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User Manual - Leading Edge Turbines

1. REQUIRED eee CHASSIS GROUND GA CTRL 008A_ poe 4 OPTIONAL NI FUSE OR BREAKER RECOMMENDED 1 BATTERY DISCONNECT CHASSIS GROUND OPTIONAL X P x Ded lul TN uu BATTERY BANK d WIRED TO APPROPRIATE CAPACITY amp VOLTAGE TRISTAR DIVERSION CONTROLLER REQUIRED DUMP LOAD 9555555 Fig 13 Typical Marine system wiring diagram Tristar disconnects when the stop switch is activated useful when the LE 450 turbine amp Tristar controller are to be used in conjunction with shore power and engine alternator power sources Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 16 of 48 TOWER OR SUPPORT STRUCTURE RUN STOP SWITCH BOX REQUIRED PN GA CTRL 008A EARTH GROUND SEE RUN STOP SWITCH USER MANUAL FOR DETAILED INSTRUCTIONS CHASSIS GROUND Canine Edge J ay OPTIONAL J FUSE OR BREAKER RECOMMENDED BATTERY DISCONNECT CHASSIS GROUND OPTIONAL iz cene OVER VOLTAGE PROTECTION OVER VOLTAGE RECOMMENDED PROTECTION MASTERVOLT WINDMASTER 500 230VAC GRID TIE INVERTER 50HZ GRID Fig 15 Typical Grid Tie system
2. 20 Annual Maintenance 20 After five years of normal operotion 20 Other Consideratiolls smenasi 20 E R 21 22 Discla MI SE 23 Appendix 1 Tristar 45A Diversion Charge Controller relevant extracts 24 Appendix 2 Run Stop Switch User Manual 29 Appendix 3 System Trouble Shooting svacsccciscsccnsscnscersssaccesstaxseecpedssceceneadsnssdealeateaeds 43 Appendix 4 Turbine Site SelectiOl oss cett 47 Warranty Registration Please register your product with us so that we can administer your warranty entitlement Please register at www leturbines com support warranty registration Customers are required to keep an original copy of their invoice should questions arise requiring reference to purchase information Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 2 of 48 Carine Edge Read this first Don t connect the wind turbine in the wrong polarity Make sure you connect the ve of the turbine to the ve of the battery red to red and the ve of the turbine to the ve of the battery black to black Failing to do so will damage the equipment and invalidate your warranty Don t connect the Diversion Charge Controller in series with the turbine Always ensure that the turbine and the controller are connected
3. The total amount of energy available in the wind increases drastically with small increases in wind speed Therefore it is very important that you site your turbine in the best possible location The proposed installation site for your wind turbine must have a good average wind speed of a minimum of 4 0m s 9mph and low wind turbulence Wind turbulence is caused by obstructions to the wind such as trees and buildings Excessive turbulence will hamper the performance of your turbine Small wind turbines operate best in steady airflows Free flowing airstreams are more consistent in direction and wind speed which results in more overall power being generated by the wind turbine system Gusty conditions often result in a turbine hunting the wind reducing the amount of overall power generated Gusty and turbulent conditions also exert fluctuating forces upon the turbine that can reduce the reliability and lifespan of the system Wind shadowing and barriers Wind barriers are simply obstacles that impede the flow of the wind such as trees and buildings A large wake of turbulent airflow will occur for a long distance downwind of a barrier It is not desirable to locate a turbine in this zone Tel 44 0 845 652 0396 WIND DIRECTION SS hc SS m TURBULENT p ad p AIRFLOW ZONE S 2 X HEIGHT D 2 P 22 HEIGHT OBSTRUCTONS lt B x t 2 X HEIGHT 20 X H
4. 44 0 845 652 0396 www leturbines com Designed in accordance with EN BS 61400 2 Safety of Small Wind Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 23 of 48 Carine Edge Appendix 1 Tristar 45 Diversion Charge Controller Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 24 of 48 Edge Introduction Please read this manual and the specific manual for the Tristar Charge Controller before attempting to assemble install or operate your Tristar Charge Controller This will assure optimum performance and safety The Tristar Charge Controller and Dump Load is a 3 party solution designed to prevent 12 24 or 48V batteries from overcharging The Tristar Charge Controller and dump load operates like an electrical overflow for your batteries As the turbine charges the batteries the State of Charge SOC and battery voltage will rise As the batteries become fully charged and are no longer able to accept any further electrical energy the battery voltage will rise At this point the Tristar controller begins to bleed power into the dump load This energy is then dissipated as heat into the surrounding environment More or less power is diverted to the dump load according to how much is being supplied to the battery from the turbine Safety Precautions Safety must always be your primary concern during the assembly installat
5. 48 Edge Self Testing Diagnostics The TriStar performs a continuous self test to monitor controller and system operation Detected problems are classified as either faults or alarms Typi cally faults are problems that stop the normal operation of the controller and require immediate attention Alarms indicate an abnormal condition but will not stop the controller s operation If a problem is detected the TriStar will alert the user to an existing fault or alarm In this situation the LED indicators will flash a particular sequence Section 3 3 references these sequences with their associated faults and alarms Flashing LED sequences can indicate conditions ranging from a simple battery service reminder to an existing short circuit in the system It is recommended that the user become familiar with the LED indications and their meanings If a TriStar meter option has been added more detailed information concerning faults and alarms will be available Menus provide text displays of the specific fault as well as indicating on the standard display screens when a problem exists Consult the meter manual for further details General Troubleshooting TriStar is not powering up Confirm that all circuit breakers and switches in the system are closed Check all fuses Check for loose wiring connections and wiring continuity Verify that the battery voltage is not below 9Vdc brownout section 3 4 Verify that the battery po
6. Fig 8 Fig 8 Check blade rotation Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 10 of 48 Carine Edge 7 Fit the Nose Cone The nose cone can now be fitted to the rotor This is done by aligning the five mounting holes of the nose cone with those on the rotor hub plate Use five M5 x 12 Cap Heads to secure the nose cone in position see Fig 9 M5 x 12 Cap Head Screw Fig 9 Attach the nose cone 8 Prepare the Turbine Mount If you have purchased a LE 450 mount bracket or tower from a Leading Edge Turbines dealer then please refer to the separate installation instructions supplied with the product If you have sourced your own tower mount bracket 6 5 mm diameter holes will need to be drilled in order to secure the turbine These holes should be drilled 10 mm amp 25 mm from the top of the tower mount bracket and should be perpendicular to the surface and skewed by 90 degrees The holes should penetrate both sides and cross the centre line of the tubular section see Fig 10 1 902 248 30 984 394 25 00 10 00 4 HOLES DRILL 27 00 THRO Fig 10 Drill through top of tower mount bracket Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 11 of 48 Carine Edge 9 Install the Transmission Cables When your tower or mount bracket is ready to receive its turbine the next stage is
7. The T5 45 will not provide enough margin for wind gusts and overloads so a T5 60 should be used The diversion load should be sized for 52 5A 15096 of the source current up to 60A the rating of the TriStar 60 If 55A is selected for the diversion load the load must be capable of diverting 55A at 30V maximum battery voltage If a 30V heating element is used it would be rated for 1 650 watts or from 1 575W to 1 800W per the load range noted above If a 2 000 watt 120 volt heating element is used 13 of these elements in parallel will be required for the diversion load 4 2 amps per element Table in 6 4 4 x 13 54 6 amps Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 37 of 48 Caine Edge The minimum diversion load would be the source output 35A times the voltage 30V This would require a 1 050 watt heating element rated at 30 volts Or if a 2 000W heater element rated for 120 volts is used 9 heater elements will be required to draw the required minimum diversion load at 30 volts 65 Requirements To comply with NEC 690 72 B the following requirements will apply when the TriStar is being used as a diversion charge controller in a photovoltaic system 6 5 1 Second Independent Means if the TriStar is the only means of regulating the battery charging in a diversion charging mode then a second independent means to prevent overcharging the battery must b
8. Yaw Shim if mounting to a 48 3mm Dia Pole installed power transmission cables are not yet connected to any batteries and are shorted together This will prevent the turbine from operating during the installation process Once this has been done connect the turbine output cables to the transmission cables using a suitable terminal block with a minimum rating of 40 Amps Offer the turbine up to the support structure and push the turbine body onto the tower Ensure that no cables are snagged Use the M6 x 70 Cap Heads along with two washers and an anti vibration nut to secure the turbine using the holes previously drilled and the hole in the yaw pivot see Fig 11 Ensure that M6 set screws are securely fastened Depending on the exact dimension of the tower it may be necessary to use the supplied shim plate to ensure that the turbine is a snug fit upon the tower M6 X 70 Cap Heads Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 12 of 48 Edge Electrical Installation Please refer to Figs 12 14 for appropriate generic wiring diagrams In a battery charging renewable energy system there may be different ways of wiring small wind turbines photovoltaic panels charge controllers and batteries together This type of system will often expand organically but the following guidelines should be followed e Follow the appropriate electrical code The elec
9. but the same 100 watts only equates to 6 66 watts when the batteries are at 15 volts When using a current measuring device such as an ammeter the current reading must be qualified against the voltage reading in order to calculate an accurate power output e Measurement errors can easily occur whilst measuring both the wind and power output of the turbine For example in marine applications the wind speed measurement is often made at the top of the mast which will be approximately 10m above the height of the wind turbine The measured wind speeds at this height will be much higher than the wind speeds that the turbine experiences This may lead to the assumption that the turbine is underperforming in any given wind speed Furthermore current shunts are often used in Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 46 of 48 Carine Edge low voltage DC systems due to the amount of currents flowing Ensure that high quality shunts are employed for accurate current readings Appendix 4 Turbine Site Selection Turbine Site Selection The turbine location is a very important factor in the overall performance of your small wind turbine system Good site selection will maximise the power that your turbine will be able to deliver Installing a wind turbine in a bad position is similar to installing a solar panel system in the shade it will not maximise the performance of your investment
10. cases auto and manual mode the pushbutton can be used to start and stop battery equalization NOTE Confirm all dip switch settings before going to the next installation steps C REMARQUE Confirmez les r glages de tous les commutateurs dip avant de passer aux tapes suivantes d installation Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 32 of 48 Caine Edge The TriStar s third mode of operation is diversion load battery charge control As the battery becomes fully charged the TriStar will divert excess current from the battery to a dedicated diversion load This diversion load must be large enough to absorb all the excess energy but not too large to cause a controller overload condition 6 1 Diversion Charge Control TEE HERE HEHEHE HEHEHE HEHEHE HEHEHE E EEE THEE HEE EEE E EH In the diversion mode the TriStar will use PWM charging regulation to divert excess current to an external load As the battery becomes fully charged the FET switches are closed for longer periods of time to direct more current to the diversion load As the battery charges the diversion duty cycle will increase When fully charged all the source energy will flow into the diversion load if there are no other loads The generating source is typically a wind or hydro generator Some solar systems also use diversion to heat
11. is possible to connect your LE 450 to a grid tie grid connect inverter It is recommended that only grid tie inverters supplied by Leading Edge Turbines are used to ensure that an appropriate MPPT curve has been programmed e Installation on Yachts with shore power amp engine alternator power sources When installed on a sailboat the LE 450 may be required to work alongside shore power systems and engine alternators In these cases it is important to ensure that the Tristar charge controller does not unintentionally dump power from the shore power or engine alternator This can be prevented by ensuring that the regulation set points on the shore power system and engine alternator are set below the regulation points of the Tristar diversion charge controller This means that power from the shore power system and or engine alternator will never be unintentionally dumped through the dump load If it is not possible to set the regulation points of the shore power engine alternator below that of the Tristar or similar charge controller then the system should be wired in accordance with Fig 14 on Page 16 and the stop switch should be activated when the engine alternator or shore power system are in use This will disconnect the diversion charge controller during use of shore power engine alternator and will prevent unintentional dumping of power from these sources Please refer to the following wiring diagrams as a guide Tel
12. to a yacht that is healing in the wind the turbine will favour the windward side Issue The turbine never seems to reach its operating speed and does not give any or very little power output Potential Causes e You may have installed a 24V turbine on a 12V battery system This means that the turbine will reach its cut in RPM prematurely and this in turn will stall the blades Ensure that you have the correct voltage turbine for your application Issue A slight oscillation can be observed in the turbine tail fin whilst the turbine is rotating at certain speeds Potential Causes e to the nature of small wind turbines a small level of oscillation is acceptable as the turbine passes through certain speeds This oscillation movement can be minimised by ensuring that the distance between each tip is within tolerance please see step 4 page 8 Ensure also that the assembled rotor is correctly and concentrically fitted to the drive bearing housing Issue When fitted to a yacht vibration is transmitted through to the hull of the vessel Potential Causes e Small wind turbines are electro mechanical devices and as a result a small amount of hum can be present during the operation of the LE 450 Depending on the type and method of mounting to a yacht some of the natural hum of the turbine alternator can be transmitted to the hull of the vessel In order to limit or avoid this vibration transmission it is recommended that app
13. toutes les sources d alimentation au contr leur sont d connect es Step 2 Mounting Locate the TriStar on a wall protected from direct sun high temperatures and water Do not install in a confined area where battery gasses can accumulate NOTE When mounting the TriStar make sure the air flow around the controller and heat sink is not obstructed There should be open space above and below the heat sink and at least 75 mm 3 inches dearance around the heat sink to allow free air Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 27 of 48 Caine Edge flow for cooling CP REMARQUE Lors du montage du TriStar assurez vous que l coulement d air autour du contr leur et du puits de chaleur n est pas obstru Un espace doit se trouver au dessus et en dessous du puits de chaleur et un d gagement de 75 mm 3 po doit exister autour du puits de chaleur pour permettre l coulement de l air des fins de refroidissement Before starting the installation place the TriStar on the wall where it will be mounted and determine where the wires will enter the controller bottom side back Remove the appropriate knockouts before mounting the controller The knockouts are sized for 1 inch and 1 25 inch conduit Figure 2 3 Step 2 Mounting Dimensions Step 2 Mounting continued Refer to Figure 2 3 2 Use the template provided in the shipping carton for locating the mounting holes
14. 1 53 13 268 337 00 Fig 2 Operating Envelope Every day winds Power Output Watts Wind Velocity m s Fig 3 Energy Conversion Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 6 of 48 Carine Edge Package Contents Your LE 450 turbine will arrive containing the components shown below If any of the items are missing or damaged please contact your dealer immediately lt ES p m lt LE 450 Chassis Oty 1 Rotor Blade Qty 5 Hub Plate Oty 1 gt 3j 17 x M6 Nylock Nuts bis 34 x M6 Plain Washers 15 x M6 x 16 Cap Heads ww 11 x M5 Plain Washers ER 6x M5 x2 0 Hex Heads 5 x M5 x 12 Cap Heads 2x M6 x 70 Cap Heads Nose Cone Qty 1 User Manual Qty 1 Fixings Bag Qty 1 Tools Required For Assembly You will require the following tools to assemble your LE 450 turbine e 10mm spanner amp 10 mm ratchet one of each required e 8mm spanner or ratchet e Aset of Metric Standard Hexagon Keys e Electrical screw drivers e Power drill e 6 5mm diameter twist drill bit suitable for drilling through steel e Digital multi meter capable of measuring DC Volts measure or steel rule e Thread locking compound e g Loctite e Protective Gloves Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 7 of 48 Carine Edge Mechanical Assembly P
15. 4 144 Off On On 5 14 6 On Off Off 6 148 On Off On 7 15 0 On On Off 8 Custom On On On ON DIV 13 8V OFF DIV 14 0V DIV 14 2V Figure 23 Step 3 DIP Switches 4 5 6 Select one of the 7 standard diversion charging algorithms or select the custom DIP switch for special custom settings using the PC software Refer to Section 6 3 for information describing the 7 standard diversion charging algorithms Refer to Section 9 0 of this manual for battery charging information Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 31 of 48 Edge DIP Switch Number 7 Select Diversion Switch 7 On ji Figure 2 3 Step 3 DIP Switch 7 In the Diversion Charge Control mode DIP switch 7 must be in the ON position DIP Switch Number 8 Battery Equalization Equalize Switch 8 Figure 2 3 Step 3 DIP Switch 88 In the Auto Equalization mode switch 8 On battery equalization will automatically start and stop according to the battery program selected by the DIP switches 4 5 6 above See Section 6 0 for detailed information about each standard diversion battery charging algorithm and equalization In the Manual Equalization mode switch 8 Off equalization will occur only when manually started with the pushbutton Automatic starting of equalization is disabled The equalization will automatically stop per the battery algorithm selection In both
16. 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 14 of 48 d Leading Edge LE 450 TURBINE PN GA LETU 016 EE id PV coi MN PANEL ARRAY amp TOWER OR SUPPORT STRUCTURE EARTH GROUND 9 e RUN STOP EL 1 MANUAL FOR m L 1 DETAILED INSTRUCTIONS m 4 SWITCH BOX 4 f A M AMMETER REQUIRED D E hi OPTIONAL PN GA CTRL 008A gt d i Suse 1 WP PR RB 4 FUSE OR BREAKER CHASSIS GROUND V RECOMMENDED i CHASSIS GROUND biog tul BATTERY DISCONNECT AMMETER y A Y d OPTIONAL OPTIONAL i n 5 1 NL zuo FUSE OR BREAKER RECOMMENDED BATTERY rouno OPTIONAL Nd CONTROLLER NEUE l4 BATTERY BANK WIRED TO APPROPRIATE CAPACITY amp VOLTAGE TRISTAR DIVERSION CONTROLLER REQUIRED DUMP LOAD CC 555555 Fig 12 Typical Hybrid wind PV System wiring diagram Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 15 of 48 Carine Edge LE 450 TURBINE PN GA LETU 016 TOWER OR SUPPORT STRUCTURE 0 EARTHGROUND lo 1 RUN STOP o SWITCH BOX EN DETAILED INSTRUCTIONS
17. 5 rotor blades to the hub plate Check the Tip Spacing Although the turbine blades are fitted with location keyways it is important to check the tip spacing Lay the assembled rotor blade on a flat surface Using a tape measure or long steel rule ensure that the spacing between each tip is equal to within a tolerance of 1 5 mm Adjust the blades as required Output performance may suffer if the blades are inaccurately set see Fig 6 Fig 6 Checking tip spacing Ensure distance between each tip is equal Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 9 of 48 Edge 5 Fit the Rotor Blade Assembly The assembled rotor blades can now be fitted to the LE 450 chassis This is done by offering the rotor hub plate against the drive shaft protruding from the front of the chassis M5 x 20 mm Hex Head screws should then be used to fix the rotor hub in position using the six tapped holes in the drive shaft Ensure that all screws are securely tightened and that the rotor blades are fitted with the flat side of the blade facing forwards Thread locking compound should be used on the screw threads Rotor Hub fixings Fig 7 Fitting the rotor blades to the chassis 6 Check the Blade Rotation Once the blades have been fitted and secured to the chassis ensure that they rotate freely Take this opportunity to check that all of the blade and hub fixings are secure see
18. Carine Edge LE 450 Turbine Installation amp Operation Guide 1m Diameter Micro Wind Turbine for generating clean and renewable electricity anywhere the wind blows Leading Edge Turbines Ltd Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Cun Edge Contents lp 2 3 lits eco 4 Precauti NS ar 5 Mechanical 5 5 lt 5 Electrical Safety 5 6 Package CODES Roo eo 7 TGols Reguired Far a DEEP do cies 7 Mechanical Assembly Proced urreeeeeeeee 8 I mre alate TET 13 Fig 13 Typical Hybrid wind PV System wiring 15 Fig 14 Typical Marine system wiring diagram eere 16 Fig 15 Typical Grid Tie system wiring 17 its iSi T 18 AEEA EAA 20 Post Installation Checks to be carried out one month after installation
19. EIGHT Topography For areas of undulating ground the turbine should be installed in the highest possible position avoiding wind barriers and turbulence For areas that are generally flat the turbine can be installed in any position Remember that the LE 450 has a low voltage output so it is important to keep the cable run to the batteries inverter as short as possible Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 47 of 48 Edge Surface roughness of the ground Long grass crops or bushes will have the effect of slowing the wind down even at the height of the tower Try to install your turbine where the ground is smooth to increase the overall power production of the system Contact Us Your Local Distributor Leading Edge Turbines Ltd Skyrrid Farm Pontrilas Hereford HR2 OBW UK UK 0845 652 0396 Outside UK 44 1981 241 668 info leturbines com www leturbines com Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 48 of 48
20. and for stripping the wires Use two of the 10 screws provided for the two keyhole slots Leave the screw heads protruding enough to lock inside the keyhole slots about 3 8 mm 0 150 inch Mount the controller and pull it down to lock the screws into the slots Use the Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 28 of 48 Carine Edge remaining two screws to fasten the controller to the wall Provide for strain relief for the bottom knockouts if conduit will not be used Avoid excessive pulling forces on the terminals from the wires Step 3 Adjust the DIP Switches An 8 position DIP switch is used to set up the controller for its intended use All major functions can be set with the DIP switches See Section 7 0 for additional custom settings using PC software NOTE The DIP switches should be changed only when there is no power to the controller Turn off disconnect switches and remove all power to the controller before changing a DIP switch A fault will be indicated if a switch is changed while the controller is powered The Diversion Charge Control functions that can be adjusted with the DIP switches follow System Voltage 2 3 Diversion Charge Algorithm 4 5 6 Select Diversion Mode 7 Battery Equalization 8 Figure 2 3 Step 3 Diversion DIP Switch Functions As shown in the diagram all the positions are in the OFF position except switch numb
21. ative terminal of the battery bank should also be earthed This provides protection against the build up of static and lightning strikes The tower should be earthed separately with its own ground rod if there is a long transmission distance between the tower and batteries An appropriate surge arrestor could also be used to help prevent damage to the battery charging system during a lightning strike Ensure that the earth cables are of the same rating as the positive and negative cables e Cable Selection The cable size table should be used to select the minimum sized cable for a given transmission distance Voltage drop in the cable will be improved if a larger cable is used We recommend using Tri Rated cable as it should comply with the wiring codes for your area e Fuses The turbine and charging circuit should be protected with a suitably rated slow blow DC fuse or DC circuit breaker Please refer to the table below for the correct rating The fuse or breaker should be positioned between the turbine and batteries on the positive cable If a stop switch is used recommended the fuse should be positioned between the switch and the batteries LE 450 Nominal DC Fuse DC Circuit Breaker Rating Output Voltage 12V 40 Amp 24V amp Grid tie 20 Amp Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 13 of 48 Carine Edge e Run Stop Switch A simple switch arra
22. cern during the assembly installation and operation of your LE 450 turbine Always be aware of the risks involved with mechanical and electrical installation work If in doubt about any issue regarding your turbine please seek further assistance before proceeding Installation of the LE 450 turbine should only be undertaken by suitably competent and qualified personnel Mechanical Safety Hazards e The main rotor is the most obvious and serious mechanical safety risk When the turbine is operating at its rated performance the blades will be very difficult to see due to the speed of rotation Never approach the turbine whilst it is operating Always shut down the turbine by activating the stop switch Ensure that the turbine is installed in a suitable position where nobody can approach or interfere with the path of the rotor blades e Working with tools of any kind be dangerous Your LE 450 turbine requires some basic mechanical assembly with rudimentary hand tools If you are in any doubt about how to use these tools correctly please seek advice from a suitably experienced person e Your LE 450 turbine will inevitably be installed upon a tower or other support mount This may mean working at height Always ensure that all personnel in the immediate vicinity are aware of any lifting hoisting operations that will be occurring Check there are no loose components or tools likely to fall and cause injury during the lifting operation Where poss
23. d control 2 3 Auto voltage select 4 5 6 Lowest battery charging voltage 7 Must turn ON to select Diversion 8 Manual Equalization To configure your TriStar for the diversion battery charging and control you requii follow the DIP switch adjustments described below To change a switch from OFF ON slide the switch up toward the top of the controller Make sure each switch is fully in the ON or OFF position DIP Switch Number 1 Control Mode Solar Battery Charging Control Switch 1 Figure 23 Step3 DIP Switch 1 For the Diversion Charge Control mode move the DIP switch to the ON position as shown DIP Switches Number 2 3 System Voltage Voltage Switch 2 Switch 3 Auto Off Off 12 Off On 2 na E 1 Figure 2 3 Step 3 DIP Switches 2 3 The auto voltage selection occurs when the battery is connected and the TriStar starts up There should be no loads on the battery that might cause a discharged battery to indicate a lower system voltage The DIP switch default voltages are for 12V 24V or 48V lead acid batteries Although the auto voltage selection is very dependable it is recommended to use the DIP switches to secure the correct system Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 30 of 48 Edge DIP Switches Number 4 5 6 Diversion Charge Control Battery Type Switch 4 Switch 5 Switch 6 Off 1 13 8 Off Off 2 14 0 Off Off On 3 142 Off On Off
24. d to the dump load usually a resistive heater element The battery voltage will begin to drop to normal levels during the regulation period Once the battery voltage is back within acceptable limits the charge controller will switch the turbine output back to the batteries Refer to the charge controller user manual for specific operational instructions e Shut Down By activating the stop switch the output from cables of the turbine are shorted together This effectively puts an infinite load on the generator causing the turbine to stall When the stop switch is activated the turbine may still rotate slowly during high winds but the rotor blades will not be able to build up any significant speed It is not recommended that the stop switch is activated whilst the rotor is spinning at high speed This sudden braking action will stress the blades and other components Only activate the stop switch during a lull when the rotor is not spinning excessively fast Warning Using the Run Stop Switch in strong winds 40 mph In certain strong wind conditions the rotor can overpower the electromagnetic braking which allows high currents to be produced in the stator coils If this situation occurs for prolonged periods damage to the turbine can occur Therefore the Run Stop switch should only be used to slow the unit prior to manually mechanically tethering the turbine in very high winds Either restrain the blades or swing the turbine
25. e added to the system The second means can be another TriStar or a different means of regulating the charging 6 5 2 150 Percent Rating The current rating of the diversion load must be at least 150 of the TriStar source current rating Refer to Section 6 2 Diversion Current Rating The maximum allowable current ratings for both TriStar versions are summarized below Max Input Current Max Diversion Load Ratin TS 45 30A 45A TS 60 40A 60A CAUTION The NEC requirement that the diversion load must be sized at least 15096 A of the controller rating does NOT mean the diversion load can exceed the maximum current rating of the TriStar NEVER size a diversion load that can draw more than the 45 amps or 60 amps maximum rating of the TriStar controllers A PRUDENCE l obligation de la CNE indiquant que la charge de diversion doit tre 150 plus grande que la puissance nominale du contr leur NE signifie PAS que la charge de diversion peut d passer l intensit maximum du TriStar Ne dimensionnez JAMAIS une charge de diversion qui peut appeler plus de 45 A ou l intensit maximum de 60 A des contr leurs TriStar 6 6 Additional Information Visit Morningstar s website www morningstarcorp com for additional diversion charge control information The website provides expanded technical support for more complex diversion load systems Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 38 of
26. e which means that the rotor hub plate can rattle slightly Potential Causes e rotor hub fixings have been positioned incorrectly in the drive bearing hub Remove the fixings and replace them in the next hole over This should allow the fixings to be completely tightened meaning that the rotor hub plate will be correctly installed Issue A slight oscillation can be observed in the turbine tail fin whilst the turbine is rotating at certain speeds Potential Causes e Due to the nature of small wind turbines a small level of oscillation is acceptable as the turbine passes through certain speeds This oscillation movement can be minimised by ensuring that the distance between each tip is within tolerance please see step 4 page 8 Ensure also that the assembled rotor is correctly and concentrically fitted to the drive bearing housing Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 44 of 48 Edge Issue The turbine frequently comes to rest in the same horizontal position regardless of which direction the wind is coming from Potential Causes e Turbines require that their towers are vertical Although the LE 450 is fitted with counterweights to compensate for the pitching and rolling of a yacht it is still recommended in all applications that the turbine tower is set to be perfectly vertical The LE 450 is designed to be slightly tail heavy so that when it is fitted
27. ed by LET or by non authorised dealers of LET products e Damaged caused by the use of non genuine parts or from the use of liquid agents or lubricants in or on the turbine tower or control equipment e Damage caused by operating the turbine in conditions outside of those specified in the Owner s Guide including but not limited to allowing the turbine to run while disconnected from the batteries or not configuring the Tristar charge controller for diversion mode e Damage caused by modifications to the turbine tower or control equipment not approved by LET e Damage caused to the turbine tower and control equipment by improper storage or transport e Damage caused by lightning strikes flooding fire etc e Damage due to extremely high winds and storm conditions 18m s 40mph and locations off shore e Damage caused by flying debris e Damage to batteries due to excessive deep discharge short circuiting excessively high load over charging loss of electrolyte or any condition outside of the manufacturer s specification for battery use e Damage occurring as a result of not operating the turbine at a safe distance from individuals or property e Damage caused by unsatisfactory tower support structure design Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 22 of 48 Carine Edge e Damage caused by incorrect connection to external electrical equipment or failure to observe cu
28. ems can deliver a serious amount of current A short circuit in the battery circuit can lead to hundreds of Amps flowing through the battery cables This will cause a heat build up and ultimately an electrical fire Batteries are also susceptible to exploding when shorted Always use insulated electrical tools when working on the battery s electrical connections Batteries are very heavy Do not attempt to move batteries by yourself Always use manual handling tools and an assistant Always keep lead acid batteries the correct way up Do not allow the acidic electrolyte to spill or come into contact with your skin Always follow the manufacturer s safety instructions when handling lead acid batteries Ensure that the Universal Run Stop switch is correctly wired as per these instructions and wiring schematics Incorrect wiring may lead to a short circuit being placed across the batteries which can lead to fire or explosion Please use common sense when installing and operating your turbine and associated equipment Installation Please refer to electrical schematic for appropriate generic wiring diagrams If the cables you are using don t easily fit into the run stop switch terminals the cable can be reduced to 4mm2 or 2 5mm2 before entering the run stop switch The cable can then be increased again to its previous size after the switch and this will have a negligible effect on volt drop The Universal Run Stop Switch can either be m
29. er 1 which is in the ON position NOTE The DIP switches should be changed only when there is no power to the controller Turn off disconnect switches and remove all power to the controller before changing a DIP switch A fault will be indicated if a switch is changed with the controller powered REMARQUE Les commutateurs DIP ne doivent tre chang s que si le contr leur est hors tension Mettez les interrupteurs sur arr t et mettez le contr leur hors tension avant de changer un commutateur DIP Une panne sera indiqu e en cas de changement d un commutateur quand le contr leur est sous tension CAUTION The TriStar is shipped with all the switches in the OFF position Each switch position must be confirmed during instal lation A wrong setting could cause damage to the battery or other system components PRUDENCE Le TriStar est exp di avec tous les interrupteurs en position ARR T La position de chaque interrupteur doit tre confirm e pendant l installation Un mauvais r glage peut endommager la charge ou d autres composants du syst me The DIP switch settings described below are Diversion Charge Control only The DIP switches are shipped in the OFF position With switches 2 8 in the OFF gt Y Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 29 of 48 Edge position the following functions are present Switch Function 1 Must be ON loa
30. ese are extremely powerful magnets and can cause injury if not handled with respect Take care when working with tools made of ferrous materials such as spanners and screwdrivers close to the LE 450 alternator The magnetic forces between ferrous materials and the magnet rotor within the alternator maybe very strong This may cause a sudden snapping action that can pinch or trap your fingers or skin Fig 4 Checking magnet rotor rotation and coil disc continuity Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 8 of 48 Carine Edge 3 4 Rotor Blade Assembly Take the five rotor blades and rotor hub plate Be careful when handling the blades they may have sharp edges Use a 10 mm socket amp hexagon key and three M6 x 16 mm Cap Heads to attach each blade to the hub plate see Fig 5 Ensure that the cap head end of the screw is on the inside of the blades thus allowing the washers and nuts to locate on rotor hub plate side The blades should all be fixed to the hub plate on the same side with the blades in the same orientation It is important that a washer is used underneath the anti vibration nuts Three set screws three washers and three anti vibration nuts should be used on each blade Tighten the fixings until the blades are safely secured Do not over tighten the nuts as this may damage the blades and fixings Nuts amp Washers on this side Fig 5 Attaching the
31. g Edge Turbines dealer for more information on this Note Never allow the turbine to run off load with no connection to a battery bank or grid tie inverter Doing so will allow open circuit voltages to be generated by the turbine These voltages may be dangerous and may damage the stator coils within the turbine Fig 16 Tethering the rotor blades using the hole on the tail fin shown on an LE 300 Turbine Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 19 of 48 Carine Edge Maintenance Please follow the preventive maintenance programme listed below This will ensure that the turbine operates reliably and safely with good efficiency Always shut down the turbine before attempting to carry out maintenance Post Installation Checks to be carried out one month after installation e Check that the tower mount pins are secure and have not worked loose Adjust if required e Ensure that the rotor hub is still securely fitted e Ensure that the rotor blades rotate freely Monitor the output Ensure that the turbine and charge controller are functioning correctly Annual Maintenance e Inspect the tower support structure e Remove the turbine from its installation to a suitable workbench e Remove the rotor blade assembly e Inspect the edges of the rotor blades for damage such as dents or chips The blades will become unbalanced if they are damaged This will cause vib
32. gs are designed to help the installation engineer or turbine user to identify and resolve any issues with the system as a whole Before referring to the trouble shooting guide ensure that the turbine has been correctly installed as per the instructions described earlier in this user manual Common Problems pertaining to Installation Issue The turbine spins extremely quickly and noisily but doesn t deliver any electrical current to the batteries Potential Causes e The turbine may be running in an off load state meaning that the circuit from the turbine to the batteries is not complete In this situation the turbine is free spinning and the turbine may be generating higher voltages than anticipated from the turbine output cables Check that all of the connections from the turbine through the run stop switch to the batteries are correct If a fuse or circuit breaker has been fitted to the turbine ensure that this is correctly closing the circuit Never leave the turbine running in an off load state as it may cause damage to the turbine during high winds e The turbine may have developed an internal wiring fault which has resulted in a broken circuit In this situation the turbine is free spinning but no voltage will be measureable at the turbine output cables If an internal fault is present please contact your dealer or Leading Edge Turbines for further advice Issue The rotor hub plate fixings do not correctly grip the rotor hub plat
33. hever comes first LET will supply non wearing parts at no cost For minor component failures replacements may be sent directly to the customer dealer for replacement by them For more serious defects we may suggest a return to base arrangement for replacement or repair In these cases the purchaser will be responsible for taking the turbine off the tower mast and paying the return carriage costs Where a turbine is to be replaced it must be returned to LET before the replacement unit is despatched Should the product prove to be irreparable LET reserves the right to substitute an equivalent product if available This warranty does not extend to servicing a faulty turbine on location In all cases LET will take reasonable action to ensure customer satisfaction You should always receive a warm courteous service in or out of your warranty period Your turbine must be installed and operated in accordance with the guide Failure to do so will result in this warranty becoming null and void Any unauthorised modifications to the turbine design will void the warranty and may compromise the safety of the machine What is not covered by your warranty e Damage caused by unsatisfactory installation of the turbine tower and or control equipment e Damage caused by the neglect of periodic maintenance in the manner recommended in the installation manual e Damage caused by repair or maintenance performed using methods not specifi
34. ible all assembly work should be completed at ground level In the case of roof mount brackets a suitable fitter should carry out the installation with the appropriate equipment for working at height e Ensure that the batteries are disconnected during the installation procedure e Twist the turbine output cables together to create a short circuit during the mechanical installation process This will prevent the turbine from spinning up during the installation e Never install the turbine upside down or in any orientation other than that depicted on the installation instructions e Install your turbine during a calm day e When performing routine inspection or maintenance always stop the turbine by activating the stop switch Electrical Safety Hazards e The LE 450 generates rectified DC voltage Even at these low voltages there are inherent risks Caution should always be used when connecting the LE 450 to the electrical system e sure that you have followed the cable sizing chart to ensure that the correct size of transmission cable has been selected If a cable of insufficient cross sectional area is used heat may build up in the cables causing a potential fire hazard A properly sized fuse or circuit breaker should be used in the cables connected to the battery This will stop the risk of short circuit currents Using cables of insufficient cross sectional area may also reduce the power transmission efficiency of the turbine e Ba
35. ic durable and yield excellent performance Specific LE 450 turbine features e Innovatively designed axial flux alternator using neodymium iron boron magnets e Alaser cut aluminium chassis using Yaw wing design to ensure responsive yawing and to reduce weight e Maintenance free low friction bearing in both main shaft and yaw assemblies e Extremely quiet injection moulded blades with Whispower geometry and aerofoil design e Long life yaw pivot slip rings and wipers e Easytower top installation e Simple design for low cost and durability e Fully marinised using stainless steel fixings and anodised aluminium components e Low mass to help reduce exerted forces and ensure easy installation The LE 450 has been designed for both land based and marine environments Thanks to its unique design the LE 450 will minimise corrosion in both normal and salt water operating conditions Applications include e Telecommunications e Security cameras e Sailboats yachts e Remote homes caravans e Street lighting and road signage Complementary installation with photovoltaic modules for home power e Farm utilities electric fencing irrigation etc e Wind electric water pumping e Cathodic protection e Monitoring sites e The Developing World Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 4 of 48 Edge Safety Precautions Safety must always be your primary con
36. ight winds Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 40 of 48 Carine Edge Introduction Please read this manual thoroughly before attempting to assemble install or operate your Universal Run Stop Switch This will assure optimum performance and safety The Universal Run Stop Switch is designed to allow the user to dynamically brake an LE 450 turbine at will This is achieved by disconnecting the power output of the turbine from the relevant load and diverting it to a short circuit which then applies the dynamic braking effect on the permanent magnet alternator of the turbine This will bring the turbine to a near stop for maintenance only The Universal Run Stop Switch can be used with turbines of different manufacture as long as the relevant turbine has the following characteristics 3 Phase Wild AC not exceeding 500 V amp 16 A Wild DC not exceeding 150 V amp 10A Mechanically and electrically capable of dynamic braking Operation amp Specification The Universal Run Stop Switch should be operated during low speeds as repeated use at high speeds may cause damage if the turbine head it was not designed to withstand repeated dynamic braking operations The switch has two positions Position 1 Turbine Stop position The turbine is dynamically braked and may be seen to rotate very slowly Position 2 Turbine Run position The turbine output is allowed to flo
37. ion and operation of your turbine and charge controller Always be aware of the risks involved with mechanical and electrical installation work If in doubt about any issue regarding your turbine system please seek further assistance before proceeding Mechanical Safety Hazards Whilst installing the charge controller or when performing routine inspection or maintenance always stop the turbine by activating the stop switch Electrical Safety Hazards The Tristar controller and dump load operates with low voltage DC Even at these low voltages there are inherent risks Caution should always be used when connecting a turbine or charge controller to the electrical system Location The Tristar controller and dump load should be mounted in an adequately ventilated area which is not exposed to direct moisture or spray The dump load elements become hot during normal operation and should not be covered or blocked The Dump load should not be mounted on a flammable surface due to the high temperatures that can be achieved by the dump load Ensure that you have followed the cable sizing guidelines to ensure that the correct size of cable has been selected If a cable of insufficient cross sectional area is used at any point in the electrical system heat will build up in the cables causing a potential fire hazard A properly sized fuse or circuit breaker should be used in the cables connected to the battery This will stop the risk of short circui
38. load s rated voltage the power can be calculated by the ratio of the voltages squared For example a 120 volt 1000 watt heating element being used at 60 volts 1000W x 60 120 250 watts The 1000W element will only dissipate 250W when being used at 60 volts NOTE The loads heating elements can be used at the manufacturer s voltage rating or at a lower voltage Do not use the load at a higher voltage than the load s rating Q REMARQUE Les charges l ments de chauffe peuvent tre utilis es la tension nominale du fabricant ou une tension inf rieure N utilisez pas la charge une tension sup rieure la tension nominale 9 644 Maximum Diversion Load The diversion load should never exceed the TriStar s current rating 45A or 60A Note that the load is not limited by the source wind hydro and will draw its rated current from the battery The following table specifies the absolute maximum diversion loads that can be used with each TriStar version These loads heating elements are rated for the same voltage as the system voltage Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 36 of 48 Edge Nominal Voltage TriStar 45 Tridtar 60 48V 2700W at 60V 3600W at 60V 24V 1350W at 30V 1800W at 30V 12V 675W at 15V 900W at 15V These maximum power ratings are translated to the equivalent at 120 volts in the following table If using heating elements rated f
39. ngement can provide a safe and easy way of stopping the turbine for maintenance Leading Edge Turbines can supply a switch which is best for this purpose As the switch is thrown the batteries are disconnected and the turbine is shorted reducing the blades to a slow rotation Refer to the generic wiring diagrams If the cables you are using don t easily fit into the run stop switch terminals the cable be reduced to 4mm2 or 2 5mm2 before entering the run stop switch The cable can then be increased again to its previous size after the switch and this will have a negligible effect on volt drop e Charge Controllers We recommend Tristar controllers for hybrid wind PV systems as this allows you to set the regulation voltage very accurately The Tristar should be used in Diversion mode along with a suitable Dump load Please see Appendix 1 for details on wiring and configuring the Tristar diversion controller e Hybrid Systems The LE 450 turbine can be used in parallel with PV panels We recommend that the PV panels are wired independently with a separate charge controller specifically designed for use with them and connected in parallel with the battery bank see Fig 13 The Tristar diversion charge controller can then be configured to regulate at a slightly higher voltage than the PV charge controller This will prevent the charge control systems for interfering with each other e Use of Grid Tie Inverters It
40. nstallation Wiring for Diversion Charge Control Step Diversion Charge Control 1 Remove the access cover 2 Mount the TriStar using the enclosed template 3 Adjust the 8 switches in the DIP switch Each switch must be in the correct position 4 Attachthe RTS if battery charging will be temperature compensated 5 Connect battery voltage sense wires recommended 6 Connectthe battery power wires to the TriStar Then connect the diversion load wires Step Diversion Charge Control continued 7 Connect a computer to the TriStar if making adjustments with PC software 8 Replace the cover NOTE TriStar negative terminals are common negative Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 26 of 48 Edge Steps 4 5 and 7 are optional 2 3 Installation Steps The TriStar controller must be installed properly and in accordance with the local and national electrical codes It is also important that the installation be done safely correctly and completely to realize all the benefits that the TriStar can provide for your solar system Refer to Sections 4 0 and 9 0 for information about the TriStar s standard battery charging programs and general charging needs for different battery types Refer to Section 5 0 for load control information and Section 6 0 for diversion Recommended tools wire cutter phillips screwdrivers wire stripper tor
41. only 15 30 and 60 volts for 12 24 and 48 volt systems Peak Load Current At the maximum battery voltage this is the current the diversion load will Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 35 of 48 Caine Edge draw This peak load current must not exceed the TriStar s rating NOTE Because the battery can supply any size load the peak load current is not limited by the source hydro or wind rating The diversion load s power rating is the critical specification for reliable battery charging REMARQUE La batterie pouvant fournir une charge de n importe quelle dimension le pic d intensit de la charge n est pas limit par la source puissance hydro ou olienne La puissance nominale de la charge de diversion constitue la sp cification critique pour une charge fiable de la batterie Q y 6 4 8 Load Power Ratings The power rating of the diversion load will depend on the voltage of the battery being charged If the heating element is not rated for the same voltage as the diversion system the power rating of the load must be adjusted to the diversion system s voltage The manufacturers typically rate the heating elements for power at a specified voltage The peak load current at the load s rated voltage will be the power divided by the rated voltage I P V For example 2000W 120V 16 7 amps of current If the load is being used at a voltage less than the
42. or 120 volts the power ratings of all the elements can be simply added up and the sum compared with this table and no further math is required Nominal Vo Tristar 45 Tristar 60 48V 10 800W at 120V 14 400W at 120V 24V 21 600W at 120V 2B 800W at 120W 12V 43 200W at 120V 57 600W at 120V To illustrate the same point from the opposite perspective a heating element rated for 120 volts will draw reduced load current as indicated by the following table A standard 2 000 watt 120 Vac heating element is used as the reference Voltage Power Current 120V 2000 Ww 16 74 60V 48V nominal 500 W amp 3A 30V 24V nominal 125W 42A 15V 12V nominal 31W 21A Whether using dc rated loads the first table or 120V elements the total diversion load current must not exceed the current rating of the TriStar 64 5 Minimum Diversion Load The diversion load must be large enough to divert all the current produced by the source wind hydro etc This value is the maximum battery voltage times the maximum source current For example if a hydro source can generate up to 30 amps of current in a nominal 48 volt system 60V maximum the minimum diversion load size 60V x 30A 1 800 watts for loads rated at 60 volts General Sizing Example Consider a 24V system with a wind turbine that is rated to generate 35A of current A TriStar 45 will not provide the 15096 diversion load margin and the T5 45 is only rated for 30A of source current
43. ounted in the enclosure box supplied which in turn can be mounted on an internal panel or the switch can be integrated into an existing panel If the unit is to be integrated into an existing panel a suitable cut out as detailed on the wiring diagram will need to be made Switch Wiring for LE 450 Turbine please ensure all 12 screw terminals of the switch are screwed closed before finally placing the top cover on the switch SHORT CIRCUIT LINK BETWEEN 3 amp comm BLK 30 TERMINAL 3 304 TERMINAL e 5mm2e RED sence p 2 e e e e e l uU ae P WILD DC 1 TO BATTERIES TURBINE E 2 5mm2 BLK LX Pomme BLK 6 e e e e 5 11 NEVER USED 79 ee e e6 NUT USED NUT USED R OR VE BATTERY VE DL 300 TERMINAL TERMINAL Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 42 of 48 Edge Appendix 3 System Trouble Shooting Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 43 of 48 Carine Edge Introduction Small wind turbines are a complex mixture of mechanical aerodynamic electrical electronic and civil engineering Even with the most careful installation it is possible that problems may occur during the installation or at some point during the life of the turbine The following headin
44. published by the relevant manufacturer e Where lead acid batteries are used it is especially important that they are maintained carefully Failure to do so will result in the batteries being rendered useless within a short period of time Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 20 of 48 Edge Spares The following components may need to be replaced during the service life of your LE 450 turbine Please contact your nearest Leading Edge Turbines Dealer and quote the part numbers listed below Rotor Blade set of 5 DP LETU 145 X5 Magnet Rotor SA LETU 031 Stator 12V 24V 48V SA LETU 027 Yaw pivot amp Slip ring module SA LETU 016 Yaw Shim DP LETU 153 Nose cone DP LETU 338 Drive bearing set of 2 OS 090 X2 Rotor bearings and housing DP LETU 155 Run Stop Switch GA CTRL 008A Tristar Diversion Controller GA CTRL 002A 500W Dump Load 12V 24V 48V CA CTRL 006 H M Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 21 of 48 Carine Edge Warranty Your LE 450 turbine from Leading Edge Turbines LET carries a two year warranty as supported by a retailer s receipt The warranty starts from the date of installation or ninety 90 days after shipment from the LET factory whic
45. que wrench to 50 in Ib slotted screw drivers flashlight Before starting the installation review these safety notes Do not exceed a battery voltage of 48V nominal 24 cells Do not use a battery less than 12V 6 cells Do not connect a solar input greater than a nominal 48V array for battery charging Never exceed a Voc open circuit voltage of 125V Charge only 12 24 or 48 volt lead acid batteries when using the standard battery charging programs in the TriStar Verify the nominal charging voltage is the same as the nominal battery voltage Do not install a TriStar in a sealed compartment with batteries Neyer open the TriStar access cover unless both the solar and battery power has been disconnected Never allow the solar array to be connected to the TriStar with the battery disconnected This can be a dangerous condition with high open circuit solar voltages present at the terminals Follow the installation steps in order 1 through 8 Step 1 Remove the Cover Remove the 4 screws in the front cover Lift the cover until the top edge clears the heat sink and set it aside If an LCD meter display is attached to the cover disconnect the RJ 11 connector at the meter for access CAUTION Do not remove the cover if power is present at any of the terminals Verify that all power sources to the controller are disconnected PRUDENCE N enlevez pas le couvercle en cas de tension une des bornes V rifiez que
46. ration noise and poor performance If many dents have occurred along the edges of the blades a new set of rotor blades should be fitted part numbers available in the Spares section e Inspect the roots of the blades attachment tabs for signs of stress cracking or fatigue A new set of rotor blades should be fitted if any cracks of fractures have occurred part numbers available in the Spares section e Remove any build up of dirt and debris from the rotor blades using a mild detergent and warm water e Check the blade hub fixings for tightness e Carefully remove the yaw mount bracket by unscrewing the four connection screws from the sides of the LE 450 chassis Inspect the slip rings and wipers for obvious signs of wear Replace the wipers if required part numbers available in the Spares section Reassemble the yaw pivot carefully do not to pinch any cables e Check that all electrical connections are sound and free from corrosion e Generally ensure that the turbine is in good working condition and is safe for continued use After five years of normal operation e We recommend that the rotor bearings and rotor blades should be replaced after five years of continuous operation This will ensure that the turbine s performance and safety is not compromised Other Considerations e The equipment used in the charging system batteries charge controller PV panels invertors etc should be maintained according to the instructions
47. rocedure 1 2 Unpacking Inspect the contents of the box and ensure that all items are present and undamaged If any of the components are missing or damaged please contact your dealer immediately Check Magnet Rotor amp Continuity Ensure that the main shaft is free turning and does not scrape or rub as it rotates see Fig 4 You may feel a slight resistance from the bearings at this stage The bearing units used in the magnet rotor assembly are factory lubricated and sealed for life It will take approximately 100 hours of normal operation for the seals to bed in and the lubrication to be distributed correctly around the bearing raceways and ball cages During this period you may notice a reduced performance caused by the additional friction of the bearing seals In operating temperatures of 10 degrees Centigrade or lower this bedding in period will be extended by a further 50 hours of normal operation Connect a digital multi meter to the positive red and negative black output leads extending from the yaw pivot With the multi meter set to detect DC Volts 0 20V approx a voltage should be displayed when the magnet rotor is spun This voltage will vary with the speed of rotation If the magnet rotor rubs or no voltage is detected whilst turning the magnet rotor please contact your dealer immediately Warning The magnet rotor within your LE 450 turbine is constructed using neodymium iron boron rare earth magnets Th
48. ropriate anti vibration mountings and bushes are used upon the structure used to support the turbine Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 45 of 48 K Edge Common Problems pertaining to low turbine output Issue e The turbine seems to be operating correctly but the electrical output appears to be low There are many reasons why the turbine may be demonstrating outputs that are lower than anticipated These reasons can stem from turbulence erroneous measurements through to battery type and condition Potential Causes e Turbulence is the most common reason why turbines do not perform to their specification Turbines require clean un turbulent laminar air flows in order to operate at their peak performances This means that turbines need to be carefully sited in order to avoid areas of turbulence unfortunately this is not always possible and compromises need to be made Please see Appendix 4 for information about siting your turbine for best performance Turbulence created by trees structures and general topography will all create eddy currents in the wind which will severely reduce the turbine s efficiency Generally the turbine should be positioned on a tower as high as possible above any local features of the topography e Ensure that the correct minimum and maximum cable sizes have been installed see section 9 page 11 of this user manual Using a cable that is too
49. rrent regulations concerning connection to external electrical networks equipment or any other devices If you should experience a problem with your turbine your first port of call should be the reseller or installer from whom you purchased the product They should be able to resolve the problem quickly and efficiently If you are unable to contact the original reseller then please contact us directly Please quote the serial number of your turbine when dealing with warranty issues The serial number can be found on the nameplate positioned on the underside of the chassis Disclaimer e All specifications are subject to change without prior notice e information given in this user manual is believed to be accurate and reliable Leading Edge Turbines assumes no responsibility for omissions or inaccuracies e user of this information and product assumes full responsibility and risk e The LE 450 turbine is a source of electrical power It must be installed in accordance with local building and electrical regulations Consult your local planning zoning office for details e The LE 450 turbine has moving parts that may cause injury due to poor installation and unsafe operation Leading Edge Turbines assumes no responsibility for problems caused by unsafe or unsatisfactory installation or operation Designed amp Manufactured in the UK by Leading Edge Turbines Ltd Skyrrid Farm Pontrilas Hereford HR2 OBW Tel
50. sible for any damage resulting to the system battery or other system components Refer to Morningstar s Limited Warranty in Section 10 0 A PRUDENCE Si la capacit du TriStar est d pass e et que le contr leur d connecte la charge de diversion Momingstar ne sera pas responsable de tout dommage r sultant de la batterie du syst me ou d autres composants du syst me Reportez vous a la Garantie limit e de Morningstar dans la Section 10 0 6 3 Standard Diversion Battery Charging Programs DIDI The TriStar provides 7 standard diversion charging algorithms programs that are selected with the DIP switches An 8th algorithm can be used for custom setpoints using the PC software Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 33 of 48 Edge The table below summarizes the major parameters of the standard diversion battery charging algorithms Note that all the voltages are for 12V systems 24V 2X 48V 4X All values are 25 C 77 F A B D E Time PWM Until Time Equalize Equalize Switches Absorp Float float Equalization in Equal Interval Cyde 4 5 6 hours hours hours off off off 13 8 13 6 4 14 1 3 28 3 off off on 14 0 13 6 4 143 3 28 3 off on off 14 2 13 6 4 145 3 28 4 off on on 144 136 4 147 4 28 4 on off off 14 6 137 4 149 4 28 5 on off on 148 137 15 1 4 28 5 on or off 15 0 137 4 153 4 28 5 on on on Custom Custom C
51. small may lead to volt drop losses especially on a 12V system Alternatively using a cable that is large than the recommended size may lead to the turbine becoming stalled or semi stalled which will impair performance e During operation the turbine alternator will become warm and even hot especially during high wind events When this happens the resistance in the alternator coils dramatically increases which causes the alternator efficiency to drop drastically This effects the overall output of the turbine Performance will drop after the turbine has heated up due to prolonged high end running e Different battery technologies have different rates at which they can absorb power from a wind turbine The batteries will draw all of the power possible from a wind turbine until they reach their absorption limit Generally more battery capacity can be added to increase the rate at which they can absorb power Battery age and condition will also affect the rate at which the batteries can absorb power older batteries or those in a poor condition will not draw the same power levels from the turbine as newer batteries in good condition e Poor state of your batteries caused by sulphation If your batteries routinely rest at less than 12 5V it is likely that your batteries are in poor condition and unable to draw full power from the turbine When the turbine is operating at 100 watts this will equate to 8 7 amps whilst the batteries are at 11 5 volts
52. t currents Batteries used in renewable energy systems can deliver a serious amount of current A short circuit in the battery circuit can lead to hundreds of Amps flowing through the battery cables This will cause a heat build up and ultimately an electrical fire Batteries are also susceptible to explode when shorted Always use insulated electrical tools when working on the battery s electrical connections Batteries are very heavy Do not attempt to move batteries by yourself Always use manual handling tools and an assistant Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 25 of 48 Carine Edge Always keep lead acid batteries the correct way up Do not allow the acidic electrolyte to spill or come into contact with your skin Always follow the manufacturer s safety instructions when handling lead acid batteries Please use common sense when installing and operating your turbine and Charge Controller Electrical Installation Please refer to the overall electrical schematic in the turbine installation for appropriate generic wiring diagrams In a battery charging renewable energy system there may be different ways of wiring small wind turbines photovoltaic panels charge controllers and batteries together This type of system will often expand organically but the following guidelines from the Morningstar Tristar user manual should be followed Diversion Figure 22c I
53. terie CAUTION The diversion load must be able to absorb the full power output of the 741 Suitable Loads for Diversion Water heating elements are commonly used for diversion load systems These heating elements are reliable and widely available Heating elements are also easy to replace and the ratings are stable NOTE Do not use light bulbs motors or other electrical devices for diversion loads These loads will fail or cause the TriStar to disconnect the load Only heating elements should be used REMARQUE N utilisez pas d ampoules de moteurs ou d autres appareils lectriques pour les charges de diversion Ces charges ne fonctionneront pas ou provoqueront une d connexion de la charge par le TriStar Seuls les l ments de chauffe doivent tre utilis s Water heating elements are typically 120 volts Elements rated for 12 24 and 48 volts are also available but more difficult to source The derating for 120 volt heating elements is discussed in 6 4 3 below 6 4 2 Definition of Terms Maximum Source Current This is the maximum current output of all the energy sources hydro wind solar etc added together This current will be diverted through the TriStar to the diversion load Maximum Battery Voltage This maximum voltage is the PWM regulation voltage selected with the DIP switches plus the increase with an equalization plus the increase due to lower temperatures The highest battery voltage is comm
54. time in equalization the manual pushbutton can be used to continue for one or more additional equalization cycles 3 1 Battery Charging References The diversion load battery charging is similar to conventional solar charging Refer to the following sections in this manual for additional battery charging information 41 Four stages of charging applies to diversion 43 Temperature Effects and Battery Voltage Sense 44 Equalization 45 Float Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 34 of 48 Caring Edge 90 Battery Information 64 Selecting the Diversion Load PPP It is critical that the diversion load be sized correctly If the load is too small it cannot divert enough power from the source wind hydro etc The battery will continue charging and could be overcharged If the diversion load is too large it will draw more current than the rating of the TriStar The controller s overload protection may disconnect the diversion load and this will result in all of the source current going to the battery source but the load must never exceed the current rating of the TriStar controller Otherwise the battery can be overcharged and damaged PRUDENCE La charge de diversion doit tre capable d absorber toute la puissance de sortie de la source mais la charge ne doit jamais d passer l intensit nominale du contr leur TriStar pour ne pas surcharger et endommager la bat
55. to 90 degrees away from the wind and tether it in this position A hole for tethering is provided in the tail fin of the LE 450 see Fig 16 e Operation of the LE 450 in High Winds Every effort has been taken to ensure that the LE 450 will withstand the forces exerted by strong winds However the raw power in high winds is immense and the stresses placed upon the turbine are magnified by gusty and turbulent conditions Where possible the turbine should be shut down and tethered in advance of particularly strong consistent winds 60 mph and storm conditions This will decrease the wear and tear on the machine and will help to avoid a failure Protect the turbine from extreme winds as you would protect other items of your property Refer to the Shut Down procedure above Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 18 of 48 Edge e Grid tie Applications When connected to a grid tie inverter the LE 450 will operate in much the same manner as when it is charging batteries except for the use of dump loads It is important that the Grid tie inverter characteristics are matched to the power curve of the turbine to ensure optimum performance An appropriate electrical interface may also be required depending on the inverter equipment being used It is generally only recommended that Leading Edge Turbines approved and programmed inverters be used with the LE 450 Refer to your Leadin
56. to run the cables from the top of the tower to where the electrical controller and batteries grid tie inverter will be located Follow the table below to select the correct wire size cross sectional area This will vary depending on your nominal battery voltage and the distance that the cables will be run Careful selection of the cable size is required It will not only affect the safety of the system but also the overall efficiency A cable of insufficient cable size will cause a voltage drop wasting the power that has been generated The cable sizes listed below have been selected with efficiency and cost in mind as it is unlikely that your turbine will be running at full capacity 100 of the time If in doubt consult your local electrical supplier The cable should be installed in accordance with local electrical regulations and guidelines If in doubt use a local electrical contractor to complete the cable installation Warning If a cable of insufficient cross sectional area is used heat will build up in the cables causing a potential fire hazard Cable capacities quoted below are based upon Tri Rated cables BS6231 Transmission Distance LE 450 Nominal Output 10 Metres 30 Metres 100 Metres Voltage 30 Feet 90 Feet 300 Feet 12 Volts 6mm 10 mm Not Recommended 24 Volts amp Grid tie 1 5 mm 6 mm 16 mm 10 Mount the LE 450 Turbine onto the Support Structure Ensure that the previously Use
57. to the battery separately Ensure the blades are fitted in the correct orientation Consult the diagram on page 9 Blades fitted back to front it will severely impair power production Don t allow the turbine to run without being connected to the battery Failing to do so will result in the turbine freewheeling causing premature wear and tear and unnatural blade noise Failing to do so will invalidate your warranty The Tristar charge controller must be configured for Diversion mode Failing to do so will invalid your warranty as this can burn out the stator http youtube com c LeadingEdgeTurbines Visit our YouTube channel for assistance in wiring up the equipment configuring the Tristar charge controllers and more Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 3 of 48 Carine Edge Introduction Please read this manual thoroughly before attempting to assemble install or operate your LE 450 small wind turbine This will assure optimum performance and safety Leading Edge Turbines has spent many years developing the ideas and technology behind your turbine The LE 450 features an array of innovations and construction techniques as well as heavy duty engineering to ensure optimum efficiency and a long operating life All of these features have evolved from the long and successful history of the LE 300 turbine The LE 450 has been designed to be simple econom
58. trical wiring of your LE 450 turbine and associated electrical systems must be done in accordance with national and local electrical codes and regulations e Do not connect the turbine or batteries during the installation Ensure that the turbine is not running or connected to the batteries during the installation or wiring process Connect the output cables of the turbine together to prevent the rotor from starting up e Galvanic corrosion of electrical joints Try to avoid connections between dissimilar metals For example connecting copper and aluminium together will result in galvanic corrosion of the connection This will increase the electrical resistance of the connection wasting energy and reduce the mechanical integrity of the joint Where possible use a fluxed solder to make electrical joints e Protect the cables The power transmission cables must be protected from mechanical damage and fatigue Run the cables through an approved conduit trunking e Cable strain relief Prevent mechanical strain on the transmission cables running down the tower from the turbine Clip the cables to the inside of the tower Failure to do this will result in excessive mechanical strain on the cable joints within the slip ring assembly and may cause a failure Cable ties or cable glands are a good way to prevent mechanical strain on the cables e Earth the system The turbine tower should have its own separate earth point The neg
59. ttery systems can deliver a serious amount of current A short circuit in the battery circuit can lead to hundreds of amps flowing through the battery cables This will cause a heat build up and ultimately an electrical fire Batteries can explode when shorted Always use insulated electrical tools when working on the battery s electrical connections e Batteries are very heavy Do not attempt to move batteries by yourself Always use manual handling tools and an assistant e Always keep lead acid batteries the correct way up Do not allow the acidic electrolyte to spill or come into contact with your skin or face Always follow the manufacturer s safety instructions when handling lead acid batteries e Never run the LE 450 off load with the output cables not connected to anything Please use common sense when installing and operating your turbine Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 5 of 48 Edge Specifications Turbine Name LE 450 Part Number GA LETU 016 Nominal Voltage 12V 24V 48V DC or Grid tie optimised Rotor Diameter 1000 mm Rated Wind Velocity 8 m s Rated Output 105 Watts Max Output 450 Watts Start up Wind Velocity 2 m s Total weight 8 5 Kg Tower mount 48 3 mm 50 mm Outer Diameter Tube Chassis Construction Aluminium Rotor Blades 5 off Glass Reinforced Nylon Fig 1 Overall View 39 370 8 809 20 533 51000 00 223 75 52
60. ustom Table 63 Standard Diversion Charging Programs A PWM Absorption Voltage This is the PWM Absorption stage with constant voltage charging The PWM absorption voltage is the maximum battery voltage that will be held constant B Float Voltage When the battery is fully charged the charging voltage will be reduced to the float voltage for all diversion settings The float voltage and transition values are adjustable with the PC software C Time Until Float This is the cumulative time in PWM before the battery voltage is reduced to the float voltage If loads are present during the PWM absorption the time to transition into float will be extended D Equalization Voltage During an equalization cycle the charging voltage will beheld constant at this voltage Equalizations are manual and can be selected for automatic See Section 4 4 1 E Time in Equalization Charging at the selected equalization voltage will continue for this number of hours F Equalization Interval Equalizations are typically done once a month The cycles 28 days so the equalization will begin on the same day of the week Each new cycle will be reset as the equalization starts so that a 28 day period will be maintained G Maximum Equalization Cycle If the battery voltage cannot reach the equalization voltage the equalization will terminate after this number of hours to avoid over gassing or heating the battery If the battery requires more
61. w straight through the switch to the relevant output Safety Precautions Safety must always be your primary concern during the assembly installation and operation of your turbine and other associated equipment Always be aware of the risks involved with mechanical and electrical installation work If in doubt about any issue regarding your turbine system please seek further assistance before proceeding Mechanical Safety Hazards Whilst installing the Universal Run Stop Switch ensure that the turbine is suitably restrained and not allowed to operate during the installation Electrical Safety Hazards The LE 450 generates rectified DC voltage and the Universal Run Stop Switch also operates at these voltages Even at these low voltages there are inherent risks Caution should always be used when connecting the LE 450 or other equipment to the electrical system Ensure that you have followed the cable sizing guidelines to ensure that the correct size of cable has been selected If a cable of insufficient cross sectional area is used at any point in the electrical system heat will build up in the cables causing a potential fire hazard A properly sized fuse or circuit breaker should be used in the cables connected to the battery This will stop the risk of short circuit currents Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 41 of 48 Carine Edge Batteries used in renewable energy syst
62. water rather than open the solar array and lose the energy The most important factor for successful diversion charge control is the correct sizing of the diversion load If too large the controller s protections may open the FET switches and stop diverting current from the battery This condition can damage the battery If you are not confident and certain about the installation a professional installation by your dealer is recommended 6 2 Diversion Current Ratings TOOT RTT TEETH TEE EE OTT T EEE EOE ET EEE HOOT EE EEE EOE EET EEE EOE TET TEE TOOT TTT TE THOTT TTT The maximum diversion load current capability for the two TriStar versions is 45 amps TS 45 and 60 amps TS 60 The diversion loads must be sized so that the peak load current cannot exceed these maximum ratings See section 6 4 below for selecting and sizing the diversion loads The total current for all combined charging sources wind hydro solar should be equal or less than two thirds of the controller s current rating 30A TS 45 and 40A TS 60 This limit will provide a required margin for high winds and high water flow rates as well as a margin for error in the rating and selection of the diversion load This protects against an overload and a safety disconnect in the TriStar controller which would leave the battery charging unregulated CAUTION If the TriStar s rating is exceeded and the controller disconnects the A diversion load Morningstar will not be respon
63. wer connection is not reversed polarity Flashing Sequencing LEDs Reference Section 3 3 for a list of LED indications and their corresponding faults alarms Self Test Indication R Y G sequencing Self testing will also detect various system wiring faults outside the TriStar Check for both TriStar faults and external system wiring problems The RTS or Battery Sense is not working properly R Y G Y sequencing LEDs indicates an RTS or Sense fault Check for a reverse polarity connection on the sense leads Verify that the RTS and Sense connections are wired to the correct terminals Check for shorts and continuity in the cables Verify that good electrical contact is made at the terminals Note that if the TriStar is restarted with an RTS or Sense fault present it will not detect the RTS or Sense connection and the LED indication will stop Troubleshooting Diversion Control Diversion load is too small so PWM reaches 9996 Diversion load is burned out so PWM reaches 9996 Diversion load is too large so TriStar faults on overcurrent An overtemperature condition may have caused the load to be disconnected The RTS is not correcting for high or low temperatures Voltage drops between the TriStar and battery are too high Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 39 of 48 Edge Appendix 2 Run Stop Switch User Manual Only operate in l
64. wiring diagram www leturbines com Skyrrid Farm Pontrilas Hereford HR2 OBW UK Page 17 of 48 Tel 44 0 845 652 0396 Edge Turbine Operation The LE 450 turbine is based on a simple design for ease of installation and reliable operation You may notice the following behaviour during normal operation e Cut in The turbine will not begin to charge the batteries until the rotor is spinning at approximately 300 RPM Whilst operating below this speed the turbine will be off load and freewheeling Once the turbine output voltage becomes equal to the nominal battery voltage at around 300 RPM the turbine will come on load and begin to deliver current to the batteries During the off load stages of rotation the rotor blades rotate very freely This allows the rotor to build up speed and allows aerodynamic lift to be generated by the blades e Normal Operation Once the rotor is spinning at 300 RPM current will be delivered to the batteries As the rotor speed increases so too will the current and voltage Excessive wind speed may increase the battery voltage to a high level Once this happens the diversion charge controller will recognise that the battery voltage is too high and begin dumping power to the heater module e Charge Regulation Once the charge controller has switched over to the dump load the turbine will no longer be charging the batteries Instead the power from the turbine will be delivere

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