This detailed guide chronicles the DIY installation of a 1600W wind turbine, offering a step-by-step account of the entire process, from assembly to connection. The author shares practical insights gained from their personal experience, highlighting both the straightforward aspects and the challenges encountered along the way. This project showcases a cost-effective approach to harnessing wind energy for supplemental power, perfect for individuals with basic DIY skills and a desire for greater energy independence.The installation, completed in approximately a day and a half, focuses on a safe and robust mounting system using readily available materials. Learn how to optimize wind capture through strategic placement, and discover the importance of incorporating safety features like lightning suppression (planned for future upgrades). This guide also covers the integration of the wind turbine with existing solar and generator systems, providing a comprehensive overview of a successful off-grid power solution.
Pros And Cons
- Relatively easy assembly (took about a day and a half for the reviewer)
- Works with a pre-wired control panel (including dual brake switch and dual rectifier, offering redundancy)
- Requires a taller pole than what was used by the reviewer for optimal performance (due to safety concerns regarding violent storms)
- Power output not yet tested due to lack of wind in August
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Turbine Assembly and Installation
The installation process was surprisingly straightforward. I completed all the wiring and assembly myself in about a day and a half. Having access to the shop roof significantly simplified the process, allowing me to work comfortably.
I assembled the tail fin, then mounted the blades onto the hub. Each component was hoisted individually to the roof. The power unit was secured to a 2-inch galvanized schedule 40 pipe, which is crucial for mounting.
I mounted the power head, then attached the tail fin. The cabling was run, and finally, the blades were bolted on. This order prevents the blades from spinning while working on the wiring.
Pole Mounting and Height Considerations
The pole extends only four feet above the shop roof. While recommendations suggest a greater height, the prevalence of severe storms in my area influenced this decision. Safety concerns played a significant role.
Future plans include adding lightning suppression and an automatic disconnect for enhanced safety. However, considering the typical lack of thunderstorms in August, the current height is deemed sufficient for now.
The location overlooking a vast flood plain from a hilltop provides excellent wind exposure without obstructions. This enhances wind capture for optimal power generation.
Internal Shop Mounting and Pipe Connections
The 2-inch pipe runs through a 4x6 beam inside the shop, providing a strong and secure mount. A hole was drilled in the roof to accommodate the pipe, sealed with silicone for weatherproofing.
An additional 1 1/4-inch pipe was added to extend the reach and provide sufficient length for secure bolting to the beam. The connection between the two pipes was achieved through a tight fit, requiring some manipulation.
The 1 1/4-inch pipe was carefully inserted into the 2-inch pipe using a saw to create slots and then pounded in using a sledgehammer. This created a very strong connection.
Control Panel and Wiring
The Missouri Wind and Solar pre-wired control panel includes a dual brake switch and rectifier (though only a single one is used for the 1600W turbine). This setup provides redundancy.
The control panel also features a voltage reducer, a Midnight Classic charge controller, two breakers, and cabling that connects to the battery bank. A temperature sensor for lead-acid batteries is included, but not used with lithium batteries.
The wiring was mostly straightforward; the only challenge was programming the charge controller, for which tech support was readily available and helpful.
Current Sharing and Conclusion
Current sharing between the wind turbine, solar array, and generator is seamless. All devices connect to the bus bars on the battery rack, and voltage readings are consistent.
While the turbine hasn't yet generated power in the current calm conditions (August), the system shows no issues. The charge controller reads voltage correctly, indicating proper functionality.
This DIY 1600W wind turbine project was successful. Future updates will provide real-world power generation data once wind conditions are favorable.