Bergey 24 VDC B, Owner'S Manual

8 

Tilt-up Type Towers:

  If you have a tilting 

tower, such as the BWC Tilt.Tower, the following 
procedure is recommended: 

Tools Required: 

17 mm box end wrench 
17 mm socket and ~ 300 mm (12”) ratchet 

drive 

8 mm socket or wrench 
pliers 
crimpers for wiring terminals (U-shaped 

crimp preferred over straight crimp) 

thread locking compound (like Loctite 242) 
tape measure, 12 ft. 

Procedure: 

 
Step 1:  

With the tower tilted down, place the powerhead 
of the wind turbine near the top end of the tower. 
 
The tower wiring is connected to the XL.1 wind 
turbine at the slip-ring using two small screws and 
ring terminals crimped to the two conductors.  Cut 
the outer insulation on the wire back about 60 mm 
(2.5 in).  Strip the insulation off the outer 12 mm 
(1/2 in) of each conductor and crimp on the ap-
propriate ring terminals (several sizes are pro-
vided to match possible wire sizes).  Attach the 
two power conductors to the slip-ring assembly 
with the screws provided.  The polarities of the 
connections are marked.  If your conductors are 
color-coded we recommend making note of the 
colors connected to positive and negative leads. 
 
The slip ring assembly is not designed to support 
the weight of the down-tower wire.  A strain reliev-
ing installation is required, as shown in Figure 7.  
Use the two nylon cable ties provided to secure 
the tower wiring to the tower adapter casting.  Af-
ter completing the connections, pull on the tower 
wire to make sure that it is secure before mount-
ing the wind turbine on the tower. 
 

Step 2: 

Raise the tower about 1 meter (3 ft) off the ground 
to provide room to assemble the XL.1 turbine.  We 
recommend fashioning a temporary support stand 
to hold the tower up during turbine assembly. 
 

Step 3:  

Mount the wind turbine tower adapter to the top of 
the tower using the six M10 x 1.5 bolts and six 
washers.  We strongly recommend applying Loc-
tite 242 (Thread Locking Compound) to the 

threads prior to installation to reduce the likelihood 
of loosening due to vibration.  We recommend 
using a torque wrench to achieve the proper fas-
tener torque on the tower mounting bolts.  The 
recommended toque is 54 N.m (40 ft-lbs). 
 

Power
Cables

Nylon
Cable
Ties

Turbine
Mounting
Bolts

Figure 7, Turbine Mounting

Step 4: 

Complete the wiring to the PowerCenter before 
adding the blades.  This is recommended so that 
you can test the DC polarity of the wiring by spin-
ning the alternator by hand.  It is very important 
that the polarity [positive (+) and negative (-)] is 
correct when the turbine is connected to the Pow-
erCenter.  The best way to ensure this is to com-
plete the wiring and then test the polarity with a 
Volt-Ohm-Meter.   
 
Wiring recommendations are provided in Section 
7 and in Appendix 1, section D.  Turning the alter-
nator by hand will provide enough voltage to make 
this check.  Carefully mark the positive and nega-
tive electrical leads for later reference. 
 

Step 5:  

Turn the XL.1 powerhead upward so that the al-
ternator is facing up.  Attach the blades as shown 
in Figure 8 using the M10 hardware provided.  We 
recommend bolting one blade up solidly and leav-
ing the other two somewhat loose while you check 
the tip-to-tip blade distance.  We recommend 
checking, and adjusting as necessary, the blade 
tip spacing to ensure that the blade tips are 
equally spaced.  This step will help make the wind