Ampair AQUAIR 100 Instruction Manual

AQUAIR 100
TM
Operation Installation & Maintenance Manual
Manufactured by Ampair
®

Aquair 100
TM
Manual
Ampair
®
, 2007 www.ampair.com Page 2 of 23
CONTENTS
CONTENTS ................................................................................................................................2
SAFETY: READ BEFORE ASSEMBLING OR USING.................................................................3
Use..........................................................................................................................................3
Connection ..............................................................................................................................3
Protection ................................................................................................................................3
SYSTEM DESCRIPTION ............................................................................................................5
Introduction..............................................................................................................................5
The generator ..........................................................................................................................5
Water mode .............................................................................................................................5
Wind mode ..............................................................................................................................6
INSTALLATION...........................................................................................................................7
Water mode installation ...........................................................................................................7
Wind Mode Installation - Hoist In Rigging (HIR) .......................................................................9
Wind mode installation – Pole Mount.....................................................................................11
Wind mode installation – Stern Mount Kit...............................................................................13
ELECTRICAL INSTALLATION..................................................................................................14
CHARGE CONTROL REGULATION.........................................................................................15
Installation of charge control regulator ...................................................................................16
AQUAIR OPERATION & PERFORMANCE...............................................................................18
Operation – Water Mode:.......................................................................................................18
Operation – Wind Mode: ........................................................................................................18
MAINTENANCE AND SPARES ................................................................................................20
Inspection ..............................................................................................................................20
Major disassembly .................................................................................................................21
WARRANTY..............................................................................................................................23
SERVICING & REPAIRS...........................................................................................................23

Aquair 100
TM
Manual
Ampair
®
, 2007 www.ampair.com Page 3 of 23
SAFETY: READ BEFORE ASSEMBLING OR USING
Use
Avoid sailing in shallow water; through coral or weed; or near nets, lines, traps, pots, and buoys
with the Aquair in water mode.
When first using the Aquair in either wind or water mode it is advisable to do it in fairly calm
weather and low wind or water speeds.
WARNING: In either wind or water mode an Aquair is a piece of rotating equipment and
should be treated with care. Never allow it to become entangled in hair, clothing,
or equipment. It is capable of causing GRAVE INJURY and should be treated
with the same respect as a boat or aircraft propeller.
Connection
NEVER CONNECT WITHOUT RECTIFIERS
The generator must never be connected to a system without its rectifiers in circuit, to do so risks
discharging the battery to which it is connected.
CORRECT CONNECTION
It is important to connect the system in such a way that the generator cannot feed any electrical
load without the battery being connected. The generator output should therefore go to the
battery side of any isolator switch. Failure to observe this point could place over-voltage on the
system and damage sensitive electronic equipment.
Protection
PROTECTING THE SYSTEM
Do not omit the fitting of fuses, simple in-line fuse carriers maybe used in the battery line.
Fuses = 10 Amp - 12V systems: 5 Amp - 24V systems
OBSERVE POLARITY
Reverse polarity will blow the battery fuse or destroy the rectifiers if no fuse is fitted. When
wiring the system be aware that if the generator is connected to the battery REVERSE
POLARITY the output rectifiers may be destroyed or the internal soldered connections to the
brush holders may melt. Check and do ble-check polarity before final connection.
CORE 1 (formerly BROWN) = + Positive
CORE 2 (formerly BLUE) = - Negative.
DISCONNECTING THE GENERATOR
When disconnecting the generator please be aware that when it is spinning, the output voltage,
in the absence of a battery, will rise. This can give a mild electric shock to a person handling the
connections.
WHEN TO FIT A REGULATOR
It is advisable to fit a voltage regulator if the Aquair is regularly left to charge batteries when
insufficient or no loads are present. Under these conditions overcharge will slowly drive off the
battery electrolyte, which, if not topped up, will eventually damage the batteries.
CAUTION
When planning your installation, observe the following:
1. Avoid operating the Aquair with the tow rope skipping. If it is skipping the tow rope will
constantly jerk both the generator and mounting. If the boat is going this fast use the
coarse turbine.

Aquair 100
TM
Manual
Ampair
®
, 2007 www.ampair.com Page 4 of 23
2. Regularly inspect a newly installed system to check that all is well. Do not limit this to
monitoring the electrical output, but also check for smooth mechanical operation. Any
defects need to be remedied immediately.
3. Finally, in water mode, connect a safety line (well clear of the propeller) to save the
generator should it become detached from its mounting.

Aquair 100
TM
Manual
Ampair
®
, 2007 www.ampair.com Page 5 of 23
SYSTEM DESCRIPTION
Introduction
The Aquair 100 is a dual capability generator, which can be either water or wind driven. It is
capable of supplying up to 100 watts of electrical power at either 12 or 24 volts for charging
batteries.
The generator
This unit consists of a two-part cast aluminium body, the two parts sealed by an “O" ring. Two
six-pole magnetic rotors run with their poles in line on a stainless steel shaft. The shaft runs in
two sealed and grease packed ball bearings, with the front bearing protected by a shaft seal.
Two six-pole stators are arranged with their poles staggered at 30 degrees to minimise
“cogging” or break out torque and so allow easy starting. The unit is assembled with one stator
in the main body casting and the other in the nose casting. During assembly these are precisely
aligned on the test bench to give optimum performance. A small timing mark is made at the
junction of the case halves to allow accurate re-assembly. The AC output from each stator is
full-wave rectified by bridge rectifiers, one per stator. The DC output of the two rectifiers is
paralleled and passes to the output cable. The output is isolated from the case.
Water mode
In water mode the generator body is mounted in a stainless steel gimbal ring. The body pivots
on two stainless steel pins running in acetal (delrin) bushes. The pivot pins are retained in the
ring by two clevis pins.
Figure 1. Water Mode.
Gimbal Ring: The gimbal ring is attached to the boats stern pulpit, or other convenient
horizontal structure, by two lanyards, one at the top, one at the bottom. These lanyards must be
located by the fixings provided on the gimbal ring, at 90 degrees to the pivot axis. This
arrangement gives freedom to move about the horizontal axis due to the gimbal ring pivots and
about the vertical axis due to the lanyards. A permanent deck mount option is available (see
Figure 6).
Towed T rbine: This consists of an aluminium propeller mounted on a stainless steel shaft with
a “D” loop for rope attachment. This is attached to the generator by 30 metres (100 ft.) of 12mm
braid on braid polyester rope via a bow shackle and acetyl shaft connector. The shackle and
shaft connector are attached to the generator shaft by an M6 x 30mm stainless steel cap screw
with shake-proof washer. The shaft connector is made to break at a load of approx. 300kg
(700lb) to safeguard the generator in the event of the towed turbine being caught on rocks, coral
etc. For boats consistently exceeding 8 knots, a coarse pitch, towed turbine is available.

Aquair 100
TM
Manual
Ampair
®
, 2007 www.ampair.com Page 6 of 23
Wind mode
HOIST IN THE RIGGING
In wind driven mode the generator is
removed from its gimbal ring and fitted with
two swivel tubes containing PTFE bearings
in stainless steel swivels. These tubes are
located in the body positions previously
occupied by the gimbal pivot bushes. The
unit can then be hoisted aloft on a halyard
or other suitable hoist attached to the upper
swivel “D” ring. The lower swivel tube is tied
in a triangular arrangement by 3 ropes, to
provide stability.
POLE MOUNT
Alternatively, the generator can be pole
mounted using a pivot and bush
arrangement. In most respects this is the
same as the hoist in rigging kit (i.e. remove
the generator from the gimbal ring, add the
tail fin, and add the wind turbine blades)
except that the body fits into a pole mount
using a special adaptor.
Figure 2. Wind Mode Hoist in Rigging Figure 3. Wind Mode Pole Mount
Tail Vane: An aluminium alloy tail vane (tail fin) is attached to the rear of the generator body by three
M6x 6mm stainless steel screws with shake-proof washers and nuts. The vane is provided with a grab
hole at its lower rear corner to turn the unit crosswind to stop the wind turbine rotating.
Wind T rbine: This consists of six cambered and twisted compression moulded blades of glass-fibre
reinforced polypropylene. This material has exceptional fatigue resistance and retains its durability
down to sub-zero temperatures. The blades are factory selected for balance to less than a gram and
are delivered as colour coded matched pairs. The blades are retained by M8x40mm stainless steel
bolts with shake-proof washers and nuts, two of each per blade, in a hub assembly consisting of two
aluminium alloy plates mounted on a turned and anodised aluminium alloy hub centre piece. The hub
centre is bolted to the plates by three M6x40mm stainless steel screws with shake-proof washers and
nuts. The hub is fitted to the generator shaft by two M6x30mm stainless steel cap screws with shake-
proof washers. Three bungs in the front hub plate allow access to the shaft screws, one bung being
notched to clear the front cap screw head.

Aquair 100
TM
Manual
Ampair
®
, 2007 www.ampair.com Page 7 of 23
INSTALLATION
Water mode installation
Figure 4. quair 100 Towed Turbine NOTE Safety line not shown
KEY:
1. Generator Assembly 6. Shaft Connector 11. Pivot Pin(2)
2. Gimbal Ring 7. Bow Shackle 12. Pivot Bush (2)
3. Location Fasteners (2) 8. Fisherman’ s Bend 13. Clevis Pin (2)
4. Clove Hitch 9. Tow Rope 14. Standard Pitch Turbine
5. Shaft Fasteners 10. Lock Ring (2) 15. Coarse Pitch Turbine
(grooved)
PRE INSTALLATION CHECK
Check that a complete and undamaged set of parts has been received.
The Aquair 100 12v or 24v water generator set consists of the generator body, complete with shaft
connector and shackle mounted, by means of acetal bearings with stainless steel pivot pins, clevis pins
and locking rings, to a stainless steel gimbal ring. One standard pitch towed turbine and 30 metres (100
ft.) of 12mm braid on braid rope.
Conversion: If converting from wind operation, then proceed as follows: Assemble gimbal ring to
generator applying silicone grease to the acetal bushes to prevent them seizing in the body casting due
to salt build-up. Insert the pivot pins, clevis pins and locking rings, similarly greased.
WATER MODE INSTALLATION
Fitting to the Stern: Attach rope lanyards to gimbal ring top and bottom using the fixings as a means
of positive location (see figure 5) It is suggested that a clove hitch knot is used passing either side of

Aquair 100
TM
Manual
Ampair
®
, 2007 www.ampair.com Page 8 of 23
the fixing, otherwise the ring will slip around the rope. The lanyards should be as short as possible
consistent with freedom to twist, and secure the free ends. This will ensure self-alignment of the
generator shaft with the water turbine towrope. There has to be freedom to turn to port and starboard to
follow the boat, otherwise the bearings are excessively loaded. If the stern pulpit, or other structure
used as a mounting, is not robust and absolutely rigid, it is recommended that it be counter-braced to
some strong point on the boat in order to prevent damage should the tow rope and water turbine
become snagged. The generator and gimbal ring are designed to withstand an ultimate load of 450 kg
(1000 lb) and the shaft connector is designed to break at 300 kg (700 lb). Remember to se strong
eno gh lanyards and knots.
Figure 5. Lanyards
Tow T rbine: Attach the acetyl shaft connector and shackle to the Aquair shaft with the M6 cap screw
and shake-proof washer provided. Attach towrope to shackle and tow turbine, we suggest a fisherman’s
bend knot with the free ends whipped to the rope. These connections need to be neat and tidy to give
smooth operation avoiding extraneous noises and vibration.
Permanent Deck Mo nt: This is available for those wishing to make a fixed installation of the Aquair.
The unit consists of a welded stainless steel frame in which the Aquair is mounted. This provides a very
neat arrangement where the existing gimbal ring provides horizontal movement and the deck mount
pivots allow vertical movement. This allows the application of the Aquair where no stem rail or structure
is present, such as on a double-ended yacht or a catamaran. The unit is simply bolted through the
deck. Note that where possible it is preferable to mount the gimbal ring with lanyards which are both
cheaper and provide better shock absorption.
Figure 6. Stern Deck Mount.

Aquair 100
TM
Manual
Ampair
®
, 2007 www.ampair.com Page 9 of 23
Wind Mode Installation - Hoist In Rigging (HIR)
Figure 7. quair Wind kit Hoist in Rigging.
KEY:
1. Generator Assembly 6. Hub Plate (2) 11. Shaft Fasteners
2. Swivel Tube 7. Blade Fasteners (12) 12. Tail Vane
3. Swivel Tube Fasteners 8. Hub Fasteners (3) 13. Tail Vane Fasteners
4. Blade (6) 9. Hub Centre
5. Bung (3) 10. Guide Hole
PRE INSTALLATION CHECK
Check that a complete and undamaged set of parts has been received.
The Aquair HIR set contains six wind turbine blades packed as three colour-coded & balanced pairs;
one hub assembly complete with plastic bungs; two swivel poles; one tail vane; two hardware kits:
Kit 1: Wind blade fixings Kit 2: HIR fixings
12 M8 x 40mm hex bolts 2 M8 x 50mm hex bolts 1 5mm hexagon wrench
(Allen key)
12 M8 nuts 2 M8 nuts 3 M6 x 16mm screws
12 M8 shake-proof washers 2 M8 shake-proof washers 3 M6 shake-proof washers
2 M6 x 30mm cap screws 3 M6 plain washers
2 M6 shake-proof washers 3 M6 nuts

Aquair 100
TM
Manual
Ampair
®
, 2007 www.ampair.com Page 10 of 23
CONVERSION FROM TOW MODE TO WIND (for HIR kit):
Conversion: Find a suitable location for suspending the Aquair 100. The fore triangle is a safe area
away from the cockpit. Remove the locking rings from the clevis pins and remove clevis pins, and pivot
pins from the acetal bushes to release the generator. If stiff to remove, the bushes may be gently prised
out by introducing a small lever
through the holes in the sides of
the pivot housings and engaging
the groove in the bush. If
completely corroded in, then fill
centre hole with grease and use
pivot pin as a piston to knock into
hole and force bush out.
Otherwise, the bush will have to
be drilled out and replaced.
Remove the acetal shaft
connector.
Swivel Poles: Attach the swivel
poles to the generator “ears” using
the M8x50mm bolts, shake-proof
washers and nuts provided. Do not
fit the turbine and tail vane.
S spension: Partially hoist the
Aquair 100 to enable assembly of
the tail vane and wind turbine. To
minimise sway, connect the lower
swivel to the deck by three guys at
approximately 120 degrees to
each other, viewed from above.
Do not apply excessive tension
since this will result in rapid wear
of the PTFE swivel bearings.
Cable: Secure the output wire to
the lower swivel pole, allowing as
much slack as possible without
causing the cable to snag in the
turbine.
Wind vane: Using the three
M6x16mm screws, washers and
nuts provided, fit the vane (tail fin)
to the rear of the Aquair body.
Wind t rbine assembly: First,
check that the hub plates are
correctly fitted to the hub-centre.
(Some plates had a small hole
near one of the 12 blade fixing
holes and these should line up.)
The blades are supplied as colour
coded pairs (see the colour code
on the blade base). These pairs
should be assembled finger tight
to the hub, in opposite positions,
using the M8x40mm bolts shake-
proof washers and nuts provided.
The bolts are a deliberately tight fit
but may be screwed in using a socket spanner.
Note. The concave (hollow) side of the blade faces the wind.
Tighten the blade bolts working on opposite pairs in sequence. It is a good idea to re-tighten fixings
after a few hours use since some compression of the materials may have taken place. It is usual to
Figure 8: quair Hoist In Rigging
Mounting

Aquair 100
TM
Manual
Ampair
®
, 2007 www.ampair.com Page 11 of 23
leave the blade ‘disc’ assembled and store it as a disc after assembling it for the first time.
Fitting the wind t rbine: Remove the plastic bungs from the hub plate to gain access to the hub-
centre to shaft fixing holes. Carefully align the wind turbine hub and gently slide on to the shaft. Using
the M6x30mm cap screws shake-proof washers and hexagon wrench provided, fit the turbine to the
shaft. Tighten fully.
CAUTION: Leave a loop where the cable passes the swivel. This will allow the unit to rotate in the wind.
Do not make the loop so big as to risk fouling the blades.
DANGER: The wind t rbine blades are easily capable of ca sing grave personal inj ry, even in
light wind, and sho ld be treated with the same respect as an aircraft propeller.
• It is essential that the wind turbine be hoisted well above head height.
• Do not let go of the blades until all personnel are clear. Rotate the Aquair to face the wind
and step back before letting go.
Wind mode installation – Pole Mount
Figure 9. quair Wind Kit - Pole Mount
KEY:
1. Generator Assembly 7. Hub Centre 13. Mounting Pole
2. Blade (6) 8. Guide Hole 14. Pole Collar
3. Bung(3) 9. Turbine Fasteners (2) 15. Collar Fasteners (2)
4. Hub Plate (2) 10. Pivot Shaft 16. Tail Vane
5. Blade Fasteners (12) 11. Pivot Fasteners (1) 17. Tail Vane Fasteners (3)
6. Hub Fasteners (3) 12. Pivot Bush
PRE INSTALLATION CHECK
Check that a complete and undamaged set of parts has been received.
The Aquair pole mount set contains: six wind turbine blades packed as three colour-coded & balanced
pairs; Hub assembly and 3 plastic bungs; 800mm pole. tail vane; one pole mount adaptor set
comprising an aluminium alloy pivot, acetal bush and aluminium alloy collar.

Aquair 100
TM
Manual
Ampair
®
, 2007 www.ampair.com Page 12 of 23
Figure 10: Pole Mount daptor
The hardware kits contain:
Kit 1: Wind blade fixings Kit 2: PM fixings
12 M8 x 40mm hex bolts 1 M8 x 50mm hex bolt 3 M6 x 16mm screws
12 M8 nuts 1 M8 nut 3 M6 shake-proof washers
12 M8 shake-proof washers 1 M8 shake-proof washer 3 M6 plain washers
2 M6 x 30mm cap screws 3 M6 nuts
2 M6 shake-proof washers 2 M6 x 20mm screws
1 5mm hexagon wrench
(Allen key)
2 M6 shake-proof washers
Note it is also possible to purchase the Pole Mount (i.e. 800mm pole + a aptor) or just the Pole Mount
A aptor for those who alrea y have the HIR kit an are creating an alternative mounting position.
Installation differs from the hoist method as follows:
1. Find a suitable position in which to
mount the pole which many clients will
incorporate in some form of stern gantry.
2. Adaptor set: Insert the acetal bush in
the top of the pole, with the holes in the
bush lined up with those in the pole.
Pass the anodised collar over the pole
and hold the collar so the threaded holes
line up with those in the pole, whilst
inserting the two M6x20mm screws with
shake-proof washers just enough to
enter the thickness of the bush. Do not
fully screw in.
3. Pivot: Insert the pivot in one “ear” of the
Aquair 100 body so the cable exit gland
is downwards and, using the M8x50mm
bolt, shake-proof washer and nut, tighten
firmly.
4. Place the Aquair 100 on the pole, gently
guiding the pivot down into the bush on
the top of the pole. Fully tighten the two
M6x20mm screws in the anodised collar.
The threads now protrude into the
groove in the pivot effectively trapping it
in place.
5. Secure the cable in such a way that the
Aquair can turn at least 360 degrees in each
direction.
6. Finally, assemble the tail vane and then the wind turbine as for the HIR kit above.
CAUTION: Leave a loop where the cable passes the adaptor. This will allow the unit to rotate in the
wind. Do not make the loop so big as to risk fouling the blades.
DANGER: The wind t rbine blades are easily capable of ca sing grave personal inj ry, even
in light wind, and sho ld be treated with the same respect as an aircraft propeller.
• It is essential that the wind turbine be hoisted well above head height.
• Do not let go of the blades until all personnel are clear. Rotate the Aquair to face the
wind and step back before letting go.

Aquair 100
TM
Manual
Ampair
®
, 2007 www.ampair.com Page 13 of 23
Wind mode installation – Stern Mount Kit
The Aquair Pole Mount Generator can be
mounted on the stern mount kit of the Ampair
100 Wind Generator. The Ampair 100 Stern
Mount Kit includes an upright pole in three
sections complete with joiner pieces, a backstay
bracing strut, and two wire stays.
If wishing to use a Stern Mount Kit with an Aquair
100 please advise when ordering as it is a
special item.
See Ampair 100 manual for Stern Mount Kit
installation instructions.

Aquair 100
TM
Manual
Ampair
®
, 2007 www.ampair.com Page 14 of 23
ELECTRICAL INSTALLATION
Cables: The Aquair 100 is fitted with 5m of 1.5sq mm cable. Having sited the Aquair 100 on the boat,
measure the cable run distance to the batteries. If this distance is less than 10 metres (20 metres 24v
systems), use 1.5sq mm (16 AWG) cable. If less than 20 metres (40 metres 24v systems), use 2.5sq
mm (14 AWG) cable. Use a similar type of cable to that on the Aquair. Always use tinned stranded
conductors.
Connectors: To carry power from the Aquair to the wiring on the boat we recommend that a quality
watertight connector be fitted. In the case of a wind and water combination, a watertight socket can be
fitted at each site. Alternatively, an extension cable with in-line connectors can be used for the wind
mode. The plugs and especially the sockets should have watertight caps when not in use.
Installation: Wiring between the deck socket (or junction box, deck gland etc.) and the battery area
should be clipped at regular intervals to the structure for safety and a neat job
Protection: The simplest possible arrangement feeds the power from the Aquair directly to the battery,
through an in-line fuse rated at 10 Amps (5 Amps 24v system) in the positive line next to the battery.
Figure 12. Basic Wiring
Wiring options: In fig. 12, two optional components have been added to show where they might be
wired in the circuit.
o The switch, which may be used as a simple means of charge control, should be rated at
15 Amps DC to ensure long life.
o The ammeter is wired in series (assuming it to be of the internal shunt variety) in one
line. This allows the machine output to be seen at all times. As shown, the positive (+)
connection of the ammeter is made to the generator, whilst the negative (-) is made to
the battery. Never connect an ammeter across the s pply.
CAUTION: IT IS MOST IMPORTANT TO FIT A FUSE. The fuse should be next to the battery
terminal since, in the event of a fault or damage to the cable, the battery will supply a
large fault-current.
CAUTION: When wiring the system be aware that if the Aquair is connected to the battery with
REVERSE POLARITY the output rectifiers can be destroyed. Check and do ble-check
polarity before final connection.
CABLE COLOURS: Core 1 (formerly BROWN) = + Positive
Core 2 (formerly BLUE) = - Negative.
CAUTION: The Aquair generator output MUST GO STRAIGHT TO THE BATTERIES. If the Aquair
is connected on the DOWNSTREAM (load-side) of the battery isolator switch, it leaves
scope for damage to electrical equipment on the boat. Under these conditions it is
possible to run the Aquair whilst the battery is isolated. This can subject the system to
excess voltage.
Core 1 = +
(formerly BROWN)
Core 2
= +
(formerly
BLUE)

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TM
Manual
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®
, 2007 www.ampair.com Page 15 of 23
CHARGE CONTROL REGULATION
In the water mode it is not recommended to use a regulator with the Aquair towed turbine as it can
interfere with normal operation and cause the turbine to alternately surge and slow as the regulator
disconnects and connects the generator to the battery. This can cause the rope to kink and become
tangled. Ordinarily on cruising yachts the running loads approximately balance the Aquair charge.
Should this not be the case, then a simple switch or removable connector can be used to allow the
turbine to spin freely when not required.
In the wind mode an Aquair used as a semi-permanent wind charger may well need regulation, in
which case the appropriate model should be wired for connection in the wind mode only.
Ampair manufactures three Charge Control Regulators for protecting lead acid batteries from
overcharge. They are not “shunt” type regulators, which dissipate excess charge as heat, but an
electronic power switch, which disconnects the generator from the battery at the regulation voltage.
Regulators S1B & S3B have a single 100-watt input (Ampair, Aquair or UW). Regulator type S1B has
one output battery connection. Regulator S3B has three output connections to serve up to three battery
banks with a common negative. The third regulator D1B has two 100 watt inputs (any two from Ampair,
Aquair, UW or solar panels), supplying a single battery bank at a fixed regulation voltage.
All regulators have 2 level sensing. The lower voltage (Lo) connection regulates at 0.4 Volts below the
high (Hi) connection for 12V systems (0.8V for 24V systems). “Hi’ connection is appropriate for liquid
electrolyte batteries and/or live aboard situations. ‘Lo” connection for gel batteries and/or infrequent
use.
The battery voltage is sensed at the regulator output connection, therefore install the regulator as near
the battery as practicable and keep the connecting cables short.
Regulator type S1B has one output battery connection. Regulator S3B has three output connections to
serve up to three battery banks with a common negative. The third regulator D1B has two 100 watt
inputs (any two from Ampair, Aquair, UW or solar panels), supplying a single battery bank at a fixed
regulation voltage.
All regulators feature the same multi-stage regulation programme which has regulation voltages of Lo =
13.6V. Hi = 14.0V for l2V systems (27.2V & 28.0V for 24V systems).
Charging is continuous until the Lo or Hi voltage is reached, depending on the battery output used. The
generator is now disconnected from the battery. Off-charge, the battery voltage will fall. At a voltage of
0.5V below the regulation voltage a 30-second time delay is activated. This delay prevents the regulator
from oscillation (hunting) when charging batteries under load. After 30 seconds has elapsed, the
generator-to-battery connection is remade and charging continues to the regulation cut-out voltage.
A cycle counter counts the charge/disconnect cycles and at the tenth cycle increases the regulation
voltage for one cycle only by 0.4 volt to Lo 14.OV or Hi 14.4V for 12V systems (0.8V for 24V systems
Lo = 28.OV, Hi = 28.8V). This provides an equalisation charge for the battery. Subsequent cycles return
to the lower settings until a further 9 cycles are completed.
Ammeter: We recommend fitting an ammeter to monitor charging.
Use 10A for 12v, 5A for 24v. Fit an ammeter with a linear scale (moving coil type) or low outputs will be
indiscernible.
F ses: Battery protection fuses should be fitted. Use l0A in 12v system, 5Amp for 24v.
Wiring: Use suitably insulated cable of 1.5 sq. mm (16 A.W.G.) between regulator and battery in single
source systems; 2.5 sq. mm (14 A.W.G.) for dual source. For input wiring to the regulator see
appropriate generator wiring section. The use of screened cables is recommended if the cables run
close to equipment radiating strong electrical fields e.g. radio transmitters or aerials.

Aquair 100
TM
Manual
Ampair
®
, 2007 www.ampair.com Page 16 of 23
Installation of charge control regulator
Make sure the generator is not operating whilst connecting to the regulator. Connecting with live wires
can damage the electronic regulation circuit.
At initial start-up, allow a time of 1-2 minutes for circuit timing functions to become active.
Protecting the system:
Fuse warning - never omit fuses, simple in-line fuse carriers may be used, they protect your system
from excessive battery currents in the event of a serious electrical fault. If they keep blowing, find out
why.
Fuses = l0A for 12V systems; 5A for 24V systems.
The regulators are internally protected by SAE fuses, which are not substitutes for battery protection
fuses. The fuses must be next to the battery terminals since, in the event of a fault, the batteries would
source the fault current. Check and double-check polarities before making connections, insert the fuses
in the fuse carriers last of all.
Corrosion:
This is the enemy of all electrical connections, especially in marine environments. Site regulators in a
weather proof location, as dry as possible, and splash proof. Inspect all terminations and connections
for signs of corrosion. Rectify by cleaning, remaking etc. Use tinned copper wire for extension leads to
prevent corrosion spreading inside cable insulation.
Operating problems:
A digital multi-meter is useful for checking operational faults, if no permanent monitoring instruments
are used. Battery voltage levels and those of the charging source can be read directly. Charging current
readings will require the multi-meter to be installed in line. In this way currents into and out of the
regulator can be observed. Do not remove battery connections since regulator operation depends on a
very small supply current. If the regulator is suspect then it can be temporarily bypassed by connecting
the source positive direct to a battery positive. The negative connections are common and do not need
disturbing unless regulator replacement is necessary. Use the multi-meter continuity range to confirm
all cable runs are low resistance.
Operation:
When installed, the generator and regulator will run and maintain the batteries automatically. The unit
may be run in conjunction with any other charge-source with no known interactive problems. Regular
battery inspection and topping up must still be carried out to obtain maximum battery life.
Fa lty reg lator:
Each regulator is individually tested and a chart recording kept of its operation. Each regulator has a
unique serial number and a test date. Please provide these with any queries. If the regulator is suspect,
then it can be temporarily bypassed i.e. connect the rectifiers directly to the battery terminals observing
correct polarity. If this reinstates correct charging, then the regulator must be serviced or replaced.
Regulators draw a small current (typically 1mA at 12V) from the battery to activate the sense and
control circuits. Witho t this connection the reg lator will be inoperative.
SERVICING.
If the regulator is suspect, then it can be temporarily by passed i.e. connect the generator directly to the
battery terminals observing correct polarity. If this reinstates correct charging, then the regulator must
be serviced or replaced. Regulators draw a small current (typically 1mA at 12v) from the battery to
activate the sense and control circuits. Without this connection the regulator will be inoperative.

Aquair 100
TM
Manual
Ampair
®
, 2007 www.ampair.com Page 17 of 23
Figure 13: Charge control regulators

Aquair 100
TM
Manual
Ampair
®
, 2007 www.ampair.com Page 18 of 23
AQUAIR OPERATION & PERFORMANCE
Operation – Water Mode:
It is assumed that the Aquair has been installed in accordance with the INSTALLATION section and
that the water turbine and towrope are attached.
Streaming: Lay the towrope out on the deck in such a way that it can be played out without risk of
snagging or knotting when the turbine is put in the water. This should be done when the boat is under
way. Slight tension should be applied as it runs out to prevent the turbine grounding in shallow water.
The towrope should not pass close to steering gear etc., which could cause chafing or worse.
CAUTION: The faster the speed of the boat the greater the forces on the mounting system (and the
reduced time to respond to any mishaps). Therefore it is advisable to reduce speed
when streaming the turbine, at least until the crew have become proficient.
WARNING: Once streamed the tow line and swivel are a piece of rotating equipment and should be
treated with the appropriate level of care. Do not allow the tow rope to become entangled
in hair, loose clothing, or rigging.
Adj stment: The standard pitch water turbine is likely to surface at speeds in excess of 7 knots,
depending on sea state and the height above the water at which the Aquair is mounted. This can lead
to snatching on the rope as the turbine jumps as it breaks surface and the possibility of the rope
knotting or the turbine turning turtle and picking up its own rope. Matters can be improved (at the
expense of performance at lower speeds due to increased droop) using one or more of the following
methods:
1) Increase diameter of rope to 14mm and/or increase length of line to 40-50m.
2) Add weight to the turbine, e.g. stainless steel or brass tubing on the shaft. Some customers
have used sacrificial zinc anodes, of the type for clamping around a shaft, either on the
turbine or the rope.
3) Place a short length of tubing over the end of the line to turbine shaft connection. This will
stiffen the joint and keep the turbine inline.
Smaller yachts with lower cruising speeds (e.g. 35 foot length) may be able to shorten the rope by 10m
to reduce drag without compromising performance. A coarse pitch turbine is recommended for boats
that consistently exceed 8 knots. It will surface at 12 knots. There will, however, be a significant loss of
performance at speeds below 8 knots (see graph of water driven performance). A coarse pitch water
turbine has been used successfully at speeds up to 20 knots by increasing the rope diameter to 14mm
and shortening its length to 15 metres so as to stay in the same wave as the boat. Coarse pitch
turbines have a circumferential groove around the propeller for identification.
Recovery: Since the rope is spinning, to avoid hand injury, the boat should be slowed to 1-2 knots
when hauling in. A useful device, to help when hauling-in whilst under way, may be made from a large
plastic funnel, with most of the spout cut off, slit down the side and fitted with Velcro straps. This is slid
down the towrope where it will stop the turbine spinning, allowing easier retrieval. Alternatively use a
split fender with its centre hollowed out. Another technique is to take a sausage fender with a karabiner
(sprung shackle) and clip it over the rope at either end. It will run down to the turbine and stop it
spinning and simultaneously keep it near the surface.
CAUTION: To avoid personal injury, wear sturdy gloves as a precaution. Reduce speed when
hauling-in since the water turbine has considerable torque.
Operation – Wind Mode:
Starting p: It is assumed that the Aquair has been assembled and installed in accordance with the
section on INSTALLATION. The unit is not designed for permanently unattended operation, it is
important to occasionally check to see that the output cable has not trapped round the swivel (or pole)
due to wind veer/boat movement.
Stopping: The wind turbine has been designed to survive storms, however, it is a good plan to stop the
machine if a gale is expected. To do this, proceed with caution, approach the Aquair from downwind
and grasp the tail vane with a boathook or similar. Carefully turn the machine off wind and, when the
blades stop, throw a rope over them and tie down. If a hurricane is expected take the unit down.
CAUTION: To avoid personal injury, wear sturdy gloves as a precaution. The wind turbine blades
are capable of causing GRAVE INJURY and should be treated with the same respect as
an aircraft propeller.

Aquair 100
TM
Manual
Ampair
®
, 2007 www.ampair.com Page 19 of 23
These graphs show the Aquair 100
performance and drag at a range of
speeds.
Figure 16. Wind Driven Performance
The drag due to the wind turbine is
about 22kg (50lbs) at 50 knots wind
speed.
Figure 14. Water Driven Performance
Figure 15. Water Driven Drag

Aquair 100
TM
Manual
Ampair
®
, 2007 www.ampair.com Page 20 of 23
MAINTENANCE AND SPARES
Figure 17. Sectioned Drawing
KEY:
1. After-body 2. Bearing (2): 15x3 x11mm sealed
3. Stator (2) Six pole 4. 0’ ring: international size 358
5. Fore-body 6. Rotor (2) Permanent Magnet
7. Internal circlip: 35x1.5mm 8. Shaft seal 15x35x7mm rubber coated, plain
lip
9. Shaft: with two M6 tapped holes 10. Body fasteners (2): M8x25mm hex set screw
with shake-proof, fibre & plain washer
11. Cable gland with strain relief 12. Output cable: 5m of 1.5sq mm, twin-cored,
tinned copper wire, outer sheath of low
temperature grade PVC
13. Rectifiers (2): rated at 25 Amp 600v 14. Rectifier fasteners (2): M5x16mm pan head
screw & shake-proof washer
15. Rectifier cover 16. Cover fasteners (4): # 8x3/8” self tapping
screw & M4 fibre washer
Inspection
The shaft seal protecting the front bearing should be renewed regularly, particularly after long ocean
voyages. The bearings should be replaced when they become noisy.
In water mode, regularly inspect the following: suspension lanyards, shaft connector & shackle, tow
rope attachments and gimbal pivot components.
Inspect the body and tow turbine occasionally, cleaning off any corrosion and re-painting any damaged
areas. The shaft connector has a second set of holes, which can be used once the original holes show
signs of wear or elongation.
If the tow turbine blade tip becomes bent as shown in Fig. 18, this will cause a change in pitch,
increased drag and premature surfacing. View the trailing edge of the blade, edge on, as shown. The