Chispito Wind Generator Installation
 
Welcome to the exciting world of energy production.  You have taken a step towards self-sustainability. We hope that you completely enjoy the Chispito Wind Generator and that it provides your power system with a dependable and renewable source of energy.

The Chispito Wind Generator is a 100 Watt machine. It outputs 14 volts at 275 rpm, so it will start putting power into your batteries in low wind speeds.

Chispito is a perfect addition to an existing solar, or other alternative energy, home system. On its own, it will power lights, radio, and conservative usage of appliances such as computer, satellite, blender, drill, and much more!

 
Included In This Package

In addition to this kit, you will need: spade connectors, a tower, #10 (or thicker) stranded wire, a shunt type charge controller (using a MPPT charge controller will not only prevent your batteries from overcharging, it will also convert extra volts into amps, increasing the rated output of your power source), batteries, and an inverter if ac appliances are to be used.

ASSEMBLY
1) Line up the holes of each blade with the holes on the hub.
2) Using the ¼” bolts and washers, bolt the blades onto the hub. For the inner three holes, use two washers per bolt, one on each side of the blade. For the outer three holes, just use one washer next to the head of the bolt. Tighten. Do not attach the blade assembly to the motor yet.
3) Have your tower ready, with a positive and negative #10 (or thicker) stranded wire coming out the top of the 1 ½” tower pipe, which should be lowered to a manageable height (at least 2 ½’ off the ground). 
4) Strip the ends of the wires and crimp a spade connector onto each wire.
5) Make sure the two wires coming out of the bottom of the tower pole are wrapped together, to form a closed circuit. This is a safety precaution; it puts a load on the wind generator to prevent it from spinning around fast while you’re working on it.
6) Grease the outside of the top of the tower pole, where the wind generator will go.
7) Hold the main wind generator unit close to the tower pole, so that the mounting pipe is lined up with the tower pipe.
8) Thread the two wires from the tower through the mounting pipe of the generator, and slip the mounting pipe over the tower pipe.
9) Connect the wires to the one-way diode, as shown below.

10) With needle nose pliers or channel locks, hold the back of the motor’s shaft (located under the PVC motor sleeve, near the diode) securely.
11) Place the hub assembly onto the front part of the motor’s shaft, and turn counterclockwise until it tightens and stops. Release the needle nose pliers or channel locks.
12) Raise the pole of the tower to an upright, level position, and then secure that position using guy wires and turnbuckles (please consult the tower section of this manual for a full description of building and raising a hinged tower).
13) Unwrap the two wires at the bottom of the pole and wire them into the stop switch, as shown below. 

14) Wire up the rest of your power system, including stop switch, fuse, charge controller, batteries and inverter. The Chispito Wind Generator is best suited for 12 or 24 volt systems.
15) Turn the stop switch to the on position.

SAFETY CONSIDERATIONS
Electricity, especially when spinning blades are also involved, can be extremely dangerous.

The user of this information and product assumes full responsibility for his/her safety.

Here are some of the things you need to consider:
· Always ground and fuse your electrical system, as well as each component within it. 
· Always stand upwind when viewing the wind generator to avoid debris in case of failure.
· Always attach safety ropes and/or cables when erecting your tower and/or wind generator.
· Always wire connections securely with proper insulation such as heat shrink tubing and/or electrical tape.
· Never touch the positive and negative wires at the same time while they are connected to the battery.
· Never leave your wind generator unconnected to anything, unless it is on the ground. It must be connected to a battery or other load. Or you can short it out by crossing the positive and negative wires FROM THE WIND GENERATOR together, to provide a closed circuit. If you do not do one of these, it can spin freely and attain dangerous speeds.
· Never expose batteries to heat, sparks or flames. Do not smoke near batteries.  They can ignite and explode easily.

Additional Safety Considerations
 http://www.velacreations.com/safety.html

TOWER
The tower is one of the most important components in your wind generator system. It must be strong, stable, level, easily raised and lowered, and well anchored. This is the system we use, and can recommend.

The higher the tower, the more wind your generator will be exposed to. This design is based on a 20’ tower (the minimum we recommend). For each additional 20’ length of tower, you will need an extra set of guy wires and the stakes will need to be further from the base.

You will need:
1x 20’section of 1½” Steel Pipe, threaded at one end
1x 1½” U-bolt, to attach guy wires (instead of u-bolt, we weld on a heavy chain)
1x 6”x1¼” threaded Steel Nipple
2x 1¼” Steel Elbows
2x 2’ x 1¼” Steel Nipples
1x 1½” Steel T
4x Guy stakes (we use rebar bent into a W shape)
4x Turnbuckles
4x 25’ lengths of 1/8” (minimum) Steel Cable
8x 1/8” (minimum) Cable Clamps
Approx. 10’ of Steel Wire
2x 30’ Safety Ropes (needed only to attach guys to turnbuckles; they can then be removed)
At least two people

The Base
1) Dig a hole, 1’ around and 2’ deep.
2) Feed the 6’x1¼” nipple through the horizontal part of the 1½” T.
3) Screw the two 1¼” elbows into each end of the 6”x1¼” nipple, making sure the elbows point in the same direction.
4) Screw the two 2’x1¼” nipples into the free ends of the elbows.
5) Set this base into your hole, so that the T just clears the ground.
6) When the T is perfectly level and the 2’ nipples point straight down, fill the hole with concrete.

The Stakes
1) Mark out where you want your stakes:
- They must be evenly spaced from the center (the base) and from each other.
- They must follow the direction of the T, so that the line between one set of opposite stakes cuts through the horizontal part of the T, and the line between the other set of opposite stakes cuts through the vertical part of the T.
- They must be at least 50% of the tower’s height away from the base.
2) Dig a hole, 2’ deep, at each spot marked, and concrete in the stakes.
3) Attach a turnbuckle to each stake, using several wraps of steel wire.

Wait at least a full day for the concrete to set up.

The Pole
1) Drill a large hole, about 1’ from the bottom of the 1½” tower pipe, for the wires from the generator to exit the pipe.
2) Screw the pipe into the vertical part of the base’s T.
3) Make four strong, flexible rings out of steel wire, about 5” in diameter. For each ring, loop the wire around several turns and twist it closed.
4) Place the 1½” U-bolt around the pipe, 3’ from the top.
5) Thread the four wire loops around the U-bolt, lining each one up with one of the stakes.
6) Tighten the bolts of the U-bolt.
7) Thread one end of a 25’ length of steel cable through each loop, and secure each one using a cable clamp.
8) Thread a safety rope through each of the two loops that face the two directions the pole can fall.

Raising the Tower
It is a good idea to raise and secure the tower for the first time without a wind generator on it, as it will be lighter.
1) Raise the pole in the air and tie the safety ropes to something solid (a truck or building, for example).
2) Get the pole fairly level and attach the guy wires to the turnbuckles. Secure using the other four cable clamps. 
3) Turn the turnbuckles to tighten the guys and level the pole exactly.
4) Mark the turnbuckle you will be releasing. Then release it and lower the pole.
5) Remove the safety ropes.
6) Mount the wind generator and raise the tower.
7) Screw in the turnbuckle up to the mark you made.

Complete Chispito Construction Manual
 http://www.velacreations.com/chispito.html

Tower Construction
 http://www.velacreations.com/tower.html

Products and Accessories
 http://www.velacreations.com/store.html

Discussion Forum
 http://www.velacreations.com/forum