Newmeil X-400 User manual

INSTRUCTION
MANUAL
2015 V1.0

2
I Contents
Ⅰ. Introduction……………………………….……....………3
Ⅱ. Security & Warnings..……………………..……………4
Ⅲ. Features & Technology………………………….….…6
Ⅳ. Technical Specifications…………………….…………9
Ⅴ. System………………………………………………….……11
Ⅵ. Peripheral Material/Devices……………….……..15
Ⅶ. Assembly…………………………………………….…..…18
Ⅷ. Maintenance & Check-ups…………………..….…22
Ⅸ. Troubleshooting…………………………………..…...24
Ⅹ. Warranty……………….…………………………..………26
Ⅺ. Notes………………………………………………...……..27

X-400W Wind Generator Instruction Manual
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I Introduction
Thank you for purchasing the 400W (X-400) wind turbine. We are proud
to supply this product which is the result of our long experience and technical
expertise with small wind generators. Our wind turbines are designed to charge
batteries (Off-Grid system) to provide you with electricity.
Wind is a free and natural energy. However wind speeds can vary in
accordance with time, weather and location. Therefore expect the turbine
output to vary with the wind conditions. Even though we cannot change this
elementary law, we, Newmeil, have developed a range of products that are
designed to get the maximum out of the wind's power. All our turbines feature:
low wind speed (start 2.0m/s) performance, very high system efficiency and
very low noise and vibration. They are constructed and designed to provide the
owner with many years of trouble-free service, with minimum maintenance.
This manual contains information about product features, assembly and
installation, safety precautions, maintenance procedures and peripheral
equipment selection.
We strongly recommend that you read this manual before you try to use the
product.
If ever the product did not function properly, do not attempt to repair or
modify it. Instead contact a trained professional to solve the problem or the
dealer from whom you have purchased this equipment.
Please note that:
- The specifications of this product may change due to improvements
without prior notice.
- Wind turbines are technical products that must be handled with caution;
always have a trained professional to help or/and advise you.

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I Security & Warnings
Newmeil turbines are designed for your personal safety, however there
are still some dangers involved in the mechanical and electrical equipment. In
this section you will find all the important information you need to be aware of
before installing your wind generator. Safety should always be your top priority
when installing your wind turbine system.
Please read this information carefully as improper installation could result in
injury, death or damage to the wind turbine.
- Ensure the mounting pole is suitable, and there is sufficient clear area
where the turbine is to be installed. If the pole and the location are not
suitable for the installation of the product, the pole may break or fall
over resulting in injury, death or damage to the turbine.
- Before mounting the turbine onto the pole, check and make sure that all
screws and moving parts are fastened tightly.
- Do not install the turbine next to electric or telephone lines.
- Do not install the turbine on a pole that is not perfectly vertical.
- Install the turbine at a sufficient height in order to prevent injury or
death.
- Never touch any moving part of the turbine with your hands or any part
of your body. Spinning blades can cause injury or death even at low wind
speeds.
- The wind turbine should never be operated without being connected to a
controller and battery.
- Be extremely careful, in order to avoid electrical shock.

X-400W Wind Generator Instruction Manual
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- Stopping the turbine – This operation might be necessary to undertake
battery maintenance. If possible, stop the turbine should be done in low
wind speed conditions. Orienting the turbine tail fin upwind to slow the
turbine; this should slow it sufficiently for it to be secured to the pole
with a rope. Avoid leaving the turbine tied up for a long time. However if
you need to store the turbine, we recommend that the turbine be
removed and covered up before storing it in a dry location for protection
- If a storm arises switch-on the brake mode. In case of a hurricane, the
rotor blades should be tied to the tower, especially when on boats.
- The turbine will rotate in accordance with varying wind direction, please
be very careful if it is necessary to approach it for installation or
maintenance.
- Do not attempt to modify the turbine.
- Always contact your dealer for repairs or replacement parts.
- Never touch together non-insulated wires.
- Trained professionals should perform all mechanical and electrical
assembly. If any doubt arises contact your dealer.

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I Features & Technology
Newmeil wind turbines are high quality products. Our wind turbines
feature advanced technology for performance and durability. Here are some
of the features and technology used in our products.
All our products are designed and tested at our manufacturing facilities.
We take particular attention to our customer’s feedback and to the current
markets. We aim to produce a product of superior quality and that has a long
life span. They are built and designed to be quiet, and to not cause vibrations.
Moreover our turbines are designed to be very efficient, even at low wind
speeds.
The following technologies are included in your wind generator
Advanced Generator Technology: We use the
strongest magnets (Neodymium Iron Boron Magnets)
and most advanced technology for our rotor.
Experiments show that the Neodymium Iron Boron
Magnet is lighter in weight and more efficient than
any other material. And our rotor tangential structure
design also contributes to the whole motor superiority.
Using high temperature durable lacquered wire materials, plus vacuum
impregnation treatment, greatly improves the insulation performance and
durability of the stator.
Having two bearings allows the wind turbine to start faster than a single
bearing wind turbine. Thanks to this technology you can start producing
energy at wind speeds as low as 1.8m/s. The Double bearing system also has
the advantage of reducing vibrations emitted by the generator.

X-400W Wind Generator Instruction Manual
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Carbon Fibber Composite Blades: For same length blades, due to airfoil
differences, output power and efficiency is not same. Therefore, optimizing
the design of the blade's airfoil is very important. With our technology on
fluid dynamics and aerodynamics, together the adoption of European
advanced design idea, our blades are recognised for good start up
performance and higher output than competitors.
Besides, another plus about our blades is the carbon fibre composite
materials. Using the most advanced technologies, our blades contain 20%-
30% carbon fibre. Carbon fibre is light weight, flexible and has a long life
span. Due to these features, the blades have the advantage of bending at
high speeds, thus reducing airflow force and slowing down in very high wind
speed conditions. Whilst other blades made with glass fibre materials, can
be tough, sometimes in strong wind conditions, these blades can’t reduce
very high wind forces , thus damaging the installation
In order to keep the wind turbine quiet and without vibration when rotating,
we fully enclose the blade mounting nuts to the hub connection
Aerodynamic Design: Using high strength aluminium
alloy materials, plus precision die casting technique,
makes our wind turbine body light weight, very strong,
corrosion resistant and durable.
Besides, aerodynamic design makes our wind turbines
more effective and also more pleasing to the eye. All
our turbines have a powder-coated finish, giving them perfect paintwork and
feel, as well as a long life span by protecting the body from any weather
conditions, and making them easier to clean. Besides, aerodynamic design
also contributes to this super low noise.

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Double bearing yaw body structure: In order to
obtain a vibration-free system, we use double
bearings instead of single in the yaw body structure.
This double bearing structure can significantly
reduce vibrations , and can be very helpful and
necessary in street light project which is installed
high from ground.
Integrated one slip ring : Poor quality slip rings can cause high current
losses, thus in strong wind conditions, slip
ring/brush will overheat and cause damage. Our
slip ring is an integrated one; there are high
volume copper materials involved. This slip ring
can stand up to 200A instant current. Its design
is very smooth, thus quickly turning the
blades into the wind direction, to give a higher
efficiency.
Double Security System: All our wind turbines are
equipped by not one but two security systems. If the wind
is too strong and the rotor speed is too high our security
systems will directly act on the generator to prevent
damage to the system.
To conclude, good quality, reliable performance and long time durability are
our main concerns. Most of all, we produce good quality products, at an
affordable price for all our customers.

X-400W Wind Generator Instruction Manual
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I Technical Specifications
Datasheet
X-400 Wind Turbine Layout

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Model name IDEAL400
Model number X-400
Wind turbine type Horizontal axis, up-wind
Rotor diameter 1300mm
Net weight 7.5kg
Tower diameter 48-50mm
Number of blades 3
Blades material 20% carbon fibre reinforced plastic
Blades weight 300g a piece
Body material High pressure aluminium die casting
Product finish Thermosetting powder coating
Tower connection Bolt-on clamp
Start up wind speed 2.0m/s
Cut-in wind speed 2.5m/s
Survival wind speed 50m/s
Rated power 400W
Rated rotor speed 500-1000 rpm
Maximum power 500W
Rated output voltage Off-Grid 12V/ 24V/ 48V DC
Working temperature range From -40℃ to 60℃
Sound pressure level 35dB at 5m/s, 5m behind the rotor
(Air density of 1,225 kg/m³)
Generator
Synchronous type, three-phase power
generator with neodymium magnets
Double copper winding
Braking system Electro-magnetic & blade over speed
aerodynamic braking system
Yaw control 360° free yaw
Direction control Tail tracing
Recommended system 12V/100AH
Product life span 15 years
Note: The turbine produces power at cut-in speed, but it requires higher wind
speed to charge batteries.

X-400W Wind Generator Instruction Manual
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Electrical Production
I System
In order to work, your wind turbine must be connected to several
peripheral accessories. To use the electricity produced by your generator you
will need to connect it via an Off-Grid system.
Before connecting the system, you need to be aware of the risks that an
electrical set-up implies:
- Do not touch defective cables with your body or metal tools.
- Do not connect devices together when you are not instructed to.
- Respect all the safety warnings regarding the devices themselves.
- The installation and operation of a wind turbine system may be subject to
local government codes, comply with them also.

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Off-Grid system
If you live in a remote area and have no access to power lines consider the
Off-Grid solution. The wind turbine is directly connected to your home and can
therefore power your electric appliances without using the grid. For this
installation you will need storage devices such as batteries.
(Refer to the “Peripheral product” section of this manual)
1.Wind generator wiring diagrams

X-400W Wind Generator Instruction Manual
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2.Wind solar hybrid wiring diagrams

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3.Wind solar hybrid wiring diagrams

X-400W Wind Generator Instruction Manual
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I Peripheral Material / Devices
As explained in the system section, several devices are required for your
wind turbine system to operate, you will need:
 A tower / pole
 Controller
 Battery (for off-grid)
 Inverter
 Electric Cables
The selection of the correct peripheral material/devices is of critical importance; in case
of doubt consult your dealer.
Ⅰ. Tower
The mounting tower is an extremely important element of your system. Pay
attention to the following details:
- Location and Height of the tower: Select a free and safe location with an
ample amount of wind. We recommend a pole of around 8 meters.
Your pole should detain the following features:
 3mm and above thickness
 Pole outside diameter 48~50mm
 6m high
 Turbine should be 3m above any obstacles
- The upper part of the tower that will be attached with the wind turbine has to
fit the following confine:

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You can install your wind turbine on 3 types of towers:
a. Guyed-wire tower
This tower consists of a narrow steel pipe that is supported by guy wires. This
type of towers can also be set up with a tilt-up feature.
b. Free-standing tower
This tower consists of a single steel pipe with a freestanding design. It requires
a significant foundation.
c. Roof-top tower
This tower consists of a mast attached to the sidewall of a building. For this installation
contact your dealer first for further information.
Ⅱ. Controller/Inverter
The controller and the inverter are the main electric devices of your system.
Refer to the system section of this manual to identify the capacity and type of
controller/inverter your installation requires.
Recommended controller/inverter specifications
Use controllers and inverters provided by Newmeil or recommended by your
dealer.
Ⅲ. Fuse (Optional)
For more protection you can use an external fuse to protect your system from
reverse connection between the turbine and the batteries.
Ⅳ. Stop switch (Optional)
In order to be convenient to stop wind generator rotating in case of gust wind
condition; maintenance service or stop charging when batteries are full, etc,
users could install an stop switch. Recommended size of stop switch minimum
25A .

X-400W Wind Generator Instruction Manual
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Recommended fuse specifications
For 400W 12V wind generator we recommend a minimum of 30A -50A
For 400W 24V wind generator we recommend a minimum of 20A -25A
Ⅴ. Batteries
If your wind turbine operates with an Off-Grid system, batteries are required to
store energy.
The total capacity of your batteries has to be equal to the rated voltage of your
wind turbine. You can find this information on the turbine packaging.
For a prolonged use, we recommend to use deep cycle batteries .
Recommended battery specifications
We recommend at least 100AH/12V deep cycle AGM battery or Li-ion battery
For 400W 12V model: 150AH/12V x 1 pieces
For 400W 24V model: 100AH/12V x 2 pieces
Ⅵ. Electrical Cables
The electrical current the wind turbine produces flows in your system through
cables. It is important to use suitable cables to connect the generator and your
batteries or controller/inverter.
Recommended cables specifications

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I Assembly
You should have received your turbine pre-assembled. In order to
complete the assembly you will just need to assemble the blades to the hub
and the hub to the turbine. Instructions are given in the next page.
Before installing the wind turbine, proceed to a check up of your package.
NO.1 1 pcs generator body
NO.2 1 pcs nose cone
NO.3 1 pcs hub
NO.4 3 pcs blade
NO.5 10 pcs nut (M6)
NO.6 6 pcs socket cap screw(M6X22)
NO.7 4 pcs socket cap screw(M6X35)
NO.8 1 pcs nut(M16 x1.5)
NO.9 1 pcs allen key(8mm)
NO.10 1 pcs allen key(6mm)
NO.11 1pcs TPE slip cover
NO.12 1 pcs controller
NO.13 1 pcs operation manual

X-400W Wind Generator Instruction Manual
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Blades, hub and cone assembly
What you will need for this assembly :
- Body n°1 (x1)
- Blade n°4 (x3)
- Hub n° 3 (x1)
- Nose cone n°2 (x1)
- Screw n°6 (x6)
- Nut n°5 (x6)
- Nut n°8 (x1)
- Hex key n°9 (x1)
- Hex key n°10 (x1)
Step 1
 Screw the blades to the hub
 For each blade use hex key n°10 (allen
key 6mm )and one screw n°6 (socket
cap screw M6X22) and nut n°5 (Nut
M6 )
 Screw all 3 blades
 Check for tighness
Step 2
 Mount the hub and blades to the body shaft
 Screw lightly with nut n°8

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Step 3
 Fasten nut n°8 with hex key n°9 (allen key8mm )
 Check the tightness and free rotation
Step 4
 Clip the nose cone on the hub
Final Mechanical Check
- Check the tighness of all screws and bolts
- Ensure free rotation of the hub and yaw axis
Before Connecting ensure that :
- All final mechanical checks have been made
- Cables are not trapped
- All electrical connections are secured