Leading Edge LE-450 Original operating instructions

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LE-450 Turbine
Installation & Operation Guide
1m Diameter Micro Wind Turbine for generating clean and renewable
electricity anywhere the wind blows…
Leading Edge Turbines Ltd

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Page 2 of 47
Contents
Contents......................................................................................................................2
Read this first ..............................................................................................................3
Introduction ................................................................................................................4
Safety Precautions ......................................................................................................5
Mechanical Safety Hazards.....................................................................................5
Electrical Safety Hazards.........................................................................................5
Specifications ..............................................................................................................6
Package Contents........................................................................................................7
Tools Required For Assembly .....................................................................................7
Mechanical Assembly Procedure................................................................................8
Electrical Installation.................................................................................................13
Fig-13: Typical ‘Hybrid’ wind /PV System wiring diagram ..................................116
Fig-14: Typical ‘Marine’ system wiring diagram ..................................................16
Turbine Operation ....................................................................................................17
Maintenance.............................................................................................................19
Post-Installation Checks (to be carried out one month after installation) ...........19
Annual Maintenance.............................................................................................19
After five years of normal operation.....................................................................19
Other Considerations ............................................................................................19
Spares........................................................................................................................20
Warranty...................................................................................................................21
Disclaimer .................................................................................................................22
Appendix 1: Tristar 45A Diversion Charge Controller relevant extracts ..................23
Appendix 2: Run / Stop Switch User Manual............................................................28
Appendix 3: System Trouble-Shooting .....................................................................42
Appendix 4: Turbine Site Selection...........................................................................46
Warranty Registration
Please register your product with us so that we can administer your warranty
entitlement.
Please register at www.leturbines.com/support/warranty-registration/
Customers are required to keep an original copy of their invoice should
questions arise requiring reference to purchase information.
15

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Page 3 of 47
Read this first
Don’t connect the wind turbine in the wrong polarity
Make sure you connect the +ve of the turbine to the +ve of the battery (red to
red) and the -ve of the turbine to the -ve of the battery (black to black). Failing
to do so will damage the equipment and invalidate your warranty.
Don’t connect the Diversion Charge Controller in series with the turbine
Always ensure that the turbine and the controller are connected to the battery
separately.
Ensure the blades are fitted in the correct orientation
Consult the diagram on page 9. Blades fitted back to front it will severely
impair power production.
Don’t allow the turbine to run without being connected to the battery
Failing to do so will result in the turbine freewheeling causing premature wear
and tear and unnatural blade noise. Failing to do so will invalidate your
warranty.
The Tristar charge controller must be configured for Diversion mode
Failing to do so will invalid your warranty as this can burn out the stator.
http://youtube.com/c/LeadingEdgeTurbines
Visit our YouTube channel for assistance in wiring up the equipment,
configuring the Tristar charge controllers and more.

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Page 4 of 47
Introduction
Please read this manual thoroughly before attempting to assemble, install or operate your LE-450
small wind turbine. This will assure optimum performance and safety.
Leading Edge Turbines has spent many years developing the ideas and technology behind your
turbine. The LE-450features an array of innovations and construction techniques as well as heavy-
duty engineering to ensure optimum efficiency and a long operating life. All of these features have
evolved from the long and successful history of the LE-300 turbine.
The LE-450 has been designed to be simple, economic, durable and yield excellent performance.
Specific LE-450turbine features:
Innovatively designed axial flux alternator, using neodymium iron boron magnets
A laser-cut aluminium chassis using 'Yaw-wing' design to ensure responsive yawing and to
reduce weight
Maintenance-free, low friction bearing in both main shaft and yaw assemblies
Extremely quiet injection moulded blades with 'Whispower' geometry and aerofoil design
Long-life yaw pivot slip-rings and wipers
Easy tower-top installation
Simple design for low cost and durability
Fully marinised using stainless steel fixings and anodised aluminium components
Low mass to help reduce exerted forces and ensure easy installation.
The LE-450has been designed for both land-based and marine environments. Thanks to its unique
design, the LE-450will minimise corrosion in both normal and salt water operating conditions.
Applications include:
Telecommunications
Security cameras
Sailboats, yachts
Remote homes / caravans
Street lighting and road signage
Complementary installation with photovoltaic modules for home power
Farm utilities (electric fencing, irrigation, etc.)
Wind-electric water pumping
Cathodic protection
Monitoring sites
The Developing World.

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Page 5 of 47
Safety Precautions
Safety must always be your primary concern during the assembly, installation and operation of your
LE-450turbine. Always be aware of the risks involved with mechanical and electrical installation
work. If in doubt about any issue regarding your turbine, please seek further assistance before
proceeding. Installation of the LE-450turbine should only be undertaken by suitably competent and
qualified personnel.
Mechanical Safety Hazards
The main rotor is the most obvious and serious mechanical safety risk. When the turbine is
operating at its rated performance, the blades will be very difficult to see, due to the
speed of rotation. Never approach the turbine whilst it is operating. Always shut down the
turbine by activating the stop switch. Ensure that the turbine is installed in a suitable
position where nobody can approach or interfere with the path of the rotor blades.
Working with tools of any kind can be dangerous. Your LE-450turbine requires some basic
mechanical assembly with rudimentary hand tools. If you are in any doubt about how to
use these tools correctly, please seek advice from a suitably experienced person.
Your LE-450turbine will inevitably be installed upon a tower or other support mount. This
may mean working at height. Always ensure that all personnel in the immediate vicinity
are aware of any lifting / hoisting operations that will be occurring. Check there are no
loose components or tools likely to fall and cause injury during the lifting operation. Where
possible, all assembly work should be completed at ground level. In the case of roof mount
brackets, a suitable fitter should carry out the installation with the appropriate equipment
for working at height.
Ensure that the batteries are disconnected during the installation procedure.
Twist the turbine output cables together (to create a short circuit) during the mechanical
installation process. This will prevent the turbine from ‘spinning up’ during the installation.
Never install the turbine upside down or in any orientation other than that depicted on the
installation instructions.
Install your turbine during a calm day.
When performing routine inspection or maintenance, always stop the turbine by activating
the stop switch.
Electrical Safety Hazards
The LE-450generates rectified DC voltage. Even at these low voltages there are inherent
risks. Caution should always be used when connecting the LE-450to the electrical system.
Be sure that you have followed the cable-sizing chart to ensure that the correct size of
transmission cable has been selected. If a cable of insufficient cross-sectional area is used,
heat may build up in the cables causing a potential fire hazard. A properly sized fuse or
circuit breaker should be used in the cables connected to the battery. This will stop the risk
of short circuit currents. Using cables of insufficient cross-sectional area may also reduce
the power transmission efficiency of the turbine.
Battery systems can deliver a serious amount of current. A short circuit in the battery
circuit can lead to hundreds of amps flowing through the battery cables. This will cause a
heat build-up and ultimately an electrical fire. Batteries can explode when shorted. Always
use insulated electrical tools when working on the battery’s electrical connections.
Batteries are very heavy. Do not attempt to move batteries by yourself. Always use manual
handling tools and an assistant.
Always keep lead-acid batteries the correct way up. Do not allow the acidic electrolyte to
spill or come into contact with your skin or face. Always follow the manufacturer’s safety
instructions when handling lead-acid batteries.
Never run the LE-450 'off-load' with the output cables not connected to anything.
Please use common sense when installing and operating your turbine!

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Page 6 of 47
Specifications
Turbine Name: LE-450
Part Number: GA-LETU-016
Nominal Voltage: 12V / 24V / 48V DC or Grid-tie optimised
Rotor Diameter: 1000 mm
Rated Wind Velocity: 8 m/s
Rated Output: 105 Watts
Max Output: 450 Watts
Start-up Wind Velocity: 2 m/s
Total weight: 8.5 Kg
Tower mount: 48.3 mm / 50 mm Outer Diameter Tube
Chassis Construction: Aluminium
Rotor Blades (5-off): Glass Reinforced Nylon
Fig-2: Operating Envelope
Fig-3: Energy Conversion
Fig-1: Overall View

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Page 7 of 47
Package Contents
Your LE-450turbine will arrive containing the components shown below. If any of the items are
missing or damaged, please contact your dealer immediately.
Tools Required For Assembly
You will require the following tools to assemble your LE-450turbine:
10 mm spanner & 10 mm ratchet (one of each required)
8 mm spanner or ratchet
A set of Metric Standard Hexagon Keys
Electrical screw drivers
Power drill
6.5 mm diameter twist drill bit, suitable for drilling through steel
Digital multi-meter capable of measuring DC Volts
Tape measure or steel rule
Thread locking compound e.g. Loctite.
Protective Gloves
LE-450 Chassis: Qty 1
Rotor Blade: Qty 5
Hub Plate: Qty 1
Nose Cone: Qty 1
User Manual: Qty 1
17 x M6 Nylock Nuts
34 x M6 Plain Washers
15 x M6 x 16 Cap Heads
11 x M5 Plain Washers
6 x M5 x2 0 Hex Heads
5 x M5 x 12 Cap Heads
2 x M6 x 70 Cap Heads
Fixings Bag: Qty 1

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Page 8 of 47
Mechanical Assembly Procedure
1) Unpacking - Inspect the contents of the box and ensure that all items are present and
undamaged. If any of the components are missing or damaged, please contact your dealer
immediately.
2) Check Magnet Rotor & Continuity - Ensure that the main shaft is free turning and does not
scrape or rub as it rotates - see Fig 4. You may feel a slight resistance from the bearings at
this stage. The bearing units used in the magnet rotor assembly are factory lubricated and
sealed for life. It will take approximately 100 hours of normal operation for the seals to
‘bed-in’ and the lubrication to be distributed correctly around the bearing raceways and
ball cages. During this period you may notice a reduced performance caused by the
additional friction of the bearing seals. In operating temperatures of –10 degrees
Centigrade or lower, this ‘bedding-in’ period will be extended by a further 50 hours of
normal operation. Connect a digital multi-meter to the positive (red) and negative (black)
output leads extending from the yaw pivot. With the multi-meter set to detect DC Volts
(0-20V approx), a voltage should be displayed when the magnet rotor is spun. This voltage
will vary with the speed of rotation. If the magnet rotor rubs, or no voltage is detected
whilst turning the magnet rotor, please contact your dealer immediately.
Warning: The magnet rotor within your LE-450turbine is constructed using neodymium iron
boron rare earth magnets. These are extremely powerful magnets and can cause injury if not
handled with respect. Take care when working with tools made of ferrous materials (such as
spanners and screwdrivers) close to the LE-450 alternator. The magnetic forces between ferrous
materials and the magnet rotor within the alternator maybe very strong. This may cause a
sudden snapping action that can pinch or trap your fingers or skin.
Fig-4: Checking magnet rotor rotation and coil-disc continuity

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Page 9 of 47
3) Rotor Blade Assembly - Take the five rotor blades and rotor hub plate. Be careful when
handling the blades, they may have sharp edges. Use a 10 mm socket & hexagon key and
three M6 x 16 mm Cap Heads to attach each blade to the hub plate - see Fig-5. Ensure that
the cap head end of the screw is on the inside of the blades (thus allowing the washers and
nuts to locate on rotor hub plate side). The blades should all be fixed to the hub plate on
the same side, with the blades in the same orientation. It is important that a washer is
used underneath the anti-vibration nuts. Three set-screws, three washers and three
anti-vibration nuts should be used on each blade. Tighten the fixings until the blades are
safely secured. Do not over-tighten the nuts as this may damage the blades and fixings.
Fig-5: Attaching the 5 rotor blades to the hub plate
4) Check the Tip Spacing - Although the turbine blades are fitted with location 'keyways', it is
important to check the tip spacing. Lay the assembled rotor blade on a flat surface. Using
a tape measure or long steel rule, ensure that the spacing between each tip is equal to
within a tolerance of +/-1.5 mm. Adjust the blades as required. Output performance may
suffer if the blades are inaccurately set - see Fig-6.
Fig-6: Checking tip spacing
Ensure distance between
each tip is equal
Nuts & Washers
on this side

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Page 10 of 47
5) Fit the Rotor Blade Assembly - The assembled rotor blades can now be fitted to the LE-450
chassis. This is done by offering the rotor hub plate against the drive shaft protruding from
the front of the chassis. M5 x 20 mm Hex Head screws should then be used to fix the rotor
hub in position using the six tapped holes in the drive shaft. Ensure that all screws are
securely tightened and that the rotor blades are fitted with the flat side of the blade facing
forwards. Thread-locking compound should be used on the screw threads.
Fig-7: Fitting the rotor blades to the chassis
6) Check the Blade Rotation - Once the blades have been fitted and secured to the chassis,
ensure that they rotate freely. Take this opportunity to check that all of the blade and hub
fixings are secure - see Fig-8.
Fig-8: Check blade rotation
Rotor Hub fixings

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Page 11 of 47
7) Fit the Nose Cone - The nose cone can now be fitted to the rotor. This is done by aligning
the five mounting holes of the nose cone with those on the rotor hub plate. Use five M5 x
12 Cap Heads and five M5 washers to secure the nose cone in position - see Fig-9.
Fig-9: Attach the nose cone
8) Prepare the Turbine Mount - If you have purchased a LE-450mount bracket or tower from
a Leading Edge Turbines’dealer, then please refer to the separate installation instructions
supplied with the product. If you have sourced your own tower / mount bracket, 6.5 mm
diameter holes will need to be drilled in order to secure the turbine. These holes should be
drilled 10 mm & 25 mm from the top of the tower / mount bracket and should be
perpendicular to the surface and skewed by 90 degrees. The holes should penetrate both
sides and cross the centre line of the tubular section - see Fig-10.
Fig-10: Drill through top of tower / mount bracket
M5 x 12 Cap
Head Screw +
M5 Washers

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Page 12 of 47
9) Install the Transmission Cables - When your tower or mount bracket is ready to receive its
turbine, the next stage is to run the cables from the top of the tower to where the
electrical controller and batteries / grid-tie inverter will be located. Follow the table below
to select the correct wire size (cross-sectional area). This will vary depending on your
nominal battery voltage and the distance that the cables will be run. Careful selection of
the cable size is required. It will not only affect the safety of the system, but also the
overall efficiency. A cable of insufficient cable size will cause a voltage drop, wasting the
power that has been generated. The cable sizes listed below have been selected with
efficiency and cost in mind, as it is unlikely that your turbine will be running at full capacity
100% of the time. If in doubt, consult your local electrical supplier. The cable should be
installed in accordance with local electrical regulations and guidelines. If in doubt, use a
local electrical contractor to complete the cable installation.
Warning: If a cable of insufficient cross-sectional area is used, heat will build up in the cables
causing a potential fire hazard. Cable capacities quoted below are based upon ‘Tri-Rated’ cables
(BS6231).
Transmission Distance
LE-450Nominal Output
Voltage
10 Metres
(30 Feet)
30 Metres
(90 Feet)
100 Metres
(300 Feet)
12 Volts
6 mm²
10 mm²
Not Recommended
24 Volts
1.5 mm²
6 mm²
16 mm²
48 Volts
1.5 mm²
2.5 mm²
4 mm²
10) Mount the LE-450 Turbine onto the Support Structure - Ensure that the previously
installed power transmission cables are not yet connected to any batteries and are
‘shorted’ together. This will prevent the turbine from operating during the installation
process. Once this has been done, connect the turbine output cables to the transmission
cables using a suitable terminal block with a minimum rating of 40 Amps. Offer the turbine
up to the support structure and push the turbine body onto the tower. Ensure that no
cables are snagged. Use the M6 x 70 Cap Heads along with two washers and an anti-
vibration nut to secure the turbine using the holes previously drilled and the hole in the
yaw pivot - see Fig-11. Ensure that M6 set-screws are securely fastened. Depending on the
exact dimension of the tower, it may be necessary to use the supplied shim plate to ensure
that the turbine is a snug fit upon the tower.
Fig-11: Fitting the turbine onto the support structure
M6 X 70 Cap Heads
Use Yaw Shim if mounting to
a 48.3mm Dia Pole

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Page 13 of 47
Electrical Installation
Please refer to Figs 12 - 14 for appropriate generic wiring diagrams. In a battery charging renewable
energy system there may be different ways of wiring small wind turbines, photovoltaic panels,
charge controllers and batteries together. This type of system will often expand ‘organically’, but
the following guidelines should be followed:
Follow the appropriate electrical code - The electrical wiring of your LE-450turbine and
associated electrical systems must be done in accordance with national and local electrical
codes and regulations.
Do not connect the turbine or batteries during the installation - Ensure that the turbine is
not running or connected to the batteries during the installation or wiring process.
Connect the output cables of the turbine together to prevent the rotor from starting up.
Galvanic corrosion of electrical joints - Try to avoid connections between dissimilar
metals. For example, connecting copper and aluminium together will result in galvanic
corrosion of the connection. This will increase the electrical resistance of the connection
(wasting energy), and reduce the mechanical integrity of the joint. Where possible, use a
fluxed solder to make electrical joints.
Protect the cables - The power transmission cables must be protected from mechanical
damage and fatigue. Run the cables through an approved conduit / trunking.
Cable strain relief - Prevent mechanical strain on the transmission cables running down
the tower from the turbine. Clip the cables to the inside of the tower. Failure to do this will
result in excessive mechanical strain on the cable joints within the slip-ring assembly and
may cause a failure. Cable ties or cable glands are a good way to prevent mechanical strain
on the cables.
‘Earth’ the system - The turbine tower should have its own separate earth point. The
negative terminal of the battery bank should also be earthed. This provides protection
against the build-up of static and lightning strikes. The tower should be earthed separately
with its own ground rod if there is a long transmission distance between the tower and
batteries. An appropriate surge arrestor could also be used to help prevent damage to the
battery charging system during a lightning strike. Ensure that the earth cables are of the
same rating as the positive and negative cables.
Cable Selection - The cable size table should be used to select the minimum sized cable for
a given transmission distance. Voltage drop in the cable will be improved if a larger cable is
used. We recommend using ‘Tri-Rated’ cable as it should comply with the wiring codes for
your area.
Fuses - The turbine and charging circuit should be protected with a suitably rated
‘slow-blow’ DC fuse or DC circuit breaker. Please refer to the table below for the minimum
fuse rating. Because a wind turbine is very unlikely to produce a current surge an in-line
fuse is only really protecting against short circuit. The fuse or breaker should be
positioned between the turbine and batteries (on the positive cable). If a stop switch is
used (recommended) the fuse should be positioned between the switch and the batteries.
LE-450 Nominal
Output Voltage
DC Fuse / DC Circuit Breaker Rating
12V
50 Amp
24V
30 Amp
48V
15 Amp

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Page 14 of 47
Run / Stop Switch - A simple switch arrangement can provide a safe and easy way of
stopping the turbine for maintenance. Leading Edge Turbines can supply a switch which is
best for this purpose. As the switch is thrown, the batteries are disconnected and the
turbine is ‘shorted’ reducing the blades to a slow rotation. Refer to the generic wiring
diagrams.
If the cables you are using don’t easily fit into the run / stop switch terminals, the cable
can be reduced to 4mm2 or 2.5mm2 before entering the run / stop switch. The cable can
then be increased again to its previous size after the switch and this will have a
negligible effect on volt drop.
Charge Controllers –We recommend Tristar controllers for hybrid wind/PV systems as this
allows you to set the regulation voltage very accurately. The Tristar should be used in
Diversion mode along with a suitable Dump load. Please see Appendix 1 for details on
wiring and configuring the Tristar diversion controller.
‘Hybrid’ Systems -The LE-450turbine can be used in parallel with PV panels. We
recommend that the PV panels are wired independently with a separate charge controller
specifically designed for use with them and connected in parallel with the battery bank -
see Fig-13. The Tristar diversion charge controller can then be configured to regulate at a
slightly higher voltage than the PV charge controller - This will prevent the charge control
systems for interfering with each other.
Installation on Yachts with shore power & engine alternator power sources- When
installed on a sailboat, the LE-450may be required to work alongside shore power systems
and engine alternators. In these cases, it is important to ensure that the Tristar charge
controller does not unintentionally ‘dump’ power from the shore power or engine
alternator. This can be prevented by ensuring that the regulation set points on the shore
power system and engine alternator are set below the regulation points of the Tristar
diversion charge controller. This means that power from the shore power system and / or
engine alternator will never be unintentionally ‘dumped’ through the dump load. If it is not
possible to set the regulation points of the shore power / engine alternator below that of
the Tristar (or similar charge controller), then the system should be wired in accordance
with Fig 14 on Page 16 and the stop switch should be activated when the engine alternator
or shore power system are in use. This will disconnect the diversion charge controller
during use of shore power / engine alternator and will prevent unintentional dumping of
power from these sources.
Please refer to the following wiring diagrams as a guide.

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Page 15 of 47
Fig-12: Typical ‘Hybrid’ wind/PV System wiring diagram
+--
+
A
LE-450
TURBINE
(PN: GA-LETU-016)
RUN / STOP
SWITCH BOX
(REQUIRED)
PN: GA-CTRL-008A
AMMETER
(OPTIONAL)
FUSE OR BREAKER
(RECOMMENDED)
BATTERY DISCONNECT
(OPTIONAL)
TRISTAR DIVERSION
CONTROLLER
(REQUIRED)
BATTERY BANK
(WIRED TO APPROPRIATE
CAPACITY & VOLTAGE)
TOWER
OR
SUPPORT
STRUCTURE
SEE RUN / STOP SWITCH
USER MANUAL FOR
DETAILED INSTRUCTIONS
EARTH GROUND
CHASSIS GROUND
CHASSIS GROUND
A
CHASSIS GROUND
PV
PANEL
ARRAY
AMMETER
(OPTIONAL)
FUSE OR BREAKER
(RECOMMENDED)
BATTERY DISCONNECT
(OPTIONAL)
DUMP LOAD
PV CHARGE
CONTROLLER

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Page 16 of 47
Fig-13: Typical ‘Marine’ system wiring diagram (Tristar disconnects when the stop switch is
activated –useful when the LE-450 turbine & Tristar controller are to be used in conjunction with
shore power and engine alternator power sources).
+--
+
-
+-
+
A
LE-450
TURBINE
(PN: GA-LETU-016)
RUN / STOP
SWITCH BOX
(REQUIRED)
PN: GA-CTRL-008A
AMMETER
(OPTIONAL)
FUSE OR BREAKER
(RECOMMENDED)
BATTERY DISCONNECT
(OPTIONAL)
BATTERY BANK
(WIRED TO APPROPRIATE
CAPACITY & VOLTAGE)
TOWER
OR
SUPPORT
STRUCTURE
SEE RUN / STOP SWITCH
USER MANUAL FOR
DETAILED INSTRUCTIONS
EARTH GROUND
CHASSIS GROUND
CHASSIS GROUND
TRISTAR DIVERSION
CONTROLLER
(REQUIRED)
DUMP LOAD

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Page 17 of 47
Turbine Operation
The LE-450turbine is based on a simple design for ease of installation and reliable operation. You
may notice the following behaviour during normal operation:
Cut-in - The turbine will not begin to charge the batteries until the rotor is spinning at
approximately 300 RPM. Whilst operating below this speed, the turbine will be ‘off-load’
and freewheeling. Once the turbine output voltage becomes equal to the nominal battery
voltage (at around 300 RPM), the turbine will come ‘on-load’ and begin to deliver current
to the batteries. During the off-load stages of rotation, the rotor blades rotate very freely.
This allows the rotor to build up speed and allows aerodynamic lift to be generated by the
blades.
Normal Operation - Once the rotor is spinning at 300 RPM, current will be delivered to the
batteries. As the rotor speed increases, so too will the current and voltage. Excessive wind
speed may increase the battery voltage to a high level. Once this happens the diversion
charge controller will recognise that the battery voltage is too high and begin 'dumping'
power to the heater module.
Charge Regulation - Once the charge controller has switched over to the dump load, the
turbine will no longer be charging the batteries. Instead, the power from the turbine will
be delivered to the dump load (usually a resistive heater element). The battery voltage will
begin to drop to normal levels during the regulation period. Once the battery voltage is
back within acceptable limits, the charge controller will switch the turbine output back to
the batteries. Refer to the charge controller user manual for specific operational
instructions.
Shut Down - By activating the stop switch, the output from cables of the turbine are
‘shorted’ together. This effectively puts an infinite load on the generator causing the
turbine to stall. When the stop switch is activated the turbine may still rotate slowly during
high winds, but the rotor blades will not be able to build up any significant speed. It is not
recommended that the stop switch is activated whilst the rotor is spinning at high speed.
This sudden braking action will stress the blades and other components. Only activate the
stop switch during a ‘lull’ when the rotor is not spinning excessively fast.
Warning –Using the Run /Stop Switch in strong winds > 40 mph.
In certain strong wind conditions the rotor can overpower the electromagnetic braking,
which allows high currents to be produced in the stator coils. If this situation occurs for
prolonged periods, damage to the turbine can occur. Therefore the Run / Stop switch
should only be used to slow the unit prior to manually / mechanically tethering the
turbine in very high winds. Either restrain the blades or swing the turbine to 90 degrees
away from the wind and tether it in this position. A hole for tethering is provided in the
tail-fin of the LE-450 (see Fig 16).
Operation of the LE-450 in High Winds - Every effort has been taken to ensure that the LE-
450will withstand the forces exerted by strong winds. However the raw power in high
winds is immense and the stresses placed upon the turbine are magnified by gusty and
turbulent conditions. Where possible the turbine should be shut down and tethered in
advance of particularly strong, consistent winds (60+ mph) and storm conditions. This will
decrease the wear and tear on the machine and will help to avoid a failure. Protect the
turbine from extreme winds as you would protect other items of your property. Refer to
the Shut Down procedure above.

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Page 18 of 47
Note: Never allow the turbine to run off-load with no connection to a battery bank or grid-tie
inverter. Doing so will allow open circuit voltages to be generated by the turbine. These voltages
may be dangerous and may damage the stator coils within the turbine.
Fig-16: Tethering the rotor blades using the hole on the tail-fin
(shown on an LE-300 Turbine)

Tel: [phone] Skyrrid Farm, Pontrilas, Hereford. HR2 0BW. UK www.leturbines.com
Page 19 of 47
Maintenance
Please follow the preventive maintenance programme listed below. This will ensure that the
turbine operates reliably and safely with good efficiency.
Always shut down the turbine before attempting to carry out maintenance.
Post-Installation Checks (to be carried out one month after installation):
Check that the tower mount pins are secure and have not worked loose. Adjust if required.
Ensure that the rotor hub is still securely fitted.
Ensure that the rotor blades rotate freely.
Monitor the output. Ensure that the turbine and charge controller are functioning
correctly.
Annual Maintenance:
Inspect the tower / support structure.
Remove the turbine from its installation to a suitable workbench.
Remove the rotor blade assembly.
Inspect the edges of the rotor blades for damage such as dents or chips. The blades will
become unbalanced if they are damaged. This will cause vibration, noise and poor
performance. If many dents have occurred along the edges of the blades, a new set of
rotor blades should be fitted (part numbers available in the Spares section).
Inspect the roots of the blades (attachment tabs) for signs of stress cracking or fatigue. A
new set of rotor blades should be fitted if any cracks of fractures have occurred (part
numbers available in the Spares section).
Remove any build-up of dirt and debris from the rotor blades using a mild detergent and
warm water.
Check the blade hub fixings for tightness.
Carefully remove the yaw mount bracket by unscrewing the four connection screws from
the sides of the LE-450chassis. Inspect the slip rings and wipers for obvious signs of wear.
Replace the wipers if required (part numbers available in the Spares section). Reassemble
the yaw pivot carefully (do not to pinch any cables).
Check that all electrical connections are sound and free from corrosion.
Generally ensure that the turbine is in good working condition and is safe for continued
use.
After five years of normal operation:
We recommend that the rotor bearings and rotor blades should be replaced after five
years of continuous operation. This will ensure that the turbine’s performance and safety
is not compromised.
Other Considerations:
The equipment used in the charging system (batteries, charge controller, PV panels,
invertors, etc.) should be maintained according to the instructions published by the
relevant manufacturer.
Where lead-acid batteries are used, it is especially important that they are maintained
carefully. Failure to do so will result in the batteries being rendered useless within a short
period of time.

Tel: [phone] Skyrrid Farm, Pontrilas, Hereford. HR2 0BW. UK www.leturbines.com
Page 20 of 47
Spares
The following components may need to be replaced during the service life of your LE-450turbine.
Please contact your nearest Leading Edge Turbines’Dealer, and quote the part numbers listed
below.
Rotor Blade (set of 5) DP-LETU-145 (X5)
Magnet Rotor SA-LETU-031
Stator (12V / 24V / 48V) SA-LETU-027
Yaw pivot & Slip ring module SA-LETU-016
Yaw Shim DP-LETU-153
Nose cone DP-LETU-338
Drive bearing (set of 2) OS-090 (X2)
Rotor bearings and housing DP-LETU-155
Run / Stop Switch GA-CTRL-008A
Tristar Diversion Controller GA-CTRL-002A
500W Dump Load (12V / 24V / 48V) CA-CTRL-006