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SA WIND ENERGY

Wind Turbine Hybrid Wind Charge Controller

Manual:
CSX-4 and CSX-5
Hybrid wind and solar controller

Please read the instructions before installing

SA WIND ENRGY – Hybrid Charge Controller

Introduction:
The function of the charge controller is to monitor the battery voltage, and once it reaches
full charge, disconnect energy sources (wind turbine and / or solar panel), to avoid
overloading the battery bank. Furthermore, at risk to the turbine (excessive rotation), the
controller actuates the braking automatically. Also, in case of risk to the controller, such as
over temperature, load interruption occurs and braking of the turbine. Other protections
are also present, such as input voltage limits.
The lstapower controller allows direct connection of wind generator (three-phase turbine
with permanent magnets,) and 12/24/48V battery bank, to generate a complete solution
to battery charge with power wind. It also has input for solar cell panel (600W maximum),
to use solar and wind energy (hybrid system). The hybrid system as an interesting
combination, since often days of little wind exhibit good insulation, and vice versa.
All the controller circuit is designed with electronic components without the use of
electromechanical components (relays). This contributes to a long service life and
substantially increases the reliability of the installation.
The whole set is packaged in a metal housing of high mechanical strength which removes the
heat generated efficiently, avoiding overheating.

Connection:

The controller has the following connections:

The main connector has seven contacts: three contacts for the three phases of the wind
turbine (PHASE A, B, C), a contact to the positive terminal of the battery (BATTERY+), a
contact to the negative terminal of the battery (BATTERY-), a contact to the negative
terminal of the solar panel (SOLAR-), and a contact to the positive terminal of the solar
panel (SOLAR+).

Internally there is a 40A fuse protect the circuit in the event of a short circuit. Normally, this
fuse should not burn because there is protection against reverse polarity, both the battery
and solar panel.
Two LED lights (yellow and red) indicate the operation of the controller. They are located to
the left of the main connector (front view), as shown in the drawing.

As the braking is based on dynamic friction, that is, the energy generated by the turbine
itself, will not necessarily completely stopping. A braked wind turbine could continue to
rotate, but with a low speed. In case of strong winds (above 35 km/h) may occur that the
turbine falls your speed when there is a wind temporary interruption, allowing your
downswing. Once at low speed, the turbine will remain so until manual braking is off, even if
the wind returns to levels above 45 km / h.
Frequently asked questions

Do I have to program the display myself?

No, the display is already programmed, and it is not possible to change the settings, it is locked by us.
Why does the display flash?
The display flashes when the maximum voltage is reached, and the braking system has activated the
relays to switch off this alarm and just press the middle button once and it stops flashing.
How do I know that the wind turbine is producing energy?
To know if it is producing energy, you need to install a wattmeter, which can be installed between
the charge controller and the batteries. What does the percentage on the display mean?
This percentage is linked to the charging voltage of the batteries. When this voltage reaches its
maximum, the display shows 100%, for example on 24 V models, when the voltage reaches 28 V, it
marks 100% and the brake is activated by switching on and the red LED lights up.
What do the LEDs mean?
There are two LEDs, one yellow and one red. Yellow lights constantly, indicating that the battery is
connected, and the red one lights only when the brake is activated, waits 3 seconds and then goes
out.
What should I do during a storm?
The system is designed to break the turbine automatically, but if the wind exceeds 60 km / h, we
recommend that you brake the turbine manually with the switch on the controller connection to
avoid overloading the system.

Connection

The controller has the following connections:

The main connector has seven contacts: three contacts for the three phases of the wind
turbine (PHASE A, B, C), a contact to the positive terminal of the battery (BATTERY+), a contact
to the negative terminal of the battery (BATTERY-), a contact to the negative terminal of the
solar panel (SOLAR-), and a contact to the positive terminal of the solar panel (SOLAR+).
Internally there is a 40A fuse protect the circuit in the event of a short circuit. Normally, this
fuse should not burn because there is protection against reverse polarity, both the battery and
solar panel.

Two LED lights (yellow and red) indicate the operation of the controller. They are located to
the left of the main connector (front view), as shown in the drawing.

As the braking is based on dynamic friction, that is, the energy generated by the turbine itself,
will not necessarily completely stopping.

A braked wind turbine could continue to rotate, but with a low speed. In case of strong winds
(above 35 km / h) may occur that the turbine falls your speed when there is a wind temporary
interruption, allowing your downswing. Once at low speed, the turbine will remain so until
manual braking is off, even if the wind returns to levels above 45 km / h.
 Operation:
The mechanical assembly of the controller must always be vertical, with connectors for battery
connection, wind turbine and solar panel in the lower position. This ensures efficient cooling by
convection.
Connect the battery bank to the controller. The wiring to the battery bank must have a 6 mm2 of
copper in diameter and preferably as short as possible (less than 3 meters between controller and
battery bank). After a moment, the two LEDs (red and yellow), indicating system startup. Soon after,
the yellow LED should be activated, indicating that the controller measured the voltage of the
battery bank, and initialize its internal constants properly
When connecting pay attention to the polarity battery. If reversed there will be no damage to the
system, but the controller will remain de-energized.
Once energized the controller, place the three wind turbine wires shorted together to force the
turbine stop. Beware of terminals open turbine, since this situation can arise high voltages if the
propeller is moving. Wait about 30 seconds to perform complete cycle of braking, then remove the
short circuit between the turbine wires and connect to the corresponding terminals (phase A, B, C).
The order of the wires is irrelevant. Do not do this operation if there is strong wind, because the little
time with open wires may be sufficient to speed propeller and generate high voltages at its terminals.
In this case, first stop mechanically the propeller spinning before handling the wires of the wind
generator. •
Once energized the controller, place the three wind turbine wires shorted together to force the
turbine stop. Beware of terminals open turbine, since this situation can arise high voltages if the
Warning: the wires of wind generator open can generate very high voltages if
the propeller is moving, with electrical shock hazard. Always should do short
circuit the terminals or stop mechanically the turbine- before handling it.
propeller is moving. Wait about 30 seconds to perform complete cycle of braking, then remove
the short circuit between the turbine wires and connect to the corresponding terminals (phase
A, B, C). The order of the wires is irrelevant. Do not do this operation if there is strong wind,
because the little time with open wires may be sufficient to speed propeller and generate high
voltages at its terminals. In this case, first stop mechanically the propeller spinning before
handling the wires of the wind generator.

Characteristics
• Input for wind generator 800/100/2000W.
• Input for solar panel 600W.
• Operation in 12/24/48V.
• Reverse polarity protection on the battery.
• Short-circuit protection (internal fuse 40A).
• Reverse polarity protection on the solar panel.
• Reverse Current protection at night in the solar panel.
• Disconnection and brake of the turbine by overspeeding.
• Turbine brake soft, avoiding mechanical shock.
• Turbine brake operates without even energy.
• Manual brake Switch
• Status display via two LED light
Operation
The mechanical assembly of the controller must always be vertical, with connectors for battery
connection, wind turbine and solar panel in the lower position. This ensures efficient cooling by
convection.
Connect the battery bank to the controller. The wiring to the battery bank must have a 6 mm2 of
copper in diameter and preferably as short as possible (less than 3 meters between controller and
battery bank). After a moment, the two LEDs (red and yellow), indicating system startup. Soon after,
the yellow LED should be activated, indicating that the controller measured the voltage of the battery
bank, and initialize its internal constants properly
When connecting pay attention to the polarity battery. If reversed there will be no damage to the
system, but the controller will remain de-energized.
Once energized the controller, place the three wind turbine wires shorted together to force the
turbine stop.
Beware of terminals open turbine, since this situation can arise high voltages if the propeller is
moving. Wait about 30 seconds to perform complete cycle of braking, then remove the short circuit
between the turbine wires and connect to the corresponding terminals (phase A, B, C). The order of
the wires is irrelevant. Do not do this operation if there is strong wind, because the little time with
open wires may be sufficient to speed propeller and generate high voltages at its terminals. In this
case, first stop mechanically the propeller spinning before handling the wires of the wind generator.
If the installation has solar panel connect it to the controller. The system is connected and
ready to operate. Press the manualbrake button to release the brake. If the turbine was
mechanically immobilized can be released.
When reach full charge voltage, the red LED is turned on and the charge of the battery bank is
interrupted.

Characteristics:
• Input for wind generator 800/100/2000W.
• Input for solar panel 600W.
• Operation in 12/24/48V.
• Reverse polarity protection on the battery.
• Short-circuit protection (internal fuse 40A).
• Reverse polarity protection on the solar panel.
• Reverse Current protection at night in the solar panel.
• Disconnection and brake of the turbine by overspeeding.
• Turbine brake soft, avoiding mechanical shock.
• Turbine brake operates without even energy.
• Manual brake Switch
• Status display via two LED lights.

Technical specifications:
 12V 24v 48v Battery
battery Battery
Minimum 6,0V 6V 6V
voltage to
controller
startup
Voltage for 12,5V 24,5V 48,8V
battery charge
start
Voltage for 14,8 V 28,5V 58,5,5 V
battery charge
end
Minimum 6,0V 17,5V 17,5 V
voltage to detect
battery
Maximum input 60,0V 60,0V 80,0V
voltage
Wiring 6mm2 6mm2 4mm2
recommendedfo
r battery bank
Maximum 3m 3m 3m
distance for
battery bank
Maximum 40A 40A 35A
current to
charge
Maximum 2500 rpm 1500 RPM 1200RPM
speed turbine
Maximum power 800W 1000W 2000W
inwind
turbine
Maximum power 600W 600W 600W
insolar input
Recommended 12V / 24V /100A 4 X 12v 100A
minimum 100Ah
battery
Internal fuse 50A 50A 40A

Information about the Display:

1. Out -battery charging program
2. 48.7V Current battery voltage
3. 0.00% Percentage linked to the wind turbine brake; this percentage is not linked to the
battery charge but to the wind turbine brake based on the Voltage coming from the
wind turbine.
4. the Display is factory locked and it is not possible to change the brake voltage
parameters
5. the display will flash when the turbine is braked, just press the central button once
and it will stop flashing.