Spreco Silentwind Instruction For Use & Installation Instructions

instructions for use / installation manual

SILENTWIND

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Dear customer

We thank you having bought our product . You have decided on a new generation of
windgenerator. Compared to traditional windgenerators the essential advantages of
our product are safety, security, efficiency and very little noise emission. You will also
profit from our experience of more than 30 years with various windgenerators used
offshore sailing. For long distance cruising the availability of electric energy without
the possibility of grid connection is essential .

Fair winds at any time

The Spreco Team

Please note that this manual is part of the product and must be read closely. Please
study the information carefully before installing the Silentwind generator. This manual
should always be kept near the product and passed on to future owners.

This manual is addressed to the person installing the Silentwind generator. This
person should be familiar with electric wiring and the use of appropiate tools.
Otherwise the Silentwind generator should be installed by a specialist.

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Contents:

1. Operation and use 4

2. Safety instructions 4

2.1. Mechanical risks 5

2.2. Electrical risks 6

2.3. Installation risks 6

3. Technical data 6

3.1. Windgenerator 6

3.1.1. Electrical data 6

3.1.2. Mechanical data 6

3.2. Charge controller 6

3.2.1 Electrical data 7

3.2.2 Mechanical data 7

3.3. Dimensions 7

3.4. Power diagram 8

4. List of enclosed parts 8

5. Operation description 9

6. Diameters of cables 9

7. Installation 9

8. Getting started 11

9. Run and stop 12

10. Charging indicator 12

11. Check ups 12

11.1. Blades 12

11.2. Screw terminals 13

11.3. Bearings / Gaskets 13

11.4. Corrosion protection 13

11.5. Mounting construction 13

11.6. Electrical system 13

12. Maintenance 13

13. Trouble shooting 14

14. Attachment / sketches 16

15. Warranty 19

16. Warranty note 21

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1. Operation and use

It´s most efficient to use the regenerative electric sources of both wind and sun
combined to charge your batteries so that you can make use of daylight and wind for
24 hours. Our hybrid charge regulator is suitable for both sources. You can also
charge the batteries of an electric vehicle with this unit.
Further applications are:
Any application without grid connection, research units, traffic management systems,
emergency systems, street lamps, billboard illumination, projects in developing
countries, wireless LAN access points, holiday homes with inverters for independent
provision of electricity wherever there is no grid connection available or too
complicated to install.
The Silentwind generator is ultralight and aerodynamic so that it is possible to
connect various windgenerators in case your need for energy is high. As noise
emission is very low you can opereate the Silentwind generator in neighbourhoods
and on sailing yachts without annoying your neighbours.
Our charge regulater is suitable both for 12 and 24 volt usage and can be connected
to the Silentwind generator and solar panel.
Another advantage of the Silentwind generator ist hat it does not have any inbuilt
electronics which means that there is hardly any maintenance work on the mounted
windgenerator. The electric power is led down to the charge regulator by three
cables. The hand laminated carbon fiber blades were successfully tested in a wind
tunnel up to wind speeds of 35m/s 63 knots according to DIN EN 61400-2. Therefor
you need not worry about the Silentwind generator in any storm conditions. For
maintenance work there is an additional manual stop switch.

2. Safety instructions

Due to the high RPM and the electric energy that windgenerators generate their use
may be dangerous. Therefore carefully read the following safety instructions.

2.1. Mechanical risks

For various reasons the turning rotor system must be handled with caution. You
cannot see the end of the blades in high wind speeds so that you do not recognise
the inherent danger. Due to their aerodynamic shape the blades have very sharp
edges that may hurt you in high wind conditions. Never ever try to touch the

turning rotor system ! Never ever try to stop the turning rotor system manually.

Make sure that you install the windgenerator in a position that nobody can touch the
blades. Especially on boats ensure a sufficient height above deck.
The blades are produced from carbon fibre which is extremely solid even in high wind
speeds. Therefore keep away from the turning blades in any case. However they can
break because of ropes or other parts touching the blades in very strong winds. If
one of the blades is damaged, activate the brake function manually with the stop
switch of the charge regulator. If one of the blades is damaged, the rotor system will
be out of balance which may be a risk for the whole mounting construction. This has
to be considered before mounting the windgenerator in a safe position.

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Before you install the windgenerator on a mast construction make sure that the 3­phase wiring is disconnected from the charge regulator or fix one blade so that the
system cannot turn. You can also connect the 3 AC wires to block the system whilst
mounting. Another possibility to install the system is to screw the hub with the blades
to the shaft at the very end of the mounting procedure. The mast must be well fixed
so that it is safe in strong wind and sea conditions. Please ask a professional who is
able to assess the load that the system generates in strong wind conditions.

2.2. Elecrical risks

An idle running windgenerator can generate an AC voltage of 40 volt AC /15amp per
phase. Only connect all components if you are familiar with electric wiring. The high
voltage can cause serious injuries and fire if you do not pay attention to safety. Never
ever touch the open end of the wires. The currents on charging the batteries can
reach more than 30 A DC. The whole wiring electric components and connection
points must be able to carry a current of 40 A. Find information about suitable cable
dimensions on page 9

Warning:
Wires with insufficient diameters can cause fire.

Make sure that the wires are run so that mechanical damages cannot occur. A
damaged cable is a severe safety risk. Install a fuse to the batteries positive pole as
closel as possible to the battery. In any case a short circuit of the poles must be
avoided.

Warning:
A short circuit can cause fire and explosion. Never ever install batteries where sparks
can cause this risk. Always ensure sufficient ventilation!

The electrical installation should be carried out by persons with suitable skills who
know what they do. Before a storm the Silentwind generator should be manually
stopped with the stop switch on the charge regulator. In case of storms we
recommend to fix one rotorblade to the mast because of the risk of flying objects.

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2.3. Installation risks

Only use mounting constructions that can take the load of the generator and the blast
pressure of the wind in any condition.

Working on the mounting unit should only be carried out on a calm day. Make sure
that nobody is close to the mast.

Disconnect the battery from the charge regulator when working at the system.
The turning of the blades must be avoided by fixing one blade to the mast.

3. Technical data

3.1. Windgenerator

3.1.1. Electrical data

Type of generator

Permanent magnet generator, 3 phases,
Neodymium-magnets
Rated voltage

12 VDC
Rated power

400 Watt
Rated peak power at

13,5 m/s
Start up speed

2,2 m/s
Start of charging

3 m/s
Charge indicator

Blue LED on the buttom of housing

3.1.2. Mechanical date

Safety test in wind tunnel

122 km/h without failure
Rotordiameter

1,15m
Number of blades

3
Weight of blades

140g/blade
Material of blades

Carbon fibre, hand laminated
RPM range

480 – 1420 RPM
weight

6,8kg (Generator)
Package dimensions

740x370x220mm weight: 9,8kg
Colour

white RAL 9010, powder coated
Warranty

36 months

3.2. Charge regulator

Charge and power management of the provided external hybrid-charge controller
Type 1: W+S 1
Maximum voltage adjustable for acid, gel and AGM batteries.
Brake mode: electronically or manually with inbuilt Stopp switch for maintenance
work (see enclosed manual)

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3.2.1. Electrical data

System voltage

12/24 VDC
Max. input current windgenerator

30 A
Max. input current solar

10 A ( 100Wp)
LCD + LED displays

W, V, A, kWh, Ah, load data

3.2.2 Mechanical data

weight

1,15kg (regulator)
Package dimensions

190x120x65mm
Warranty

24 months

3.3. Dimensions

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3.4. Power diagram

4. List of enclosed parts

All information is reliable. The producer does not take any resonsibility for
inaccuracies. The user of both the instructions and the product takes any
responsibility and any risk. All specifications are subject to change without notice.

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5. Operation description

All windgenerators use the cinetic energy of the wind. This energy is turned into a
turning motion by the blades and thereby changed into 3 phase AC power. The
power of the energy increases in line with the wind speed exponentionally. This
means that a double wind speed generates octuple power. This must be especially
considered in storm conditions.

Our spbΩ blades are produced of high-tensil carbon fibre and are hand laminated
with epoxy resin. This material provides the maximum consistency at lowest weight.
This material is also used in formula 1 and airspace industry. Therefore these CF
blades are extremely light, but resist even strongest wind conditions. They have been
successfully tested at Deutsche WindGuard – according to DIN EN 61400-2 (VDE 0
127-2) at windspeed of 122 km/h at 5480 RPM This is an equivalent of sonic velocity
at the tips of the blades. For every-day use and safety reasons we have equipped the
charge regulator with an additional electronic and manual stop switch.

6. Diameters of cables

12 Volt systems

Distance from
windgenerator to the
charge regulator in m

< 11

12 – 18

19 – 29

30 – 44

45 – 68

69 – 110

Cable diameter in mm2

6

10

16

25

35

50

24 Volt systems

Distance from
windgenerator to the
charge controller in m

< 11

12 – 18

19 – 29

30 – 44

45 – 70

71 – 113

Cabel diameter in mm2

2.5 4 6

10

16

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7. Installation

Before mounting the Silentwind generator onshore find a suitable position fort he
windgenerator. It is an ideal position if the wind flows against the blades without any
obstructions. This means that the generator is mounted as high as possible. The
height depends on the distraction of the wind by surrounding objects. You can simply
test this by fixing a 3 m long – 4cm wide plastic band at the top of a min. 4 meter
pole. You can use a 2nd band at 2 meter height. This does not apply to mounting the
generator on boats.

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If the upper band flows horizontely straight or up to 30 degrees only you have found
the suitable position. In case the band shows more than 30 degrees or turns round
the mast, the position is unsuitable. This test should be carried out at moderate wind
conditions and only gives an orientation. We recommend to do various tests to get a
better assessment. You need not do this test if the windgenerator is mounted far
away from obstructions.

Note: Please note that the Silentwind generator can never be fully efficient

if it is not mounted in the prevailing wind direction or distracted by
obstructions. Therefore it is important to find a position that is not
obstructed by obstacles !

Having found the suitable position an appropriate mast with suitable equipment must
be chosen. The outer mast diameter must have 48mm and it should be inox steel or
alumine. Please also consider possible maintenance work. The mast with mounted
windgenerator should be able to take a wind blast pressure of 250Nm. Grounding of
the mast is highly recommendable. On boats you can use the central ground for mast
and engine. Ask a specialist for advice.

Once the mast is mounted you can start the relatively simple installation of the
Silentwind generator. First connect the 3 CF blades to the assembly hub (see page
17, sketch 4) with the enclosed srews (page 18, sketch 9). The enclosed nylon discs
protect against electrolytic corrosion. The fastening torque is 7-8Nm equivalent to a
weight of 7-8 kilo on a 10cm long lever arm, upright to the lever arm.
If the fastening torque is too high, this will destroy or damage the blades. If the
fastening torque is not high enough, the blades can get lose. A wrong fastening
torque is a considerable safety risk.

Regularly control the fixation of the blades !

Before fixing the blades finally move the 3 blades in a position opposite to the
running direction. The running direction is clockwise looking from the front. Then fix
the blades as described above. The blades should not be out of balane then. The
blades have been balanced statically and dynamically. In case of damage of only one
blade you can buy a single one. When ordering one blade the purchasing department
needs the exact weight of the undamaged blades.

After connecting the blades the set is fixed to the generator shaft with the enclosed
srew nut and enclosed hexagon socket srew key. After that you snap the nose cone
into place on the assembly hub. (see page 17, sketch 5,6 and 7)

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Then you connect the three AC outlet cables which have to be led from the
Silentwind generator to the charge regulator. Use the three enclosed crimp
connectors. We also enclose a strain relief gadget for these connections. (see page
18, sketch 10,11)

Attention During this procedure the 3 AC wires at the end must be connected

together. Otherwise the rotor system may start running and you can get
injured.

At last you mount the Silentwind generator to the mast. Fix the 4 hexagon screws to
the yaw clamp after having put in the rubber pad (see page 18, sketch 8)

8. Getting started

Before getting started your Silentwind generator check the correct mounting and
installation according to the following check list:

OK

Kontrolle

Mast construction:

Optional;
check according to instruction, especially all srew connections, bracing, vertical
position. Grounding and lightning protection according to local regulations

Electric installation:

Check battery status and correct polarity

Charge regulator:

Well fixed and correct polarity? Attention: connect the battery cable first to the
charge regulator, stop switch in position ON?

Fuse:

40 Amp. Fuse connected as close as possible to the battery

Wiring:

All cables connected in line with plan? Check the polarity of all wires on the
screw connection poles. Is the 3 phase cable of the Silentwind generator
connected to the charge regulator? Are the cables correctly crimped and ist he
strain relief mounted?

Yaw shaft:

Ist he rubber pad well placed?

Rotor blades:

Mounted in line with instructions ?

Assembly hub:

Is the assembly hub fixed to the generator shaft? Is the central srew nut
fastened with 30 Nm ?

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Connection to 3 phase rectifier (optional) or the enclosed charge regulator. According
to the charge regulator ordered please read the enclosed manual.

Congratulations now you can go ahead .

9. Run and Stop

Switch the enclosed stop-switch or the stop-switch of the charge regulator in position
run. If the wires are correctly connected to the battery (without having mixed up the
polarity) the Silentwind generator should start charging if windspeed is sufficient. You
can control this on the LCD-display of the charge regulator.

10. Charging indicator

A blue LED at the bottom of the body shows you when the charging process starts.
This depends on the state of charge of the battery – normally 12.5 volt.

Attention If you operate the system with a 3 phase rectifier (optional), you must

manually disconnect the battery. Otherwise there is a risk of overcharging
and explosion due to a mixture of hydrogen and oxygen in case of
sparks. The use of a rectifier may prolong the charging process.

11. Check ups

Your Silentwind generator was constructed for long term use without any
maintenance. However, simple and regular check ups ensure the necessary security.

Saftey first !

Before you start the check up make sure that the blades are stopped and the battery
is not connected to the charge regulator.

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The following check ups should be carried out at regular 12 months intervals:

11.1 Rotor blades

Check if the blades show damages like broken edges, damaged surface or cracks. If
you notice any damage, the generator must not be used any longer. Check the
screwing one day after mounting and after that every 3 months. Eventually that you
can turn to a longer interval.

11.2 Srews

Check that all accessible screws are correctly fixed. Especially the hexagon srews of
the connection to the hub, the central shaft nut and the fixing of the mast must be
checked (see page 10, 11 and page 17, sketch 4, 5 ,6 ,7 and page 18, sketch 8, 9).

11.3 Bearings and gaskets

The bearing of the generator shaft and the bearing of the yaw shaft are permanently
lubricated. Please check these bearings as to free movement, bearing play and
watertightness. Deficient bearings must be replaced.

11.4 Corrosion protection

The complete housing is made of seaworthy alumine and additionally powder coated.
If the outer layer is damaged, there is a risk of corrosion. Please paint these spots
with suitable varnish (RAL9010)

11.5 Mounting construction

Check this construction in line with the instructions concerned (optional).

11.6 Electrical system

Please first stop the Silentwind generator so that all wires carry no voltage. Check if
all connections are properly fixed and not corroded. Possible corrosions must be
removed and treated with contact spray. Give special attention to the battery
connections: they must be clean and greased with vaseline. Check the battery in line
with the instructions of the producer and (if necessary) refill with destilled water. In
case more than 1 battery is used check that all batteries have the same capacity and
state of charge.

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12. Maintenance

Maintenance of the Silentwind generator is not necessary.
The Silentwind generator is produced for troublefree long-term use.

13. Troubleshooting

In case of problems, however, these can be easily solved.

Windgenerator doesn´t start to run:

Possible Cause

Test

Solution

Not enough wind

Measure the wind speed
(Anemometer)

Wait for more wind, start
up speed is 2,2m/s
Stop switch activated

Switch to run
Enclosed stop switch
wrong installed

Install in line with
instruction
Generator shaft sluggish

Turn manually

Connection windgenerator
charge regulator short
circuit of AC cables, short
circuit of generator,
customer service

Windgenerator doesn´t charge:

Possible cause

Test

Solution

Not enough wind

Measure the wind speed

Start up of charging
depends on the battery
status, check the
adjustment of the charge
regulator
Electric wiring interrupted

Check wires, connections
and gadgets

Replace damaged wires or
gadgets
Fuse is gone

Check fuse

Replace fuse ore cool
down the automatic circuit
breaker
Carbon brushes in the yaw
shaft have no contact

Check carbon brushes and
springs

Replace carbon brushes
and reactivate springs

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Battery is not fully charged:

Possible cause

Test

Solution

Old, damaged battery
deficient

Test battery status and
liquid of every battery

Replace battery refill
destilled water (not
necessary for Gel oder
AGM)
Fuse gone

Check fuse

Replace fuse, find cause of
deficiences
Charge regulator wrongly
installed

Check in line with manual

Correct installation

Charge regulator stop
switch is in position stop

Switch stop switch in
position RUN

Observe manual
instructions
Deficient generator

Check AC voltage, AC
srew terminals

Check all 3 cables after
disconnecting from charge
regulator as to short circuit
Deficient charge regulator,
mix up of polarity

Check adjustments
according to instructions

Repair customer service /
replacement

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14. Attachment / sketches

sketch 1

sketch 2 sketch 3

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sketch 4 sketch 5

sketch 6 sketch 7

18

sketch 8 sketch 9

sketch 10 sketch 11

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15. Warranty

Spreco Lda. guarantee that all appliances sold by the company do not show any
material or processing defects within the period of warranty.

Period of warranty for Silentwind generator: 36 months
Charge regulator W + S 1 24 months

If material or processing defects are detected in this period, Spreco Lda. will repair
the appliance or replace broken parts of the appliance at their expense.

Guaranty is only provided if the warranty note (page 21) is filled in properly and the
original invoice can be presented.

Guaranty does not cover:

• Regular checkups, maintenance, repair or replacement of worn out parts.

• Charges for transport, freight and the risk of transport which are directly

related to the case of warranty.

• Damages that have been caused by wrong use or mistreatment of the
appliance, especially if the damage is due to mounting the system to an
inappropriate / unsuitable mast (construction). In case of damage the
customer will have to prove that the windgenerator has been mounted to an
appropriate mast (construction).

• Damages caused by acts of nature beyond control Spreco Lda. cannot be held
responsible for, especially lightning, flooding, snow (ice) load, fire etc.

If the appliance must be demounted for a warranty case and mounted again after
repair or replacement, the expenses for these procedures are not covered by Spreco
Lda. Whether repair or replacement is appropriate or necessary is up to Spreco Lda.
decision only. If neither repair nor replacement are possible, the customer is only
entitled to withdraw the order.

Soweit zwingendes Recht nichts anderes vorsieht, beschränken sich die Ansprüche
des Käufers gegen die Firma Spreco Lda. auf diese Gewährleistungsbestimmungen
und weder Spreco Lda., noch die Vertreiber der Produkte übernehmen darüber
hinaus eine Haftung für unmittelbare oder mittelbare Schäden aus irgendeiner
ausdrücklichen oder einer möglicherweise Schlussfolgerungen zulassenden
„praktizierten“ Garantie für dieses Gerät.

Otherwise the general terms of delivery for products and services of the electricity
industry in Portugal are applied.

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Notice:

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16. Cerificate of guarantee

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Guarantee(

(

Name und Anschrift des Käufers /
Name and address of the purchaser:

Seriennummer Windgenerator /
Serialnumber windgenerator:

Seriennummer Laderegler
Serialnumber charge controller:

Verkäufer (Firmenstempel / Unterschrift) /
Purchaser (company stamp / signature):

Kaufdatum /
date of purchase:

Die genauen Garantie-Bedingungen finden Sie in der Gebrauchsanweisung auf Seite 19.
The exact warranty conditions you can find in the user manual on page 19.

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