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its been a while :-)


By electronbaby, Section Wind
Posted on Tue Aug 09, 2005 at 03:44:02 AM MST
here she is..

the new (old lol) 16' machine whizzing away.






the pic is a little blurry because i snapped these basically in the dark a while ago. ive been too busy to make a posting (shame on me, i know ive been slacking). almost have the new house/ barn done and had other pics but lost a hard drive the other day and my pics went bye bye :-/ oh well. i have to take more.
Anyway, this machine is very similar to the 15' machine DanB built for Matt except im running it with a larger diameter prop. It sits on an eighty foot commercial communications tower that some one had given me and it took a while to get it up because the tower needed some work done to it to allow for it to hold this beast up comfortably. The tower is 2' across each leg (3 leg tower). Its a guyed tower. Im using 2 sets of 3/8"-7 strand to hold it up (heavy stuff). One at 40' and the other at 68'.







these pics show the top section that i more or less built from scratch. the triangular plates are  .5" steel and the mast section is made from 3.5" steel box stock. there are also pieces of 4" box that the mast slides into with gussets on the top plate. this allows me to set the height of the mast and secure it with locking pins (3/4" bolts)
The turbine sits 12' above the top of the lattice tower, so i had to weld nuts to the mast to allow me to screw in rungs to climb up and service it. when im done, the rungs are removed to make sure the prop will never hit the mast. it seems to work great.  :-)




Here is my cutler hammer kill switch.  :-)
works like a champ. its not an outdoor enclosure, but its what i had laying around, so i built a little hut for it and u-bolted it to the tower. The power cable you see coming out the bottom is 10AWG extention cord (the heavy black stuff you use for 220 single phase). i had some of that laying around. works great. its about 90' of that stuff and then i have it spiced into 3 runs of 2AWG that runs to the house (about 100' away).
As it turns out, this is too little of a resistance to allow the prop to speed up past 100RPM. It stalls. Cut in is at 60 rpm, and it makes 10 - 12A almost all the time. In 30mph gusts ive seen it make 40A, 1kW (24v system). I think its capable of more, but i have to agree with Dan that things seem peaceful and safe, when your making plenty of power, and the machine runs quiet and slow. :-)
I might try to fool around with it to squeeze out some more juice, but for now, its fine.




This is the battery bank this machine feeds. 1680Ah @ 24v. these are 2v lead acid cells. the price was right (free), and they seem to have a bunch of life left in them. its actually 2 parallel strings of 24v. so there is 24 cells. they weigh over 2 tons. very big. They drive a trace sw plus 4024, and will eventually move into their own insulated room, as soon as its finished (it was really cold this past winter).




here is my panel. I also use an ALM off the inverter to control my dump loads. NOT THE BEST WAY OF DOING IT!! if the inverter fails, so does your load. I just havent come across the right stuff yet to do it with DC, which is where im headed. The 24v relay panel is under the ALM, and this is what will eventually switch (primary relays) different DC resistive loads.

Im having way too much fun. Just wish the house was done so i could get settled and build more turbines :-P

RoyR

its been a while :-) | 8 comments (8 topical)

Re: its been a while :-) (3.00 / 0) (#1)
by richhagen on Mon Aug 08, 2005 at 11:03:21 PM MST

Nice looking setup, I am jealous.  80' tower, 15 foot machine, at least 240 watts or so most of the time.  What is not to like.  Those look like old Telco cells, if so don't discharge them too deeply, everything I've read says they don't have good tolerance for that, but with modest use they last a very long time.  Rich Hagen
'A Joule saved is a Joule made'


Re: its been a while :-) (3.00 / 0) (#3)
by electronbaby on Tue Aug 09, 2005 at 06:09:36 AM MST

Rich, they are telco cells. Bell Cells to be exact. they are lead acids, not lead calcium, so i think they will stand up to a little more abuse, but not much. the plates are horizontal, round, and really thick. they were free :-) Im curious to see how long these last. I dont have many loads on them because the house isnt fully up and running yet, but they have been getting me through construction phase for almost 2 years now. they seem to be ok. im well aware of the shallow discharge rate of telco cells, although not ideal, they did fit the budget  :-)
Have Fun!! RoyR KB2UHF
[ Parent ]


Re: its been a while :-) (3.00 / 0) (#2)
by zubbly on Tue Aug 09, 2005 at 04:47:10 AM MST

hi Roy!

now you got me all excited and a little more encouraged to finish my own  :)

i have a tower very similar to yours, but i think not quite as robust. the tower was also given to me and does need some work and new mounting hardware made up for it. i am currently working on a way to make it a tilt up as my days of climbing to the top and hauling everything up on a rope are quickly comming to an end. this one will end up about 65 foot at the centre prop line.

your battery  setup and controls look great! (embarrased to show anyone mine LOL)

just curious about one thing for sizing purposes. what have you used for the anchors for the guy wires? i am planning on using 1 foot diam sono tube fill with cement 4 feet into the ground (i think it will be enough). the more opinions on this the better.

great job, i am sure that tower and unit will be there for many years  :)

have fun
zubbly



Re: its been a while :-) (3.00 / 0) (#4)
by electronbaby on Tue Aug 09, 2005 at 06:20:57 AM MST

Zubbly, I stressed about anchors for a while. was gonna try the Dead Man approach (i have a backhoe at my disposal) but ended up going the screw in route. I made three screw in anchors out of heavilly galvanized 5/8" steel J-bolt type concrete tower anchors. They were 7 feet long and I went and cut off the J part at the bottom. I then cut out 3 circles out of 1/4" steel, 7" in diameter. Drilled a center hole, cut the radius with the torch and ground it sharp. I then put it in the vise and bent it apart so that it resembled an auger type screw kinda deal lol. i welded it on the bottom, and with a long steel bar, and a friend, drove them 6.5' into the ground at a 45 degree angle. Thats what i used for anchors. Very strong. I will try to take some pics later  :-)

Have fun,
RoyR
Have Fun!! RoyR KB2UHF
[ Parent ]



Re: its been a while :-) (3.00 / 0) (#5)
by Volvo farmer on Tue Aug 09, 2005 at 07:08:04 AM MST

Please do post some pictures. I'm about to need some anchors and yours sounds like the solution I've been looking for.

I have a telco right next door to my shop in town. Last year they switched out all the batteries that look just like yours. I know the guys that work there and I asked, pleaded, begged and offered to bribe but they would not let me have or buy those batteries. The excuse was something about liability, the environment and recycling.

Nice looking setup!

Volvo Farmer


[ Parent ]



Re: its been a while :-) (3.00 / 0) (#6)
by DanB on Tue Aug 09, 2005 at 08:54:15 AM MST

Beautiful job there Roy - it's nice to hear from you again!!

I remember how you wound this stator up.   My thought would be - when your in the mood and it's easy, open up the airgap a bit.  60rpm is a bit low of a cutin speed for it I think, I expect if you cutin more like 80 rpm (which would probably be about 1/8" more distance between the magnet rotors) it would do better all around and the stalling issue may largely go away.  I don't think adding resistance should be necessary here.   retired my old 14' machine, but we frequently see 2KW + from Matt's 15 footer, 1KW happens all the time with it, I expect you should see the same, the machines are identical in their magnets, and stator.

It is nice to start out slow and safe though...
Again - very nice to hear from you again and it's a beautiful thing!  I can't wait till I have the time to start building stuff in my shop again!



Re: its been a while :-) (3.00 / 0) (#7)
by libra on Fri Aug 12, 2005 at 07:19:36 AM MST

I also have a 24v alternator with close spacing for my air gap. Since mine is still on the ground I guess I will have to open the airgap now rather than later. I have a 15' prop which is larger than Matt's and yet electronbaby has a 16' prop and still experiences drag. I am surpised that even with the larger prop there is drag.
Would someone expain why the drag even with the 18' prop.
More info   my cble run is 300' of 00 teck cable (the wires are 3/8 soild copper and my system is 24v)

Libra

[ Parent ]



Re: its been a while :-) (3.00 / 0) (#8)
by electronbaby on Sun Aug 14, 2005 at 09:45:43 AM MST

Libra, the magnets I used on this machine are massive. I have no doubt they could be capable of much more power. However, I dont think it would be safe, in the long run, to run the machine this way. The stator could possibly overheat. I think the main issue here is to get the prop to run at a more efficient RPM. If I was to widen the airgap, the prop would run faster, and cause less drag on the alternator. If you were to widen it too much, you would lessen the amount of power produced, and possible cause the prop to spin too fast, resulting in early furling. A 16' or 17' prop at 350 RPM does not sound too appealing to me (a little too fast)  :-P

So I think Dan is right. 1/8" seems appropriate. I want to make a new prop for this one also, so i think I will wait a while (leave it how it is for now) till I can get around to making a new prop of the same diateter. I was never happy with the way the original came out.

The only thing I really like about a small, tight airgap is how fast the the machine shuts down when you pull the kill switch on the tower.   :-P

Have Fun!!
RoyR
Have Fun!! RoyR KB2UHF
[ Parent ]



its been a while :-) | 8 comments (8 topical)
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