The Enertech 1500 flies again

 

The process of practicing the assembly of new blades to the rotor proved to be well worth the time and effort. I did it 3 times with my helper and we improved the process every time. For dis-assembly I set up some scaffolding.

 Layout of all the pieces and tools that would be needed.

One item of business that needed to be taken care of was the "bird cage". After considerable thought and some trial and error I decided to screw on a sleeve of 1/4" hardware wire to the bottom of the Nacelle flange. Then I closed off the bottom with two half pieces and attached them to the bottom of the sleeve with hog rings. Since the triangular mounting/leveling plates do not rotate I had to cut an opening in the bottom to go around the main shaft. The "bird cage" will rotate with the Nacelle. Even if those crafty birds can somehow fly straight up they will have a heck of a time getting to the slip rings and wiring. Then ther is a plate of 1/4" hardware wire blocking entrance to the inside of the Nacelle. The last time the bird wedged its way into the Nacelle where the wire overlaps behind the rotor plate. This was necessary because the Nacelle top half opens to allow for maintenance. I think the last time it was a pair of birds. The female built a nest and got trapped in the Nacelle then the male tried to save her by going up the bottom. 

So there it is in all its glory ready for some wind. 

 

Practicing blade assembly to hub

 

First there was the little issue of the destructive work on the turbines wiring done by a bird ! You can see the amount of the gray PVC plastic protector ring that has been pecked away in the effort to gain access to the Nacelle where the birds mate was trapped. Note: The mate died inside the Nacelle. This #10 stranded wire must have been in the way and had to go. There were two wires attached to this slip ring and in order to reconnect I had to attach a single #10 wire to the slip ring terminal clamp and then make a Y connection with a wire nut to the two wires. I tested it when I got down and it worked.

My plan is to set up a practice zone where I could simulate the same distances, stances and out of reach conditions that I would have to overcome if I were going to re-mount the three blades I made and balanced. Better to practice close to the ground and tools then 50 feet in the air and exercise of getting anything I needed. I will practice this just like I was assembling the ISS in space.

Had to take a break today and run some 7th and 8th grade students through the KidWind program. The school is right behind my house. You can see the teachers cars in the back ground.

I decided to hot glue the mounting plates to the blades and also hot glued one of the bolts into the blade. This way I had less to assemble and when I went to hang the blade from a single bolt it would stay in the hole and not get knocked back. This worked like a charm.

OK so the first blade was easy. Learned the best position to have it in when raised. Also decided to get a box end wrench with a racket built in to use instead of a socket and ratchet. 

Now the blades have to be attached to the rotor hub in the vertical down position. This required a way to swing the 1st blade up and hold it. I used a cargo jack like they use in trucks and semi trailers to secure loads. I made a soft pad with a hole in it that slipped over the blade. As you can see in the picture it did the trick. Blade #2 was on.

Gravity was against me and I needed to figure out how to get the blades in the "bunny ear" position and hold them so the third blade could be attached. I would use the cargo jack again by slipping it over the blade at the 4 o'clock position and wind it around. Again holding it in place and then bolt on blade #3.

I will now figure out how to attach the nose cone and secure it with it's three screws. I believe this will have to be done from the upper position platform on the tower. I will set up a ladder to simulate this and give it a go. Practice a few more times and then go for the real thing. Doing all this makes me think a little more about solar!