Bergey Windpower Wind Turbines 10 kW, 15 kW
Bergey BWC XL.1 1000 watt
No longer manufactured.
Repair parts available.
For 12, 24, 36, 48 volt battery charging
8.2 ft diameter Rotor
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
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.
We have known Bergey since the late 1970's.
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: ~
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
24 volt Owner Manual
Excel 1 48 volt Owner Manual
Tilt-up Tubular Towers
Some of these parts are no longer available.
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.
W060 20 lbs
W063 4 lbs
Triple Slip Ring is not available.
Slip Ring C2
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.
60' (18 meters) 1TU18
80' (24 meters) 1TU24
100' (30 meters) 1TU30
80' Tilt-up Tower diagram
Bergey EXCEL 10 Wind Turbine
Monthly Kilowatt Hours
estimate for average wind speeds
||AWEA Rated Power:
8.9 kW @ 24.6 mph (11m/s)
Peak Power: 12.6 KW
AWEA Annual Energy: 13,800 kWh @ 11 mph (5 m/s) average
Cut-In Wind Speed: 5.6 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: 23 ft. (7 m)
Weight: 1200 lb. (545 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: 12 kW Powersync II (Outdoor Rated NEMA 3R
Remote Monitoring via Internet & Smart Phones (Optional)
and 100 ft. Guyed Lattice Tower
EXCEL 10 Wind Turbine $35,000
100' Guyed Lattice Tower $20,000
Tower Wiring Kit $2000
Anchor Bolt Template $625
Shipping & Delivery $4000
250' Wire Run $3600
Electrical Contractor $2000
Turbine Set-Up & Crane $3000
Misc. Costs $800
Building Permit $800
Sales Tax $7000
Prices change rapidly.
Actual cost will vary.
Double the output by using the 15 kW Turbine.
Bergey EXCEL 15 Wind Turbine
|AWEA Rated Pawer
||15.6 kW at 11m/s (24.5 mph)
|AWEA Rated Sound Level
|AWEA Rated Annual Energy
||29,800 kWh at 5 m/s (11 mph)
|Start-up Wind Speed
||4.5 m/s (10 mph)
|Cut-in Wind Speed
||2.5 m/s (5 mph)
||15 kW @12 m/s (27 mph)
|Cut-Out Wind Speed
|Max Design Wind Speed
||60 m/s (134 mph)
||3 Blade Upward
||31.5 ft (9.6m)
|Max Rotor Speed
|Blade Pitch Control
||None, Fixed Pitch
|Over Speed Protection
||Blade Stall, with dump load
||None, Direct Drive
||-40 to +60 Deg. C (-40 to +140 Deg. F)
||Permanent Magnet Alternator
||3 Phase AC, Variable Frequency 240 VAC,
1Ø, 60 Hz with Powersync III inverter
BWC EXCEL Wind Turbine 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.
||10 KW BWC EXCEL
48 volt Battery charging $35,000
23' Blade diameter.
Suited for large rural homes, remote villages and facilities, eco-tourism
resorts, and larger telecommunications sites. Includes a voltage regulator.
10 KW BWC EXCEL
23' Blade diameter. Can provide most of the electricity for an average total electric home at
moderate wind sites. The Powersync ll inverter is the most advanced in the industry and it
carries a full UL certification to the latest utility standards.
15 KW BWC EXCEL Grid Connect 31.5'
Blade diameter. Includes
20 kW Powersync lll and dump load, AWEA rated power 15.6 kW, Peak Power 21.8
kW, AWEA Annual Energy 30,100 kWh, cut-in wind speed 5 mph, start-up wind
speed 10 mph, Can be used on the Self-Supporting towers up to 100'.
Guyed Lattice Tower 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
The EXCEL 10 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
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
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
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
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.