Leading Edge LE-600 Original operating instructions

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LE-600 Turbine
Installation & Operation Guide
1.55m Diameter Micro Wind Turbine for generating clean and
renewable electricity anywhere the wind blows…
Leading Edge Turbines Ltd

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Contents
Contents......................................................................................................................2
Read me First ..............................................................................................................3
Introduction ................................................................................................................4
Safety Precautions ......................................................................................................5
Mechanical Safety Hazards.....................................................................................5
Electrical Safety Hazards.........................................................................................6
Specifications ..............................................................................................................7
Tools Required For Assembly .....................................................................................8
Mechanical Assembly Procedure................................................................................9
Electrical Installation.................................................................................................16
Fig-12: Typical ‘Stand-Alone’ Battery Charging Wiring Diagram..........................18
Fig-13: Typical ‘Hybrid’ Wind /PV System Wiring Diagram ..................................19
Turbine Operation ....................................................................................................20
Maintenance.............................................................................................................21
Post-installation Checks (to be carried out one month after installation): ..........21
Annual Maintenance:............................................................................................21
After Five years of normal operation:...................................................................21
Other Considerations: ...........................................................................................21
Spares........................................................................................................................22
Warranty...................................................................................................................23
Disclaimer .................................................................................................................24
Appendix 1: Tristar 45A Diversion Charge Controller relevant extracts ..................25
Appendix 2: Run / Stop Switch User Manual............................................................41
Appendix 3: Turbine Site Selection...........................................................................43

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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. Failing to do so will damage the equipment and invalidate your
warranty.
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.
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 controller and more.

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Introduction
Please read this manual thoroughly before attempting to assemble, install or operate your LE-600
small wind turbine. This will assure optimum performance and safety.
Leading Edge Turbines have spent many years developing the ideas and technology behind your
turbine. The LE-600 turbine features an array of innovations and construction techniques as well as
heavy-duty engineering to ensure optimum efficiency and a long operating life.
The LE-600 has been designed to be simple, economic, durable and yield excellent performance.
Your LE-600 turbine features:
•Innovatively designed axial flux alternator, using neodymium iron boron magnets
•A laser-cut, aluminium chassis using 'Yaw-wing' design to ensure responsive yawing
•Maintenance-free, low friction bearing arrangements
•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 longevity
•Fully marinised using stainless steel fixings and anodised aluminium components
•Low mass to help reduce exerted forces and ensure easy installation
•Lightweight aluminium design.
The LE-600 has been developed for both land-based and coastal environments (but not for sea-
based applications). Thanks to its unique design, the LE-600 is not susceptible to corrosion in
normal or salt water operating conditions.
Applications include:
•Complementary installation with photovoltaic modules
•Radio repeater stations and rural broadband
•Cathodic protection
•Monitoring sites/meteorology
•Security systems
•Remote Homes
•Farm utilities (electric fencing, irrigation, etc.)

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Safety Precautions
Safety must always be your primary concern during the assembly, installation and operation of your
LE-600 turbine. 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-600 turbine 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-600 turbine 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-600 turbine 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-600 generates 3-Phase AC voltage from the turbine head and rectified DC voltage
from the rectifier box. Even at low voltages there are inherent risks. Caution should always
be used when connecting LE-600 to the electrical system.
•Ensure 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.
•Batteries 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-600 'off-load' with the output cables not connected to anything.
Please use common sense when installing and operating your turbine!

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Specifications
Turbine Name: LE-600 Turbine
Part Number: GA-LETU-009
Nominal Voltage: 12V / 24V / 48V
Rotor Diameter: 1540 mm
Rated Wind Velocity: 8 m/s
Rated Output: 160 Watts
Max Output: 750 Watts (900 Watts in certain applications)
Rated RPM: 550
Start-up Wind Velocity: 2 m/s
Total weight: 19.5 Kg
Tower mount: 60.3/50.0 mm Outer Diameter Tube x 3 / 4 mm Wall
Chassis Construction: Aluminium
Rotor Blades (3-off): Glass Reinforced Nylon
Fig 2: Operating Envelope
Fig-1: Diametric View

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Fig 3: Power output
Package Contents
Your LE-600 Turbine will arrive containing the components shown below. If any of the components
are missing or damaged, please contact your dealer immediately.
LE-600 Chassis: Qty 1
Rotor Blade: Qty 3
Hub Plate: Qty 1
Nose Cone: Qty 1
User Manual: Qty 1
Rectifier: Qty 1

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Tools Required For Assembly
You will require the following tools to assemble your LE-600 Turbine:
•10mm A/F spanner & 10 mm ratchet (one of each required)
•13mm A/F spanner & 13 mm ratchet (one of each required)
•A Set of Metric Standard Hexagon Keys
•Electrical screw drivers
•Power drill
•6.5 mm & 3.0 mm diameter twist drill bit, suitable for drilling through steel
•Digital multi-meter capable of measuring DC & AC Volts
•Tape measure or steel rule
•Thread-locking compound (Loctite 243 or similar)
3 x M6 x16 Cap Heads
9 x M8 x60 Hex Heads
3 x M6 Washers
12x M8 Nylock Nuts
18 x M8 Washers
3x M8 x12lg Cap Head
2x M6 x75C/sunk
1x Rectifier
Fixings Bag: Qty 1

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Mechanical Assembly Procedure
1) Unpacking - Inspect the contents of the box and ensure that all items are present and free
from damage. 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 bearing
seals to ‘bed-in’ and the lubrication to be distributed correctly around the 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 any two of the three output leads
extending from the yaw pivot. With the multi-meter set to detect AC Volts (0-20V), 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-600 Turbine is constructed using neodymium iron
boron rare earth magnets which are semi-exposed until the turbine is fully assembled. 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 LE-600
alternator. The magnetic forces between ferrous materials and the magnet rotor within the
alternator may be 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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3) Rotor Blade Assembly - Take the three rotor blades and rotor hub plate. Be careful when
handling the blades, they have VERY SHARP EDGES. Use a 13 mm A/F socket and hexagon
key and three M8 x 60mm long set screws to attach each blade to the hub plate - see Fig-5.
Ensure that the cap head end of the screw is on the rotor hub plate side (thus allowing the
washers and nuts to locate inside of the blades. 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. 3 set-screws, 3 washers and 3
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 3 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

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NOTE: Depending on the type of support structure being utilised for the LE-600, it is sometimes
advisable to fit the main rotor set to the turbine chassis at this stage. However in other
circumstances it will be easier to fit the turbine chassis to the support structure before fitting the
main rotor set. The installer must use judgement as to the best order in which to fit the turbine
together, depending on the merits of the installation and therefore the remaining installation
steps maybe completed in an alternative sequence.
5) Fit the Rotor Blade Assembly - This is done by offering the rotor hub plate against the
drive hub protruding from the front of the chassis. M6 x 16 long cap head screws should
then be used to fix the rotor hub in position using the three unused tapped holes in the
drive shaft. Ensure that all 3 screws are securely tightened and that the rotor blades are
fitted with the flat side of the blade facing towards the magnet rotor. Thread-locking
compound should be used on the screw threads.
Fig 7: Fitting the rotor blades to the chassis

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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

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7) Fit the nose cone –Do not over-tighten nose cone bolts as the nose cone is a plastic part
and is liable to crack if over-tightened.
The nose cone can now be fitted to the rotor. This is done by aligning the mounting slots of
the nose cone with the corresponding 'barbs' on the rotor blades. Once the nose cone is
fitted correctly over the blades and runs concentrically, fix it in position using Qty 3 M8 x
12lg Cap head screws using Loctite. The screws enter through the mount holes in the nose
cone and align with the 3 tapped holes in the hub plate. Ensure that the nose cone is
secure and true before finally tightening the fixings.
Fig 9: Attach the nose cone

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8) Prepare the Turbine Mount - If you have purchased a LE-600 mount 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, 7 mm
diameter holes will need to be drilled in order to secure the turbine. These holes should be
drilled 14 mm and 29 mm from the top of the tower / mount bracket and should be
perpendicular to the surface and skewed by 90 degrees. The hole 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
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 rectifier
box / 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-600 Nominal
Output Voltage
10 Metres
25 Metres
50 Metres
12 Volts
16 mm² (3-Core)
25 mm² (3-Core)
50 mm² (3-Core)
24 Volts
4 mm² (3-Core)
10 mm² (3-Core)
16 mm² (3-Core)
48 Volts
1.5 mm² (3-Core)
2.5 mm² (3-Core)
4 mm² (3-Core)

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10) Mount the LE-600 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 75 Amps (12V), 40 Amps
(24V), 25 Amps (48V). 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 75 countersunk set-
screws along with washers and thread-locking compound to secure the turbine using the
holes previously drilled in the support structure - see Fig-11. Ensure that the M6 set-screws
are securely fastened.
Fig 11: Fitting the turbine onto the support structure

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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-600 turbine 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 correct
rating. 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-600 Nominal
Output Voltage
DC Fuse / DC Circuit Breaker Rating
12 V
60 Amp
24 V
30 Amp
48 V
20 Amp

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•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 rotor 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 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 –A Tristar 45A or 60A Diversion Charge Controller is recommended to
manage the power output from the turbine to the batteries. The diversion charge
controller operates by increasingly switching output to a dump load once the batteries
begin to reach high voltages. The dump load consumes the ‘excess’ power from the
turbine. This means that the turbine’s power output is always utilised whether the
batteries are fully charged or not. Larger capacity battery banks will be able to store more
energy and so the dump load will be used less. Do not use a photovoltaic type
charge controller with your LE-600 turbine.
•‘Hybrid’ Systems -The LE-600 Turbine can be used in parallel with PV panels. The PV
panels must be wired independently with a separate charge controller specifically
designed for use with PV panels and connected in parallel with the battery bank - see Fig-
13.
Please refer to the following wiring diagrams as a guide.

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Fig-12: Typical ‘Stand-Alone’ Battery Charging Wiring Diagram

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Fig-13: Typical ‘Hybrid’ Wind /PV System Wiring Diagram

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Turbine Operation
The LE-600 Turbine 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 290 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 290 RPM), the turbine will come ‘on-load’ and begin to deliver current
to the batteries. During the off-load stages of rotation, the blades will 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 more than 290 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. This arrangement is more effective than stop/starting the turbine incessantly.
•Shut Down - The run/stop switch should only be used to slow the unit prior to taking it
down or tethering the turbine. By activating the stop switch, the output from the 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.
High winds - In certain high wind conditions, the rotor can overcome the electromagnetic
braking, which allows high currents to be produced in the stator coils. If this situation
occurs with the wind driving the braked alternator for prolonged periods, damage to the
turbine will occur.
•High Winds - Every effort has been taken to ensure that the LE-600 will 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 winds of 27m/s (60
MPH). 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.
Note: Never allow the turbine to run off-load with no connection to a battery bank. 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.