Air Breeze battery charging wind turbine User manual

Southwest Windpower, Inc.
1801 West Route 66
Flagstaff, Arizona 86001
Toll Free Phone: [phone]
Phone: [phone]
Fax: [phone]
www.airbreeze.com
OWNER’S MANUAL
Installation
Operation
Maintenance
!February 2008 Southwest Windpower, Inc.
All Rights Reserved

Air Breeze Owner’s Manual 3
Southwest Windpower
Congratulations on your purchase and welcome to our family!
Dear Air Breeze Owner,
Thank you for your purchase of Air Breeze. You have purchased the most advanced battery charging wind turbine in the world! We believe you will find it
easy to install your Air Breeze and are confident you will experience years of dependable service from it.
Before going any further, please complete and return the Warranty Registration Card. Note - Southwest Windpower does not sell or distribute your per-
sonal information to any third party. We understand and respect your privacy.
If you have any questions or comments, we would like to hear from you. Please call during working hours (Monday-Friday – 8:00am to 5:00pm Arizona
Standard Time). Our numbers are 928-779-9463, toll-free 866-805-9463.
Again, welcome to our family and thank you for investing in the future of wind energy with Air Breeze.
Sincerely,
Southwest Windpower
Enter the serial and model numbers below
Serial Number __________________________________
Model Number __________________________________
Air Breeze Installation Manual
Document No. 3-CMLT-1327-01
Revision: A
AIR, AIR 403, AIR-X, AIR Wind Module are trademarks of Southwest Windpower !2007 Southwest Windpower, Inc.

4 Air Breeze Owner’s Manual
1) SAVE THESE INSTRUCTIONS. This manual contains important instructions that must
be followed during assembly, installation and maintenance.
2) Read, understand and respect all warnings.
3) Do not install Air Breeze on a windy day.
4) If unusual noise or operation is experienced, turn off machine and contact authorized
service personnel.
5) During assembly and installation properly torque all fasteners.
6) Use only proper grounding techniques as established by the NEC.
7) Properly complete the Warranty Registration Card.
8) Breeze must be installed in accordance with this manual and local and national build-
ing codes. Failure to comply with this manual and local codes may affect and possibly
void your warranty.
9) Rotating blades are a serious mechanical hazard. Install Air Breeze so no one can come
into contact with blades.
10) Observe wire size and fuse recommendations listed in the Wiring Section of this manual.
TIP: Indicates instruction or advice
that may simplify or ease task or
operation.
IMPORTANT: Indicates instruction
or advice that is critical for correct
assembly or operation. Damage
to equipment may result if not
heeded.
In this manual you will see the
following icons:
One - Important Safety Instructions
READ THESE INSTRUCTIONS IN THEIR ENTIRETY BEFORE ASSEMBLING, INSTALLING OR OPERATING YOUR AIR BREEZE
LAND USE: Specific to Land Use.
MARINE USE: Specific to Marine
Use.
WARNING: Indicates risk of severe
injury or death or possible severe
damage to equipment - proceed
with caution and follow instructions.

Air Breeze Owner’s Manual 5
Contents
1) IMPORTANT SAFETY INSTRUCTIONS__________________ 4
WARRANTY _________________________________________ 6
TECHNICAL SPECIFICATIONS ________________________ 7
2) TURBINE ASSEMBLY ________________________________ 8
3) SITING______________________________________________ 9
4) TOWERS ____________________________________________ 10
4-1 Tower Options___________________________________ 10
4-1-1 27 ft (8.3 m) Tower Kit_______________________ 11
4-1-2 29 ft (8.8 m) Tower Kit_______________________ 11
4-1-3 45 ft (13.7 m) Tower Kit _____________________ 12
4-1-4 Marine Tower Kit ___________________________ 12
4-1-5 RV Tower Kit ______________________________ 13
5) WIRING OPTIONS____________________________________ 14-15
5-1 Hybrid System Wiring_____________________________ 16
5-2 Multiple Air Breeze Wiring _________________________ 17
5-3 Wire Size _______________________________________ 18-19
5-4 Stop Switch _____________________________________ 19
5-5 Fuses, Circuit Breakers, Ammeter___________________ 20
5-6 Batteries _______________________________________ 20
5-7 Turbine Grounding _______________________________ 20-21
5-8 Tower Grounding ________________________________ 21
5-8-1 Electrodes Driven in Soil______________________ 21
6) INSTALLATION ______________________________________ 22
6-1 Wire Connections ________________________________ 22
6-2 Mounting on Tower_______________________________ 23
6-3 Final Connections ________________________________ 23
7) AIR BREEZE OPERATION _____________________________ 24-26
7-1 Operational Summary _____________________________ 24
7-2 Operating Modes ________________________________ 24
7-3 Voltage Regulation _______________________________ 25
7-3-1 Adjusting Regulation Voltage__________________ 25
7-3-2 Using an Alternate Charge Controller ___________ 25-26
8) MAINTENANCE ______________________________________ 26
9) TROUBLE SHOOTING ________________________________ 27
10) EXPLODED VIEWS & PARTS LIST ____________________ 28-29
11) EC DECLARATION OF CONFORMITY _________________ 30

6 Air Breeze Owner’s Manual
Hardware Warranty
Southwest Windpower, Inc., (“Southwest Windpower”) will repair or replace free of
charge any part or parts of the Southwest Windpower Air Breeze (Land or Marine) Wind
Turbine determined by Southwest Windpower to be defective in materials and/or work-
manship under normal authorized use consistent with product instructions for a period of
three years from the date the original purchaser (“Customer”) receives the Wind Turbine
(“Start Date”). This warranty extends only to the original purchaser. The Customer’s sole
and exclusive remedy and the entire liability of Southwest Windpower, its suppliers and
affiliates under the warranty is, at Southwest Windpower’s option, either (i) to replace
the Wind Turbine with new or reconditioned Wind Turbine; (ii) to correct the reported
problem; or (iii) to refund the purchase price of the Wind Turbine. Repaired or replaced
products are warranted for the remainder of the original warranty period.
Restrictions
Problems with the Wind Turbine Products can be due to improper use, improper main-
tenance, non-Southwest Windpower additions or modifications or other problems not
due to defects in Southwest Windpower’s workmanship or materials. No warranty will
apply if the Wind Turbine (i) has been altered or modified except by Southwest Wind-
power; (ii) has not been installed, operated, repaired, or maintained in accordance with
instructions supplied by Southwest Windpower; (iii) or (iv) has been exposed to winds
exceeding 120 mph (54 m/s), or has been subjected to abnormal physical, thermal
or electrical stress, misuse, negligence, or accident. If Southwest Windpower’s repair
facility determines that the problem with the Wind Turbine is not due to a defect in
Southwest Windpower’s workmanship or materials, then the party requesting warranty
service will be responsible for the costs of all necessary repairs and expenses incurred
by Southwest Windpower.
Warranty Claims & Return Procedures
In order to be eligible for service under this warranty, the Customer must submit a
service request for Wind Turbine covered by this warranty within the warranty period by
contacting Southwest Windpower in writing or via telephone and obtaining a Return
Authorization (“RA”) number. This RA must be obtained before returning any product
under this warranty.
Notification must include a description of the alleged defect, the manner in which the
Wind Turbine was used, the serial number, and the original purchase date in addition
to the name, address, and telephone number of the party requesting warranty service.
Within 3 business days of the date of notification, Southwest Windpower will provide
the Customer with an RA number and the location to which the Customer must return
the defective Wind Turbine. Any Wind Turbine requiring warranty shall be transported
at the expense and risk of the party requiring warranty service, including but not limited
to proper packaging of the Product. The Customer must return the entire Wind Turbine
kit within 30 days after issuance of the RA number. Southwest Windpower will be
under no obligation to accept any returned Wind Turbine that does not have a valid RA
number. Customer’s failure to return the Wind Turbine within 30 days of its receipt of
an RA number may result in cancellation of the RA. All parts that Southwest Wind-
power replaces shall become Southwest Windpower’s property on the date Southwest
Windpower ships the repaired Wind Turbine or part back to the Customer. Southwest
Windpower will use all reasonable efforts within five days of receipt of the defective
Wind Turbine to repair or replace such Wind Turbine. If a warranty claim is invalid for
any reason, the Customer will be charged at Southwest Windpower’s then-current
rates for services performed and will be charged for all necessary repairs and expense
incurred by Southwest Windpower.
Disclaimer
EXCEPT FOR THE EXPRESSED WARRANTY SET FORTH ABOVE, SOUTHWEST
WINDPOWER DISCLAIMS ALL OTHER EXPRESSED AND IMPLIED WARRAN-
TIES, INCLUDING THE IMPLIED WARRANTIES OR FITNESS FOR A PARTICULAR
PURPOSE, MERCHANTABILITY AND NON-INFRINGEMENT. NO OTHER WAR-
RANTY, EXPRESSED OR IMPLIED, WHETHER OR NOT SIMILAR IN NATURE TO
ANY OTHER WARRANTY PROVIDED HEREIN, SHALL EXIST WITH RESPECT TO
THE PRODUCT SOLD UNDER THE PROVISIONS OF THESE TERMS AND CON-
DITIONS. SOUTHWEST WINDPOWER EXPRESSLY DISCLAIMS ALL LIABILITY
FOR BODILY INJURIES OR DEATH THAT MAY OCCUR, DIRECTLY OR INDIRECT-
LY, BY USE OF THE PRODUCT BY ANY PERSON. ALL OTHER WARRANTIES ARE
EXPRESSLY WAIVED BY THE CUSTOMER.
Limitation of Liability
UNDER NO CIRCUMSTANCES WILL SOUTHWEST WINDPOWER OR ITS AFFIL-
IATES OR SUPPLIERS BE LIABLE OR RESPONSIBLE FOR ANY LOSS OF USE,
INTERRUPTION OF BUSINESS, LOST PROFITS, LOST DATA, OR INDIRECT, SPE-
CIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES OF ANY KIND REGARD-
LESS OF THE FORM OF ACTION, WHETHER IN CONTRACT, TORT (INCLUDING
NEGLIGENCE), STRICT LIABILITY OR OTHERWISE, RESULTING FROM THE DE-
FECT, REPAIR, REPLACEMENT, SHIPMENT OR OTHERWISE, EVEN IF SOUTH-
WEST WINDPOWER OR ITS AFFILIATE OR SUPPLIER HAS BEEN ADVISED
OF THE POSSIBILITY OF SUCH DAMAGE. (Note: some states and provinces
do not allow the exclusion or limitation of incidental or consequential damages, so
these limitations may not apply to you.) Neither Southwest Windpower nor its affiliates
or suppliers will be held liable or responsible for any damage or loss to any items or
products connected to, powered by or otherwise attached to the hardware. The total
cumulative liability to Customer, from all causes of action and all theories of liability, will
be limited to and will not exceed the purchase price of the Product paid by Customer.
This warranty gives the Customer specific legal rights and the Customer may also have
other legal rights that vary from state to state or province to province.
Air Breeze 3-Year Limited Warranty
3-CMLT-1331 REV NC 10-07
WIND TURBINE WARRANTY AGREEMENT

Air Breeze Owner’s Manual 7
Air Breeze Technical Specifications
Model Air Breeze
Weight 13 lb / 6 kg
Rotor Diameter 46 in / 1.17 m
Start Up Wind Speed 6 mph / 2.7 m/s
Kilowatt Hours/month 38 kWh/month @ 12 mph / 5.4 m/s avg. wind speed
Maximum Wind Speed 110 mph
Rated Power 200 watts @ 28 mph / 12.5 m/s wind speed
Certifications: CSA (certificate 1954979)
12 volt and 24 volt Air Breeze wind turbines are eligible to bear the CSA mark with “C” and
“US” indicators. The “C” and “US” indicators signify that the product has been evaluated to
the applicable CSA and ANSI/UL standards for use in Canada and the US.
Voltage Regulation Set Point (factory setting)
12 Volt Systems 14.1 Volts
24 Volt Systems 28.2 Volts
48 Volt Systems 56.4 Volts
Regulator Adjustment Range
12 Volt Systems 13.6 to 17.0 Volts (approximately)
24 Volt Systems 27.2 to 34.0 Volts (approximately)
48 Volt Systems 54.4 to 68.0 Volts (approximately)
Recommended Fuse Size
12 Volt Systems 20 amp (slow blow)
24 Volt Systems 10 amp (slow blow)
48 Volt Systems 5 amp (slow blow)
Tower Loads
Shaft Thrust* 52 lb @ 100 mph wind speed (230 N @ 45 m/s)
*Value does not include safety factor. SWWP recommends safety factor of 1.5.
26.6 in (67.5 cm) 46 in
(1.15 cm)
2.0 in
(5 cm)
22.5 in (56 cm)
minimum safe pole
length above
obstructions
24.5 in radius
(61 cm)

8 Air Breeze Owner’s Manual
Your Air Breeze is delivered partially assembled. Assembly requires mount-
ing the blades on the blade hub, securing the hub to the turbine body and
installing the nosecone on the blade hub. The necessary hex key (Allen)
wrenches are furnished with Air Breeze.
Torque Specifications:
Blade to hub screw, 1/4 - 20 x 1.25, socket head screw 10 ft-lbs (13.6 Nm)
Hub to rotor nut, 5/8-18, 50 ft-lbs (68 Nm)
Yaw clamp bolts, M5-0.8 x 35 mm 6 ft-lbs (8 Nm)
Start the assembly by mounting the blades (Item1) to the blade hub as
shown in Fig. 1. Place a nylock nut (Item 4) in the hexagonal detent on the
back of the blade hub while positioning the blade on the hub.
The blades must be “tilted” into position on the hub and can only be
installed in one orientation.
Place a washer (Item 2) on a 1/4 - 20 socket head screw (Item 3) and
coat the screw threads with Tef-Gel. Pass the screw through the base of
the blade and screw it into the nylock nut. Tighten the screw to 10 ft-lbs
(13.6 Nm). Repeat for the remaining two blades. Nylock nuts may only be
used one time; replace after each use.
If Air Breeze is to be installed on a “tilt-up” tower, mount the blade/hub
assembly to the turbine now. Coat the alternator rotor shaft threads and
blade hub bore with Tef-Gel and slide the hub onto the shaft. Start the
5/8-18 hub nut on shaft threads and “spin” the hub completely onto the
turbine alternator shaft. Fully tighten the hub to 50 ft-lbs (68 Nm) by
inserting a 5/16 inch hex key wrench in the turbine alternator shaft and
turning the shaft while turning the blades.
If Air Breeze is to be installed after the
tower is erected, it will be safer and
easier to first install the turbine body on
the tower and then install the hub/blade
assembly. This will avoid attempting to
mount the turbine while the blades are
spinning – a dangerous condition.
Snap the nosecone into position over the outside edges of the blade hub.
Make sure all three edges of the nosecone snap over the edge of the
blade hub. After installation tug on the nosecone to make sure it is secure-
ly attached.
3
1
2
4
1- blades
2- washer
3- 1/4 - 20 socket head screw
4- nylock nut
Two - Air Breeze Turbine Assembly
IMPORTANT: Tef-Gel is a corrosion inhibitor and
is especially important in marine applications.
WARNING: Don’t
attempt to mount the
turbine while blades
are spinning.
Fig. 1 Air Breeze Blade Attachment Detail.

Air Breeze Owner’s Manual 9
Small changes in wind speed can have a dramatic effect on power produc-
tion. The siting of your wind turbine should be carefully considered. Each
installation is different and is often a compromise among tower height, dis-
tance from the battery bank, local zoning requirements and obstacles such
as buildings and trees.
In general the higher the tower, the greater the wind speed and ultimately
power production. However, towers are expensive and can easily exceed
the cost of the turbine.
The minimum recommended tower height is 25 ft (7.6 m) on open ground
or 20 ft (6 m) above nearby obstructions. (Fig. 2) Try to locate the wind
turbine in the “cleanest” turbulent free air as possible. Turbulence will
reduce the efficiency of the wind turbine and may accelerate wear on rotat-
ing components.
Safety must be the primary concern when selecting the mounting location. Install
Air Breeze so there is no possibility of accidental contact with rotating blades even
if it requires installing the wind turbine in a less than ideal location. Safety has pre-
cedence over efficiency.
Three - Air Breeze Siting
WARNING: Install Air Breeze so there is no
possibility of accidental contact with rotating
blades even if it requires installing the wind
turbine in a less than ideal location.
20 feet (6 m)
Prevailing wind
Fig. 2 Optimal Air Breeze location.
(6 m)

10 Air Breeze Owner’s Manual
The Air Breeze is designed to mount on tubing or pipe with a nominal
1.875 – 1.900 inch outside diameter. This dimension enables constructing
a tower from a range of readily available materials including 1 1/2 inch
Schedule 40 steel pipe and 2 inch SS-20 galvanized fence tubing (0.090
inch wall thickness). Under no circumstances should plastic pipe be used
to construct a tower.
Four - Air Breeze Towers
WARNING: Plastic pipe should NEVER be used to construct a tower.
Fig. 3. Tower Options
29 ft (8.8 m) Tower
27 ft (8.3 m) Tower
4-1 Tower Options
Southwest Windpower offers a number of tower choices for Air Breeze.
The following section provides a summary of the available towers. User
manuals for the towers and tower kits are available online and you are
encouraged to review them in order to make the most informed
tower selection. See Fig. 3.
IMPORTANT: User manuals for towers and tower kits
are available online at www.windenergy.com. Southwest
Windpower recommends reviewing them to make an
appropriate tower selection for your Air Breeze.
45 ft (13.7 m) Tower

Air Breeze Owner’s Manual 11
Fig. 5. 29 ft (8.8 m) Tower Kit
4x
4x
4x
x8
29'EZ TOWER KIT
x16
Fig. 4. 27 ft (8.3 m) Tower Kit
x8
27' AIR TOWER
x4
x2
4-1-1 27 ft (8.3 m) Tower Kit
(Southwest Windpower part number 1-TWA-10-01)
The 27 ft (8.3 m) Tower Kit includes a tower clamp/guy wire assembly
and all necessary hardware and fasteners to erect a 27 ft tilt-up tower
using Schedule 40 steel pipe or tubing with an outside diameter of
1.875 inch. See Fig. 4.
Note: Anchors and pipe or tubing are not furnished with the kit so
you have the flexibility to use the most appropriate components
for the installation.
4-1-2 29 ft (8.8 m) EZ – Tower
(Southwest Windpower part number 1-TWA-11-01)
The 29 ft (8.8 m) EZ Tower is a complete kit that includes all materials required
to assemble a 29 ft guy wire tilt-up tower. Anchors, guy wire assemblies, galva-
nized steel tubing and all fasteners are included with the kit. See Fig. 5.

4-1-4 Marine Tower Kit
(Southwest Windpower part number 1-TWA-20-02)
The Marine Tower Kit is specifically designed to aid mounting
the turbine on a boat deck. Kit includes powdercoated alu-
minum mast and stays, vibration damping mounts and all necessary
marine grade hardware to install the kit. See Fig. 7.
12 Air Breeze Owner’s Manual
3x
8x
45' AIR TOWER
16x
x2
Fig. 6. 45 ft (13.7 m) Tower Kit
4-1-3 45 ft (13.7 m) Tower Kit
(Southwest Windpower part number 1-TWA-10-02)
The 45 ft (13.7 m) Tower Kit includes tower clamp/guy wire assemblies and all
necessary hardware and fasteners to erect a 45 ft tilt-up tower using Schedule
40 steel pipe or tubing with an outside diameter of 1.875 inch. See Fig. 6.
IMPORTANT: User manuals for towers and tower kits are available online
at www.windenergy.com. Southwest Windpower recommends reviewing them
to make an appropriate tower selection for your Air Breeze.
Fig. 7. Marine Tower Kit
Note: Anchors and pipe or tubing are not furnished with the kit so you have
the flexibility to use the most appropriate components for the installation.

Air Breeze Owner’s Manual 13
IMPORTANT: User manuals for towers and tower kits are available online
at www.windenergy.com. Southwest Windpower recommends reviewing
them to make an appropriate tower selection for your Air Breeze.
4-1-5 RV Tower Kit
(Southwest Windpower part number 1-TWA-12)
The RV Tower Kit is a telescoping tower system specifically designed
for use with an RV. The un-extended tower is approximately 6.5 ft (2
m) tall and extends to a height of 25 ft (7.6 m) using a twist and lock
mechanism. The tower also folds for easy storage. See Fig. 8.
Fig. 8. RV Tower KitClose-up of RV Tower Kit

14 Air Breeze Owner’s Manual
Ground
Chassis
Rod
Ground
Tower Ground
Battery
Black Lead
Turbine Negative
Red Lead
Disconnect
Turbine Positive
Fuse or
Breaker
Box
Switch
User Power
Stop
Center Junction
Turbine Ground
Green Lead
Earth Ground
Battery Bank
Tower
Amp
Meter
AIR BREEZE
Wind Turbine
Generator
Five - Air Breeze Wiring Options
The recommended way to connect the turbine to your battery bank
is to wire the turbine directly to its own set of battery posts. This will
allow the turbine to operate independently. The Air Breeze’s internal
regulator will monitor the battery and maintain the charge as neces-
sary. Figs. 9 and 10 represent typical single turbine installations.
Fig. 10 includes an up-tower junction box for UL (Underwriters
Laboratory) compliance. Contact Southwest Windpower for more
information about this configuration.
TIP: Wire turbine directly to
battery bank to its own set of
battery posts.
Fig. 9. Single Turbine Installation

Air Breeze Owner’s Manual 15
User Power
Red Lead
Disconnect
Battery
Green Lead
Switch
Earth Ground
Stop
Turbine Ground
Amp
Meter
Black Lead
Turbine Negative
Earth Ground
Battery Bank
Box
Lightning Arrestor
Turbine Positive
Junction Box
Center Junction
Up-Tower
Tower
Chassis
Ground
AIR BREEZE
Wind Turbine
Generator
Fuse or
Breaker
Fig. 10. Single Turbine Installation with Up-Tower Junction Box
Fig. 10 represents a system with an Up Tower Junction Box.
The junction box may be installed close to the top of the tower
to ease installing a Lightning Arrestor or it may be mounted
close to the tower base and incorporate the stop switch.
Typically installing the box will require drilling holes in the
tower to install the box – be careful not to compromise the
tower strength.

16 Air Breeze Owner’s Manual
Stop
Breaker
Wind Turbine Generato
r
Switch
Black Lead
Turbine Negative
Red Lead
Turbine Positive
Battery
Disconnect
Fuse or
User Power
Box
Center Junction
Turbine Ground
Green Lead
Earth Ground
Battery Bank
Tower Ground
Ground
Chassis
Rod
Ground
Disconnect
Battery
Meter
Amp
Controller
Diversion Load
Load
(Optional)
Resistive
Meter
Amp
Controller
PV Solar Array
PV Charge
AIR BREEZE
Tower
Fuse or
Breaker
Fig. 11. Hybrid System with Solar Panels
5-1 Hybrid System Wiring
Fig. 11 represents a typical “hybrid”
system with solar panels. Some charg-
ing sources (solar panels, fuel-powered
generators, additional wind generators,
etc.) connected to the same system
may cause interference with the Air
Breeze internal electronics and result
in pre-regulation. The interference will
not harm the turbine; it will just cause
it to spin slowly as if “braked” or it may
stop the turbine. If this occurs, test for
possible interference by disconnecting
the other charging sources to determine
the possible cause. If possible wire the
turbine and PV panels to their own set
of battery posts.
TIP: In this figure the Air Breeze
internal regulator is used. A
diversion type external regulator
could also have been used.
TIP: Voltage “pre-regulation”
may be prevented by increasing
the regulation set point. See
section 7-3-2.

Air Breeze Owner’s Manual 17
Switch
Stop
Battery Bank
Earth
Ground
Generator
Green Lead
Tower Ground
Turbine Ground
Black Lead
Turbine Negative
Red Lead
Turbine Positive
AIR BREEZE
Wind Turbine
Tower
Ground
Rod
Fuse
or
Breaker
Red Lead
Turbine Negative
Black Lead
Green Lead
Turbine Positive
Generator
Stop
Switch
Turbine Ground
AIR BREEZE
Wind Turbine
Tower Tower Ground
Fuse
or
Breaker
Turbine Positive
Meter
Generator
Tower Ground
Stop
Green Lead
Switch
Red Lead
Turbine Ground
Amp
Black Lead
Turbine Negative
AIR BREEZE
Wind Turbine
Tower
Battery
Disconnect
Fuse
or
Breaker
Fuse
or
Breaker
Fig. 12. Multiple Air Breeze Wiring
5-2 Multiple Air Breeze Wiring
Method One:
Each Air Breeze is treated
separately. Each turbine
will have its own wires, stop
switch and fuse and will
connect directly to the
battery using the internal
regulator to control
charging.
Method Two:
Wire each turbine to a “bus”
and then run one set of
wires from the bus to the
battery. Each turbine’s inter-
nal regulator or an external
diversion type regulator may
be utilized. A “bus” system
typically results in reduced
wire costs.
It is possible to wire multiple
Air Breeze turbines together.
A typical multi-turbine system
is depicted in Fig. 12.
There are two methods used
to accomplish this task.
Stop
Breaker
Wind Turbine Generato
r
Switch
Black Lead
Turbine Negative
Red Lead
Turbine Positive
Battery
Disconnect
Fuse or
User Power
Box
Center Junction
Turbine Ground
Green Lead
Earth Ground
Battery Bank
Tower Ground
Ground
Chassis
Rod
Ground
Disconnect
Battery
Meter
Amp
Controller
Diversion Load
Load
(Optional)
Resistive
Meter
Amp
Controller
PV Solar Array
PV Charge
AIR BREEZE
Tower
Fuse or
Breaker

18 Air Breeze Owner’s Manual
5-3 Wire Size
All electrical systems lose energy due to resistance in conductors: the wires.
• Large wires have less resistance but can be considerably more costly.
• Resistance losses will also increase with increasing current, therefore, if
yours is a high wind site, it may be worthwhile to go with a larger size wire
to take advantage of the greater power production potential of your site.
• Conversely, in low wind sites it may not be cost effective to increase the
wire size since power production will be low.
The following wiring sizes provide maximum annual energy losses of 5% or
less for sites with a 12 mph average wind speed (assuming the standard
Rayleigh distribution of wind speeds) which is sufficient for most sites.
To determine the size wire, measure the distance from the batteries to your
Air Breeze. Be sure to include height of the tower. Refer to the appropriate
chart for your system voltage and number of turbines and select the wire size.
We recommend these as the minimum wire sizes; for optimal performance
use the largest wires that are practical and affordable. Local, state, and na-
tional electrical codes have precedence over these recommendations and
must be followed to ensure the safety of your system.
Note: Wiring Resistance and Regulation
Depending on your exact system configuration including other charging
sources in your system, wiring resistance may affect the regulation set point
of the turbine. Higher wiring resistance (smaller wires) will tend to lower
the voltage at which the turbine enters regulation and stops charging. The
recommended wiring sizes should provide little effect on the regulation set
point, but all installations should be observed over time to ensure that the
batteries are charged to the proper voltage.
TIP: Smaller wires will lower the voltage at which
the Air Breeze enters regulation and stops charging.
Number of
Turbines:
0-30 ft
(0-9 m)
30 ft-60 ft
(9-18 m)
60 ft-90 ft
(18-27 m)
90 ft-150 ft
(27-46 m)
150 ft-190 ft
(46-58 m)
190 ft-250 ft
(58-76 m)
250 ft-310 ft
(76-95 m)
310 ft-390 ft
(95-119 m)
390 ft-500 ft
(119-152 m)
18/10 mm26/16 mm24/24 mm22/35 mm21/50 mm20/50 mm200/10 mm2000/90 mm2000/90 mm2
26/16 mm24/25 mm21/50 mm200/70 mm2000/90 mm20000/120 mm2*** *** ***
34/25 mm22/35 mm20/50 mm2000/90 mm20000/120 mm2*** *** *** ***
12 Volt Systems, AWG / Metric Wire Size mm2
*** If your system requires this length of wire, consider using parallel wires.
Number of
Turbines:
0-30 ft
(0-9 m)
30 ft-60 ft
(9-18 m)
60 ft-90 ft
(18-27 m)
90 ft-150 ft
(27-46 m)
150 ft-190 ft
(46-58 m)
190 ft-250 ft
(58-76 m)
250 ft-310 ft
(76-95 m)
310 ft-390 ft
(95-119 m)
390 ft-500 ft
(119-152 m)
114/2.5 mm212/4 mm210/6 mm28/10 mm26/16 mm24/50 mm24/10 mm24/90 mm22/90 mm2
212/4 mm28/10 mm26/16 mm24/25 mm24/25 mm22/35 mm22/35 mm21/50 mm20/50 mm2
310/6 mm28/10 mm26/16 mm24/25 mm22/35 mm22/35 mm21/50 mm20/50 mm200/10 mm2
24 Volt Systems, AWG / Metric Wire Size mm2

12mm
2
1
3
4
Air Breeze Owner’s Manual 19
5-4 Stop Switch (Southwest Windpower part number 2-ARAC-101)
MARINE USE:
A Stop Switch is
standard equipment
with the Marine
Breeze.
Fig. 14. Stop Switch Assembly
Southwest Windpower recommends the use of a stop switch to provide a
convenient method for shutting down your Air Breeze. A switch is supplied
with each Marine Breeze as standard equipment and is available for purchase
from Southwest Windpower for the Land Breeze.
Install and wire the switch as shown in Fig. 13. A “break then make” switch
must be used. The switch first disconnects the battery and then shorts the
turbine output wires together causing the turbine to stop spinning (in high
winds the blades may spin slowly). Shorting the turbine does not cause any
damage or additional wear on the unit.
The stop switch model offered by Southwest Windpower is sufficient for most
systems, but it should not be used in applications where a code compliant
switch is necessary.
48 Volt Systems, AWG / Metric Wire Size mm2
1. Use either the rubber sleeved nut or the knurled nut but do not use both.
2. Drill 12 mm (0.4725 in) hole in panel.
3. The backing jam nut may be adjusted to allow the switch to mount flush with
the panel.
4. No larger then 8 gauge wire should be connected directly to switch. Short
lengths (inches) of 8 gauge wire may be used as a transition to larger
gauge wire. Eye connectors are recommended.
5. Large gauge wire should be supported. The switch terminals
are not to bear the weight of the wire.
BATTERY
BLACK
FUSE
WIRE
SWITCH
TURBINE
STOP
RED
WIRE
Fig. 13. Stop Switch Wiring
Stop Switch Assembly
NOTE: The center post
must be positive from the
turbine. Outside posts can
be swapped as either
battery positive or battery/
turbine negative.
Number of Turbines: 0-90 ft (0-27 m) 90 -250 ft (27-76 m) 250 -310 ft (76-95 m) 310 -500 ft (95-152 m)
1 14/2.5 mm212/4 mm210/6 mm28/10 mm2
2 12/4 mm28/10 mm26/16 mm24/25 mm2
3 10/6 mm28/10 mm26/16 mm24/25 mm2

20 Air Breeze Owner’s Manual
5-5 Fuses, Circuit Breakers and Ammeter
Air Breeze is capable of producing high amperages. As with all electrical
installations, you must protect each of your turbines with a fuse or circuit
breaker. Wire Air Breeze with an appropriate size “slow-blow” fuse or circuit
breaker between it and the batteries. Refer to installation figures at the start
of Section 5. If a stop switch is used, the fuse or circuit breaker should be
placed between the switch and the batteries.
Recommended Sizes for Circuit Breakers or Slow-Blow Fuses
• 12-volt model: 20 amps D.C.
• 24-volt model: 10 amps D.C.
• 48-volt model: 5 amp D.C.
Circuit Breakers are available from Southwest Windpower. Part numbers are
listed below.
5-6 Batteries
There are many battery choices available – flooded lead acid, absorbed
glass mat (AGM), gel cell and NiCad. The type of battery utilized will de-
pend largely on the battery bank location and cost. For battery installations
where fumes can be safely ventilated and the potential for acid leakage
accommodated, the flooded lead acid battery is typically the most economi-
cal choice.
Minimum recommended battery bank size:
• 12-volt systems – 400 Amp-hours
• 24-volt systems – 200 Amp-hours
• 48-volt systems – 200 Amp-hours
There are several informative web sites with battery information including:
• www.batterycouncil.org
• www.windsun.com/Batteries/Battery_FAQ.htm
Fig. 16 Ammeter
(Amp Meter)
PN 2-ARAC-102
Fig. 15 Circuit Breaker
30A: PN 2-ARAC-103
50A: PN 2-ARAC-104
IMPORTANT: Never use “automotive” batteries or any battery
other than a “deep-cycle” battery.
5-7 Turbine Grounding
Proper grounding of the Air Breeze provides protection to individuals and
equipment by eliminating the possibility of dangerous voltage potentials.
There are two aspects to grounding any electrical system – grounding one of
the conductors of the electrical system and grounding all metal structures in
the system that may have a voltage potential caused by an electrical failure.
In a typical Air Breeze installation grounding one of the conductors is ac-
complished by connecting the Air Breeze negative (black) conductor to
an “earth” ground close to the battery bank. Installation and connection to
grounding rods is described in the following section on Tower Grounding.
Grounding the metal structures in the system – typically this includes the
tower and turbine – is accomplished by connecting the structures together
using conductors of the same size as the positive and negative conductors
and then routing a conductor to an earth ground.
While not necessary, an ammeter (sometimes called an Amp Meter) is an
excellent addition to any system. The Amp Meter allows you to monitor the
current output of your turbine. Place it in between your turbine and the bat-
tery on the positive lead. It will give you instantaneous readings of output in
amps.