ARE110 Wind Generator (2.

5 kW)
Grid-Connect Model

Owners Manual
Installation, Operation, & Maintenance

Manufactured in the USA by:

ABUNDANT RENEWABLE ENERGY
22700 NE Mountain Top Road
Newberg, OR 97132
www.AbundantRE.com
(503) 538-8298 (Telephone)
(503) 538-8782 (Fax)
Table of Contents
1. Safety Warning 3
2. Introduction 4
3. Wind Generator Specifications 5
4. Equipment Supplied 6
5. Required Installation Tools 7
6. Choosing Sites for Wind Generators 7
7. Electronics Installation
A. Resistor Load 8
B. Inverter 9
C. Voltage ClampTM 9
D. Electrical Schematic 10
8. Towers & Rigging 11
9. Wire Size Recommendations 11
10. Turbine Assembly Instructions 11
A. Position the Tower 11
B. Check the Yaw Head Axle 12
C. Electrical Connection: Yaw Head to Tower 12
D. Mount Yaw Head to Tower 13
E. Mount Alternator to Yaw Head 13
F. Wire the Yaw Head Terminal Strip 14
G. Test the Electrical Connections 16
H. Install Tail Boom to Yaw Head 16
I. Install Blades & Nose Cone 19
11. Generator Start-up, Shut-down, & Reset 20
A. Prior to Generator Start-up… 21
B. Generator Start-up Procedure 21
C. Voltage Clamp™ Operation in Decreasing Wind… 21
D. Generator Shut-down & Reset Procedures 21
12. Voltage ClampTM Operation & Faults 22
13. Inspection & Maintenance 23
14. Troubleshooting 23
15. Component List & Drawing 24
16. Warranty 25

Page 2 of 26
1. SAFETY WARNING!
• Electrical shock hazard: The wind generator can produce
high voltages – sometimes more than 400 volts. These
voltage levels can cause serious injury or death. No wires
or electrical connections should be touched or handled
without ensuring that the wind generator has been braked
to a complete stop and the AC power to the inverter and
Voltage Clamp™ (grid-tie controller) is off. After these
steps are taken, approximately five (5) minutes is required
for system voltage to decay to safe levels.

• The ARE110 is a powerful machine and can cause injury

if not assembled and erected properly (according to the
instructions and using appropriate equipment).

• Do not approach the machine while the blades are spinning

– they can cause serious injury!

Please Note:
ABUNDANT RENEWABLE ENERGY has made every effort to
ensure that the information presented in this manual is
accurate but assumes no responsibility for any errors or
omissions. Users of this information and ARE products
assume full responsibility and risk.

Page 3 of 26
2. Introduction
This manual contains all necessary information for assembling, operating, and
maintaining the ARE110 (2.5 kW) direct grid-connect wind generator. Please
read it carefully and retain it for future reference.
The ARE110 is ruggedly built. It operates at a relatively low rotational speeds
(low RPM), which – together with a small number of moving parts – ensures a very
long life with little maintenance. Its large swept area, high-efficiency blades and
alternator, and optimized power electronics ensure maximum energy capture from
low and high wind speeds. The simple, upwind side furling system (with gravity
return) protects the machine by reliably swinging the rotor out of winds higher than
11 m/sec (25 mph).

Figure 1. ARE110 wind generator

Page 4 of 26
3. Wind Generator Specifications
Configuration Three-blade upwind
Over-Speed Control, Mechanical Side furling with gravity return
Over-Speed Control, Electrical Pulse-width modulated resistor loading
Rated Power 2.5 kW (2500 watts)
Rotor Diameter 3.6 m (11.8 ft)
Swept Area of Blades 10.2 m2 (110 sq. ft.)
Cut-in Wind Speed 2.5 m/s (6 mph)
Start-up Wind Speed 3 m/s (7 mph)
Rated Wind Speed 12 m/s (25 mph)
Blade Quantity, Construction Three (3), molded fiberglass
Blade Rotational Speed 0–340 rpm
Alternator Type/Construction Neodymium permanent magnet
Alternator Electrical Output 3-phase, variable voltage (0 - 410 VAC)
Tower-Top Weight 143 kg (315 lbs.)
Maximum Lateral Thrust 160 Kg (350 lbs.)
Table 1. ARE110 specifications

ARE110 Wind Generator

Power Curve
3000

2000
Power (watts)

ARE110 gen
power curve based
on measured data;
power data above
25 mph based on a
small number of
1000 data points

0
0 5 10 15 20 25 30 35 40
Wind Speed (mph)

Figure 2. ARE110 power curve

Page 5 of 26
 A R E 1 1 0 W in d G e n e r a to r s
M o n th ly E n e r g y E s tim a te s
800

600
Energy Production (kWh)

400

200

0
8 10 12 14
A v e r a g e L o c a l W in d S p e e d (m p h )

Figure 3. ARE110 monthly energy estimates graph

4. Equipment Supplied
Qty. Item Description
1 Alternator (high-voltage)
3 Bolts (alternator-mount) with star washer – M16-2.0 x 30mm
1 Yaw head with slip rings
4 Bolts (tower-mount) with self-locking nut - M16-2.0 x 70mm
3 Blades
6 Studs, hex (blade-mount) with self-locking nut - M12-1.75
1 Plate (blade-clamping)
1 Nose cone
3 Bolts (nose-cone mount) with washers & lock washers - M6-1.0 x 16mm
1 Tail boom, inner (gusset) with tail hinge pin, tail pin latch, & E-clip retainer
1 Tail boom, outer (sq. tube 1.5" x 92")
1 Bolt (tail boom) - M16-2.0 x 70mm
1 Tail fin (with ARE logo)
3 Bolts (tail fin mount) with (2) washers and self-locking nuts – M14-2.0 x 60mm
1 Tail weight (approx. 3 lbs.)
1 ARE Voltage ClampTM (grid-tie controller)
1 ARE resistor load
1 Inverter - 2500U SMA Windy Boy (2.5 kW)
Table 2. Equipment Supplied with grid-connect ARE110 wind generators

To Be Purchased from Other Suppliers:

• Appropriately sized wiring, as described in Section 9 (“Wire Size
Recommendations”) and in Section 7 (“Electrical Schematic”)
• Cable support grips for wires (see Section 10, Part C)
• Sub-panel or AC circuit breakers
Page 6 of 26
5. Required Installation Tools
Ratchet for sockets
8” extension for ratchet
Sockets: 10, 13, 17, 19, 22, & 24mm
Wrench, Allen – 4 mm
Wrench, adjustable – 8”
Screwdrivers – Phillips (#2) & flat-head (1/8” max width)
Wire Strippers
Torque wrench – range: 10–170 N-m (7–120 lb-ft)
Locking pliers (Vise-Grips)
Thread-locking compound (e.g. Loctite® 242® Threadlocker, Med-Strength/Removable)
Hole saw or stepped drill bit for ½” conduit (suggested size)

6. Choosing Sites for Wind Generators

To ensure satisfactory performance from the wind generator, care must be taken in
the choosing the site for the machine. Buildings, trees, and rocky outcrops can
disrupt the smooth flow of wind, creating “wind shear”. This results in significantly
lower wind velocities and higher turbulence near the ground. Turbulence is
detrimental to wind generators, as the swirling air causes the turbine to yaw
continually, which unduly stresses mechanical components, greatly increases wear
and tear, and reduces the useful life of equipment.

Smooth, laminar airflow

2H Turbulent airflow
H

2H 20 H
Sharp edges create turbulence Turbulent air flow created by obstructions
Figure 4. Turbulence illustrations (courtesy of P. Gipe)

As a general rule, therefore, wind turbines should be mounted at twice the height
of any “bluff body” obstructions. Alternatively, locate the turbine 10 meters (30
feet) plus the blade length above the tallest trees, buildings, or other (non-bluff
body) obstructions within 150 meters (500 feet). The power (P) obtainable from
the wind is proportional the cube of the wind speed (v3), and wind speed increases
with height (H) from the ground. [P α v3 and v α H]. According to this principle, a
26% increase in wind speed from a higher tower will yield a 100% increase in
power from the turbine. A little more money spent on a taller tower harvests the
same power as two (2) machines!

Preference should be given to the prevailing wind direction, but please note that
tall features downwind of the generator can also slow wind flow passing through
the turbine’s blades.
Page 7 of 26
7. Electronics Installation
It is important to install the ARE Voltage ClampTM (grid-tie controller), resistor
load, and Windy Boy inverter prior to installing the wind turbine. This will provide a
control system for the turbine and allow the brake to be used during turbine
installation.

Figure 5. ARE Voltage ClampTM, ARE resistor load, & SMA Windy Boy inverter

Installation Instructions
It is suggested that a piece of 3/4” plywood be mounted to the wall where your
wind turbine electronic equipment will be installed. This will provide a secure
substrate to which to mount equipment. It also provides for adequate flexibility in
mounting the equipment without needing to rely on stud spacing or special wall
anchors.

A. Resistor Load
The resistor load enclosure must be mounted so that the resistors are
horizontal and that the terminal block is in the lower right hand corner. Do not
locate this device near flammable substances or loose cloth. Ensure a
minimum of 12” clearance on all sides of the resistor load enclosure, as air
must be permitted to flow freely through the box.

B. Inverter
Follow the instructions included with the SMA Windy Boy inverter for
mounting procedures and requirements.
CAUTION: The SMA Windy Boy 2500U inverter is heavy (approximately 30
kg / 65 lbs.) and requires proper mounting. Please see SMA installation
instructions.

C. Voltage ClampTM
The ARE Voltage Clamp™ should be mounted on a vertical surface in a dry
location. It should be mounted in suitable location to provide easy access to
the red “STOP” button and so that the enclosure door may be opened fully.
Conduit holes must be sawed or drilled in the bottom of the Voltage Clamp™
(see Figure 6 below).

Page 8 of 26
Figure 6. Suggested drilling/sawing locations on bottom of Voltage Clamp™

See the Wiring Diagram for proper connection and wire sizes. Ensure all
wiring is in accordance with local codes and laws. Wire the Windy Boy to the
“– OUT” and “+ OUT” slots of the Voltage Clamp’s din-rail mounted terminal
block (pictured below in Figure 7)
POLARITY IS IMPORTANT! Wiring the Windy Boy inverter with reverse
polarity will damage the equipment and result in an expensive repair bill. See
your SMA Windy Boy manual for instructions on wiring and operating the
Windy Boy inverter.

Bi-metallic temperature
switch terminal locations
(+TS, -TS)

Figure 7. Control board mounted on Voltage ClampTM door

& main din rail terminal block mounted inside Voltage ClampTM

After all electrical equipment has been installed and all connections made,
press the “STOP” button to ensure that the brake is engaged. Also turn off
the circuit breakers to the inverter and to the Voltage ClampTM. This will
ensure that the equipment will not be energized while the wind turbine is
being installed.
Page 9 of 26
 D. Electrical Schematic

Page 10 of 26
Figure 8. ARE110 electrical schematic
NOTE: All wire sizes 12 – 10
AWG, 600V minimum unless
noted otherwise (see Table 3
for run from turbine to
Voltage Clamp)
8. Towers & Rigging
Great care should be taken in the selection and preparation of the wind turbine
tower, as this can be the most difficult and most crucial aspect of a wind energy
equipment installation. Guyed, tilt-up pipe tower kits manufactured by ARE are
specifically designed for the ARE110 and are recommended. ARE assumes no
responsible for assuring the suitability of towers provided by other suppliers. ARE
tilt-up towers can be easily lowered for servicing and do not require climbing.
Consult with ARE for assistance with alternative tower selection and qualification.

9. Wire Size Recommendations

The following table lists the recommended MINIMUM wire gauge, based on the
one-way wire run distance from the tower top to the building entrance (where it
connects to system electronics). These recommendations are intended to limit the
voltage loss to less than 5%. Ensure that the wire insulation is rated for outdoor
use and for at least 600 volts. NOTE: The Voltage Clamp’s main terminal block
does not accept wire sizes larger than 10 AWG. If a larger wire size is used, the
wire size must be “stepped down” prior to insertion into this terminal block.
150 feet 300 feet 500 feet 1000 feet 2500 feet
12 AWG 12 AWG 12 AWG 12 AWG 10 AWG
Table 3. Wire size recommendations

10. Turbine Assembly Instructions

If using an ARE tilt-up tower kit, the tower should first be assembled, raised, and
all rigging adjusted so that the tower stands vertically and can be raised and
lowered properly. See the tower installation manual for details.
Assemble the wind turbine onto the lowered tilt-up tower. Although one person
can assemble the machine with mechanical aids, it is advisable to have an
assistant, as many parts are heavy and cumbersome to maneuver into position.
Keep the alternator covered as long as possible to prevent dirt or metal objects
from entering the alternator and becoming lodged between the magnets and rotor.

Assembly Procedure:
A. Position the Tower
If using an ARE tilt-up tower kit, the top of the lowered tower should be
supported at approximately 1 meter (3 feet) above the ground.

Page 11 of 26
B. Check the Yaw Head Axle
Ensure that the yaw head axle rotates freely within the outer housing (see
Figure 9 below).

Yaw head axle

NOTE: DO NOT
TIGHTEN THIS NUT.
It is intended to be
loose in order to allow
yaw head rotation.

Figure 9. Yaw head axle

C. Electrical Connection: Yaw Head to Tower

Splice the three power wires and the ground wire with suitable splices.
Ensure they are insulated for 600 volts. Use wire support devices such as
cable support grips (see Figure 10 below) to bear the wire weight and remove
tension from wire splices. On ARE tilt-up towers, the bolt which holds the
tower top flange may be used to carry wire support devices (see Figure 11).

Four (4) wire connections are made at the yaw head – three (3) for the power
from the generator leads (black) and one (1) for the ground (green).

NOTE: Each wire should

be supported individually.

Figure 10. Cable support grip (a.k.a. “Kellem’s grip”)

Page 12 of 26
D. Mount Yaw Head to Tower
Attach the yaw head to the tower top flange using M16-2.0 x 70mm bolts,
washers, and self-locking nuts (provided). Fasteners should be tightened to
163 N-m (120 lb-ft) torque. Ensure that the wires are not pinched between
the top flange and the yaw head mounting flange (see Figure 11 below).
Install M14 bolts so
that bolt heads face
the generator (i.e. bolt
heads face upward on
the erect tower).

This bolt may be

used to bear the
weight of cable
support grips.

Ensure wires
are not pinched
during
assembly.

Figure 11. Mating the tower top to the yaw head flange

E. Mount Alternator to Yaw Head

Line up the alternator mount holes with the yaw mount. CAUTION: The
alternator weighs approximately 84 kg (185 lbs.) and is very awkward to
hold, so plan this step carefully. The tail gate of a pick up truck works well;
alternatively, a wheelbarrow or large storage drum could be used. The tower
may need to be raise or lowered slightly to facilitate aligning the yaw head
and alternator holes.
Line up the bolt holes and pass the alternator lead wires through the hole
provided, taking care not to pinch the lead wires between mating surfaces.
Apply thread-locking compound and tighten the three (3) M16-2.0 x 30mm
bolts (with star washers) to a 163 N-m (120 lb-ft) torque (see Figure 12
below).

Three (3) M16

bolts attach the
alternator to the
yaw head.

It may be
necessary to
remove the yaw
head access
door in order to
fasten all bolts.

Figure 12. Bolting the yaw head to the alternator

Page 13 of 26
F. Wire the Yaw Head Terminal Strip
Connect the alternator lead wires to the terminal strip mounted on the yaw
head access door. Match the label of each wire to labels on the terminal strip
(see Figure 13 below). Alternator power output leads are labeled ‘A’, ‘B’, and
‘C’; lead ‘Z’ is used with ARE’s optional Lightning Protection System and
must also be attached to the terminal strip. The ground stud is used for the
Lightning Protection System. Do not attach any of the generator wires to the
ground stud.

Attach alternator
lead wires to the
terminal block on
the yaw head
access door and
secure wire with
screw and
clamping plate.

Figure 13. Yaw head terminal block wire connections

Ground Stud –
Do NOT attach
generator wires here

Figure 14. Yaw head ground stud location

Page 14 of 26
Examine all the slip ring brushes to verify firm contact with the slip rings (see
Figure 15 below). Check to see that brushes can be pulled back from the
rings and return freely. If a brush sticks: Loosen the top nut in quarter-turn
increments until the brush springs back. CAUTION: Do not loosen the top
nut excessively, as this may result in improperly seated brushes.

Adjustment
Nut

Slip Ring

Slip Ring
Brush

Bottom slip
ring to be
used only
for ground
connection

Spacer

Figure 15. Close-up view of yaw head slip rings

Reattach and close the yaw head access door (if removed in prior step).
While closing the access door, make certain that wires are not pinched and
do not interfere with the slip ring mechanisms. Use the M6 bolt to hold the
door in place (as shown in Figure 16 below).

Use this bolt to hold the door

in the closed position.

Tighten bolt fully to ensure

that it does not back out.

Yaw head access door.

Figure 16. Access door lock

Page 15 of 26
G. Test the Electrical Connections
Manually rotate the turbine blades at a steady rate while another person (at
the tower base junction box) uses a voltmeter to verify consistent AC voltage
readings across the three wires lead wires. This verification will require three
voltage readings: A-B, B-C, A-C). During this step, the lead wires should not
be connected to electronic equipment (Voltage ClampTM / grid-tie controller).

If the measured voltages between lead wires are approximately equivalent,

the turbine’s lead wires can be connected to the lines that run to the Voltage
ClampTM and subsequent electronic equipment.
If the measured voltages are not approximately equivalent, check all
connections in the yaw head and tower to ensure there are no short-circuits
or open connections. Verify that the slip ring brushes are making positive,
firm contact with their respective slip rings.

H. Install Tail onto Yaw Head

Pin latch plate

on inner tail
boom section

Figure 17. Tail pin latch plate

Page 16 of 26
Remove the pin latch plate from the inner tail boom section (see Figure 17
above). Align the two (2) hinge eyes of the inner tail boom section with the
two (2) bronze bushings (inserted in holders on the rear of the yaw head).
Install the tail pivot pin to join the tail to the yaw head (see Figure 18 below).

Notch

Tail Pin

Groove

Figure 18. Tail pin installation onto yaw head

Align the notch in the hinge pin with the pin latch plate and secure in place.
Apply thread-locking compound and tighten the two M6-1.0 x 16mm bolts
to 10 N-m (7 lb-ft) torque. Install the E-clip retainer into the groove at the
bottom of the hinge pin. Vise grips are a useful tool for the E-clip retainer
installation (see Figure 19 below).

Latch
plate:
Install in
notch

E-clip: Install
in groove.

Figure 19. Close-up views of tail pin latch plate & E-clip retainer installation

Page 17 of 26
Note Figure 20 below for the correct holes to use when mounting the tail fin to
the tail boom. Mount the tail fin to the outer tail boom section (square tube)
with the two (2) inner bolt holes. Use M14-2.0 x 60mm bolts with washers
and self-locking nuts.

Install these
two bolts first
The bolt in this
hole acts as a
“stop” for the
tail weight
[Bolt & tail fin
omitted for
clarity]

Use these holes

to mount tail fin to Install tail
tail boom [All round weight into
holes – no slots] tail boom

Figure 20. Mounting the tail fin Figure 21. Inserting the tail weight

Install the tail weight in the end of the outer tail boom, as shown in Figure 21
(above). Install the last (outermost) bolt to secure the tail fin. The tail weight
will be captured between the two (2) outer bolts (see Figure 21 above).
Tighten the M14 fasteners to 60 N-m (45 lb-ft) torque.
Install the outer tail boom into the inner tail boom, and secure with an M16-2.0
x 60mm bolt and self-locking nut (see Figure 22 below). Tighten the M16
fastener to 80 N-m (60 lb-ft) torque.

Inner tail
boom

M16-2.0 x
60mm bolt with
self-locking nut

Outer tail
boom

Figure 22. Assembling the outer & inner tail booms

Page 18 of 26
I. Install Blades & Nose Cone
Apply thread-locking compound and screw the six (6) blade stud bolts into
the threaded holes on the front of the alternator drum. IMPORTANT: The
shorter threaded section of the stud must screw into the alternator drum (see
Figure 23 below). Tighten the blade studs to 80 N-m (60 lb-ft) torque.

Blade stud for

mounting blades

Figure 23. Mounting blades to alternator

Install the three blades onto the blade studs. The studs are equally spaced,
so you may start with any two studs. Orient the blades so that the blue
leading edges will rotate clockwise (CW – see Figure 24 below).

Leading edge of blade

Trailing edge of blade

Figure 24. Blade edges & rotation direction

After placing the three (3) blades, install the blade clamping plate over the six
(6) blade studs with the nose cone mounting brackets between the blades
and pointing toward the alternator (see Figure 25 below). Secure the plate
with M12-1.75 self-locking nuts, tightened to 20 N-m (15 lb-ft) of torque.

Page 19 of 26
 Nose cone mounting
brackets: locate between
blades and orient pointing
toward the alternator.

Figure 25. Close-up view of nose cone mounting bracket

Install the nose cone and secure with three (3) M6-1.0 x 16mm bolts, washers
and lock washers (see Figure 26 below).

M6-1.0 x 16mm
bolts, washers,
and lock washers

Figure 26. Nose cone installation

Rotate the blades slightly about the alternator’s axis to verify that the rotor
can turn freely. Double check all fasteners and electrical connections are
secure.
Ensure that the turbine will not encounter any physical interference prior to
beginning the tower-raising.
IMPORTANT: Ensure that the STOP button on the Voltage ClampTM (grid-tie
controller) is pressed. This will engage the brake and keep the turbine from rotating
during the tower raising. Raise the tower and secure base and/or guy cables.
Ensure that the tower is vertical so that the turbine can properly yaw (turn to face into
the wind).

11. Generator Start-up, Shut-down, & Reset

CAUTION: ALLOWING THE WIND GENERATOR TO ROTATE UNLOADED
CAN RESULT IN VERY HIGH VOLTAGES WHICH CAN CAUSE INJURY OR
DEATH AND CAN DESTROY EQUIPMENT.
Page 20 of 26
A. Prior to Generator Start-up (Verify the Following):
• All electronic equipment installed per Section 7 of this manual.
• All electronic equipment wires double-checked for proper location.
• Circuit breakers to electronic equipment placed in the OFF position.
• STOP button on the Voltage Clamp™ is in the depressed position.
• Wind turbine installed per Section10 of this manual.
• Wind turbine and tower erected and properly secured per tower instructions.

B. Generator Start-up Procedure:

1. Turn ON the circuit breaker for the SMA Windy Boy inverter. Rotate the STOP
button clockwise (CW) 1/6th of a turn and release. NOTE: The Windy Boy will
not immediately show signs of turning on, as its display only energizes once the
turbine starts to run.
2. Turn on the circuit breaker for the Voltage ClampTM. This will start a 5 minute
wait period. The RED and GREEN lights will flash. NOTE: If STOP button is
still depressed, the RED light illuminate steadily.
3. After the 5 minute wait the flashing RED light will turn off. The GREEN light will
continue flashing slowly. Once sufficient wind is available, the turbine blades will
start to spin, activating the Voltage Clamp’s “START UP MODE”.
4. When the generator’s rectified voltage reaches approximately 180 VDC, the
Voltage ClampTM will perform a test to verify proper installation and functioning of
the resistors (load and brake). Upon successful test results, the GREEN light’s
flash rate will accelerate -- flashing ON and OFF in approximately ½-second
intervals. This is the Voltage Clamp’s “WAITING MODE”.
5. The Voltage ClampTM will attempt to maintain a generator output range of 300-
325 VDC while the Windy Boy inverter comes online and synchronizes waveforms
with the utility grid (approximately five minutes). The Voltage ClampTM will
perform a test approximately once per minute to verify that the inverter is
connected to the grid.
6. After the Windy Boy inverter is connected to the utility grid, the turbine will enter
the “RUN MODE” and the GREEN light will be illuminated steadily (not flashing).
7. The system will operate automatically, and monitoring is not required.

C. Voltage ClampTM Operation in Decreasing Wind Speeds

• If the generator’s rectified voltage drops below 240 VDC, the Voltage ClampTM
returns to the WAITING MODE.
• If the generator’s rectified voltage drops below 90 VDC, the Voltage ClampTM
returns to the START UP MODE.
NOTE: If the wind speed and conditions are such that the system voltage remains
between 250 VDC and 280 VDC, the GREEN light may flash while the Windy Boy
continues sending power to the utility power grid. Also in light winds the GREEN
light may go between flashing and steady as the DC voltage of the system rises and
falls with wind gusts. Both of these conditions are normal in light winds.

D. Generator Shut-down & Reset Procedures

To shut down the wind energy system, press the red mushroom emergency STOP
pushbutton. To reset the system, depress the STOP button, then rotate the STOP
button clockwise (CW) 1/6th turn and release.

Page 21 of 26
12. Voltage ClampTM Operation & Faults
Lights
Mode Green Yellow Red Mode / Fault Description Solution / Comments
START UP MODE: The system is
Slow Slow flash: ON for 2 seconds,
Flash
initializing and going through system
OFF for 2 seconds
checks.
WAITING MODE: The generator’s
rectified voltage has reached
Normal Operation

approximately 180 VDC, and the

Fast Fast flash: ON for 1/2 second,
Flash
Voltage Clamp™ is performing a test
OFF for 1/2 second
to verify proper installation and
functioning of the resistors (load &
brake).
RUN MODE: The system is producing
Steady energy, which is being used by
On
N/A
domestic loads or being sent to the
utility grid.
RESISTOR LOADING: The system
The light intensity increases
Steady voltage is approaching the upper
Variable approximately in proportion to
On Intensity limits of the WB inverter's acceptable
the quantity of energy being
range. The load resistors are being
diverted to the load resistors.
used to slow the turbine rotor.
OVER-VOLTAGE FAULT (560 VDC):
Steady After a 5 minute delay, the
Flash The rectified system voltage exceeds
On system will automatically reset.
560 VDC, and the brake is applied.
After a 5 minute delay, the
system will automatically reset.
OVER-VOLTAGE FAULT (570 VDC):
Slow This is a separate, redundant
The rectified system voltage exceeds
Flash over-voltage protection fault
570 VDC, the brake is applied.
from the "Over-voltage fault
(560 VDC)".
Auto-Reset

OVER-TEMPERATURE FAULT: One

Faults

of the two bi-metallic temperature

The system will not reset until
switches has tripped and the turbine's
Slow the temperature decreases
Flash
brake has been applied. Temper-
below 60°C and the bi-metallic
ature switches are set at 60°C
switch closes again.
(140°F) and located inside the resistor
enclosure and the Voltage Clamp™.
LOSS OF GRID POWER: If at any
When grid power is restored
time the grid power to the system is
the system will start up
lost, the Windy Boy inverter will
automatically and follow the
disconnect from the grid and the
START UP MODE procedure
Voltage Clamp™ will activate the
detailed above.
brake. All system lights will go out.
Check all electrical connec-
Manual Reset

LOAD/BRAKE RESISTOR TEST

tions and ensure that brake
Required

FAILED: The once-per-minute test

Fault

Steady and load connections are

performed by the Voltage Clamp™ to
On correct in Voltage Clamp™
verify proper connection and function
enclosure. Manually reset the
of load & brake resistors has failed.
system.*

Table 4. Voltage Clamp™ Operation & Faults

* TO MANUALLY RESET THE SYSTEM:

Depress the STOP button, then rotate the STOP button clockwise (CW) 1/6th turn
and release.
Page 22 of 26
13. Inspection & Maintenance
Frequency Category Task Comments
Listen for unusual
If detected, such warning signs
alternator or blade noise,
Continually Turbine should prompt a detailed
and look for excessive
inspection.
vibration.
Verify that tower guy These tasks apply only to ARE
Tower cables, saddle clamps, guyed tilt-up towers. For other
Every 6
and shackles are tight. towers, please reference
months
Check all cables for manufacturer's documentation for
Tower
excess fraying or rust maintenance schedules
This should be done by close visual
Inspect the blades for inspection: by lowering the tower
Turbine
leading edge wear. (if tilt-up) or by climbing it (if free-
standing).
Every 12 Check the upper guy
Tower These tasks apply only to ARE
months joints for wear and/or rust
guyed tilt-up towers. For other
Verify (with torque towers, please reference
wrench) that all cable manufacturer's documentation for
Tower
clamps continue to firmly maintenance schedules
grip guy cables
Table 5. Inspection & Maintenance Schedule

14. Troubleshooting
Symptoms Possible Causes Solutions
Shorted wires or alternator
Turbine fails to turn (or Remove short
windings
turns very slowly) in
Shorted diodes Replace faulty diode(s)
significantly windy
conditions Failed bearings Replace bearings
Foreign body in generator Remove obstruction
Low output Insufficient wind Improve tower location/height
Turbine vibrates
Blades out of balance Check blades for water intrusion
excessively
Turbine fails to swing Tower top not vertical Adjust guy cables
into the wind Yaw bearing worn Replace yaw bearing
Turbine running at high Cables disconnected Fix cables
speed no output Slip Rings Failed Replace Slip Rings
Voltage Clamp RED TM
See “Voltage Clamp Operation & Faults” section above.
light illuminates (solid)
Table 6. Troubleshooting Guide

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 15. Component List & Drawing

NOTE: Exploded drawing and component list to be added in an addendum.

Item Description Qty Item Description Qty Item Description Qty

Table 7. Component list

Page 24 of 26
 Five-Year Limited Warranty for
ABUNDANT RENEWABLE ENERGY
Wind Generators

WARRANTY AGREEMENT
In order to validate this Warranty Agreement, the Customer must detach, complete, and return the
ARE Mail-in Warranty Form (page 2 of this Agreement) within one (1) month of installation or seven
(7) months of receipt of warranted ARE products, whichever occurs first.
Abundant Renewable Energy (ARE) warrants that the wind turbines it manufactures will be in good
working order, in accordance with ARE standard specifications, upon delivery to its customers and for
a period of 66 months from the date of delivery or 60 months from the date of installation, whichever
occurs first. During the warranty period ARE will, at its sole discretion, repair, replace, or refund the
purchase price of defective components and assemblies. Repair parts or replacement product may be
new, remanufactured, or refurbished, at the sole discretion of ARE. ARE is not responsible for any
costs associated with the installation, removal, reinstallation, or transportation to ARE (or to an ARE
dealer) of defective ARE products. Return freight to the customer will be provided by ARE. Product or
components returned to ARE, which are not defective or which sustained damage not covered under
this warranty, will be tested and/or repaired at ARE’s standard labor rates. Only warranty claims
submitted to ARE in writing within 15 days of problem origin will be honored.

GOVERNING LAW AND DISPUTE RESOLUTION

This Agreement will be interpreted and enforced according to Oregon state laws or U.S. federal laws,
whichever has jurisdiction. Oregon law, without reference to conflicts of laws principles, shall control
the interpretation and enforcement of this Agreement.

In the event that any dispute, controversy, or claim between the Parties arising out of or relating to this
Agreement cannot be settled by negotiation or mediation, the parties agree to have the dispute or
claim submitted for private arbitration. Any arbitration is to be conducted in Multnomah or Yamhill
County, Oregon. Judgment upon the award may be entered into the Circuit Court of Multnomah
County.

EXCLUSIONS
This warranty does not cover the following:
• Towers, equipment, materials, or supplies not manufactured or supplied by ARE (Towers
manufactured or sold by ARE are covered by their own separate warranty.)
• ARE equipment which has been improperly installed or modified without approval from ARE
• Damage or loss from winds in excess of 45 m/s (100 mph)
• Lightning damage or other “acts of God”. (The ARE lightning protection package provides its
own individual warranty related to lightning damage to wind generators and related controls)
• Incidental or consequential damages
• Damage to product incurred during shipping

PRODUCT CHANGES
ARE reserves the right to make design changes, improvements, or additions to its products without
obligation to install such changes or improvements in existing products.

Page 25 of 26
 ARE Wind Generators
Warranty Agreement Form

Customer / End User Name _________________________________________

Customer Address ________________________________________________

______________________________________________________________

______________________________________________________________

Customer Phone ______________________ Email _____________________

ARE Dealer / Installer Name & State (if applicable) ________________________

______________________________________________________________

Product Part Number (e.g. ARE110) ____________________________________

Alternator Serial # _________________________________________________

Mainframe / Yaw Head Serial # _______________________________________

Controller / Voltage ClampTM Serial # _________________________________

Inverter Serial # (grid-tie systems only) ____________________________________

Resistor Load Serial # ______________________________________________

Date Product Received _______________ Installation Date ______________

Dealer Signature (if applicable) ________________________________________

End User Signature ________________________________________________

Send Completed Form to:

ABUNDANT RENEWABLE ENERGY
22700 NE Mountain Top Road
Newberg, OR 97132
Phone: (503) 538-8298
Fax: (503) 538-8782
Email: Info@AbundantRE.com
Website: www.AbundantRE.com

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