Standard Controller Manual Document #: 0401M01 REV : 1.1 Approval: Date: March ‘08 Page 1 of 19 Registration Number 2006/005438/07 VAT Registration Number 4870231406 Tel: +27 (0)41 401 2500 Website: www.kestrelwind.co.za Kestrel Standard Controller Type 0401 User Manual Revision 1.1 (03-08) Revision 1.0 (12-07) For the following models of Type 0401 Standard Dump Controller Type 0401–0600-012 (e150-001-012) 600W 50A Type 0401-0600-024 (e150-001-024) 600W 35A Type 0401-0600-048 (e150-002-048) 600W 20A Type 0401-0800-012 (e220-001-012) 800W 50A Type 0401-0800-024 (e220-001-024) 800W 35A Type 0401-0800-048 (e220-001-048) 800W 20A

Standard Controller Manual Document #: 0401M01 REV : 1.1 Approval: Date: March ‘08 Page 2 of 19 CONTENTS PAGE 1 Safety Considerations 1.1 Mechanical Safety 3 1.2 Electrical Safety 3 1.3 Installation Hazards 3 1.4 Operational Safety 3 2 Standard Controller Overview 2.1 Standard Controller Description 4 2.2 Identification and Markings 5 2.3 Applications and uses 5 3 Standard Controller Assembly 3.1 Components Supplied 6 3.2 Components not Supplied 6 3.3 Tools Required 6 3.4 Unpacking 6 4 Installation Instructions 4.1 Typical Installation Example 7 4.2 Mounting the Standard Controller 8 4.3 Electrical...

Standard Controller Manual Document #: 0401M01 REV : 1.1 Approval: Date: March ‘08 Page 3 of 19 1 Saffetty Consiiderrattiions 1..1 Mechaniicall Saffetty 1..2 Ellecttrriicall Saffetty 1..3 IInsttallllattiion Hazarrds 1..4 Operrattiionall Saffetty Note: The Standard Controller Type 0401 must be installed with a separate divert resistor. DO NOT OPERATE THIS CONTROLLER WITHOUT A BATTERY CONNECTED Disclaimer Kestrel Wind Turbines makes every effort to give accurate information in this manual and is in no way liable for any error or omission. The user of this manual assumes full responsibility and...

Standard Controller Manual Document #: 0401M01 REV : 1.1 Approval: Date: March ‘08 Page 4 of 19 2 Sttandarrd Conttrrollllerr Overrviiew 2..1 Sttandarrd Conttrrollllerr Descrriipttiion 2..2 IIdenttiiffiicattiion and Marrkiings 2..3 Applliicattiion and Uses 2 STANDARD CONTROLLER OVERVIEW 2.1 Standard Controller Description IMPORTANT: A suitable divert power resistor must be installed with this product Sustainable/renewable energy sources such as wind turbines and solar panels generate uncontrolled power that must be regulated to facilitate the correct and safe charging of storage batteries. The...

Standard Controller Manual Document #: 0401M01 REV : 1.1 Approval: Date: March ‘08 Page 5 of 19 2.2 Identification and Markings On the Standard Controller enclosure is a product rating plate and serial number, if the controller does not carry this stamp it does not carry a Kestrel warranty and may not be authentic. *NOTE: Product Rating label example (above) is for format only, details may vary On the front cover of the charge controller are two switches which are labelled accordingly. Removing the front cover reveals internal connection labels. 2.3 Applications and Uses The Kestrel Standard...

Standard Controller Manual Document #: 0401M01 REV : 1.1 Approval: Date: March ‘08 Page 6 of 19 3 STANDARD CONTROLLER ASSEMBLY 3.1 Components Supplied The following components are supplied: Standard Controller assembly User Manual 3.2 Components Not Supplied The following components are necessary to complete an installation: Electrical crimp terminals Wall fixing screws 20mm cable glands Suitable fixing screws or bolts 3.3 Tools Required The following hand tools are required for Standard Controller installation: Small size electrical screwdriver Medium size electrical screwdriver Wire strippers...

Standard Controller Manual Document #: 0401M01 REV : 1.1 Approval: Date: March ‘08 Page 7 of 19 4 INSTALLATION INSTRUCTIONS 4.1 Typical Installation Example A typical battery charging installation is shown below. The system comprises a Kestrel wind turbine, a Standard Controller, diversion resistor, battery and an inverter. The inverter is additional and converts the battery dc power into standard ac power such that common mains powered appliances can be supplied. DO NOT OPERATE THIS CONTROLLER WITHOUT A BATTERY CONNECTED NOTE: The load circuit breaker and inverter are additional equipment and...

Standard Controller Manual Document #: 0401M01 REV : 1.1 Approval: Date: March ‘08 Page 8 of 19 4.2 Mounting the Controller The Kestrel Standard Controller Type 0401 is only suitable for indoor installation. The unit is vertically mounted using the four internal fixing holes provided. Use secure fastening with suitable wall plugs or bolts. Allow a minimum of 100mm (4”) space all around the unit for cooling. It is normal for the regulator to become quite hot at times as it dissipates unwanted energy. Do not place any objects on the top of the enclosure. The unit relies on the free passage of air...

Standard Controller Manual Document #: 0401M01 REV : 1.1 Approval: Date: March ‘08 Page 9 of 19 4.3 Electrical Wiring Observe the Polarity at all times. Only connect +VE RED cables to +VE RED terminals and -VE BLACK cables to -VE BLACK terminals. Otherwise, equipment damage may result and any warranty will be invalidated. PLEASE FOLLOW THE INSTRUCTIONS BELOW ! CONSULT SECTION 5 FOR WIRE SIZE RECOMMENDATIONS The Standard Controller is provided with two pairs of +VE and -VE clearly marked terminals for "TURBINE" and "BATTERY" and one pair of DIVERT RESISTOR terminals clearly marked R1A and R1B...

Standard Controller Manual Document #: 0401M01 REV : 1.1 Approval: Date: March ‘08 Page 10 of 19 4.4 Adjusting the Charging Voltage Always switch the turbine brake on (S1 ON) and the battery circuit breaker off (Q1 OFF) before adjusting the charging voltage jumper The Kestrel Standard Controller Type 0401 is suitable for all lead acid batteries whether vented, semi-sealed or sealed and the charging voltage may be adjusted. When the cover is removed, the jumper is visible in the middle of the control board. The charging voltage may be adjusted to the following table. There are five positions for...