AMPAIR 100 Operation Installation

AMPAIR 100 Operation Installation
AMPAIR® 100
Operation Installation & Maintenance Manual
Manufactured by Ampair ®
© Ampair, September 2008
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Page 1 of 24
Ampair® 100 Manual
CONTENTS
CONTENTS.................................................................................................................................2
SAFETY - READ BEFORE ASSEMBLING OR USING................................................................3
Use ..........................................................................................................................................3
Connection...............................................................................................................................3
Protection.................................................................................................................................3
PACKING LIST - PRE-INSTALLATION CHECK..........................................................................4
SYSTEM DESCRIPTION.............................................................................................................6
Introduction ..............................................................................................................................6
The generator ..........................................................................................................................6
INSTALLATION ...........................................................................................................................7
Choice of mounting position (land based units) ........................................................................7
Mechanical aspects of land installations...................................................................................8
Choice of mounting position (marine units)...............................................................................8
ELECTRICAL INSTALLATION ..................................................................................................11
CHARGE CONTROL REGULATION.........................................................................................12
Installation of charge control regulator....................................................................................12
FINAL ASSEMBLY ....................................................................................................................15
OPERATION & PERFORMANCE..............................................................................................15
INSPECTION & MAINTENANCE...............................................................................................17
Inspection ..............................................................................................................................19
Major disassembly .................................................................................................................21
WARRANTY ..............................................................................................................................24
SERVICING & REPAIRS ...........................................................................................................24
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Ampair® 100 Manual
SAFETY - READ BEFORE ASSEMBLING OR USING
Use
Stopping: The wind turbine has been designed to survive storms; however, it is a good plan to
stop the machine if a hurricane is expected or to carry out inspection. To do this, proceed with
caution, approach the Ampair from downwind and grasp the tail vane (use a boathook for marine
generators). Then carefully turn the machine off wind and, when the blades stop, throw a rope
over them and tie down. Never throw a rope into the turning blades.
To avoid personal injury wear sturdy gloves as a precaution. The wind turbine blades are
capable of causing GRAVE PERSONAL INJURY and should be treated with the same respect
as an aircraft propeller
When first using the Ampair it is advisable to do it in fairly calm weather and low wind speeds.
WARNING:
An Ampair is a piece of rotating equipment and should be treated with care.
Never allow it to become entangled in hair, clothing, or equipment. It is capable of
causing GRAVE INJURY and should be treated with the same respect as an
aircraft propeller.
WARNING:
Check all fixings at regular intervals, especially after severe winds.
Connection
NEVER CONNECT WITHOUT RECTIFIERS
The generator must never be connected to a system without its rectifiers in circuit, to do so risks
discharging the battery to which it is connected.
CORRECT CONNECTION
It is important to connect the system in such a way that the generator cannot feed any electrical
load without the battery being connected. The generator output should therefore go to the
battery side of any isolator switch. Failure to observe this point could place over-voltage on the
system and damage sensitive electronic equipment.
Protection
PROTECTING THE SYSTEM
Do not omit the fitting of fuses, simple in-line fuse carriers maybe used in the battery line.
Fuses = 10 Amp - 12V systems:
5 Amp - 24V systems
OBSERVE POLARITY
Reverse polarity will blow the battery fuse or destroy the rectifiers if no fuse is fitted.
When wiring the system be aware that if the generator is connected to the battery
REVERSE POLARITY the output rectifiers may be destroyed or the internal soldered
connections to the brush holders may melt. Check and double-check polarity before final
connection.
CORE 1 (formerly BROWN ) = + Positive
CORE 2 (formerly BLUE) = - Negative
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Ampair® 100 Manual
DISCONNECTING THE GENERATOR
When disconnecting the generator please be aware that when it is spinning, the output voltage,
in the absence of a battery, will rise. This can give a mild electric shock to a person handling the
connections.
WHEN TO FIT A REGULATOR
It is advisable to fit a voltage regulator if the generator is regularly left to charge batteries when
insufficient or no loads are present. Under these conditions overcharge will slowly drive off the
battery electrolyte, which, if not topped up, will eventually damage the batteries.
CAUTION
When planning your installation, observe the following:
1. Regularly inspect a newly installed system to check that all is well. Do not limit this to
monitoring the electrical output, but also check for smooth mechanical operation. Any
defects need to be remedied immediately.
2. Do not assemble the generator, vane and turbine until the electrical installation is
complete.
3. Fit the tail vane first. If you fit the wind turbine first the machine will turn out of control &
be a danger to approach.
4. Take care when disconnecting the generator in a high wind as the terminal voltage is
enough to give a mild electric shock.
5. Very careful attention must be given to the strength and integrity of the mounting. This
should be capable of withstanding a peak horizontal load of 120kg (250lbs).
Note. The mounting pole should be vertical. The space between the blade tips and the
mounting pole must be left clear. i.e. no clamps or other items should diminish this
clearance. The pole base should have a rigid mounting. (The mounting should not rest
on a resonant surface such as the centre of a cabin roof since this may transmit any
vibration making the machine audible inside).
6. When mounting the Ampair on its pole or bracket the cable needs to be fed down
through the mounting. When arranging this cable make sure it cannot chafe at the point
where it leaves the mounting pole. Either lead the cable out of the bottom of the pole in a
gentle curve or drill an exit hole in the pole large enough to take a rubber grommet to
protect the cable from the sharp edges of the hole.
PACKING LIST - PRE-INSTALLATION CHECK
AMPAIR GENERATOR
Check that a complete and undamaged set of parts has been received. Have you received the
voltage ordered 12V or 24V? The recyclable carton contains:
• Generator, complete with assembled hub and pivot.
• Ampair 100 manual
• Six wind turbine blades: three colour coded pairs (see coloured code on base of blade).
• Direction vane (tail fin)
• Two hardware kits:
Kit 1. Wind Vane Fixings
Wind Vane Clamp Plate (Marine)
3 M8 x 25mm screws
6 M8 plain washers
3 M8 nyloc nuts
© Ampair, September 2008
Kit 2. Blade Fixings
12 M8 x 40mm fasteners
12 M8 shakeproof washers
12 M8 nuts
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Ampair® 100 Manual
AMPAIR STERN MOUNT KIT (SMK)
The Ampair SMK carton contains:
• Pole A, 800mm, Four 6.5mm holes each end, two 10.2mm holes centrally
• Pole B, 800mm, Four 6.5mm holes each end.
• Pole C, 970mm, 25mm OD, strut pole,
• Stay wires, two, terminated by thimbles and "D" ring nuts.
• Bag 1, containing, yoke, two angle feet and backstay clamp shell.
• Bag 2, containing, two anodised aluminium alloy joiner tubes.
Two hardware kits:
Kit 1. Strut, yoke & feet fixings
1 M6 x 40mm screw
2 M6 x 35 hex screw
3 M6 shakeproof washers
3 M6 Nyloc nuts
1 M10 threaded rod 75mm
2 M10 shakeproof washers
1 M8 x 60mm hex bolt
2 M8 plain washers
1 M8 Nyloc nut
Kit 2: Joiner tube fixings:
16 M6 x 10mm screws
16 M6 shakeproof washers
Fig 1. Stern
Mount Kit
This arrangement places the blade tips 2 metres (7 feet) above the base fixing. If there is a
raised area adjacent upon which people may stand, raise this base accordingly.
MIZZEN BRACKET
The Ampair Mizzen bracket carton contains:
• the bracket
• 2 M10 x 150mm threaded rod
• 8 M10 nuts
• 8 M10 plain washers
• 4 M10 shakeproof washers
Fig 2. Mizzen
Bracket
Fig 3. Gantry
Mount
GANTRY MOUNT
Carton contains:
Pole with base flange (800mm height x 48mm outside diameter)
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Ampair® 100 Manual
SYSTEM DESCRIPTION
Introduction
The Ampair is a wind driven generator capable of supplying up to 100Watts of electrical power at
either 12 or 24 volts for charging batteries.
The generator
The unit consists of a two part cast aluminium body, the two parts sealed by an "O" ring. Two six
pole permanent magnet rotors run, with their poles in line, on a stainless steel shaft. The shaft
runs in two sealed grease-packed ball bearings with the front bearing protected by a shaft seal.
Two six-pole stators are arranged with their poles staggered at 30 degrees to minimise
"cogging" or break-out torque and so allow easy starting. The unit is assembled with one stator
in the main body casting and the other in the nose piece. During assembly these are precisely
aligned on the test bench to give optimum performance. A small timing mark is made at the
junction of the case halves to allow accurate re-assembly.
The alternating current output of the stators is rectified by two bridge rectifiers, one per stator.
The DC output of the two rectifiers is paralleled and passes to two carbon brushes mounted in
brush holders located on the sides of the lower body section. The carbon brushes carry the
output to two phosphor-bronze slip rings mounted on the stationary pivot shaft, allowing the
machine to rotate to follow the wind. To absorb any electrical noise arising from the slip-rings
and brushes, a metal oxide varistor is wired across the output between rectifiers and brushes.
The output is electrically isolated from the case.
The body is mounted on the pivot shaft where it runs on a sealed grease-packed ball bearing at
the top and a composite plain bearing at the base. The top bearing is captive in the body; the
lower bearing is located in the body by a stainless steel spiral retaining ring. The pivot section
contains an "O" ring seal on each brush holder cap, an "O" ring around the lower bearing to
body junction and a "V" seal where the pivot shaft passes through the lower bearing.
The pivot axis passes through the centre of gravity of the assembled machine. This is necessary
to ensure alignment into the wind in light breezes without undue spinning.
The wind turbine consists of six cambered and twisted compression moulded blades of glassfibre reinforced polypropylene. This material has exceptional fatigue resistance and retains its
durability down to sub-zero temperatures.
The blades are factory selected for balance to less than one gramme and are delivered as
colour coded matched pairs. The blades are retained by M8 x 40mm stainless steel fasteners
with shakeproof washers and nuts, two of each per blade, in a hub assembly consisting of two
aluminium alloy plates mounted on a turned and anodised aluminium alloy hub centre piece.
The hub centre is bolted to the plates by three M6 x 40mm stainless steel screws with
shakeproof washers and nuts. The hub is fitted to the generator shaft taper where a dowel pin is
located to prevent relative rotation and retained by an M10 plain washer and nyloc nut with a
left-handed thread.
An aluminium alloy tail vane is clamped to the rear of the generator body using three M8 x
25mm stainless steel screws, six plain washers and three lock nuts. The vane of marine
generators is provided with a grab hole at its lower corner to facilitate turning the unit cross-wind
to stop the wind turbine rotating when required.
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Ampair® 100 Manual
Low Temperature Operation: Plastic materials do not perform well in extreme cold, becoming
brittle and breaking. This applies to wind turbine blades, whether glass filled or not. Operation at
around 0°C should not be a problem, but most materials are vulnerable at –20°C and cannot be
warranted to survive indefinitely. Ampair’s glass filled polypropylene blades, moulded with large
sized fibres in a compression process, are superior to nylon, carbon polymer or other plastics in
this respect. However, when ice factors are also considered, the prediction of blade reliability is
even more difficult. Other materials are also suspect. Examples are Nitrile used in exposed seals
and “O” rings and basic PVC cable sheathing. For this reason Ampair uses Neoprene and
Viton™ components where possible and "Arctic" grade PVC. Grease used in sealed bearings
allows performance to –30°C or below, but component tolerances (ball and ring) can lead to
greater friction and increased wear causing reduced bearing life.
INSTALLATION
Never assemble the generator, vane and turbine until the electrical installation is prepared.
Choice of mounting position (land based units)
The wind generator should be sited as high as practicable, clear of windbreaks or buildings and
away from sources of turbulence. These conditions are shown diagrammatically below.
Figure 4: Wind Turbine Location Guides
Warning: Before a wind generator is installed in an excessively windy location, the operators
must satisfy themselves that the site is suitable. It may be necessary to log site wind speed and
direction data at various heights prior to installing the machine. Any indication of turbulence
means that the generator should be re-sited or raised above the turbulence. Wind data must be
local and not from close-by. Wherever possible avoid roof top mounting which can give rise to
turbulence, shock loads and vibration.
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Ampair® 100 Manual
Mechanical aspects of land installations
Free-standing installations should generally conform to Figure 5 below. Very careful attention
must be given to the strength and integrity of the mounting. This should be capable of
withstanding a peak horizontal load of 120kg (250lbs). The main components are:
Mast: of steel tube (water pipe or scaffold tube), alloy tube or wood (telegraph pole) If the guys
are unsuitable (grazing cattle) then use a telegraph pole one third buried or a lattice tower as an
expensive alternative.
Guys: Usually galvanised steel wire protected by
plastic sheath and fitted with end thimbles. Don’t
use a material that will stretch or deteriorate. Three
equally spaced guys (120°) will assist raising and
lowering the assembled mast. A high mast will
require intermediary guying. The top guys hold the
mast upright, the lower prevent it from buckling. The
top fixing point should allow for minimum overhang
of the generator, i.e. be only a short distance below
the wind turbine blade tips.
Tensioners: The simple and easiest method of
tensioning guys, but adjustment must be uniform,
since it is the guys that resist the thrust of the wind
turbine.
Fig 5: Pole Mount Layout
Ground anchors: These should be suitable
eyebolts fixed in the ground and in line with the guys. Anchors in soft earth may require
concrete, gravel or clay soils require “auger” type anchors (see Figure 6) and rocky ground may
need drilling and expanding rock anchors. Only the eye should be visible above ground. Avoid
waterlogged soils which have poor holding and always
anchor below the frost level.
Base: This is to carry the weight of the generator and
mast only. Fixing again depends on the ground state but
metal pegs driven into soil are often sufficient. A lattice
tower would need a concrete base with rawlbolt fixings. It
is often convenient to make a pivot arrangement for the
base in-line with one guy anchor to aid raising and
lowering.
Fig 6: Ground Anchor
Lightning: Directly earth all metalwork. Bury output
cables (½m depth) between mast and battery position for
better protection than suspending in air. Either run cabling
through plastic conduit or use a type specified for burying.
Choice of mounting position (marine units)
There are four basic alternatives in the confined quarters of most small boats as shown in Fig 7:
a) On a tall stayed pole on the stern of a boat (the stern mount kit).
b) On a bracket on the mizzen mast of a yacht (the mizzen bracket).
c) On a custom made welded ‘pushpit’ structure, "A" frame, gantry etc. (gantry mount).
d) At the main or mizzen masthead of a yacht.
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Ampair® 100 Manual
Fig 7: Alternative Mounting Positions
On a small boat space is at a premium and so the aim should be to get the wind turbine high up,
away from people on the busy deck. This has the advantage of placing the turbine up where the
wind is stronger, but has the disadvantage of adding top weight. Mast tops are generally the
most congested location on a boat and so these are seldom utilised as a mounting location,
irrespective of top weight considerations but are excellent when achieved. On ketches (other
than junk rigged ones) the mizzen mast provides a good location, but for sloops stern pole
mounts or stern gantry mounts are more typical compromises. The advantage of a stern pole is
that it can be de-rigged fairly easy (e.g. to put a boat into racing trim for a season) whereas
gantries are for committed cruisers and will also typically be designed as tender davits, aerial
mounts, and solar panel mounts.
Very careful attention must be given to the strength and integrity of the mounting. This should be
capable of withstanding a peak horizontal load of 120kg (250lbs). Note. The mounting pole
should be vertical. The space between the blade tips and the mounting pole must be left clear,
i.e. no clamps or other items should diminish this clearance. The pole base should be mounted
where the structure is very rigid. The mounting should not rest on a resonant surface such as the
centre of a cabin roof since this may transmit any vibration making the machine audible inside.
Installing Stern Mount Kit
a) Check: Ensure that a complete and
undamaged set of parts has been received.
b) Pole position: The pole base fixing may
be moved to one side provided that, when
viewed from above, the angle between the
strut and either wire is greater than 45
degrees.
c) Pole assembly: Using the joiner tubes
Figure 8: SMK Components
and M6 x 10mm screws and shake-proof washers,
assemble the poles so that pole A (holes in the
middle) is the top pole, pole B (no holes in the middle) is the middle pole and the Ampair pole
becomes the bottom pole (two holes only at one end for fixing the feet).
A thread locking solution (e.g. Loctite 641) will stop screws shaking loose due to long term
vibration. It may be easier to feed the cable through the poles as they are assembled.
d) Feet: Using the M8 x 60mm bolt, washers and nut, fix the feet to the pole end and screw
down the feet. The feet should be arranged so the pole can pivot in line with the strut. This
usually means aligned fore and aft unless the pole is off-centre.
e) Stay Wires: Having assembled the poles with joiner tubes, site the pole and attach the two
stay wires with the yoke in place on the pole. Find suitable points for the stay wire base fixings,
allowing for the fact that these will be under considerable tension in use. "Bottle screws" are
suggested as a tensioning method.
f) Backstay strut: File the groove in the strut pole end and clamp shell to accommodate the
backstay wire diameter less 0.5mm. Cut the strut pole to length required. Drill the hole for the
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Ampair® 100 Manual
strut to yoke bolt in situ to ensure correct orientation of holes. Ideally the strut should form a right
angle with the backstay.
Installing Mizzen Bracket
The major load that the bracket has to withstand is one of torsion, hence the box section. At
100mm wide this is close to the width of many mizzen masts and any slight difference can be
accommodated by bending the end plates to suit or by spacing with nuts and washers.
Drill through the end plates and mizzen and fit using M10 fixings. Use at least four Monel rivets
on each side or two M10 bolts/studding right through the mast. If the mast is hollow use spacer
tubes to avoid crushing. Do not insert rubber washers as in time these will deform and then the
load bearing structure will fatigue. Leave a minimum of 50mm (2”) blade tip clearance. Attach
fairleads to prevent running rigging flapping into the turbine.
Fig. 9. Mizzen bracket mounting
Installing Gantry Mount
The gantry mount is simply a pre-welded pole structure in alacromed and powder coated alloy
that can be bolted onto an existing structure.
The top is pre-drilled and reamed to accept the
Ampair pivot.
Do not insert rubber washers as in time these
will deform and then the load bearing structure
will fatigue. Leave a minimum of 50mm (2”)
blade tip clearance. Attach fairleads to
prevent running rigging flapping into the
turbine.
Figure 10: Gantry Mount
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Ampair® 100 Manual
ELECTRICAL INSTALLATION
Cables: The Ampair 100 is fitted with 5m of 1.5sq mm cable. Having sited the Ampair 100
measure the cable run distance to the batteries. If this distance is less than 10 metres (20
metres 24v systems), use 1.5sq mm (16 AWG) cable. If less than 20 metres (40 metres 24v
systems), use 2.5sq mm (14 AWG) cable. Use a similar type of cable to that on the Ampair.
Always use tinned stranded conductors for marine locations. When mounting the Ampair on its
pole or bracket, the cable needs to be fed down through the mounting. When arranging this
cable make sure it cannot chafe at the point where it leaves the mounting pole. Either lead the
cable out of the bottom of the pole in a gentle curve or, drill an exit hole in the pole large enough
to take a rubber grommet to protect the cable from the sharp edges of the hole.
Connectors: To carry power from the Ampair to the wiring on the boat or building we
recommend that a quality watertight connector be fitted. In the case of combination of locations,
a watertight socket can be fitted at each site. The plugs and especially the sockets should have
watertight caps when not in use.
Installation: Wiring between the socket (or junction box, deck gland etc.) and the battery area
should be clipped at regular intervals to the structure for safety and a neat job
Protection: The simplest possible arrangement feeds the power from the Ampair directly to the
battery, through an in-line fuse rated at 10 Amps (5 Amps 24v system) in the positive line next to
the battery as shown in Figure 11 below.
Figure 12. Basic Wiring
CORE 1 = +
(formerly brown)
Wiring options: In fig. 12, two optional components have been added to show where they might
Ampair
be wired
in100
the circuit.
o TheCORE
switch,
which may be used as a simple means of charge control, should be
2=rated(formerly
at 15 Amps DC to ensure long life.
blue)
o The ammeter
is wired in series (assuming it to be of the internal shunt variety) in
one line. This allows the machine output to be seen at all times. As shown, the
positive (+) connection of the ammeter is made to the generator, whilst the
negative (-) is made to the battery. Never connect an ammeter across the
supply.
Figure 11: Basic Wiring Diagram
CAUTION:
IT IS MOST IMPORTANT TO FIT A FUSE. The fuse should be next to the battery
terminal since, in the event of a fault or damage to the cable, the battery will
supply a large fault-current.
CAUTION:
When wiring the system be aware that if the Ampair is connected to the
battery with REVERSE POLARITY the output rectifiers and brush fuses can
be destroyed. Check and double-check polarity before final connection.
CABLE COLOURS: CORE 1 (formerly BROWN) = + Positive
CORE 2 (formerly BLUE) = - Negative.
CAUTION:
The Ampair generator output MUST GO STRAIGHT TO THE BATTERIES. If the
Ampair is connected on the DOWNSTREAM (load-side) of the battery isolator
switch, it leaves scope for damage to electrical equipment on the boat. Under
these conditions it is possible to run the Aquair whilst the battery is isolated. This
can subject the system to excess voltage.
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CHARGE CONTROL REGULATION
An Ampair used as a semi-permanent wind charger may well need regulation, in which case the
appropriate model should be wired in the system. Ampair manufactures three Charge Control
Regulators for protecting lead acid batteries from overcharge. They are not “shunt” type
regulators, which dissipate excess charge as heat, but an electronic power switch, which
disconnects the generator from the battery at the regulation voltage.
Regulators S1B & S3B have a single 100-watt input (Ampair, Aquair or UW). Regulator type S1B
has one output battery connection. Regulator S3B has three output connections to serve up to
three battery banks with a common negative. The third regulator D1B has two 100 watt inputs
(any two from Ampair, Aquair, UW or solar panels), supplying a single battery bank at a fixed
regulation voltage.
All regulators have 2 level sensing. The lower voltage (Lo) connection regulates at 0.4 Volts
below the high (Hi) connection for 12V systems (0.8V for 24V systems). “Hi’ connection is
appropriate for liquid electrolyte batteries and/or live aboard situations. ‘Lo” connection for gel
batteries and/or infrequent use.
The battery voltage is sensed at the regulator output connection, therefore install the regulator
as near the battery as practicable and keep the connecting cables short.
All regulators feature the same multi-stage regulation programme which has regulation voltages
of Lo = 13.6V. Hi = 14.0V for l2V systems (27.2V & 28.0V for 24V systems).
Charging is continuous until the Lo or Hi voltage is reached, depending on the battery output
used. The generator is now disconnected from the battery. Off-charge, the battery voltage will
fall. At a voltage of 0.5V below the regulation voltage a 30-second time delay is activated. This
delay prevents the regulator from oscillation (hunting) when charging batteries under load. After
30 seconds has elapsed, the generator-to-battery connection is remade and charging continues
to the regulation cut-out voltage.
A cycle counter counts the charge/disconnect cycles and at the tenth cycle increases the
regulation voltage for one cycle only by 0.4 volt to Lo 14.OV or Hi 14.4V for 12V systems (0.8V
for 24V systems Lo = 28.OV, Hi = 28.8V). This provides an equalisation charge for the battery.
Subsequent cycles return to the lower settings until a further 9 cycles are completed.
Ammeter: We recommend fitting an ammeter to monitor charging.
Use 10A for 12v, 5A for 24v. Fit an ammeter with a linear scale (moving coil type) or low outputs
will be indiscernible.
Fuses: Battery protection fuses should be fitted. Use l0A in 12v system, 5Amp for 24v.
Wiring: Use suitably insulated cable of 1.5 sq. mm (16 A.W.G.) between regulator and battery in
single source systems; 2.5 sq. mm (14 A.W.G.) for dual source. For input wiring to the regulator
see appropriate generator wiring section. The use of screened cables is recommended if the
cables run close to equipment radiating strong electrical fields e.g. radio transmitters or aerials.
Installation of charge control regulator
Make sure the generator is not operating whilst connecting to the regulator. Connecting with live
wires can damage the electronic regulation circuit.
At initial start-up, allow a time of 1-2 minutes for circuit timing functions to become active.
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Protecting the system:
Fuse warning - never omit fuses, simple in-line fuse carriers may be used; they protect your
system from excessive battery currents in the event of a serious electrical fault. If they keep
blowing, find out why.
Fuses = l0A for 12V systems; 5A for 24V systems.
The regulators are internally protected by SAE fuses, which are not substitutes for battery
protection fuses. The fuses must be next to the battery terminals since, in the event of a fault,
the batteries would source the fault current. Check and double-check polarities before making
connections, insert the fuses in the fuse carriers last of all.
Corrosion:
This is the enemy of all electrical connections, especially in marine environments. Site regulators
in a weather proof location: as dry as possible, and splash proof. Inspect all terminations and
connections for signs of corrosion. Rectify by cleaning, remaking etc. Use tinned copper wire for
extension leads to prevent corrosion spreading inside cable insulation.
Operating problems:
A digital multi-meter is useful for checking operational faults, if no permanent monitoring
instruments are used. Battery voltage levels and those of the charging source can be read
directly. Charging current readings will require the multi-meter to be installed in line. In this way
currents into and out of the regulator can be observed. Do not remove battery connections since
regulator operation depends on a very small supply current. If the regulator is suspect then it can
be temporarily bypassed by connecting the source positive direct to a battery positive. The
negative connections are common and do not need disturbing unless regulator replacement is
necessary. Use the multi-meter continuity range to confirm all cable runs are low resistance.
Operation:
When installed, the generator and regulator will run and maintain the batteries automatically.
The unit may be run in conjunction with any other charge-source with no known interactive
problems. Regular battery inspection and topping up must still be carried out to obtain maximum
battery life.
Faulty regulator:
Each regulator is individually tested and a chart recording kept of its operation. Each regulator
has a unique serial number and a test date. Please provide these with any queries. If the
regulator is suspect, then it can be temporarily bypassed i.e. connect the rectifiers directly to the
battery terminals observing correct polarity. If this reinstates correct charging, then the regulator
must be serviced or replaced. Regulators draw a small current (typically 1mA at 12V) from the
battery to activate the sense and control circuits. Without this connection the regulator will
be inoperative.
SERVICING
If the regulator is suspect, then it can be temporarily by passed i.e. connect the generator
directly to the battery terminals observing correct polarity. If this reinstates correct charging, then
the regulator must be serviced or replaced. Regulators draw a small current (typically 1mA at
12v) from the battery to activate the sense and control circuits. Without this connection the
regulator will be inoperative.
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Figure 12. Charge Control Regulator - Wiring Diagrams
The use of screened cables is recommended if the cables run close to equipment radiating
strong electrical fields e.g. radio transmitters or aerials.
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FINAL ASSEMBLY
See sectioned drawing, figure 15.
a) Mounting the Ampair: Put a thin film of grease on the pivot shaft and its fixing screw threads
to prevent corrosion. Bring the Ampair body to the mounting arrangement, pass the 2 core cable
down the mounting pole, insert the pivot shaft of the Ampair into the top and secure the
fasteners. The top of the pole is made to compress the lower pivot bearing "V" seal by about
2mm, if you have made your own fixing tube, be aware of this point to ensure free turning and
weather proof sealing.
b) Output Cable: Make the final electrical connections to the battery, as shown in the electrical
section, Insert the fuse or fuses in their carriers.
CAUTION:
To avoid injury, fit the tail vane first. If you fit the wind turbine first, the machine
will turn out of control and be a danger to approach.
c) Tail Vane: Clamp the tail vane using the M8 x 25mm screws washers and lock nuts.
d) Wind turbine: Assemble the blades to the hub with the concave or hollow side facing the
wind. Using the M8 x 40mm fasteners, shakeproof washers and nuts, fix the blades in place
observing the colour-coded pairs. These must go opposite each other.
WARNING:
FAILURE TO INSTALL BLADES IN MATCHING PAIRS CAN CAUSE THE
MACHINE TO RUN OUT OF BALANCE.
The holes in the blades are a deliberately tight fit and it may be necessary to turn the fasteners
as they are inserted. First, evenly tighten all the nuts by hand, then, fully tighten opposite pairs
with a spanner. Finally, recheck the tightness of all the nuts.
CAUTION:
Put a rope over the Ampair passing through the blades to prevent its turning as
you carry out the final checks. Once the mounting is complete, make sure all
personnel are clear, turn the Ampair to face the wind and whilst holding the vane
step back and remove the rope.
OPERATION & PERFORMANCE
STARTING & STOPPING
Starting: It is assumed that the Ampair has been assembled and installed in accordance with
INSTALLATION section in which case it will now be operating.
Stopping: The wind turbine has been designed to survive storms; however, it is a good plan to
stop the machine if a hurricane is expected or to carry out inspection. To do this, proceed with
caution, approach the Ampair from downwind and grasp the tail vane (use a boathook for marine
generators). Carefully turn the machine off wind and. when the blades stop, throw a rope over
them and tie down. Never throw a rope into the turning blades.
CAUTION:
To avoid personal injury wear sturdy gloves as a precaution. The wind turbine
blades are capable of causing GRAVE PERSONAL INJURY and should be
treated with the same respect as an aircraft propeller.
© Ampair, September 2008
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Page 15 of 24
Ampair® 100 Manual
PERFORMANCE
The graph shows the output for a range of wind speeds. The drag due to the wind turbine is
about 22kg (50lbs) at 50 knots wind speed.
Figure 13: Ampair 100 Wind
Generator Power Curve
Figure 14: Ampair 100 Wind
Generator Speed Curve
© Ampair, September 2008
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Ampair® 100 Manual
INSPECTION & MAINTENANCE
Figure 15: Sectioned Drawing
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Page 17 of 24
Ampair® 100 Manual
KEY TO SECTIONED DRAWING
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
Tail vane
M8 x 25 screw, plain washer x 2, & nyloc nut (3 of each)
After-body
Rear ball bearing: Type 6202. 15 x 35 x 11mm with frictionless cover
Six pole stator (2 off)
Shaft
"O" ring seal: international size 358
Fore-body
Six pole permanent magnet rotor (2 off)
Front ball bearing: Type 6203. 17 x 40 x 12mm with frictionless cover
Internal circlip: 40 x 1.75mm
Shaft seal: 17 x 40 x 7mm rubber coated, plain lip
Hexagon head set screw M8 x 25mm, fibre washer, plain washer & shakeproof
washer (2 of each)
Wind turbine blade (6 off, available as balanced pairs)
Nut Nyloc M10 left handed thread & plain washer
Hub plate rear (1 off)
M8 x 40mm square shoulder fasteners, shakeproof washer & nut (12 off)
Sealing cap
Hub plate front
Dowel for locating hub centre
Ball bearing: Type 6202 15 x 35 x 11mm with double seals
Slip-ring assembly
Lower bearing (composite)
O" ring seal: international size 332
Spiral retaining ring
Pivot
V" seal (neoprene)
Output cable: tinned, stranded copper flex, twin 1.5 mm2 arctic grade PVC sheath
Mounting pole
Socket cap screw M8 x 16 and shakeproof washer
Cable gland with flexible tail
Brush cap, brush, "O" ring seal (international size 012 neoprene), brush holder &
spring connector (2 of each)
Suppressor: metal oxide varistor
Rectifier with M5 x 16mm pan head screw (2 of each)
Rear cover plate
Self-tapping screw, Number 8 x 3/8" UK designation (4 off)
© Ampair, September 2008
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Page 18 of 24
Ampair® 100 Manual
General characteristics
Figure 16: Ampair 100 Wind
Generator Dimensions
Ampair Body
Shaft diameter
Pivot shaft diameter
Body height (from machine base)
Body diameter
Body length (including shaft)
Body length
Generator body and pivot weight
17mm
40mm
275mm
175mm
290mm
240mm
9kg
(1.58")
(10.75")
(6.89")
(11.4")
(9.5")
(21 lb)
928mm
284mm
800mm
44mm
38mm
480mm
12.5kg
(36.5")
(11.2")
(31.5")
(1.75")
(1.5")
(19")
(28 lb)
Assembled Ampair Wind Generator
Wind turbine diameter
Tip of blades below top of pole
Mounting pole length
Mounting pole outside diameter
Mounting pole inside diameter
Turning radius
Mounted weight excluding poles
Electrical
Output nominal voltage
12V or 24V
Peak output power
100W
The output is fully rectified and isolated from the case.
Inspection
Check all fixings at regular intervals, especially after severe winds. First stop the machine, see
section on Stopping.
CAUTION:
To avoid personal injury wear sturdy gloves as a precaution. The wind turbine
blades are capable of causing GRAVE PERSONAL INJURY and should be
treated with the same respect as an aircraft propeller.
© Ampair, September 2008
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Page 19 of 24
Ampair® 100 Manual
Regularly inspect the following:
• Hub to shaft nut (priority number 1)
• Blade fasteners & nuts
• Hub-centre screws
• Wind turbine blades
• Tail vane screws
• Pole mount screws
• Brushes
The Ampair wind generator should be inspected regularly, particularly after stormy weather, for
signs of accidental damage. Any minor nicks in the edge of a blade may be dressed out but the
blade must be replaced if there is any sign of damage or cracking near the root. Since the
blades are supplied as matched, balanced pairs, any damaged blade must be replaced along
with its opposite number. The unit may be run with two blades missing, whilst the replacements
are obtained, at reduced performance since difficulty in starting will be encountered.
SMOOTH RUNNING
The design of the blades makes the Ampair a very quiet running machine. If vibration is
encountered, this is evidence that the turbine is running out of balance. To prevent any resultant
noise and the risk of fixings working loose, it is most important to take action. Remove the
turbine, take out the blades and examine them to check that the pairs are placed opposite. If
they are correctly assembled and the machine is still vibrating, contact Ampair.
To confirm correct blade performance, firstly weigh the blades, the pairs should be the same
weight, within one gram. Secondly, lay the assembled turbine on a flat surface face down, this
will reveal any blade bend as the tips should be above the surface by an equal amount plus or
minus 3 mm.
Any other machine noise should also be investigated. Only after very extended running life
should there be any detectable bearing noise. If this is the case, refer to the maintenance
section for instructions on their replacement.
WARNING:
NEVER ALLOW THE MACHINE TO RUN OUT OF BALANCE
The blade material has exceptional fatigue resistance which is of the utmost importance in
hostile locations such as tropical sunshine and mountain tops. The material is, however, subject
to slow degradation due to ultra violet light which increases towards the tropics and with altitude.
This process is slow and when it becomes apparent as a white powderiness of the blade
surface, particularly along leading and trailing edges, the blades may be carefully painted with
two-pack polyurethane after a light sanding. DO NOT MIX UP THE BALANCED PAIRS.
The shaft seal protecting the front bearing should be renewed after 2 - 3 years of regular use.
Also the lower bearing and "O" seal. The bearings should be replaced when they become noisy.
Regularly check the security of the fixings on hub, vane and pole.
If damage to the paint occurs, clean off any corrosion and repaint.
Clean the brushes, taking care not to damage the brush spring when handling.
© Ampair, September 2008
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Page 20 of 24
Ampair® 100 Manual
Major disassembly
a) Stop the Ampair see Section on Stopping.
b) Disconnect from the batteries, removing the fuses first, see Figures 4 & 5 (Circuit diagrams).
c) Remove the wind turbine. The centre nut has a left handed thread and so is rotated
clockwise to remove. Pull the hub away from the machine and give a very careful tap on the
end of the shaft with a rubber faced mallet if necessary. If difficulty is encountered in
removing the hub from the shaft, avoid hammering on the shaft-end. Ampair offer a purpose
made puller, you can improvise a puller out of a piece of metal plate, drilled for the three hub
centre plate fixings, and three M6 x 60mm bolts.
d) Remove the tail vane.
e) Feed some excess cable length up the pole.
f) Remove the fasteners from the pivot and lift the machine off the pole.
PIVOT SECTION
With the machine on the bench, undo the two black brush holder caps and remove the brushes
to a safe place. Prise out the end of the spiral retaining ring from around the pivot lower bearing.
Withdraw the pivot assembly, a good tug may be needed. Inspect the slip rings, clean if
necessary. Inspect the lower bearing, if this is loose, obtain a replacement. Inspect the top
bearing in the pivot housing. Inspect the "O" rings and "V" seal, replace if worn. It is sometimes
easier to remove the Ampair generator head with the pivot in situ. Disconnect the battery first
and remove the brushes. Uncoil the retaining ring and lift the body over the pivot. The exposed
slip-ring must be protected from the environment if the generator is removed for further
servicing.
When reassembling put silicone grease (not petroleum grease or jelly) around the shaft where it
passes through the lower bearing. Slide the bearing and "V" seal down the shaft about 20mm
and wipe grease around the shaft. Slide the bearing back up the shaft and remove the excess
grease, wipe a fillet of grease around the point where the "V" seal sits and slide the "V" seal into
place. Before reinsertion wipe the slip rings to remove any trace of contamination due to
handling and put grease around the lower bearing "O" ring. Gently slide into place and wind the
spiral retaining ring into its grove. Clean and replace the brushes. Re-check the pivot for excess
side play, if this is suspect replace the lower bearing and "O" ring. Failure to do so may wear the
pivot. If the rectifier cover is removed, it must be totally resealed before returning the Ampair to
service.
ELECTRICAL SECTION
Figure 17: Ampair 100 Internal Wiring Diagram
© Ampair, September 2008
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Page 21 of 24
Ampair® 100 Manual
Note: By far the most common cause of reduced output is corroded wiring between Ampair and
battery. Before suspecting the machine, check any screw terminal or crimp connections and all
cable runs between Ampair and battery.
Possible faults to consider if reduced output is suspected:a) Poor wiring connections. Inspect all the screw terminals in the Ampair circuit for signs of
fatigue or corrosion.
b) Sticking brushes or associated brushgear contact problems. See Pivot Section.
c) Faulty Rectifiers. The rectifiers and metal oxide varistor should last the life of the machine.
The most likely cause for their demise is accidental reverse polarity connection of Ampair to
battery. If this is suspected the rectifier diode bridges must be checked. Reverse polarity
connection can also melt the solder on the brush holder spring connections, these can be
checked by removing the pivot and looking into the lower body section.
A simple method of checking the machine's output is to disconnect it from the battery and short
together its output leads whilst turning the shaft by hand. A marked increase in resistance to
turning should be felt as the shorting occurs.
RECTIFIER DIODE TEST:
This test will show if the rectifier diodes are either open or short circuit. If your multi-meter
has a diode check feature, select this (if not select the highest resistance range).
Connect the meter leads to the DC output and note the reading. Now reverse the
connections.
METER LEAD POSITION
CONCLUSION
MULTIMETER SETTING
DIODE TEST
OHMS x 100
RED meter lead to positive
No reading
or
Many Megohms* OK
Reading
or
Low resistance
Failed
BLACK meter lead to positive 1.2V (two diode or
Markedly less*
OK
drops)
No reading
or
High resistance
Failed
*This test is not as conclusive as the diode test method, however, provided the first
reading is a very high resistance and the second reading far lower, then the test is valid.
Actual values will depend on the voltage supplied by the particular meter for its
resistance ranges and some meters cannot check 2 diodes in series.
The rectifiers are located in the small box on the back of the Ampair body. To inspect them
remove the four screws and the plate. This has been sealed with polyurethane sealant. After
removing the screws insert a thin blade to cut the seal. The sealant must be renewed on reassembly after the mating faces have been cleaned. Failure to do this can cause severe brush
gear corrosion in future. Unsolder the ‘commoning’ links between the rectifier outputs and check
outputs separately. If a new rectifier has to be fitted, unhook the spring connections to the brush
holders in the lower body section noting polarity, (CORE 1 (formerly Brown wire) = positive
output = upper brush holder) and unsolder the four stator wires from the rectifiers.
d) Faulty stator. Check A C input to rectifiers or check for coil continuity and isolation from the
case. The resistance should be less than two Ohms (approx. three Ohms 24V units)
© Ampair, September 2008
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Page 22 of 24
Ampair® 100 Manual
Note: Do not attempt to modify a 12V machine to 24V. Whilst at first sight this may appear
possible by connecting the outputs of the stators in series, greatly reduced output will be
encountered since they are not in phase. A 24V machine with 24V windings is available.
ALTERNATOR SECTION
Referring to figure 15. undo the two M8 x 25mm screws on the front of the Ampair and pull the
nose piece away from the main body. Do this very carefully as it cannot be withdrawn far due to
the front stator wiring connection. The shaft and bearings are located using Loctite anaerobic
adhesives so some force may be necessary to part them. A puller may have to be improvised to
do this. This job should, therefore, be done on a suitable work bench. The rear bearing needs a
bearing puller to remove it, if no puller is available, a dummy shaft may be fixed in the bearing
centre using epoxy adhesive and, when cured, the bearing worked loose. The front bearing may
be drifted out following removal of the seal and circlip.
Prior to re-assembly, the bearing housings, the bearings inner and outer surfaces and the shaft
surfaces should all be thoroughly cleaned and de-greased. When re-assembling use adhesives
as follows:
Stator to body
Loctite 648
Bearings to body
Loctite 641
Shaft to bearings
Loctite 641
When replacing the fore-body, make sure that the "O" ring is in place and well smeared with
silicone grease. Assemble the body checking that the wiring to the front stator cannot touch the
rotor. Ensure that the timing marks on the body junction line coincide. If the "cogging" or break
out torque has been correctly minimised, 12 minor, equal "lumps" of resistance per revolution
will be felt when turning the shaft by hand. This resistance should not exceed 2 kg-cm (30oz-in).
When doing this make sure that the output leads are not shorted together.
STATOR/ROTOR REPLACEMENT
This is normally a factory operation. Rotor damage is unlikely, but sometimes occurs due to
corrosion or other mechanical problems. Considerable force is necessary to break the adhesive
bond between the rotor and shaft and a bearing press with guide tools to protect the shaft is
needed. Rotor/shaft assemblies can be returned for replacement.
Stator failure only normally occurs due to salt water immersion. Any accident causing this
necessitates the immediate cleaning of all parts with fresh water and then drying thoroughly.
Leaving to dry naturally causes the loss of stator winding insulation due to salt corrosion
resulting in electrical leakage and shorted turns. Stator replacement involves baking in an oven
to break adhesive bonds prior to drifting out the old stators, thoroughly cleaning the castings and
replacement fitting/wiring. Full workshop facilities are needed for this.
RECOMMENDED SPARES
To cater for the possibility of accidental damage, it is suggested that a spare pair of
blades be carried. Other spares worth considering are:
Shaft seal
Pivot seal
Pivot lower bearing
Brush set
2 bearings
Rectifier assembly
© Ampair, September 2008
Replacement may be required after 1-2 years use.
Replacement may be required after several years.
Replacement may be required after several years.
In case of loss during servicing.
Unlikely to be required but an insurance policy
Unlikely to be required unless polarity is accidentally
reversed, however, another insurance policy.
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Ampair® 100 Manual
WARRANTY
Please see Ampair terms and conditions, available on request. Please keep your invoice as
proof of purchase.
SERVICING & REPAIRS
Units should be returned to:
Ampair
Park Farm, West End Lane, Warfield
Berkshire RG42 5RH
United Kingdom
Tel +44 (0) 1344 303 313
Fax +44 (0) 1344 303 312
Email: service@ampair.com
Web: www.ampair.com
Ampair reserves the right to change specifications, without prior notice, in the interest of product
development.
© Ampair, September 2008
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