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!