Final Assembly Instructions for the TLG-500 Wind
(at the bottom is a link to a text only page for printing)
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When your unit arrives please open the top of
the box and remove the flat rotor box, which has the Boast Buster blades,
hub, and hardware, along with the rectifier diode.
Please get assistance when you are ready to lift the generator yaw assembly
out of the box. The unit weighs about 40 pounds without the rotor blade
Assembly of the Boast Buster
or Cy-Clone Rotor
Remove all hardware from the shipping flat.
Before you mount the blades please place a thin layer of silicone around the
mounting holes up to the end of the arm, and one pencil size lines down the
center and one pencil size at outside edge of the hub arm opposite of the
bolt holes. This will dampen harmonic noise from the hub to the blades.
Insert all blade front washers onto the blades as shown in (figure D)
Insert the bolts into the hub arm as shown in (figure D1) add the flat
washer then the locknut to the bolt.
NOTE: the flat side of the blade runs flush (smooth) with the side of
the hub arm.
Also use a spot of grease or anti-seize on your bolts. Since they are
stainless steel there is a risk of seizing the threads if you don't
Tighten the center bolt snug to where you could tap the blade and move it if
Use (something straight) a mini level etc to help you align the blade edge
to the hub arm. (if needed)
Tighten up the remaining two bolts along with the center one that you just
Recheck the blade to make sure it is still running straight down the hub
Repeat the process for the remaining two blades.
The rotor is now assembled and ready to mount to
the TLG-500 head.
At this time you have a decision to make!
Are you going to mount the rotor to the generator and raise it as
a complete unit?
Or are you going to mount the rotor to the generator after the yaw
assembly has been mount on the pole?
Proceed to the correct procedure below per your decision.
Mounting the Boast Buster
or Cy-Clone Rotor to the TLG-500
Hook all three of the lead wires of the generator
together to apply the shunt brake.
Place the large flat washer on the generator shaft.
Sit the hub of the rotor on the generator shaft (remember the
bolts of the rotor will be on the left-hand side of the hub arm that is
closest to the 12 o'clock position as you are looking at it. Place the
nut on the shaft and snug down the hub to get it started.
Remove the shaft nut and place the lock washer on the top of the hub.
This allows the hub to mount the shaft easier since it is zero tolerance
Put a drop of grease our anti-seize on the bolt and tighten the nut with a wrench or socket. Make
it tight but don't be stupid! ;)
That completes the rotor to the generator head, either on
the pole or on the ground
The Boast Buster should look like this mounted on the
Hooking up the wires of the generator head to the drop
wire (extension cord)
See figure E below for reference
Run the extension cord through the strain relief on the yaw
assembly. (figure E)
Tighten the two screws on the strain relief.
Cut and strip the wires of the extension cord.
It is ok to cut down the length of the wire coming out of the TLG-500 head
to make a neater install.
Place a piece of heat shrink tubing (not supplied as it is optional) over
each wire of the generator head.
Twist the wires from the extension cord and the TLG-500 together.
Solder or use wire nuts on each wire then cover with heat shrink tube, OR use a good amount of electrical tape.
Wiring Note: When
you get to the rectifier it does
not matter which of the 3 wires go where on the it, (it's AC).
Mounting the Yaw Assembly to the Pole
NOTE: If you
purchased a split collar (LC-split1.5) with the unit please install the collar at exactly
2 inches down from the top of the pipe before you place the TLG-500 on the
pole. The split collar really simplifies the mounting on the pole
process. With a split collar you can just sit the generator assemble
on the pole and tighten the two set screws without having to raise the unit
from resting on top the pipe.
There are two set screws in the lower bearing housing.
(figure F) You will need a 3/16" Allen wrench for this part.
Sit the TLG-500 over the 1 1/2" pipe unit it touches the strain relief
Raise the unit 3/16 of an inch up and tighten the first of the two set
screws with your 3/16" Allen wrench.
Tighten the second set screw... NOW back it off and retighten it again.
You will notice is goes in a bit further.
Repeat the back off, and retighten process to the other set screw to make
sure both set screws on the bearing are seated in the pipe.
Hooking the extension cord to the supplied 3-phase
rectifier at the battery bank
Once you have the extension cord ran to the battery bank
stripe the outside isolation back so that you have about 6 inches of wire
Place one each supplied crimp connectors to each wire of the extension cord.
(solder the tip if you want on each connector)
NOTE: When hooking the terminals to the rectifier make sure you do not short
your nut driver/tool against any other part of the rectifier. The
generator may be turning and putting out power during this part and damage
to the rectifier may occur.
Place one heavy gauge wire in each on the supplied crimp connectors for the
positive and negative battery leads.
See figure G below for the layout of the rectifier contacts.
Wiring Note: It does
not matter which of the 3 wires go where on the rectifier, (it's AC).
Wiring Note: The bottom
portion of the rectifier with the white plastic is the positive + output.
The following image shows how Dave from Auto Climate
Systems installed his rectifier with a 30 Amp automotive breaker
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