Coleman 600 Watt WIND TURBINE User manual

600 Watt WIND TURBINE
User’s Manual

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Congratulations on your Coleman® wind product purchase. This product is designed to the highest
technical specifications and standards. It will supply years of maintenance free use. Please read
these instructions thoroughly prior to installation, then store in a safe place for future reference. If at
any time you are unclear about this product, or require further assistance please do not hesitate to
contact our trained professionals operating the customer support line 1-888-478-6435 or email to
[email protected]
1. SAFETY
Your 600 Watt Wind Turbine is designed with your personal safety as the first priority. However,
there are still some inherent dangers involved with any electrical and/or mechanical equipment.
Safety must be the primary concern as you plan the location, installation and operation of the
turbine. Please read the following:
Important Safety Instructions
Please take the time to read through this manual prior to assembly.
1) Place this instruction manual in a safe place for reference.
2) Wait until a calm day to install or perform maintenance on your Turbine.
3) Listen to your Turbine. Should you hear any mechanical noise, maintenance
may be required. Please contact Sunforce Products Customer Service.
4) After installation re-adjust and tighten the screws and bolts.
5) Adhere to proper grounding techniques as established by the NEC.
6) Your Wind Turbine must be installed in accordance with this manual and local and
national building code. Incorrect installation may void your warranty.
7) Wind turbine blades spin at a potentially dangerous speed.
Never approach a turbine in motion.
8) Note wire size (gauge chart included) prior to wiring. Any under sizing of wire can be
potentially dangerous.
1.1 Mechanical Hazard
Rotating blades present the most serious mechanical hazard. The rotor blades are made of very
strong thermoplastic. At the tip, the blades may be moving at velocities over 15m/s. At this speed,
the tip of a blade is nearly invisible and can cause serious injury. Under no circumstances should
you install the turbine where a person could come in contact with moving rotor blades.
1.2 Electrical Hazard
The 600W Turbine is equipped with sophisticated electronics designed to provide protection from
electrical dangers. Please note that the inherent personal dangers from electrical current still
exist, therefore caution should always be used when connecting this and other electrical devices.

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Heat in a wiring system is often a result of too much current flowing through an undersized wire
or through a bad connection. Please consult wire guide table below.
Batteries can deliver a dangerous amount of current. If a short circuit occurs in the wiring from
the batteries, a fire can result. In order to avoid this threat, a properly sized fuse or circuit breaker
is required in the lines connecting to the battery.
Choosing your 600 Watt Wind Turbine’s location
Prior to the mounting of your 600 Watt Wind Turbine, you must carefully consider a location.
Things to consider when choosing your location:
A) Distance from any obstacles (trees, buildings, etc.) that will cause turbulence.
B) Distance from MPPT controller and battery bank.
C) Any local zoning restrictions.
D) Clearance of power lines.
In general terms, the higher the tower the less obstruction to air flow, leading to a more efficient
chare capacity. The minimum recommended tower height is 30 ft or 20 ft above nearby
obstructions as shown below.

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2. MODEL AND SPECIFICATION TABLE
2.1 Specification Table
Model
600W Turbine
Related speed
12.5 m/s (41 ft/s)
Related power
600 W #
Voltage with MPPT
12 or 24 V ##
Rotor diameter
0.65 m (2.1 ft)
Cut-in wind speed
4.5 MPH
Survival wind speed
157 MPH
Number of Blades
3
Blade material
Fiber glass
Suggested battery capacity
>100 A/Hr
2.2 Performance specifications
The following power curve shows the performance you should expect from your wind turbine.
During smooth, steady wind speed, you can expect to see output resembling the curve
illustrated below. To convert between power and current, use the following formula:
POWER = VOLTAGE ×AMPS

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3. Digital-controlled MPPT Wind Power Charger
Please see included Manual for your MPPT Charge Controller.
MCU fully digital-controlled MPPT wind power charger.
SEPIC conversion, large DC input voltage range.
Smart load management function, braking function.
Rated Output Power :
600W Max.
Battery Voltage Range:
12V or 24V DC
Input Voltage Range
5~75 Vrms
Charger Efficiency:
>87%
Battery Protection Voltage:
12V - 14.4V(Lead-acid batteries) or
15.8V(deep-cycle Battery)
24V - 28.8V (Lead-acid batteries)
or 30V (Deep-cycle batteries)
Rated Load Current:
35A Max.
Over-Speed Braking:
≦1400 rpm
Caution: Please review the following wire gauge table to install the correct wire gauge. We
recommend these as the minimum wire sizes for optimal performance. Always use the largest
gauge wires that are practical and affordable. Local, state, and or national electrical codes take
precedence over these general recommendations.
System protection (see also included manual)
Your MPPT charge controller comes equipped with state of the art overcharge protection.
Temperature of the internal circuitry is moderated by an internal fan that is activated at 45

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C(110F). When the temperature of the MPPT exceeds 65C(150F) the MPPT will automatically
shut down and apply the braking system to your Wind Turbine to prevent damage.
3.1 System wiring diagrams
There are multiple options to connect your Wind Turbine dependant on your power requirements
and available components.
Single Turbine installation:

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Multiple Turbine installation:

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Hybrid Solar/Wind System
A typical “hybrid” system (Photovoltaic and Wind combined) is wired as follows. Whenever
feasible wire the turbine and solar panels to their own set of battery terminals.

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4. PACKAGE CONTENTS
Check the parts listed with the contents of the box and make sure that you have everything
needed for assembly.
Figure 1
Caution: The edges of the blades are sharp. Please handle with care.
Name
Quantity
Turbine
1
Blades
3
MPPT Charge Controller
1
Hub
1
Vertical Tail
1
Nose Cone
1
Amp Meter
1
Nut (M14xP2.0)
1
Hex Screw(M6xL30)
6
Nut (M6)
6
Hex Screw (M5xL12)
1

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Spring Washer (M14)
1
Stop Screw (M5xL20)
1
Hex Sleeve
1
Hex Key no.5
1
Hex Key No.3
1
Rubber Spacer
1
Hex Screw (M5xL20)
4
Screw Pack
Washer (M5)
4
Nut (M14xP2.0)
1
Hex Screw (M6xL30)
6
Nut (M6)
6
Hex Screw (M5xL12)
1
Spring Washer (M14)
1
Rubber Spacer
1
Hex Screw (M5xL20)
4
Washer (M5)
4
Replacement
Screw Pack
Stop Screw (M5xL20)
1
5. INSTALLATION PROCEDURE
Step 1: Open box to ensure all parts are present, remove the hub from the box.
Figure 2

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Step 2: Fasten the blades on the hub with the nuts.
Figure 3
Figure 4
Caution: Make sure that all of the bolts are secured with nuts.
Step 3: How to install the hub.
Figure 5

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Adhesive strip should be wrapped around your Tower (tower not included) to
increase secure connection to the Yaw shaft.
Step 4: Remove wind turbine from the box and put the cables through the mast.
Figure 6
Step 5: To install the wind turbine to your chosen tower (tower not included) securely fasten the
bolt by using the hex wrench.
Figure 7

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Step 6: Install the hub on the wind turbine using the M14 nut and spring washer.
Figure 8 Figure 9
Caution: Make sure the nut is secured with the spring washer.
Step 7: Put the sleeve inside the nose cone and fasten the nose cone to the hub. Apply pressure
to the connections to ensure a secure fit.
Figure 10 Figure 11
Figure 12

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Step 8: Tail Fin assembly. Use the four supplied HEX screws, to firmly connect the Tail Fin to the
hub.
Figure 13
Step 9: Final product diagram.
Figure 14

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6. MAINTENANCE
Your 600 Watt Wind Turbine has been designed to run for long periods without requiring any
maintenance. Performance will be enhanced if you periodically inspect your system. Review the
following simple maintenance procedures and implement every six months.
Caution: Do not go near the wind turbine during operation.
Caution: The blades are sharp. Please handle with care.
• Check blades for superficial damage. Replace blades if damaged. It is important to not use
blades that are damaged, as you will lose overall balance, resulting in decrease in efficiency.
Should you notice damage to the blades you must replace all 3. The blades are balanced as
sets.
• Check the blade bolts and the hub nut for tightness.
• Check nosecone for cracks and tighten nuts.
• Wipe any excess dirt build-up from the blades.
• Check all electrical connections to make sure they are tight and free from corrosion.
• Check the voltage of your battery bank with a multi-meter and clean the terminals.
• We suggest replacing the blades every five years for optimal performance.
7. FAQS
How does the 600 Watt Wind Turbine control power and RPM in high winds?
Your Turbine’s operation will be halted to reduce the risk of damage due to overcharge and over
spin of the rotor blades. This process of braking is handled internally through your Turbines
electronics.
What is the maximum wind speed the 600 Watt Wind Turbine will survive and do I need to
take it down in a storm?
Your wind turbine is designed to operate in most climatic conditions. Should you expect or
experience winds of 150MPH upwards, please turn off the MPPT controller which will manually
apply the braking system to protect from any over spin. Once the Turbine has stopped, it is
possible to lay down the Tower to offer further protection.
How long will the bearings or other wearing parts last?
According to engineering calculations, the bearings should have a 10-year life span in 12 mph (6
m/s) average wind speed sites. Bearing life will vary from one application to another; however,
you should expect at least a five-year performance in adverse conditions and 10 years in normal
conditions.

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Can the 600 Watt Wind Turbine be connected in reverse-polarity to the battery without
causing any damage?
Reverse polarity will cause damage to both your MPPT controller and battery if not quickly
remedied. Always double check any wiring to reduce the risk of reverse polarity. Your turbine is
equipped with polarity protection to reduce the risk of damage, but it is still possible to degrade
your wiring and cause damage to the overall system.
Will it hurt my 600 Watt Wind Turbine to short-circuit the output?
No, the 600 Watt Wind Turbine is designed to be short-circuited as a normal shutdown
procedure by a fuse. The function of the stop switch is to both disconnect the turbine from the
batteries as well as short-circuit the output of the turbine.
Where can I locate tubing to make a tower?
Your 600 Watt Wind Turbine is designed to make mounting as simple and straightforward as
possible. Should you not wish to purchase the custom tower kit feel free to utilize schedule 40
1.5 inch steel tubing. This should be available through your local hardware outlet.
What is the difference between copper and aluminum wire?
Generally aluminum wire is less conductive, so it must be bigger for the same amp load and
resistive losses as copper. The 600 Watt Wind Turbine uses copper or tinned copper for the yaw
wires.
What battery should I choose for my 600 Watt Wind Turbine?
There are multiple battery options in today’s market– flooded lead acid, absorbed Glass mat
(AGM), gel cell and NiCad. There is no definitive choice for your alternative energy needs.
Normally the choice of battery is determined by availability and pricing. Should you have
questions regarding batteries please consult a local battery supplier. Or view:
www.batterycouncil.org. The capacity of your battery bank is determined by your use. Below is a
good guideline.
• 12-volt systems – 400 Amp-hours
• 24-volt systems – 200 Amp-hours

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Possible Battery Configurations (suggested)
Is lightning protection necessary?
You should ground your 600 Watt Wind Turbine. Proper grounding (illustrated below) provides
protection to individuals and equipment by eliminating the possibility of dangerous voltage.
Remember, a steel tower is a conduit for lightning.
Every wind turbine and turbine tower needs to be grounded at the tower base

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even though the system may be grounded at the battery bank. Grounding the tower at its base
may help prevent shocks to persons touching the tower due to lightning or electrical faults.
Please take the time to review the National Electrical Code (NEC) and local
building and zoning regulations for complete requirements. Even in “Off Grid Systems”
There are multiple ways for tower grounding., The most common method is a copper clad steel
electrode(s) driven into the soil. Please view the following grounding diagram.
What effect does radio interference have on my 600 Watt Wind Turbine?
The internal circuitry of the 600 Watt Wind Turbine is shielded and filtered to prevent radio
interference, and has been tested to insure electro-magnetic compatibility.
What effect does my 600 Watt Wind Turbine have on radio transmissions?
The 600 Watt Wind Turbine normally does not affect radio transmitters. Care should be taken,
however, to route power lines from the 600 Watt Wind Turbine away from the power and antenna
lines of a radio transmitter. An old ham radio operator’s trick is to twist positive and negative
wires together to provide an even distribution of EMF noise across both wires, which serves to
cancel out the electrical noise created. This technique can be used on the 600 Watt Wind
Turbine power lines, on the radio’s power lines, and on transmission wires. Transmission lines

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should always be kept as far from power lines as is practically possible. Proper grounding of the
Turbine and other system components must also be observed.
Will it affect the regulation of my 600 Watt Wind Turbine to install an RF (radio frequency)
filter?
An RF filter should not affect the regulation of the Turbine, but any electronic devices placed in
line with the turbine must be rated for the proper current and voltage. It is best to place any line
filters on the power lines for the load device that requires it, and as close to the device as
possible.
Trouble shooting
You may require an extra person to assist with these tests.
1) Remove the blade/hub from the turbine. Replace the rotor hub nut on the rotor shaft.
2) Quickly spin the rotor shaft manually with your fingers while connecting and disconnecting
the red and black wires (turbine must not be connected to batteries).
3) With the red and black wires connected to each other, the shaft should be more difficult to
turn. When the wires are disconnected it should spin freely. Should this not be true please
contact supplier or Sunforce Products.
4) With your 600 Watt Wind Turbine connected to your battery bank, use an electric hand drill to
spin the rotor shaft.
5) Below 500 RPM, the rotor should spin freely without friction.
6) At 500 RPM and above, the Wind Turbine should be charging the battery. You should feel
resistance on the rotor shaft. If the shaft is not rotating, contact your turbine dealer or
Sunforce Products. Be aware your battery banks need to be under 12V or 24V for this testing
as the Turbine needs to read a charge.
WARRANTY
Sunforce Products warrants your product to be free from defects in material and/or workmanship for a period
of 5 years from original date of purchase. Warranty coverage is extended only to customer (original purchaser).
If product proves defective during warranty period, Sunforce Products, at its option will:
1. Replace wind turbine with new or a refurbished product.
2. Correct reported problem
Customers warranty continues to be valid on repaired or replaced product from original warranty date.
Restrictions
This warranty covers defects in manufacturing discovered while using the product as recommended by the
manufacturer. The warranty does not apply to a) equipments, materials, or supplies not manufactured by
Sunforce Products. b) Product that has been modified or altered other than by Sunforce Products or without

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prior Sunforce Products approval. c) Has been exposed to winds exceeding 157mph d) Windstorms, lightning
and Hail damage e) Repairs performed by other than authorized Sunforce Products support staff. f) All acts
of God; misuse, negligence or accidents. g) Tower foundation and wire h) has not been installed, operated,
repaired or maintained in accordance with the instructions supplied by manufacturer. Any service identified in
the above list or product is found not to have any defect in manufacturers’ workmanship or materials the
customer will be responsible for the costs of all repairs and expenses incurred by Sunforce Products.
Disclaimer
EXCEPT FOR THE EXPRESSED WARRANTY SET FORTH ABOVE, THE MANUFACTURER
DISCLAIMS ALL OTHER EXPRESSED AND IMPLIED WARRANTIES, INCLUDING THE
IMPLIED WARRANTIES OR FITNESS FOR A PARTICULAR PURPOSE, MERCHANTABILITY
AND NON-INFRINGEMENT. NO OTHER WARRANTY, EXPRESSED OR IMPLIED, WHETHER
OR NOT SIMILAR IN NATURE TO ANY OTHER WARRANTY PROVIDED HEREIN, SHALL
EXIST WITH RESPECT TO THE PRODUCT SOLD UNDER THE PROVISIONS OF THESE
TERMS AND CONDITIONS. THE MANUFACTURER EXPRESSLY DISCLAIMS ALL LIABILITY
FOR BODILY INJURIES OR DEATH THAT MAY OCCUR, DIRECTLY OR INDIRECTLY, BY USE
OF THE PRODUCT BY ANY PERSON. ALL OTHER WARRANTIES ARE EXPRESSLY WAIVED
BY THE CUSTOMER.
Warranty Claims & Return Policies
To be eligible for service under this warranty, customer must either contact manufacturer either through
written request or by telephone to submit a service request for the wind turbine covered by this warranty
within specified period (5 years from original date of purchase) and request a return authorization (RA)
number, This RA # must be issued before any product can be returned.
All notifications must include the following information:
a) Description of alleged defect
b) How the wind turbine was being used
c) Serial #
d) The original purchase date
e) Name, phone #, address of party requesting warranty
Within 2 to 3 business days Sunforce Products will provide the customer with an RA# and will direct customer
to location where the product is to be returned. Once an RA# has been issued the customer has 30 days to
return the product. Failure to deliver the product within the 30 days results in the RA# no longer being valid
and a new RA# must be issued. Manufacturer is under no obligation to accept any product that is returned to
them without a proper RA #.