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

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1. SAFETY PRECAUTIONS
The AIR-X has been designed with your safety in mind. However, there are inherent dangers
involved with any electrical and/or mechanical equipment.
Safety must be the primary concern as you plan the location, installation and
operation of the turbine. At all times be aware of electrical, mechanical and rotor blade
hazards.
1.1 Mechanical Hazard
Rotating blades present the most serious mechanical hazard. The AIR X’s rotor blades are
made of very strong thermoplastic. At the tip, the blades may be moving at velocities over
275 miles per hour (440 km/hr). At this speed, the tip of a blade is nearly invisible and can
cause serious injury. Under no circumstances should you install the turbine where a
person could come in contact with moving rotor blades.
CAUTION: DO NOT INSTALL THE TURBINE WHERE ANYONE CAN APPROACH
THE PATH OF THE BLADES.
1.2 Electrical Hazards
The AIR-X is equipped with sophisticated electronics designed to provide protection from
overcurrent electrical dangers. The internal electronics of the AIR-X prevent open circuit
voltages from rising above 20 volts for 12-volt systems or above 40 volts for 24-volt systems.
Please note that the inherent personal dangers from electrical current still exist, therefore
caution should always be used when connecting this and other electrical devices.
Heat in wiring systems is often a result of too much current flowing through an undersized
wire or through a bad connection. It is important to follow the wire-sizing chart in Section
3.1.2 on page 10 to insure a safe electrical system.
CAUTION: FOLLOW THE WIRE SIZING CHART IN SECTION 3.1.2 ON PAGE 10
TO HELP AVOID THE RISK OF AN ELECTRICAL FIRE.
Batteries can deliver a dangerous amount of current. If a short occurs in the wiring from the
batteries, a fire can result. In order to avoid this threat, a properly sized fuse or circuit breaker
is required in the lines connecting to the battery. Refer to Section 3.1.4 on page 12 for fuse
sizing information.
CAUTION: FUSE ALL CONNECTIONS. FOLLOW THE FUSE SIZING GUIDELINES
IN SECTION 3.1.4 ON PAGE 12 TO MINIMIZE THE RISK OF FIRE AND/OR AN
ELECTRICAL FAILURE.

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1.3 Installation
CAUTION: INSTALLATION PROCEDURES SHOULD BE PERFORMED AT
GROUND LEVEL.
CAUTION: MAKE SURE THAT ALL BATTERIES ARE DISCONNECTED
THROUGHOUT THE INSTALLATION PROCESS.
CAUTION: NEVER INSTALL THE AIR-X UPSIDE DOWN.
Please follow these precautions during the installation process:
• Choose a calm day.
• THINK SAFETY! Have someone available to help during the installation process.
• Disconnect batteries from turbine wiring.
• Prior to attaching the wires to the battery, tie the wind turbine output lead wires (positive
= red; negative = black) together near the battery to be sure that the rotor will not spin-up
during installation.
NOTE: Do not install the blade assembly until the turbine is mounted on the tower.
1.4 Operation
Check support structures, blades, and electrical systems on a regular basis.
• The rotor blades are very strong; however, if they come in contact with a solid object,
they can break. Use common sense about safety when locating the turbine.
• When performing periodic inspections, or at anytime when you must approach the path of
the blades, disconnect the power leads from the battery and tie the wind turbine output leads
together to stop (slow down) the blades from rotating. The turbine can also be shut down
through the use of a stop switch. Please refer to Figure 2 on page 12 on how to install a stop
switch in your system.
• Please note that there is a short break-in period with new turbines. The bearings in both
the turbine yaw and the turbine rotor will require approximately 60-100 hours of operation in
normal wind speeds (approximately 18 – 20 mph, 8 – 9 m/s) before they are running at peak
efficiency. During this break-in period, the turbine operation might appear sluggish.
CAUTION: NEVER APPROACH THE TURBINE DURING OPERATION.
USE COMMON SENSE AND PLEASE BE CAREFUL

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2. PACKAGE CONTENTS
Compare the parts shown in Figure 1 to ensure that the contents of the box contain all
necessary parts.
CAUTION: THE EDGES OF THE ROTOR BLADES ARE SHARP. PLEASE
HANDLE WITH CARE.
Figure 1
5/16” Hex Key
3/16” Hex Key
5/32” Hex Key
Yaw
Shaft
LED
Main Body
A
lternator Shaft
Hub
Nose Cone
¼” Socket Head Cap Screw (6)
¼” – 20 Nut (6)
Rotor Blades (3)
AIR-X
Owner’s Manual

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3. WIRING AND INSTALLATION PROCEDURES
Your AIR-X is shipped partially disassembled. Refer to Figure 7 on page 19 for assembly
instructions. Please completely read all procedures before beginning installation.
NOTE: Do not install the blade/hub assembly until the turbine is mounted on the tower
Required Tools:
• 5/16” hex key wrench (included)
• 3/16” hex key wrench (included)
• 5/32” hex key wrench (included)
• Torque wrench with 5/16”, 3/16”, and 5/32” hex drives (optional)
• Soldering iron or propane torch
• Rosin core solder
• Electrical tape or 1/4” (6-7mm) heat shrink
• Wire strippers
• Wire crimpers
3.1 Wiring
3.1.1 Electrical Connections
NOTE: Refer To All Local and National Codes Before Installation.
CAUTION: MAKE SURE THE TURBINE IS DISCONNECTED FROM THE
BATTERIES DURING INSTALLATION.
Avoid connecting different metals together (i.e., copper and aluminum). This will cause a
galvanic cell that will erode one of the metals. When such connections cannot be avoided,
consult your dealer or an electrical supply house for anti-oxidant compounds. If possible
solder wire termination ends.
CAUTION: CONNECTIONS SHOULD BE INSPECTED PERIODICALLY FOR
SIGNS OF CORROSION AND CLEANED WHEN NECESSARY.
NOTE: All electrical power cables should be physically protected. Run the wires inside the
tower or conduit for maximum protection.
NOTE: The yaw can support a total of 150 lbs. (68 kg) in wire weight. For higher wire
weights, you must install a strain relief to minimize the stress put on the hanging wires. The
average weight of copper wire is .323 lb/in3 or 8941 kg/m3. Use the table below multiplied by
length multiplied by the number of wires to calculate the approximate weight of your wiring
system.

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A
WG SIZE 14 12 10 8 6 4 3 2 1 0 2/0 3/0 4/0
X-Section
A
rea [in2]
0.004 0.005 0.008 0.013 0.021 0.033 0.041 0.052 0.069 0.083 0.105 0.132 0.166
X-Section
A
rea [mm2]
2.68 3.31 5.26 8.37 13.3 21.1 26.7 33.6 44.2 53.5 67.4 85.0 107
Wire Color Codes
RED = positive
BLACK = negative
GREEN = earth ground
3.1.2 Wire Size
To select the appropriate size wire, measure the distance from the batteries to your AIR-X,
then refer to the following wire sizing chart as minimum sizes. If cost is not an issue, a larger
sized wire will improve the performance of your AIR-X.
All electrical systems lose energy from the resistance of the wires used. Larger wiring sizes
have smaller losses, but can be considerably more costly. The following wiring sizes provide
maximum annual energy losses of 5% or less for sites with a 12mph average wind speed
(assuming the standard Rayleigh distribution of wind speeds,) which is sufficient for most
sites. If you know your average wind speed to be different, compensate the wiring
LENGTHS given in the charts using the factors given at the end of this section. Table entries
with a “*” denote cases which should use additional bus lines.
We recommend these as the minimal wire sizes; for optimal performance you should use the
largest wires that are practical and affordable. Local, state, and national electrical codes
supercede these recommendations, and should be followed to insure the safety of your
system.
12V AIR-X: Wire Size, Considering 12mph (5.2 m/s) Wind Average and 95% Energy
Transmission Efficiency. Wire Size: AWG / sq mm
# Turbines 0-30ft 30ft-60ft 60ft-90ft 90ft-150ft 150ft-190ft 190ft-250ft 250ft-310ft 310ft-390ft 390ft-500ft
1 8g/8 6g/13 4g/21 2g/34 1g/53 0g/53 00g/67 000g/85 000g/85
2 6g/13 4g/21 1g/44 00/67 000g/85 0000g/107 * * *
3 4g/21 2g/34 0g/53 000g/85 0000g/107 * * * *
Fuse: 50 Amp Slow-Blow per turbine
* If your system requires this length of wire, consider using additional, parallel wire(s).
24V AIR-X: Wire Size, Considering 12mph (5.2 m/s) Wind Average and 95% Energy
Transmission Efficiency. Wire Size: AWG / sq mm
# Turbines 0-30ft 30ft-60ft 60ft-90ft 90ft-150ft 150ft-190ft 190ft-250ft 250ft-310ft 310ft-390ft 390ft-500ft
1 14g/2.7 12g/3.3 10g/5.3 8g/8 6g/13 4g/21 4g/21 4g/21 2g/34
2 12g/3.3 8g/8 6g/13 4g/21 4g/21 2g/34 2g/34 1g/44 0g/53
3 10g/5.3 8g/8 6g/13 4g/21 2g/34 2g/34 1g/44 0g/53 00g/67
Fuse: 30 Amp Slow-Blow per turbine