TPW-400DT 12/24V 400W Turbine
User Guide
A. NOTICE
1. This information is believed to be reliable; however, we assume no
responsibility for inaccuracies or omissions. The user of this
information and product assumes full responsibility and risk.
2. All specifications are subject to change without notice.
3. Wind turbines must be installed following the guidelines
established by local regulations.
B. SAFETY PRECAUTIONS (Important)
1. Safety must be the primary concern as you plan the location,
installation and operation. Please be aware of electrical,
mechanical and blade hazards.
2. DO NOT install the turbine where anyone could approach the
blades.
3. Use common sense and be careful.
4. Select the correct wire size, and the correct fuse size.
5. When installing, please make sure that the turbine is disconnected
from the batteries.
6. Do not let the blades spin freely until the turbine is mounted on the
pole.
7. Never approach the turbine during operation.
C. About this wind turbine
1. The wind turbine has an embedded charge controller with dump
load. It controls battery charging and protects the wind turbine in
high winds.
2. The wind turbine is designed to charge Lead-Acid batteries. It is
12V/24V auto select. It can only work with a 12V or 24V battery
voltage. Please Do Not connect it to other battery voltages.
3. When connecting to the battery, please make sure that the RED
wire (+) of the wind turbine connects to battery V+ (positive) and
the BLUE wire (-) of the wind turbine connects to battery V(negative).
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1
Mainbody
1 pcs
2
Hub
1 pcs
3
Nose Cone
1 pcs
4
Blade
6 pcs
5
Tail Vane
1 pcs
6
Manual
1 pcs
7
Fastener & Tools
→
Multi-meter
Wrench or spanner
Soldering iron
Screw driver
Heat shrink or electrical tap
Fastener
Pcs
M16 Nut
1
For Hub
Φ6*30 Screw
15 + 1(spare)
For blades & tail
M6 Nut (Nyloc)
15 + 2(spare)
For blades & tail
5mm Hex Key
1
4. Incorrect battery voltage or incorrect wire connection may
damage the wind turbine, and these are not covered by the
warranty.
D. Package Contents
Figure 1: Package list
The wind turbine is shipped partially disassembled. Please compare the
parts shown above to ensure that all necessary parts are included.
E．Preparing for installation
E.1 The following general tools may be required for installation.
E.2 Pole or Mast
1. This wind turbine is designed to fit an aluminum or steel tube with
an inside diameter of 41mm. An inside diameter 41mm (1.6” or 1
5/8”) steel pole is readily available（water pipe or scaffold tube).
Usually it has an internal weld seam. The wind turbine mount has a
flat on one side to clear the seam. Please do not use plastic pipe.
2. A suitable mounting pole can be erected using a 6 meter
galvanized pipe supported by 3 or 4 guy wires. Figure 4
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Distance From Batteries to Turbine
0-9M
9-18M
18-27M
27-45M
Wire X-Section Area for
12V Wind Turbine
4mm
2
12AWG
6mm
2
10AWG
8 mm
2
9AWG
10mm
2
8AWG
Wire X-Section Area for
24V Wind Turbine
2.5mm
2
14AWG
4mm
2
12AWG
6mm
2
10AWG
8mm
2
8AWG
Figure 2: Blade and pole clearance
Figure 4: Typical Mounting
Figure 3: Mounting Pole Preparation
3. Make sure a minimum 50 cm
clearance is provided
between the blade tips and
any obstructions. Refer to
Figure 2.
4. Mark and centre-punch two
positions diametrically opposite,
at 90° to the pipe seam, 20mm
from top of the tube (Refer to
Figure 3). Then drill two 10.5mm
diameter holes.
E.3 Wire
If the cross section area of the wires is NOT sufficient, the wires will heat
up and could create a fire hazard. Please choose the right size of wire.
Minimum Wire Size (X-Section Area):
F. Installation
F.1 Please follow these precautions during the installation:
1. THINK SAFETY! Have someone available to help when installing.
2. Disconnect batteries from turbine.
3. Be careful not to pinch the wires when attaching the turbine to
pole.
F.2 Step-By-Step Instructions
F.2.1 Connect the wires and mount the turbine
1. Run the 2 wires from the battery location, through the pole to the
top of the pole. DO NOT connect the wires to the battery until
everything else has been completed. Strip the insulation back
from each side of wires. Mark both ends of the wires with tape to
identify the polarity: Red = Positive (+); Blue = Negative (-)
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CAUTION: If you are uncertain of the polarity of the wires, simply spin the
rotor shaft clockwise and measure the voltage direction with a volt meter.
2. Connect the Red(+) and Blue(-) wires from the wind turbine to the
wires from the battery location. Insulate the connections using
either heat shrink tubing or a quality electrical tape or wire nuts.
3. Once the wires are attached to the turbine, gently pull the wires
down through the tower sliding the yaw shaft into the steel pipe.
Slide the yaw shaft down inside the end of the pole carefully, so as
not to pinch the wires. Leave enough slack in the wires so that, if
necessary, the turbine can be removed from the pole. Strain
relieve the wires so the weight of the long wires isn’t pulling on the
red and blue turbine wires.
4. Once the yaw shaft is mounted in the pole,
a. First, firmly tighten the two 10mm screws with a wrench.
b. Then, firmly tighten the two 10mm nuts.
Figure 5
CAUTION: Make sure that your turbine is securely attached to the pole.
Remember that this attachment will have to hold in high winds.
Figure 6.1: Blades & Hub Figure 6.2: Cotter Pin Figure 6.3: Tail Attachment
F.2.2 Fix the blades, the Hub and the tail
1. Hold the shaft with a screw driver, turn the Hub counter-clockwise
to remove the Hub from the shaft if necessary.
2. Attach the blades to the Hub. Securely tighten all the screws and
nuts. (Figure 6.1)
CAUTION: Make sure the front face of the blade is toward the wind.
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3. Put the M16 nut onto the middle of the Hub, then put the Hub on
the top of the rotor shaft. Hold on the rotor shaft with a screw driver
and turn the Hub clockwise to tighten it onto the shaft. (Figure 6.1)
4. Insert the cotter pin into the small hole on the top of the shaft.
(Figure 6.2)
5. Assemble the nose cone to the head of the shaft by snapping into
place.
6. Attach the tail vane to the tail bracket, securely tighten the screws
and nuts.
F.2.3 Connect the wires
1. Run the wires from the wind turbine to the battery. Attach wires to
the battery.
Wind turbine Red = Battery Positive (+);
Wind turbine Blue = Battery Negative (-)
CAUTION: If the battery is not connected properly, it may damage the
wind turbine.
2. Now you have completed the installation process.
F.3 Operation
Check support structures, blades, and electrical systems.
1. Do not let the rotor blades come in contact with a solid object.
Use common sense about safety when locating the turbine.
2. Before you inspect the wind turbine or approach the path of the
blades, disconnect the power leads from the battery. The turbine
should slow down or stop spinning. Be very careful when working
near a spinning turbine. Wait till the turbine stops spinning then tie
one of the blades to the mounting pole using a rope or bungee.
3. Note: The bearings in the turbines may require about 100 hours of
operation in normal wind before they are running at peak
efficiency. It is called ‘break-in period’.
4. When expecting high winds such as from a Hurricane, it’s best to
remove the hub/blade assembly before the storm and then
re-install after the storm passes. Removal is simple and involves
only one cotter pin and one nut.
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G. Specification
Wind turbine
Please Check
No output
If battery is well connected,
Battery voltage, make sure it is not over-charged, or failed.
Disconnect Wind Turbine from batteries and measure voltage
output when the turbine is spinning. Should be able to measure
over 12VDC.
Vibration
Check if all the fasteners are fixed tightly.
Click-click noise
Check if all the fasteners are fixed tightly.
Check if the blades move smoothly.
Rotor Diameter
1.12M
Net Weight
7.8Kg
Cut-in Wind Speed
2.1M/S
Rated Power
250W
Max Power
400W
Pole Dimensions
Inner Diameter 41mm
Package Weight
9.5Kg
Figure 7: 400W Wind Turbine Specification
H. Additional Information
1. How the embedded controller works:
a. The embedded PWM controller is mounted inside the wind
turbine body. It continuously monitors and controls the
output of the wind turbine to optimize battery charging and
protect the wind turbine from over-speed.
b. The controller continually feeds any excess current to the
embedded dump load located in the tail section of the
turbine in order to control the wind turbine output and
rotational speed.
Caution: If the batteries are fully charged and the wind is strong, the
dump load may get extremely hot. In order to avoid serious burns,
never touch the dump load.
2. Trouble shooting
An AMP meter is recommended to be connected in your system, to verify the
output current when the blades are rotating.
If you can’t determine cause of the problems, such as: big vibration; no output; very
small output in large wind. Please:
1. Uninstall the wind turbine immediately and check if there is obvious damage
on the shell, blades or yaw part.
2. Spin the shaft or hub by hand, to see if it is easy to turn.
3. Disconnect the wind turbine from the battery. Spin the shaft or the hub, test the
output voltage. This open-connect voltage
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can easily exceed 12V.
4. Connect the turbine to the battery directly with an ampere meter, spin the
turbine by hand or by tools, to see the charge current is OK.
Typical Charge Current Vs Windspeed
Limited Warranty
Tycon Power Systems wind turbines are supplied with a limited 24 month
warranty which covers material and workmanship defects. This warranty
does not cover the following:
▫ Parts requiring replacement due to improper installation, misuse,
poor site conditions, faulty power, etc.
▫ Lightning damage.
▫ Physical damage to the external & internal parts.
▫ Products that have been opened, altered, or defaced.
▫ Units that were not properly grounded.
▫ Usage other than in accordance with instructions and the normal
intended use.
Do not return any products until you receive a Return Material
Authorization (RMA) number. Products received without a valid RMA
number will be rejected and returned to sender.
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Warranty Repairs
All returns must have a valid RMA number written clearly on the outside of
the box. Without an RMA number the shipment will be refused. For
customers located in United States and Canada, customer pays all
shipping charges incurred to ship the product to Tycon Power
Systems. Tycon Power Systems pays shipping charges to return the
product to the original purchaser. For all other countries, the original
purchaser shall pay all shipping, broker fees, duties and taxes incurred in
shipping products to and from Tycon Power Systems. Provided the
goods have not been modified or repair attempted by someone other than
Tycon Power Systems, at the option of Tycon Power Systems, products
may be returned either as repaired or replaced. If it is determined that
there is no fault found (NFF) on a unit within warranty, the customer will be
charged $75 USD for testing time. For products out of warranty, the
standard NFF charge is $200. This charge will be at the discretion of
Tycon Power Systems. The RMA number is valid for 14 days from date of
issue. The product must be received by the repair depot within these
14-days or the shipment may be refused.
Shipping and Damage Claims
All shipping damage claims are the purchaser's responsibility. Inspect
each shipment upon delivery and IMMEDIATELY report all damage, to the
carrier. There may be time limits and inspections may be required.
Phone: 801-432-0003
support@tyconpower.com
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