Chinook 200 Original operating instructions
Chinook 200 Micro-Turbine
Installation & Operation Guide
1m Diameter Micro Wind Turbine for generating clean and renewable
electricity anywhere the wind blows…
User Manual (Chinook 200) Rev D Final Page 1
Contents
Disclaimer...................................................................................................................................3
Introduction.................................................................................................................................4
Safety Precautions.......................................................................................................................5
Specifications..............................................................................................................................6
Package Contents........................................................................................................................7
Assembly.....................................................................................................................................8
Electrical Installation...................................................................................................................13
Turbine Operation........................................................................................................................16
Maintenance.................................................................................................................................17
Replacement Parts........................................................................................................................18
Warranty.......................................................................................................................................19
User Manual (Chinook 200) Rev D Final Page 2
Disclaimer
•All specifications are subject to change without prior notice.
•The information given in this user manual is believed to be accurate and reliable.
•Chinook Turbines assumes no responsibility for omissions or inaccuracies.
•The user of this information and product assumes full responsibility and risk.
•The Chinook 200 Micro-Turbine is a source of electrical power. It must be installed in accordance
with local building and electrical regulations. Consult your local planning (zoning) office for details.
•The Chinook 200 Micro-Turbine has moving parts, and Sharp Blades that may cause injury due
to poor installation and unsafe handling or operation.
•Chinook Turbines assumes no responsibility for problems caused by unsafe or unsatisfactory in-
stallation or operation.
Made in MONTANA, USA by:
Chinook Turbines LLC
1646 East Highwood Rd
Belt,MT 59412
www.chinookturbines.com
User Manual (Chinook 200) Rev D Final Page 3
Introduction
Please read this manual thoroughly before attempting to assemble, install or operate your Chinook 200
small wind turbine. This will assure optimum performance and safety.
The Chinook 200 has been designed to be simple, economic, durable and yield excellent performance.
Your Chinook 200 turbine features:
•Innovative design axial flux alternator using neodymium iron boron magnets.
•Stamped aluminium chassis.
•Maintenance-free, low friction bearing.
•Extremely quiet injection moulded blades with a new airfoil design.
•Long-life yaw pivot slip-rings and wipers.
•Easy tower-top installation.
•Simple design for low cost and durability.
The Chinook 200 is most at home in land-based environments Thanks to its unique design, the Chinook
200 is not susceptible to corrosion in normal operating conditions. For Marine installs, Please contact us
for a Chinook 200 with Stainless Steel bearing option.
Applications include:
•Remote Homes / Off Grid
•Wind-electric water pumping
•Street lighting and road signage
•Complementary installation with photovoltaic modules for home power
•Farm utilities (electric fencing, irrigation, etc)
•Cathodic protection
•Monitoring sites
•Telecommunications
•The Developing World
User Manual (Chinook 200) Rev D Final Page 4
SAFETY
Safety must always be your primary concern during the assembly, installation and operation of your Chi-
nook 200 turbine. Always be aware of the risks involved with mechanical and electrical installation work. If
in doubt about any issue regarding your turbine, please seek further assistance before proceeding.
Mechanical Safety Hazards
•The main rotor is the most obvious and serious mechanical safety risk. When the turbine is oper-
ating at its rated speed, the blades will be very difficult to see due to the rotation speed. Never
approach the turbine while it is operating. Always shut down the turbine by activating the stop
switch. Ensure that the turbine is installed in a suitable location where nobody can ap-
proach or interfere with the path of the rotor blades.
•Working with tools of any kind can be dangerous. Your Chinook 200 turbine requires some basic
mechanical assembly with rudimentary hand tools. If you are in any doubt about how to use these
tools correctly, please seek advice from an experienced person.
•Your Chinook 200 turbine will inevitably be installed upon a guyed tower or building mount. This
may mean working at height. Always ensure that all personnel in the immediate vicinity are aware
of any lifting / hoisting operations that will be occurring. Check there are no loose components or
tools likely to fall and cause injury during the lifting operation. Where possible, all assembly work
should be completed at ground level.
•Ensure that the batteries are disconnected during the installation procedure.
•Twist the turbine output wires together (to create a short circuit) during the mechanical installation
process. This will prevent the turbine from ‘spinning up’ during the installation.
•Never install the turbine upside down or in any orientation other than that depicted on the installa-
tion instructions.
•Install your turbine during a calm day.
•When performing routine inspection or maintenance, always stop the turbine by activating a stop
switch or by shorting out the turbine output once disconnected from the battery.
Electrical Safety Hazards
•The Chinook 200 generates rectified DC voltage. Even at these low voltages there are inherent
risks. Caution should always be used when connecting the Chinook 200 to the electrical system.
•Ensure that you have followed the wire-sizing chart to ensure that the correct size of wire has
been selected. If wire of insufficient size is used, heat will build up in the wires causing a potential
fire hazard. A properly sized fuse or circuit breaker should be used in the wires connected to the
battery. This will stop the risk of short circuit currents.
•Batteries used in renewable energy systems can deliver a serious amount of current. A short cir-
cuit in the battery circuit can lead to hundreds of amps flowing through the battery cables. This
will cause a heat build up and ultimately an electrical fire. Batteries are also susceptible to ex-
plode when shorted. Always use insulated electrical tools when working on the battery’s electrical
connections.
•Batteries are very heavy. Do not attempt to move batteries by yourself. Always use manual han-
dling tools and an assistant.
•Always keep lead-acid batteries the correct way up. Do not allow the acidic electrolyte to spill or
come into contact with your skin or face. Always follow the manufacturer’s safety instructions
when handling lead-acid batteries.
Please use common sense when installing and operating your turbine!
User Manual (Chinook 200) Rev D Final Page 5
Specifications
Turbine Name: Chinook 200
Part Number: T200
Nominal Voltage: 12 / 24V DC
Rotor Blades: Glass Reinforced Nylon
Rotor Diameter: 1 Meter (3.28 Feet)
Rated Wind Velocity: 8m/s (17.89 mph)
Rated Output: 85 Watts
Max Output: 300 Watts
Rated RPM: 900
Start-up Wind Velocity: 3.5m/s (7.8 mph)
Total weight: 6.3 Kg (14 lbs)
Tower mount: 1.5” Sch 40 Diameter pipe
Chassis Construction: Aluminium
User Manual (Chinook 200) Rev D Final Page 6
Package Contents
Your Chinook 200 Turbine will arrive containing the components shown below. If any of the components
are missing or damaged, please contact your dealer immediately.
•3 Blades
•1 Turbine Chassis
•1 Controller
•1 Spinner (Nose Cone)
•1 Blade mounting plate
•Hardware Kit with allen wrenches and Manual
User Manual (Chinook 200) Rev D Final Page 7
Mechanical Assembly Procedure
1) Unpacking- Inspect the contents of the box and ensure that all items are present and free from
damage. If any of the components are missing or damaged, please contact your dealer immedi-
ately.
2) Check Magnet Rotor & Continuity- Ensure that the magnet rotor is free turning and does not
scrape or rub on the coil disc as it rotates. You may feel a slight resistance from the bearings at
this stage. The bearing units used in the magnet rotor assembly are factory lubricated and sealed
for life. It will take approximately 100 hours of normal operation for the bearing seals to ‘Break-in’
and the lubrication to be distributed correctly around the bearing raceways and ball cages. During
this period you may notice a reduced performance caused by the additional friction of the bearing
seals. In operating temperatures of –10 degrees Centigrade or lower, this ‘Break-in’ period will be
extended by a further 50 hours of normal operation. Connect a digital multi-meter to the positive
(red) and negative (black) output leads extending from the yaw pivot. With the multi-meter set to
detect DC Volts (0-20V), a voltage should be displayed when the magnet rotor is spun. This volt-
age will vary with the speed of rotation. If the magnet rotor rubs, or no voltage is detected when
turning the magnet rotor, please contact your dealer immediately.
User Manual (Chinook 200) Rev D Final Page 8
Warning: The magnet rotor on your Chinook 200 turbine is constructed using neodymium iron
boron rare earth magnets. These are extremely powerful magnets and can cause injury if not han-
dled with carefully. Take care when working with tools made of ferrous materials (such as
wrenches and screwdrivers) close to the magnetic poles. The magnetic forces between ferrous
materials and the magnet rotor will be very strong. This may cause a sudden snapping action that
can pinch or trap your fingers or skin.
Rotor Blade Assembly- Take the three rotor blades and rotor hub plate. Be careful when handling the
blades, they may have sharp edges. Use a 10mm socket & hexagon key and three M6 x 16mm long
cap-screws to attach each blade to the hub plate. The blades should all be fixed to the hub plate on the
same side, with the blades in the same orientation. It is important that a washer is used underneath the
Nylock nuts. 3 set-screws, 3 washers and 3 Nylock nuts should be used on each blade. Tighten the
Screws until the blades are safely secured. Do not over-tighten the nuts as this may damage the blades
and fixings. NOTE: the rotor hub plate has 3- clinch nuts installed for the spinner attachment, the flat side
of the clinch nut is the FRONT of the plate.
User Manual (Chinook 200) Rev D Final Page 9
Check the Tip Spacing- Lay the assembled rotor blade on a flat surface. Using a tape measure or long
steel rule, ensure that the spacing between each tip is equal to within a tolerance of +/-1.5mm. Adjust the
blades as required. Output performance may suffer if the blades are not spaced equally.
Fit the Rotor Blade Assembly- The assembled and balanced rotor blades can now be fitted to the Chi-
nook 200 chassis. This is done by placing the rotor hub plate against the bearing house on the turbine. In
the hardware kit you will find 4 ea 5mm X 12 hex head screws. NOTE, you will have 3 ea 5mm X 14 hex
head screws that are LONGER for use on the Nose cone. Ensure that all 4 screws are securely tightened
and that the rotor blades are mounted with the flat side of the blades facing forward.
User Manual (Chinook 200) Rev D Final Page 10
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