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WIND TURBINE INSTALLATION INSTRUCTIONS.
 
 

 
WIND TURBINE INSTALLATION INSTRUCTIONS EXPLORING AC AND DC MYTHS
 
 

 
 
 
 
 
 
 
 
 
 
 
BLADES AND HUB
 
 
https://www.youtube.com/watch?v=67gKDjyJizE&feature=youtu.be
 
PROPER SPACER INSTALLATION MORE HERE
 
ARE YOUR BLADES ON BACKWARDS? If your performance is bad and the blades
do not spin fast you could have your blades on BACKWARD! Let's check out your blades!
 
Look in between the two bolt holes on the blade handle and you will see that ONE side has a dimple (injection mark)
The blade side with the small dimple between the bolt holes gets faced towards the hub and thus also faces the PMA.
 
If this dimple is facing into the wind you have bolted on your blades backwards and they need to be flipped over and reversed.
 
 

 
 
 
 
 

 FOR TWIN TAIL TYPES

SEE THIS PHOTO
 
 
 
 
NO FUSE AND YOU LOSE
Unprotected stator coils can overheat in severe wind storms!
ALSO DO NOT FORGET TO PUT A FUSE (BREAKER) ON EACH TURBINE!
 
FOR WIND SCORPION and GHOST (For all #SCS and #PC PMA's)
 
10 amp AC breaker for 48 volt systems
20 amp AC breaker for 24 volt systems
40 amp AC breaker for 12 volt systems
 
 
FOR FIREBIRD (For all #SC PMA's)
 
15 amp AC breaker for 48 volt systems
30 amp AC breaker for 24 volt systems
50 amp AC breaker for 12 volt systems
 
BATTERY CONTROLLERS INFO
For those of you using batteries link here to find out MORE about BATTERY controllers.
For others who are direct grid-tieing you will not need a controller but refer to the instructions of your grid tie manufacturer recommendations.
 
NOTE: For those of you using a DIRECT WIRED type grid tie do not purchase a Battery Controller since they are not needed in most case as the build in MPPT does that job.
 
 
 
TURN OFF ALL ELECTRICITY BEFORE MAKING ANY
POWER CONNECTIONS OR ELSE THIS COULD HAPPEN
 
Info on parallel and series wiring for 12 and 24 volt batteries
 
 
 
 
 
 
 
 
ONLY tighten the Blade Bolts with 5 ft. lbs. of torque or the mounting handles will crack!!
 
 
Installation
Any licensed general contractor can install this for you. If you can work with pipe, cement and electricity you can easily install an wind turbine.
Using #4 or #6 Welding Cable For Your Wind Turbine Generator Pivots! -
Slip Rings are not the correct technology for small wind turbines.
Welding wire is actually much more dependable and can't ever snap
off in freezing cold weather like the carbon brushes on slip rings can.
 
Using ONE large cable provides proven 50 year + durability
Do not use three finer wires like 12 , 14 or 16 AWG in three phase PMA output types! Use at least 10 AWG down the pole!
 
 
Sources for WELDING CABLE and LUGS
 
For the best price on Welding Cable call - Maney Wire & Cable at TOLL FREE Ph. 877-469-9473
 
If you need a tough but smaller wire size you can also try "#UL1028 #8 Gauge" - Maney Wire & Cable sells that too!
 
No one can give you lower pricing on wire and cable than-
 
Maney Wire & Cable Company / Call - Ph. 877-469-9473 or 909-230-4900
 
Maney Wire & Cable / 3559 EAST GUASTI RD. UNIT E / ONTERIO, CA 91761 / http://www.maneywire.com
 
Use Welding Cable For Your Wind Turbine / Generator Pivots! -
Slips Rings Are Out Dated! - Here are all the good reasons why!
 
Welding cable is a highly specialized power transmission medium used for grueling applications that demand extreme resistance to twisting, turning, abrasion and pulling. Welding wire is also exposed to UV rays 10 x more intense then the Sun in welding rooms so it can withstand very high levels of UV radiation too. Welding cable is made using hundreds of very small, soft and ductile strands of annealed copper wire so it will last for well over 50 years while being subjected to over 2,000,000 cycles of twists, tugs, bends, turns and all other types of 'torques'. It is also water tight and the special rubber jacket is especially made to withstand millions of hours of abrasive action.
The professional welders who have used this great cable for almost a century dragging it over their rough shop floors decade after decade. Many welding machine's used during WWII in ship building are still using the original cable that was supplied with those machine over 70 years ago and they are still going strong with no sign of replacement needed any time soon.
 

To replace the slip rings in your old wind turbine or to install one of ours you will need two pieces of 6# welding wire, one red and one black. This will go inside the pole tower and can withstand lots of twisting and turning motion.
You will also need to purchase a water pipe as your mounting pole. Choose schedule #80 -1.5" water pipe if you live in a real windy or storm prone area. This pipe is available at any 'Home Depot' type hardware store. I would recommend you have them cut the pipe at 17 feet. This will give you 3 feet cemented into the ground and a nice tall 14 foot tall mast that will not require messy looking guy wires.
14 feet is just high enough to easily be worked on with a 12 foot painters ladder and is tall enough so kids can't get cut by the spinning blades. While you are at the hardware store buy a post hole digger and a few bags of premixed "post hole" cement too. Remember the welding wire is only to hold up top the twisting action of the turbine head in the pole. Welding wire is too expensive for long under ground runs. The longer run of wire can be done with UF type direct burial type wire. 10 gauge 4 conductor is fairly cheap. Double the wires up for maximum amperage. Twist the black and the white together to become the positive and then the green and copper together for the negative. A 250 foot box is about $120.00 at the Home Depot - Run this wire under ground as UF type wire is a water proof, direct burial type wire that is easy to install without need for conduit.. Finally connect this wire to your battery with the proper fusing. You are basically done with the hard part. What you do with your battery power is your own prerogative, grid feeding, powering an power inverter, heating water etc.
 
*Note: IF you use a foot pipe over 12 feet tall on a wind turbine that has a 65" or smaller blade diameter it will need guys wires or need to be at least Schedule #80 to resist bending when a storm hits!!! However wind turbines that have a greater than 65" diameter MUST have guys wire AND be mounted with schedule #80 pipe!

 

Is #6 AWG wire large enough for your lateral wire run?

Maybe not if you have a long run.

 

 
BATTERY OVERCHARGE PREVENTION REGULATION - LINK HERE
 
NOTE: NEVER EVER USE SOLID STATE CONTROLLERS PLACED DIRECTLY IN BETWEEN THE WIND TURBINE AND THE BATTERY!
ALWAYS HOOK POWER DIRECTLY TO THE BATTERY AND THEN RUN A BATTERY CONTROLLER AND THEN DUMP ANY EXTRA POWER!
That is the problem!!  Wind turbine MAY NEVER go through a change controller since it is PULSATING AC or DC power (Also called WILD AC)
You must go from the turbine RIGHT into the rectifier and THEN right into the battery. THEN you need a battery controller like our SEA440
LINK-  http://www.hydrogenappliances.com/batteryregulator.html
 
 
STOPPING THE TURBINE FROM SPINNING? NOT SMART!!!
NOT GOOD! ELECTRIC BRAKES BURN PMA COILS OUT -
FREE WHEELING IN STORMS IS PREFERRED! NEVER TRY
TO STOP A TURBINE FROM SPINNING BY SHORTING THE
OUTPUT WIRES TOGETHER!!
 
You can ground or "short" the wires together in order to stall-out your wind turbine blades from spinning BUT ONLY in wind UNDER 20 MPH
 
If you use "SHORTING" as a high speed braking system your going to FRY your coil! Todays small wind turbines are designed to take 135 MPH winds and survive. Do not forget to build your towers extra tough!
 
No Slip Rings - "THE 'RUBBER BAND EFFECT"
 
Have you ever played with a RUBBER BAND POWERED plane as a kid??
Our wind turbines can only make so many turns before it desperately wants to go the other way and UNWIND.
 
NOTE: This "TWISTED WIRE THING" is an OVER RATED problem for a tiny 22 lb. wind turbine!
These are not a the heavy 200 lbs. + wooden turbines of 60 years ago that needed slip rings.
 
More On "No Slip Rings" - Our advice on slip rings is to use heavy rubber coated welding cable and don't worry about twisted wire. Twisted wires in the pole are an overrated problem in modern small wind turbines. Heavy rubber welding cable tends to simply unwind when it is under tension and the wind turbine head favorers turning in the opposite direction to effect unwinding. Welding cable has also magical qualities when it comes to taking continuous twisting and has incredible abrasion resistance when rubbing inside the pipe. Welding cable will last for about 50 years (Not even slip rings will last 50 years)
NO OTHER TYPE OF WIRE HAS ALL THESE QUALITIES EXCEPT WELDING CABLE! USE IT!!!!!!!!!!!!
 
In all our testing slip rings eventually failed and required maintenance while over 40,000 small turbines equipped with #6 rubber welding cable operated with an exceptional 100% dependability factor for over 24 years now and counting. 100% reliability
 
NEW AGE - Why do you assume that the wires on a tiny modern wind turbine would "BIND" ?
These turbines are so scrony at only 19 lbs. They are so tiny they can't bind. Wind turbine have never before in WORLD history weighed this little.
The advent of carbon fiber blades have changed the rules forever.
In this new era, new ways of thinking have started. Any slightly twisted wires tend to just "UN-WIND" like a rubber band does.
 
Yet more on the - "NO SLIP RINGS" Topic
If you have #6 rubber welding cables and put them in a wind turbine tower pipe you can only turn them about 20 or 30 times in any one direction before they get tight. Interestingly enough this point they react like a giant Rubber-Band and try to turn the other way trying to unwind themselves. A simple rubber tension system was born from welding cable! It's very reliable, cheap and never fails. No moving or rubbing parts to fail. Welding cable is specially made cable designed to endure endless abrasion, twisting, bending and turning motions offering at least half a century of service life or more. Especially if it's in a dark pipe with no UV shining on it. It should last a life time.
 
 
For most PMA's you can use any type of 10AWG Contractor Extension Cord.
 
The yellow stuff is the best. Just cut the end's off and use this type of super heavy contractor cord.
 
REMEMBER THAT THE EVOLUTION OF THE MODERN WIND TURBINE NOT TO USE SLIP RINGS COMES FROM THE USE OF HEAVY RUBBER WELDING WIRE. USING A CHEAP EXTENSION CORD IS NOT PART OF THAT EVOLUTION AND IT WILL NOT WORK FOR VERY LONG. ALSO USE THE VOLTAGE DROP CALCULATOR AND LOOK UP THE POWER LOSSES CAUSED BY USING UNDERSIZED 12 or 14 GAUGE EXTENSION CORD ON 3-PHASE INSTEAD OF #10 GAUGE MIN!
 
(OR USING #6 WELDING WIRE ON DC SYSTEMS)
 
 
BUY A THREE PHASE (3-phase) rectifier HERE
 
WILL RAIN OR SNOW SHORT OUT MY PMA?
Clean rain water and snow CANNOT conduct electricity!
No it will not, and here is why. The turbine gets very hot in higher winds so it MUST be 'open-vented' in order to stay cool.
This type of unit can actually run under water in rain water which contains no electrically conductive mineral salts like tap water or ground water does. Pure rain and snow as found on the top of the wind turbine pole are non-conductive until they touch the earth and soak up salts and minerals and only THEN become's electrically conductive and ONLY THEN. It is a big misconception that water is thought to be automatically electrically conductive in all of it's many states. Pure snow and rain water have Zero PPM 'dissolved-solids' chemically speaking so it can not harm or short out an open PMA resting on the top of a pole high up in the air.
MORE:
 
LEARNING ABOUT WATER AND ELECTRICITY - We have sold over 230,000 of these and wet conditions never harms them. Also RAIN and SNOW do not contain any minerals so they are ZERO PPM dissolved solids and are thus NOT electrically conductive. Only GROUND water, ocean water and tap water are electrically conductive. Rain water can NOT conduct electricity,, if it could millions of power poles and transmission wires would be blown out of the sky line every time it rains and this is not the case.
 
More on PMA water
 
Rain water is SO clean that it can not conduct electricity.
(that is the reason rain water does NOT leave "WATER SPOTS",,, Rain water does not contain minerals in it.
Only minerals in TAP WATER and GROUND WATER cause water to become highly electrically conductive.
Also most of our PMA's can get over 300 F. during wind stormy so they need a big vent hole in order to stay cool.
As far as the water the gap in the stator is plenty large for rain water drainage. Do not worry.
 
WATER IN CEMENTED TOWER PIPES;
Drill a small 1/4 drain hole at the cement or ground level of the pipe. Fill the pipe with a few cups of liquid cement (water mixed with Portland cement powder only, NO sand or rock!!!) When this mixture comes out of your 1/4" drill hole then chase it with a gallon of clear water. If it clogs during pouring use a piece of wire until it flows clear water. DONE! - Water in pipe problem gone!!!!!!!!!!!
 
 
Tower strength
We only talk in terms of lateral loading or in simpler term sideways thrust or loading. Your Hornet turbine creates 1100 lbs of lateral loading at 115 MPH.
That is like a car with a rope tied to the top of your tower applying 1100 lbs to the tip of the mast in an attempt to pull it down. Your tower manufacture should understand this.
If you are in a cold area also remember about 'icing" that brings down more towers than just wind alone. In other words BUILD YOUR TOWERS TOUGH!
Using schedule #80 1.5" steel water pipe is the best choice over the cheaper and more common schedule #40 pipe.
Warnings;
PMA's are very polarity sensitive. Make sure you connect positive to positive when making your final battery connection!!! If you see sparks coming from the connector at the time of electrical hook up you may have the positive lead going to negative side of the battery. This may cause fires and burn out the coils in your PMA immediately.
 
Please note that these blades are very sharp and can cause severe injury if handled improperly. Treat these blades with the same respect you would have for a sharp sword.
 
These blade sets can turn at well over 2000 RPM on a windy day and can cause severe bodily injury when they are spinning. Use extreme caution! Never mount or work on a wind turbine on a windy day. Never place a turbine in any area that can be accessed by inexperienced persons or children. We assume no liability for ANY injuries caused by these products.
 
If you short out the PMA wires to prevent free spinning you could burn out the PMA. Never connect the positive to the negative output wires of the PMA together!!
 
QUESTIONS AND ANSWERS
 
Q. How do you get the electricity down from the generator as it changes direction to face the wind? Would the wire get twisted without sliprings?
 
A. Our turbines do not have a tail that flips to the left or right in high winds so how can the wires get twisted??? This is a 70 year old misconception left over from a bygone era when ALL wind turbines made in the 1930's would turn in one direction for high wind protection. This would set the stage for twisted wires since an old style wind turbine would tend to make one to many left or right turns.
Now in the age of carbon fiber and other advanced materials blade can take winds at hurricane speeds that would normally snap old style wooden propellers. Now-A-Days using rubber welding wire is all that is required for dependable power transmission down the pole. Weld Cable is made for twisting, abrasion and tension resistance. Like a giant rubber band welding cable will never be able to make enough turns to get twisted-up before it desperately wants to release it's build up of tension energy and literally unwind itself in the pole. Welcome to the new millennium and evolution from old ideas.
 
THINK ABOUT IT - A wind turbine manufacture brags about there brushless PMA's since brushes are undependable, they admit to the terrible dependability of carbon brush generators!
Now in the very next breath they then brag about the carbon brushes in there wonderful slip-ring assembly !! See a conflict of interest here ??

 

"Carbon brushes wear out, sooner or later but most often they fail by snapping like ice sickles in any

freezing weather and those are just a few of the cold hard facts against the use of carbon brushes in general"

 

 

OTHER TOWER IDEAS USING WOOD FRAME

 

 
GET READY FOR THE WIND STROM More Hubbub / Self Straightening Hub - "Hub-Bub Talk HERE"
 
 
BATTERY TALES:
 
Hints for people that are attempting to operate a household and are not on the grid:
Get a fork lift battery! Try calling places that sell used fork lifts. The 12 volt batteries that run fork lifts are the best! Many of these old batteries are discarded because they can no longer operate a fork lift for a full 8 hour work day but they still have enough operational life to run your household for many decades. Many can be bought at recycling prices and still have 100 times more amperage than a brand new bank of automotive type batteries that will only last for 2 or 3 years.
 
Lifespan of battery types while engaged in demanding alternative energy use:
Cheapest bargain store bought automotive battery - 6 to 8 months life before it goes to the junk heap.
Professional battery store bought T105 battery - 2 to 3 years life before it goes to the junk heap.
Professional battery store bought L-16 battery - 4 to 7 years life before it goes to the junk heap.
Industrial bought Fork Lift battery - The one I own is 31 years old now, I will let you all know when it finally dies.
 
Customer Comments: "My fork lift battery has been powering our home for 27 years now and still charging strong!
I feel sorry for the people using 105's or L-16's, that is a great way to go if your goal is to
create a mountain of useless lead within your life time or run out of power in the middle of dinner.
This is the best advice you are ever going to get and it is your funeral if you do not listen!
Our 12 volt /110 AC inverters can run for weeks at a time on our monster sized fork lift battery."
 
Other peoples installations:
 
Tech notes: If you use guy wires or guy chains
be very sure to use heavy 'DRAW BAR' springs
to take up any slack in the wires or chains if
the pole sinks down into wet soil during storms.
 
Custom 8 blade Hornet made by LES
Pivot leverage arm on 40 foot main mast
Pivot leverage hinge point in concrete and wiring including negative ground
 
 

 

 

 

 

If you do not like guy wires try these design

using only a 5 foot long piece of 1.5" by

#80 gauge pipe on the top and then

2.5" schedule #40 in the middle with a

threaded adapter and then 3" schedule #40

at the base.

 

 

 

DO NOT USE schedule #40 pipe on the top!

The top piece of 1.5" pipe must be schedule #80!

 
 
WHAT IS A WIND SHADOW?
Never mount your wind turbine lower than surrounding trees!
The "Wind Shadow" effect can severely disturb air flow and wind turbines
experiencing turbulent wind eddies will never work properly.
In an area with lots of trees you must find a way to get the turbine mounted
at least 10 feet higher than the trees.
 
 
Here is a wind turbine that is lower than the surrounding trees and it does not get up to full speeds.
Wind turbine is in the center of this photo and hard to spot (not the one on the right)
Wind Shadow behind surrounding trees is a very serious problem that must be solved
by mounting turbines on very tall towers that are at least 10 feet taller than the trees.
 
 
NEW AGE Americana - The new look in American Suburbia - SEE MORE
 

SEE INSTALLATION VIDEOS COMING SOON

 
FOR GRID FEEDING YOU MUST BUY 24 OR 48 VOLT RATED WIND TURBINE'S
 
For 48 Volt Battery Charging and Grid Feeding -
SPIN YOUR POWER METER BACKWARDS AND
SAVE MONEY ON YOUR MONTHLY POWER BILL
 
GRID FEED With WIND POWER
 
Grid Feed with our 48 volt Hornet models HT48SC or HT48SCS
Keep in mind that you should have at least 4 to 6 wind turbines to justify the cost of
this grid Inverter. One wind turbine and one grid feeder is NOT a smart idea!
Think "Mini Wind Farm" here and then you are on the right track!
The GTFX3048 is a nice grid feeding unit for you to buy.
 
For technical questions check with:
 
http://outbackpower.com/products/sinewave_inverter/grid_tie -
http://outbackpower.com/pdfs/manuals/gtfx_gvfx.pdf
 
 
Please be sure to check this link for current availably, compatibly,
pricing and to familiarize yourself with all the statistics and other
data before buying a Grid feeding inverter from them.
 
 
RUN YOUR POWER METER BACKWARDS!
 
 
 
 
Build a Mini Wind Farm and Grid Tie to turn you power meter backwards.
 
 
Three Phase Power Transmission? Why Would You Use It?
Hear The Other Side Of The Story.
 
Stop and think about it, AC is just a FLIP FLOPPING DC signal.
VOLTS = PRESSURE so AC has NO more pressure than DC does!
 
 
"THE ONLY REASON YOU SHOULD EVER USE THREE PHASE IS TO RUN OR OPERATE AN INVERTER,
TRANSFORMER OR OTHER POWER DEVICE THAT SPECIFICALLY REQUIRES 3-PHASE POWER INPUT"
 
A. Wire Breakage
I would NOT recommend the 3 phase method since you will have 3 small wires twisting in the pole and this is going to cause an electrical failure sooner or later.
With three wire stuffed into ONE wire pack they tend to always get knotted and kinked up when twisting just a little bit. To much stress.
The way we install our systems using just one LARGE welding wire for the positive power going down the pole has enjoyed a 100% success rate! It is very durable.
 
B. Slowing Rust & Corrosion / DC negative grounding.
Another great unseen benefit for using the pole as the ground wire is that this STOPS rust by effectively ending electrolysis!!!
Negative ground DC systems are extremely effective at slowing the oxidation of metal also known as "Rust & Corrosion"
This is why autos and even bridges like the Golden Gate are negatively grounded with a DC power systems to slow Rust & Corrosion.
 
Breaking the AC/DC Long Distance Power Transmission Myth-
A Higher Voltage has much more to do with long distance power transmission over any of the AC / DC power arguments.
 
FACT: 48 Volts of DC power will have demonstrable less
"Line Losses" levels when compared to say, 12 volts of AC power! Why?
 
Ultimately it is actually higher voltage that moves amperage in a wire since VOLTAGE = PRESSURE in electronic terms. So if you need to run a power line 300 feet or more then you should seriously consider a 48 volt battery and power Inverter system! So why do power companies use AC power for long distances? Using 50,000 Volts of DC would be ineffective since they are not trying to charge a battery.
AC power is easy to re-convert within any coil transformer. The important part is that they are using 50,000 volts of HIGH VOLTAGE and that is the real key here and forget that it is AC or DC but rather concern yourself with the voltage. For long distances HAVING HIGH VOLTAGE is the BIG key!
All power is actually DC if you think about it! AC power is just DC power that is flip flopping back and forth at 60 cycles. All power is DC in nature BUT not all power is HIGH VOLTAGE and that's the important part you need to remember.
 
 
 
 
 
WHAT's Better? AC or DC?
Let's find out the truth on an engineering calulator.
 
 
Change only the AC or DC parameter where it says "CHANGE THIS" in the chart below-
AC can also be single phase (2 wire) so do not worry about changing the wire count or it will confuse
the calculation, leave it at two or three wires what ever you like as it will make no big difference
Now check the results. All other parameters being equal DC is just about the same as AC by a tiny amount only.
If you need to send power long distances using higher voltage 48 volt models is the most important fact.
 
Example: A 48 volt DC will send power way further than the best 24 volt AC!
 
(Using a 48 volt DC system is probably the best choice for long runs
since it's a negative ground and the ground can act as a gigantic wire and a lightning rod
for diverting  lightning strikes outside the PMA and steering them to the negative or
ground wire thus saving your PMA from any destruction. This can only happen with a DC PMA )
 
LINK HERE  Voltage Drop Calculator
http://www.calculator.net/voltage-drop-calculator.html
 
NOTE: ALWAYS MOUNT FUSES, VOLT METERS AND AMP METERS ON THE NEGATIVE WIRE TO PREVENT CORROSION!
For PMA's without large gold hub spacer
 
 


 
SPACERS - CLICK HERE
 
 
CLICK HERE FOR OLDER MODEL MIDDLE OF YEAR 2001 INSTRUCTION SHEETS
 
CLICK HERE FOR FIRST MODEL YEAR 1992 INSTRUCTION SHEETSnd turbines w
Do you have low wind and can't get up to charging voltage?? - Try SERIES / PARALLEL wiring for battery charging.
ORDER 10G YELLOW WIRE CONNECTORS HERE
 
See if you are in a windy area - Click here for a wind map of the U.S.A.
 
Questions??? For Fast Email Service Email Us Please.
 
For FAST Technical Support Please Email Us Now!
 
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WIND TURBINE INSTALLATION INSTRUCTIONS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

WIND TURBINE INSTALLATION INSTRUCTIONS