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Solutions that might help:
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Other topics include:
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Read the most common type of question asked.
Answers to letters and design considerations. Your answer may be here.
Q: I NEED TO LOWER MY UTILITY BILL. How long will it take to pay back my investment in wind power?
A: AS LITTLE AS 2-3 MONTHS TO AS LONG AS 5 YEARS Two or three times longer if you used all professional installers.
If you make your own props and buy the gens, use scrap water pipe towers, your pay off period (money you would have spent on utility power, applied to the cost of your system), can be a year or two.
If you purchase the gear from us, about 3-5 years, depending on your wind speed.
If you used the ultimate surplus/cheapie generators and made your own rotors and all scrap/surplus parts, you can pay off the cost of the system with your utility bill savings in under a year, as little as a few months if you get everything from scrap yards and have good winds - we'll show you how.
This will give you an idea of how large an airfoil (or how many) you need. Use this information
and review your utility bills. This will tell you how much power you need to make.
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WILL A $1000.00 10 FOOT AIRFOIL AND GENERATOR FROM WINDGENSUPERSTORE MAKE AS MUCH POWER AS A $6000.00 UNIT OTHER PLACES OFFER. Yes, in fact, since we can custom carve the airfoil profile to match YOUR SPECIFIC WIND CONDITIONS you may get even MORE POWER from a WindGenZen airfoil and generator. Our LARGE AIRFOILS can compete with systems costing 3 to 12 times more, as shown on the comparison chart covering wind generators from arould the world. Most of the added expense of other systems are for towers and expensive grid-ties. Our classes show you how to slash that part of the equation by using inexpensive rugged heads/mounts you can make for less than $50.00 with parts from a hardware store (no welding required), and simple and complex circuits, wind switches, load/power dumping and more. We teach and have students all around the world. The step-by-step classes are included with your blade and gen. WILL I HAVE PROBLEMS WITH PERMITS? Depending on your location and the type of installation ( avoid a grid-tie to make things easier), you might and might not, but with rising oil prices, the political climate is changing drastically. Many states and communities are easing up on home owners and even encouraging self-installed wind generators that don't tie to the grid - you simply need a second subpanel (less than $100.00) and outlets dedicated to your alternative energy system - no grid tie required and that helps getting a permit easier. There are also forums and chat rooms where you can learn how to fight city hall with a video camera and a few pointed questions. If your electrical system meets code, you have a licensed electrician install the subpanel or make sure you use the proper components (right size fuses etc.), are using the power in your home and not sending it to the grid, the simple question to ask your building and planning department is:
because there is nothing dangerous about my system.
We suggest you bring the press or a video camera to a Board of Supervisors or City Hall meeting. That single step often causes politicians to think very hard about options and figure out what is best for their citizen's long term financial picture. Also, decisions are often made without quite so much red tape when the right answer is rather obvious, even to a child and their vote on the issue is public record, timely and newsworthy. Some communities on this map encourage wind generators. Others do not, but with public awareness, that is quickly changing. DO YOU SHIP INTERNATIONALLY? WHAT ARE THE SHIPPING AND HANDLING CHARGES? Yes, we have customers around the world.
However please note that England, Australia and New Zealand and many overseas
destinations have length limits on longer blades via U.S. Post
so long blades must be shipped UPS and are quite
expensive to ship.To solve that, we suggest you order either large 10 foot three tip airfoils which are made of (3) five foot airfoils, or buy in multiple units to reduce your price. Always check INTERNATIONAL SHIPPING RESTRICTIONS before ordering. GENERAL S/H CHARGES: Click a price lists on the left sidebar. It will ask you for your destination and then click BUY for any item you are interested in and the S/H charge will be shown on the purchase order. Hubs are usually included with blades and we mount them on finished blades. GENERAL SHIPPING AND HANDLING CHARGES: Within the U.S.A.
Add 10-15 percent to U.S. S/H prices. To Europe, England, Asia, Africa, South and Central America Add 50-80 percent to U.S. S/H prices, except the 6 and 7 foot airfoils; triple the S/H price. However the 10 foot airfoils are about the same as 3 five foot airfoils. Length Restrictions for International shipments, especially ENGLAND, Australia, New Zealand Many countries besides these three countries have postal length restrictions. For some places it is 60 inches (U.K. countries). But then Ireland didn't have that restriction and now it does-we don't know why. Columbia and many developing nations have a 42 inch restriction. Please review postal length restrictions at this URL before ordering. WHAT DO I DO TO PREVENT OVERCHARGING? DO YOU HAVE A PART FOR THAT? The class on circuits is at http://windgenzen.com - click the online class and use the password from the order status screen at our website. It's free to blade customers only. Students who bought the CD or online class also get the online blade carving class free. Then look at the 'simple and complex' circuits and decide what you want, whether it's wind switches, diodes, power burn off or disconnect on full charge. One way some folks do it is to flip the gen positive to gen ground which locks the blades. The gen positive is disconnected from battery positive for this. MOST people simply drive a heavy load like a refer or heater or pump when batteries reach full charge; the selenoid diagram at the site. Another option is to drive a bleed off battery system that has a big invertor on it that is connected to something like a water heater. This works well for people with homes and is better than locking blades down when fully charged. You really don't ever want to be losing power. Instead, use it...somewhere. Some people buy expensive trace controllers to stop charging and we don't recommend them. They die eventually and are expensive to replace and again, lose power. The first thing to consider is the battery bank size. You want to make sure you have enough batteries for 2-3 days of no wind. I run 10 golf carts on my boat to form 5 12 volt banks. I rarely hit overcharge and if I do I can let it trickle in and that will desulfate my plates. Works for me. WHAT IS MY BIGGEST EXPENSE WITH A WIND GEN SYSTEM? We hope it's your batteries and invertor! If you get a reasonably priced blade and generator, this is where you will spend your money. On many systems when you buy expensive wind generators, you spend as much for the gen and blade as for batteries and an invertor: bad idea! We offer much more cost effective solution and system estimater and systems you can make for under $100.00, so you have more to spend on those big ticket items. POWER OUTPUT, MOTOR RPM, VOLTAGE OUTPUT/INPUT?
Note: we provide generator/motors to wind generator customers AT OUR COST. These are often ametek motors from third party vendors and
we guarantee they will work or are replaced. Our vendors are professional surplus houses, electronic gear reps etc. Not all motors
are rated for this or that voltage, but ALL are guaranteed to work within the parameters below and ALL will
work with wind generator blades to provide 12-18 volts of charging power from wind power as described herein. Please remember
we cannot and will not guarantee a specific ametek model number and as these motors get rare and hard to find, please consider yourself lucky that
we sell them at cost for our blade customers. They aren't easy to come by and are considered 'The Gems' of the industry.
The ability to CHARGE BATTERIES always depends on the wind speed, blade size, air foils used, generator installed etc.
There is an amp chart for the common ametek motors at
WindGenZen.Com that shows amperage output. Generally ALL Ametek motors
we order for customers produce 12 volts at 300-400 RPM. This is why we only recommend the
WindGenZen NASA blades for Ametek motors, treadmill motors etc., as the airfoil
of these blades is designed to drive PM motors requiring higher RPMs, yet
remain quiet due to the very high stall speed. In addition to voltage to
charge batteries, noise is a function of tip stall, so whatever blade you choose you need to make sure it can
continue to deliver power beyond 20 knots; almost all hollow metal blades and most
hollow carbon fiber blades start to stall at 20-25 knots, become very noisy (really
irritating you and your neighbors) and we highly recommend you go listen to blades
in medium to strong winds before purchasing this type of hollow airfoil: they are loud and obnoxious.
The folks who have 'thrown away' their gens due to this noise have remarked that the WindGenZen NASA airfoil
is so quiet they would reconsider a wind generator after seeing one in action; the gen bearings make more noise!
As for voltage and RPM, Ametek motor specs vary from vendor to vendor; surplus houses rarely have the same
motors for more than a few weeks and then get a different batch. We offer them to our blade customers
at our cost, as well as in auctions at special prices and they range from 24 volts at 325 RPM
to 72 volts at 1850 RPM. Since voltage is a linear function of RPM, what you
need is a motor that produces 12 volts at about 300-400 RPM; any overall rated
voltage is fine. We studied the Ametek specs from the factory and for a given length
and diameter, the actually wattage (ability to charge batteries) is within 5% from model to model within a given length; longer gens usually
have higher wattage ratings as long as it produces about 12 volts within 300-400 RPM.
We also avoid the smaller 1/2 inch shaft and deal almost exclusively with the
more robust/powerful/higher output 5/8 shaft gens.
We purchase from several vendors as they often run out and
we have to 'ask around' to find them. Ameteks are getting harder and harder to find and all ametek motors we
purchase for customers produce 12 volts at 300-400 RPM.
NOTE: if you want a specific ametek motor, we do not provide this as
there is no guarantee of what is available. Motors vary from 5-7 inches long
and all have a 4 inch diamter housing with a 5/8 shaft. We cannot and do not
guarantee any other specification except the linear output of at least 12
volts at about 300-400 RPM. Overall wattage from all our vendors is within 5% (depending on length) regardless of the Ametek model. We suggest you visit the Ametek website and look up the specs on these and that's what you will find for any given length.
Please do not bid on our auctions or purchase a motor from us if you need a more critical specification than this.
Also if you have purchased a 6 foot or larger blade, while the ametek gens are fine if you have
medium to strong wind conditions, those blades can easily drive the 1/4 and 1/3 HP
motors also listed at our website. To get the most out of your blade, we suggest
you consider the extra money - well spent - on larger PM Motor/Generators.
WHAT BLADE SIZE DO I NEED?
We always suggest you start small (4-6 ft) and grow as you can afford more batteries
and a larger invertor.
Here is a letter to 'Russ' about his new 4 foot mahogany blade compared to the 4 and 6 footers I run that gives you an idea how to select blades:
Dear Russ,
Your mohogany 4 footer is the identical blade I fly in storm (most of winter) conditions, except I cut yours with thinner tips for the high winds you guys get next to Lake Michigan.
However, I fly them both on a LARGER gen ($50.00) so, here's the differences. The trick is to match the airfoil and blade length to the gen to the wind speeds expected:
You'll see more acceleration with a 4 footer on a smaller gen and hence more power for year round performance. Your 4 beats my 4 in lower to medium winds because it can easily drive your gen. It has a hard time driving mine in winds under 20 knots so I don't get much of a charge; another reason I gave mine wider tips; yours spins faster than mine in the same winds with the same gen.
So you get higher output than my 4 footer will produce in winds under 20 knots.
But I double that output by flying my 6 footer in those conditions and that blade is easily capable of driving the larger gen I run; they have TWICE the wind swept area.
Comparing 4 footer to 4 footer, you won't see the higher output I get when it's really blowing like last night (40+) unless you go to the larger gen, but if you HAD the larger gen, in high winds your blade would actually beat mine because it has the thinner tips.
Got it? We are the only blade shop that will custom carve to local wind conditions. At the windgenzen.com website there
is a page on airfoils. We can provide a 'hollow' blade for low winds (noisy, but they start up sooner) and
NASA or NACA airfoils and Wortman designs. Wide tipes, thinner tips...whatever you want we will help you get the most
power for the wind conditions you expect....free.
We are always adding larger blades and invertor gear at our website - click here.
WHAT ENGINEERING PROBLEMS WILL I HAVE ONCE I GET THE BLADE AND GEN?
Several engineering tasks remain when ANY wind generator land at your door:
"Finally have my generator working! It's pumping out electricity
like crazy. I have two questions for you. As the wind speed
shifts the unit swings from side to side. Will a bigger tail fix
this? Also I'm thinking that I need to work a couple of bungee
cords into the lines that hold the bottom of the pole in place
as there is a fair amount of noise inside the boat from the
vibration above decks. Any ideas?
"Dear BR, the larger tail will help; most folks basically use a triangle of 3 to 9 square feet pointing into the wind on a rod that is almost as long as the blades are wide. One problem folks have when using our larger blades is that they do require larger tails than little air-x and amp-air generators. Blades are bigger, more power, bigger tail.
As for vibration, I use 1 to 1.5 inch fat, braided nylon tubing around all metal poles/masts/sockets etc. and that usually kills it.
Nice to hear our BLADES aren't making any noise; they are notoriously quiet compared to other wind gens, eh? Make sure the bottom of the mast/pole is IN A PADDED SOCKET and you'll be fine.
Try it and let me know how it works."
CAN THESE DIODES HANDLE MY GEN OUTPUT?
While using a diode may be smart, many pros find the voltage loss unacceptable.
We suggest you consider using a WIND SWITCH which has much less loss. The
complete class is available
at our website but here's a diagram to get you started.
WHAT AIR FOIL SHOULD I SELECT?
We suggest you consider the air foil carved by
WindGenZen.Com which is based on a very fast, powerful and quiet shape
or
visit our website for graphs on start up and stall speeds (noise) for
different configurations.
IS 2-0 CABLE OK OR SHOULD I GO WITH 1-0?
2 0 ('2-ought') is plenty for the point the gens leave the control box and head for the batteries. By now you should have built the lil control box with the 50-100 amp rotary switch or double throw single pole switch etc. in 'the diagram'. As for gen to control box connection, 4-6 guage is plenty if run is under 50 feet and that cuts costs, but yes, you can spend the 2-0 everywhere if you have the budget, but it's a waste. Look at the wires leaving the gens. Triple that size and you're good for 50 feet.
I use exterior yacht style power cord for mine (4 guage) and have about a 25 foot run to my manual override switch (overrides the wind switch) and then on to the rotary switch (or you can use the double throw/single pole as in diagram) and then goes on to tag my main post in my fuse panel which my marine A/B switch also lights up and then goes on to feed my fuse panel which feeds the boat subpanel switches with all the gizmos on it. That main post tag allows me to select which battery bank to charge and gives me a convenient place for invertors, other battery chargers etc.
HOWEVER, since I do not run a voltage regulator, (they eat power), it's a bit dangerous; if I turned OFF the A/B switch and turned on my sensitive navigation equipment it would get hit with 20-30 volts in high winds and that would mean an expensive repair. I will probably add a voltage regulator that specifically manages the nav equipment in the future, but if I find it's a power hog (they are notorious), I will regret it. The other option is to install a relay that triggers on 18 volts (also on the diagram) and dumps power to heavy load. This protects the sensitive gear as most automotive/marine electronics can handle 18-20 volts and the relay would divert the rest.
Q: I DECIDED WHICH KIT TO GET. HOW MUCH DO I PAY?
Each link on the left menu leads to prices and shipping charges. Click the buy button
under any item and it will walk you through the payment process.
IF I DON'T LIKE MY NASA BLADE OR GENERATOR, CAN I GET A FULL REFUND?
If you buy and fly our blades and aren't happy with the output or if the generator
you choose is too large or too small, we refund 100% - no questions asked.
If you won the blade at an auction or paid via PayPal, you are responsible for
those fees. We don't refund eBay, PayPal or wood stock fees. Sorry.
The most common type of return/exchange/refund is undersizing your generator.
Many people expect our large 6 foot blade to match to the small cheap generators found
for $25.00 (some vendors charge $500-$1000 for these systems-OUCH!)
and while this is a fair combination in light winds, you waste a lot of power and
should have spent a little more and gotten a LARGER generator. The 6 foot NASA
AIRFOIL BLADES are flat out, unconditionally the most powerful blade on the
market for winds from 12-60 knots - guaranteed!
If you have wind and want lots of power, buy large blades and larger gens: our blades will drive them easily.
If you don't have wind, buy large blades and small gens to match your conditions. That's the elusive, but realistic and simple recipe for success.
Personally, in San Francisco, I run a slightly larger generator that costs $35.00 (plus s/h) with
my 4 foot blade in storms and my 6 foot blade the rest of the time and that provides
my nearly 100% of my power requirement at anchor, where I have lived for 4 years.
One winter I was able to drive a 30 website apache webserver with that system for
24 hours a day, 7 days a week, for a month. However, winds aren't always present
and vary by region so your results will be different.
If you need to process a refund or exchange equipment, click here.
The reason we prefer you ask questions through our website is
that:
Dear Tony,
Thanks for writing this way; personally and not through eBay. It
has a lot more room for questions and since we teach and try to
provide support, I am sure there will be a lot more than 'two
questions'. Let's address yours for now.
Two Questiuons Please:
Q: - Do you have schematics available for building a wind switch?
A: You bet. Our website has a free online class for blade customers. The circuit class has wind switches and all kinds of diagrams, from simple to complex. Basically it is a bit of styrofoam and a bilge float switch on a PVC pipe. I made several prototypes a few years ago and this one has outlasted all the others...in storms and in light air and is durable, pretty accurate (use bolts shoved into the foam paddle to counter-balance and adjust) and CHEAP. The class and all diagrams, including desulfators, various mounts and power burn off circuits is all free for blade customers.
Q: - What can I use to measure the AH or KW produced by a wind generator?
A: I use a standard volt meter with a 50 volt range. Some folks use an inline amp meter and while they burn very little power, I don't like anything extra that takes away from my wind power. For example, the diode (no wind switch) method uses 1.4 forward voltage (loss) and that's one reason I went with the wind switch. If you put an amp meter in there I would make it a brief on/off deal so you can take it out of the circuit as needed.
Q: I have an Ametek 50 VDC.
A: GREAT! Those work well.
Q: We have an outback charge controller (can dump to it) so I don't really need another charge controller.
Or do I?
A: I avoid charge controllers per se but folks who leave blades unattended for days/weeks need them. I let the gens fully charge the batterys and then dump the excess to either another bank or a fridge or a water maker etc. and switch it manually. Batteries like a little 'over charge', especially if you run a lot of golf cart batteries like I do (10 of them). You could let the large battery bank like mine go to 18 volts (while charging) and it actually ends up desulfating the plates a bit so it extends their life. If I were to put 10 amps into a single battery-POOF!-FIRE-MELTED PLATES, but even at 20 amps, divided by 10 batteries, that is about 2 amps per battery which is a nice trickle and at 18 volts, keeps the plates clean. HOWEVER, most folks don't run 10 golf carts like I do. If you only have 1 or 2 batteries, at 10 amps each in an overcharge state, you could burn the place down or destroy the batteries and a charge controller makes sense.
The problem with charge controllers is they eat juice, are expensive and I have seen even the nice TRACE units die...at $500-$1000 for some of these things, that's another expensive that I feel isn't required...PUT YOUR MONEY IN MORE BATTERIES. That's the best investment you can make.
Q: I will be in the market for blades as I'm planning on building a second generator.
A: Great.
Q: Thanks - Tony
A: No sweat. Write anytime.
Our eBay feedback says things like 'More support than my
therapist.'
To further prove support and teaching are number one at KCK,
here's a reply to a gent in a place that lives somewhere I WISH
I had a tower located. Wow. I am drooling. Check out the wind maps
for his home and you will too.
Hi. My name is Don and I am interested in wind
power. I have contacted other suppliers and they tell
me I need a 10kw to operate my whole home. With a
$60,000.00 price tag it is too expensive. However I am now
interested in a 3kw. However your web site is very
confusing to me, so my question is what would I need
and what would it cost. I am not interested in carving a blade.
I have limited knowledge of windmills. However I have built one
that has a gm alternater and two batterys it was fun to build
although it doesn't work that well. It does lead to a lot of
conversations. I would like to be connected to the grid but
building it comes first. I live in Nova Scotia, Canada. Thanks
for your time. Looking forward to hearing from you.
Dear Don,
You are in luck and I am envious of your geographic location. Nova Scotia?
Darn near the wind capital of the Americas.
First, we teach. KCK is made up of teachers that volunteer for
free children's PC labs (since 1983). While I know most folks
don't want to carve blades, that's where people on even tighter
budgets than yours start. Fine; you don't have to and yes, you
can do this for a fraction of $60k. That is absurd. I won't get
into the firm that quoted you that. I am sure they have done
many systems, charge a fair and competitive price and still, it
is absurd.
I can find a 10kw generator that can be driven with a blade for
$50 bucks - used. It would take time and calls to
engineering/rat-pack friends and perhaps a few months of salvage
research, but I know one friend with a 30kw gen (weighs probably
2 tons) and is the size of a large washing machine, in his
backyard.
I can get a 10kw generator that, with the right design can be
driven to power a home for under $2500.00-new.
I can find 3kw used gens for under $500.00 from several surplus
houses.
We can find 3kw new gens for under $2000.00 - closer to $1200.00
- $1500.00 - new.
In all cases it is always the SHIPPING that kills you...it is
usually more than the price of the item and that really shocks
people...especially overseas where it can be double the price of
the item to get it from the U.S. to say 'England' or Saudi
Arabia. Yes, it is rather ironic, but we have large blade customers in the
oil capital of the middle east. Go figure.
Now onward for blades; the trick is to match generator rated RPM
with the right airfoil and right blade SIZE.
As a rule, 1kw requires a blade of 8 - 12 feet in diameter.
3kw requires 13-18 feet diameter.
10kw requires 23-28 feet diameter.
Most of the blades we sell are much smaller than that. We target
cabins, RVs, sailors and a few folks who want them for their
homes/ranches, such as pump houses and barns etc. We also make
larger 1-5kw blades but if you want 10kw from a single gen, go
to Bergey...the caddilac in the industry.
We don't recommend it. Tower and wiring prices go sky high.
Maintenance costs goes out the roof.
When it's down, EVERYTHING is down.
Several smaller redundant systems with 2-4 towers is a bit wiser
(our thinking).
Installation grunt work for a 3kw gen is a fraction of a 10kw
fat gen.
Maintenance and replacement costs are much less.
When it's down, other gens are still going.
When you want/need blades for replacements or to expand the
system, they are a fraction of the price of a single large 10kw
airfoil setup.
If you want a gen at the barn and 2-3 at the house, smaller
systems with shorter wire runs are the only way to go.
So...in most cases, several smaller gens can out perform single
large systems in an DOLLAR PER AMP comparison and in a LONG TERM
COST ANALYSIS...smaller systems pay for themselves MUCH FASTER
than single large systems.
But this only works if you do a lot of the work yourself and,
like any large purchase, LEARN, SHOP AND KNOW WHAT YOU WANT and
get a feel for what is available before spending money.
So you want blades to drive ABC generator?
Questions begin. What are the RPM characteristics of the
gen...what voltages is it creating at what RPMs.
For example 10kw gens are often in the 100-250 AC range and
since RPM varies with wind speed, it is called 'WILD CAT AC'.
You have to take that voltage and rectify it and pump it into
large battery banks (normal way to store it). There are losses
whenever you rectify voltage. Look at the heat sinks on a large,
automotive garage style charger (inside those wheeling carts).
BIG FLAT PLATES where heat is lost...that's power going out the
window unless you heat some water with them.
Then in the smaller 1-3kw range you are often also getting AC
and that means a big rectifier and the losses there as well.
Whenever you have these losses you need to practically DOUBLE
the size of the gen to achieve what a similar DC generator would
be producing. It's not quite that bad but it isn't much better
than that when you consider all the other costs of that added
weight flying on top of your tower. For example, I would rather
have a single 1.5 kw DC gen than a 3kw AC gen-much lighter,
cheaper and easier to maintain the DC gen and it's overall power
output isn't much less (a little, but not much), than a 3kw ac
unit after the rectifier process is done...plus I don't need a
rectifer to get battery power from the DC gen. I just need
cables to put a few batteries in series (say to form a 48 or 72
volt system).
It's not until you get into the .5 - 1.5 kw range that DC is
commonly available and you don't have all those losses or
expenses.
So, how much extra gear do you want to go huge and what sort of
payoff does huge provide? Not much but it sure costs a lot
more.
How much savings do you have for towers, more batteries, perhaps
a grid tie or a larger invertor if you go a bit smaller and
stick with DC and to get the SAME OUTPUT, erect 1 or 2 more
towers and perahsp even BEAT the big AC unit's output?
I'd rather spend my money on battery storage and a real invertor
than be strapped for funding those items because my generator
cost as much as a nice car.
I'd rather get 3 or 4 sets of blades instead of spending twice
as much on a single set.
I'd rather build 3 or 4 20-40 foot towers that my friends and I
could set with a pickup truck or a good block and tackle for a
1.5 or even 2kw DC gen than a 50-100 foot tower for a big old
10kw gen that requires a crane when things need maintenance-and
they do, especially when you are first starting out and are
debugging things -
Common example: OOOPS! That large surplus gen didn't work out.
Put it on eBay for half of what you paid for it, eat the
$200-$300 loss, get a different unit, drop a tower yourself and
put the new one up, put the tower back up, ahhhh....good
powerband characteristics, easy to do maintenance and ok...now
that this one works, let's get 2 or 3 or 4 more of those
blade/gen combinations and do it again...cheaply and easily with
knowledge of what works and what doesn't and plenty to spare for
the BIG TICKET ITEMS, like a few tons of batteries and really
nice invertor, grid tie to sell power back to utility companies
etc. etc.
AND the smaller units pay for themselves in a fraction of the
time of larger units. The LARGER THE UNIT, the LONGER IT TAKES
for the DOLLAR PER AMP cost to pay for the unit. Period...a
universal equation.
Look at the comparison chart at http://windgenzen.com.
Note the increase in COST PER AMP as you go bigger.
Ok, enough said.
Now airfoils (our specialty).
We use a NASA 0417 and NACA 4418 airfoil; it doesn't start as
'quickly' as hollow metal blades because as EVERYONE KNOWS in
the wind gen biz, low wind speeds are worthless for power.
BUT manufacturers want to tout numbers such as 'starts in 4
knots of wind'. Ok, go buy a cheap wind guage and go outside on
a 4 knot breeze and tell me how much power you are going to get
from that? Power is a function of wind velocity CUBED so you
double the wind speed and get 8 times the power. Got that?
Important to always remember it. Wind goes to 8 knots and you
have 8 times the power of a 4 knot breeze. Wind goes to 16 knots
and you have how much more power than that 4 knot breeze? Try 8
times 8 or 64 times the power. And 12 to 15 knots is just
getting started. So what does that tell you about the value of
extreme low wind conditions? Worthless. A waste of grease in the
bearings.
Kick the wind up to 20-30 knots and at 32 knots compared to 4
knots you have 64 times 8 or 500 times the power. Yup. Go look
it up.
Give me a gen that works well in 15-40 knots of wind and a blade
set designed to drive THAT gen and I am a happy guy. That blade
set will probably start in 9-12 knots of wind and deliver a
great, wide powerband all the way up to 40-60 knots.
HOLLOW LOW WIND BLADES (punched/rounded metal being the common
type), start in 3-5 knots and in EVERY SINGLE CASE, they start
to stall at 18-25 knots (huge dip in their powerband graphs) and
they get noisy, vibrations come into play and they have to shut
down or furl out of the wind.
This is acceptable if you have 5-15 knot breezes every day of
the year...get a low wind blade and get as much power as you can
and be thankful you have dim lights at night. It would be better
to use solar if wind is that poor.
But, back to my first paragraph...folks in Nova Scotia have no
such restrictions. I have friends there. There are places the
wind howls 50 knots every single day. Give me a blade that loves
a 20-50 knot breeze and doesn't stall until the extreme upper
end and now you have how much? Uh, we figured hundreds and
hundreds times the power of the low wind blades.
Our blades are designed by a NASA physicist who sails and uses
them and taught us to make them. He likes our workmanship and
airfoils so much now we carve HIS blades. A compliment from a
great teacher to a great student (us).
Our blades and airfoils are also discussed extensively on our
website-check the airfoil link at http://windgenzen.com.
Our blades don't follow the same design characteristics as
anufacturers who want low wind blades. We don't care about 4-7
knots of wind. We start up in 9-12 knots and our ramp is much
steeper than theirs is. We have designed blades with the advice
of a high speed turbine enginer blade designer, both hollow and
a well formed airfoil and guess what; the hollow ones start
sooner but never reach the output or RPMs of a good airfoil.
Period. We did the test, saw it live and don't do it anymore.
We've also done the tests with common car alternators. The
problem there is electricity is required to ignite the field
around that becomes the magnets in the units. Because these
alternators are designed for cars with engines turning at
2000-5000 RPM, there isn't enough wind power until it is howling
at 40 knots to break even; the field requires too much juice and
the RPMs at 300-1000 RPMs with a 6 foot blade aren't enough to
make the voltage that can charge a battery. End of story.
I know of one Kiwi who used the 2 to 1 belt pulley set up (with
20-30% losses in friction), but he wanted cheap, commonly
available, gets some power at 15 knots and is happy. I would
rather get the right gen/alternator.
The right unit has MAGNETS to create the magnetic field. No
electricty is required to ignite a coil. Permanent Magnet
Generators are cheap-the ametek is the standard darling of the
industry for folks running 4-8 foot blades to get 100-400 watts
and they are refurbished, widely used and are cheap-under $100
bucks.
Permanent magnet alternators are a bit more pricey and are
usually new-expect to pay $150-$400 bucks for a similar unit as
the ametek, however a good PM DC motor capable of producting a
full kw easily can be had at a junk yard for less than $50 bucks
and might cost you $700 new if you shopped at the wrong
place.
It all depends on whether you want new or used and whether or
not you are willing to take a chance, save a few hundred bucks
and swap a gen or two before finding the right surplus one that
worked well.
If you want a common gen, look in the mailed catalogs. You can
get several 5kw gens for under a grand. Yes, they are AC. Yes I
think a 2-3kw DC gen would be a better choice-almost as much
power since you don't have to rectify it. There are new DC
motors in the 1-5 HP range that have RPM characteristics that
work well, but since they don't make as many of them as 5kw gens
(Coleman, Sears, etc. uses the common 3600 RPM 110vac gen and
they are very common and cheap), well you will pay a bit more
for a DC unit that puts out comparable power and it may even
weigh a bit more. Oh well. Spent a little more, got a DC gen,
didn't have to mess with a rectifer and I can pick and choose a
motor with good RPM characteristics. THEN consider the blade
length to do the job, get a blade slightly larger than required
if winds are light and slightly smaller/cheaper than required if
you get a lot of 40-50 knot winds and you can, with a good,
thrifty shopping strategy, put together a 10kw system for under
$10,000.00, batteries and invertor included. Grid ties to sell
power back to utility companies get a bit pricey and the
engineers you need on site get pricey too, but that's another
ball game in the 'pays for itself' equation altogether.
So, you probably didn't want to 'learn' all this stuff and
perhaps my email reply was a bit long winded, but we are getting
a lot of requests for the 1-5kw blades (we don't usually do them
except for the NASA guy - he likes 10 foot and larger blades we
make), since we aren't a carbon fiber/fiberglass shop.
We specialize in making the finest wooden blades and NASA/NACA
shapes on the planet. That's what we do best-a very quiet, very
powerful, wide powerband blade.
We do not make 'start up fast in low wind speed' blades. If you
want it to start faster, reduce the size of the gen or add 10
percent to the length of the blade and get 20% more power; a
blade that normally starts in 9 knots now starts in 7. Add
another 10% to the length and now it starts in 5.5 knots, but by
maintaining a good airfoil shape, you still get the 30-50 knot
winds the hollow blades miss out on and where is the real power
going to be? Get it?
If not or if I have totally confused you, take a look at the
simple airfoil diagrams at our site at http://windgenzen.com.
Take a look at the price comparisons, then go on to the FAQs
page and guess what? I have had so many recent requests for
exactly this 'Can you tell me if...' question that now this Q&A
answer and discussion has been posted there as well. Thank you
for an opportunity to teach you and others these lessons. Have a
great day.
p.s. if you do want a large 3kw system from us, we make a 3
bladed prop (120 degrees apart), of 3 7.5 foot blades (15 foot
diamter), and sell the blades and stainless hub, welded by Barry
Breeden, vice chairman of the American Welding Society, one of
the top 10 welders in the entire U.S., and the blade is, as
always, our world famous NASA design. Jerry (the old NASA
physicist), loves these projects. We look at your local
conditions expected and lay out a custom airfoil shape for the
winds we think you'll get. We are the ONLY firm on the planet
who does this free of charge on a customer by customer basis.
It's because we are nutz about getting the right blade to match
the right gen to match the local wind conditions.
That is, beyond everything else discussed by all the enthusiasts
and manufacturers, those three combinations are really all that
matter. A light wind blade won't work well in a strong wind
area: you lose tons of power when the gen tops out early. A high
wind blade or a gen that is too large won't do well where winds
are low: it takes 15-20 knots to get it going and you miss the
nice powerband in the 10-20 knot range. We shoot for a wide
powerband that kicks off in 9-12 knots and screams from there
right up the scale.
That's how we do it, that's our philosophy and since I have to
LIVE on this power 12 months a year and run laptops, skillsaws,
refers, lights, grinders etc. on my sailboat, that philosophy
has worked well for me in real life application. Any other
airfoil, from my experience, is a waste of time and money. Give
me a real airfoil made to do real work in real wind conditions
where there is really available power and things work well. Give
me a blade that starts too soon and I have to listen to it buzz
in 20 knots and I am losing power since those tips have stalled;
just shoot me please. I can't sleep to take me out before I rip
it down and throw it overboard.
Give me a blade that only runs in high winds (the Wortman
airfoils love high winds) and they don't start up until things
get stormy and after about 50-60 knots of wind, it's probably
safer to manually or automatically start shutting down the
system anyway. We are talking hurricane forces so...
Give me a blade that operates from 10-60 knots and I am a happy
guy.
I am typing this question/answer reply right now on power that
comes from that type of airfoil. Go figure.
So, if you want a 15 foot, 3kw, 3 blade prop made of 3 7.5 foot
blades and a stainless hub, the blades are $400 each ($1200.00
for a set of 3) and the hub is $200.00 from Barry who also welds
Triton Missle Launch tubes to mil-spec. Our wooden blades are
gorgeous, well carved, balanced, tested and finished to be
beautiful.
We can even shoot them with two part LPU yacht paint (see
website for enduthane specs) and they will last a very very long
time. At $200.00 per blade for that deluxe coating, they should.
But half of that expense is to satisfy your inner child's need
to have black blades with yellow tips (red looks good too).
We even had a girl in the south who wanted a white blade with
red tips, a flag blade (red white and blue), a clear coat grain
shows blade and a (ahem), rainbow blade. Hmmmm....we were so
thrilled making them for her we even got old Jerry to sign them
To Britanny, from Jerry, NASA AAmes. A special treat for her and
they are also shown at our website, but I doubt you want a
rainbow blade at $400.00 for the coating per blade alone or a
flag blade at $300 for the coating. Those bits of art take time
and money. If you aren't rich, stick with a blade you can
afford, a system you can afford while you learn what you really
want and need (how many) and parts you can lift with basic tools
without hiring a crane at $500 per hour.
We show folks how to get the LOWEST COST PER AMP. That's our
goal here at KCK. We teach. Support is always number one and
despite all the hype about this or that gen, we always say 'ANY
WIND GEN IS BETTER THAN NO WIND GEN.' Period. Get a 4 foot blade
from ANY manufacturer and learn the basics and start building
your system if that's the price range that helps you get you
into the game.
But get started...please. Fossil fuels aren't getting cheaper,
the air isn't getting cleaner and at this rate we may have to
'liberate' Saudi Arabia (?!?) next just to keep the lights on in
New York and L.A.
And that's a crying shame considering the wind blows free and it
doesn't take the price of a Ferrari to get going...the price of
a good VW is all you need to light up an energy wise home and
perhaps the price of a good used GM Truck can keep you fat and
happy with power to burn.
My approach to the industry is, like most people, biased
by my own personal background. Before my aerodynamic education
began with tutoring from Jerry, my specialty was writing
financial analysis software for banks, HMOs and large corporations.
I look at QAUR (Quality Assurance and Utilization Reveiw) reports
and projections with a keen eye towars getting the most bang
for the buck. So when it came time to designing my system,
after sorting through literally hundreds of graphs and charts
on various airfoil shapes, I settled on a few and they have
all served me well and they will serve 70% of the global
population quite well as well.
To make sure I had made a sound decision (an informal audit), I
tried some of the other airfoils, flew blades on car alternators, have
used diodes and wind switches, tried different large/small blades on
large/small gens, and tried shapes that many manufacturers 'claim' are the
'computer designed' best, or 'start in as little as...' etc. and
if you are in a place where there is little wind, they may be
just what you need. If so, DO NOT BUY OUR AIRFOILS. We can't
compete in 4 knots of wind. We don't try.
Or if you insist on a WindGenZen NASA airfoil, at least make
sure you get a blade that is a bit larger than the one
recommended for the generator you intend to use. That solution
will solve your low wind problem in a jiffy.
And if you are so lucky as to have the words 'Nova
Scotia' in your address, be thankful and if you can see the
North Atlantic from your front porch, you are gifted. You are
kings of the world in this wind gen realm and if you are still
paying for power to light up your TV, PC and microwave it's high
time you reconsidered your available resources, define a
reasonable budget based on what you've paid for that fossil
based power over the years and look at your skill sets (towers
are not hard to erect if you work within reason) and employ an
intelligent approach and deploy a cost effective solution. I am
simply green with jealousy for the power you have at hand and I
live in San Francisco where winds aren't exactly light. But we
are a drop in the bucket compared to you. Remember - wind speed
affects power to the cube. Actually it's 2.7, not 3, but that's
close enough even for this old auditing salty sailor.
And ANOTHER DONALD wrote us, this time from Maine.
His letter is a good overview of alternative energy
in general:
"I am uneducated in this power process and just looking into it.
Thanks,
Don
DEAR DON,
WOW MAINE! Must be great wind up there.
Here's the lay of the alt-energy landscape:
Let's start with the easy one: Tidal Power.
a) if it's flowing down a stream of back and forth in a gulley and you can lay copper wire to a spot with max ebb/flood, great. TONS of power. Except here in California where you'd go to jail for tapping it unless you had a 10 year 10 million dollar state environmental impact study done. Sad.
b) if you want to catch the up/down motion of waves, there are a few ways to do that. Seems like a very high maintenance deal to me considering the corrosion and impacts and storms.
Here is a lesson that applies to tidal, hydro and wind power: the power (at least for air) increases to the 2.7 (most folks say the cube) of the speed. So a wind at 20 knots which is twice as fast as 10 knots has 8 times the power or 2 to the 8th power.
Water due to it's density is probably even worse, but regardless, even if it was the same, when a big storm hit a tidal generating station, that, from my experience with wind and sailboats, would be too ugly to pay for. But then my opinion is total speculation and the guy who harnesses (and markets) wave action affordably and available for the mass market will get rich.
Next hydro, as in streams and creeks;
Great if you have them. Often little rivlets can generate quite a bit of power over the 24/7 clock they enjoy.
Next, solar panels. The most expensive invention in the industry, dollars per pound and dollars per amp. I avoid them, but then I have good wind and I must admit those 30-60 days a year I have no wind, well a solar panel would be nice to have, but at what cost? $500-$1000 or twice that actually to even come close to my $200 wind gen on a lazy 'teens wind' afternoon? And most panels don't put out much at all if conditions aren't clear so...
Next, solar heat collectors for hot water:
Great stuff. Make them out of copper pipe laying on black sheet metal and build a wood box around it with a clear lexan/acrylic cover. Put it on a slant and put the INSULATED tank at the top of the run and it will be too hot to shower without a cold mix...unless the roof is loaded with snow and then you probably have lots of wind and storms and can make hot water with a 12 volt element...
...finally wind.
Cheap and do-it-yourselfers can make a lot of amps for very little money. We try to keep students focused on the batteries and invertors as far as cash outlay goes. Some firms charge $500-$1000 for gens that barely make 1/2 HP. We have one that makes .75 to 2kw for about $400.00 and we have less expensive ones than that. For example the 6 ft. blade and larger ametek motor (cheap, refurbished motors) beat the $800 Air X Marine by a 2 or 3 to one margin (the meter blew out at 3 times the amps). So for about $200 you an beat an all pro expensive unit with 15 amps when the expensive unit is only making about 5 amps.
With wind there are a lot of choices. We have a comparison link at the http://windgenzen.com site and wind maps and wood tensiles etc. We are an edu site and push folks to do it themselves.
For folks who don't want to make blades, we make the most beautiful, powerful blade on the net; based on a NASA airfoil it kicks butt and looks great. We make them in a variety of sizes and even sell blanks with the lines drawn so you can take a crack at carving them.
Finally, once you have 2 wires supplying some charging current to a battery, we suggest 6 volt golf cart batteries-use 2 in series to make 12 volts. I have done the marine battery thing, the big diesel battery, the RV gel and deep cycle batteries and nothing has ever come close to lasting as long as the 6 volt golf carts. For a 6 foot blade I use 10 of them to form 5 seperate 12 volt cells.
I run it to an invertor to drive my laptop and other gear onboard my boat. I also have a fat 3000 watt invertor for bigger things like skillsaws and drills and the microwave. The rest of the time I use the small one.
There is a switch for on/off/brake and a switch for manual or wind switch only contact and a few meters to see how I am doing. That's about it. The entire mount and circuits classes are included with the blades and you can make them for under $25.00. Jerry the NASA physicist who taught us to make blades keeps his rig simple and so should you. Just a thought.
Got it all?
Let me know if this was the sort of overview you sought and write anytime.
Klamath Falls is in a basin and I am concerned that a low wind propeller would not get enough wind to work.
I would guess the winds at 20 mph with gusts to 25 or 30 at the
worst time of year in the winter? during the summer they are
lower. In the high single digits in the afternoons to the low
teens, as a general rule. I think the low teens would be the
average? I thought and was hoping that your propeller was more
or less for all wind senarios and quiet. Please advise what you
think would be best. I will try to call you tomorrow.
Looking forward to your reply.
Thanks,
Dan
Dear Dan,
Every airfoil has a range it works best in; that is the STARTUP SPEED and the STALL SPEED define the start and end of the range. As a rule, hollow blades, like metal ones, start sooner (as low as 3 knots) and stall sooner (usually 18-25 knots)...since there is no amperage at the low end, as a rule we avoid them and prefer a blade that starts 2-5 knots later (9-12 knots) and stalls much higher (40-50 knots). Look at the difference in range also. The first blade has a low range of 3-25 or 22 knot power band spectrum. The 2nd blade has a 9-50 knot range or a 41 knot power band spectrum. When a blade stalls it makes noise and vibration. I live with my blade on a mast; it has to be quiet or it's toast. Period. I want max output when winds are good and when winds are light I either swap to a SMALLER GENERATOR that starts sooner than the big boys or a BIGGER BLADE which will drive the big generator up sooner in light winds. This way I have the best of both worlds - wide power band and light wind performance when required.
Most folks want one blade to do everything and if you can accept the loss of power at the top end and want a hollowed, fast start blade, we can carve that. If you want a quiet blade with a wide powerband, we can carve that. We can carve compound blades that do both - each change affects the airfoil characteristics. Today I carved a blade like that for an Australian - fast tips and a hollow core/center portion to get the max power from that region. Hey...whatever folks want we do.
So...in your case I would consider a smaller gen or bigger blade for low wind months OR with the 3/4 HP motor (fat boy at the site) and a 7 foot blade you can control the load on the motor (and output you receive per RPM) and let her rip in light winds (low load) and crank out some mega-amps in high winds; that motor is easier to manipulate for optimum performance in a given season than an ametek.
Nobody makes a single blade that does both low wind and high wind performance; think about it. If I make a wide spectrum blade how can it compete with a specialty cut made for 3-5 knots? No way.
And the 3-10 knot blade won't compete with a blade made for 10-30 or 12-40 or 15-50 etc.
Each blade has it's own powerband characteristics; angles of attack, tip chords, aspect ratios (height of crown/apex vs. chord) and other 'cuts' that make them all unique. The good news is most changes won't affect a blade by more than 10-15 percent so it's fun to play and at worst you just get a lousy blade. MOST lousy blades are low wind blades (my experience). I have a friend at the harbor who threw rope into his neighbors Air X because those hollow blades make people want to kill their neighbors and rope was more effective at getting the message across. I had a sailor at anchor pull up next to me and say he was amazed at how quiet our blades are as he had thrown his gen overboard (literally) for the helecopter noise it made. So...power band and vibration and wear and tear on the gen and bearings are all something to consider when you have to live with them and rely on them. Low wind gens just don't cut it for me if you get my drift.
It all depends on what you want from your system - max power by each season or an overall performer or a gen you can control etc.
Take care and write anytime.
Dear Sir, Madam,
I have a studenthouse on Curacao, one of the islands of the
Netherlands Antilles in the Caribbean. The location is direct to
the coast. The yearly average wind is 6,5 m/sec. The monthly
average windspeeds varies between 5 m/sec and 7,5 m/sec. During
95% of the time we have the passat wind from the east.
We are using about 950kW per month.I expect that it can be
decreased to 750kW per month by using special lamps,
photo-electric switches, and other actions.
I am not interested in charging batteries but supplying my own
electricity and eventually supplying electricity back to the
grid. I want to supply at least 500kW electricity per month by
myselves.
Perhaps you can send me a detailed proposal.
However, I am worried about the fact that you are using
generators designed for 1750 rpm, while your rotor can do
perhaps 200 rpm, (i do not believe in up to .... figures) and
hopefully do 12 volt, the minimum for a converter. So, many
perhaps and hopefullies. Also, the blades should not be noisy
and/or vibrating for ourselves and the neighbours, because we
live in the town Willemstad.
Let me know what you can do.
best regards Cor Pronk
PS I have a bachelor degree in electronics and know also
something powerelectricity. The voltage here is 127 / 230 Volts
50 Hz. A mix from USA and Europe. I intend to build the system
by myselves.
--
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Virusvrij.
Voor meer informatie, zie http://www.caiway.nl/
Dear Cor Pronk,
Congratulations on your ability to make homes by the sea...a
magic quality about your life. I live at
http://eduhosting.org/pics/myboat.jpg - as you can see, I enjoy
the magic of the sea myself.
This is where the wind generators I make are designed and
tested.
The NASA Physicist who taught me to make this airfoil also has a
sailboat in the harbor. He travels from San Francisco to Hawaii
to Alaska each year and uses his blade for power.
The airfoil design is very quiet and very powerful and we show
people how to achieve the LOWEST COST PER AMP. There are larger
systems and smaller systems, but nobody provides this type of
guarantee; lowest cost per amp. We do this because we teach. We
come from a teaching background and the revenue from the wind
generators (and other products) helps fund our FREE PCs FOR KIDS
program (since 1983).
The generators work; I have lived at anchor for 4 years with 90%
of my power coming from them. They work well.
We make blades in all sizes, from small 4 foot blades (see the
photos at the website - http://windgenzen.com) to larger 7, 8,
10, 12 and 15 foot blades. Capable of driving up to 3kw PM DC
Motors (5 HP).
We always suggest people start small - 4 to 7 feet - so they
have a system that is easy to build, easy to maintain, and they
LEARN about the entire system and performance expectations
BEFORE they spend a lot of money. This is the wise path to a new
venture.
We do NOT believe you should buy LARGE generators just because
you want to make a lot of power. Large generators mean big
towers, big cables, cranes and large expenses. 2 or 3 small
generators are easy to manage. 1 large generator is not. 2 or 3
small generators will still make power in case one is down for
maintenance or repair. 1 large generator does not have this
safety factor built in.
And yes, our blades are quiet. Yes they are powerful. The RPM
ratio is from 200 - 1500 RPM depending on wind speed.
The most common RPM range is 300-800 RPM.
The generators, all of the Permanent Magnet DC motors (some AC
motors for larger gens) are going to create voltage that varies
with RPM.
To manage this output you need batteries. Period. The larger
gens make a WILDCAT AC (hz and voltage varies) so this must be
rectified and poured into the batteries. Use GOLF CART 6 volt
batteries - they last for 5 to 10 years if you use a
desulfator/reconditioner on them. There are circuits at the
website that include diagrams for these or you can get a
commercial unit for $100.00 or less.
And from the batteries you use an invertor. Period.
They are cheap and make power from 110VAC 60hz or 230, 460, etc.
60 or 50 hz. We have them at the website too. You can also find
them from other sources.
We provide inexpensive blades and generators because we believe
you should spend your money on a good battery bank and good
invertor bank.
If maintenance is a problem, then perhaps a gel battery bank is
better. Also FORKLIFT 2 volt batteries are great. Even better
than golf cart batteries. They are very heavy, thick plates,
last a long time.
DO NOT USE RV DEEP CYCLE BATTERIES. They are better than car
batteries but not nearly as good as others I suggest here.
WHEN you have this refined sine wave AC from the battery and
invertor THEN we can talk about how much power you need.
In your case you want 500kwh (kilowatt hours) from the system.
So you need to make about 15 - 20 kwh per day.
So you need to figure HOW MANY HOURS the wind blows and HOW
STRONG IT IS FOR THOSE HOURS. A light wind 24 hours a day will
not make as much power as a STRONG GUSTY WIND for 8 hours.
When you have determined how much real wind you have, THEN you
can decide what size of blade and generator and how many
generators you will need to achieve your goal.
Or you can do it another way: try the monster 7 foot gen with
the 3/4 HP motor and get it as high as possible. If noise and
vibration are issues, this is a good way to start because it
spins slower than the smaller 4 foot blades, although both are
very quiet. In 12-20 knots of wind for most of the day you will
easily make 5 - 10 kwh per day, perhaps even twice that much if
you have good wind for long periods. I am familiar with the
Passat wind you describe; I sail. That wind is famous with
sailors around the world.
Watch the amp meter through the day. Jerry, the NASA physicist
takes hourly amp readings on his sailboat and matches them to
wind speeds. You do not have to do that forever, but it is a
good idea to do it when you first start out...for 1 or 2 days
and later, when winds are stronger or lighter.
WHEN you have some of this data, THEN you have an education in
wind power and THEN you can make an EDUCATED PURCHASE of the
quantity and equipment to do the job. If you are uneducated, you
spend too much; sometimes 5 to 10 times too much in this
industry.
If you waste time getting too much education, sometimes it isn't
worth the trouble, but in the case of wind power, a fairly new
airfoil technology and commodity on the energy scene, it makes
sense to get an education because the price/performance graphs
vary so widely.
So, we teach (since 1983). We are here to teach you. Write
anytime and ask more questions. Support is number one at KCK and
we mean it.
Thank you.
HOW TO SET UP YOUR HOME FOR ALTERNATIVE ENERGY>
Dear Wind Generator Super Store folks,
I have a home with a lot of wind and am interested in
your systems. I like the price and the wood blades look
strong. I have some questions though.
First, why should I get wood instead of a composite material
like fiberglass. Fiberglass lasts forever and wood seems to
have a problem with maintenance. Also, there are wind generators
using metal turbines and carbon fiber. Why wood? What problems
will I have with that material compared to other choices?
Do you use other types of materials for the units?
Next, I do not want to have to design anything. I want a
system that has everything in the box so I just plug it in
and it works. Do you guarantee your system is like that?
Finally, do I need batteries and an invertor or can I wire it direct
to my home? What about selling power back to the utility company?
Do I need a big generator or should I use several small ones.
Let me know what I need to buy, total please, and how much time
it will take to install it all and flip a switch and have power.
Also, why should I get your system when there are firms that
have been around for over 20 years. What is the advantage of
your design over other designs?
Dear Arthur,
First, thank you for writing. We are an educational firm and
love seeing new students interested in wind generator technology
and will try to help you decide which path to choose; there are
several.
Next, since we try to help folks get "the lowest cost per amp",
it means most people would rather spend 10 minutes to build
a mount for the generator and spend $25.00 in parts, than
pay at LEAST $25.00 in shipping to have metal passed around
the country, PLUS the cost of the purchase of that metal
mount. To us, it is better to spend your money on things
you cannot obtain locally, such as a 220VAC invertor or
a grid tie package. It doesn't make sense to ship batteries
or masts/towers around the country. It does make sense to buy
an inexpensive wind generator so you have more money to spend
on a big invertor or a lot of batteries.
Let's go over a few items you will need to either buy from
us (or some firm) and the ones you can quickly make yourself
and save a lot of money on:
If you want to save a lot make it yourself.
We have classes.
Otherwise, (and especially if you want BIG blades), it pays
to have someone make your blade for you. Ours are designed by
a NASA Physicist with 30+ years of wind tunnel testing experience,
who sails a large boat with a 9 foot wind generator on it (yes-9 feet)
and who has worked on spy planes and gliders etc. and knows the
numbers. This isn't to say our 'wood airfoil' is better than
some computer cut/designed airfoil, but rather, just to
assure you they are gorgeous, fast and they are quiet. Sound
is a big factor in our design as I live with one over my bunk and
wouldn't have anything to do with the industry or technology if
I couldn't sleep at night.
Next, you asked about wood vs. modern materials. That is
a personal choice and should include a few facts on the
materials:
But it isn't that tough to maintain a gorgeous blade
with natural oils in it to protect against rot (the premium
hardwood blades we offer have this) and keep them coated
so they can actually outlast all the other gear.
It isn't hard at all. Imagine a 1 inch thick by 4 inch wide
plank (actually much smaller due to the carving/shape). I
carve them and I coat them as do the crew in the shop. It
takes me about 3 minutes to sand/prep a blade for a shoot
(coating it) and about 3 minutes to do the shoot - MAX!
if you can't dedicate 5-10 minutes a year to recoat your blades,
no matter what system you buy, you will have a failure because
you don't have any time to maintain it. Wind Generator failures
are not pretty. Whether it is a fire due to a dying gen/brushes/
bearings or a fried/corroded cable or a loose blade or bolt,
face it...you are going into the POWER business. That means a
lot of kinetic energy is going to be transferred to electron
movement and that means you need a rig that can take all that
energy/load. If you use big blades you need good struts/supports/bolts
and a durable gen, thick wire, good batteries etc. In short,
this isn't a little bike in the corner with a light generator
on it. For homes you are going to be running 2 horsepower to
10 horsepower generators.
The good news is they need about 1/100th the maintenance of
a 2 horsepower gas engine. Literally...about 1/100th the
maintenance.
Some folks want a huge 10kw gen and rotor. Others want to consider smaller,
more manageable units. We suggest this approach is best
as it allows you to learn/grow without throwing $50,000.00
into the equation at a time when you know nothing except
'expert advice'. Be aware that these expert installers
make their money selling huge systems; systems you can
do yourself with just a little training. Again, we are
an educational firm. We design classes for large EDU
publishers. We don't think setting up a wind generator
is that difficult and we teach kids (lots of kids) so
most of our diagrams and webpages are geared for idiots.
We even have a 'blonde-proof' wiring diagram, although
we have to be careful about that term since Jerry, the
NASA Physicist who designs our airfoils is blonde...well,
sorta gray, but...
One thing to remember: 10kw gens require 20-30 feet diameter rotors.
They also need cranes to lift them and maintenance is a big problem
if they ever need to come down or go back up. Everything becomes
very expensive in this size. A neighbor of mine has a company
in Canada and California and does these huge systems; typically
for $40,000.00 to $70,000.00 and more. We can show you how to
get just as much power for less than 1/4th that price, but it
does require an educational process. If you don't want to
learn about how to do it inexpensively and reduce long term
maintenance costs along the way, get an expert, pay the big
bucks and stop researching it on the internet; go back
to golf.
If you want to know what you are doing, spending, expect to
get for power, expect to have to maintain, then starting
smaller is a better option; you can buy as you learn and
don't have to break the bank for a system that can put
out just as much power as a huge one.
Solar panel systems do not enjoy this type of advantage because
the panels themselves are very very expensive no matter who
installs them. Wind power is a different animal; much cheaper
per amp and since that means most of the budget revolves around
the batteries and invertor, which solar also requires, it
means a little knowledge can quickly help you build the
size of a system you need to do the job without wasting money.
For large homes we suggest a 2kw generator (there is
one at our site that matches our 7 foot props) and if the
site has a long run from the gen to the battery bank then
you will need welding cable. We suggest you have a battery
house right under the tower and if the run is long then
you may want to consider a high voltage AC gen which can
drive the power longer distances than DC.
However, inexpensive AC gens are not usually 60 hz; they
vary with blade RPM and so it is called WILDCAT AC. This
means you will probably have to convert it to DC with
transformers and diodes and charge batteries to drive an
invertor anyway, so if you want the most power for the
least money, put the batteries under the tower and after
you make nice stable 60 hertz AC power, THEN you
can go a long long way with that power to a distant
home.
So, assuming you are using (4) 2500 watt gens to make
10000 watts of power, you would spend about $800.00
on 4 gens.
Assuming you go with one big gen, such as the 10kw system
from Bergey, that price tag is $21,000.00. If you went with
3 small ones from a firm such as the Whispers which have a
3200 watt model, those are about $5500.00 or $15,000.00 for
three.
Compare that to $800.00 and you have a lot more to spend
on (here is your first quiz)...
At this website you can get a 2kw PLUS (2500 peak, rated for
continuous duty at 2200 watts) gen and 7 foot diameter rotor for under $500.00 - take 4 of those and
for under $2,000.00 you have a 10kw system which is much
less money that anything else we have seen on the market and
about 1/10th the price of the two 'name brand' systems listed
above. This is a comforting figure down the road when
something dies and you need to replace it. Think MONEY
DOES NOT GROW ON TREES and things come into perspective.
It is true we haven't been making wind generators for 20
years; perhaps after 5 or 10 years we will double or triple
our prices, but since we are an edu firm that delivers free
PCs and wind gens to schools and kids in remote locations
that have no power, that sort of increase in our pricing isn't
likely. Again, our motto:
Our website has classes included with the purchase that
show mounts starting at $25.00 you can build with no welding,
in less than 10 minutes, with zero tools (a pipe wrench helps but
isn't required) and is as strong as anything you can buy for
$500.00 or whatever else is included in those $21,000.00 price
tags.
if that isn't cheap enough, you can't afford the wire for the
system anyway. Larger systems will require a somewhat larger
mount, but again, this is easily done for $100.00 for even
the most grand system you could imagine for your home, so....
That mount and gen and blade have to sit on something that can
rotate. The anticipated problems of cable twist are actually
no problems at all, in fact, things like contacts on rotating
rings etc. bring a lot of problems (such as cost and corrosion)
into the equation and most, if not all designers prefer direct
cable to the gen. There are methods for insuring the cable doesn't
twist on this page. Read them after we finish this little lesson.
You can easily build 20 foot towers with simple water pipe
and guy wires; it is done all the time in this industry and 20
feet is plenty high for power.
If you want to go higher, there are 50 and even 100 foot towers
starting at $200.00 and going up to several thousand dollars. Again,
we suggest a smaller, budgeted approach to the first tower you
build and then, if you decide you have some extra cash to burn,
go for some monster your neighbors can all see. Think about it,
find out what works for you and your region and save some money
by purchasing AFTER you get an education.
Some folks spend a fortune on expensive 'exterior/coated' thick wire
and most folks find that welding cable is much less expensive,
lasts forever, can take a huge amount of current without losses
and is easy to find anywhere. We don't deal with cable or towers
as it never made sense to us to ship heavy, common items around
the country/world. Use welding cable and you'll be fine. Get
the largest "ought" cable you can afford. Thumb size is a good
size for gens running over 1kw or that have long runs. Pinkie
size (man) is the minimum for gens that are under 1kw or
that have short runs. If you are going less than 30 feet and
have a very small gen (you aren't lighting up a home), you
can go even smaller, but we don't recommend it. Remember
you are making electrons and they get hot, they can weld, they
can start fires and will do it quickly if the cable is too
small: spend your money here.
All over this website are the reasons you should plan on
having them in the system and which types to use; golf carts
(6 volts) or forklift batteries (2 volts), wired in series to
make 12 volts DC.
They also help even out the gusts/lulls and surges on the
entire circuit. Expect to have at least 10 golf carts, probably
more (at about $100.00-$150.00 a pair or $500.00 for a set) and
even better would be to have 12 or 16 or, after connecting them,
8 12 volt cells that can be split into different banks as
needed for maintenance, swapping out old batteries etc.
Also, there are simple desulfating units you can get for as
low as $69.00 and these will triple the life of the batteries.
You need to take that DC power and make a nice clean 60 hertz
(50 in Europe) 110 or 220 volt AC line. Since you saved a fortune
on the rest of the system, we recommend you consider a Trace Grid
Tie - very expensive. So let's get this AFTER you hook up
your first system and that way you will have a nice large invertor
to spare for the day WHEN (not IF, it is WHEN) that Trace
invertor dies and you need to run heavy appliances like microwaves
and skillsaws.
So, a 3000 watt 110 VAC invertor or better still, a 5000 watt
220 VAC invertor is recommended if you are trying to run a home.
These are on our website and available all over the world.
Also, consider smaller invertors for 90% of your power usage. This
way you don't put all that load on the single most expensive
piece of gear in the system. It is much better to fry a $50 or
$100 piece of gear than lose a $500 or $1000 piece of gear.
The only time you really need to use the big boy is for heavy
appliances. We recommend using smaller ones whereever you
have commonly used, repetitive duty appliances, like a freezer
in the garage or a computer in a bedroom. Save the big boy for
big appliances like electric dryers and welders and table
saws, microwaves and heaters. This keeps the overall costs
down dramatically over a 10-20 year period.
Fine. You can do it after you have built a system capable of
handling all of your needs. Don't get pie in the sky at the
start of your education. WHEN you have disconnected from
the grid for at least a year or two, THEN you have had plenty
of time to save all those big bucks not paying electric
bills and can hire a certified, licensed, alternative energy
electrician/engineer to do the job right. While it isn't
that hard to learn how to do a grid tie, most states and
utility companies require a licensed pro to do the job.
Forget it for now: focus on you and your family now and
after you get everything covered and don't have an
electric bill, then you can easily afford the pro
required to do the grid tie, plus the Trace (or other
brand) gear to do the job. Compared to all the other
costs mentioned herein, this is the largest and the one
you really have no control over unless you are a licensed
installer: you will have plenty of time to learn that if
you so desire.
We suggest you get every other aspect in place, working
and do it inexpensively while you learn before spending
the money to do a grid tie. WHEN you have eliminated your
need for eleectricty, THEN you can afford the PRO. There
is no point doing it before that time; think about it.
Perhaps instead of buying a grid tie, you may want to
get a rack of solar PV panels going. These are very very
expensive compared to wind generators, but the fact is,
a really reliable system will have a good rack of at least
1 or 2kw (80 - 160 amps at 12 volts) and at an approximate
rule of thumb cost of $100.00 per amp, that is
$8,000.00 in solar PV panels minimum if you want to have
alternative energy on windless days. A few seasons of
not paying electric bills can pay for those PV panels
and then you are truely self-sufficient come rain or shine,
wind or no wind, you are 100% off the grid.
THEN and only then should you worry about grid tie systems,
selling power back to electric companies and all the
new gizmos, forms, permits and expenses that expansion will
require...lots and lots of expenses just in the paperwork
alone. Some firms list all the local laws for what is
required, but the bottom line is, the entire process of
worrying about the grid tie is 100 times more expensive
and complicated than the entire front end of just setting
up a wind generator and battery/invertor system, so again,
we suggest you start small, get your home 100% off the grid with
the savings and then worry about selling power back to
the utility company (or a neighbor).
Most likely you will have a seperate panel for the AC that comes
from the invertor and usually this will be near your main
panel that your utility company ties into your home. You
will either need to be able to disconnect the utility company
from the main panel and tie the generator panel to the
home (any licensed electrician or Union Electrician Foreman
can do that job for $30-$50/hr in less than 8 hours),
or you will need to install wiring from the invertor/gen panel
to the places of your home where you want this power to
be tapped. Going through the attic or basement and laying
in new outlets is a good way to go as it completely
isolates you from the utility company grid and yet delivers
power to each room and anyone (most people) can lay wire and
install outlets; almost any $10-$20 experienced handyman can
do this job, although again, we recommend hiring a licensed
electrical contractor who can do it blindfolded, and as
they say in the electrical trade: "Get it right the first time."
I am a Union Electrician and was a landlord for 15 years; it
isn't that hard to do this aspect of the job no matter whic
way you choose.
Thank you.
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