Leading Edge LE-v50 Original operating instructions

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Rev K Page 1 of 30
LE-v50 & LE-v50 Extreme Turbine
Installation & Operation Guide
A micro vertical axis turbine for trickle charging and low power
applications...
Leading Edge Turbines Ltd

Tel: [phone] Skyrrid Farm, Pontrilas, Hereford. HR2 0BW. UK www.leadingedgepower.com
Rev K Page 2 of 30
Contents
Contents......................................................................................................................2
Read this first ..............................................................................................................3
Introduction ................................................................................................................4
Safety Precautions ......................................................................................................5
Specifications ..............................................................................................................6
Package Contents........................................................................................................7
Tools Required For Assembly .....................................................................................7
Mechanical Assembly Procedure................................................................................8
Electrical Installation.................................................................................................11
Turbine Operation ....................................................................................................16
Maintenance.............................................................................................................17
Spares........................................................................................................................18
Warranty...................................................................................................................19
Disclaimer .................................................................................................................20
Appendix 1: DL-300 Charge Controller User Manual ...............................................22
Appendix 2: Run / Stop Switch User Manual............................................................25

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Rev K Page 3 of 30
Read this first
1. 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.
2. 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.
3. On arrival, ensure the main rotor is free turning
The stub shafts may have shifted in transit, causing the main rotor to rub
against the cowling as it turns. See instructions on page 8 to reset the stub
shaft positions.
4. Do not mount upside down
Cables are at the bottom of the turbine, not the top.
http://youtube.com/c/LeadingEdgeTurbines
Visit our YouTube channel for assistance in wiring up the equipment,
configuring the DL-300 and run/stop switch and more.

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Rev K Page 4 of 30
Introduction
This installation manual covers the both the standard LE-v50 and the LE-v50 Extreme wind turbine.
All references to the LE-v50 includes the LE-v50 Extreme; the LE-v50 Extreme is painted black and
optimised for locations where winds regularly gust to more than 27m/s (60mph).
Please read this manual thoroughly before attempting to assemble, install or operate your small
wind turbine. This will assure optimum performance and safety.
The LE-v50 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-v50 has been designed to be simple, economic, durable and yield excellent performance.
Specific LE-v50 turbine features:
•Innovatively designed axial flux alternator, using neodymium iron boron magnets
•Bearing support at both ends of the savonious rotor to provide stability and longevity
•Maintenance-free, low friction bearings
•Silent operation
•Easy 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.
LE-v50 has been designed to for both land-based and marine environments. Thanks to its unique
design, the LE-v50 will suffer minimal corrosion in both normal and salt water operating conditions.
Applications include:
•Marine trickle charging
•Data logging/acquisition and environmental monitoring
•LED lights
•Data communications
•CCTV cameras

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Rev K Page 5 of 30
Safety Precautions
Safety must always be your primary concern during the assembly, installation and operation of your
LE-v50 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-v50 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 may be very difficult to see, due to the
speed of rotation. Never approach the turbine whilst it is operating at speed. Ensure that
the turbine is installed in a suitable position where nobody can interfere with the rotor
blades.
•Working with tools of any kind can be dangerous. Your LE-v50 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-v50 turbine will inevitably be installed upon a mast or tower or other support
structure. 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.
•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.
Electrical Safety Hazards
•The LE-v50 generates rectified DC voltage. Even at these low voltages there are inherent
risks. Caution should always be used when connecting the LE-v50 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. 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.
Please use common sense when installing and operating your turbine!

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Rev K Page 6 of 30
Specifications
Turbine Name: LE-v50 Part Number: GA-LETU-010A
Turbine Name: LE-v50 Extreme Part Number: GA-LETU-020A
Rotor Diameter: 270 mm Rated Wind Velocity: 8 m/s
Nominal Voltage: 12 / 24V / 48V DC Rated Output: 12 Watts
Cut-in Wind Velocity: 4 m/s Chassis Construction: Aluminium
Total weight: 9.0 Kg Rotor Blades (3-off): Aluminium
Fig 1: Operating Envelope

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Rev K Page 7 of 30
Package Contents
Your LE-v50 turbine will arrive containing the components shown below. If any of the components
are missing or damaged, please contact your dealer immediately.
Tools Required For Assembly
You will require the following tools to assemble your LE-v50turbine:
•13 mm A/F spanner & 13 mm ratchet (one of each required)
•8mm A/F spanner or ratchet
•A set of Metric Standard Hexagon Keys
•Electrical screw drivers
•Power drill
•8.5 mm diameter twist drill bit, suitable for drilling through steel (if standard mount
brackets are being used)
•Digital multi-meter capable of measuring DC Volts
LE-v50 Turbine: Qty 1
User Manual: Qty 1

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Rev K Page 8 of 30
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 Main Rotor & Continuity - Ensure that the main rotor is free turning and does not
scrape or rub as it rotates - see Fig 4. As the turbine is shipped in a horizontal orientation,
it may be the case that the upper or lower stub shafts or cowlings have shifted during
transit.
If the turbine blades feel stiff and do not rotate freely, follow the below steps to reset the
stub shaft positions:
A) Remove the M5 cowling fixings and then the cowlings themselves.
B) Slightly slacken the M5 fixings on the upper and lower stub shafts.
C) Hold the turbine vertically and rotate the main rotor blades.
D) The stub shafts will now reposition themselves and the turbine will rotate freely.
E) Retighten the upper and lower stub shaft fixings and check that the turbine still
rotates freely.
F) Reposition and fix the cowlings ensuring that they do not rub upon each other..
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 rear of the turbine. With the multi-meter set to detect DC Volts
(0-20V), a voltage should be displayed when the main rotor is spun by hand. This voltage
will vary with the speed of rotation. If no voltage is detected whilst turning the rotor,
please contact your dealer immediately.
Fig 3: Checking voltage output
Upper Stub Shaft Fixings
Lower Stub Shaft Fixings

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Rev K Page 9 of 30
3) Remove the turbine from the transit packing –Use a pair of 13mm A/F spanner and or
ratchet to remove the M8 fixings from the transit base board.
4) Fix the turbine in its mounting Position –With the turbine removed from the baseboard, it
can now be fitted in its intended position. The cables should come out of the bottom of
the turbine when mounted. The LE-v50 is supplied as standard with two universal flat
mounting brackets. Dimensions of the brackets can be found below. Using U-bolts, the
turbine can be fixed to a 50mm outer diameter pole.
Ensure that the turbine is mounted vertically and on a flat and smooth surface.
Incorrectly mounting the turbine may cause the main spine to distort which may result in
the turbine not rotating freely.

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Rev K Page 10 of 30
5) Install the Transmission Cables- 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. Once the transmission cable installed, it can be
connected to the LE-v50.
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-v50 Nominal Output
Voltage
10 Metres
(30 Feet)
30 Metres
(90 Feet)
100 Metres
(300 Feet)
12 Volts
1.5 mm²
4 mm²
Not Recommended
24 Volts
1.5 mm²
2.5 mm²
10 mm²
48 Volts
1.5 mm²
1.5 mm²
4 mm²

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Rev K Page 11 of 30
Electrical Installation
Please refer to Figs 4 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-v50 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.
•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-v50 Nominal
Output Voltage
DC Fuse / DC Circuit Breaker Rating
12V
6 Amp
24V
3 Amp
48V
1.5 Amp

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Rev K Page 12 of 30
•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. A run / stop switch is optional on the LE-v50 turbine. See Appendix for more
information.
•Charge Controllers –Normally, the LE-v50 turbine does not require any external charge
control equipment to be installed in the system. Due to the low Tip Speed Ratio of the
turbine, the turbine output decreases naturally as the battery voltage increases –this
provides a natural form of charge regulation. However, in extreme wind environments
(such as arctic conditions) and special systems, it is possible to install a DL-300 charge
controller. See Appendix for more information.
•‘Hybrid’ Systems -The LE-v50 turbine 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.
Please refer to the following wiring diagrams as a guide.

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Rev K Page 13 of 30
Fig 4: Simple ‘Stand-Alone’ battery-charging wiring diagram
LE-v50 Turbine
Battery Bank
(wired to the
appropriate voltage
and capacity)
+VE
Transmission
Cable (Red)
-VE
Transmission
Cable (Black)

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Rev K Page 14 of 30
Fig 5: ‘Stand-Alone’ battery-charging requiring DL-300 controller

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Rev K Page 15 of 30
Fig 5: Typical ‘Hybrid’ wind / solar system

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Rev K Page 16 of 30
Turbine Operation
The LE-v50 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 120 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 120 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 120 RPM, current will be delivered to the
batteries. As the rotor speed increases, so too will the current and voltage.
•Shut Down (If Run / Stop switch is fitted) –A run / stop switch is not required with the LE-
v50 turbine but one can be installed if desired (see appendix 2). By activating the stop
switch, the output 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 - Every effort has been taken to ensure that the LE-v50 will withstand the
forces exerted by strong winds. The turbine will continue to generate power whilst
surviving the immense forces that are exerted by high winds. The LE-v50 Extreme is
designed for locations where winds regularly gust to over 27m/s (60mph).

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Rev K Page 17 of 30
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 turbine mount fixings are secure and has not worked loose. Adjust if
required.
•Ensure that the rotor blades rotate freely.
•Ensure that all electrical connections are sound.
Annual Maintenance:
•Inspect the turbine & support structure.
•Ensure that the bearings are smooth and free running.
•Inspect 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).
•Remove any build-up of dirt and debris from the rotor blades using a mild detergent and
warm water.
•Check the blade fixings for tightness.
•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 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.

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Rev K Page 18 of 30
Spares
The following components may need to be replaced during the service life of your LE-v50 turbine.
Please contact your nearest Leading Edge Turbines’Dealer, and quote the part numbers listed
below.
Rotor Blade: DP-LETU-145
Rotor Bearing Housing: DP-LETU-198
Bearing Service Kit: OS-296
Stator (48VDC): SA-LETU-006/48V
Stator (24 VDC): SA-LETU-006/24V
Stator (12 VDC): SA-LETU-006/12V
Bridge Rectifier: OS-019
Upper Stub Shaft: DP-LETU-199B
Run / Stop Switch Box: GA-CTRL-008A
DL-300 Charge controller (12V / 24V): GA-CTRL-001

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Rev K Page 19 of 30
Warranty
Your LE-v50 turbine from Leading Edge Turbines (LET) carries a two-year warranty, as supported by
a retailer’s receipt. The warranty starts from the date of installation or ninety (90) days after
shipment from the LET factory, whichever comes first.
LET will supply ‘non-wearing’ parts at no cost. For minor component failures, replacements may be
sent directly to the customer / dealer for replacement by them. For more serious defects we may
suggest a ‘return-to-base’ arrangement for replacement or repair.
In these cases, the purchaser will be responsible for taking the turbine off the tower/mast and
paying the return carriage costs.
Where a turbine is to be replaced, it must be returned to LET before the replacement unit is
despatched. Should the product prove to be irreparable, LET reserves the right to substitute an
equivalent product, if available.
This warranty does not extend to servicing a faulty turbine on location.
In all cases LET will take reasonable action to ensure customer satisfaction. You should always
receive a warm, courteous service in or out of your warranty period.
Your turbine must be installed and operated in accordance with the guide. Failure to do so will
result in this warranty becoming null and void. Any unauthorised modifications to the turbine
design will void the warranty and may compromise the safety of the machine.
What is not covered by your warranty?
•Damage caused by unsatisfactory installation of the turbine, tower and/or control
equipment.
•Damage caused by the neglect of periodic maintenance in the manner recommended in
the installation manual.
•Damage caused by repair or maintenance performed using methods not specified by LET
or by non-authorised dealers of LET products.
•Damaged caused by the use of non-genuine parts, or from the use of liquid agents or
lubricants in or on the turbine, tower or control equipment.
•Damage caused by operating the turbine in conditions outside of those specified in the
Owner’s Guide – including, but not limited to, allowing the turbine to run while
disconnected from the batteries or not configuring the Tristar charge controller for
diversion mode.
•Damage caused by modifications to the turbine, tower or control equipment not approved
by LET.
•Damage caused to the turbine, tower and control equipment by improper storage or
transport.
•Damage caused by lightning strikes, flooding, fire, etc.
•Damage due to extremely high winds and storm conditions (27m/s+, 60 mph+) or locations
off-shore. LE-v50 Extreme is warranted to 35m/s, 80mph.
•Damage caused by flying debris.
•Damage to batteries due to excessive deep discharge, short-circuiting, excessively high
load, over charging, loss of electrolyte, or any condition outside of the manufacturer's
specification for battery use.
•Damage occurring as a result of not operating the turbine at a safe distance from
individuals or property.
•Damage caused by unsatisfactory tower / support structure design.

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Rev K Page 20 of 30
•Damage caused by incorrect connection to external electrical equipment, or failure to
observe current regulations concerning connection to external electrical networks,
equipment or any other devices.
If you should experience a problem with your turbine, your first ‘port-of-call’ should be the reseller
or installer from whom you purchased the product. They should be able to resolve the problem
quickly and efficiently. If you are unable to contact the original reseller, then please contact us
directly.
Please quote the serial number of your turbine when dealing with warranty issues. The serial
number can be found on the nameplate positioned on the underside of the chassis.
Disclaimer
•All specifications are subject to change without prior notice.
•The information given in this user manual is believed to be accurate and reliable. Leading
Edge Turbines assumes no responsibility for omissions or inaccuracies.
•The user of this information and product assumes full responsibility and risk.
•The LE-v50 turbine is a source of electrical power. It must be installed in accordance with
local building and electrical regulations. Consult your local planning (zoning) office for
details.
•The LE-v50 turbine has moving parts that may cause injury due to poor installation and
unsafe operation. Leading Edge Turbines assumes no responsibility for problems caused by
unsafe or unsatisfactory installation or operation.
Designed & Manufactured in the UK by:
Leading Edge Turbines Ltd
Skyrrid Farm,
Pontrilas,
Hereford.
HR2 0BW
Tel: [phone]
www.leadingedgepower.com
Compliant with
EN BS 61400-2: Safety of Small Wind
Turbines