600 Watt MARINE WIND TURBINE
Contents
1. 600 Watt MARINE WIND TURBINE User s Manual Congratulations on your Sunforce Purchase This product is designed to the highest technical specifications and standards It will supply years of maintenance free use Please read these instructions thoroughly prior to installation then store in a safe place for future reference If at any time you are unclear about this product or require further assistance please do not hesitate to contact our trained professionals operating the customer support line 1 888 478 6435 or email to info sunforceproducts com The Sunforce 600 Watt Marine Wind Turbine is designed for watercrafts and any area in close proximity to salt water The heavy duty powder coating adds enhanced resistance to the effects of the sun wind and water All components have been tested to perform without degradation under marine conditions 1 SAFETY Your Sunforce 600 Watt Wind Turbine is designed with your personal safety as the first priority However there are still some inherent dangers involved with any electrical and or mechanical equipment Safety must be the primary concern as you plan the location installation and operation of the turbine Please read the following Important Safety Instructions Please take the time to read through this manual prior to assembly 1 Place this instruction manual in a safe place for reference 2 Wait until a calm day to install or perform maintenance on2. A 4 3 1 System wiring diagrams There are multiple options to connect your Wind Turbine dependant on your power requirements and available components Single Turbine installation X8 8 oval M Amp Meter Hatter T urtene Ral i Hater cont Negative Multiple Turbine installation P M per ong 7 pev Ped pert pon aN prem pev PRH unum MPPT pex anje pe Pg pex Hybrid Solar Wind System 12V or 24 Solar Arras Amp Meter A typical hybrid system Photovoltaic and Wind combined is wired as follows Whenever feasible wire the turbine and solar panels to their own set of battery terminals 4 PACKAGE CONTENTS Check the parts listed with the contents of the box and make sure that you have everything needed for assembly Figure 1 Vertical Stabilizer e r Generator Hub va ki W e 7 e d 4 gt M ke LI 1 2 D Nose Cone Caution edges of the blades are sharp Please handle with care Vertical Tail Hex Seow 6 Screw Rubber Spacer 5 INSTALLATION PROCEDURE Step1 Open box to ensure all parts are present remove the hu
3. Please handle with care Check blades for superficial damage Replace blades if damaged It is important to not use blades that are damaged as you will lose overall balance resulting in a decrease in efficiency Should you notice damage to the blades you must replace all 3 The blades are balanced as sets Check the blade bolts and the hub nut for tightness Check nosecone for cracks and tighten nuts Wipe any excess dirt build up from the blades Check all electrical connections to make sure they are tight and free from corrosion Check the voltage of your battery bank with a Multi meter and clean the terminals Sunforce Products suggests replacing the blades every five years for optimal performance 7 FAQS 1 How does the Sunforce Products 600 Watt Wind Turbine control power and RPM in high winds Your Turbine s operation will be halted to reduce the risk of damage due to overcharge and over spin 14 of the rotor blades This process of braking is handled internally through your Turbines electronics 2 What is the maximum wind speed the Sunforce Products 600 Watt Wind Turbine will survive and do need to take it down in a storm Your wind turbine is designed to operate in most climatic conditions Should you expect or experience winds of 150MPH upwards please turn off the MPPT controller which will in turn manually apply the braking system to protect from any over spin Once the Turbine has stopped it is possible
4. dangerous voltage Remember a steel tower is a conduit for lightning Every wind turbine and turbine tower needs to be grounded at the tower base even though the system may be grounded at the battery bank Grounding the tower at its base may help prevent shocks to persons touching the tower due to lightning or electrical faults Please take the time to review the National Electrical Code NEC and local building and zoning regulations for complete requirements Even in Off Grid Systems There are multiple ways for tower grounding the most common method is a copper clad steel electrode s driven into the soil Please view the following grounding diagram fe Tower pee Clamp Grounding Conductor 6 AWG Min Must be secured and buried for protection Grounding Wire Clamp _ Grounding Rod Existing Grade Foundation 2 ec s T Jd 4 LN N Bee e mt 2 NU 10 What effect does radio interference have on my Sunforce Products 600 Watt Wind Turbine The internal circuitry of the Sunforce Products 600 Watt Wind Turbine is shielded and filtered to prevent radio interference and has been tested to insure electro magnetic compatibility 11 What effect does my Sunforce Products 600 Watt Wind Turbine have on radio transmissions 17 The Sunforce Products 600 Watt Wind Turbine normally does not affect radio transmitters Care should be taken however to route power lines from the Sunforce Products
5. schedule 40 1 5 inch steel tubing This should be available through your local hardware outlet 7 What is the difference between copper and aluminum wire Generally aluminum wire is less conductive so it must be bigger for the same amp load and resistive losses as copper Sunforce Products 600 Watt Wind Turbine uses copper or tinned copper for the yaw wires 8 What battery should choose for my Sunforce Products 600 Watt Wind Turbine There are multiple battery options in today s market flooded lead acid absorbed Glass mat AGM gel cell and NiCad There is no definitive choice for your alternative energy needs Normally the 15 choice of battery is determined by availability and pricing Should you have questions regarding batteries please consult a local battery supplier Or view www batterycouncil org The capacity of your battery bank is determined by your use Below is a good guideline 12 volt systems 400 Amp hours 24 volt systems 200 Amp hours 9 Is my Sunforce Products 600 Watt Wind Turbine protected from salt corrosion Yes All components have been rigorously tested to perform under marine conditions Possible Battery Configurations suggested 12 24 VOLT BATTERIES IN PARALLEL 16 9 Is lightning protection necessary You should ground your Sunforce Products 600 Watt Wind Turbine Proper grounding illustrated below provides protection to individuals and equipment by eliminating the possibility of
6. to lay down the Tower to offer further protection 3 How long will the bearings or other wearing parts last According to engineering calculations the bearings should have a 10 year life span in 12 mph 6 m s average wind speed sites Bearing life will vary from one application to another however you should expect at least a five year performance in adverse conditions and 10 years in normal conditions 4 Can the Sunforce Products 600 Watt Wind Turbine be connected in reverse polarity to the battery without causing any damage Reverse polarity will cause damage to both your MPPT controller and battery if not quickly remedied Always double check any wiring to reduce the risk of reverse polarity Your turbine is equipped with polarity protection to reduce the risk of damage but it is still possible to degrade your wiring and cause damage to the overall system 5 Will it hurt my Sunforce Products 600 Watt Wind Turbine to short circuit the output No the Sunforce Products 600 Watt Wind Turbine is designed to be short circuited as a normal shutdown procedure by a fuse The function of the stop switch is to both disconnect the turbine from the batteries as well as short circuit the output of the turbine 6 Where can locate tubing to make a tower Your Sunforce Products 600 Watt Wind Turbine is designed to make mounting as simple and straightforward as possible Should you not wish to purchase the custom tower kit feel free to utilize
7. 600 Watt Wind Turbine away from the power and antenna lines of a radio transmitter An old ham radio operator s trick is to twist positive and negative wires together to provide an even distribution of EMF noise across both wires which serves to cancel out the electrical noise created This technique can be used on the Sunforce Products 600 Watt Wind Turbine power lines on the radio s power lines and on transmission wires Transmission lines should always be kept as far from power lines as is practically possible Proper grounding of the Turbine and other system components must also be observed 12 Will it affect the regulation of my Sunforce Products 600 Watt Wind Turbine to install an RF radio frequency filter An RF filter should not affect the regulation of the Turbine but any electronic devices placed in line with the turbine must be rated for the proper current and voltage It is best to place any line filters on the power lines for the load device that requires it and as close to the device as possible Trouble shooting You may require an extra person to assist with these tests 1 Remove the blade hub from the turbine Replace the rotor hub nut on the rotor shaft 2 Quickly spin the rotor shaft manually with your fingers while connecting and disconnecting the red and black wires turbine must not be connected to batteries 3 With the red and black wires connected to each other the shaft should be more difficult to turn When t
8. F THE POSSIBILITY OF SUCH DAMAGE Note some states and provinces do not allow the exclusion or limitation of incidental or consequential damages so these limitations may not apply to you Neither the manufacturer nor its affiliates or suppliers will be held liable or responsible for any damage or loss to any items or products connected to powered by or otherwise attached to the hardware The total cumulative liability to Customer from all causes of action and all theories of liability will be limited to and will not exceed the purchase price of the Product paid by Customer This warranty gives the Customer specific legal rights and the Customer may also have other legal rights that vary from state to state or province to province For more information or technical support 1 888 478 6435 www sunforceproducts com info sunforceproducts com 600 011711 20
9. b from the box Figure 2 Step2 Take out the blades from box and fasten the blades on hub with nuts 10 Figure 3 Figure 4 Caution Make sure that all of the bolts are secured with nuts otep 3 How to install the hub Figure 5 Adhesive strip should be wrapped around your Tower not included to increase secure connection to the Yaw shaft 11 otep 4 Take out the wind turbine from box and put the cables through the mast Figure 6 otep 5 To install the wind turbine to your chosen tower not included securely fasten the bolt by using the hex wrench Figure 7 otep 6 Install the hub on the wind turbine using M14 nut and spring washer 12 Figure 8 Figure 9 Caution Make sure the nut is secured with the spring washer Step Put the sleeve inside the nose cone and fasten the nose cone to the hub Apply pressure to the connections to ensure a secure fit Figure 10 Figure 11 Figure 12 Step 8 Tail Fin assembly Use the four supplied HEX screws to firmly connect the Tail Fin to the hub 13 Figure 13 6 MAINTENANCE Your Sunforce Products 600 Watt Wind Turbine has been designed to run for long periods without requiring any maintenance Performance will be enhanced if you periodically inspect your system Review the following simple maintenance procedures and implement every six months Caution Do not go near the wind turbine during operation Caution The blades are sharp
10. ce Products approval c Has been exposed to winds exceeding 157mph d Windstorms lightning and Hail damage Repairs performed by other than authorized Sunforce Products support staff f All acts of God misuse negligence or accidents g Tower foundation and wire h has not been installed operated repaired or maintained in accordance with the instructions supplied by manufacturer Any service identified in the above list or product is found not to have any defect in manufacturers workmanship or materials the customer will be responsible for the costs of all repairs and expenses incurred by Sunforce Products Disclaimer EXCEPT FOR THE EXPRESSED WARRANTY SET FORTH ABOVE THE MANUFACTURER DISCLAIMS ALL OTHER EXPRESSED AND IMPLIED WARRANTIES INCLUDING THE IMPLIED WARRANTIES OR FITNESS FOR A PARTICULAR PURPOSE MERCHANTABILITY AND NON INFRINGEMENT NO OTHER WARRANTY EXPRESSED OR IMPLIED WHETHER OR NOT SIMILAR IN NATURE TO ANY OTHER WARRANTY PROVIDED HEREIN SHALL EXIST WITH RESPECT TO THE PRODUCT SOLD UNDER THE PROVISIONS OF THESE TERMS AND CONDITIONS THE MANUFACTURER EXPRESSLY DISCLAIMS ALL LIABILITY FOR BODILY INJURIES OR DEATH THAT MAY OCCUR DIRECTLY OR INDIRECTLY BY USE OF THE PRODUCT BY ANY PERSON ALL OTHER WARRANTIES ARE EXPRESSLY WAIVED BY THE CUSTOMER Warranty Claims amp Return Policies To be eligible for service under this warranty customer must either contact manufacturer either through written request or by telephone to
11. h current flowing through an undersized wire or through a bad connection Please consult wire guide table below Choosing your Sunforce 600 Watt Wind Turbine s location Prior to the mounting of your Sunforce 600 Watt Wind Turbine you must carefully consider a location Things to consider when thinking about your location A Distance from any obstacles that will cause turbulence trees buildings etc B Distance from MPPT controller and battery bank C Any local zoning restrictions D Clearance of power lines E When mounting on a boat be aware of moving objects that may obstruct the turbines blades In general terms the higher the tower the less obstruction to air flow leading to a more efficient charge capacity The minimum recommended tower height is 30 ft or 20 ft above nearby obstructions for land installations as shown below Prevailing wind ee 2 MODEL AND SPECIFICATION TABLE 2 1 Specification Table Cut in wind speed 4 5 MPH Survival wind speed 157 MPH Blade material Fiber glass Suggested battery capacity 2100 A Hr 2 2 Performance specifications The following power curve shows the performance you should expect from your wind turbine During smooth steady wind speed you can expect to see output resembling the curve illustrated below To convert between power and current use the following formula POWER VOLTAGE AMPS 700 600 500 400 300 200 100 0 0 2 4 6 8 10 12 14 16 Power o
12. he wires are disconnected it should spin freely Should this not be true please contact supplier or Sunforce Products 4 With your 600 Watt Wind Turbine connected to your battery bank use an electric hand drill to spin the rotor shaft 5 Below 500 RPM the rotor should spin freely without friction 6 At 500 RPM and above the Wind Turbine should be charging the battery You should feel resistance on the rotor shaft if the shaft is not rotating contact your turbine dealer or Sunforce Products Be aware your battery banks needs to be under 12V or 24V for this testing as the Turbine needs to read a charge Warranty sunforce Products warrants your product to be free from defects in material and or workmanship for a period of 5 years from original date of purchase Warranty coverage 1s extended only to customer original purchaser If product proves defective during warranty period Sunforce Products at its option will 1 Replace wind turbine with new or refurbished product 2 Correct reported problem Customers warranty continues to be valid on repaired or replaced product from original warranty date 18 Restrictions This warranty covers defects in manufacturing discovered while using the product as recommended by the manufacturer The warranty does not apply to a equipments materials or supplies not manufactured by sunforce Products b Product that has been modified or altered other than by Sunforce Products or without prior Sunfor
13. submit a service request for the wind turbine covered by this warranty within specified period 5 years from original date of purchase and request a return authorization RA number This RA must be issued before any product can be returned All notifications must include the following information a Description of alleged defect b How the wind turbine was being used c Serial d The original purchase date e Name phone address of party requesting warranty Within 2 to 3 business days Sunforce Products will provide the customer with an RA and will direct customer to location where the product is to be returned Once an RA has been issued the customer has 30 days to return 19 the product Failure to deliver the product within the 30 days results in the RA as no longer being valid and a new RA must be issued Manufacturer 15 under no obligation to accept any product that 1s returned to them without a proper RA 7 Limitation of Liability UNDER NO CIRCUMSTANCES WILL THE MANUFACTURER OR ITS AFFILIATES OR SUPPLIERS BE LIABLE OR RESPONSIBLE FOR ANY LOSS OF USE INTERRUPTION OF BUSINESS LOST PROFITS LOST DATA OR INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES OF ANY KIND REGARDLESS OF THE FORM OF ACTION WHETHER IN CONTRACT TORT INCLUDING NEGLIGENCE STRICT LIABILITY OR OTHERWISE RESULTING FROM THE DEFECT REPAIR REPLACEMENT SHIPMENT OR OTHERWISE EVEN IF THE MANUFACTURER OR ITS AFFILIATE OR SUPPLIER HAS BEEN ADVISED O
14. utput W Wind speed m s 3 Digital controlled MPPT Wind Power Charger Please see included Manual for your MPPT Charge Controller v MCU fully digital controlled MPPT wind power charger v SEPIC conversion large DC input voltage range v Smart load management function braking function 12V 14 4V Lead acid batteries or 15 8V deep cycle Battery 24V 28 8V Lead acid batteries or 30V Deep cycle batteries Rated Load Current 35A Max Over Speed Braking lt 1400 rpm Caution Please review the following wire gauge table to install the correct wire gauge Sunforce Battery Protection Voltage recommends these as the minimum wire sizes for optimal performance Always use the largest gauge wires that are practical and affordable Local state and or national electrical codes take precedence over these general recommendations 12 Volt Systems AWG Metric Wire Sire emm Number ei 0 30 30940 90 150 1500 1908 190 9 250 8 250 8 310 310 8 290 ff 500 Turbines 0 9 9 18 mi 18 27 mi 27 4 6 46 58 mi 55 76 m 7695 66 119 mi 179 152 3 1 4 2 H 4 4 24 Voll Systems AWG Metric Wire Sire mee Number 0 30 20 1 60 40820 90 91 190 18 150 1 190 190 1250 250 310 1 310 1 390 A 390 1 500 Turte e 09 9 m 9 18 m 15627 ei 77 46 m 46 58 mi 5576 76 95 95 119 ei 119 152 m i
15. your Turbine 3 Listen to your Turbine should you hear any mechanical noise maintenance be required please contact Sunforce Products Customer Service 4 After installation re adjust and tighten the screws and bolts 5 Adhere to proper grounding techniques as established by the NEC 6 Your Sunforce Wind Turbine must be installed in accordance with this manual and local and national building code Incorrect installation may void your warranty 7 Wind turbine blades spin at a potentially dangerous speed this must be respected Never approach a turbine in motion 8 Note wire size gauge chart included prior to wiring Any under sizing of wire can be potentially dangerous 1 1 Mechanical Hazard Rotating blades present the most serious mechanical hazard The rotor blades are made of very strong thermoplastic At the tip the blades may be moving at velocities over 15m s At this speed the 2 tip of a blade is nearly invisible and can cause serious injury Under no circumstances should you install the turbine where a person could come in contact with moving rotor blades 1 2 Electrical Hazard The 600W Turbine is equipped with sophisticated electronics designed to provide protection from electrical dangers Please note that the inherent personal dangers from electrical current still exist therefore caution should always be used when connecting this and other electrical devices Heat in a wiring system is often a result of too muc
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