Building a system manual for an RE system?

[TomW]

The system here kind of grew from my little hobby into a "mission critical" system.

Since I am unlikely to outlive her [long story I won't get into] I need to put together a system manual for her to use if / when she has to deal with the RE system. Currently I do all the monitoring and maintenance.

She will not be lowering turbines for maintenance, etc but she should know when they need attention at least.

I guess I am looking at this from the ground up so mostly hunting ideas.

Our system currently consists of:

A 24 volt system.

850 watts of tracked solar.

One 10 foot Otherpower Volvo style turbine.

One "Zubbly" [RIP] 6.5 foot conversion.

One Outback 2524FX inverter.

One 230 pound bipedal autonomous charge controller [me].

650 AH of 24 volt Deka D-series lift truck battery

Various computer based logging systems that display on a local web page.

In July, so far we gathered a shade over 100 KWH in RE. Not off grid but it all helps.

I just want her to be able to continue using the system when I am gone. Hate to see all my efforts end up on Ebay or in someones garage moldering or worse fail in use here due to lack of proper attention.

I have written tech manuals, test, repair and troubleshooting guides before but all were geared towards technical folks. Amy couldn't be further from "technical" so it has to be written for the non technical crowd.

I suspect many out there could use such a document. Whatever I come up with will be put into a .pdf  for use.

Worst bit is, even I am not 100% sure what to do all the time but make educated guesses. My system is pretty much undocumented and unlike any other I ever heard of.

Any input appreciated.

Thanks.

Tom

[SparWeb]

I wrote a "manual" for lowering my tower for my wife last year.  It's the first page in a binder marked "tower" where I keep all my other notes about building the windmill.  It's always on the first page.  Any time I change something about the tower, I change the manual.  The process of writing it out made ME more methodical and think more clearly about what I do, too.

Lowering the tower is the one risky operation that must be done correctly to avoid disaster (yes, I know what you're thinking, aside from THAT mistake).  When I finish installing the winch on the tower, I will re-write my instruction sheet, too.

My instruction sheet fits on ONE page, so anyone can carry it around without getting half of it lost or being on the wrong page.  It has a diagram with labelled parts on the top and step-by-step instructions which refer to the diagram, using the same terminology, on the bottom.

My wife is happy to flip the XW4024 inverter from "search" to "continuous" and back, can shut down the windmill (one kill switch), and is also comfortable driving the tractor, so maybe I've got it easy.

In your case, if there are lots of things that have to be done manually while you're away, then the instructions become more complex.  Still try to make them step-by-step, acting it out yourself, and maybe make a cover-page which is the schedule to do the work by.  When describing a decision to be made, use "measurement"- "criteria"- "action"- "alternative".  Kind of like programming computer, only in complete sentences.

I hope that helps.

... [long story I won't get into] ...

Now I'm worried.  Here's to many more years of your crusty wisecracks and unabashed honesty!

[Bruce S]

TomW;

Here's what I've been doing.

I am taking each piece of my system ( as little as it may be)and writing it out in long hand. I then have our daughter (Amy) read it back to me step by step as she points to each item or each reading.

As we go through those steps if there's something she doesn't understand I make side notes.

The notes instead of being put in a document format, is in a bullet-point setup which now includes pictures of the devices.

It's very slow going, but we're getting through it, I too started this since I am now back to traveling for the company and if I get hit by a bus in Tokyo, they can at least know how to disconnect it without smoking something or get hurt.

Hope this helps;

Bruce S

[ghurd]

I figure a lot of smart people put a lot of effort into figuring out this kind of thing.

It looks like for trouble shooting they usually come up with a

Problem - Cause - Possible Solution chart.

For daily use it seems to be a list of "Never Do THIS" kind of thing.

Never let the 24V battery get to 33V,

Never let the 24V battery get below 24.4V except in an emergency.

Etc.

G-

[tecker]

Very nice idea Tom I would like to throw that into an "As built" web page if you don't think It a parasitic idea .  

[richhagen]

Tom, I hope you are OK out there, my little world would get a little bit less interesting if there were no more posts, comments, or corrections from you on here. . . .

Like yours, my system is a one off design, and not exactly like anything I've seen.  Yours is much more complex than mine because you've got the big wind turbines in addition to your solar and they require a lot more attention.  I've just got two solar setups and the occasional small test mill rigs.  I can leave the basic part of my system completely unattended in my absence as it will switch between grid and re power.  Still if I walk out the door and get hit by a bus, I suspect my systems would wind up being parted out or scrapped for lack of the knowledge of how to take advantage of them or at least upon their failure at the first need for human intervention.  

I have found that the easier you make something to use, the more likely it is to get used.  The manual is a good idea, although it will necessarily be a bit complex to a non-technical person. (especially the part that covers the 230 pound bipedal autonomous charge controller)  If you know there will be a time when you will no longer be managing it, then I would recommend using the current time at lessening some of the more intensive management issues.  For example, add an automatic voltage controlled diversion or dump load instead of manually disconnecting and shorting the mills to control the voltage - especially since you are indicating the current controller may some day no longer be in service.  Although you have probably already done this, I would also recommend talking to her about what she is comfortable with doing to manage the system, and what she is not.  Train her on the stuff she will have to do and know and have her do it now, while you are there to monitor and correct any issues.  You will have to plan for how the other maintenance/management items, those that she can not or will not do, will be completed in your absence.

We are all mortal, none of us, and nothing that we build will last forever.  The longest lasting impacts are the knowledge/values/culture that we pass on to those who come after us.  Look at how much our world has changed because of the collective knowledge that we have acquired in just the past two hundred years or so, and it is not because we are any more intelligent than our ancestors back then.  I'd like to think that you have passed on a bit of that knowledge here, and will continue to do so in the future.  Rich

[DamonHD]

Hi TomW,

Please don't get moved from "full support" to "paying customers only" just yet.  B^>

For me, my tiny off-grid system is not worth worrying about and my main RE system is grid-tied, comes with a manual, requires no intervention unless something actually breaks, and is entirely off-the-shelf standard kit.  Any half-brained RE company should be able to fix it.

Thus I hope that if I expire (or move out) before it expires my absence should be irrelevant.

But yes, I would have your alternative operator use the system as if you weren't there from now on for at least a few days or weeks with you only stepping in if (say) she's about to lay a wrench across the main bus...  Then you'll quickly and practically find out what needs more explanation and documentation.

Rgds

Damon

[Madscientist267]

Tom -

Sad truth is, unless she shares your deep interest in the entire system both as a source of power and as a hobby, it isn't likely she'll keep up with it anywhere near the degree you do, even with a decent manual. My wife would run it into the ground until it wasn't useful anymore and then just plug everything back into the grid... and she's halfway technical.

Anything that doesn't have simple cause/effect (dropped cup, water spilled), the layman falls short in operating (chronic low battery is... not enough wind? excessive load? sulfation? charge controller?). Its the same reason that a BS error message on a computer somehow makes sense to a trained eye, but Joe Q. Average has no clue what he's looking at.

Think about all the times that you had to revert to intuition to solve various problems for you with the system, and you'll have the hardest (if not impossible) part of the manual to conjure...

I'm thinking you'd be better off asking a friend that you know understands what you have to come and maintain it. Set up failsafes that get as close to what you would do manually for normal operation, and let it go at that.

Steve

[TomW]

Ok, folks. Nice ideas and I will be thinking of how to integrate them as I get going on it "for real".

Don't get all freaked out, I am not slated for final check out just yet. 2 sets of "experts" predicted my imminent demise 20 years ago and again 3 years ago. I am still here!

No regrets if I go tomorrow. I made a pact with myself when I survived combat wounds from my tour in 'Nam that I would never worry about dying again. I never have. I should have been more careful with high speed motor vehicles, however. Being fearless is not the same as being indestructible.

Thanks for the replies.

Tom

[zeusmorg]

 The first thing i'd do is write up a maintenance schedule. Detail out what to check and on what schedule. Have columns for test parameters. Then once you complete that, I'd write up equipment specific manuals. How to troubleshoot faults in each part of your specific system.

 It would also be good to get her familiar with as much of the equipment as possible even though she doesn't do the "work" herself, she can oversee someone else doing it and have an idea of how it should be done.

 Simple things like checking batteries with a hydrometer, checking voltage seems to daunt some people until they are actually shown how to do it and how to do it safely!

 It may be good to add in failsafe stuff as much as possible too.

 You do have a nice system, even though i am not familiar with all of it's complexities. I've always preached KISS and in the case of someone else using a system  It's important!

 I know several people that have put together such system manuals for people that babysit the system when the owner goes on vacation.

 That first schedule I mentioned also helps you when something does go at fault, you can look back in the log section to see things you may have forgotten over time.

 

[Airstream]

Card System.

Daily - Weekly - 30 day / 60 day / 180 day / Annual ...

Using a card system anyone can usually maintain anything as long as its in the cards.

[gotwind2]

Hi Tom.

Please don't take this the wrong way, but maybe the kindest thing to do, (as you do have grid power) would be to sell off most of your RE kit for the best price to the right home whilst your still active and have a say in the matter.

This would at least offer your wife some additional funds to help with the electricity bills in the future and relieve her of any worry about maintaining your RE system.

Just offering my thoughts, I hope you are around for a lot lot longer to delete my postings ;-)

Ben.

[bob g]

i like the idea of writing to a 4th graders level of understanding, much like

the way they used to write up military manuals

perhaps segment the system and color code it, then put each into a section

within a large 3ring binder

section one:  windgen #1, (the big blue fan thing out in to the west of the barn)

then insert a picture of the beast, that is large enough and good enough no one but

an idiot could mistake it for anything other than what it is.

the subsection, general maintenance, weekly, monthly quarterly, annually

diagnostics, noise, vibration, visual inspection,

emergency concerns, how to shut it down, how to shut it out of the system,

then a section on how to service the thing on the tower,

then a section on how to get it down and back up again,

then a section on manufactureing a repair details

etc

if you do this for each major component of your system, it should be such that she

can manage a certain amount of maintenance or hire out to someone that armed with your book can put her back in business again without haveing to reverse engineer something that might appear to be from a martian probe, with egyptian hyroglyphics,

you know how it is when you want to take apart a laptop computer and all those well hidden screws? you end up wrecking the thing needlessly trying to effect a simple repair.

i don't think it is something that can be done overnight, but if you setup an outline or format and follow the same conventions throughout it should come together fairly quickly.

and the guy that has to follow up after you will be forever greatful for your efforts, believe me i know,, i follow up on systems repairs quite frequently that there is no schematic for, just mile of conduit and jillions of conductors going everywhere.  its nice to find a hand sketched piece of brown paper bag tucked away with some details of a system that some guy went to the trouble to document.

saves a lot of time and mucho aggravation.

good luck with the project, and here's to a long life my friend

bob g

[TomW]

After reading and pondering all replies I have decided to consider the turbines as "my hobby" and concentrate on the core system of batteries, Inverter and Solar setup.

That will simplify things. If I move on then she can decide if she wants to deal with it with whatever documentation I have managed to assemble for them, just sell them off for cash, run them til they quit or whatever she wishes. I figure someone could use them if she is not interested in the hassle or cannot find someone to do the upkeep. We do not really know of anyone local who does DIY RE at all. Lots of folks with RE systems but all "store bought" stuff installed by pros.

The core system requires very little hands on really. If it is connected to the grid it will keep the batteries properly charged and with the water saver battery caps it has only used a couple liters of water in 6 months. I run the inverter off the grid because I do some predictive assumptions on power getting replaced by the system and do not allow it to charge. I don't use voltage as an indicator as much as SG. Very hard to get a voltage reading that is not taken either under charge or under load so some folks would freak out at my minimum voltage readings if taken under load. Ditto high volts under charge.

I really could use a clutch of small manual transfer switches for certain loads which would allow finer tuning of the loads by switching 15 amp circyuit loads on or off the inverter. Currently I use a system of plugs and outlets.

Anyway.

Still pondering so keep the ideas coming.

Thanks to all who responded.

Tom

[fabricator]

For someone who is as totally non mechanically inclined as you describe, maybe it would be a good idea to look into a local RE installer if there is one locally.

Have them come out and give you a ball park on what it would cost to do annual and semi annual checkups.

Your decision on the wind sounds pretty good, the things involved in a wind system maintenance can be downright life threatening to someone who has no idea of what they are getting into.

[bj]

Tom--Had to think this over for a few days, after I picked myself up off the floor.  Decided to try to put myself in your shoes. Some similar problems.

A manual is always a good idea, but, I would concentrate on the why of what needs to be done.  My better half is a smart lady, but most of this is out of her interest.  Having said that, when the opportunity comes up, and I explain the whys of how things are done, she has a better knowledge

base to make her own decisions.  Which is what it will all boil down to

eventually.

Putting the whys into whatever manual you decide is appropriate, means that you don't have to make it a passion like we do, you just have read up, refresh your understanding, and do whatever is necessary.

Anyway, just my take on things, hope the doctors continue to be wrong for

a long, long time.

bj