AIR-X LAND 400 User manual

The New 400 watt turbine!
Owner’s Manual
Wind Turbine Serial Number ___________________________________
REPS
Renewable Energy
Production Solutions
Bockholm, 21760 Houtskär
www.reps.fi, [phone]

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NOTICES:
• This information is believed to be reliable; however, Southwest Windpower, Inc. assumes
no responsibility for inaccuracies or omissions. The user of this information and product
assumes full responsibility and risk.
• All specifications are subject to change without notice.
• Wind generators, like other sources of electrical power, must be installed following the
guidelines established by state and local regulations. Consult a local electrical contractor or
the local planning and zoning office for details and regulations.
• For your convenience and protection write the serial number of your wind turbine on the
front of this manual. Store your purchase invoice with this manual as well. You will need this
information in the event of a warranty claim. It also helps the customer service department at
Southwest Windpower when you have questions about your specific turbine. Thank you.
Made in the USA by:
Southwest Windpower, Inc.
1801 W. Route 66
Flagstaff, Arizona 86001
Toll Free Phone: [phone]
Phone: [phone]
Fax: [phone]
E-mail: [email protected]
Web: www.windenergy.com
AIR, AIR 403, AIR-X and AIR Wind Module are trademarks of Southwest Windpower
 2002 Southwest Windpower, Inc.

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CONGRATULATIONS!
You have just purchased the most advanced battery charging wind turbine in the world!
We believe you will find it easy to install your AIR-X; however, it is important that you read
this entire manual thoroughly prior to installation to assure proper performance and safety.
Southwest Windpower has over 12 years of experience in designing and manufacturing
small wind generators. In just five years, over 45,000 AIRs have been sold throughout the
world.
What makes the AIR-X unique in comparison to other turbines is the use of state-of-the-art
technology like Iron Boron Neodymium magnets, carbon reinforced engineering
thermoplastics, high-quality aluminum castings, stainless steel hardware and integrated,
microprocessor based control electronics. The turbine comes standard with a built-in voltage
regulator, quiet computer controlled stall of the blades in high winds, and the best global
warranty program in the industry.
The AIR-X is for use in applications where salt corrosion is not expected to be a concern.
The AIR-X Marine is designed for offshore and or land-based coastal applications.
If you have any questions after thoroughly reading the manual, please contact your
authorized distributor/dealer or Southwest Windpower, Inc.
Enjoy.

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New Features of the AIR-X
The AIR-X is the latest evolution of the AIR series of wind turbines from Southwest
Windpower. From the outside, the AIR-X looks almost identical to the AIR 303 and AIR
403. The improvements are almost all inside the turbine.
The AIR-X Features:
• New Electronics: The AIR-X incorporates an entirely new rectifier and controller. The
microprocessor based controller provides voltage regulation, peak power tracking, and
quiet, stall control in high winds. The AIR-X uses a synchronous rectifier bridge which
results in cooler, more efficient operation. The AIR-X also incorporates a voltage
boosting function which allows the turbine to reach charging voltage at a much lower
RPM.
• New Alternator: A more efficient alternator has been built into the AIR-X. The
alternator was designed to complement the peak power tracking ability of the control
electronics. The alternator uses a larger wire size than that of the AIR 403, and thus has
lower internal resistance. The result is cooler operating temperatures for improved
reliability. The strong permanent magnet rotor can be felt in rotating the rotor shaft; a
slight “catch” can be felt when spinning the shaft with your fingers. This is normal, and is
quickly overcome when the blades begin spinning.
• New Blades: The rotor blades use a highly efficient, true airfoil. They are manufactured
using a precision injection molding process that produces blades of exceptional
consistency. The result is quieter performance and minimal vibration. The AIR-X blades
differ from the AIR 403 blades in their tip angles. The AIR-X blades have an increased
tip angle which improves their ability to start rotating, and moves “flutter” to higher wind
speeds. Unlike the AIR 403 and earlier 303, the AIR-X does not rely on blade flutter for
over-speed protection. The control electronics will slow the blades before the turbine
reaches the point of flutter. Increasing the tip angle helps to ensure that the flutter noise
is not heard.
• New Yaw Shaft: The yaw shaft is the part of the turbine that mounts to the tower and
allows the turbine to rotate into the wind. The AIR-X features a new yaw shaft that allows
for stronger clamping forces to the tower, and more rigidity in the turbine.
The AIR-X also retains these features of the AIR 403:
• Hysteresis Braking: The regulation control circuitry incorporates hysteresis. This will
lock the turbine in a silent regulation mode once the batteries are fully charged. The
turbine begins producing power again when the battery voltage drops slightly below fully
charged. This means, for a factory set 12V turbine, the turbine will regulate (shut down)
when the batteries have reached 14.1V, and will resume charging when the voltage
drops to 12.75V. Minimal output is wasted, as non-charging battery voltages above
12.75V represent mostly a “surface charge” with very little energy. This feature prevents
the turbine from fluctuating in and out of regulation mode, resulting in a quieter, better-
behaved machine.
• New Body, New Hub: The AIR-X body is made from a precision casting process that
not only enhances fit and finish, but also leads to a stiffer, more durable body. The
aluminum casting also acts as a heat sink and transfers heat from the stator and the
electronics into the wind flowing past the turbine. The die cast aluminum hub design has
been engineered to be the strongest, stiffest hub we have ever produced.

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Table of Contents
1. Safety Precautions……………………………………………………….. 6
1.1 Mechanical Hazards 6
1.2 Electrical Hazards 6
1.3 Installation 7
1.4 Operation 7
2. Package Contents………………………………………………………… 8
3. Wiring and Installation Procedures……………………………………. 9
3.1 Wiring………………………………………………………………….. 9
3.1.1 Electrical Connections 9
3.1.2 Wire Size 10
3.1.3 Grounding 11
3.1.4 Fusing 12
3.1.5 Stop Switch 12
3.1.6 System Wiring Diagrams 13
3.2 Mounting to Tower………………………………………………… 18
3.2.1 Attaching to Pole 18
3.3 Hub and Rotor Assembly………………………………………… 19
3.3.1 Mounting Blades 19
3.3.2 Mounting Hub and Rotor 20
3.3.3 Attaching Nose Cone 20
3.4 Step-By-Step Instructions…………………………………………. 20
4. Testing………………………………………………………………………. 22
4.1 General Discussion of Operation…………………………………. 22
4.1.1 Alternator 22
4.1.2 Voltage Regulator 22
4.1.3 Over-Speed Protection 22
4.1.4 Five Spinning Conditions 23
4.2 Bench Testing………………………………………………………… 24
4.3 Performance Testing……………………………………………… 25
4.4 Adjusting the Internal Regulator………………………………….. 25
5. Trouble Shooting………………………………………………………….. 26
5.1 Assembly……………………………………………………………… 26
5.2 Electrical System………………………………….…………………. 26
5.3 Elevation………………………………….………………...…………. 27
6. Warranty Policy……………………………………………………………. 28
7. Specifications……………………………………………………………… 29
7.1 Technical Specifications 29
7.2 Performance Specifications 30
7.2 Sphere of Operation 31
7.3 Exploded View of AIR-X 31
8. Maintenance………………………………………………………………... 32
9. System Requirements and Considerations………………………… 32
9.1 Batteries 32
9.2 Regulator Options 33
10. Siting……………………………………………………………………….. 35
11. Towers……………………………………………………………………… 37
11.1 Guyed Towers 37
11.2 Roof Top Mounting 37
12. Frequently Asked Questions………………………………………….. 39
13. Accessories………………………………………………………………. 45
14. References………………………………………………………………… 47