Installation Manual For Helix HT Series Wind Turbines - Current ...

Please read this manual carefully
Before installation and retain for future reference
Installation Manual for
Helix HT series Wind Turbines
Registered office:No 1 Tai Mong Tsai Road, Sai Kung, Hong Kong Company Registration Number: 33649039-000-05-06-7
Telephone: +852 2791 7767 Facsimile: +852 2792 2782 Email: sales@egl-energy.com
Page 1 of 15

Contents
Introduction Page 4
Characteristics Page 4
Scope of use Page 4
Prior to Installation Page 5
Site Selection Page 5
Preparation for Installation Page 7
Wind Turbine Mounting Page 8
Towers and mounting structures Page 8
Recommended Cable Sizes Page 9
Assembling Rotor Blades Page 10
Wind Turbine Charge Controller Page 12
Safety Page 15
Maintenance Page 15
Registered office:No 1 Tai Mong Tsai Road, Sai Kung, Hong Kong Company Registration Number: 33649039-000-05-06-7
Telephone: +852 2791 7767 Facsimile: +852 2792 2782 Email: sales@egl-energy.com

IMPORTANT NOTE !
SAFETY WARNING
The Helix range of wind turbines can generate very high voltages and currents and
can cause serious personal injury or death if not handled properly.
When installing a HELIX wind Turbine please seek the assistance of a qualified
electrical engineer if in any doubt.
Registered office:No 1 Tai Mong Tsai Road, Sai Kung, Hong Kong Company Registration Number: 33649039-000-05-06-7
Telephone: +852 2791 7767 Facsimile: +852 2792 2782 Email: sales@egl-energy.com
Page 3 of 15

INTRODUCTION
Congratulations on your acquisition of your Helix HT series wind turbine which should
give you trouble free service with minimal maintenance or intervention.
The wind turbine is a means to harness the power in the natural wind. Quite simply,
the vanes have been carefully designed to capture the power in the wind and turn the
turbine to generate useful electricity that can be stored in batteries for later use.
The wind turbine generates a three phase AC output and is fed to a wind turbine
charge controller which rectifies the AC to DC and intelligently charges up the
storage batteries in the designed system.
The stored DC power can then be used to power DC loads or converted to 110V or
220V AC via an appropriate inverter to power AC loads.
Characteristics of EGL Helix wind turbines
• Helix range of wind turbines have low start upwind speeds with little flutter in
operation giving a stable product and low noise. They have been designed for
ease of installation and require low maintenance.
• Inclusion of special internal bearings and electrical bush connections to
eliminate any cable twists when rotating on its vertical axis.
• Wind turbine blades optimized and aerodynamically designed then
manufactured by precise injection molding process with a special material
giving a high energy coefficient ratio in terms of size of blades, materials used
and wind swept area.
• Optimized matching of blade size to generator design to obtain best drag
torque characteristics.
• Magnetic brake incorporated in the controller.
• Intelligent controller to guard against overcharge and over-discharge
situations to protect batteries.
• Controller incorporates LED indicators to indicate status of various
parameters of the wind turbine system.
Scope of use
The Helix range of wind turbines are designed for standalone applications where
charge is to be stored in batteries and power loads in remote and rural areas where
mains electricity is not available or not economically viable to extend to that area.
It is not suitable for grid tie applications.
Registered office:No 1 Tai Mong Tsai Road, Sai Kung, Hong Kong Company Registration Number: 33649039-000-05-06-7
Telephone: +852 2791 7767 Facsimile: +852 2792 2782 Email: sales@egl-energy.com
Page 4 of 15

Installation
Note: The installation guide show here is for the model Helix HT-400.
Installation of other Helix models should be made with these notes as
reference.
Prior to Installation
• If possible install the wind turbine on a windless day. Work in daylight. When
mounting the wind turbine immobilise the rotor by tying a blade with strong
rope to a fixing to prevent blades from turning during installation. Release the
blades when installation of controller is complete and safe to put the wind
turbine into proper operation.
• We must emphasize that the wind turbine generates serious levels of
electrical power and serious injury and death can result through improper
handling and use.
• Seek the services of a qualified electrician or electrical engineer.
• Ensure kit has been stored properly and has not been exposed to rain during
storage or been saturated in water. Check no liquids have been spilt on the
kit. Do not store near radiators or areas of excessive heat.
• Do not attempt to open the generator housing, it is difficult to disassemble
and reassemble without the right tools and skills.
• Assess site and choose a stable and solid structure to mount the wind turbine
on.
• Ensure that the controller is housed in a suitable weatherproof cabinet if it is
to be installed outdoors. Also ensure there is sufficient ventilation if batteries
are housed in the same cabinet to avoid any build up of hydrogen gasses
from the batteries.
• Ensure that the whole installation is properly earthed. Drive an earthing rod
next to installation if necessary and connect to this earth.
Site Selection
The selection of a suitable site will have a direct effect on the amount of power
generated, so choose your site carefully.
Ideally choose a location that has no trees over 8 metres tall within a 100m radius of
the site. Most sites will not be able to meet this ideal situation so choose a site which
is reasonably unobstructed by buildings and trees around the site.
As a general rule, the higher the wind turbine can be safely mounted, and within
reason, the more wind will be present.
Registered office:No 1 Tai Mong Tsai Road, Sai Kung, Hong Kong Company Registration Number: 33649039-000-05-06-7
Telephone: +852 2791 7767 Facsimile: +852 2792 2782 Email: sales@egl-energy.com
Page 5 of 15

There are exceptions where the wind turbine can be surrounded by high rise
buildings yet still generate power due to the quirks of wind tunnel effects of the
surrounding buildings.
If possible seek the assistance of professionals on wind patterns for your area.
Registered office:No 1 Tai Mong Tsai Road, Sai Kung, Hong Kong Company Registration Number: 33649039-000-05-06-7
Telephone: +852 2791 7767 Facsimile: +852 2792 2782 Email: sales@egl-energy.com
Page 6 of 15

Preparation for installation
1. Check contents of wind turbine kit
Please check the contents of the boxed kit to ensure all materials are present before
proceeding to avoid frustration and complications.
Helix HT-400
Item Description
Quantity
Main wind turbine generator body 1
Rotor blades 3
Blade mounting flange 1
Nose cone 1
Wind Turbine charge controller 1
Bolts for mounting blades on blade
mounting flange
M8 x 35mm Bolt 6
M8 x 30mm Bolt 3
Ø 8mm Plain washer 9
Ø 8mm spring washer 9
M8 locking nut with nylon
embedded locking ring
9
(not to be reused if blades
disassembled and reassembled)
Bolt and accessories for mounting
nose cone
M6 x 45mm hexagonal head bolt 1
Ø 6mm plain washer 1
Ø 6mm spring washer 1
M6 Hexagon key tool 1
Plastic nose cone tip 1
Bolts for optional use to mount wind
turbine using supplied mounting
shoulder pipe
M8 x 20mm Bolt 4
Ø 8mm Plain washer 4
Ø 8mm spring washer 4
Registered office:No 1 Tai Mong Tsai Road, Sai Kung, Hong Kong Company Registration Number: 33649039-000-05-06-7
Telephone: +852 2791 7767 Facsimile: +852 2792 2782 Email: sales@egl-energy.com
Page 7 of 15

Wind turbine mounting shoulder pipe (optional use) 1
Charge Controller 1
These instructions 1
2. Wind Turbine mounting shoulder pipe
There is supplied with the kit a mounting shoulder pipe. This pipe is a matched fit for
the wind turbine mounting stem. Once the wind turbine has been fitted into the pipe
turn the wind turbine stem until the threaded holes on the stem line up with the holes
on the shoulder pipe. The wind turbine can now be securely fastened to the shoulder
pipe using the M8 x 20mm bolts, Ø 8mm washers and the Ø 8mm spring washers.
The shoulder pipe has been supplied so that the user can use it as a easy to carry
sample for engineering planning purposes, template, or can be welded to a tower or
structure where the wind turbine is to be installed.
Wind Turbine mounting shoulder pipe
Threaded holes in wind turbine stem
3. Towers and mounting structures
Various mounting arrangements can be designed, fabricated and utilized to mount
the wind turbine.
There are various masts that can be used such as guyed masts, self supporting
towers, and adhoc improvised structures.
Registered office:No 1 Tai Mong Tsai Road, Sai Kung, Hong Kong Company Registration Number: 33649039-000-05-06-7
Telephone: +852 2791 7767 Facsimile: +852 2792 2782 Email: sales@egl-energy.com
Page 8 of 15

It is important that whatever structure is used it must be designed to be sturdy, stable
and safe to hold the wind turbine. It is recommended to seek the services of a steel
structure engineer.
Check with your local government offices or relevant government authorities of your
country for design guidelines to ensure that the structure designed and built meets
local safety regulations.
Example of self supporting pole with wind
turbine adapted for street lighting
application
4. Recommended cable sizes
The following is intended to be a guide and if in doubt seek the services of an
electrician or electrical engineer.
The table gives distances between the wind turbine and controller. Read down the
appropriate column against the system voltage to find the recommended cable size
to be used. Cable size is cross sectional surface area of each core.
Distance between wind turbine and
wind turbine controller
Less than 50
metres
50 to 100
metres
100 to 150
metres
12 volt system 6 mm sq. 8 mm sq. 16 mm sq.
24 volt system 4 mm sq. 6 mm sq. 10 mm sq.
48 volt system 4 mm sq. 6 mm sq. 10 mm sq
Registered office:No 1 Tai Mong Tsai Road, Sai Kung, Hong Kong Company Registration Number: 33649039-000-05-06-7
Telephone: +852 2791 7767 Facsimile: +852 2792 2782 Email: sales@egl-energy.com
Page 9 of 15

5. Assembling the rotor blades
Use the 9 x M8 bolts, washers, spring washers and locking nuts.
Step 1
Line up the rotor and blade to ensure right faces of each piece are presented
correctly.
Lineup the rotor and blade to ensure
correct faces of each piece are presented
correctly
Insert the M8 x 35mm bolt and ensure
bolt head sits in recess
On blade side place plain washer then
spring washer over bolt thread
Screw on Locking Nut and tighten well
Registered office:No 1 Tai Mong Tsai Road, Sai Kung, Hong Kong Company Registration Number: 33649039-000-05-06-7
Telephone: +852 2791 7767 Facsimile: +852 2792 2782 Email: sales@egl-energy.com
Page 10 of 15

Fix all three blades using two M8 x 35mm
and one M8 x 30mm on each blade as
shown on diagram opposite
The whole rotor blade assemble can now be fitted onto the main shaft of the wind
turbine generator. The shaft is tapered and the hole in the wind turbine blade
assemble is also tapered so it will only fit in one direction.
Slide complete assembly onto the shaft and secure using the washer, spring washer
and left handed thread nut that is delivered loosely fitted on the shaft.
Lastly, fit the nose cone onto the assembly and fasten in with the M6 x 45mm bolt,
washer and spring washer supplied and tighten with the hexagonal tool key supplied.
Finally push on the finishing plastic nose cone tip. The wind turbine is now ready for
deployment.
Registered office:No 1 Tai Mong Tsai Road, Sai Kung, Hong Kong Company Registration Number: 33649039-000-05-06-7
Telephone: +852 2791 7767 Facsimile: +852 2792 2782 Email: sales@egl-energy.com
Page 11 of 15

Wind Turbine charge controller
(HT-C12400)
The main purpose of this wind turbine charge controller is to take the generated AC
power from the wind turbine and rectify and condition the power to charge up the
deep cycle batteries in the system.
It has built in intelligence and will also monitor various parameters of the system and
take appropriate actions.
Figure 1 Figure 2
Protection of the wind turbine
When the wind speed reaches 20 m/s and beyond the charge controller recognizes
that the level of generated power has reached such a state that there is potential of
electrical damage to the wind turbine or the charge controller itself. It will disconnect
and open circuit the output leads of the three phases from the wind turbine so
renders the system idle until such time the wind speed drops and the power
generated is back within the prescribed limits.
Protection against over discharge
With any stored power system using batteries, one must not allow the batteries to be
over discharged or permanent damage to batteries may result and certainly their life
cycle will be reduced permanently. The charge controller monitors the charge in the
batteries and will disconnect the power from
Protection against over charge
The controller ensures that the batteries are not over charged which can again
damage the batteries and reduce their lifespans.
Registered office:No 1 Tai Mong Tsai Road, Sai Kung, Hong Kong Company Registration Number: 33649039-000-05-06-7
Telephone: +852 2791 7767 Facsimile: +852 2792 2782 Email: sales@egl-energy.com
Page 12 of 15

Indicators
Referring to figure 2
Item Number
Indication or use
1 LED indicator to inform that wind turbine is generating power.
Flickering green means power being generated but of not
significant magnitude. Constant green is useful charge being
generated.
2 LED Synchronisation, when this LED is green it indicates that
useful power generated by the turbine is being usefully
deployed to charge batteries
3 LED green indicates that solar panels are generating power
4 RED LED indicates over charge
5 Green LED indicates batteries are fully charged
6 This is the brake switch. This switch allows current to be fed
back to the rotor windings of the wind turbine and effectively
turns coils into magnets and lock the armature in place. This
switch should be thrown into BRAKE position when
impending Typhoon or storm is forecasted. If winds are
sufficiently strong the rotor will still turn even in BRAKE mode,
this is perfectly normal but its turning speed can be seen to be
retarded. Light will still operate as normal providing sufficient
charge is present in batteries. Remember to put the switch
back to ‘RUN’ when storm has passed.
7 Green LED indicated batteries are at medium charge levels
8 Green LED indicates that batteries are at low charge
9 RED LED indicates batteries at extremely low charge / or
depleted
Check with a ohmmeter that all three phases (wires) of the wind turbine outputs are
not open circuit before wiring up.
Registered office:No 1 Tai Mong Tsai Road, Sai Kung, Hong Kong Company Registration Number: 33649039-000-05-06-7
Telephone: +852 2791 7767 Facsimile: +852 2792 2782 Email: sales@egl-energy.com
Page 13 of 15

A summary of technical details
Parameter
Specification
Rated Power 400 watts 800 Watts
Operating Voltage in conjunction with 12V / 24V
24V / 48V
appropriate charge controller
Rotor Diameter (metres) 1.7 1.7
Start up Wind Speed (m/s) 2.5 - 3 3.5
Cut in Wind Speed (m/s) 4 4.5
Rated Wind Speed m/s 12 12
Cut Out Wind Speed (m/s) 20 20
Survival Wind Speed (m/s) 50 50
Type of operation
Off Grid standalone
applications
Off Grid standalone
applications
Explanations
Start up wind speed
This is the minimum wind speed in metres per second when the wind turbine will start
to turn. It is actually not generating any significant or useful power.
Cut In wind speed
This is the minimum wind speed in metres per second when the wind turbine actually
starts to generate power.
Cut Out wind speed
This is the wind speed in metres per second when the wind turbine is deemed to be
generating too high a voltage and power and is at risk of electrical damage. The
associated charge controller will automatically open circuit the wind turbine outputs to
avoid any potential electrical damage to the wind turbine.
Survival wind speed
This is the wind speed when the wind turbine is at risk of physical damage (not
electrical).
Registered office:No 1 Tai Mong Tsai Road, Sai Kung, Hong Kong Company Registration Number: 33649039-000-05-06-7
Telephone: +852 2791 7767 Facsimile: +852 2792 2782 Email: sales@egl-energy.com
Page 14 of 15

Safety
Always seek the services of a qualified electrician to perform preventative
maintenance or repair works as there are some very high and dangerous levels of
voltage present.
Install proper circuit breakers in line with local electrical regulations. Always isolate
properly and in an orderly manner before performing any maintenance or trouble
shooting work.
Maintenance
It is recommended that a preventative maintenance programme be exercised
- Every12 months check and tighten all bolts and nuts and check for rust on
any fixing post
- Every 12 months oil all moving parts.
- Every 24 months check and replace bearings if necessary. Use a qualified
electric motor maintenance electrician as this is a specialized job that requires
the correct tools.
- Every 24 months check for corrosion of body of the wind turbine and paint if
necessary talking care not to get paint into bearings at shaft end.
Further information
If in doubt please contact :-
EGL-Energy Limited
1 Tai Mong Tsai Road
Sai Kung, N.T.,
Hong Kong
Tel: +852 2791 7767
Fax: +852 2792 2782
Mob:+852 9310 8102
Web: www.egl-energy.com
Registered office:No 1 Tai Mong Tsai Road, Sai Kung, Hong Kong Company Registration Number: 33649039-000-05-06-7
Telephone: +852 2791 7767 Facsimile: +852 2792 2782 Email: sales@egl-energy.com
Page 15 of 15