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LE-600 Turbine Installation & Operation Guide

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1. 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 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 41 of 48 46 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 6 5 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 51 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 be 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 45 15 60 40 60A CAUTI
2. 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 23 Step 3 Diversion DIP Switch Functions As shown the diagram all the positions are in the OFF position except switch number 1 which is in the 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
3. Edge LE 600 Turbine Installation amp Operation Guide 1 55m 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 Page 1 of 48 d Leading Edge Contents 2 Read me 4 eaa 4 Safety PRO 5 Mechanical Safety lt 5 Electrical Safety 5 AE ONS 5 straid aea eco eet eigen ete saed 6 Required For Assembly 7 Mechanical 8 Electrical 15 Fig 12 Typical Stand Alone Battery Charging Wiring Diagram 17 Fig 13 Typical Hybrid Wind PV System Wiring 18 Fig 14 Typical Grid Tie System Wiring Diagram ccssccccsssscecesessteeeessseeeees 19 20
4. 60 578 27 697 1538 68 703 50 a 10 866 276 00 16 835 427 60 Fig 2 Operating Envelope LE 600 Cine Edge 700w 4 4 58 29 15 600 50 25 13 8 500w 42 21 10 z 400 33 17 8 8 5 8 5 300w 25 136 5 200w 178 4 100w 8 4 2 4 6 8 10 12 14 16 18 ms 3 8 77 116 15 5 194 23 3 27 2 311 34 9 Knots Wind Velocity Fig 3 Energy Conversion Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 6 of 48 4 Leading Edge Package Contents Your LE 600 Turbine will arrive containing the components shown below If any of the components are missing or damaged please contact your dealer immediately LE 600 Chassis Qty 1 Rotor Blade Qty 3 8 Operstion ourde Nose Cone Qty 1 User Manual Qty 1 Tools Required For Assembly You will require the following tools to assemble your LE 600 Turbine 10mm A F spanner amp 10 mm ratchet of each required 13mm A F spanner amp 13 mm ratchet one of each required A Set of Metric Standard Hexagon Keys e Electrical screw drivers Power drill 3x 9x 3x 12x 18 x 3x 2x 1x Hub Plate Qty 1 M6 x16 Cap Heads 8 x60 Hex Heads M6 Washers 8 Nylock Nuts M8 Washers 8 x12lg Cap Head M6 x75C sunk Rectifier Fixings Bag Qty 1 e 6 5mm amp 3 0 mm diame
5. 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 Newer 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 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
6. 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 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 circuit 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 t
7. 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 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 power 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 sequenc
8. Wind PV System Wiring Diagram Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 19 of 48 4 Leading Edge RUN STOP SWITCH BOX REQUIRED PN GA CTRL 008A amie BOX SUPPUED 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Fig 14 Typical Grid tie System Wiring Diagram Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 20 of 48 4 Leading Edge Turbine Operation The LE 600 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 290 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 290 RPM the turbine will come on load and begin to deliver current to the batteries During the off load stages of rotation the blades will 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 more than 290 RPM current will be delivered to the batteries As the rotor speed increases so too will the current and voltage Excessive wind speed
9. 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 Never install the turbine upside down or in any orientation other than that depicted on the installation instructions 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 LE 600 generates 3 Phase AC voltage from the turbine head and rectified DC voltage from the rectifier box Even at low voltages there are inherent risks Caution should always be used when connecting LE 600 to the electrical system Ensure 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 Batteries systems can deliver a serious amount of current A short circu
10. 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 4 6 4 3 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 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 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 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 rating or at a lower voltage Do not use the load at a higher voltage than the load s rating REMARQU
11. 3 22 Post installation Checks be carried out one month after installation 22 Ann al M intena eE 22 After Five years OF normal aeaaeai 22 Other Considerations E 22 23 Wari O 24 E E i 25 Appendix 1 Tristar 45A Diversion Charge Controller relevant extracts 27 Appendix 2 Run Stop Switch User 44 Appendix Se Turbine Site SOLS CU ON aos 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 4 Leading 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 Di
12. 3 inches 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 30 of 48 Edge flow for cooling REMARQUE Lors du montage du TriStar assurez vous que l coulement d air autour du contr leur et du puits de chaleur rest 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 de chaleur pour permettre 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 23 2 Use the template provided the shipping carton for locating the mounting holes 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 k 4 Leading Edge Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 32 of 48
13. 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 25 of 48 4 Leading Edge Disclaimer e All specifications are subject to change without prior notice e The 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 600 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 600 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 44 0 845 652 0396 www leturbines com Compliant with EN BS 61400 2 Safety of Small Wind Turbines Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 26 of 48 d Leading Edge Appendix 1 Tristar 45 60 Diversion Charge Controller Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 27 of 48 Leading Edge Introduction Please read this manual and the specific
14. ANK WIRED TO APPROPRIATE CAPACITY amp VOLTAGE 555555 555 LE DL 300 CONTROLLER QTY 2 REQUIRED PN GA CTRL 001A SEE LE DL 200 USER MANUAL FOR DETAILED INSTRUCTIONS gt Farm FONTrilas HKZ UK www leturbines com Page 17 of 48 4 Leading Edge Fig 12 Typical Stand Alone Battery Charging Wiring Diagram Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 18 of 48 Leading Edge LE 600 TURBINE GA LETU 009 OR SUPPORT EARTHGROUND STRUCTURE RUN STOP SWITCH RUN STOP SWITCH BOX REQUIRED GA CTRL 008A lt Laak T RECTIFIER BOX AMMETER OPTIONAL FUSE OR BREAKER RECOMMENDED BATTERY DISCONNECT OPTIONAL BATTERY BANK WIRED TO APPROPRIATE CAPACITY amp VOLTAGE TRI STAR 45 REQUIRED PN GA CTRL 002 CHASSIS GROUND SUPPLIED CHASSIS GROUND 555 1000W DUMP LOAD REQUIRED PN GA CTRL 007 PANEL ARRAY 400W MAX AMMETER OPTIONAL FUSE OR BREAKER RECOMMENDED BATTERY DISCONNECT OPTIONAL Fig 13 Typical Hybrid
15. E Les charges l ments de chauffe peuvent tre utilis es a la tension nominale du fabricant ou une tension inf rieure N utilisez pas la charge une tension sup rieure la tension nominale 644 Maximum Diversion Load The diversion load should never exceed the TriStar s current rating 45 or 60 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 40 of 48 Edge Nominal Vol Tridtar 45 TriStar 60 48 2700W at 60V 3600W at 60W 24 1350W at 1800W at 12 675W at 15V S00W at 15W These maximum power ratings are translated to the equivalent at 120 volts in the following table If using heating elements rated for 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 TriStar 45 TriStar 60 48 10 800W at 120V 14400W at 120V 24V 21 600W at 120 28 800W at 120V 12 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 ta
16. ON The NEC requirement that the diversion load must be sized at least 150 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 42 of 48 Edge Self Testing Diagnostics Troubleshooting Diversion Control 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
17. ROM 257 0 s Pale BLK ae TURBINE 6 2 5 11 2 5mm2 BLK 10 e 2 omme BLK e we e e 9 30A TERMINAL 30A TERMINAL Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 46 of 48 Leading Edge Appendix 3 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 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 Qmph 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 ge
18. and electrical installation work If in doubt about any issue regarding your turbine please seek further assistance before proceeding Installation of the LE 600 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 can be dangerous Your LE 600 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 600 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 possible all assembly work should be completed at ground level In the case of roof mount brackets a suitable fitter should carry out the
19. atings 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 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 commonly 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 1 ering 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
20. ble A standard 2 000 watt 120 Vac heating element is used as the reference Voltage Power Current 120V 2000 W 16 74 48V nominal 500 W 30V 24V nominal 125W 42 15 12 nominal 31W 21A Whether using de 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 curent For example if a hydro source can generate up to 30 amps of current in a nominal 48 volt 60V maximum the minimum diversion load size 60V x 1 800 watts for loads rated at 60 volts General Sizing Example Consider 24V system with a wind turbine that is rated to generate 35 of current A TriStar 45 will not provide the 150 diversion load margin and the 5 45 is only rated for 30A of source current The 5 45 will not provide enough margin for wind gusts and overloads so TS 60 should be used The diversion load should be sized for 52 54 150 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 maximum battery voltage 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
21. connecting 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 10 A 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 2 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 flow 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 install
22. d 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 600 Turbine is constructed using neodymium iron boron rare earth magnets which are semi exposed until the turbine is fully assembled These 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 LE 600 alternator The magnetic forces between ferrous materials and the magnet rotor within the alternator may be 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 4 Leading Edge 3 Rotor Blade Assembly Take the three rotor blades and rotor hub plate Be careful when handling the blades they have VERY SHARP EDGES Use a 13 mm A F socket and hexagon key and three M8 x 60mm long set screws to attach each blade to the hub plate see Fig 5 Ensure that the cap head end of the screw is on the rotor hub plate side thus allowing the washers and nuts to locate inside of the blades The blades should all be fixed to the hub plate on the same side with th
23. ds 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 600 Refer to your Leading 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 Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 22 of 48 Leading 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 e Monitor the output Ensure that the turbine and charge controller are functioning correctly Annual Maintenance e Inspect the t
24. e Earth the System The turbine tower should have its own separate earth point The negative 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 600 Nominal DC Fuse DC Circuit Breaker Rating Output Voltage 12V 60 Amp 24V 30 Amp 48 20 GT1 16 Amp Tel 44 0 845 652 0396 Skyrrid Farm Pontri
25. e blades in the same orientation It is important that a washer is used underneath the anti vibration nuts 3 set screws 3 washers and 3 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 Fig 5 Attaching the 3 rotor blades to the hub plate 4 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 Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 9 of 48 4 Leading Edge NOTE Depending on the type of support structure being utilised for the LE 600 it is sometimes advisable to fit the main rotor set to the turbine chassis at this stage However in other circumstances it will be easier to fit the turbine chassis to the support structure before fitting the main rotor set The installer must use judgement as to the best order in which to fit the turbine together depending on the merits of the installation and therefore the remaining installation steps maybe completed in an alternative
26. e 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 600 Nominal Output Voltage or GT Variant 10 Metres 25 Metres 50 Metres 12 Volts 16 mm 3 Core 25 mm 3 Core 50 mm 3 Core 24 Volts 4 mm 3 Core 10 mm 3 Core 16 mm 3 Core 48 Volts 1 5 mm 3 Core 2 5 mm 3 Core 4 mm 3 Core GT1 25 110 Volts 1 5 mm 3 Core 2 5 mm 3 Core 4 mm 3 Core Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbin
27. es a two year warranty from the original purchase date Please keep your receipt as proof During the warranty period any component found to be defective in material or workmanship will at the discretion of Leading Edge Turbines be replaced or repaired at no charge For minor component failures replacements may be sent directly to the customer dealer for replacement For more serious defects we may suggest a return to base arrangement for replacement or repair In all cases Leading Edge Turbines will take reasonable action to ensure customer satisfaction You will always receive a warm courteous service in or out of your warranty period Your turbine must be installed and operated in accordance with this guide and local electricity codes 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 If your turbine is commissioned by Leading Edge Turbines the following are excluded from the warranty e Damage caused by the neglect of periodic maintenance in the manner recommended e Damage caused by repair or maintenance performed using methods not specified by Leading Edge Turbines or by non authorised dealers of Leading Edge Turbines 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
28. es com Page 13 of 48 4 Leading Edge 10 Mount the LE 600 Turbine onto the Support Structure Ensure that the previously 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 connecter supplied by Leading Edge Turbines supplied separately or a suitable terminal block with a minimum rating of 75 Amps 12V 40 Amps 24V 25 Amps 48V 20 Amps GT1 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 75 countersunk set screws along with washers and thread locking compound to secure the turbine using the holes previously drilled in the support structure see Fig 11 Ensure that the M6 set screws are securely fastened Fig 11 Fitting the turbine onto the support structure Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 14 of 48 d Leading 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 fo
29. flux alternator using neodymium iron boron magnets e aluminium chassis using Yaw wing design to ensure responsive yawing e Maintenance free low friction bearing arrangements Extremely quiet injection moulded blades with Whispower geometry and aerofoil design Long life yaw pivot slip rings and wipers e Easy tower top installation e Simple design for low cost and longevity e Fully marinised using stainless steel fixings and anodised aluminium components Low mass to help reduce exerted forces and ensure easy installation Lightweight aluminium design The LE 600 has been developed for both land based and marine environments Thanks to its unique design the LE 600 is not susceptible to corrosion in normal or salt water operating conditions Applications include Marine e Remote Homes Caravans Street lighting and road signage e 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 Telecommunications e The Developing World Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 4 of 48 Leading Edge Safety Precautions Safety must always be your primary concern during the assembly installation and operation of your LE 600 turbine Always be aware of the risks involved with mechanical
30. ftware 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 35 of 48 d Leading Edge DIP Switch Number 7 Select Diversion Switch 7 ON 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 Manual Off Figure 2 3 Step 3 Switch 8 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 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 gt REMARQUE Confirmez les r glages de tous les commutateurs dip avant de passer aux tapes suivantes d insta
31. h switch is fully in the ON or OFF position DIP Switch Number 1 Control Mode Solar Battery Charging Control _ Switch 1 Charging Off Load On Figure 2 3 Step3 DIP Switch 1 AR 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 24 On Off 48 On On OFF 1 456 1 456 Figure 2 3 Step 3 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 voltage Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 34 of 48 4 Leading Edge DIP Switches Number 4 5 6 Diversion Charge Control Battery Switch 4 Switch 5 Switch 6 1 13 8 Off Off Off 2 14 0 Off Off On 3 142 Off On Off 4 14 4 off On On 5 14 6 Off Off 6 148 On Off On 7 15 0 On On Off 8 Custom On On On 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 so
32. ing 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 Diversion load is too small so PWM reaches 99 Diversion load is burned out so PWM reaches 99 Diversion load is too large so TriStar faults on overcurrent 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 43 of 48 4 Leading Edge Appendix 2 Run Stop Switch User Manual Only operate in light winds Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 44 of 48 d Leading 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 a solution designed to allow the user to brake dynamically an LE 600 at will This is achieved by dis
33. ing the Universal Run Stop Switch ensure that the turbine is suitable restrained and not allowed to operate during the installation Electrical Safety Hazards The LE 600 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 LE 600 or other equipment to the electrical system The LE 600 can generate high voltage AC and the Universal Run Stop Switch also operates at these voltages Such voltages bring with them significant risks Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 45 of 48 Leading Edge Ensure that you have followed the cable sizing guidelines in order to select the correct size of cable 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 Batteries used in renewable energy systems can deliver a serious amount of current A shorting of 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 wor
34. it 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 Never run the LE 600 off load with the output cables not connected to anything Please use common sense when installing and operating your turbine EY Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 5 of 48 4 Leading Edge Specifications Turbine Name LE 600 Turbine Part Number GA LETU 009 Nominal Voltage 12V 24V 48V or Grid tie optimised Rotor Diameter 1540 mm Rated Wind Velocity 7 2 m s Rated Output 160 Watts Max Output 600 Watts 900 Watts in certain applications Rated RPM 550 Start up Wind Velocity 2 m s Total weight 19 5 Kg Tower mount 60 3 mm Outer Diameter Tube x 3 4 mm Wall Fig 1 Diametric View Chassis Construction Aluminium Rotor Blades 3 off Glass Reinforced Nylon
35. king 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 or face 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 The Universal Run Stop Switch can either be mounted 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 600 Turbine please ensure all 12 screw terminals of the switch are screwed closed before finally placing the top cover on the switch 20 3 POLE CHANGEOVER SWITCH 3 25mm2 BLK 2 5mm2 BLK 2 8 1 7 ee P
36. las Hereford HR2 OBW UK www leturbines com Page 15 of 48 d Leading Edge e Run Stop Switch A simple switch arrangement 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 rotor 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 can be reduced to 4mm2 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 Two LE DL 300 Diversion Charge Controllers are recommended to manage the power output from the turbine to the batteries These diversion charge controllers operate by increasingly switching output to a dump load once the batteries begin to reach high voltages The dump load consumes the excess power from the turbine This means that the turbine s power output is always utilised whether the batteries are fully charged or not Larger capacity battery banks will be able to store more energy and so the dump load will be used less Do not use a photovoltaic type charge controller with your LE 600 turbine For hybrid or more complex systems we recommend that a 45 A or 60 A Diversion Controller is utilised t
37. 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 ARRET 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 Pe Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 33 of 48 67 ceasing Edge position the following functions are present Switch Function 1 Must be load 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 requil 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 eac
38. llation Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 36 of 48 d Leading 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 61 Diversion Charge Control Pere ee eee eee eee eee eee ee ee eee eee ee ee ee eee eee ee ee eee eee eee eee eee ee ee ee ee eee ee ee eee eee 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 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
39. llowing guidelines should be followed e Follow the appropriate electrical code The electrical wiring of your LE 600 turbine and associated electrical systems must be done in accordance with national and local electrical codes and regulations 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
40. manual for the Morningstar 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 374 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 installation 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
41. 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 delivered 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 This arrangement is more effective than stop starting the turbine incessantly e Shut Down By activating the stop switch the output from the 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 Very high
42. mposants du syst me Reportez vous la Garantie limit e de Morningstar dans la Section 10 0 6 3 Standard Diversion Battery Charging Programs eee ee eee eee eee eee eee ee eee eee ee eee eee ee ee eee eee eee ee ee ee eee 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 37 of 48 3 1 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 F G Time Until Time Equalize Equalize Switches Absorp Float Equalization Equal Interval Cycle sa Voltage Voltage hours Voltage off off off 13 8 136 4 14 1 3 28 3 off off on 140 13 6 4 143 3 28 3 off on off 14 2 136 4 14 5 3 28 4 off on on 144 136 4 14 7 4 28 4 on off off 14 6 137 4 149 4 28 5 on off on 148 137 4 15 1 4 28 5 on or off 15 0 137 4 153 4 28 5 on on on Custom Custom Custom Table 63 Standard Diversion Charging Programs PWM Absorption Voltage This is the PWM Absorption stage with constant voltage charging The PWM absorption voltage is the ma
43. nerated 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 WIND DIRECTION TURBULENT a AIRFLOW ZONE OBSTRUCTIONS 2 X HEIGHT 2 X HEIGHT 20 HEIGHT 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 LE300 has a low voltage output so it is important to keep the cable run to the batteries inverter as short as possible 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 Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 47 of 48 d Leading Edge Contact Us Your Local Distributor Leading Edge Turbines Ltd Skyrrid Farm Pontrilas Heref
44. o 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 28 of 48 4 Leading 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 Tristar user manual should be followed Figure 2 2 Installation 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 Attach the RTS if battery charging will be temperature compensated 5 Connect battery voltage sense wires recommended 6 Connect the battery power wires to the TriStar Then connect the diversion load wires Ste
45. ogether with a separate dump load e Hybrid Systems The LE 600 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 PV panels and connected in parallel with the battery bank see Fig 13 For hybrid or more complex systems we recommend that a 45 Aor 60A Diversion Controller is utilised together with a separate dump load e Use of Grid tie Inverters It is possible to connect your LE 600 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 Please refer to the following wiring diagrams as a guide Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 16 of 48 Leading Edge Tel 44 0 845 652 usyo TOWER OR SUPPORT STRUCTURE RUN STOP SWITCH BOX REQUIRED PN GA CTRL 008A RECTIFIER BOX SUPPLIED AMMETER OPTIONAL FUSE OR BREAKER RECOMMENDED BATTERY DISCONNECT cassis OPTIONAL LE 600 TURBINE s PN GA LETU 009 EARTH GROUND SS Ss SEE RUN STOP SWITCH USER MANUAL FOR DETAILED INSTRUCTIONS Le peo eee eee Reg CHASSIS GROUND lt BATTERY B
46. ord HR2 OBW UK UK 0 845 652 0396 Outside UK 44 1981 241 668 info leturbines com www leturbines com
47. ower support structure e Remove the turbine from its installation to a suitable workbench e Remove the rotor blade assembly 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 vibration 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 4 connection screws from the sides of the LE 600 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 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 continuo
48. p _ Diversion Charge Control continued 7 Connect a computer to the TriStar if making adjustments with PC software 8 Replace the cover CP NOTE TriStar negative terminals are common negative d Leading Edge Steps 4 5 and 7 are optional 2 3 Installation Steps SOE TEETER EEE REET TERT ERE EERE EEE EEE He The TriStar controller must be installed properly and 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 torque 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 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
49. s similar to conventional solar charging Refer to the following sections in this manual for additional battery charging information 4 1 Four stages of charging applies to diversion 43 Temperature Effects and Battery Voltage Sense 44 Equalization 45 Float 6 4 2 Edge 90 Battery Information Selecting the Diversion Load 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 CAUTION The diversion load must be able to absorb the full power output of the 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 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 batterie 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 r
50. sequence 5 Fit the Rotor Blade Assembly This is done by offering the rotor hub plate against the drive hub protruding from the front of the chassis M6 x 16 long cap head screws should then be used to fix the rotor hub in position using the three unused tapped holes in the drive shaft Ensure that all 3 screws are securely tightened and that the rotor blades are fitted with the flat side of the blade facing towards the magnet rotor Thread locking compound should be used on the screw threads Fig 7 Fitting the rotor blades to the chassis Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 10 of 48 4 Leading Edge 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 Fig 8 Fig 8 Check blade rotation Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 11 of 48 4 Leading Edge 7 Fit the nose cone Do not over tighten nose bolts as the nose cone is a plastic part and is liable to crack if over tightened The nose cone can now be fitted to the rotor This is done by aligning the mounting slots of the nose cone with the corresponding barbs on the rotor blades Once the nose cone is fitted correctly over the blades and runs concentrically fix it in position using Q
51. ter twist drill bit suitable for drilling through steel Digital multi meter capable of measuring DC amp AC Volts measure or steel rule e Thread locking compound Loctite 243 or similar Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 7 of 48 4 Leading Edge Mechanical Assembly Procedure 1 Unpacking Inspect the contents of the box and ensure that all items are present and free from damage If any of the components are missing or damaged please contact your dealer immediately 2 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 bearing seals to bed in and the lubrication to be distributed correctly around the 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 any two of the three output leads extending from the yaw pivot With the multi meter set to detect AC Volts 0 20V a voltage shoul
52. 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 EEO EEE EE EE EEO E EEE EEE EEE EEE 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 75 45 40 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 responsible 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 co
53. 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 off load e Damage caused by modifications to the turbine tower or control equipment not approved by Leading Edge Turbines e Damage caused to the turbine tower and control equipment by improper storage or transport e Damage caused by lightning strikes e Damage due to extremely high winds and storm conditions 60 mph e Damage caused by flying debris e Aesthetic phenomena that do not affect performance e Damage caused by unsatisfactory installation of the turbine tower and or control equipment e Damage caused by unsatisfactory tower support structure design e Damage caused by incorrect connection to external electrical equipment or failure to observe current 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 will 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 Tel
54. ty 3 M8 x 1216 Cap head screws using Loctite The screws enter through the mount holes in the nose cone and align with the 3 tapped holes in the hub plate Ensure that the nose cone is secure and true before finally tightening the fixings Fig 9 Attach the nose cone Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 12 of 48 Leading Edge 8 Prepare the Turbine Mount If you have purchased LE 600 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 7 mm diameter holes will need to be drilled in order to secure the turbine These holes should be drilled 10 mm and 25 mm from the top of the tower mount bracket and should be perpendicular to the surface and skewed by 90 degrees The hole should penetrate both sides and cross the centre line of the tubular section see Fig 10 2 374 60 30 MATL 2 HOLES DRILL THRO 1 142 29 00 SIDE ELEVATION ELEVATION Fig 10 Drill through top of tower mount bracket 9 Install the Transmission Cables When your tower or mount bracket is ready to receive its turbine the next stage is to run the cables from the top of the tower to where the rectifier box electrical controller and batteries grid tie inverter will be located Follow the table below to select th
55. us operation This will ensure that the turbine s performance and safety are 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 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 23 of 48 4 Leading Edge Spares The following components may need to be replaced during the service life of your LE 600 turbine Please contact your nearest Leading Edge Turbines Dealer and quote the part numbers listed below Rotor Blade qty 3 matched set Slip Ring Wiper qty 1 Slip Ring qty 1 Coil disc 12 VDC Coil disc 24 VDC Coil disc 48 VDC Coil disc GT1 Yaw Bearings amp Housing Rotor Bearings amp Housing Run Stop Switch Box DL 300 Diversion Controller DP LETU 041G DP LETU 185 DP LETU 140 SA LETU 005 12V SA LETU 005 24V SA LETU 005 48V SA LETU 005 GT1 DP LETU 184 DP LETU 160 GA CTRL 008A GA CTRL 001A Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 24 of 48 Leading Edge Warranty Your LE 600 Turbine carri
56. version Charge Controller in series with the turbine Always ensure that the turbine and the controller are connected to the battery separately Failing to do so will damage the equipment and invalidate your warranty 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 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 controller and more Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 3 of 48 4 Leading Edge Introduction Please read this manual thoroughly before attempting to assemble install or operate your LE 600 small wind turbine This will assure optimum performance and safety Leading Edge Turbines have spent many years developing the ideas and technology behind your turbine The LE 600 turbine features an array of innovations and construction techniques as well as heavy duty engineering to ensure optimum efficiency and a long operating life The LE 600 has been designed to be simple economic durable and yield excellent performance Your LE 600 turbine features Innovatively designed axial
57. winds Due to the configuration of the low friction high efficiency alternator the electromagnetic braking effect is not as strong as with more conventionally designed turbines In certain high wind conditions the rotor can overcome the electromagnetic braking which allows high currents to be produced in the stator coils If this situation occurs with the wind driving the braked alternator for prolonged periods damage to the turbine will occur Therefore the braking switch should only be used to slow the unit prior to manually mechanically tethering the turbine in during very high winds e High Winds Every effort has been taken to ensure that the LE 600 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 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 Tel 44 0 845 652 0396 Skyrrid Farm Pontrilas Hereford HR2 OBW UK www leturbines com Page 21 of 48 4 Leading Edge e Grid tie Applications When connected to a grid tie inverter the LE 600 will operate in much the same manner as when it is charging batteries except for the use of dump loa
58. ximum 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 Time Until Float This is the cumulative time in PWM beforelthe 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 be held 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 are 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 time in equalization the manual pushbutton can be used to continue for one or more additional equalization cycles Battery Charging References The diversion load battery charging i

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