Ken's TLG-500 Wind Farm in Wisconsin

Check out the average output from each unit that Ken reports from months of monitoring.

Ken started with 4 units, then went to 6 units, then 8 units, and he now has 10 units.

The Wind Farm shown below puts out 82 amps in a 16 mph wind!

Comments below the image.
NOTE: Update by date of entry from Ken below.


5 of his 10 units shown



all in a row


Note the logo on the blades


Cooked 30 Amp Breaker

Control center

Comments from Ken about his impressive wind farm
Above 16 mph wind average output to come.

Hi Terry. 
   These are the last ones I'm sending for now.( about 26 total)   Hope they transferred ok. 
    These TLG 500 generators perform better than you advertise and they are beautiful to watch with the sunlight or moonlight reflecting off the spinning blades and tail. With a stainless steel rotor shaft with a diameter of about 2 3/8" , the aluminum alloy case, aluminum blades and aluminum tail, all put together with stainless steel bolts, it should work well for many years. It looks over built, like something we would build here on the farm. It starts charging 1 amp at about 5 mph, keeps charging a little down to about 2-3 mph and has no noticeable cogging.
   I have been keeping track of the output amps for about a month now. Long term averages should be close to this. I have a stationary and handheld anemometer.  there is also a 24 hour internet accessible real time wind speed indicator located 2 miles from here which is always on my desktop screen.
   So far the average output readings for each generator in unobstructed wind are as follows;
1 amp at 5 mph,
2 amps at 7 mph,
3 amps at 9 mph,
4 amps at 11 mph,
5 amps at 12 mph,
6 amps at 13 mph,
7.5 amps at 15 mph,
8 amps at 16 mph,
   Most of the winds in our area are in the 2 to 16 mph range. One evening we had sustained winds of 25 to 35 mph for about 4 hours and the generators were putting out 18 to 25 amps each.
With six units that's 108 to 150 amps of power into a 12 volt battery bank.
The six TLG-500 generators put out a total of about 50 amps in a 16 mph wind!  Very impressive for small wind generators and a lot better than I had hoped for!!  
  I'll send amperage readings for winds above 16 mph when I gather enough data to get accurate averages.
    Thanks, Ken

Below is what Ken did to his units to seal them up far and beyond the stock bearing seals.
Like I told Ken, over kill on protections can never be a bad thing.
No doubt Ken is a thinker!

His comments about the seals are below the images.

The seals Ken bought
from the auto parts store
to install in the front

The front seal installed

A solo plastic cup was used to
seal the back of the unit

straight on view of the cup
with silicone holding it in place

The silicone grease Ken used
to lube the front seal

I didn't take any pics of grinding off the inner lip of the seals with my die grinder-- just enough so the rear lip barely touched the shaft.  I left the front lip as it was.  On the front of the generators, I only ground the slot through the first ridge ( about 1/8" ) so it shouldn't hurt the strength of the outer case, but will still drain any moisture away. Before installing the seal, I put a little silicone around the bottom third of the seam where the bearing meets the case so if any moisture ever got that far it could not seep down where the bearing meets the case. It would drain out the front through the hole in the bottom of the seal.
Don't know if any of this was necessary but it gives me peace of mind.

The silicone grease ( Dow Corning 33 ) that I sent you a picture of is the grease that I put on the lip of the seals when I installed them over the shaft. It is low temp grease and stays soft in cold weather  Less friction, I think.
For the rear cover and the Jell-O mold to protect the yaw bearing, I used regular 100% silicone caulk in a caulking gun, the type used for caulking windows etc. 

More info added 3-18-07

Winds 10 to 15 mph for most of today.  meter reads 25 to 45 amps.   The generators are doing great!!
Today we are keeping the battery bank at full charge, having a few house lights on, running the garage door opener and a couple of other circuits. In addition, the dump circuit keeps a small  500 watt milk house heater running about 1/2 to 3/4 of the time in the house.
I only have 1,100 amp hours of battery storage at this time. I need at least 3 times that amount for these generators. I should be charging the batteries to get through the low wind days instead of dumping good juice all day long.
                 Talk to you later,      ken

Update added 1-2-08

Hi Terry:
   Sorry it took a while to get back to you. It's been dark and cloudy for most of the last few weeks and the sun finally came out for a few minutes today so I could take some pics of all 10 gens.  The cooked auto-reset breaker is a 30 amp. I have been replacing them with 40 amp breakers.  I am in the process of re doing the whole setup so each gen will have a heavy duty shutoff box and it's own amp meter ( 0-50 amp,  class 1.5 meter )) and a separate meter to keep a running total of amp hours produced by the system. It's cold out so it's slow going.  Also, I have had to get larger wire to go from  the rectifier of each gen. to the batteries.( about 2-3 feet ).  I was using red #10 wire for this but some of the wires have turned into a brownish-dark red color.  I'm thinking they were  too hot, so I'm switching to #8 wire.
   On one windy day a while back when I only had 8 gens on line, the winds were 25-30 mph with 35 + mph gusts and two of my meters ( accuracy:  1.5 class) were reading 356 amps to the batteries during the gusts. Even if the meters were reading 4% high, it would still be 341 amps for 8 gens or 42.6 amps ( 511 watts ) per gen during the gusts.  It may be more than that because  I do not know if the amp meters were actually reading high ( they were only a couple of months old ) and I do not have any input controllers on my system so the input voltage is whatever the 20 deep cycle and 2 regular batteries and the diversion circuits can hold it down to. This is usually not more than 15-16 volts because the diversion loads kick in at 15 volts.
   I currently have two 5,000/10,000 watt inverters. One for regular power and one for diversion loads.  I had two 1,500/3,000 watt inverters for diversion loads but they both overloaded and died ( at the same time ) on a recent windy day  with all 10 gens on line. I do have back up diversion loads that kick in so the batteries do not totally fry if the diversion inverter dies.
   We do not have many windy days here, but the winds are pretty decent when they do come.  So far it looks like all of the gens perform about the same no matter where they are located. Some do better one day and others do better when the wind comes from a different direction.  The individual amp meters should help show output differences with different wind directions.
    When I get the whole system redone I hope to get more accurate performance data for you.
                                                     Later, ken

Update added 2-26-08

Complete Power Center with Brake Controls

59.4 Amps in a 10 to 12 mph wind

Have not had much good wind lately ( I believe around 10 to 12 mph when these pics were taken)   but here are a couple of pics of my setup with the meters and the turbine brakes. One pic is of the inside of one of the brake switch boxes with 3/8 " copper tubing in place of fuses One TriMetric meter measures total input amp hours from the turbines and the other measures total amp hours used by me.  In these pics, one meter is set to measure amps in and the other is set to read volts. As you can see, even the turbines in the field in clear air vary quite a bit. Wind is from the west so all 3 turbines in the field should be getting the same air, but apparently not.
                       Later, ken

Update added 2-29-08

232 Amps @ 13.1 volts = 3039.2 Watts in 20 to 25 mph wind.
That's 3 Kw average output!

Click image for larger view

Hi Terry.

Here is a pic of meters with a little better wind showing 232 amps.
The voltage at the 2500 amp-hour battery bank reads over 18 volts if I shut off the dump load for a few seconds.
The meters show the output of the three turbines on 35 foot towers in the field. The wind varies a lot even between these three and more so between all ten, so it's hard to tell exactly what the average wind speed was. Anemometer was showing 20-25 mph.
At the time the pic was taken, most of the house was running on battery power PLUS the 2,800 watt dump load was ON.

Update added 11-30-08

370 Amps @ 14.5 volts = 5365 Watts in a 30 mph wind.
That's over 5 Kw average output proving there is nothing out there up to 2 Kw that can hold a candle to our 500 watt unit.

Click image for larger view

Hi Terry;
I sent you this picture on Saturday, April 26th, 2008  but didn't see it on your website.  I may have just missed it or maybe it did not go through to you. It shows 370 amps at 14.5 volts. Well over 5 KW. The wind was  around 30 mph or a little more.

Later, ken

Ken now has 12 TLG-500 units in his wind farm (see top image)

General Information & Output Performance Charts for the TLG-500

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MSRP $1800.00

Direct Price $1375.00

Generator Specifications
12 Volt Battery Environment 24 Volt Battery Environment Industry Standard Instantaneous Rating


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