Ampair 300 Operation & Maintenance Manual

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Ampair ® 300 (Mk1, "Pacific") Wind Turbine Manual

Date: 02 Feb 2011

CD 2300

Issue: 1.2

Page 1 of 34

Ampair

300 Wind Turbine

Operation & Maintenance Manual

- 1 -

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Page 1 Ampair ® 300 (Mk1, “Pacific”) Wind Turbine Manual Date: 02 Feb 2011 CD 2300 Issue: 1.2 Page 1 of 34 ® Ampair 300 Wind Turbine Operation & Maintenance Manual - 1 - © Ampair, April 2007...
Page 2: Table Of Contents
SERVICING, REPAIRS, & DISPOSAL ....................33 Disclaimer: The information in this manual is believed to be correct and reliable. However Ampair assumes no responsibility for inaccuracies and omissions. The user of this information and product assumes full responsibility and risk.
Page 3: Introduction
Ampair is shortened to AMPAIR. 1.2 Applications The electrical power produced by the Pacific 300 wind turbine charges 12 volt or 24 volt DC batteries. Alternating current (AC) electrical appliances can be supplied by connecting a 220/240 volt or 110 volt inverter to the batteries.
Page 4: Safety Instructions
Please read this manual carefully before starting assembly and installation, or before conducting maintenance. This manual provides information that is critical to ensuring your safety during assembly, operation, and in case of trouble. If you have further questions please contact your dealer, an Ampair service partner, or Ampair itself.
Page 5 Provide sufficient ventilation to the battery compartment. Do not locate ignition sources within the battery compartment. The regulators manufactured by Ampair are charge control regulators. However if you have chosen to install (perhaps) cheaper and (definitely) less effective dump regulators then you should be aware that these can become very hot.
Page 6 Ampair ® 300 (Mk1, “Pacific”) Wind Turbine Manual Date: 02 Feb 2011 CD 2300 Issue: 1.2 Page 6 of 34 on a boat, note that the mounting has to withstand both the thrust from the wind, as well as the weight of the turbine, and the inertial loads arising from vessel motions.
Page 7: Technical Characteristics
Issue: 1.2 Page 7 of 34 3 TECHNICAL CHARACTERISTICS 3.1 Required space The Pacific 300 is designed for installation on 2" and 3" mounting systems. The diagram below shows the external dimensions in millimetres (mm): 3.2 Technical data Nominal power...
Page 8: System Description
160 Newtons 3.3 System description The Ampair 300 is a wind driven generator (a wind turbine) capable of supplying up to 300 Watts of electrical power at either 12 or 24 volts for charging batteries. A complete system includes the generator, the rectifier, the field wiring, and normally a stop switch and a regulator, plus of course batteries and a mounting.
Page 9: Installation
It is best to transmit electrical power as AC at as high a voltage and as low a current as possible so as to minimise losses due to the resistance of the wiring system. For this reason the rectifier of the Pacific 300 is not fitted inside the generator but is instead supplied as a separate unit for fitting adjacent to the regulator and or battery.
Page 10: Wind Turbine Packing List
Ampair ® 300 (Mk1, “Pacific”) Wind Turbine Manual Date: 02 Feb 2011 CD 2300 Issue: 1.2 Page 10 of 34 4.2 Wind turbine packing list The Pacific 300 Wind Turbine is packaged in recyclable cardboard cartons. The cartons contain: - 10 - © Ampair, April 2007...
Page 11: Accessories Packing Lists
5mm and 6mm Rotor blade 4.3 Accessories packing lists 4.3.1 Basic Pacific 300 stern mount kit (SMK) The basic Ampair 300 Stern Mount Kit (SMK) carton contains: Pole A, 800mm, Four 6.5mm holes each end, two 10.2mm holes centrally Pole B, 800mm, Four 6.5mm holes each end.
Page 12: Tools
4.3.6 Pacific 300 basic regulator The Ampair 300 Basic Regulator comes in two versions: the 12 volt or the 24 volt version. It is not possible to convert these from one to the other. The carton contains:...
Page 13: Choosing A Mounting
Where and how to mount a wind turbine is critical. The consequences of selecting a poor location can be unsafe operation, poor reliability, and low power output – or all three. As well as reading these guidance notes, if in doubt please consult Ampair or your distributor for advice. 4.5.1 Siting land based units The wind turbine should be sited as high as practicable, clear of windbreaks or buildings and away from sources of turbulence.
Page 14 Ampair ® 300 (Mk1, “Pacific”) Wind Turbine Manual Date: 02 Feb 2011 CD 2300 Issue: 1.2 Page 14 of 34 Mast: of steel tube (water pipe or scaffold tube), alloy tube or wood (telegraph pole). If the guys are unsuitable...
Page 15 Very careful attention must be given to the strength and integrity of the mounting. This should be capable of withstanding a peak horizontal load of 140 kg (300 lbs). Bear in mind that the blades will flex slightly in extreme weather conditions and so sufficient clearance must be left for this. The mounting should not rest on a resonant surface such as the centre of a cabin roof since this may transmit any vibration making the machine audible inside.
Page 16: Electrical Installation
Ampair ® 300 (Mk1, “Pacific”) Wind Turbine Manual Date: 02 Feb 2011 CD 2300 Issue: 1.2 Page 16 of 34 4.5.5 Mechanical installation of Pacific 300 mizzen bracket The major load that the bracket has to withstand is one of torsion, hence the box section. At 100mm wide this is close to the width of many mizzen masts and any slight difference can be accommodated by bending the end plates to suit or by spacing with nuts and washers.
Page 17 Ampair ® 300 (Mk1, “Pacific”) Wind Turbine Manual Date: 02 Feb 2011 CD 2300 Issue: 1.2 Page 17 of 34 4.6.1.2 Wiring diagram with regulator DC colour code: Block diagram Red = positive (+) Black = negative (-) Fuse sizing:...
Page 18 + *separate rectifier and regulator such as PR-300 used in single in / single out configuration DC colour code: Connection diagram Red = positive (+) (separate regulator and Black = negative (-) rectifier) Fuse sizing:...
Page 19: Electrical Components
Page 19 of 34 If the Pacific 300 wind turbine is connected on the load side of the battery isolator switch, it may damage electrical equipment. Under these conditions it is possible to run the wind turbine whilst the battery is isolated, but this can subject the system to excess voltage.
Page 20 4.7.2 Fuses and circuit breakers Fuses or miniature circuit breakers (MCBs) should always be fitted. The simplest possible arrangement feeds the power from the Ampair directly to the battery via an in-line fuse in the positive line near to the battery.
Page 21 A separate rectifier should be mounted near the regulator and/or the battery. It should be mounted on a heat sink (supplied with Ampair rectifiers) and connected as shown in the diagram below. DC colour code:...
Page 22 (two separate battery banks). The PR-300 regulator voltage set point can be adjusted using internal links. In the PR-300 fuses are used in other links to set 12/24 volt operation and to determine the input and output channels. The PR-300 has its own output fuse (i.e. no separate fuse is required in the battery compartment).
Page 23: Final Assembly
Do not service regulators with the wind turbine running. First stop the wind turbine, then remove wires (or fuses), then service the regulator. 4.7.7 Batteries We recommend large battery banks. A minimum 300 AmpHour battery bank is advisable, and 400 or 500 AmpHours would be sensible. 4.8 Final assembly Assemble the blades onto the generator before putting the tailfin on and then putting the entire unit on the mounting system.
Page 24 Ampair ® 300 (Mk1, “Pacific”) Wind Turbine Manual Date: 02 Feb 2011 CD 2300 Issue: 1.2 Page 24 of 34 HINT: If replacing an old hub/blades it will be necessary to prevent the generator shaft rotating so as to undo the existing bolt from the existing hub.
Page 25: Operation & Performance
Set stop switch to „stop‟. d) Mount the Ampair. Put a thin film of grease on the pivot shaft and its fixing screw threads to prevent corrosion. Bring the Ampair body to the mounting arrangement, pass the three core cable down the mounting pole, insert the pivot shaft of the Ampair into the top and secure the fasteners.
Page 26: Performance
Ampair ® 300 (Mk1, “Pacific”) Wind Turbine Manual Date: 02 Feb 2011 CD 2300 Issue: 1.2 Page 26 of 34 5.2 Performance The graph shows the output for a range of wind speeds. The drag due to the wind turbine is about 160 Newtons (16 kg / 35lbs) at 20 metres per second (40 knots) wind speed.
Page 27: Inspection & Maintenance
The design of the blades makes the Ampair a very quiet running machine. If vibration is encountered, this is evidence that the turbine is running out of balance. To prevent any resultant noise and the risk of fixings working loose, it is most important to take action.
Page 28 Inspect the lower bearing, if this is loose, obtain a replacement. Inspect the top bearing in the pivot housing. Inspect the "O" rings and "V" seal, replace if worn. It is sometimes easier to remove the Ampair generator head with the pivot in situ. Disconnect the battery first and remove the brushes. Uncoil the retaining ring and lift the body over the pivot.
Page 29 Referring to the exploded diagram of the wind turbine, undo the six M5 x 50 mm screws on the front of the Ampair and pull the front fore-body flange away from the main body. Do this very carefully as it must be withdrawn true or it will jam on the stator.
Page 30 Ampair ® 300 (Mk1, “Pacific”) Wind Turbine Manual Date: 02 Feb 2011 CD 2300 Issue: 1.2 Page 30 of 34 causes the loss of stator winding insulation due to salt corrosion resulting in electrical leakage and shorted turns. - 30 -...
Page 31: Drawings And Component List
Ampair ® 300 (Mk1, “Pacific”) Wind Turbine Manual Date: 02 Feb 2011 CD 2300 Issue: 1.2 Page 31 of 34 6.2 Drawings and component list 6.2.1 Exploded drawing - 31 - © Ampair, April 2007...
Page 32 Ampair ® 300 (Mk1, “Pacific”) Wind Turbine Manual Date: 02 Feb 2011 CD 2300 Issue: 1.2 Page 32 of 34 6.2.2 Key to exploded drawing Part Number Spares Kit Description CIRCI47-1 Front bearing retaining circlip WSHR47-4 Front bearing washer BRNG-6204-2RS...
Page 33: Recommended Spares
Web site: www.ampair.com Dorset, DT11 0HZ At the end of an Ampair 300‟s service life it may be disposed of via normal local recycling facilities. Lead free solders have been used; the main metal components are iron, stainless steel, aluminium, copper, and brass;...
Page 34 CD 2300 Issue: 1.2 Page 34 of 34 300 complies with the WEE and RoHS directives. The packaging materials are only cardboard. Expanded foams have deliberately not been used as a packaging material. - 34 - © Ampair, April 2007...