AERO4GEN OWNERS MANUAL
Contents
1. No 1 BATTERY No 2 BATTERY TWIN BATTERY VOLTAGE REGULATOR WIRING DIAGRAM 162. 2 5 mm 4 0 mm 2 5 mm Useful wire cross sectional area mm conversion to AWG 25mm 14 AWG 4 0mm 12 AWG 6 0 mm 10 AWG 10 0 mm 8 AWG If the Aero4gen is connected directly to the battery terminals we recommend a 20 Amp fuse for 12V Models and a 15 Amp fuse for 24v Models is fitted in the red positive wire from the generator to the battery so that if a dead short occurred it would prevent serious damage to the wiring and the generator The RED OUTPUT WIRE output is connected to the POSITIVE terminal of the battery The BLACK OUTPUT WIRE to the NEGATIVE terminal of the battery VOLTAGE REGULATION The output wires of the Aero4gen can be connected directly to the terminals of the battery that requires charging as shown in Fig 5 however if the terminal voltage of the battery is not continually monitored for over voltage 14 2v for 12v batteries and 28 4v for 24v batteries the battery can be seriously damaged Fitting an LVM voltage regulator will protect the battery from becoming over charged You may well have chosen a voltage regulator when purchasing the Aero4gen but we would recommend you look at page 15 SELECTING THE CORRECT LVM VOLTAGE REGULATOR to make sure you have purchased the correct unit You may also consider installing an ammeter voltmeter or an amphour meter all are available from LVM part number as follows LVM66 0 5A Ammeter LVM67 0 20A Ammeter LVM68 0 30A Ammeter L
3. Small amount of Loctite 638 in tube Tools required Hammer Circlip pliers Pozi drive screwdriver Piece of hardwood and a brass rod 12mm diameter X 250mm long or similar 1 2 CD 10 1 12 13 14 15 Disconnect output leads and remove generator from mast Remove fan and tailfin assembly Remove the front circlip on the main shaft Remove 6 off self tapping screws retaining the rear cover Place a piece of hard wood on a concrete floor Holding the generator with the rear cover held back and main shaft downwards lift and force downwards the generators main shaft onto the piece of hard wood This should displace the main shaft inwards Alternatively the main shaft can be pressed out or hammered out but take care not to bruise the end of main shaft The main shaft rotor assembly should now have moved inwards into the main housing Using a piece of brass rod or similar so as not to damage the end of the main shaft tap the shaft through both the bearings and remove rotor assembly from the rear of the main housing Having removed the rotor from casting Check the main shaft for wear particularly the areas the main bearings are positioned If the shaft wear is found to be excessive a new shaft will have to be fitted Contact LVM Ltd Using the brass rod and a hammer knock out the main bearings from the casting Refit new main bearings using a little Loctite Bearing Fit smeared o
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5. AERO4GEN OWNERS MANUAL CE LVM 412 12 Volt LVM424 24 Volt PARTS CHECK LIST ME S Generator M8 grub screws fitted SN Tail Tube Ik o 00 Tailfin ie Fan Hub Bossed Fan Clamp Plate Fan Blades Hub Cover WEI 8 5 Kg M6 X 25 Stainless Steel Screws I M6 Stainless Steel Nyloc Nuts Aero4qen Performance M6 Stainless Steel Washers 20 M4 X 25 Stainless Steel Screws M4 Stainless Steel Nuts A M4 Stainless Steel Washers X Allen Key 4 mm A F orn Allen Key 5 mm A F AR M6 X 20 Allen Bolt With Spring Washer See Push fit connectors Male Push fit connectors Female s 0 M6 Black Nut Covers ee al 15 10 Amps output 12v O N N Q Q G O O O O 0 10 20 30 40 50 60 Wind speed knots Note Amps Output of a 24V model will be half shown above Guarantee Thank you for purchasing this product It has been manufactured to exacting standards and LVM Limited guarantees that should any defect in materials or workmanship occur within ONE YEAR of the date of purchase we will repair or replace the defective part free of charge Damage caused by misuse failure to follow instructions negligence and modification or transit damage will not be warranted LVM Limited will not be liable for
6. ROGEN HOUSE OLD OAK CLOSE ARLESEY BEDS SG15 6XD 01462 733336 FAX 01462 730466 Aero4gen mounting kits Mk2 Mounting kit includes 1x 1 O D Stainless steel tube 1200mm long 1 x 1 Stanchion mount base 1 x 1 to 1 Universal plate MK4 Mounting kit includes 1 x 1 5 Stainless steel tube 1450mm long 1 x 1 5 Stanchion mount base 1 x 1 to 1 5 Universal plate MK6 Mounting kit includes 1 x 1 5 O D Stainless steel tube 2 900mm long 1 x 1 5 Stanchion mount base 1 x 1 to 1 5 Universal plate 10 Metres of 4mm Dia Stainless steel wire rope 3 x Wire rope terminal tensioners 3 x Wire rope terminals 3 x Deck U bolts 2 x 1 5 U bolts 1 x 4 hole plate KEY DIMENSIONS WHEN CONSTRUCTING A MIZZEN MAST MOUNTING AEROGEN TROUBLE SHOOTING The AERO4GEN is design to give many years of reliable service as it contains really only two moving parts and one electronic component they are the permanent magnet rotor the slipring brush assembly and a rectifier The only parts that can wear are Main bearing ball races pivot shaft ball races and the carbon brushes which make contact with the sliprings For safety reasons fan blades are designed to brake off if by accident an arm or hand is caught in the fan SIMPLE TEST A simple test to prove there is an output voltage from the generator can be carried out whilst the generator is in it s working position Di
7. TE 2 THE ON OFF ON SWITCH MUST NOT BE LEFT IN THE OFF POSITION THE OFF POSITION S ONLY REQUIRED TO GIVE THE SWITCH CONTACTS GOOD ELECTRICAL SEPARATION BRAKE SWITCH WIRING DIAGRAM Sen erin BE tes AEROGEN DOUBLE POLE AEROGEN MODEL RATING ad ON OF ON OUTPUT 212 5A 12V DC SWITCH A 224 3A 24V DC RED J BLACK ae are 412 15A 12V DC 424 10A 24V DC RED Been 412F 15A 12V DC II o 424F 10A 24V DC 612 20A 12V DC 624 15A 24V DC SWITCH POSITIONS aa F n CHARGE 612F 20A 12V DC v 1 B BRAKE 624F 15A 24V DC B Ic B NOTE A BRAKE SWITCH MUST aR 5 ONLY BE USED IN THE AIR MODE WHEN FITTED TO THE PASSING THROUGH THE OFF POSITION AQUA4EROGEN i NEVER FIT A BRAKE SWITCH TO AN AQUAGEN IN WATER TOW MODE RED H BLACK RED O BLACK TO FUSE A 20 AMP DOUBLE POLE AMMETER IF FITTED ON OFF ON SWITCH TB REGULATOR TO FUSE SUITABLE FOR ALL OR BATTERY AMMETER IF FITTED AEROGEN MODELS TB REGULATOR REAR VIEW OF A TYPICAL DOUBLE POLE OR BATTERY LVM PT NO SWITCH 020 ON OFF ON SWITCH SHOWING WIRE CONNECTIONS FUSE HOLDERS AND FUSES FOR AEROGENS FUSE RATING LVM PT NO Fa 5 Amp FUSE 005 INLINE 15 Amp FUSE 015 FUSE HOLDER __ N J 20 Amp FUSE 020 ha a 100mm E 30 Amp FUSE 030 J LVM PT NO FUSE HOLDER 001 LVM LTD AE
8. VM69 0 15v dc Voltmeter LVM200 Digital Amp Hour Meter INSTALLATION PLEASE FOLLOW THESE PRECAUTIONS DURING INSTALLATION e Choose a calm day e Have someone available to help during installation e Do not install the blade assembly until the generator is mounted Whilst initially installing the generator or carrying out future maintenance it is important that the fan assembly is stationary 1 Attach the push on connectors and covers supplied to one end of your output cable Observing polarity plug them into the generator s output connectors 2 Thread the output cable carefully through the centre of your mounting tube If the bottom of the tube is not accessible a hole must be drilled to enable the cable to be brought out Be sure to leave enough slack in the cable so that if necessary the generator can be removed 3 Locate the generator on top of your mounting tube and then fully tighten the M8 clamp bolt nut on the adaptor 4 The tail assembly can now be inserted into the hole at the top of the generator ensuring that the tailfin is positioned vertically and tighten the M8 grub screws 5 Fitting the fan blade assembly onto the main shaft of the generator Grease fan hub bore then fit the fan assembly onto the generator main shaft aligning the M6 clearance hole in the fan hub boss with the M6 tapped hole in the main shaft Fit the M6 spring washer under the head of the M6 x 20 Socket Cap Screw Insert the bolt through the M6 clea
9. any loss of revenue or any consequential loss or damage to property or persons from any cause whatsoever Retain your purchase invoice as it will be needed in the event of a warranty claim What is Not Covered Damage due to lightening Damage due to improper installation Damage due to improper wiring Damage from flying debris causing blade damage Please read the manual thoroughly If you have any questions please contact us at LVM Limited Aerogen House Old Oak Close Arlesey Beds SG15 6XD Tel 44 0 1462 733336 Fax 44 0 1462 730466 E mail lvm ltd dial pipex com Web www lvm ltd com LVM Technical web site www lvm ltd dial pipex com MOUNTING This Aero4gen is fitted with an aluminium bronze mounting adaptor which is designed to clamp onto a tube diameter of 1 25 4mm 1 5 38mm LVM manufactures several mounting kits in marine grade stainless steel details of which are included in these instructions A minimum turning radius of 480mm should be allowed when selecting a position to mount the Aero4gen Great care should be taken to site the unit to avoid personal injury from the rotating blades When constructing a mounting system for the Aero4gen make sure it Description of Mean Force Force can withstand the weight of the generator together with the additional wind velocity Lbs Kg wind forces shown in the table opposite in knots If the Aero4gen is to be mounted on a yacht boat care
10. asting paintwork tap out pivotshaft assembly by hitting the base of the casting The bearings can now be removed from the pivotshaft Use Loctite bearing fit when refitting the new bearings to the pivot shaft and to the generator housing Apply silicone sealant to the bottom cover and the output wires within the adaptor when reassembling the pivot shaft assembly Refit brush cover using a new brush cover gasket 12 ELECTRICAL COMPONENT DIAGRAM OF AERO4GEN SUPPRESSION CAPACITORS 3 PHASE STATOR WINDING STAR CONNECTED TA POSITIVE SLIPRING gt NW NEGATIVE SLIPRING IP NN SOLDERED CONNECTIOI PIVOT SHAFT OUTPUT WIRES alll 3 PHASE RECTIFIER S2ovT80 BRUSH CAP ASSEMBLY CARBON BRUSH ELECTRICAL SCHEMATIC DIAGRAM OF AERO4GEN 3 PHASE STATOR WINDING STAR CONNECTED RESISTANCE OF EACH PHASE 12v MODEL 1 6 OHMS 24v MODEL 6 5 OHMS COLOUR OF STATOR banh OUTPUT LEADS 12v BLACK 24v RED 3 PHASE RECTIFIER POSITIVE SLIPRING gt NEGATIVE SLIPRING OUTPUT WIRES 13 INSTRUCTIONS FOR REMOVING AND REPLACING MAIN BEARINGS AERO4GEN Parts required 2 off Main bearings LVM Part No Bearing 783 1 off Rear cover gasket LVM Part No Gasket 548 2 off Circlips 15mm LVM Part No Circlip 862 6 off Rear cover retaining screws LVM Part No Screw 664 1 off
11. diLO3M Jeljlloeyd sbyd 62G InN JON EM OVS M3HSVM J USDA 4OLS EM LVS YIHSVMA 4OUSDM 94g14 SW SOS MAINOS M S CW d 694 M1AOO JeAoD 4psy ZZ MOLIIOVdVO 4oLlopdog uoIsseiddns Gry YAHSVM 4SUSDA uoo SW 1S8 MIYOS MOJOS BuluIbjay 10I S G XGN 799 MINOS Mesos db Jles 6xy oN a 8yS I3XSV9 1934Sb9 49400 DOY Ndo3syVY 3AVN 37114 799 N3adOS doj 19 ZJxy o d 82 M1 J8A0D UW A 8u DS Buld A JD9S Jelp J9obds P9S Jejp 6ulupeg loAld woog 6ulJpsg joAld dol HDUYS OMG ejgoo Buly dls S E60 ASSY LIVHS Aiquiessy JpUS loAld AO2 oH98 064 ONINVIS nq 0099SN Hb g loAld Woog LS6 ONIN ds Bury dis zZ ONINVAG ZZ10093SN peg JoAld dol 281 ONINVAd AOnG G20 95SN BuLpeg Jeuul UJDA 9 ONIUVI38 NINIIZOSIASN Bulipeg Juojji VIDA Y60 ASSY YOLOYSF quj ssv JOJOy X HEUS UIW 798 dI12 I2 312419 10 6 d 8Z NILSYO pelulpd Busog Apog UIDW e lt SLYVd INI4VA N3 a Oud STOPPING AEROGENS FILE BRAKE4 Your Aerogen is designed for continuous ope
12. e checked every 6 months e Check blades for damage and replace if necessary Do not use the generator with damaged or unbalanced blades This will cause unnecessary wear and possibly damage to the main bearings Check the fan hub assembly for tightness Check the mounting adaptor and your mounting system for tightness Check all external electrical connections for tightness and corrosion Wash down the generator with fresh clean water to remove debris and salt deposits that can build up If you experience a problem with your Aero4gen contact LVM to determine the nature of the problem LVM will send you replacement parts and instructions needed to repair the generator In the event that the generator is returned for repair service you will be notified of the cost for carrying out the work and will incur the transport costs S1 V H Z N3A3 YO HLM NAS TIM SAVM9 1H9I3 VZO M1AO2 LAN 29A92 NN 5lspold 9N 16Z YIHSVM J9USOM 9 06Z InN INN 99 N OW SG6 NO9S M 0S WuSZx9N ST S00 3qVl8f spplg ubj SIlMVdyV Ald IgA3SSY NV4 AHL GSONVIVE NOY TIM LINA JHL INV 30dV18 11ISOddO 19M3N1 NV NI 3AOA3y gavia JNO 30 39V V3Y8 JHL 9NIMOTIOY 2 YSHLO HOV 3LISOddo qQ39V 1d38 3HY AWVS 3H1 40 A3HL ONIGIAONd 031114 38 NYO LHSISM ANY LHSISM HOIHM LHOISM 3GV18 3HL ANY Si0V18 Z YSASMOH MOTIE NMOHS SI S00 30v18 ON ld INLLONO GAYACGNO 3
13. e the ambient temperature is always around 20 deg C then standard regulators can be used However if you intend to locate a battery where temperatures may go down to freezing and perhaps rise to tropical temperatures then you should install a regulator that is fitted with a temperature compensation circuit This automatically allows the battery to be charged at a higher voltage as the temperature drops and a lower voltage if the temperature increases Simply add T after the LVM Product No ie 4SB12 T There are two types of regulator suitable for the Aero4gen 1 Single battery regulator LVM Product No 4SB12 4SB24 These units are simply connected to the battery terminals and if the battery voltage reaches 14 2v 12v systems or 28 4 24v systems the regulator diverts powerto a high wattage wire wound dump resistor This regulator should NOT be used if you have any other form of charging system connected to the battery ie Mains charger shore power engine driven alternator THESE REGULATORS ARE NOT SUITABLE FOR YACHT INSTALLATIONS Note These regulators draw a continuous small standby current of around 10mA 15mA 2 Twin battery regulators LVM product No 4TB12 4TB24 These units are connected between the output of the Aerogen Aquagen or Solargen module and the battery terminals They control the actual output voltage of Aerogen Aquagen or Solargen by diverting power to a high wattage wire wound dump resistor when their out
14. ed MEASURING OUTPUT VOLTAGE With the generator in its operating position disconnect the generators output cable from the battery or the TB regulator if fitted and attach a multimeter set on 0 100 volts dc range to the two output leads The following open circuit voltages should be obtained at the wind speeds shown below It is most important that the wind speed is measured at the same height the wind generator is mounted 12v Model 6 knots 12v 10 Knots 25v 15 knots 35v 20 knots 47v 24v Model 6 knots 24v 10 Knots 50v 15 knots 70v 20 knots 94v If you have a lathe or some other means of turning the main shaft at a known RPM a 12v model produces 0 06v per rev and a 24v model 0 12v per rev If no voltage is present check that your extension wire connection from the actual generators output cables are not corroded or have become disconnected If there is a fuse fitted in the output cable check it has not blown Check output voltage again at the generators actual output cable If there is still no voltage output go to the instructions and tests listed under heading NO OUTPUT REDUCED OUTPUT Check blades are set at the correct angle and the concave side hollow side of the blade faces the wind The main shaft of the generator should turn freely however there will always be a slight resistance which is called the cogging effect To check the starting torque cogging effect of the generator is correct Sellotape 2 3 pound co
15. er in turn in pairs RESULT 0 Volts If in doubt about the condition of the rectifier replace with a new one Refit the 3 off 3 phase stator output leads to the centre terminals of rectifier Set the multimeter to read DC volts Attach the red test lead of the multimeter onto the plus terminal of the rectifier then the black test lead onto the negative terminal Turn the main shaft of the generator by hand any direction this should indicate a voltage on the multimeter Refit Red and Black DC output leads from the rectifier Refit rear cover using a new gasket make sure all wires are clear of the rotor CHECKING SLIPRINGS AND BRUSHES Remove the brush cover assembly 4 screws Hinge back brush cover assembly leaving the red and black wires attached Check the condition of the sliprings and clean them if necessary Check the spring loaded carbon brushes are clean and are free to move in the brush holder Set a multimeter to continuity check buzz test Check there is continuity between the top carbon brush and the positive terminal of the rectifier then check there is continuity between the bottom carbon brush and the negative terminal of the rectifier Check there is continuity between the top slipring and the red output cable of the generator Then check there is continuity between the bottom slipring and the black output cable of the generator 11 If no continuity is found on one or both output leads check the soldered joint on t
16. f the generator by hand any direction small voltage should be indicated on the multimeter Check the stator and suppression capacitors do not look burnt or overheated Check tightness of stator retaining screws If at any time the generators output leads have ever been connected to battery terminals the wrong way round or the generator has been struck by lightening then the rectifier may be have been damaged RECTIFIER TEST Readings taken of a Good Rectifier Set a multimeter to diode test then check 1 Disconnect all connectors from the rectifier 2 Attach the red test lead from multimeter to the plus terminal of the rectifier attach the black test lead to the negative terminal RESULT No Reading 3 Reverse the test leads i e attach the red test lead to the negative terminal of the rectifier then the black test lead to the plus terminal RESULT 0 8 0 9 volts 4 Connect the test leads to the 3 centre terminals of the rectifier in pairs RESULT No Reading Readings taken of a Faulty Rectifier 1 Disconnect all connectors from the rectifier 2 Attach the red test lead from multimeter to the plus terminal of the rectifier attach the black test lead to the negative terminal RESULT 0 Volts 3 Reverse the test leads ie attach the red test lead to the negative terminal of the rectifier then the black test lead to the plus terminal RESULT 0 Volts 4 Connect the test leads to the 3 centre terminals of the rectifi
17. he slipring Resolder if necessary Set multimeter to read 0 15 volts DC connect test leads of multimeter to the brushes top brush is Positive bottom brush is Negative turn generator main shaft by hand in any direction If a voltage is present then refit brush cover using a new gasket Attach the test leads of the multimeter to the output wires of the generator then turn main shaft again to check a voltage is present KNOCKING SCRAPING SOUND ONCE PER REVOLUTION Whilst the generator is in it s working position check that the M6 allen screw which retains the fan assembly to the main shaft is fully tightened Also check tightness of all other fasteners on the fan assembly mounting adaptor and tailfin Remove rear cover and check the condition of the rotor it may be rubbing on the stator Inner main bearing could be worn check for axial and radial movement Check the tightness of the 4off M5 stator retaining screws this can cause a noise if slightly loose GENERAL MECHANICAL CONTINUOUS NOISE Remove fan and check axial and radial play in the main front bearing Remove rear cover and check inner main bearing in the same manner If large amount of play is found replace main bearings Follow instructions listed REPLACING MAIN BEARINGS GENERAL ELECTRICAL VIBRATION NOISE It is normal for the Aero4gen to produce a very slight magnetic cogging vibration when rotating and an electrical vibration whilst charging This noise will be greatly amp
18. hollow side upwards See Fig 1 Then place the Bossed Hub on top locating the blades in the sockets Insert the 6 off M6 screws washers and nuts and at this stage only tighten the nuts sufficiently to lightly grip the blades See Fig 2 Turn each blade until the indicator marks on the blade and hub align this sets the blade angle See Fig 3 Then finally fully tighten the nuts and push on plastic nut covers NOTE Do NOT install the fan assembly until the Aero4gen is mounted ALIGN MARKS TAILFIN ASSEMBLY Attach the tailfin onto the tail tube using the M4 X 25 long screws washers and M4 Nyloc nuts ELECTRICAL DATA Aero4gen output wire colour Code The Red output wire is POSITIVE The Black output wire is NEGATIVE Wire Rating The output wires of the Aero4gen will require extending Electrical systems lose energy from the resistance of the wire size used The larger the wire size the smaller the loss however larger cross sectional area wire can be costly and in some cases more difficult to source The following table shows recommended wire sizes they are based ona 3 and 5 energy loss at an average wind speed of 20knots It is recommended a minimum wire size of 2 5 sq mm be used Single Wire Length 0 5 Metres 6 10 Metres 11 20 Metres Voltage Drop 3 5 3 5 3 5 12 volt Aero4gen 4 0 mm 2 5 mm 6 mm 4 0 mm 10 mm 6 0 mm 24 volt Aero4gen 2 5 mm 2 5 mm 2 5 mm
19. ins 20 30 grams on the tip of a blade Set this blade by turning the fan till it is horizontal let go of the blade and the fan should just start to turn If the fan turns ok as described above then follow instructions under heading NO OUTPUT with particular attention to the rectifier test If the fan did not turn as described in the test above follow the instructions and tests listed under headings KNOCKING SCRAPING SOUND ONCE PER REVOLUTION GENERAL MECHANICAL CONTINUOUS NOISE and NO OUTPUT 10 NO OUTPUT Remove the generator from mounting taking off the tailfin and fan assembly Remove the rear cover 6 off screws and hinge back cover A component called a rectifier that converts the 3 Phase A C output voltage of the stator into D C volts is mounted on the inside of the cover Note later models have also suppression capacitors soldered to the rectifier Disconnect the 3 push fit connectors output wires from stator which are attached to the centre terminals of the rectifier No need to remember which order or terminal they come from as they can fit on any of the 3 centre terminals Using a multimeter set on resistance measurement ohms check the resistance in turn of the of 3 output wires in pairs from the stator They should read 1 6 ohms 12v model 6 5 ohms 24v model CHECKING A C OUTPUT VOLTAGE OF STATOR Set the multimeter to read A C volts attach test leads to the 3 off stator output wires in pairs then turn the main shaft o
20. ithin the table or require full wiring diagrams please check our web site www lvm ltd com or call our sales office who will e mail fax or post you copies VOLTAGE REGULATOR TABLE Number of independent batteries to be charged SYSTEM 1 2 3 4 1 x Aero4gen 4SB or 4TB 4TB 4DU 4TB 6DU 1 x Aero4gen 5w Solargen panel 4SB or 4TB 4TB 4DU 4TB 6DU 1 x Aero4gen 10w Solargen panel 4SB or 4TB 4TB 4DU 4TB 6DU 1 x Aero4gen 17w Solargen panel 4SB or 4TB 4TB 4DU 4TB 6DU 1 x Aero4gen 25w Solargen panel 4SB or 4TB 4TB 4DU 4TB 6DU 1 x Aero4gen 35w Solargen panel 4SB or 4TB 4TB 4DU 4TB 6DU 1 x Aero4gen 50w Solargen panel 4SB or 4TB 4TB 4DU 4TB 6DU 1 x Aero4gen up to 60w Solargen panels 4SB or 4TB 4TB 4DU 4TB 6DU 15 FILE SBTB DUMP RESISTOR Al PR N TO N c p AEROGEN AQUAGEN GREY CABLE t SB UNIT FUSE BLACK CABLE N ruse RED CABLE BATTERY SINGLE BAT FRY VOLTAGE REGULATOR WIRING DIAGRAM TO AEROGEN AQUAGEN RED L O TB UNIT 7 FUSE pu JIN c BLACK CABLE FUSE BLACK 7 DUMP RESISTOR AR E _ GREY CABLE GREY CABLE RED CABLE _ RED CABLE HEAVY DUTY LINK CABLE Oo o ot la o
21. lified if the Aero4gen is mounted on a very hollow section of a yacht boat If mounted directly over sleeping quarters it may well be necessary to stop the Aero4gen at night Well known methods that can reduce vibration noise are listed below 1 Rubber mount as many fixings within the system as possible 2 Insert round insulation material the type you fit around cold water pipes to stop them freezing during winter into the bore of the 1 5 mounting tube 15mm pipe sized insulation normally fits just perfect 3 Coil a length of rope around the outside diameter of the mounting tube full length SLIGHT ELECTRIC SHOCK FROM HAND RAIL Remove the generator from mounting taking off the tailfin and fan assembly Remove the rear cover 6 off screws and hinge back cover Using a multimeter set on continuity buzzer test check the 3 Phase output wires from the stator assembly do not have continuity with the main casting i e The casting main housing of the generator should be totally isolated from the electrical output of the generator If they do have continuity a new stator assembly must be fitted contact LVM REPLACING PIVOT BEARINGS Remove the generator from it s mounting taking off the tailfin and fan assembly Remove adaptor M8 grub screw and brush cover Remove bottom cover 2 screws Clamp the pivot shaft in a vice using jaw protectors so as not to damage the pivotshaft Then using a hammer against a piece of wood to protect the c
22. n the O D of the bearings Clean the main shaft then clean the rotor magnet with sellotape sticky side to remove small pieces of steel pickup Smear a little Loctite Bearing Fit onto the main shaft close to the rotor and in the bore of the outer main bearing Insert the main shaft rotor assembly into the generator main bearings WARNING The rotor magnets are very powerful and will quickly draw the assembly into the stator When the main shaft rotor assembly is fully inserted check it rotates without rubbing Smear a little Loctite Bearing Fit on the outer main bearing inner race to shaft i e between the O D of the shaft and the I D of the inner race Push the main shaft in and out a little to spread the Loctite between the outer main bearings bore and the main shaft Fit new circlip Refit rear cover using a new gasket make sure all internal wiring is clear of the rotor 14 SELECTING THE CORRECT LVM VOLTAGE REGULATOR The output of the Aero4gen can be simply connected directly to the terminals of the battery that requires charging however if the terminal voltage of the battery is not continually monitored for over voltage 14 2v for 12v batteries and 28 4v for 24v batteries the battery can be seriously damaged Fitting an LVM voltage regulator will protect the battery from becoming over charged TEMPERATURE COMPENSATION This additional feature is available on all LVM regulators If the battery is located in a building wher
23. put voltage reaches 14 2v 12v systems or 28 4 24v systems They have two schottky blocking diodes built into the regulator which enables them to monitor and control the charge to two batteries totally independent of each other therefore making it ideal for separate charging of engine starting and domestic batteries The battery with the lowest terminal voltage will be charged first then gradually when both batteries become fully charged the Aerogen Aquagen or Solargen modules output is automatically diverted to the dump resistor this does two things it stops the batteries over charging and keeps the generator always on load Note These regulators draw NO standby current from the battery THESE REGULATORS ARE SUITABLE FOR YACHT INSTALLATIONS Also available from LVM are Diode Units LVM product No 4DU 6DU The 4DU when combined with a 2TB or 4TB regulator enables one additional battery to be charged The 6DU when combined with a 4TB regulator enables two additional batteries to be charged The Aero4gen and a Solargen modules output may often be combined the table below shows the recommended regulator for various systems Note Two batteries wired in parallel are classed as one independent battery Having selected the recommended regulator model from the table simply add the voltage required ie 4TB12 for a 12v system or 4TB24 for a 24v system Basic wiring diagrams are shown on page 18 If you cannot find your particular system or application w
24. rance hole in the outer fan hub boss and fully tighten it into the main shaft using the Allen key supplied best to increase the leverage on the allen key by fitting a tube or something similar to make sure it is fully tightened See Fig 4 the black hub cover is then pushed onto the hub boss 6 The output wires are then connected to the battery See Fig 5 The RED WIRE is connected to the POSITIVE terminal and the BLACK WIRE to the NEGATIVE terminal We recommend a 20 Amp fuse for 12V Models and a 15 Amp fuse for 24v Models is fitted in the red positive cable from the generator to the battery so that if a dead short occurred it would prevent serious damage to the wiring and the generator Note Do NOT reverse the connections from the generator to the battery ie Generator Positive to battery Negative and generator Negative to battery Positive Doing this will damage the rectifier and void your warranty WARNING THE AERO4GEN SHOULD NOT BE ALLOWED TO RUN OPEN CIRCUIT IN HIGH WINDS HIGH VOLTAGES WILL BE PRODUCED THE SUPPRESSION CAPACITORS CAN BE DAMAGED THE FAN WILL TURN FASTER SUFFERING UNNECESSARY STRESS MAINTENANCE The Aero4gen is designed to operate for long periods without needing any maintenance The life of the generator and its performance will be enhanced if periodic inspection is carried out For personal safety reasons before carrying out any inspection make sure you stop the generator from rotating The following should b
25. ration and to withstand storms However you may wish to stop the fan assembly from turning and then secure it with rope if violent storms are forecast as flying debris can cause blade breakage You can stop or slow down the fan assembly from turning manually or electrically MANUAL STOPPING The Aero4gen and Aero6gen tailfin has a hole into which should be fixed a small rope loop The unit can then be pulled out of the wind using a hook attached to a long handle The blades will slow down They should then be firmly secured with rope ELECTRICAL STOPPING A double pole on off on switch should be fitted as shown in the wiring diagram below This will short circuit the Aerogen output and the fan assembly will stop or slow down considerably You should then firmly secure the blades with rope The swiich can be left in the parked position whilst the blades are secured WARNING THE BRAKE SWITCH SHOULD ONLY BE USED TO STOP SLOW DOWN THE FAN ASSEMBLY PRIOR TO SECURING WITH ROPE IT SHOULD NOT BE USED AS A PERMANENT PARKING MECHANISM The Aerogen should always be stopped and the blades secured its output disconnected from he battery or regulator before carrying out maintenance working on it OTE 1 EVER SIMPLY SHORT THE AEROGENS OUTPUT WIRES WITHOUT FITTING A DOUBLE POLE ON OFF ON SWITCH AS BATTERY CABLES COULD BE SHORTED BY MISTAKE SERIOUS PERSONAL INJURY COULD RESULT AND EQUIPMENT DAMAGED O
26. sconnect the generators output cable from the battery or the TB regulator if fitted With the fan turning in the wind and the two output leads open circuit allow the fan to build up speed then touch the two output leads together shorting them the fan should noticeably slow down and act as a brake If this does not happen check that your extension wire connection from the actual generators output cables are not corroded or have become disconnected If there is a fuse fitted in the output cable check it has not blown The above test can also be carried out by turning the generators main shaft by hand any direction to check the braking action Note Although the instruction sheets supplied with the generator warns you not to run the generator in an open circuit condition the tests can be carried out safely at wind speeds of up to 20 knots The reasons we do not recommend generators be left in an open circuit condition is that at very high wind speeds the suppression capacitors maximum voltage may be exceeded and destroy them The following tools and equipment will be needed to carry out tests and repairs to the generator A multimeter which can read 0 100 volts DC measure resistance have a diode test and a continuity buzzer test Pozi drive screwdriver Circlip pliers Soldering iron and solder Hammer Piece of hardwood and a brass rod 12mm diameter X 250mm long or similar For pivot bearing replacement a bench vice will be requir
27. should be taken Gentle breeze 9 0 5 0 3 where to position it as the Aero4gen will always produce a very slight Moderate breeze 13 1 3 0 6 magnetic cogging vibration when rotating and an electrical vibration Fresh breeze 19 2 5 1 5 whilst charging This noise will obviously be greatly amplified if Strong breeze 24 4 5 2 mounted on a very hollow section of a yacht boat Moderate gale 30 7 3 2 Fresh gale 37 10 5 4 8 RADIO RADAR DECCA SAT NAV INTERFERENCE Strong gale 44 15 7 The Aero4gen should be mounted at least 1 Metres from any form of Whole gale 52 20 5 9 5 aerial to avoid air born interference The output cable from the Storm 60 27 12 5 generator together with the dump regulator cables if fitted should be Hurricane 68 35 16 routed at least 1 Metre from aerial cables It is most important particularly on yacht installation that the negative return cable to the battery is clean and fully tightened The safety cable fitted around a yacht boat is tensioned by a bottle screw or turnbuckle and this cable has been known to cause interference The remedy is to rope tension or use an insulated connector MIZZEN MAST MOUNTING See page 9 ASSEMBLY FAN BLADE ASSEMBLY Assemble the fan using the M6 X 25 screws M6 Nyloc Nuts and M6 Washers The best way to assemble the fan is to lay the Hub Clamp Plate on a flat surface blade sockets upwards and then insert the 6 blades concave side
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