Ampair Pacific 100 User manual

1
AMPAIR PACIFIC 100 SAFETY
Read before assembling or using
Note. Do not assemble the generator, vane and turbine
until the electrical installation is complete.
ASSEMBLY
Fit the tail vane first.
If you fit the wind turbine first, the machine will turn out
of control & be a danger to approach.
MOUNTING
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 120kg (250lbs).
Note. The mounting pole should be vertical. The space
between the blade tips and the mounting pole must be left
clear. i.e. no clamps or other items should diminish this
clearance. The pole base should have a rigid mounting.
(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).
ELECTRICAL
It is important to fit a fuse. The fuse should be next to
the battery terminal since, in the event of a fault or
damage to the cable. the battery will supply the fault
current.
CORRECT POLARITY
When wiring the system be aware that if the Pacific is
connected to the wrong battery terminals, giving
REVERSE POLARITY the output rectifiers may be
destroyed or the internal soldered connections to the brush
holders may melt.
Check and double-check polarity before final connection.
CABLE COLOURS
BROWN = (+) Positive. BLUE =(-) Negative.
CHARGE CONNECTION POINT
The Pacific Output must go straight to the batteries.If
the Pacific is connected on the DOWNSTREAM (loads
side) of the battery isolator switch. it leaves scope for
damage to electrical equipment.
Under these conditions it is possible to run the Pacific
whilst the battery is isolated. This can subject the system
to excess voltage. Take care when disconnecting the
Generator in a high wind as the terminal voltage is enough
to give a mild electric shock.
FINAL ASSEMBLY 9
OPERATION & PERFORMANCE 9
Starting & Stopping 9
Performance 9
Smooth Running 9
COMPONENT PARTS DRAWING 10
MAINTENANCE & SPARES
Key to Component Parts Drawing 10/11
DIMENSIONS 11
Inspection 12
Major Disassembly 12
Pivot Section 12
Electrical Section 13
Electrical Fault Finding Tips 13
Alternator Section 14
Stator/Rotor replacement 14
RECOMMENDED SPARES 14
WARRANTY 14
SERVICING & REPAIRS ADDRESS 14
INDEX Page
SAFETY:
Read before assembling or using 1
Assembly 1
Mounting 1
Electrical 1/2
SYSTEM DESCRIPTION
Introduction 2
The Generator 2
PACKING LIST:
Pre-installation check 3
INSTALLATION
Choice of Mounting Position 4
Hawk 2 Land Based (House/Cabin) 4
Boat Based 5
Stern Mount 5
Mounting Drawings 3-6
Mizzen Bracket 6
ELECTRICAL INSTALLATION
Charge Control Regulator 7
Regulator Wiring Diagrams 8
Owners Manual
Installation & Maintenance
Ampair Pacific 100
© This Manual is the Copyright of Ampair Jan. 2001

2
When mounting the Pacific on its pole or bracket. the
cable needs to be fed down through the mounting.
When arranging this cable make sure it cannot chafe at the
point where it leaves the mounting pole.
Either lead the cable out of the bottom of the pole in a
gentle curve or drill an exit hole in the pole large enough
to take a rubber grommet to protect the cable from the
sharp edges of the hole.
REGULATION
It is advisable to fit a Charge Control Regulator if the
Generator is regularly left to charge batteries where no
loads are present. Under these conditions over-charge will
slowly drive off the battery electrolyte which, if not
topped up, will eventually damage the batteries.
HANDLING
Stopping. The wind turbine has been designed to survive
storms, however, it is a good plan to stop the machine if a
hurricane is expected or to carry out inspection.
To do this, proceed with caution, approach the Pacific
from downwind and grasp the tail vane (use a boathook
for marine generators).
Carefully turn the machine off wind and, when the blades
stop, throw a rope over them and tie down.
Never throw a rope into the turning blades.
To avoid personal injury wear sturdy gloves as a
precaution. The wind turbine blades are capable of
causing GRAVE PERSONAL INJURY and should be
treated with the same respect as an aircraft propeller.
CHECK
Check all fixings at regular intervals, especially after
severe winds.
SYSTEM DESCRIPTION
INTRODUCTION
The Ampair Pacific 100 is a wind driven generator.
capable of supplying up to l00 Watts of electrical power
at either 12 or 24 volts for charging batteries.
THE GENERATOR
The unit consists of a two part cast aluminium body, the
two parts sealed by an "O" ring. Two six pole permanent
magnet rotors run, with their poles in line, on a stainless
steel shaft. The shaft runs in two sealed. grease-packed
ball bearings with the front bearing protected by a
shaft seal. Two six-pole stators are arranged with their
poles staggered at 30 degrees to minimise "cogging" or
break-out torque and so allow easy starting.
The unit is assembled with one stator in the main body
casting and the other in the nose piece.
During assembly these are precisely aligned on the test
bench to give optimum performance.
A small timing mark is made at the junction of the case
halves to allow accurate re-assembly.
The alternating current output of the stators is rectified by
two bridge rectifiers, one per stator.
The DC output of the two rectifiers is paralleled and
passes to two carbon brushes mounted in brush holders
located on the sides of the lower body section.
The carbon brushes carry the output to two phosphor-
bronze slip rings mounted on the stationary pivot shaft,
allowing the machine to rotate to follow the wind.
To absorb any electrical noise arising from the slip-rings
and brushes, a metal oxide varistor is wired across the
output between rectifiers and brushes.
The output is electrically isolated from the case.
The body is mounted on the pivot shaft where it runs on a
sealed grease packed ball bearing at the top and a
composite plain bearing at the base. The top bearing is
captive in the body, the lower bearing is located in the
body by a stainless steel spiral retaining ring.
The pivot section contains an "O" ring seal on each brush
holder cap, an "O" ring around the lower bearing to body
junction and a "V" seal where the pivot shaft passes
through the lower bearing.
The pivot axis passes through the centre of gravity of the
assembled machine. This is necessary to ensure alignment
into the wind in light breezes without undue spinning.
The wind turbine consists of six cambered and twisted
compression moulded blades of glass-fibre reinforced
polypropylene. This material has exceptional fatigue
resistance and retains its durability down to sub-zero
temperatures.
The blades are factory selected for balance to less than
one gramme and are delivered as colour coded matched
pairs, they are clamped between a cast aluminium nose
cone and an aluminium alloy backplate using M8 x 45
stainless steel fasteners with shakeproof washers and nuts,
(two of each per blade).
The hub is fitted to the generator shaft taper where a
dowel pin is located to prevent relative rotation and
retained by an M10 plain washer and nyloc nut with a left-
handed thread.
An aluminium alloy tail vane is clamped to the rear of the
generator body using three M8 x 25 stainless steel screws,
six plain washers and three lock nuts. The vane of marine
generators is provided with a grab hole at its lower corner
to facilitate turning the unit cross-wind to stop the wind
turbine rotating when required.

3
PACKING LIST – Pre-Installation Check
AMPAIR PACIFIC 100 GENERATOR
Check that a complete and undamaged set of parts has
been received.
Have you received the voltage ordered 12V or 24V?
Carton Contains :-
Generator, complete with assembled hub and pivot.
Pacific Manual
Six Wind Turbine Blades, three colour coded pairs
(see coloured code on base of blade).
Direction vane.
Hardware kit.
Wind Vane Fixings Blade Fixings
3 M8 x 25 set screws 12 M8 x 45 fasteners
6 M8 plain washers 12 M8 shakeproof washers
3 M8 nyloc nuts 12 M8 nuts
PACIFIC STERN MOUNT KIT (P1031)
This arrangement places the blade tips
2 metres (7 feet) above the base fixing. If there is a
raised area adjacent upon which people may stand,
raise this base accordingly.
Carton contains :-
Top Pole, 1200mm, 2 x 8.5mm holes one end,
1x 8.5mm hole at other end, + 2 x 10.5mm holes.
Bottom Pole, 1200mm, 2 x 8.5mm holes one end,
2 x 8.5mm at other end.
Strut Pole, 970mm, 25mm OD.
Stay wires: two, terminated by thimbles and "D" ring nuts.
Hardware kit: containing, yoke, two angle feet, backstay
clamp shell, anodised aluminium alloy tube joiner.
Strut, yoke, joiner tube & feet fixings:
1 M6 x 40 set screw 1 M8 x 70 hex bolt
2 M6 x 35 hex screw 2 M8 plain washers
3 M6 shakeproof washers 1 M8 Nyloc nut
3 M6 Nyloc nuts 2 M8 x 60 hex bolts
1 M10 threaded rod 85mm 2 M8 shakeproof washers
2 M10 shakeproof washers 2 M8 hex nuts
MIZZEN BRACKET (P1032)
Carton contains :-
The Bracket
2 Ml0 x 150mm threaded rod,
8 MI0 nuts,
8 Ml0 plain washers,
4 MI0 shakeproof washers
GANTRY MOUNT (P1030)
Carton contains :-
Pole with base flange (800mm x48mm outside diameter)

4
The Wind Generator should be sited as high as
practicable, clear of windbreaks or buildings and away
from sources of turbulence.
These conditions are shown diagrammatically below.
INSTALLATION
CHOICE OF MOUNTING POSITION
(Land based siting and installation)
Warning:
Before a Wind Generator is installed in an excessively
windy location, the operators must satisfy themselves that
the site is suitable. It may be necessary to log site wind
speed and direction data at various heights prior to
installing the machine.
Any indication of turbulence means that the Generator
should be re-sited or raised above the turbulence. Wind
Data must be local and not from close-by. Avoid roof top
mounting which can give rise to turbulence, shock loads
and vibration.
Installation (Mechanical)
Free-standing installations should generally conform to
Fig. 1. The main components are:
Mast: of steel tube (water pipe or scaffold tube), alloy
tube or wood (telegraph pole)
If the guys are unsuitable (grazing cattle) then use a
telegraph pole one third buried or a lattice tower as an
expensive alternative.
Guys: Usually galvanised steel wire protected by plastic
sheath and fitted with end thimbles.
Do not use a material that will stretch or deteriorate.
Three equally spaced guys (120°) will assist raising and
lowering the assembled mast. A high mast will require
intermediary guying. The top guys hold the mast upright,
the lower prevent it from buckling.
The top fixing point should allow for minimum overhang of
the Generator i.e. be only a short distance below the wind
turbine blade tips.
Tensioners: The simple and easiest method of tensioning
guys, but adjustment must be uniform, since it is the guys
that resist the thrust of the wind turbine.
Base: This is to carry the weight of the Generator and Mast
only. Fixing again depends on the ground state but metal
pegs driven into soil are often sufficient. A lattice tower
would need a concrete base with rawlbolt fixings.
It is often convenient to make a pivot arrangement for the
base in-line with one guy anchor to aid raising and
lowering.
Ground anchors:
These should be suitable eyebolts
fixed in the ground and in line
with the guys. Anchors in soft
earth may require concrete,
gravel or clay soils require
“auger” type anchors and rocky
ground may need drilling and
expanding rock anchors. Only
Good Fig 1. Bad
2H
2H
H H
10H
2H
10H
2H
H
H
H

5
the eye should be visible above ground.
Avoid waterlogged soils which have poor holding and
anchor below the frost level.
Low Temperature Operation: Plastic materials do not
perform well in extreme cold, becoming brittle and
breaking. This applies to wind turbine blades, whether
glass filled or not. Operation at around 0°C should not be
a problem, but most materials are vulnerable at –20°C and
cannot be warranted to survive indefinitely.
Pacific ’s glass filled polypropylene blades, moulded with
large sized fibres in a compression process, are superior to
nylon, carbon polymer or other plastics in this respect.
However, when ice factors are also considered, the
prediction of blade reliability is even more difficult.
Other materials are also suspect. Examples are Nitrile
used in exposed seals and “O” rings and basic PVC cable
sheathing.
For this reason Pacific uses Neoprene and Viton™
components where possible and "Arctic" grade PVC
Grease used in sealed bearings allows performance to
(minus) -30°C or below, but component tolerances (ball
and ring) can lead to greater friction and increased wear
causing reduced bearing life.
Lightning: Directly earth all metalwork. Bury output
cables (½m depth) between mast and battery position for
better protection than suspending in air. Either run cabling
through plastic conduit or use a type specified for burying.
CHOICE OF MOUNTING: (Boat based)
a) On an extended. stayed pole on the stern of a boat.
see Figure. 9
b) On a bracket on the. Mizzen of a yacht, see Figure 3
c) At the main or mizzen masthead of a yacht.
d) On a custom made welded pushpit structure, "A"
frame, gantry etc.
PACIFIC STERN MOUNT (for Marine use)
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 120kg (250lbs).
Note. The mounting pole should be vertical. The space
between the blade tips and the mounting pole must be left
clear, i.e. no clamps or other items should diminish this
clearance. The pole base should be mounted where the
structure is very rigid. 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.
a) Check. Ensure that a complete and undamaged set of
parts has been received.
b) Pole position. The pole base fixing may be moved to
one side provided that, when viewed from above, the
angle between the strut and either wire is greater than 45
degrees.
c) Pole assembly. Using the joiner tube and M6 x 12
screws and shakeproof washers, assemble the poles .
A thread locking solution (e.g. Loctite 222) will stop
screws shaking loose due to long term vibration.
It may be easier to feed the cable through the poles as they
are assembled.
d) Feet. Using the M8 x 65 bolt, washers and nut, fix the
feet to the pole end and screw down the feet.
The feet should be arranged so the pole can pivot in line
with the strut. This usually means aligned fore and aft
unless the pole is off-centre.
e) Stay Wires. Having assembled the poles with joiner
tubes, site the pole and attach the two stay wires with the
yoke in place on the pole. Find suitable points for the stay
wire base fixings, allowing for the fact that these will be
under considerable tension in use.
"Bottle screws" are suggested as a tensioning method.
Figure 9. Stern Mount Kit
f) Backstay strut. File the groove in the strut pole end
and clamp shell to accommodate the backstay wire
diameter less 0.5mm. Cut the strut pole to length required.
Drill the hole for the strut to yoke bolt in situ to ensure
correct orientation of holes.
B
C

6
Figure 2. Stern Mount Kit
MIZZEN MOUNTING
Figure 3 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.
Drill through the end plates and mizzen and fit using the
M10 fixings provided. Monel rivets are a possible
alternative to the bolted method above.
Note. Do not assemble the generator, vane and turbine
until the electrical installation is prepared
ELECTRICAL INSTALLATION
When mounting the Pacific on its pole or bracket, the
cable needs to be fed down through the mounting.
When arranging this cable make sure it cannot chafe at the
point where it leaves the mounting pole.
Either lead the cable out of the bottom of the pole in a
gentle curve or, drill an exit hole in the pole large enough
to take a rubber grommet to protect the cable from the
sharp edges of the hole.
a) Cables: Having sited the Pacific mounting. measure the
cable run distance to the batteries. If this distance is less
than 10 metres (20 metres 24V systems) use 1.5sq. mm
(16 AWG cable, if less than 20 metres (40 metres 24V
systems), use 2.5sq. mm (14 AWG) cable.
Use a similar type of cable to that on the Pacific. Always
use tinned stranded conductors
for best corrosion protection on
boats.
b) Connectors: To carry power
from the Pacific to internal
wiring we recommend that a
quality water-tight connector be
fitted
c) Installation: Wiring between the generator
(or junction box, connector etc.) and the battery area
should be clipped at regular intervals to the structure for
safety and a neat job.
d) Protecting the System: The simplest possible
arrangement feeds the power from the Pacific directly to
the battery via an in-line fuse rated at 10 Amps (5 Amps
24V System) in the positive line next to the battery.
e) Wiring Options: in Fig 4. two optional components
have been added to show where they might be wired in the
circuit. The switch, which may be used as a simple means
of charge control, should be rated at 15 Amps DC to
ensure long life.
The Ammeter is wired in series (assuming it to be of the
internal shunt variety) with one line. This will allow the
machine output to be seen at all times. As shown, the
positive (+) connection of the ammeter is made to the
generator, whilst the negative (-) is made to the battery.
Never connect an ammeter across the supply.
CAUTION. It is most important to fit a fuse.
The fuse should be next to the battery terminal since, in
the event of a fault or damage to the cable, the
battery will supply the fault-current.
CORRECT POLARITY. When wiring the system be
aware that if the Pacific is connected to the wrong
battery terminals, giving REVERSE POLARITY the
output rectifiers may be destroyed or the internal
soldered connections to the brush holders may melt.
Check and double-check polarity before final
connection.
CABLE COLOURS:-
Brown = (+) Positive : Blue = (-) Negative
CHARGE CONNECTION POINT
The Pacific output must go straight to the batteries.
If the Pacific is connected on the DOWNSTREAM
(loads side) of the battery isolator switch, it leaves
scope for damage to electrical equipment. Under these
conditions it is possible to run the Pacific whilst the
battery is isolated.
This can subject the system to excess voltage.

7
REGULATORS
AMPAIR manufacture 3 Charge Control Regulators to
protect lead acid batteries from overcharge.
These are not "shunt" type regulators, which dissipate
excess charge as heat, but an electronic power switch
which disconnects the generator from the battery at the
regulation voltage.
12V System showing 3 batteries
installed with an Ampair S-M3B Charge Control
Regulator
Regulators S-M1B & S-M3B have a single 100 watt input
(Pacific, Aquair or Solar) and 2 level sensing. The lower
voltage (Lo) connection regulates at 0.4 Volts below the
high (Hi) connection for 12V systems (0.8V for 24V
systems). "Hi" connection is appropriate for liquid
electrolyte batteries and/or live aboard situations, 'Lo"
connection for gel batteries and/or infrequent use.
The battery voltage is sensed at the regulator output
connection, therefore install the regulator as near
the battery as practicable and keep the connecting cables
short.
Regulator type S-M1B has one output battery connection.
Regulator S-M3B has three output connections to serve up
to three battery banks.
The third Regulator D-M1B has two 100Watt inputs ,
(any two from Pacific, Aquair or Solar), supplying a single
battery bank at a fixed regulation voltage.
All regulators feature the same multi-stage regulation
programme which has regulation voltages of
Lo = 13.6V, Hi = 14.0V for 12V systems
Lo = 27.2V, Hi = 28.0V for 24V systems.
MODEL (12V) S-MOB S-M3B D-M1B
Source 1 1 2
Source Power W 100 100 2 x 100
Programme M M M
Battery Banks 1 3 1
Setpoint V (low) 13.6 13.6 -
Setpoint V (high) 14.0 14.0 14.0
Equalisation V+ 0.4 0.4 0.4
MODEL (24) S-M1B S-M3B D-M1B
Source 1 1 2
Source Power W 100 100 2 x 100
Programme M M M
Battery Banks 1 3 1
Setpoint V (low) 27.2 27.2 -
Setpoint V (high) 28.0 28.0 28.0
Equalisation V+ 0.8 0.8 0.8
WIRING: Use suitably insulated cable of 1.5 sq. mm
(16 AWG) between regulator and battery, for single
source systems, 2.5 sq. mm (14 AWG.) for dual source.
For wiring to the regulator see appropriate generator
wiring section. The use of Screened Cables is
recommended if the cables run close to equipment
radiating strong electrical fields e.g. Radio transmitters or
Aerials
Charging is continuous until the Lo or Hi voltage is
reached, depending on the battery output used.
The generator is now disconnected from the battery.
Off-charge, the battery voltage will fall.
At a voltage of 0.5V below the regulation voltage a
30-second time delay is activated. This delay prevents the
regulator from oscillation (hunting) when charging
batteries under load. After 30 seconds has elapsed, the
generator/battery connection is remade and charging
continues to the regulation cut-out voltage..
A cycle counter counts the charge/disconnect cycles and
at the tenth cycle increases the regulation voltage for one
cycle only by 0.4 volt to Lo = 14.0V or Hi = 14.4V for
12V systems (0.8V for 24V systems Lo = 28.0V, Hi =
28.8V). This provides an equalisation charge for the
battery. Subsequent cycles return to the lower settings
until a further 9 cycles are completed.
Ammeter:
We recommend fitting an ammeter to monitor charging.
Fuses: Battery protection fuses should be fitted.
Use l0Amp values in 12 volt systems, 5Amp for 24volts.
PACIFIC 100
Fig. 5

8
INSTALLATION
At initial start-up, allow a gap of 1 min. for circuit
timing functions to become active.
CHARGE CONTROL Protecting the system
Fuse Warning - Never omit fuses, simple in-line fuse
carriers may be used, they protect your system from
excessive battery currents in the event of a serious
electrical fault. If they keep blowing, find out why.
Fuses = 10A - 12V systems : 5A - 24V systems.
All multistage regulators are internally protected by an
SAE cartridge fuse. These are not substitutes for battery
protection fuses. The fuses must be next to the battery
terminals since, in the event of a fault, the batteries would
source the fault current. Check and double-check
polarities before making connections, insert the fuses in
the fuse carriers last of all.
Corrosion: This is the enemy of all electrical
connections, especially in marine environments. Site
regulators in a weather proof location, as dry as possible
and splash proof. Inspect all terminations and connections
for signs of corrosion. Rectify by cleaning, remaking etc.
Use tinned copper wire for extension leads to prevent
corrosion spreading inside cable insulation.
Operating Problems: A digital multimeter is useful for
checking operation/fault finding if no permanent
monitoring instruments are used.
Battery voltage levels and those of the charging source
can be read directly. Charging current readings will
require the multimeter to be installed in line. In this way
currents into and out of the regulator can be observed. Do
not remove battery connections since regulator operation
depends on a very small supply current.
If the regulator is suspect then it can be temporarily
bypassed by connecting the source positive direct to a
battery positive. The negative connections are common
and do not need disturbing unless regulator replacement is
necessary.
Use the multimeter continuity range to confirm all cable
runs are low resistance.
Operation: When installed, the generator and regulator
will run and maintain the batteries automatically.
The unit may be run in conjunction with any other charge-
source with no known interactive problems.
Regular battery inspection and topping up must still be
carried out to obtain maximum battery life.
FAULTY REGULATOR
Stop the wind turbine from turning & tie off before
disconnecting any cables. Do not remove battery
connections when generator is supplying charge current,
as this can destroy the regulator!
If the regulator is suspect, then it can be temporarily
bypassed, i.e. connect the Pacific directly to the battery
terminals observing correct polarity. If this reinstates
correct charging, then the regulator must be serviced or
replaced.
Regulators draw a small current (typically 1mA at 12V)
from the battery to activate the sense and control circuits.
Without this connection the regulator will be
inoperative
IN-LINE
FUSE
12V-10A
24V-5A
IN-LINE
FUSE
12V-10A
24V-5A
IN-LINE
FUSE
12V-10A
24V-5A
BATTERY
S-M1B
S-M3B
BATTERIES
D-M1B
BATTERY
+
BATTERY
+
1
2
3
Fig 6

9
machine off wind and. when the blades stop, throw a rope
over them and tie down.
Never throw a rope into the turning blades.
CAUTION
To avoid personal injury wear sturdy gloves as a
precaution. The wind turbine blades are capable of
causing GRAVE PERSONAL INJURY and should be
treated with the same respect as an aircraft propeller.
PERFORMANCE
The graph shows the output for a range of wind speeds.
The drag due to the wind turbine is about 22kg (50lbs) at
50 knots wind speed.
SMOOTH RUNNING
The design of the blades makes the Pacific 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. Remove
the turbine, take out the blades and examine them to check
that the pairs are placed opposite.
If they are correctly assembled, contact Ampair .
To confirm correct blade performance, firstly weigh the
blades, the pairs should be the same weight, within one
FINAL ASSEMBLY
a) Mounting the Pacific: Put a thin film of grease on the
pivot shaft and its fixing screw threads to prevent
corrosion. Bring the Pacific body to the mounting
arrangement, pass the 2 core cable down the mounting
pole, insert the pivot shaft of the Pacific into the top and
secure the fasteners.
The top of the pole is made to compress the lower pivot
bearing "V" seal by about 2mm, if you have made your
own fixing tube, be aware of this point to ensure free
turning and weather proof sealing.
b) Output Cable: Make the final electrical connections to
the battery, as shown in the electrical section, Insert the
fuse or fuses in their carriers.
CAUTION: Fit the tail vane first.
If you fit the wind turbine first, the machine will turn
out of control and be a danger to approach.
c) Tail Vane: Clamp the tail vane using the M8 x 25
screws washers and lock nuts.
d) Wind turbine: Assemble the blades to the hub with
the concave or hollow side facing the wind.
Using the M8 x 45 square shoulder fasteners, shakeproof
washers and nuts, fix the blades in place observing the
colour-coded pairs. These must go opposite each other.
FAILURE TO OBSERVE THIS POINT CAN CAUSE
THE MACHINE TO RUN OUT OF BALANCE.
The holes in the blades are deliberately a tight fit and it
may be necessary to turn the fasteners as they are inserted.
First, evenly tighten all the nuts by hand, then, fully
tighten opposite pairs with a spanner.
Finally, recheck the tightness of all the nuts.
Note.Put a rope over the Pacific passing through the
blades to prevent its turning as you carry out the final
checks.
Once the mounting is complete, make sure all personnel
are clear, turn the Pacific to face the wind and whilst
holding the vane step back and remove the rope.
Check all fixings at regular intervals, especially after
severe winds.
OPERATION & PERFORMANCE
STARTING AND STOPPING
a) Starting up. It is assumed that the Pacific has been
assembled and installed in accordance with the
INSTALLATION Section.
b) Stopping. The wind turbine has been designed to
survive storms, however, it is a good plan to stop the
machine if a hurricane is expected or to carry out
inspection. To do this, proceed with caution, approach the
Pacific from downwind and grasp the tail vane
(use a boathook for marine generators). Carefully turn the
Fig 7

10
Fig 8

11
PACIFIC 100 COMPONENT PARTS
KEY TO CUTAWAY DRAWING
1. Tail vane
2. M8 x 25 screw,
plain washer x 2, & nyloc nut (3 of each)
3. After-body
4. Rear ball bearing: Type 6202.
15 x 35 x 11mm with frictionless cover
5. Six pole stator (2 off)
6. Shaft
7. "O" ring seal: international size 358
8. Fore-body
9. Six pole permanent magnet rotor (2 off)
l0. Front ball bearing: Type 6203.
17 x 40 x 12mm with frictionless cover
11. Internal circlip: 40 x 1.75mm
12. Shaft seal: 17 x 40 x 7mm rubber coated, plain lip
13. M8 x 25mm set screw, fibre washer, plain washer
& shakeproof washer (2 of each)
14. Wind turbine blade
(6 off, available as balanced pairs)
15. Nut Nyloc M10 left handed thread & plain washer
16. Back plate
17. M8 x 45mm square shoulder fasteners,
c/w shakeproof washer & nut (12 off)
18. Sealing cap
19. Nose Cone
20. Dowel for locating hub centre
21. Ball bearing: Type 6202
15 x 35 x 11mm
22. Slip-ring assembly
23. Lower bearing
24. "O" ring seal: international size 332
25. Spiral retaining ring
26. Pivot
27. "V" seal (neoprene)
28. Output cable: tinned, stranded copper flex,
twin 1. 5sq. mm arctic grade PVC sheath,
three metres length
29. Mounting pole
30. Socket Cap Screw
M8 x 16 & shakeproof washer
31. Cable gland with flexible tail
32. Brush cap, brush, "O" ring seal
(international size 012 neoprene),
brush holder & spring connector (2 of each)
33. Suppressor: metal oxide varistor
34. Rectifier c/w M5 x 16mm screw (2 of each)
35. Rear cover plate
36. Self-tapping screw, Number
8 x 3/8" U K designation (4 off)
DIMENSIONS.
Pacific Body.
Shaft diameter 17mm
Pivot shaft diameter 40mm
Body height (from machine base) 266mm
Body diameter 175mm
Body length (including shaft) 316mm
Body length (with lid) 263mm
Generator body and pivot weight 9kg
Assembled Pacific Wind Generator.
Wind turbine diameter 928mm
Tip of blades below top of pole 280mm
Mounting pole inside diameter 40mm
Mounting pole outside diameter 48mm
Turning radius 480mm
Weight 12.6 Kg
Electrical.
Output nominal voltage 12V or 24V
Peak output power 100W
The output is fully rectified and
isolated from the case.
280
465
928

12
INSPECTION
First. stop the machine, see section on stopping.
Caution: To avoid personal injury wear sturdy gloves as a
precaution.
The wind turbine blades are capable of causing
GRAVE PERSONAL INJURY and should be treated
with the same respect as an aircraft propeller.
Regularly inspect the following :
Hub to shaft nut (priority No. l)
Blade fasteners & nuts
Wind turbine blades
Tail vane screws
Pole mount screws
Brushes
The Pacific Wind Generator should be inspected
regularly, particularly after stormy weather, for signs of
accidental damage. Any minor nicks in the edge of a blade
may be dressed out but the blade must be replaced if there
is any sign of damage or cracking near the root.
Since the blades are supplied as matched, balanced pairs,
any damaged blade must be replaced along with its
opposite number.
The unit may be run with two blades missing, whilst the
replacements are obtained, at reduced performance since
difficulty in starting will be encountered.
NEVER ALLOW THE MACHINE TO RUN OUT OF
BALANCE
The blade material has exceptional fatigue resistance
which is of the utmost importance in hostile locations
such as tropical sunshine and mountain tops.
The material is, however, subject to slow degradation due
to ultra violet light which increases towards the tropics
and with altitude.
This process is slow and when it becomes apparent as a
white powdering of the blade surface, particularly along
leading and trailing edges, the blades may be carefully
painted with two-pack polyurethane after light sanding.
Do not mix up the balanced pairs.
The shaft seal protecting the front bearing should be
renewed after 2 - 3 years of regular use.
Also the lower bearing and "O" seal. The ball bearings
should be replaced when they become noisy, causing a
once per revolution ‘knock’.
Regularly check the security of the fixings on hub, vane
and pole. If damage to the paint occurs, clean off any
corrosion and repaint. Clean the brushes, taking care not
to damage the brush spring when handling.
MAJOR DISASSEMBLY
a) Stop the Pacific, see Section on Stopping.
b) Disconnect from the batteries, removing the fuses first,
see Figures 5 & 6 (Circuit diagrams).
c) Remove the wind turbine. The centre nut has a left
handed thread and so is rotated clockwise to remove. Pull
the hub away from the machine and give a very careful
tap on the end of the shaft with a rubber faced mallet if
necessary. If difficulty is encountered in removing the hub
from the shaft, avoid hammering on the shaft-end. Ampair
offer a purpose made puller.
d) Remove the tail vane.
e) Feed some excess cable length up the pole.
f) Remove the fastener from the pivot and lift the machine
off the pole.
PIVOT SECTION
With the machine on the bench, undo the two black brush
holder caps and remove the brushes to a safe place.
Prise out the end of the spiral retaining ring from around
the pivot lower bearing. Withdraw the pivot assembly, a
good tug may be needed. Inspect the slip rings, clean if
necessary.
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 Pacific 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.
The exposed slip-ring must be protected from the
environment if the generator is removed for further
servicing.
When reassembling put silicone grease (not petroleum
grease or jelly) around the shaft where it passes through
the lower bearing. Slide the bearing and "V" seal down the
shaft about 20mm and wipe grease around the shaft.
Slide the bearing back up the shaft and remove the excess
grease, wipe a fillet of grease around the point where the
"V" seal sits and slide the "V" seal into place.
Before reinsertion wipe the slip rings to remove any trace
of contamination due to handling and put grease around
the lower bearing "O" ring. Gently slide into place and
wind the spiral retaining ring into its grove.
Clean and replace the brushes. Re-check the pivot for
gram. Secondly, lay the assembled turbine on a flat
surface face down, this will reveal any blade bend as the
tips should be above the surface by an equal amount plus
or minus 3 mm.
Blades will be checked and re-balanced, free of charge, on
request, if returned to the factory.
Any other machine noise should also be investigated.
Only after very extended running life should there be any
detectable bearing noise.
If this is the case, refer to the maintenance section for
instructions on their replacement.

13
lead to the upper brush holder, black lead to lower holder,
and note the reading. Now reverse the connections.
*This test is not as conclusive as the Diode Test method
however, provided the first reading is a very high
resistance and the second reading far lower, then the test
is valid. Actual values will depend on the voltage
supplied by the particular meter for its resistance ranges.
The rectifiers are located in the small box on the back of
the Pacific body. To inspect them remove the four screws
and the plate. This has been sealed with polyurethane
sealant.
After removing the screws insert a thin blade to cut the
seal. The sealant must be renewed on re-assembly after the
mating faces have been cleaned.
Failure to do this can cause severe brush gear
corrosion in future.
Unsolder the commoning links between the rectifier
outputs and check outputs separately. If a new rectifier has
to be fitted, unhook the spring connections to the brush
holders in the lower body section noting polarity,
(Brown wire = positive output = upper brush holder)
and unsolder the four stator wires from the rectifiers.
ELECTRICAL SECTION
Note. By far the most common cause of reduced output is
corroded wiring between Pacific and battery.
Before suspecting the machine, check any screw terminal
or crimp connections and all cable runs between Pacific
and battery.
Possible faults to consider if reduced output is suspected:-
a) Poor wiring connections. Inspect all the screw
terminals in the Pacific circuit for signs of fatigue or
corrosion.
b) Sticking brushes or associated brushgear contact
problems. See Pivot Section.
c) Faulty Rectifiers. The rectifiers and metal oxide
varistor should last the life of the machine.
The most likely cause for their demise is accidental
reverse polarity connection of Pacific to battery.
If this is suspected the rectifier diode bridges must be
checked. Reverse polarity connection can also melt the
solder on the brush holder spring connections, these can
be checked by removing the pivot and looking into the
lower body section.
A simple method of checking the machine's output is to
disconnect it from the battery and short together its output
leads whilst turning the shaft by hand. A marked increase
in resistance to turning should be felt as the shorting
occurs.
Diode Test. This test will show if the rectifier diodes are
either open or short circuit.
If your multimeter has a diode check feature, select this (if
not select the highest resistance range) and having
removed the brush caps and brushes, apply the red meter
excess side play, if this is suspect replace the lower
bearing and "O" ring. Failure to do so may wear the pivot.
If the rectifier cover is removed, it must be totally
resealed before returning the Pacific to service.
Multimeter Setting
Lead Position Diode Test
Red to
upper holder
No Reading or Many
Megohms*
OK
Reading or Low
resistance
US
Black to
upper holder
12V
(2 diode
or Markedly
less*
OK
No Reading or High
Resistance
US
Ohms x 100 Range
Figure 10. Pacific 100 Internal Wiring

14
d) Faulty stator. Check AC input to rectifiers or check
for coil continuity and isolation from the case.
The resistance should be less than two Ohms per 12 volt
stator (approx. 4 times this for 24 volt stator)
Note. Do not attempt to modify a 12V machine to 24V.
Whilst at first sight this may appear possible by
connecting the outputs of the stators in series, greatly
reduced output will be encountered since they are not in
phase. A 24V machine with 24V windings is available.
ALTERNATOR SECTION
Referring to figure 8, undo the two M8 x 25 screws on the
front of the Pacific and pull the nose piece away from the
main body. Do this very carefully as it cannot be
withdrawn far due to the front stator wiring connection.
The shaft and bearings are located using Loctite anaerobic
adhesives so some force may be necessary to part them. A
puller may have to be improvised to do this.
This job should be done on a suitable work bench.
The rear bearing needs a bearing puller to remove it, if no
puller is available, a dummy shaft may be fixed in the
bearing centre using epoxy adhesive and, when cured, the
bearing worked loose. The front bearing may be drifted
out following removal of the seal and circlip.
Prior to re-assembly, the bearing housings, the bearing
inner and outer surfaces and the shaft
surfaces should all be thoroughly cleaned and de-greased.
When re-assembling use adhesives as follows:-
Stator to body - Loctite 648
Bearings to body - Loctite 641
Shaft to bearings - Loctite 641
When replacing the fore-body, make sure that the "O" ring
is in place and well smeared with silicone grease.
Assemble the body checking that the wiring to the front
stator cannot touch the rotor. Ensure that the timing marks
on the body junction line coincide.
If the "cogging" or break out torque has been correctly
minimised, 12 minor, equal "lumps" of resistance per
revolution will be felt when turning the shaft by hand.
This resistance should not exceed 2kg-cm (30oz-in).
When doing this make sure that the output leads are not
shorted together.
STATOR/ROTOR REPLACEMENT
This is normally a factory operation. Rotor damage is
unlikely, but sometimes occurs due to corrosion or other
mechanical problems. Considerable force is necessary to
break the adhesive bond between the rotor and shaft and a
bearing press with guide tools to protect the shaft is
needed.
Rotor/shaft assemblies can be returned for replacement.
Stator failure only normally occurs due to salt water
immersion. Any accident causing this necessitates the
immediate cleaning of all parts with fresh water and then
drying thoroughly. Leaving to dry naturally causes the loss
of stator winding insulation due to salt corrosion resulting
in electrical leakage and shorted turns.
Stator replacement involves baking in an oven to break
adhesive bonds prior to drifting out the old stators,
thoroughly cleaning the castings and replacement fitting
and wiring. Full workshop facilities are needed for this.
RECOMMENDED SPARES
To cater for the possibility of accidental damage, it is
suggested that a spare pair of blades be carried.
Other spares worth considering are:-
Shaft seal - Replacement may be required after
1 - 2 years use.
Pivot seal - Replacement may be required after
several years.
Pivot lower bearing- Replacement may be required after
several years.
Brush set - In case of loss during servicing.
2 bearings - Unlikely to be required but an
insurance policy
Rectifier assembly - Unlikely to be required unless
polarity is accidentally reversed,
however, another insurance policy.
WARRANTY
The Ampair Pacific 100 is warranted for one year from
the date of purchase.
Any faulty part will be replaced free of charge and any
faulty workmanship will be rectified free of charge upon
prepaid return of a unit to Ampair or any authorised
agents. The unit will then be returned to the customer free
of charge.
This warranty does not cover mishandling, accidental
damage or faulty installation. Nor can Ampair or its
authorised agents be liable for any consequential damage.
Ampair will, nevertheless, go to considerable lengths to
ensure customer satisfaction and fully appreciate the
problems of those in far away places.
SERVICING & REPAIRS
Ampair Pacific 100’s may be returned to: -
AMPAIR
Park Farm, Warfield, Berkshire RG42 5RH, UK
Tel: [phone] Fax: [phone]
e-mail [email protected] www.ampair.com
© This Manual is the Copyright of Ampair Jan. 2001