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Kansas Wind Power-W, 13569 214th Road, Holton, KS 66436       Phone/Fax: 785-364-4407

                           

Bergey Windpower Wind Turbines

Bergey BWC XL.1 1000 watt

New model for 12, 24, 36, 48 volt battery charging

8.2 ft diameter Rotor, 5 year warranty

The Bergey BWC XL1 is an up-wind, horizontal-axis, three-bladed turbine. The blades are made of strong pultruded fiberglass with SH3045 airfoil. They attach directly to a specially designed very-low-speed permanent magnet alternator which uses state-of-the-art neodymium super-magnets. These units also have enhanced turbine corrosion protection for marine sites and increased durability.

The cut-in speed is 6 mph with a 1000 watt output at about 25 mph. 120 mph is the maximum design wind speed. Overspeed protection is provided by the proven BWC AutoFurl passive sideways furling system. The generator and rotor turn partially sideways to the wind starting at about 30 mph. 5 year warranty from Bergey Windpower Co.

 Box is 60" x 22" x 12". We have known Bergey since the late 1970's.

New 48 volt model is similar to previous 24 volt model with new benefits.

1 -Multi voltage American made charge controller Midnight Solar Classic 250 instead of the BWC PowerCenter controller, can charge anything from 12-48 Volt.

2 -New controller has a lot more headroom so users will see more power in high wind events. Users report greater monthly production.

3 -No rectifier on the machine – this has been moved to the base of the tower in a “stop / run” box which should help reliability.

4 -“stop / run” junction box at the base of the tower makes for convenient installation and servicing as you can short the unit via a switch at the base of the tower

5 -Enclosed slip ring assembly

6 -Higher voltage stator = smaller conductor sizes (reduces installation costs). Smaller wire gauge can be used from turbine to the controller.

Click on picture for larger view

Estimated kilowatt Hours per month for various average wind speeds

Ave. Wind Speed 7.8 8.9 10.1 11.2 12.3 13.4 14.5
kwH per month 55 85 115 155 195 235 270

 
Bergey XL-1
wind generator for 12-48 volt battery charging.  
Has MidNite Solar Classic 250 charge controller, 48 volt alternator and stop-run box with rectifier diodes.
XL1-48
Wind Generator  170 lbs  $5000 
Special $4800

Bergey XL-1 wind generator for 12-24 volt battery charging.  
Has MidNite Solar Classic 250 charge controller, 24 volt alternator and stop-run box with rectifier diodes.
XL1-24
Wind Generator  170 lbs  $5000 
Special $4800


        24 volt or 48 volt Turbine only
without Charge Controller and Stop-run Box with rectifier is $4100


1800 watt, 24 volt, 60 amp Diversion Load Option. Connects to a controller such as Xantrex C60 or MorningStar TriStar TS60 (not included, See Charge Controls page). Contains air heating resistors in a metal box. Recommended for high wind locations or for extra space heating. W066  20 lbs  $425

Excel 1 24 volt Owner Manual

Excel 1 48 volt Owner Manual

Tilt-up Tubular Towers Manual

Start-up Wind Speed:  3 m/s (6.7 mph)
Cut-in Wind Speed:      2.5 m/s (5.6 mph)
Rated Wind Speed:      11 m/s (24.6 mph)
Rated Power:                 1000 Watts

Maximum Power:        ~ 2000 Watts
Cut-Out Wind Speed:  None
Furling Wind Speed:  13 m/s (29 mph)
Max. Design Wind Speed:  54 m/s (120 mph)

Blade Pitch Control:     None, Fixed Pitch
Overspeed Protection:  AutoFurl

REPLACEMENT PARTS

Units with serial numbers ending with "A" have a black main frame. Starting around 2006, the "C" series has stainless steel main frame with different tower adapter, slip rings, brushes, diode assembly.

Blade Set           W060  20 lbs  $380    

Nose Cone          W061   5 lbs   $69

Nacelle Cover     W062  15 lbs  $80
Diode Assembly  
W063   4 lbs 
$163

Magnet Can        W071  20 lbs $565

Brush Set            W064   3 lbs  $127
Brush Assembly with holder  W065  4 lbs $165
Stator, 24 volt (PowerCenter Models)
W069  20 lbs  $468
Stator, New 48 or 24 volt                   W070  20 lbs  $499
Tail Boom               W066   10 lbs  $96

Tail Fin                   W067   8 lbs   $69
PowerCenter Controller Controller parts are available to rebuild.  

                                               Must use the old housing.

 

 

 

Tilt-up Tubular Towers

Wind generator output is normally better on tall towers. The wind is usually faster and smoother up higher. The tower can be installed without concrete work in areas with good soil strength and no rocks (that would impede the screw-in guy-wire anchors). In weak or rocky soils the use of concrete to fix the anchors is required. Proper grounding is an important element in protecting the system from lightning damage.

Tower kits include galvanized 10 ft. 4.5 in. diameter tubular tower sections and associated hardware, guy anchors, guy wires and gin pole. Truck shipping.

                                                                              
60'
   (18 meters)  1TU18   $2200         

80'   (24 meters)  1TU24   $2700       

100'  (30 meters)  1TU30  $3200   

80' Tilt-up Tower diagram 

 

Bergey EXCEL 6 Wind Turbine

Monthly Kilowatt Hours Energy Output
estimate for average wind speeds

  Wind Ave 8 mph 10 mph 12 mph 14 mph 16 mph
Bergey 6 kwH 322 606 948 1309 1655
Bergey 10 kwH 409 820 1378 2027 2700

AWEA Rated Power: 5.2 kW @ 24.6 mph (11m/s)
Peak Power: 6.2 KW
AWEA Annual Energy: 9,800 kWh @ 11 mph (5 m/s) average
Cut-In Wind Speed: 4.5 mph (2 m/s)
Cut-Out Wind Speed
: None
Furling Wind Speed: 31-45 mph (14-20 m/s)
Max. Design Wind Speed: 134 mph (60 m/s)
Nominal Rotor Speed: 0-400 rpm
Type: 3 Blade Upwind, Horizontal Axis
Rotor Diameter: 20.2 ft. (6.2 m)
Weight: 770 lb. (350 kg)
Overspeed Protection: AUTOFURL
Gearbox: None, Direct Drive
Temperature Range: -40 to 140 F (-40 to 60 C)
Towers: Guyed and Non-Guyed 60-160 ft (18-49 m)
Alternator: 3Ø Neo Permanent Magnet
Inverter: 6 kW Powersync II (Outdoor Rated NEMA 3R Enclosure)
Remote Monitoring via Internet & Smart Phones (Optional)

Sample cost for 6 kW
and 80 ft. Guyed Lattice Tower

EXCEL 6 Wind Turbine    $21,995
80' Guyed Lattice Tower  $11,525
Tower Wiring Kit  $1495
Shipping & Delivery  $1800
Foundations  $3280
250' Wire Run  $2600
Electrical Contractor  $1375
Turbine Set-Up & Crane  $2000
Misc. Costs  $500
Building Permit  $500
Sales Tax  $2100
Total  $49,170
Actual cost will vary

Sample Cost for 6 kW and 80' Self-Supporting Lattice Tower     $58,290 

 

BWC EXCEL Wind Turbine 10,000 watts The BWC EXCEL is a modern 7 meter (23 ft) diameter, 10,000W wind turbine designed for high reliability, low maintenance, and automatic operation in adverse weather conditions.  The BWC Excel is a ruggedly built turbine that comes with the longest warranty (10 years) in the industry.  The BWC EXCEL was introduced in 1983 and it has been installed at over 1600 sites around the world. 

48 volt Battery charging 10 KW BWC EXCEL   Suited for large rural homes, remote villages and facilities, eco-tourism resorts, and larger telecommunications sites. Includes a voltage regulator. $32,000

Connected to the grid, the 10 KW BWC EXCEL can provide most of the electricity for an average total electric home at moderate wind sites.  The all new GridTek 10 power processor (inverter) is the most advanced in the industry and it carries a full UL certification to the latest utility standards. $32,000

The BWC EXCEL is most often installed on a guyed lattice tower, which is available in heights of 18 m (60 ft.) to 37 m (160 ft.). Prices range from
$11,000 to $24,000.

Tilt-up versions of these towers are available for sites without crane access. Prices range from a  60' tower for $14,000, 80' is $16,000 and 100' tower is $18,000. Tower raising kit is $3000 and GripHoist kit is $4000.
Self-Supporting Lattice towers range from 60' for $11,000 to 160' for $36,000.
Self-Supporting Monopole Tubular towers range from 60' for $13,000 to 120' for $29,000. A list of requirements for customer supplied towers is available.
Start-up Wind Speed:  3.4 m/s (7.5 mph)
Cut-in Wind Speed:  3.1 m/s (7 mph)
Rated Wind Speed:  13.8 m/s (31 mph)
Rated Power:  10 kW (grid & pumping), 7.5 kW for battery-charging
Cut-Out Wind Speed:  None
Furling Wind Speed:  15.6 m/s (35 mph)
Max. Design Wind Speed:  54 m/s (120 mph)
Type:  3 Blade Upwind
Rotor Diameter:  7 m (23 ft.)
Blade Pitch Control:  POWERFLEX®
Overspeed Protection:  AUTOFURL
Gearbox:  None, Direct Drive
Temperature Range:  -40 to +60 Deg. C (-40 to +140 Deg. F)
Generator:  Permanent Magnet Alternator
Output Form: 3 Phase AC, Variable Frequency (Regulated 48 - 240 VDC after VCS-10 or 240 VAC, 1Ø, 60 Hz with GridTek® inverter).

  The EXCEL is a 7 meter (23 ft) diameter three-blade upwind turbine that achieves high reliability through rugged construction and a minimum of moving parts.

  The rotor on the EXCEL has three pultruded fiber reinforced plastic (FRP) blades which are rigidly attached at their hubs.  The EXCEL blades are flexible in torsion and have a unique pitch weight attached to their outboard leading edge.  The patented Powerflex® blade system provides passive blade pitching as a function of rotor speed.  Thus, the blades are set for a higher pitch to aid start-up, but “flatten out” at speed to improve operating aerodynamic efficiency.  The airfoil used on the EXCEL is a proprietary design (BW-3) developed specifically for low Reynolds Number conditions.  This thin, highly cambered section is not affected by normal dust and residue build-up on the blade leading edge.  BWC offers an Extra-Stiff Blade Option for high-turbulence or high icing conditions.  These blades are often painted black for ice-shedding.

The blades attach directly to the outside shell of the EXCEL’s purpose-built direct drive 38-pole permanent magnet (PM) alternator.  The alternator has an “inside-out” configuration in that the outer shell (containing the magnets) rotates about the fixed internal stator structure.  Thus, the alternator incorporates the rotor hub, has no central rotating shaft, puts the front bearing in the rotor plane,and has no brushes.  The output is a sinusoidal three-phase alternating current that varies in voltage and frequency with wind speed.

  The EXCEL wind turbine series is nominally rated at 10 kW.  In a battery charging  application, however, there is an inherent load matching problem between permanent magnet alternators and battery banks.  The EXCEL-R is optimized for low wind speed performance, which maximizes energy production.  But providing the best performance in low winds results in some reduction in peak power under high wind conditions.  Therefore, the EXCEL-R is rated at 7.5 kW.

  The turbine is aligned into the wind by a tail assembly.  The tail boom and and integrated rotor/alternator assembly attach to the mainframe assembly, which incorporates the yaw-axis slip-rings and the tower interface. The geometry of the mainframe creates the passive Autofurl® high wind speed protection.  The mainframe offsets the rotor and yaw axes such that rotor thrust produces a furling moment about the yaw-axis.  The weight and inclined pivot of the hinged tail provides a preset resistance to the rotor furling moment.  Overspeed control is initiated at 13-15 m/s (30-34 mph) when rotor thrust overcomes the tail resistance and restoration is caused by gravity as the wind speed subsides.  The EXCEL has no shut-down wind speed.  The turbine can be manually shut-down using a furling winch installed at the base of the tower.

  Corrosion protection for the EXCEL is provided by hot-dip galvanizing (mainframe, tower adapter, and tail boom), electro-zinc plating, and polyurethane paint systems.  FRP components, such as the blades, are protected by ultraviolet-inhibiting resin additives and sub-surface “scrim cloth” UV barrier.  The blades have polyurethane leading edge tape for protection against erosion.  The EXCEL’s four sealed bearings are provided with static drain brushes to protect against discharge pitting.  A Marine Corrosion Option is available which substitutes stainless steel hardware and provide full encapsulation of the stator windings.

  The EXCEL has only four moving parts, no adjustable elements, and no grease fittings.  No scheduled maintenance is required beyond biannual inspections and replacement of the outer three feet of blade leading edge tape every 4-5 years.  Static components of the EXCEL are designed for a 50 year life and dynamic components are designed for a 30 year life. Predicted major overhaul requirements include blade refinishing and alternator bearing replacement at 15 years or 225,000 kWh’s.

  The VCS-10 controller, which comes with the EXCEL-R wind turbine, provides controlled rectification through a three-phase semi-converter.  The semi-converter uses phase modulation to control charging voltage and current based upon the battery bank voltage.  Safe operation of the EXCEL turbine is independent of the load conditions, allowing the controller to unload the turbine during regulation.  No auxiliary load is required.  The VCS-10 is fully solid-state and is passively cooled.  It incorporates an LCD display of DC bus voltage and status lights to indicate the charging mode of the unit.

  Since its introduction in 1983 the EXCEL has distinguished itself as the one of the most reliable wind turbines ever produced.  The Wisconsin Power & Light SWECS test program, the largest of its kind (involving SWECS from UTRC (Windtech), Windworks, Jacobs, Enertech, and Carter), showed a 99.1% availability (9.0% higher than any other unit) and an O&M cost of $0.0026/kWh for the EXCEL over a five year test program.  This is less than half the O&M costs that have been typically  reported for grid-intertied photovoltaic systems (eg, PG&E test program). 

  Another utility, Pacific Power & Light, through its subsidiary OnSite Energy, installed leading remote wind turbine products (3 kW Northern Power Systems HR-3,  10 kW BWC EXCEL, and 17.5 kW Jacobs 10-23) on a telecommunications site at Duncan Mountain, Idaho in November, 1984 for the purposes of product and technology evaluation.  The site is very remote and accessible only by helicopter during the winter.  Since installation, over fourteen years now, the BWC EXCEL has achieved nearly 100% availability.  The next most reliable turbine in the PP&L test program had an 84% availability in the first five years.  The other turbines at the site have now been decommissioned and the EXCEL is providing prime power to the telecommunications facility.

  The BWC EXCEL is the best selling wind turbine in the size range of 2-20 kW in the world.  Over 1600 units have been installed in more than 30 countries.

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Last modified: 04/05/17 
Kansas Wind Power - W,  13569 214th Road, Holton, KS 66436   785-364-4407,  All prices and specifications are subject to change without notice.