Superwind 1250 User manual

Operation Manual
Superwind 1250
March 2015

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Table of Contents: Page
1. General information and references 4
1.1 Labelling4
1.2 Range of application 4
2. Safety
instructions 5
2.1 Potential
hazards 5
2.1.1 Mechanical hazards 5
2.1.2 Electrical hazards 5
2.1.3 Hazards when mounting the wind turbine 6
3. Technical specifications 7
3.1 Main
dimensions 7
3.2 Technical data 7
3.3 Functional description / special features 8
4. Preparations for assembly 9
4.1 Packing list 9
4.2 Tools 10
4.3 Available
accessories 10
5. Electrical components and connections 10
5.1 General information 10
5.2 Wiring diagrams 11
5.2.1 Wiring diagram with a charge regulator in diversion mode 11
5.3 System
components 11
5.3.1 Wires 11
5.3.2 DC-box 13
5.3.3 Batteries 15
5.3.4 Charge regulator 15
5.4 Grounding 16
6. Wind generator assembly 16
6.1 Precautions16
6.2 Mast
mounting 16
6.2.1 Mast
recommendations 17
6.2.2 Mounting the generator to the mast 18
6.3 Assembling the wind vane 21
6.3.1 Mounting the wind vane to the wind vane supporter 21
6.3.2 Mounting the wind vane supporter to the generator unit 22
6.4 Rotor
assembly 24
6.4.1 Mounting the hub to the generator shaft 24
6.4.2 Attaching the rotor blades to the hub 27
7. Commissioning 29
7.1 Checklist 29
8. Operation 30
8.1 Safety instructions 30
8.2 RUN and STOP 30
8.3 Power control 30
8.4 Over-speed protection 31
8.5 Annual power production 31
9. Maintenance 32
9.1 Periodic inspections 32
9.1.1 Rotor
blades 32
9.1.2 Bolted
connections 33
9.1.3 Bearings 33
9.1.4 Slip rings 33

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9.1.5 Corrosion protection 33
9.1.6 Mast 34
9.1.7 Electrical system 34
9.2 Long Term Maintenance and Records 34
10. Trouble shooting 34
10.1 Wind generator does not start 35
10.2 No power output 35
10.3 Low power output 35
10.4 Battery fails to (fully) charge 35
10.5 Checking the open circuit voltage 36
11. Repairs and recommended spare parts 37
11.1 Repairs 37
11.2 Spare parts list 37
12. Warranty 38
Notices:
This information is believed to be correct and reliable. However, superwind GmbH assumes no
responsibility for inaccuracies or omissions. The user of this information and product assumes full
responsibility and risk.
All specifications are subject to change without notice.
© superwind GmbH 2015

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Thank you for purchasing a Superwind 1250.
The Superwind 1250 is an advanced wind generator of the highest quality that will reliably generate
power for many years. Reliable operation, however, depends not only on product quality, but also on
accurate assembling and installation – including proper wiring. Please read this manual completely before
starting your installation, paying particular attention to all safety instructions and warning notices. Your
safety is our highest priority.
1. General information and references
1.1 Labelling
This manual is for the Superwind 1250 wind generator.
Manufacturer: superwind GmbH
Am Rankewerk 2-4
D-50321 Brühl
Germany
Tel.: +49 / 2232 / 577357
Fax.: +49 / 2232 / 577368
e-Mail: [email protected]
Internet: www.superwind.com
The data tag listing the serial number and nominal voltage of your Superwind is located on the yaw shaft.
1.2 Range of application
The electric power generated by the Superwind 1250 can be used to charge batteries and/or directly
power 24 VDC or 48 VDC appliances (depending on the system voltage). AC appliances are supplied via
an optional inverter. There is a wide range of high quality 24 VDC or 48 VDC equipment available.
Examples include energy saving lamps, refrigerators, deep-freezers, water pumps, ventilators, consumer
electronics, TV, radio and navigation equipment, etc.
Ideal fields of application range from commercial and government applications (navigational aids, traffic
management systems, monitoring stations and transmitters) to private sector use, such as mountaintop
cabins, summer cottages or other remote locations.. Other rural uses for the Superwind 1250 include
supplying basic power demands for families, schools, small health care centres, and the like.

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The Superwind 1250 is also fully compatible with installations utilizing solar arrays. At many locations,
wind and solar energy complement each other. A wind / solar dual charging system featuring the
Superwind 1250 allows you to optimise available power sources, while requiring minimal battery
capacity.
2. Safety instructions
For your safety, please read this manual thoroughly prior to the assembly and installation of your
Superwind 1250. The information provided is to ensure your safety during mounting and operation, as
well as for maintenance and troubleshooting. If you have any additional questions please contact your
dealer, a superwind service partner or the manufacturer.
2.1 Potential hazards
There are a number of potential physical and electrical hazards associated with the installation and
operation of a wind turbine. Familiarity with safety practices and procedures beforehand is crucial, both in
avoiding injury to personnel and damage to the Superwind 1250 wind turbine.
2.1.1 Mechanical hazards
The main physical hazard is contact with a spinning rotor. The rotor blades can cause serious injury, even
at very low speed.
WARNING: Never touch the rotor blades while moving!
Never try to stop a turning rotor by hand!
Never mount the rotor in a location where it can accidentally come into contact with
personnel!
The rotor blades are constructed of glass fibre and carbon fibre reinforced plastic. This material is
extremely durable (which enables your Superwind 1250 to cope with heavy storms) however it can break
if objects are introduced into the rotor at higher rotational speeds.
WARNING: Never let anything strike the rotor while in operation!
2.1.2 Electrical hazards
Even at low wind speeds the generator can produce dangerous open circuit voltages at no-load operation
(i.e. with the electric connection to the battery disconnected). The 24 VDC version can produce up to 54
VAC between 2 phases of the wind generator wires and 72 VDC at the battery terminals of the DC-box.
The 48 VDC version can produce up to 108 VAC between 2 phases of the wind generator wires and 144
VDC at the battery terminals of the DC-box.
Charging currents can reach up to 43 Amps DC (24 V version) and up to 22 Amps DC (48 V version). As
such, all cabling, electrical components and connectors must be rated to 80 Amps (24 V version) and 40
Ampere (48 V version) respectively. Refer to Section 5.3 for additional information.
WARNING: Use of undersized cabling can resulted in overheating and failure, possibly creating fire
and shock hazard!
Fuses are installed in the DC-box to protect the cabling (see Section 5.3.2. for details). Never short-circuit
the battery, which can result in fire or explosion of the battery, along with release of acid and toxic gases.
WARNING: Never short-circuit the battery!
Unsealed lead-acid batteries produce and vent flammable hydrogen gas during charging. This creates an
explosive mixture that can easily be detonated by even the smallest of sparks (those produced by an

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electrical switch for example). To reduce the possibility of explosion, always ensure battery installations
are provided adequate ventilation and that all equipment used in the space is ignition protected.
WARNING: Never install batteries in locations where the danger of sparks exists.
Provide sufficient ventilation at all times.
The dump load (power resistor) of the optional charge regulator can become very hot. For fire protection it
must not be mounted on a flammable surface or close to flammable materials.
WARNING: Never mount the power resistor on a flammable surface.
Mount the dump load at least 40mm away from any flammable materials.
2.1.3 Hazards when mounting the wind turbine
These instructions also apply for disassembly, inspections or other work carried out on your wind
generator.
Use only mast and support designs capable of safely handling the loads of your wind generator. The mast
must not only be able to withstand your wind generator´s weight, but also the considerable thrust caused
by high wind speed. For additional details see Sections 3.2 and 6.1.
General safety precautions
1. Work on the mast or wind generator only on a calm, windless day.
2. Do not allow personnel to step under hanging loads or potential drop hazards (such as a tilted
mast).
3. Ensure all batteries are disconnected from the system prior to any work.
To prevent unintended starts, connect the generator to the DC-box and switch the brake switch 1 into the
STOP-position before mounting the rotor blades.
WARNING: Never approach a turning rotor!

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3. Technical specifications
3.1 Main dimensions
3.2 Technical data
Nominal power 1250 W
Nominal wind speed 11.5 meters per second (22.35 Knots)
Cut in wind speed 3.5 meters per second (6.8 knots)
Cut off wind speed None
Rotor diameter 2.40 m
Number of blades 3
Blade material Glass and carbon fiber reinforced plastics
Rotor speed 300 – 600 rpm
Generator Permanent magnet, 3-phase
Neodymium magnets
Nominal voltage 24 VDC or 48 VDC
Speed regulation Rotor blade pitch
Power regulation Rotor blade pitch
Brake 1 Generator short-circuit
Brake 2 Disc brake
Weight 45 kg
Rotor thrust (operation) 190 N
Rotor thrust (extreme wind speed) 1700 N

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3.3 Functional description / special features
The Superwind, like all other wind turbines, uses a part of the kinetic energy of the wind and converts it
into electricity. The power generated is approximately proportional to the cube of the wind speed, i.e.
doubling the wind speed results in eight times power output. This means that relatively little energy can be
generated during the varying wind speeds of a moderate breeze. A heavy storm however, contains such a
high quantity of energy that the wind generator must be protected against overstressing and damage. The
Superwind has been designed to achieve optimum power output for a wide range of wind speeds, while
providing maximum safety during storm conditions.
a) The rotor blades were developed using modern computerized calculation and simulation methods.
The airfoil has been wind tunnel tested and was specifically developed for small size rotors.
Relatively broad rotor blades combined with special pitch angle produces a high start-up torque, enabling
the rotor to start at only 3.5 m/s wind speed.
Note: Optimum start-up performance will be reached after a break-in period of the bearings and their
seals. The duration of the break-in period can vary depending on site wind conditions.
When using the Superwind for battery charging, please do not mistake the initial rotor start-up voltage as
that of the start of the output charging voltage as the wind speed required to start charging depends on
the battery´s state of charge and may be slightly higher than the rotor start-up wind speed.
b) A key innovation of any Superwind wind turbine is its patented aerodynamic rotor control system,
which (similar to large wind turbines) automatically adjusts the pitch angle of the rotor blades based on
wind speed. The mechanical controller is fully integrated into the hub and works without expensive
electrical or hydraulic components. Instead, the controller is actuated by forces arising from operation of
the wind turbine itself. These forces are affected by the geometric and kinematic lay-out of the rotor and
controller mechanism.
Aerodynamic forces act as control variables to automatically adjust the rotor blades for power regulation
above the nominal wind speed of the unit. Simultaneously, centrifugal forces (the second control variable
for the rotor blade adjustment) are introduced and as both the wind force and rotor speed decrease or
increase, the controller automatically limits rotor speed, even at extreme wind velocities. This unique
system is crucial in protecting the wind turbine from over-speed conditions, even during no-load operation.
As a result, the controller limits the mechanical loads at high wind speeds, enabling smooth operation
under all weather conditions.

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4. Preparations for assembly
4.1 Packing list
Please check your delivery for completeness and transport damage.
Packing list:
1 pcs Generator unit item 1
1 pcs Hub item 2
1 pcs Wind vane supporter item 3
1 pcs Wind vane item 4
3 pcs Rotor blade item 5
1 pcs DC-box item 6
1 pcs Plug 5-pole "Buccaneer" item 7
1 pcs Socket cap screw M12 x 120 item 8
4 pcs Hexagon head screw M8 x 50 item 9
4 pcs Washer 8,5 item 10
3 pcs Socket cap screw M8 x 40 item 11
1 pcs Socket cap screw M8 x 20 item 12
6 pcs Socket cap screw M10 x 45 (TUFLOK) item 13
1 pcs Operation manual item 14

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4.2 Tools
The following tools are needed for the installation of the Superwind 1250:
Allen key 6 mm
Allen key 8 mm
Allen key 10 mm
Torque wrench with suitable sockets
Set of screw drivers
Set of wrenches (mm)
Wire stripper
Crimping tool
Heat shrink or electrical tape
Multimeter
4.3 Available accessories
Charge regulator Morning Star TS-60 incl. power resistor
5. Electrical components and connections
5.1 General information
Always use caution and abide by industry accepted practices and safety procedures when working on
your Superwind or the electrical system.
Electrical system installation, maintenance, and repair should only be carried out by competent personnel
who have studied and are familiar with the information and instructions provided in this manual. If
questions arise, contact Superwind for clarification.
NOTE: All electrical components should be installed at their respective locations before making
any electrical connections.
NOTE: Ensure batteries are disconnected until the installation is complete.
WARNING: Only connect to the battery bank after the turbine installation is completed!

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5.2 Wiring diagrams
5.2.1 Wiring diagram with a charge regulator in diversion mode
(for example Morning Star TS-60)
5.3 System components
5.3.1 Wires
A five wire cable is required to connect the wind generator to the DC-box:
a) 3 output power lines
b) 2 lines for electrical control of the disc brake
The cross section (also known as diameter or gauge) of the wires to be used will depend on their length
and the rated voltage of your wind generator. After deciding on a location for the mast, measure the
distance from the mast top to the DC-box and select the minimum cross section required as provided in
the tables below. In order to keep power loss to a minimum and maintain safety, never use lines with
under-sized cross sections.
Note: All values given in the tables below are based on a voltage drop of 3%.
a) 3 power lines:
24 Volt system:
distance from mast top
to DC-box up to 5,8 m 5,9 – 9,6 m 9,7 – 15,4 m 15,5 – 24,1 m 24,2 – 33,7 m 33,8 – 48,1 m
minimum cross section
recommended per wire 6 mm²
(AWG 10) 10 mm² (AWG 8) 16 mm² (AWG 6) 25 mm² (AWG 4) 35 mm² (AWG 2) 50 mm² (AWG 1)

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48 Volt system:
distance from mast top
to DC-box up to 9,8 m 9,9 – 15,5 m 15,6 – 23,2 m 23,3 – 38,6 m 38,7 – 61,7 m 61,8 – 96,4 m
minimum cross section
recommended per wire 2,5 mm²
(AWG 14) 4 mm² (AWG 12) 6 mm² (AWG 10) 10 mm² (AWG 8) 16 mm² (AWG 6) 25 mm² (AWG 4)
b) 2 lines for electrical control of the disc brake:
For both systems (24 Volt and 48 Volt):
distance from mast top
to DC-box up to 11,1 m 11,2 – 16,4 m 16,5 – 27,0 m 27,1 – 43,0 m 43,1 – 64,2 m 64,3 – 106,7 m
minimum cross section
recommended per wire 1,0 mm²
(AWG 18) 1,5 mm² (AWG 16) 2,5 mm² (AWG 14) 4 mm² (AWG 12) 6 mm² (AWG 10) 10 mm² (AWG 8)
WARNING: Cables with insufficient cross sections can heat up and cause electrical fires!
Cables with tinned braids are recommended for offshore locations or marine applications to reduce
corrosion issues. For underground installations, the cable must be installed in conduit or be suitable for
direct bury applications.
All cables and materials (heat shrink, insulating tape, etc) should be of ultraviolet resistant materials.
Chafe protection should also be provided for the entire cable run. All penetrations into the mast,
electronics enclosure, etc, should be de-burred and the cable protected against chafe using rubber
sleeves, grommets, etc.
All wire terminations and connections must be made using suitable (preferably marine grade) crimp on
connectors.
Due to the weight of the cable, strain relief for the cable must be provided at the top of the mast top so
that connections inside the turbine and "Buccaneer" plug system will not be damaged.
Always pay attention to the correct polarity of the lines. Reversing plug connections or the positive and
negative connections at the battery will destroy the electric rectifiers inside the DC-box. During installation
or when changing out batteries clearly mark all line ends as POSITIVE (+) and NEGATIVE (-) to prevent
connection errors.
WARNING: The rectifiers inside the DC-box will be destroyed by the application of reverse polarity
anywhere within the system and if so acted upon are no longer covered under warranty!

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5.3.2 DC-box
The main function of the DC-box is to rectify the 3-phase AC current coming from the wind turbine into DC
current for battery charging.
The DC-box must be installed vertically and in a location where the heat sink (located on the top) is well
ventilated.
The front of the box contains a Voltmeter (to read battery voltage) and an Ampere meter to read DC
charging current.
The DC-box has two brake switches. These are used to shut down the wind generator should it be
necessary due to conditions, while conducting maintenance or working near the turbine, etc.
Brake switch 1 is for the generator short-circuit breaking system:
a) RUN The 3 lines from the generator are connected to the rectifier set.
b) STOP The 3 lines to the wind generator are short-circuited
Brake switch 2 is for the electrically actuated mechanical disc brake:
a) RUN The disc brake is open.
b) STOP The disc brake is closed.
NOTE: The disc brake (switch 2) can only be activated after the generator has been shorted.
As such, the disc brake can only be switched after brake switch 1 has been switched into
the STOP-position.

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Internal view:
To protect the battery against short-circuit a fuse is installed in the positive line between the rectifier set
and the battery terminal. The fuse is either an 80 amp slow-blow type (24 V-system) or 40 amp slow-blow
type (48 V-system).
WARNING: Do not install other fuses in the three AC wires between the wind generator and DC-box
as they will be blown when stopping the generator by shorting.
A 10 amp fuse is installed in the box in the positive line of the disc brake actuation.
For connecting the cables please see the terminal diagram below:
NOTE: Be sure to observe the polarity of the 2 wires for the disc brake actuation.
The 3 AC power lines (Generator ~) may be connected in any order.

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5.3.3 Batteries
The most common application of the Superwind is charging batteries. For proper battery protection, a
suitable charge regulator is mandatory. The charge regulator allows the Superwind to operate
automatically and completely unsupervised. With a proper charge controller, batteries are charged
optimally and protected against overcharging and damage, which also increases battery service life. The
Morning Star TS-60 (our recommended charge regulator) is suitable for use with all battery types.
When selecting batteries, always ensure their voltage matches the rated voltage of the system (24 V or
48 V). The rated voltage of your Superwind is specified on the unit’s data label (on the yaw shaft).
Flooded Lead-acid batteries are the most commonly used battery type known world-wide, however we
recommend the use of ‘deep cycle’ rated batteries designed for stationary use. We also recommend Deep
Cycle AGM batteries; sealed Absorbent Glass Matt batteries sometimes referred to as ‘solar system
batteries’ as they have a long life span and are usually maintenance-free and better survive an occasional
deep discharge. Car batteries (also rated as ‘starting batteries’) are not suitable because they wear out
very fast by cyclic operations associated with renewable energy based charging. Again, The Morning Star
TS-60 ,our recommended charge regulator, is suitable for use with all deep cycle battery types.
Another important criterion for battery selection is capacity, which is expressed in ampere-hours (Ah). This
value represents the quantity of energy a battery can store. The required capacity depends on your
individual situation (wind location, consumption structure, combination with other generators like PV etc.).
Consult your battery supplier for assistance with questions regarding load support, battery selection and
installation.
Follow all manufacturer’s recommendations when selecting a location for your battery installation.
Charging flooded lead acid batteries releases flammable and potentially explosive hydrogen gas.
Unsealed lead acid batteries have vent caps to release this gas, which can detonate if it is mixed with air
and a spark is present (such as from an electrical switch) or other ignition source (open hot exhaust).
WARNING: Never install batteries in a location where the danger of spark formation exists. Ensure all
battery installations are provided adequate ventilation at all times.
Batteries store a large quantity of energy, which can be suddenly discharged in the event a battery is
accidentally short-circuited. This sudden discharge can destroy the battery (resulting in the release of
battery acid and gas) and even set the battery and the cabling on fire. To protect against accidental short-
circuiting do not make battery terminal connections until all work on the electric system has been
completed.
WARNING: Never short-circuit the battery or terminals across a bank of batteries!
NOTE: Connect cabling to battery terminals only after all work on the electrical system has been
completed.
A fuse is installed inside the DC-box for protection against high current and/or a short-circuit in the
system. As a blowing fuse can cause an electrical spark, the DC-box cannot be installed in the same
area as the battery bank.
Use caution when handling corrosive battery acid, adding distilled water or performing other battery
maintenance. Follow all battery manufacturer instructions and wear protective clothing and suitable eye
protection.
WARNING: Use caution when conducting battery maintenance.
Wear protective clothing and suitable eye protection.
5.3.4 Charge regulator
Every installation should include a charge regulator to protect the batteries against overcharging.
We recommend the Morning Star TS-60 charge regulator.

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NOTE: When purchased at superwind GmbH, the charge regulator Morning Star TS-60 already
comes with the correct setup for a system with the Superwind 1250 being the only power
source to charge the batteries.
In case that additional power sources and charge regulators (for example Solar-PV,
Diesel genset, etc.) are connected to the batteries, the parameters of these devices have
to be considered for the correct setup of the Morning Star TS-60.
Please read the charge regulator installation and operation manual thoroughly and follow all installation
requirements when installing the charge regulator.
If using a charge regulator other than the Morning Star TS-60, ensure that it is a shunt-regulator design.
The series controllers often used in photovoltaic systems are unsuitable as they interrupt the electric
circuit for voltage regulation, placing the wind generator in a dangerous no-load operation condition. The
charge regulator must also be rated for current of at least 60 A (24 V version) or 30 A (48 V version).
For other suitable charge regulators, setups and system integration information please refer to our
‘alternate integrations and special applications installations instructions’ – available by contacting
superwind directly.
5.4 Grounding
Every wind turbine installation should be properly grounded to protect the system against damage by
lightning or over voltage. The design of the grounding system will depend on a number of factors,
including local conditions, the type of installation, soil, groundwater table, and the condition of any pre-
existing grounding systems. Always consult a local electrician if any grounding questions exist.
6. Wind generator assembly
6.1 Precautions
Before starting the installation of your wind generator, keep in mind the potential dangers and proceed
with caution. Use a mast and support structure capable of safely withstanding all the force loads placed
on it by your wind generator. The mast must not only be able to withstand the weight of the wind
generator, but also the thrust caused by high wind speeds as well. For instance; the maximum wind thrust
during normal operating parameters will be approx. 190 N of force. In an extreme gust (wind speed of 70
m/s) the thrust can rise up to 1700 N!
Only conduct work on the mast or wind generator on a calm, windless day.
Do not step or allow others to stand beneath hanging loads e.g. a tilted mast.
Make sure all batteries are disconnected from the system prior to conducting any work.
Prevent the wind generator from starting unintentionally during your installation. Connect the generator to
the DC-box and place the brake switch 1 into the STOP-position before mounting the rotor blades.
WARNING: Never approach a turning rotor – stay away from moving blades!
Never try to stop a turning rotor by hand.
Never install the wind generator in a location where persons can accidentally come into
contact with rotating blades.
6.2 Mast mounting
Before your Superwind is finally installed on the mast or support, the electric cables must be led through
the mast tube and connected to the DC-box (see Section 5.3).

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NOTE: The following applies to all types of mast or support installations:
Before assembling the wind generator ensure
there are no fittings, stays, etc, in the area from
the top of the mast top to a point 1300 mm
below the mast top. This is important because
as the rotor controller pitches the blades at high
wind velocities, their distance from the mast will
be reduced.
6.2.1 Mast recommendations
Refer to the drawing below for the recommended dimensions of the steel mast tube. The yaw shaft of
your Superwind 1250 has a flange which must be attached with four M10 screws and nuts (not included).

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6.2.2 Mounting the generator to the mast
The following instructions refer to a tilt-able (tip-tower) mast system.
1. Lowerthe mast.
2. Insert the turbine output and electric brake power cables into the mast tube.
3. Install the "Buccaneer" plug onto the cable (refer to the below drawing for wiring terminations).
The terminals of the plug are suitable for wires of cross section up to 6mm² (AWG 10) with ferrules.
If your cable has larger AC wires in order to minimize the voltage drop (due to table 5.3) it will be
necessary to crimp short pieces of 6mm² (AWG 10) wires to connect with the plug.

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Position the generator unit close to the mast flange.
Screw the plug onto the socket of the generator unit.

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Move the generator unit carefully towards the mast flange.
Attach the yaw shaft flange to the mast flange with 4 screws M10 with washers and nuts. (The length of
the screws required will depend on the thickness of your mast flange.)
Tighten the screws to 50 Nm. (SAE: 36.9 foot-pounds).