting the Distributor.

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ECOROTE 1500

2 ENERGY MANAGEMENT
FORMS

Ecorote 1500 power plants are intended for consumers who want to reduce
electricity costs, become independent of traditional power suppliers as well as protect the
environment.

On-Grid - a solution enabling the sale of surplus of generated and unused eclectic
energy to the power grid.

Off-Grid - island installation for people who do not have a connection to the power
grid. Our power plants are great as devices producing electricity stored in batteries
and consumed at the time of demand.

Water heating - the simplest form of managing the electricity obtained for heating
buildings and heating utility water.

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ECOROTE 1500

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ECOROTE 1500

3 LOCATION
REQUIREMENTS
The choice of a turbine operation place is a very important issue. Small changes in
wind speed can affect the decrease in energy production. The most important aspects when
choosing a wind turbine location include:

Safety requirements - the wind turbine must be placed in a safe place that does not
endanger life, health or the environment.

Roughness of the area - the rougher the surface of the earth is around the power
plant, the slower the wind will be. Large cities and forests significantly reduce wind
speed. On the other hand, water is a surface that is smooth enough that it almost
doesn't reduce the speed.

Tower height - the height of the tower should be between 5 and 15 meters. When
choosing a tower, make sure that the turbine is higher than obstacles (e.g. buildings)
in the turbine's operation area. In the case of Poland - 70% of the wind blows from
the west, therefore it should be taken into account that that direction is free of
obstacles.

Legal requirements - defining the possibilities of erecting a wind farm: IEC61400.

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ECOROTE 1500

4 WORK SAFETY RULES

HAZARDS
MECHANICAL

1 The turbine rotor during its operation can rotate at speeds up to 260 rpm. In
contact with rotating turbine components, physical damage and even loss of life
can occur. It is forbidden to:

2 stay in close proximity to an operating turbine,

3 touch blades during the turbine operation,

4 stop the turbine by hand.

5 The turbine blades must not rotate during installation, maintenance and
inspection works.

6 The turbine operation area should be difficult to access by unauthorized

persons.

ELECTRICAL

1 The wind turbine produces voltage during operation that can cause electric
shock or death. It is forbidden to perform any operations on eclectic components
when the turbine is operating.

2 Electrical components must be arranged and selected so that there is no

mechanical damage, this can lead to short circuit and fire.

3 Connection of electrical installations must be made by appropriate personnel

who has qualification certificate for voltages up to e.g. 1 kV.

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ECOROTE 1500

5 TECHNICAL DATA
TURBINE TECHNICAL PARAMETERS TABLE

Parameter 1.5 kW
Rotor diameter 2.2 m
Turbine height 1.5 m
Start speed 1.5 m/s
Rated speed 12 m/s
Total weight 155 kg
Wings and arms Aluminum structure tested for strength in extreme
conditions
Brake Electromagnetic brake
Work system Grid On/Off Grid/Hybrid
Controller Microprocessor controller
Inverter output voltage 1x230V AC or 3x230V AC 50Hz
Number of inverter phases 1 or 3
Generator output voltage AC
Noise level according to <46dB at 8m/s at a distance of 60m
PN-EN 61400-11
Working temperature From -40˚C to 70˚C
Corrosion protection Anodizing, galvanizing, varnish coat C5+M
Types of towers: Concrete and metal pillars, trusses and roof bases
Possibility of producing structures on individual
orders
Tower dimensions FROM 2 to 25 m
Compliance with CE, IEC 61400-2, 61400-11

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ECOROTE 1500

TURBINE ELECTRICAL PARAMETERS TABLE

Cp Prędkość wiatru/ Moc Turbiny/ RPM Napięcie pracy/ Prąd/ Hz
Wind Speed Power Turbine Voltage Work Current

0 0 0 0 0 0 0

0 1 0 20 43 0 5

0 2 0 39 87 0 10

0.15 3 9 59 130 0.07 16

0.3 4 41 78 174 0.24 21

0.345 5 92 98 218 0.42 26

0.37 6 171 117 261 0.65 31

0.325 7 238 137 305 0.78 36

0.39 8 426 156 349 1.22 42

0.4 9 622 176 392 1.59 47

0.418 10 892 195 436 2.04 52

0.42 11 1193 215 480 2.49 57

0.425 12 1567 234 524 2.99 62

0.435 13 2039 250 559 2.86 67

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ECOROTE 1500

6 ECOROTE 1500 TURBINE

INSTALLATION
INSTRUCTIONS

KIT 1 CONTENTS:
Shaft x 1
Blade x 4
Generator cover x 4
Upper arm shield x 1
Lower arm x 4
Upper arm x 4
Screws set:

Quantity Name
8 Hexagon head screw M12x30
8 Hexagon head screw M12x35
16 Countersunk head screw M12x20
16 Countersunk head screw M12x25
8 Countersunk head screw M4x12
4 Countersunk head screw M4x6
24 Self drilling screw with countersunk head screw 3.9x16
Spare elements

SET OF TOOLS NEEDED FOR INSTALLATION:

Torque wrench
Torque wrench socket 10, 13, 17, 19
Allen tip for torque wrench 2, 5, 8
Open-end wrench 10, 13, 17
Allen key 3

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ECOROTE 1500

Hammer 1kg

MOUNTING METHOD:

1. Unpack all components and put in a place ensuring their stable position.
2. First place the wings (Fig. 1) on a horizontal, stable surface and secure them against
uncontrolled movement.

3. Carefully slide the upper (longer) arm onto the wing profile (Fig. 2) as shown in Fig.
4. Use M12x30 and M12x35 screws to screw the arm with the wing. Use M12x35
screws from the side of the wing's leading edge (thicker section of the profile). Apply
a small amount of red thread adhesive to the screw threads and pre-tighten with a
flat spanner. Then tighten with a torque wrench with a tightening torque of 80Nm.
Apply white caps to the screws.

4. Carefully slide the lower (shorter) arm onto the wing profile (Fig. 2) as shown in Fig.
5. Then proceed in the same way as until Section 3.

5. The winglet should be fastened with six 3.9x16 countersunk self-drilling screws
through the holes finished with a cone. Screw in the screws with a screwdriver
equipped with a magnetic cross bit coupling.

6. Place the shaft (Fig. 3) on a stable, stationary platform.

7. The wings installation is shown in Fig. 7. The lower arm holder should be inserted
between the generator plates. During installation, it may be difficult to position the
arm holder between the discs, in which case the discs must be spread with the lever.
Tighten all screws by applying blue adhesive to the threads beforehand. Tightening
torque for bolts in the range of 75-80 Nm. Slightly tighten the upper arm disk with
M12x20 screws.

8. Repeat Sections 2-5 for each wing. Tighten the upper arm disc using screws with
blue adhesive applied. The tightening torque of the upper arms disk is 75-80Nm.

9. Then screw the generator covers as shown in Fig.8. Tighten the screws by applying
blue adhesive to the threads beforehand. The tightening torque for the screws is
approx. 3Nm.

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ECOROTE 1500

INSTALLATION REMARKS:
All the works should be executed in accordance with the
turbine installation instructions. The installation works must be
carefully planned.

The turbine installation should be conducted in the absence of or little wind.

The wind turbine may be installed only by a trained installation team.

All the turbine installation operations must be conducted at ground level.

Special attention should be paid to the installation of aluminum components

of the turbine, which are most exposed to mechanical damage.

Due to the size and weight of the assembled elements, all operations should
be approached with due caution and the rules of health and safety should be
observed.

A minimum of 2 people must participate during installation so that in the

event of an accident one of them can give first aid to the injured person.
When installing the blades, the rotating part of the turbine must be locked for
the reasons of safety of fitters and the risk of damage to the turbine components.

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ECOROTE 1500

FIGURE 1

Turbine blade

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ECOROTE 1500

FIGURE 2

Arms

1— Upper arm (longer) 2— Lower arm (shorter)

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ECOROTE 1500

FIGURE 3

Turbine shaft

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ECOROTE 1500

FIGURE 4

Upper arm installation

1— Upper arm (longer)

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ECOROTE 1500

FIGURE 5

Lower arm installation

1— Lower arm (shorter)

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ECOROTE 1500

FIGURE 6

Winglet installation

1— Upper arm (longer) 2— Lower arm (shorter)

3— Winglet

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ECOROTE 1500

FIGURE 7

Wing installation to the shaft

1— Countersunk head screw M12x20 2— Countersunk head screw M12x25

3— Turbine shaft 4— Turbine wing

5— Upper arm shield

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ECOROTE 1500

FIGURE 8

Generator cover mounting

1— Generator cover 2— Countersunk head screw M4x12

3— Countersunk head screw M4x6

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ECOROTE 1500

FIGURE 9

View of a turbine with 4 blades

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ECOROTE 1500

7 TURBINE INSTALLATION
ON THE SUPPORT
STRUCTURE INSTRUCTIONS

KIT 2 CONTENTS:
Vibration isolators x16
Screws set:
Quantity Name
8 Enlarged coarse round washer 13
8 Washer 13
8 Hexagon head screw with thread on the M12x70 shank part
8 Self-locking nut M12 with Teflon
16 White spinner 12

SET OF TOOLS NEEDED FOR INSTALLATION:

Torque wrench 10-110 Nm
Torque wrench socket 19
Combination wrench 19
Hammer 1kg
Crane sling 1T
20m rope

ADDITIONALLY:
A basket hoist or crane with a lifting capacity of approx. 300-500kg with a lifting
height by approx. 3-4 m higher than the height at which the fasting flange is placed.
Ladder

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ECOROTE 1500

MOUNTING METHOD:

1 Unpack all components and put in a place ensuring their stable position.
2 Hang the turbine on the installation stand on the crane sling using M12 eye bolt
and lift it to a height of approx. 20 cm from the base of the installation stand.

3 Place the vibration isolators according to Fig. 9. Using M12x70 screws with round
coarse enlarged 13 washers

4 Place the turbine on the supporting structure so that the M12x70 screws fit into
the holes according to Fig. 10.

5 Screw the turbine shaft together with the supporting structure using M12 self-
locking nuts with washers, tighten them to 15 Nm.

6 Secure all hexagon screws and nuts with plastic safety caps.
7 Check the correct tightening of the turbine components.

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ECOROTE 1500

FIGURE 9

1— Hexagon head screw with thread on the 2— Enlarged coarse round washer 13
M12 shank part

3— Vibration isolators

FIGURE 10

1— Vibration isolators 2— Enlarged coarse round washer 13

3— Hexagon head screw with thread on the M12 4— Washer 13
shank part
5— Self-locking nut M12 with Teflon 6— Turbine base
7— Supporting structure base

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ECOROTE 1500
INSTALLATION REMARKS:
The installation
conducted using a crane and a
basket hoist or a basket hoist and
ladder with the fitter protection.
It is forbidden to lift the
turbine by the arms and blades.
Before installation, make
sure that all tools have been
removed from the turbine surface.
When lifting the turbine,
attach a rope to stabilize the
turbine and control it from the
ground.
All the works should be
executed in accordance with the
turbine installation instructions.
Installation works must be
carefully planned.
The turbine installation
should be conducted in the
absence of or little wind.
The wind turbine may be
installed only by a trained
installation team.
The turbine must not be
installed upside down or in any
other position than the one
specified in the instructions.
is You can stand on the
generator during installation
operations.
It is forbidden to climb on
the turbine blades and arms.
Crane services are required
to install the turbine.
Make sure that everything
is properly tightened when lifting
the turbine components.
Due to the size and weight
of the assembled elements, all
operations should be approached
with due caution and the rules of
health and safety should be
observed.
A minimum of 2 people
must participate during installation
so that in the event of an accident
one of them can give first aid to
the injured person.
When installing the blades,
the rotating part of the turbine
must be locked for the reasons of
safety of fitters and the risk of
damage to the turbine
components.
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ECOROTE 1500

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ECOROTE 1500

8 ECOROTE 1500
CONNECTION INSTRUCTION

KIT 3 CONTENTS:
Inverter
Braking resistor
Optional island inverter (OFF GRID version)
Screws set:
Quantity Name
4 M5x8 convex head screw with hexagon socket
4 Washer 5.3
TOOLKIT:
Flat-blade screwdriver
Cross screwdriver
Crimping tool for electric terminals
Cable insulation stripping tool
Electric wire cutter

ADDITIONALLY:
YKY 4x3 mm2<=100m stranded-core wire cable
YDY 4x3 mm2 <=100m stranded-core wire cable
4 mm2 electrical ring terminals
4 mm2 tubular electrical terminals
Four-way switch SFT 440 Hager
B+C surge arresters 1/3 Phase
Box for IP65 surge arresters

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ECOROTE 1500

MOUNTING METHOD:

1 The installation is shown in the installation diagram below.

2 Ensure that the support structure on which the turbine is installed is properly
grounded. To do this, attach lightning wire or hoop iron to the shaft base.

3 When using rubber washers or other vibration dampers, remember to make a

connecting bridge between the mounting flange and the turbine base.

4 Before connecting the generator, complete the entire wiring installation and then
connect the terminals on the generator.

5 Connections should be made according to the diagram in Fig. 1. Outside, the

installation should be made with a YKY type four-core cable with a cross-section
of not less than 4 mm2. In the building, a cable with YDY type wires with 4mm2
wire cross section can be used. 4 mm2 tubular terminals should be used for each
connection.

The connection of the inverter, rectifier, braking resistor or island inverter is

shown in the Manufacturer's Operating Instructions included in the box.

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ECOROTE 1500

5mm diameter ring terminals should be used for cable ends from the generator side.
The ends should be fastened to the terminals indicated in Fig. 10 with M5x8 screws
included in the set. Use a washer under each screw.

FIGURE 2

1— Generator jumper 2— Cable clamp

3— Lightning rod clamp

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ECOROTE 1500

CONNECTIONS REMARKS:

The turbine is delivered to the recipient with jumper installed on all three
generator terminals. The task of the jumper is to electrically block the turbine
before it can be rotated.

Tower grounding should be at least R <10 Ω.

Grounding at the point of surge arresters should have at least R<10 Ω.

Surge arresters housing made in IP class at least 65.

All electrical connections should be made with due diligence.

Connection works may only be conducted by persons who have a

Manufacturer's certificate authorizing them to execute installation works.

Remember to make electrical measurements: grounding, continuity of

equipotential bonding, insulation and cables

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ECOROTE 1500

9
ECOROTE 1500 TURBINE
SUPPORTING STRUCTURES
PARAMETERS
The turbine supporting structure should be designed by a person authorized to
design this type of structure. The structure must meet the following strength conditions, as
per Fig. 2.

The place of the power plant installation must be chosen so that no person is in the turbine
work space.

The base on which the turbine will be mounted should have dimensions as per Fig. 1.

FIGURE 1

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FIGURE 2

Forces

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Ecorote 1500

10 OPERATING
RESTRICTIONS

1 After installation and connection of the turbine only by authorized persons, the
use of the turbine is maintenance-free, available to a wide range of recipients,
including people with disabilities. The usage is limited to guarantee inspections in
accordance with the guarantee conditions.

2 When operating a wind turbine, do not:

load structures contrary to the instructions,
assemble additional elements to the turbine structure,
modify and repair structures.

3 During the lifetime of the structure, the user, under pain of losing the guarantee,
is obliged to conduct periodic maintenance inspections- no requite.

4 Technical inspection required for safety after 20 years of operation.

5 Maintenance inspections should be conducted by a qualified person. Particular
attention should be paid to the technical condition of the most important
structural elements and the state of galvanized and painted coatings.

6 In order to ensure trouble-free and efficient operation of the turbine, it is

necessary to observe the periodic inspection schedule.

7 Additional inspection is required in the event of weather anomalies like

hurricane, whirlwinds, etc. In the above case, additionally the technical condition
of the turbine should be checked or, if the turbine threatens the safety, it should
be disabled.

8 Switch off
or block the turbine before starting maintenance and inspection works.

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Ecorote 1500

9 System disassembly:
When disconnecting, first turn off the inverter. Then disconnect the cable
between the generator-inverter terminals, short-circuit all 3 generator
terminals together to brake the turbine.
Activities connected with operation may be performed only by authorized persons.

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Ecorote 1500

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Ecorote 1500

WOLA RAFAŁOWSKA 191A

36-017 BŁĘDOWA TYCZYŃSKA
TEL. (17) 230 49 00

Revision 01/2019/DOK1500
Date of last update: 11/12/2019

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