AERO6GEN OWNERS MANUAL
Contents
1. During operation in very hig as the generators output is reduced The limiter can be left permanently he limiter is Intended to protect the Aero6gen from the most damaging periods during wind speeds above 45 knots combined with severe gusting condi h winds with the limiter switched in circuit the fan speed will slightly increase by the limiter in circuit when the Aero6gen is left unattended AEROGEN OUTPUT 20 AMP DOUBLE POLE A A ON OFF ON SWITCH LVM PT NO SWITCH 020 BLACK RED SWITCH POSITIONS C NORMAL POSITION g X B LIMITER POSITION C i c DUMP RESISTORS SIE RRRRRRAR Tie Link wire SENN OPERATE THE SWITCH FROM NORMAL TO LIMITER BLACK 0 RED 0O PASSING THROUGH THE OFF POSITION WARNING The dump resistors MUST be y y mounted on a heat resistant surface as they can become TO FUSE very hot when in operation AMMETER IF FITTED TB REGULATOR OR BATTERY DUMP RESISTOR VALUES 12v Model 0 68 ohms 24v Model 2 7 ohms AEROGEN OUTPUT REAR VIEW OF A TYPICAL DOUBLE POLE Baek ed RED 0 ON OFF ON SWITCH SHOWING WIRE CONNECTIONS LVM Pt No Resistor 021 LVM Pt No Resistor 030 DUMP RESISTORS TESSSSSSHSyy oO aaan A LINK WIRE o RIZR R jo BLACK 0 RED y v TO FUSE AMMETER IF FITTED TB REGULATOR OR BATTERY LVM LTD AERO2. ARE PLACED OPPOSITE EACH OTHER BLADE AND THE UNIT WILL RUN BALANC EVEN 2 BLADES IN AN EMERGENCY FOLLOWING THE BREAKAGE OF ONE BLADE REMOVE OPPOSITE ED THE FAN ASSEMBLY WILL RUN WITH 3 OR EIGHT BLAD GRAMS AERO6GEN MOUNTING KITS AEROGEY 2 off 5 U BOL 4 HOLE PLATE 3 off WIRE ROPE EA TERMINALS YTT AEROGEN 4mm WIRE ROPE STAINLESS STEEL 10 METRES AL amp E a j a oO i o J fh oA VM168 UNIVERSAL PLATE y 1 TO 1 5 Pa HAND RAIL STANCHION MOUNT BASE MK4 Mounting kit includes 1x 1 5 Stainless steel tube 1450mm long 1x 1 5 Stanchion mount base 1x 1 to 1 5 Universal plate 3 off WIRE ROPE _ TERMINAL TENSIONER 3 off iil DECK U BOLTS nl MK6 Mounting kit includes 1x 1 5 O D Stainless steel tube 2 900mm long 1 x 1 5 Stanchion mount base 1x 1 to 1 5 Universal plate 10 Metres of 4mm Dia Stainless steel wire rope 3 x Wire rope terminal tensioners 3 x Wire rope terminals 3 x Deck U bolts 2 x 1 5 U bolts 1 x 4 hole plate TROUBLE SHOOTING The AERO6GEN is designed to give many years of reliable service as it contains really only two moving parts and one electronic component they are the permanent magnet rotor the slipring brush assembly and a rectifier The only parts that can wear are Main bearing ball races pivot shaft ball races and the carbon bru
3. RADAR DECCA SAT NAV INTERFERENCE The Aero6gen should be mounted at least 2 Metres from any form of aerial to avoid air born interference The output cable from the generator together with the dump regulator cables if fitted should be routed at least 1 Metre from aerial cables It is most important particularly on yacht installation that the negative return cable to the battery is clean and fully tightened The safety cable fitted around a yacht boat is tensioned by a bottle screw or turnbuckle and this cable has been known to cause interference The remedy is to rope tension or use an insulated connector ASSEMBLY FAN BLADE ASSEMBLY Assemble the fan using the M6 X 25 screws M6 Nyloc Nuts and M6 Washers The best way to assemble the fan is to lay the Inner Fan Hub on a flat surface blade sockets upwards and then insert the 6 blades concave side hollow side upwards See Fig 1 Place the Outer Fan Hub on top locating the blades in the sockets Insert the 6 off M6 screws washers and nuts and at this stage only tighten the nuts sufficiently to lightly grip the blades See Fig 2 Turn each blade until the indicator mark on the blade and hub align as shown in Fig 3 note how the right hand side of the blade indicator mark is set to align with the indicator mark on the outer hub This sets the blade tip angle to 10 deg Then finally fully tighten the nuts and fit on the M6 plastic nut covers We recommend that the fan assembly is fi
4. but has very suddenly developed a noise Check the following 1 If the noise developed after the generator had been subjected to very high wind speeds during storms it may be the three phase rectifier has been damaged 2 If the generator is only quite new the main shaft may have worn where the bearing inner race is located on the shaft 3 Stator assembly has worked loose 4 Fan assembly locking bolt not fully tightened 5 Generator mounting arrangement not fully tightened CHECKING MAIN BEARINGS Remove fan and check axial and radial play in the main front bearing Remove rear cover and check inner main bearing in the same manner If large amount of play is found replace main bearings Follow instructions listed REPLACING MAIN BEARINGS Whilst the rear cover is removed check the tightness of the 4 off stator retaining screws ELECTRICAL VIBRATION NOISE As described on page one it is normal for the Aero6gen to produce a very slight magnetic cogging vibration when rotating and an electrical vibration whilst charging This noise will be greatly amplified if the Aero6gen is mounted on a very hollow section of a yacht boat If mounted directly over sleeping quarters it may well be necessary to stop the Aero6gen at night Well known methods that can reduce vibration noise are listed below 1 Rubber mount as many fixings within the system as possible 2 Insert round insulation material the type you fit around cold water pipes to stop them
5. freezing during winter into the bore of the 1 5 mounting tube 15mm pipe sized insulation normally fits just perfect 3 Coil a length of rope around the outside diameter of the mounting tube full length SLIGHT ELECTRIC SHOCK FROM HAND RAIL Remove the generator from mounting taking off the tailfin and fan assembly Remove the rear cover 6 off screws and hinge back cover Using a multimeter set on continuity buzzer test check the 3 Phase output wires from the stator assembly do not have continuity with the main casting i e The casting main housing of the generator should be totally isolated from the electrical output of the generator If they do have continuity a new stator assembly must be fitted contact LVM REPLACING PIVOT BEARINGS Remove the generator from it s mounting taking off the tailfin and fan assembly Remove adaptor locking bolt and brush cover Remove bottom cover 2 screws Clamp the pivot shaft in a vice using jaw protectors so as not to damage the pivot shaft Then using a hammer against a piece of wood to protect the casting paintwork tap out pivot shaft assembly by hitting the base of the casting The bearings can now be removed from the pivot shaft Use Loctite bearing fit when refitting the new bearings to the pivot shaft and to the generator housing Apply silicone sealant to the bottom cover and the output wires within the adaptor when reassembling the pivot shaft assembly Refit brush cover using a new b
6. leads of the multimeter to the output wires of the generator then turn main shaft again to check a voltage is present KNOCKING SCRAPING SOUND ONCE PER REVOLUTION Whilst the generator is in it s working position check that the M8 allen screw which retains the fan assembly to the main shaft is fully tightened Also check tightness of all other fasteners on the fan assemble mounting adaptor and tailfin Check that the safety circlip which is fitted on the end of the main shaft in front of fan assembly is not loose and making a noise Remove rear cover and check the condition of the rotor it may be rubbing on the stator Inner main bearing could be worn check for axial and radial movement Check the tightness of the 4off M5 stator retaining screws this can cause a noise if slightly loose 12 MECHANICAL NOISE If the generator did not make the noise when first installed but has very gradually developed a noise Check the following 1 Grease main bearings recommended grease Castrol Spheerol L EP2 or equivalent 2 If the generator has been operating for 3 years or more it may be the main bearings need replacing 3 If the generator is only quite new the main shaft may have worn where the bearing inner race is located on the shaft 4 Stator assembly has worked loose 5 Fan assembly locking bolt not fully tightened 6 Generator mounting arrangement not fully tightened If the generator did not make the noise when first installed
7. quality ball bearing grease preferably Castrol Spheerol L EP2 or equivalent attached to the grease nipple pump till you see the grease just start to come out of the front bearing seal LVM Ltd Aerogen House Old Oak Close Arlesey Beds SG15 6XD UK Tel 01462 733336 Fax 01462 730466 E mail lvm ltd dial pipex com www lvm Itd com LVM Technical web site www lvm ltd dial pipex com 14
8. the blade faces the wind The main shaft of the generator should turn freely however there will always be a slight resistance which is called the cogging effect To check the starting torque cogging effect of the generator is correct Sellotape 4 5 pound coins 40 50 grams on the tip of a blade Set this blade by turning the fan till it is horizontal let go of the blade and the fan should just start to turn If the fan turns ok as described above then follow instructions under heading NO OUTPUT with particular attention to the rectifier test If the fan did not turn as described in the test above follow the instructions and tests listed under headings KNOCKING SCRAPING SOUND ONCE PER REVOLUTION MECHANICAL NOISE and NO OUTPUT NO OUTPUT Remove the generator from it s mounting taking off the tailfin and fan assembly Remove the rear cover 6 off screws and hinge back the cover A component called a rectifier that converts the 3 Phase A C output voltage of the stator into 10 D C voltage is mounted on the inside of the cover Note later models have also suppression capacitors soldered to the rectifier You will note that the rectifier has 5 terminals 2 of which are marked and the remaining 3 unmarked terminals are connected to the 3 output wires from the stator 3 phase a c Disconnect these 3 push fit connectors from the rectifier then using a multimeter set on resistance measurement ohms check the resistance in turn of
9. AERO6GEN OWNERS MANUAL CE LVM612 12 Volt LVM624 24 Volt PARTS CHECK LIST 1 x Generator M10 grub screws fitted 1 x Tail Tube 1 x Tailfin 1 x Fan Hub Outer 1 x Fan Hub Inner ETE 9 5 6 x Fan Blades H 1 x Hub Cover 6 x M6 X 25 Stainless Steel Screws 10 x M6 Stainless Steel Nyloc Nuts 10 x M6 Stainless Steel Washers 6 x M6 Plastic Nut Covers 4 x M6 X 35 Stainless Steel Screws 1 x Allen Key 5 mm A F 1 x Allen Key 6 mm A F 1 x M8 X 25 Allen Bolt With Spring Washer 2 x Butt Slice Connectors Heat Sealed Type 1 x Safety Circlip The powerful Aero6gen is designed specifically for the live aboard yachtsman it operates safely and continuously in wind speeds up to 45 knots producing 30 amps 12v model and 15 amps 24v model Above this wind speed we suggest manually stopping and tying off the fan assembly to stop it turning The Aero6gen is therefore not suitable for unattended applications Aero6gen Performance Amps output 12v Guarantee Thank you for purchasing this product It has been manufactured to exacting standards and LVM Limited guarantees that should 0 Me EN AA A BA y any defect in materials or workmanship occur within ONE YEAR Wind speed knots ele of purchase we will repair or replace the defective part Note Amps output of a 24v ree or charge model will be half shown above Damage caused by misuse failure to follow instructions negligence and modification or transit damage wi
10. GEN HOUSE OLD OAK CLOSE ARLESEY BEDS SG15 6XD 01462 733336 FAX 01462 730466 FILE A6SEC5 AERO6GEN PARTS LIST Main Body Casting CASTING 729 P Rear Cover Gasket GASKET 548 No 4 X 9 Self Tap Screw SCREW 664 Grease Nipple RECOMMENED GREASE CASTROL Spheerol L EP2 OR EQUIVALENT Main Bearings MS X 35 Stator Retaining Screw SCREW 851 MS Locking Washer WASHER 445 NSK 6204DDUCM BEARING 586 i Main Shaft amp Pal Rear Cover COVER 119 P Suppression Capacitor CAPACITOR 122 os 3 Phase Rectifier RECTIFIER 885 yw Rotor Ass y ROTOR ASSY 764 Stator 12v STATOR 712 Stator 24V STATOR 024 g Stator 36v STATOR 005 20mm _ Circlip CIRCLIP 276 48V STATOR 048 Complete Brush Cap Assembly BRUSH CAP ASSY 093 Stator 5 SCREW 629 D Brush Spring SPRING 776 Top Pivot Bearing NSK6202DDU n Brush Cover COVER 022 BEARING 271 Slipring Carbon Brush BRUSH 781 n SLIPRING 951 ph Brush Cover Gasket GASKET 762 Pivot Shaft Brush Terminal Tag TAG 775 SHAFT 765 E Terminal Serew SCREW 859 20mm Circlip CIRCLIP 276 Bottom Pivot Bearing NSK6004DDU BEARING 003
11. S OUTPUT WIRES 11 RECTIFIER TEST Test and readings of a good rectifier Set a multimeter to diode test then check 1 Disconnect all connectors from the rectifier 2 Attach the red test lead from multimeter to the plus terminal of the rectifier attach the black test lead to the negative terminal RESULT No Reading 3 Reverse the test leads i e attach the red test lead to the negative terminal of the rectifier then the black test lead to the plus terminal RESULT 0 8 0 9 volts 4 Connect the test leads to the 3 unmarked terminals of the rectifier in pairs RESULT No Reading RECTIFIER TEST Test and readings of a faulty rectifier Set a multimeter to diode test then check 1 Disconnect all connectors from the rectifier 2 Attach the red test lead from multimeter to the plus terminal of the rectifier attach the black test lead to the negative terminal RESULT 0 Volts 3 Reverse the test leads i e attach the red test lead to the negative terminal of the rectifier then the black test lead to the plus terminal RESULT 0 Volts 4 Connect the test leads to the 3 unmarked terminals of the rectifier in turn in pairs RESULT 0 Volts Refit the 3 off 3 phase stator output leads to the unmarked terminals of the rectifier Set the multimeter to read DC volts Attach the red test lead of the multimeter onto the plus terminal of the rectifier then the black test lead onto the negative terminal Turn th
12. WITCH SHOULD ONLY BE USED TO STOP SLOW DOWN THE FAN ASSEMBLY PRIOR TO SECURING WITH ROPE IT SHOULD NOT BE USED AS A PERMANENT PARKING BRAKE SUGGES OD YING AN ASSI Y ae CING A NO ry y INP PO Ama AEROGEN USING A LENG ia RC DOUBLE POLE oe ON OFF ON SWITCH A RED BLACK l SWITCH POSITIONS C CHARGE B BRAKE o TBOG c B lc B AEROGEN OPERATE THE SWITCH FROM CHARGE TO BRAKE PASSING THROUGH THE OFF POSITION OOP 00 x OF ROPE E spoon RED O BLACK he i TAS i TED y Q zj I L TO FUSE I i Cl AMMETER IF FITTED i TB REGULATOR OR BATTERY AEROGEN OUTPUT RED A BLACK WRAP ROPE AROUND TWICE RED O y BLACK TO FUSE AMMETER IF FITTED iJ ae TB REGULATOR AN VIEW OR BATTERY REAR VIEW OF A TYPICAL DOUBLE POLE ON OFF ON SWITCH SHOWING WIRE CONNECTIONS AERO6GEN LIMITER WIRING DIAGRAM FILE MANLIMIT DESCRIPTION The Aero6gen was originally designed for live aboard yachtsrnen who if very high winds were forecast would stop he generator with a brake switch then tie off the blades fo stop them turning However if the Aero6gen is difficult to reach or has to be left unattended for very long periods then by wiring in wo dump resistors and a switch as shown below the Aero6gen s ouput can be limited ions where its outpu can swing violently to produce very high output currents which can cause damage to the stator windings and the rectifier OTE
13. Water Seal VRING 778 we r Bottom Cover COVER 770 P Water Seal Spacer SPACER 766 o Bottom Retaining Screws SCREW 858 _ Adaptor Locking Pin LOCKING BOLT 765 1 ne p Tk e Fi Pivot Shaft Assembly SHAFT ASSY 097 Ex OJA Slip Ring amp cable SPN M10 Nyloc Nut NUT 855 Pivot Shaft amp Circlip Nis M10 Washer WASHER 853 Top Pivot Bearing Adaptor ADAPTOR 760 Bottom Pivot Bearing Water Seal Spacer S Water Seal N M10x30 Bolt SCREW 852 Adaptor Or M10 Washer WASHER 853 Bottom Cover SY M10 Nut NUT 854 i 7 Tailfin M10 Grub Screws AFRO6GEN PARTS LIST E TAILFIN 767 P SCREW 8625 PA Fan Blade Tail Tube me BLADE 021 gall TUBE 768 P 7 k AEROGEN l NN gt M8x25mm Socket Cap Screw SCREW 857 R dh N Hub Cover NUT COVER 327 IN Fan Hub Outer HUB DRILL 757 P L M6X35 Bolt BOLT 289 M6 Washer WASHER 291 M6 Nyloc Nut NUT 290 HUB ANGLED 756 M V tL M8 Spring Washer WASHER 301 Safety Circlip CIRCLIP 861 16 Washer WASHER 291 P 6x25mm Screw SCREW 955 6 Nyloc Nut N 290 6 Plastic Nut Cover NUT COVER 024 THE BLADES SUPPLIED WITH THE GENERA ANY REPLACEMENTS SHOULD BE ORDERED WEIGHT WHICH IS SHOWN BELOW HOWEV WEIGHT CAN BE FITTED PROVIDED THEY TOR ARE A MATCHED SET QUOTING PT NO BLADE 021 AND THE BLADE ER 2 BLADES OF THE SAME WEIGHT ANY
14. allen key by fitting a tube or something similar to make sure it is fully tightened See Fig 4 Push safety circlip into the shaft groove as shown in Fig 5 then finally push fully into the groove the black hub cover is then pushed onto the hub boss AEROGEN 6 The output wires are then connected to the battery See Fig 6 The RED WIRE is connected to the POSITIVE terminal and the BLACK WIRE to the NEGATIVE terminal We recommend a 30 Amp fuse for 12V Models anda 15 Amp fuse for 24v Models is fitted in the red positive cable from the generator to the battery so that if a dead short occurred it would prevent serious damage to the wiring and the generator Note Do NOT reverse the connections from the generator to the battery ie Generator Positive to battery Negative and generator Negative to battery Positive Doing this will damage the rectifier and void your warranty WARNING THE AERO6GEN SHOULD NOT BE ALLOWED TO RUN OPEN BATTERY CIRCUIT IN HIGH WINDS HIGH VOLTAGES WILL BE PRODUCED THE FIG 6 SUPPRESSION CAPACITORS CAN BE DAMAGED THE FAN WILL TURN FASTER SUFFERING UNNECESSARY STRESS MAINTENANCE The Aero6gen is designed to operate for long periods without needing any maintenance The life of the generator and its performance will be enhanced if periodic inspection is carried out For personal safety reasons before carrying out any inspection make sure you stop the generator from rotating The following should be c
15. butt sealed splices and using a crimping tool crimp them A hot air gun can seal the joints or by carefully using a cigarette lighter with the naked flame well away from the actual plastic just use the heat This will make the plastic ends contract and grip the cable giving a waterproof joint If you decide to use some other type of connector which can accommodate a larger cable size it must be rated at 30 Amps 2 Thread the output cable carefully through the centre of your mounting tube If the bottom of the tube is not accessible a hole must be drilled to enable the cable to be brought out Be sure to leave enough slack in the cable so that if necessary the generator can be removed 3 Locate the generator on top of your mounting tube and then fully tighten the M10 clamp bolt nut on the adaptor 4 The tail assembly can now be inserted into the hole at the top of the generator ensuring that the tailfin is positioned vertically and tighten the M10 grub screws 5 Fitting the fan blade assembly onto the main shaft of the generator Grease fan hub bore then fit the fan assembly onto the generator main shaft aligning the M8 clearance hole in the fan hub boss with the M8 tapped hole in the main shaft Fit the M8 spring washer under the head of the M8 x 25 Socket Cap Screw Insert the bolt through the M8 clearance hole in the outer fan hub boss and fully tighten it into the main shaft using the Allen key supplied best to increase the leverage on the
16. d when the batteries are fully charged It must not be a type which simply open circuits the generator There are three models of 6TB regulator STANDARD As described above TEMPERATURE COMPENSATION This additional feature is available on the LVM 6TB regulator If the battery is located in a building where the ambient temperature is always around 20 deg C then standard regulators can be used However if you intend to locate a battery where temperatures may go down to freezing and perhaps rise to tropical temperatures then you should install a regulator that is fitted with a temperature compensation circuit This automatically allows the battery to be charged at a higher voltage as the temperature drops and a lower voltage if the temperature increases Simply add T after the LVM Product No ie LVM 6TB12 T LOW BATTERY ALARM DRIVE This additional feature is available on the 6TB12 and 6TB24 regulators The built in circuitry continually monitors the terminal voltage of both batteries and if either of them fall to 11v 12v models or 22v 24v models a voltage output is applied to the alarm output cable It is then a simple matter of connecting either a piezo or buzzer to this alarm output cable via a small single pole switch and then a negative connection to the piezo or buzzer Simply add A after the LVM Product No ie 6TB12 A or 6TB12 TA for temperature compensation and alarm You may also consider installing an ammeter voltmeter
17. e bearings and remove rotor assembly from the rear of the main housing Having removed the rotor from casting Check the main shaft for wear particularly the areas where the main bearings were positioned If the shaft wear is found to be excessive a new shaft will have to be fitted Contact LVM Ltd Using the brass rod and a hammer knock out the main bearings from the casting Clean all the main bearing grease from the casting Refit new main bearings sealed side of bearings outwards using a little Loctite Bearing Fit smeared on the O D of the bearings Clean the main shaft then clean the rotor magnet with sellotape sticky side to remove small pieces of steel pickup Smear a little Loctite Bearing Fit onto the main shaft close to the rotor and in the bore of the outer main bearing Insert the main shaft rotor assembly into the generator main bearings WARNING The rotor magnets are very powerful and will quickly draw the assembly into the stator When the main shaft rotor assembly is fully inserted check it rotates without rubbing Smear a little Loctite Bearing Fit on the outer main bearing inner race to shaft i e between the O D of the shaft and the I D of the inner race Push the main shaft in and out a little to spread the Loctite between the outer main bearing bore and the main shaft Fit new circlip Refit rear cover using a new gasket make sure all internal wiring is clear of the rotor Using a grease gun filled with a good
18. e main shaft of the generator by hand any direction this should indicate a voltage on the multimeter Refit Red and Black DC output leads from the rectifier Refit rear cover using a new gasket making sure all wires are clear of the rotor If in doubt about the condition of the rectifier replace with a new one CHECKING SLIPRINGS AND BRUSHES Remove the brush cover assembly 4 screws Hinge back brush cover assembly leaving the red and black wires attached Check the condition of the sliprings and clean them if necessary Check the spring loaded carbon brushes are clean and are free to move in the brush holder Set a multimeter to continuity check buzz test Check there is continuity between the top carbon brush and the positive terminal of the rectifier then check there is continuity between the bottom carbon brush and the negative terminal of the rectifier Check there is continuity between the top slipring and the red output cable of the generator Then check there is continuity between the bottom slipring and the black output cable of the generator If no continuity is found on one or both output leads check the soldered joint on the slipring Resolder if necessary Set multimeter to read 0 15 volts DC connect test leads of multimeter to the brushes top brush is Positive bottom brush is Negative turn generator main shaft by hand in any direction If a voltage is present then refit brush cover using a new gasket Attach the test
19. he generator to the battery so that if a dead short occurred it would prevent serious damage to the wiring and the generator The RED OUTPUT WIRE output is connected to the POSITIVE terminal of the battery The BLACK OUTPUT WIRE to the NEGATIVE terminal of the battery 3 VOLTAGE REGULATION The output wires of the Aero6gen can be connected directly to the terminals of the battery that requires charging as shown in Fig 6 however if the terminal voltage of the battery is not continually monitored for over voltage 14 2v for 12v batteries and 28 4v for 24v batteries the battery can be seriously damaged Fitting an LVM 6TB voltage regulator will protect the battery from becoming over charged The 6TB12 12v model or the 6TB24 24v model is designed to regulate the Aero6gen output voltage and enable two independent batteries to be charged making it ideal for the typical yacht installation i e engine starting battery and domestic battery bank There is no problem if other charging systems engine alternator shore power etc are connected to the batteries The regulator can also be used on installations charging only one battery To charge a third or fourth independent battery a 6DU diode unit must be added Full details and wiring diagrams are supplied with each regulator Contact LVM Technical sales for more information WARNING If you fit another manufacturers regulator it must be the type that diverts the generators output to a loa
20. hecked every 6 months e Check blades for damage and replace if necessary Do not use the generator with damaged or unbalanced blades This will cause unnecessary wear and possibly damage to the main bearings Check the fan hub assembly for tightness Check the mounting adaptor and your mounting system for tightness Check all external electrical connections for tightness and corrosion Wash down the generator with fresh clean water to remove debris and salt deposits that can build up 3 e The main bearings life is generally between 3 to 7 years depending on the amount of use and operating conditions To ensure long life and quiet running the bearings can be greased via the small grease nipple located on the front nose section of the housing see sectional view A good quality ball bearing grease should be used preferably Castrol Spheerol L EP2 or equivalent just a couple of pumps with a grease gun till you see the grease just start to come out of the front bearing seal After several years use the carbon brushes which collect current from the slip rings may require replacement Carbon brushes Pt No BRUSHES 781 are available complete with full instructions If you experience a problem with your Aero6gen contact LVM to determine the nature of the problem LVM will send you replacement parts and instructions needed to repair the generator In the event that the generator is returned for repair service you will be notified of the cost for carrying o
21. ll not be warranted LVM Limited will not be liable for any loss of revenue or any consequential loss or damage to property or persons from any cause whatsoever Retain your purchase invoice as it will be needed in the event of a warranty claim What is Not Covered Damage due to lightening Damage due to improper installation Damage due to improper wiring Damage from flying debris causing blade damage Please read the manual thoroughly If you have any questions please contact us at LVM Limited Aerogen House Old Oak Close Arlesey Beds SG15 6XD Tel 44 0 1462 733336 Fax 44 0 1462 730466 E mail lvm ltd dial pipex com Web www lvm ltd com LVM Technical web site www lvm l td dial pipex com MOUNTING Great care should be taken to site the unit to avoid personal injury from the rotating blades SITING AND CONSRUCTING A MOUNTING ARRANGEMENT FOR THE AERO6GEN The Aero6gen is fitted with an aluminium bronze mounting adaptor this is designed to clamp onto a 1 5 inches 38 1 mm diameter tube LVM manufactures two mounting kits in marine grade 316 stainless steel details of which are included in these instructions A turning radius of 650mm should be allowed when selecting a Description of Mean Force Force position to mount the generator as shown in the plan view wind velocity Lbs Kg above in Knots Great care must be taken to site the generator in such a way to Ge
22. ntle breeze 9 1 3 0 6 avoid personal injury from the rotating blades When Moderate breeze 13 3 1 4 constructing a mounting system for the Aero6gen make sure it Fresh breeze 19 6 3 0 can withstand the weight of the generator together with the Strong breeze 24 10 5 5 0 additional wind forces shown in the table opposite Moderate gale 30 16 5 7 5 If the Aero6gen is to be mounted on a yacht boat care should be Fresh gale 37 24 5 11 2 taken where to position it as the Aero6gen will always produce Strong gale 44 35 16 a very slight magnetic cogging vibration when rotating and an Whole gale 52 47 5 22 electrical vibration whilst charging This noise will obviously be Storm 60 63 29 greatly amplified if mounted on a very hollow section of a Hurricane 68 81 37 yacht boat If mounted directly over sleeping quarters it may well be necessary to stop the generator and tie off the blades at night Well known methods that can reduce vibration noise in the mounting are 1 Rubber mount as many fixings within the system as possible 2 Insert round insulation material the type used around cold water pipes in winter to stop them freezing into the bore of the 1 5 inch mounting tube 3 Coil a length of rope around the outside diameter of your mounting tube Full length MIZZEN MAST MOUNTING For safety reasons and because of the difficulty to easily shut down the generator we would not recommend the Aero6gen be mounted on a missen mast RADIO
23. or an amphour meter all are available from LVM part number as follows LVM67 0 20A Ammeter LVM68 0 30A Ammeter LVM69 0 15v dc Voltmeter LVM200 Digital Amp Hour Meter FIXING CENTRES N S XING CENTRES N 72 mm patam i TO AERO6GEN 240mm WIND GENERATOR oz Te M t iat N Jo a jg i N SSMS HPFPMGPy YS U onnectors oO A B Se A e NG DUMP RESISTOR a BLACK CABLE TRI RATED di RED CABLE TRI RATED 2 5mm x 100mm LONG 2 5mm x 100mm LONG DUMP RESISTORS UNI GREY CABLE 2off HIGH TEMP RADOX 2 5mm x 150 mm LONG THT GREY CABLE 2off HIGH TEMP RADOX 2 5mm x 400 mm LONG USE le RED CABLE TRI RATED USE Smm 00mm LONG 2 5 Y x 800mm LONG RED CABLE TRI RATED BLACK CABLE TRI RATED HEAVY DUTY LINK CABLE 2 5mm x 800mm LONG 1 5mm x 800mm LONG i No 1 BATTERY No 2 BATTERY INSTALLATION PLEASE FOLLOW THESE PRECAUTIONS DURING INSTALLATION e Choose a calm day e Have someone available to help during installation e Do not install the blade assembly until the generator is mounted Whilst initially installing the generator or carrying out future maintenance it is important that the fan assembly is stationary 1 The Aero6gen output cables are stripped ready to insert into one end of a butt sealed splice This type of connector is suitable for 2 5 sq mm cables Strip one end of your output cable 5 6 mm observing polarity insert them into the other end of the
24. read 0 100 volts DC measure resistance have a diode test and a continuity buzzer test Pozi drive screwdriver Circlip pliers Soldering iron and solder Hammer Piece of hardwood and a brass rod 12mm diameter X 250mm long or similar For pivot bearing replacement a bench vice will be required MEASURING OUTPUT VOLTAGE With the generator in its operating position disconnect the generators output cable from the battery or the TB regulator if fitted and attach a multimeter set on 0 100 volts dc range to the two output leads The following open circuit voltages should be obtained at the wind speeds shown below It is most important that the wind speed is measured at the same height the wind generator is mounted 12v Model 6 knots 12v 10 Knots 20v 15 knots 32 20 knots 45v 24v Model 6 knots 24v 10 Knots 40v 15 knots 62v 20 knots 90v Open circuit voltage 0 06 Volts D C per rev Aero6gen 12v 0 12 Volts D C per rev Aero6gen 24v If no voltage is present check that your extension wire connection from the actual generators output cables are not corroded or have become disconnected If there is a fuse fitted in the output cable check it has not blown Check output voltage again at the generators actual output cable If there is still no voltage output go to the instructions and tests listed under heading NO OUTPUT REDUCED OUTPUT Check blades are set at the correct angle and the concave side hollow side of
25. rush cover gasket 13 INSTRUCTIONS FOR REMOVING AND REPLACING MAIN BEARINGS Parts required 2 off Main bearings LVM Part No Bearing 586 1 off Rear cover gasket LVM Part No Gasket 548 2 off Circlips 20mm LVM Part No Circlip 276 6 off Rear cover retaining screws LVM Part No Screw 664 1 off Small amount of Loctite 638 in tube Tools and materials required Hammer Circlip pliers Pozi drive screwdriver Piece of hardwood and a brass rod 12mm diameter X 250mm long or similar A grease gun filled with good quality ball bearing grease preferably Castrol Spheerol L EP2 or equivalent 1 2 8 9 10 11 12 13 14 15 16 17 Disconnect output leads and remove generator from mast Remove fan and tailfin assembly Remove the front circlip on the main shaft Remove 6 off self tapping screws retaining the rear cover Place a piece of hard wood on a concrete floor Holding the generator with the rear cover held back and main shaft downwards lift and force downwards the generators main shaft onto the piece of hard wood This should displace the main shaft inwards Alternatively the main shaft can be pressed out or hammered out but take care not to bruise the end of the main shaft The main shaft rotor assembly should now have moved inwards into the main housing Using a piece of brass rod or similar so as not to damage the end of the main shaft tap the shaft through both th
26. shes which make contact with the sliprings For safety reasons fan blades are designed to brake off if by accident an arm or hand is caught in the fan SIMPLE TEST A simple test to prove there is an output voltage from the generator can be carried out whilst the generator is in it s working position Disconnect the generators output cable from the battery or the TB regulator if fitted With the fan turning in the wind and the two output leads open circuit allow the fan to build up speed then touch the two output leads together shorting them the fan should noticeably slow down and act as a brake If this does not happen check that your extension wire connection from the actual generators output cables are not corroded or have become disconnected If there is a fuse fitted in the output cable check it has not blown The above test can also be carried out by turning the generators main shaft by hand any direction to check the braking action Note Although the instruction sheets supplied with the generator warns you not to run the generator in an open circuit condition the tests can be carried out safely at wind speeds of up to 20 knots The reason we do not recommend generators be left in an open circuit condition is that at very high wind speeds the suppression capacitors maximum voltage may be exceeded and destroy them The following tools and equipment will be needed to carry out tests and repairs to the generator Multimeter which can
27. the of 3 output wires in pairs from the stator They should read 0 9 ohms 12v model 3 5 ohms 24v model When replacing the push fit connectors to the rectifier after the test there is no need to remember which order or terminal they came from as they can fit on any of the 3 unmarked terminals CHECKING A C OUTPUT VOLTAGE OF STATOR Set the multimeter to read A C volts attach test leads to the 3 off stator output wires in pairs then turn the main shaft of the generator by hand any direction small voltage should be indicated on the multimeter Check the stator and suppression capacitors do not look burnt or overheated Check tightness of stator retaining screws If at any time the generators output leads have ever been connected to battery terminals the wrong way round or the generator has been struck by lightening then the rectifier may be have been damaged ELECTRICAL COMPONENT DIAGRAM OF AERO6GEN ELECTRICAL SCHEMATIC DIAGRAM OF AERO6GEN SUPPRESSION CAPACITORS 3 PHASE STATOR WINDING STAR CONNECTED 3 PHASE STATOR WINDING STAR CONNECTED RESISTANCE OF EACH PHASE 12v MODEL 0 9 OHMS 24v MODEL 3 5 OHMS COLOUR OF STATOR 3 PHASE RECTIFIER 3 PHASE RECTIFIER SPRING IR 36MT40 POSITIVE SLIPRING NW NEGATIVE SLIPRING gt NEGATIVE SLIPRING BRUSH CAP SOLDERED CONNECTION ASSEMBLY N CARBON BRUSH POSITIVE SLIPRING gt gt CARBON BRUSHES PIVOT SHAFT f OUTPUT WIRE
28. tted after the generator is mounted ALIGN MARKS Fig 3 PUSH SAFETY CIRCLIP FULLY INTO SHAFT GROOVE TAILFIN ASSEMBLY Attach the tailfin onto the tail tube using the M6 X 35 long screws washers and M6 Nyloc nuts ELECTRICAL DATA Aero6gen output wire colour Code The Red output wire is POSITIVE The Black output wire is NEGATIVE Wire Rating The output wires of the Aero6gen will require extending Electrical systems lose energy from the resistance of the wire size used The larger the wire size the smaller the loss however larger cross sectional area wire can be costly and in some cases more difficult to source The following table shows recommended wire sizes they are based on a 3 and 5 energy loss at an average wind speed of 20 knots It is recommended a minimum wire size of 4 0 sq mm be used Single Wire Length 0 5 Metres 6 10 Metres 11 20 Metres Voltage Drop 3 5 3 5 3 5 12 volt Aero6gen 6 0 mm 4 0 mm 10 mm 6 0 mm 25 mm 16 mm 24 volt Aero6gen 4 0 mm 4 0 mm 4 0 mm 4 0 mm 6 0 mm 4 0 mm Useful wire cross sectional area mm conversion to AWG 2 5mm 14AWG 4 0mm 12 AWG 6 0 mm 10 AWG 10 0 mm 8 AWG 16 0 mm 6 AWG 25 0mm 4AWG If the Aero6gen is connected directly to the battery terminals we recommend a 30 Amp fuse for 12V Models and a 15 Amp fuse for 24v Models is fitted in the red positive wire from t
29. ut the work and will incur the transport costs STOPPING OR LIMITING THE AERO6GEN OUTPUT The Aero6gen is designed to operate safely and continuously in wind speeds up to 45 knots above this wind speed we suggest the generator is manually or electrically stopped and then the fan assembly is secured by rope to stop it turning However if the Aero6gen is difficult to reach or has to be left unattended for long periods in high wind speeds then by wiring in two dump resistors in series and a switch as shown on page 7 the Aero6gens output can be limited The limiter circuit is intended to protect the Aero6gen from the most damaging periods during wind speeds above 45 knots combined with severe gusting conditions where its output can swing violently to produce very high output currents which can cause damage to the stator windings and rectifier Manual stopping The Aero6gen tailfin has a hole into which should be fixed a small loop of rope Using a boat hook attached to this loop of rope the generator can then be safely turned out of the wind The blades will slow down and stop and then the fan assembly can be tied off to the tail tube See sketch below Electrical stopping A 20A double pole on off on switch can be fitted as shown in the wiring diagram below This will short circuit the Aero6gen s output and the fan assembly will stop or slow down considerably then the fan assembly can be tied off to the tail tube WARNING THE BRAKE S
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