Ampair 300 Manual

Date: 02 Feb 2011
Ampair ® 300 (Mk1, “Pacific”) Wind Turbine Manual
CD 2300
Issue: 1.2
Page 1 of 34
- 1 - © Ampair, April 2007
Ampair ® 300 Wind Turbine
Operation & Maintenance Manual

Date: 02 Feb 2011
Ampair ® 300 (Mk1, “Pacific”) Wind Turbine Manual
CD 2300
Issue: 1.2
Page 2 of 34
- 2 - © Ampair, April 2007
1INTRODUCTION.................................................................................................................................... 3
1.1 Labelling ........................................................................................................................................... 3
1.2 Applications ...................................................................................................................................... 3
2SAFETY INSTRUCTIONS ..................................................................................................................... 4
2.1 Disclaimer:........................................................................................................................................ 4
2.2 Potential sources of danger.............................................................................................................. 4
3TECHNICAL CHARACTERISTICS........................................................................................................ 7
3.1 Required space ................................................................................................................................ 7
3.2 Technical data .................................................................................................................................. 7
3.3 System description ........................................................................................................................... 8
4INSTALLATION...................................................................................................................................... 9
4.1 Installation sequence........................................................................................................................ 9
4.2 Wind turbine packing list................................................................................................................. 10
4.3Accessories packing lists................................................................................................................ 11
4.4 Tools ............................................................................................................................................... 12
4.5 Choosing a mounting...................................................................................................................... 13
4.6 Electrical installation ....................................................................................................................... 16
4.7 Electrical components .................................................................................................................... 19
4.8 Final assembly................................................................................................................................ 23
5OPERATION & PERFORMANCE........................................................................................................ 25
5.1 Starting and stopping...................................................................................................................... 25
5.2 Performance ................................................................................................................................... 26
6INSPECTION & MAINTENANCE......................................................................................................... 27
6.1 Major disassembly.......................................................................................................................... 27
6.2 Drawings and component list ......................................................................................................... 31
6.3 Recommended spares ................................................................................................................... 33
7WARRANTY......................................................................................................................................... 33
8SERVICING, 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.
All specifications are subject to change without notice.
Wind turbines, electrical power and battery systems, and wind turbine mounting systems are all capable of
causing death or serious injury or fire if incorrectly installed, operated, or maintained. If in doubt, ensure
that all activities are carried out by trained and competent personnel.

Date: 02 Feb 2011
Ampair ® 300 (Mk1, “Pacific”) Wind Turbine Manual
CD 2300
Issue: 1.2
Page 3 of 34
- 3 - © Ampair, April 2007
1 INTRODUCTION
Thank you for purchasing an Ampair 300 wind turbine.
Ampair has been producing high quality wind turbines for over thirty years. The Pacific 300 is designed
and manufactured to give you many years of trouble free power generation. However, as with any other
wind turbine, reliable and effective operation will depend on where it is located and how it is assembled
and connected. Periodic inspection and maintenance is required. Furthermore there are safety hazards
associated with all wind turbines and this is why we ask that you read this manual carefully.
1.1 Labelling
This manual applies to the Ampair 300 manufactured by Ampair.
Ampair Energy Ltd
Unit 2 Milborne Business Centre, Blandford Hill
Milborne St Andrew, BLandford Forum, Dorset, DT11 0HZ
UK
Tel. [phone]
Fax. [phone]
Internet www.ampair.com
Email [e-mail]
Ampair™ is a business of Boost Energy Systems Ltd, manufacturers of distributed energy systems for fifty
years. Ampair™ and PowerFurl™ are trademarks of Ampair and Boost Energy Systems Ltd.
The label with the model type and nominal voltage
is on the electrical box cover where the name
Ampair is shortened to AMPAIR.
The serial number of the wind turbine is stamped
on the lower left side of the main body casting on
the outside of the tail fin flange.
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.
For over thirty years wind turbines manufactured by Ampair have powered a wide variety of locations
including sailing yachts; remote houses; medical facilities; holiday homes; emergency shelters;
navigational aids; scientific and environmental monitoring stations; telecommunications systems; cathodic
protection systems; remote industrial locations; caravans and mobile homes; and increasingly are being
used to decrease dependence on centrally generated electricity in grid-connected homes, offices, and
commercial property.

Date: 02 Feb 2011
Ampair ® 300 (Mk1, “Pacific”) Wind Turbine Manual
CD 2300
Issue: 1.2
Page 4 of 34
- 4 - © Ampair, April 2007
Ampair recommends that most clients install wind turbines in combination with a proportionate amount of
solar photovoltaic panels (solar PV) as wind and solar power are highly complementary sources of
renewable, carbon neutral, non-polluting energy.
2 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.
2.1 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.
All specifications are subject to change without notice.
Wind turbines, electrical power and battery systems, and wind turbine mounting systems are all capable of
causing death or serious injury or fire if incorrectly installed, operated, or maintained. If in doubt, ensure
that all activities are carried out by trained and competent personnel.
2.2 Potential sources of danger
Wind turbines are electrical machines with high speed rotating parts which are typically mounted at height.
Thus there are a variety of sources of potential hazards which can result in death or serious injury. These
dangers exist during installation, operation, or inspection and maintenance.
2.2.1 Mechanical dangers
The main dangers are the spinning rotor and the tail. The rotor blades are very sharp and can cause very
serious injuries even at low speeds.
WARNING:
Never touch the rotating rotor (the blades or hub).
Never try to stop the rotor by hand.
Do not mount the rotor where people or animals can reach the area swept by the rotor.
The rotor blades are made of glass fibre reinforced plastic and other composites. They are extremely
strong and are designed to withstand severe weather. However the blades may break if objects (e.g.
ropes, branches, clothing, flying ice, other debris) enter the rotor. If this happens the rotor will discharge
very sharp fragments of blade and debris at high speed. Also any items that become tangled in the rotor
(such as ropes) will whip around unpredictably and with great force.
WARNING:
Avoid any objects entering the rotor.
Never try to stop the rotor by throwing a rope or other object into it.
In order to maximise aerodynamic efficiency and to minimise sound levels the rotor blades‟ trailing edges
are very sharp. Handle these carefully and use gloves if necessary.
WARNING:
Use gloves when handling the rotor and blades.
The wind turbine is free to swivel about the pivot. This means that even when the rotor is stationary it can
swivel and the tail (or rotor) may hit anybody who has approached the machine. The machine will not
make a noise as it swivels and such a blow can be with great force and little warning (especially in gusty

Date: 02 Feb 2011
Ampair ® 300 (Mk1, “Pacific”) Wind Turbine Manual
CD 2300
Issue: 1.2
Page 5 of 34
- 5 - © Ampair, April 2007
wind conditions and/or on a boat). It will swivel extremely unpredictably if the rotor is fitted but the tail is
not fitted.
WARNING:
Prevent the machine swivelling before entering the radius of the tail and rotor.
Wear a safety helmet before entering the radius of the tail and rotor.
2.2.2 Electrical dangers
The generator can produce open circuit voltages of up to 60 volts ACrms (12 volt version) and 120 volts
ACrms (24 volt version) in the wiring run between the turbine and rectifier. This is in no load operation with
the stop switch in the „on‟ position and at a wind speed of approximately 30 miles per hour (approximately
15 metres per second).
WARNING:
Avoid handling bare open circuit wiring tails unless the rotor is physically stopped.
The charging current can reach up to 25 amps DC (12 volt version) and 12.5 amps DC (24 volt version) in
the wiring run between the rectifier and the battery (or load).
WARNING:
Install cables with sufficient cross sectional area of conductor. Inadequately sized cables
can rapidly overheat and create a fire hazard.
Install electrical components of sufficient voltage and current capacity at all points in the
circuit.
The battery must never be short circuited as the fault current is extremely high. If you do so there is a
serious risk that you will set the battery and cabling on fire, as well as releasing flammable and potentially
explosive gases (hydrogen) from the battery, and you will probably destroy the battery.
WARNING:
Never short circuit the battery.
Install fuses immediately adjacent to the wind turbine side of the battery (but not within
the battery compartment as the spark from a blowing fuse could ignite an explosive
hydrogen/air mixture).
Charging lead acid batteries releases flammable and potentially explosive hydrogen gas. Unsealed lead
acid batteries have vent caps to release this gas, which can detonate if it is mixed with air and a spark is
present (e.g. from a switch or a blowing fuse) or other ignition source (e.g. naked flame or hot surface
such as an exhaust).
WARNING:
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. They must not be mounted on flammable surfaces.
WARNING:
Do not install dump regulators on or near flammable materials.
2.2.3 Dangers when mounting the wind turbine or working at height
Very careful attention must be given to the strength and integrity of the mounting. As a minimum this
should be capable of withstanding a peak horizontal load of 50 kg (100 lbs). If mounting the wind turbine

Date: 02 Feb 2011
Ampair ® 300 (Mk1, “Pacific”) Wind Turbine Manual
CD 2300
Issue: 1.2
Page 6 of 34
- 6 - © Ampair, April 2007
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.
WARNING:
Only use adequately designed mounting systems.
A fall from the height at which a wind turbine is ordinarily mounted will often result in death or serious
injury. Therefore whenever practicable carry out as much work as possible on the wind turbine at deck or
ground level. If it is necessary to work on an installed wind turbine then use an appropriate access system
such as a mast that is designed to carry the load of a person; a „man-rated‟ winch or rope access system;
a hydraulic lift or other safe working platform. Wear appropriate safety equipment and make the general
working area as a tidy and safe as possible. If possible work during daylight on windless days (and in calm
seas if on a boat). Above all else think carefully about what you need to do and plan your work carefully,
have all the tools and equipment ready before you start, then brief all the members of the work team
thoroughly –including the actions in the event of an accident and/or injury.
WARNING:
Whenever possible work on the ground or deck, not at a height.
Use safety harnesses, safety helmets, and safety slings, etc.
Use „man-rated‟ lifting equipment and access systems
Work in daylight, on windless days (and in calm seas).
Keep the work area clear, plan your work, have your entire equipment ready, and brief
the team before starting the job.
Falling objects are potentially fatal. Do not step underneath hanging loads or folding/tilted masts. Make
sure that onlookers are kept back beyond the collapse radius of any masts. Ensure that any suspended
objects or tools are secured (e.g. by safety lanyards). Prevent onlookers from approaching (e.g. erect a
safety barrier and warning signs).
WARNING:
Secure any objects that might fall.
Do not go underneath hanging loads and the work area; wear safety helmets.
Keep onlookers at a safe distance.
When working on the wind turbine, especially when working at height, it is important to make sure it is first
electrically safe. Therefore prevent it generating (use the stop switch, turn it out of wind, and/or tie one of
the rotor blades to the mounting system or mast) and disconnect it from the battery system.
WARNING:
Disconnect all batteries and other power sources.
Prevent the generator from unintended starting.
Never approach the running rotor.

Date: 02 Feb 2011
Ampair ® 300 (Mk1, “Pacific”) Wind Turbine Manual
CD 2300
Issue: 1.2
Page 7 of 34
- 7 - © Ampair, April 2007
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
300 Watts
Rated wind speed for nominal power
12.6 metres per second
(25 knots, or 29 miles per hour)
Cut in wind speed
3 metres per second
(6 knots, or 6.9 miles per hour)
Thermal cut out
None
Survival wind speed
Storm proof
Rotor diameter
1.2 metre
Number of blades
3
Blade material
Glass reinforced polyester (GRP)

Date: 02 Feb 2011
Ampair ® 300 (Mk1, “Pacific”) Wind Turbine Manual
CD 2300
Issue: 1.2
Page 8 of 34
- 8 - © Ampair, April 2007
Rotor speed
500-1400 rpm
Generator type
Permanent magnet, three phase with external rectifier
(rare earth neodymium magnets)
Nominal voltage
12 volt DC or 24 volt DC
Speed regulation
Blade pitch control above 13 metres per second
(27 knots, 30 miles per hour)
Power regulation
Blade pitch control above 13 metres per second
Brake
Generator short circuit (optional 'stop' switch)
Weight
12 kg
Housing
Die cast aluminium (powder coated)
Colour
White with red hub (other colours available on request)
Rotor thrust (at 20 metres per second)
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.
3.3.1 The generator
The unit consists of a two part cast aluminium body, the two parts sealed by an "O" ring. One twelve pole
permanent magnet rotor runs on a stainless steel shaft. The shaft runs in two sealed grease-packed ball
bearings. One three phase stator is located within the body.
The three phase alternating current output of the stator passes to three carbon brushes mounted in brush
holders located behind the lower body section, accessible through the electrical cover plate. The carbon
brushes carry the output to three brass slip rings mounted on the stationary pivot shaft, allowing the
machine to rotate to follow the wind. The output is electrically isolated from the case.
The body is mounted on the pivot shaft where it runs on sealed grease packed ball bearings 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 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, and to allow the wind turbine to be
used on small boats.
The rotor disc and hub together make up the unique PowerFurl™ furling mechanism. The three cambered
and twisted glass reinforced polyester (GRP) moulded blades have been designed to be perfectly
balanced and aerodynamically and acoustically efficient. They are mounted on an aluminium hub (shaped
like a nose cone). The purpose of the PowerFurl™ furling mechanism is to simultaneously twist all three
blades along their axis when the wind speed becomes excessive, whilst still keeping the wind turbine
facing into the wind and generating power. The three special pitching weights form an integral part of the
PowerFurl™ mechanism. The hub is fitted to the generator shaft by an M10 cap screw.
The blades have a relatively broad root section to enable them to start up in low wind speeds. This is
important as for much of the time the wind only blows at low speeds. The blades are of a rigid construction
to minimise pulsating aerodynamic noise caused by blade deflection (fluttering)
An aluminium alloy tail vane is clamped to the rear of the generator body using three M8 x 25mm stainless
steel screws, six plain washers and three lock nuts. The tail vane 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 (e.g. using a
boat hook).
All Ampair 300 units are constructed of marine grade materials. All aluminium parts are alacromed and
powder coated inside and out, or anodised. All other parts are stainless steel or composite, except for
elastomers.

Date: 02 Feb 2011
Ampair ® 300 (Mk1, “Pacific”) Wind Turbine Manual
CD 2300
Issue: 1.2
Page 9 of 34
- 9 - © Ampair, April 2007
3.3.1.1 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. Ampair‟s glass filled
polyester blades 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. For this reason Ampair uses Neoprene components where possible and
"Arctic" grade PVC cables. Grease used in sealed bearings allows performance to –30°C or below, but
component tolerances (ball and ring) can lead to greater friction and increased wear causing reduced
bearing life.
3.3.2 The rectifier
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. The rectifier is a three way bridge rectifier mounted on a heat sink.
3.3.3 Other system components
The basic wind turbine package only consists of the generator and rectifier. The other components which
can be linked together in a modular manner are described elsewhere in this manual.
4 INSTALLATION
4.1 Installation sequence
A lot of problems can be prevented if the following sequence is adhered to:
1. First check that your order is complete and undamaged, and that you have received the correct
voltage generator (12 or 24 volt). See the packing lists below to assist in this.
2. Gather your tool kit. See tool list below.
3. Plan your installation. See guidance notes below.
4. Mechanically install the mounting system.
5. Run the electrical wiring and mechanically mount any accessories (including the rectifiers on
their heatsink) but do not connect to the batteries.
6. Mechanically install the wind turbine generator, and then electrically connect it.
7. Connect to the batteries.
8. Check correct operation & installation.

Date: 02 Feb 2011
Ampair ® 300 (Mk1, “Pacific”) Wind Turbine Manual
CD 2300
Issue: 1.2
Page 10 of 34
- 10 - © Ampair, April 2007
4.2 Wind turbine packing list
The Pacific 300 Wind Turbine is packaged in recyclable cardboard cartons. The cartons contain: