Automaxx 400 Watt Turbine User manual

400 WATT WIND TURBINE
User’s Manual
Ver.2017.2.24

Table of Content
1. SAFETY .........................................................................................................1
1.1 Mechanical Hazard .....................................................................................2
1.2 Electrical Hazard .........................................................................................2
2. SPECIFICATION AND PROTECTION ...................................................2
2.1 Specifi cation ..............................................................................................3
2.2 Performance ...............................................................................................4
2.3 System Protection .......................................................................................5
2.4 Mechanical Stop Switch .............................................................................6
3. PACKAGE CONTENTS ...............................................................................8
3.1 Parts List ......................................................................................................8
3.2 System Wiring Diagrams ...........................................................................9
4. INSTALLATION PROCEDURE.................................................................10
5. MAINTENANCE ..........................................................................................13
6. FAQS ............................................................................................................14
7. TROUBLESHOOTING ..............................................................................17
8. WARRANTY ................................................................................................18
APPENDIX A IMPORTANT SAFETY INSTRUCTIONS ............................21
APPENDIX B BEAUFORT WIND SCALE .................................................23
APPENDIX C RECOMMENDED WIRE GAUGE .......................................24
APPENDIX D REGISTRATION FORM ........................................................25

1
1. SAFETY
Your wind turbine is designed with your personal safety as the first
priority. However, there are still some 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. Please read the following:
Important Safety Instructions
Please take the time to read through this manual prior to assembly.
(1) Place this instruction manual in a safe place for reference.
(2) Wait until a calm day to install or perform maintenance on your
Turbine.
(3) Listen to your Turbine should you hear any mechanical noise,
maintenance may be required, please contact The Customer Service.
(4) After installation re-adjust and tighten the screws and bolts.
(5) Adhere to proper grounding techniques as established by the National
Electrical Code (NEC).
(6) Your wind turbine must be installed in accordance with this manual
and local and national building code. Incorrect installation may void
your warranty.
(7) Wind turbine blades spin at a potentially dangerous speed this must
be respected. Never approach a turbine in motion.
(8) Note wire size (gauge chart included) prior to wiring. Any under sizing
of wire can be potentially dangerous.

2
1.1 Mechanical Hazard
Rotating blades present the most serious mechanical hazard. The rotor
blades are made of very strong thermoplastic. At the tip, the blades may
be moving at velocities over 15 m/s. 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.
1.2 Electrical Hazard
The wind turbine is equipped with sophisticated electronics designed to
provide protection from electrical dangers. 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 a wiring system is often a result of too much current flowing
through an undersized wire or through a bad connection. Please consult
wire guide table on page 4. Batteries can deliver a dangerous amount of
current. If a short circuit occurs in the wiring from the batteries, a fi re can
result. In order to avoid this threat, a properly sized fuse or circuit breaker
is required in the lines connecting to the battery.
Choosing your wind turbine’s location
Prior to the mounting of your wind turbine, you must carefully consider a
location.
Things to consider when thinking about your location
A) Distance from any obstacles that will cause turbulence, trees,
buildings etc.
B) Distance from wind turbine and battery bank
C) Any local zoning restrictions
D) Clearance of power lines

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20 feet (6m)
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In general terms the higher the tower the less obstruction to air flow,
leading to a more effi cient charge capacity. The minimum recommended
tower height is 30ft or 20ft above nearby obstructions as shown below.
2. SPECIFICATION AND PROTECTION
2.1 Specifi cation
Model 400 Watt Turbine
Rated speed 28 mph / 12.5 m/s
Rated power 400 watts
*Output Voltage 0-15V
Cut-in wind speed 6.7 mph / 3 m/s
**Survival wind speed 112 mph / 50 m/s
Rotor diameter 4 ft / 1.22 m
Number of Blades 3
Blade material Plastic steel
Suggested battery capacity >50 A/Hr

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*The 400W wind turbine operates on 0-15V output voltage, we highly
recommend using 12 AWG wire and maintaining a distance of 66ft (20m)
between the turbine and battery. Using inappropriate wire gauge will
result in a drastic increase in voltage.
**Please activate the brake manually when the wind speed exceeds 30
mph (13 m/s). The survival wind speed means the turbine can survive
the winds up to 112 mph (50 m/s) when the brake is manually activated.
Exceeding this stated wind speed will result in wind turbine failure and
collapse.
2.2 Performance
The following power curve shows the performance you should expect
from your wind turbine. During smooth, steady wind speed, you can
expect to see output resembling the curve illustrated below. To convert
between power and current use the following formula:

2.3 System Protection
Your turbine comes equipped with state of the art overcharge protection.
When the temperature of the turbine exceeds 80°C (176°F) your turbine
will automatically shut down and apply the braking system to your wind
turbine to prevent damage.
Caution 1 : Any under sizing of wire can be potentially dangerous; our
warranty doesn’t cover damage caused by improper use of wire gauge.
Caution 2 : Please review the following wire gauge table to install the
correct wire gauge.
We recommend these as the minimum wire sizes for optimal
performance for the distance from your turbine to the battery.
Always use the largest gauge wires that are practical and affordable.
Local, state, and or national electrical codes take precedence over these
general recommendations.
12V Volt Systems, AWG / Metric Wire Size mm2
0-10M 10-20M 20-30M 30-45M 45-75M
14 / 2 mm212 / 3.5 mm210 / 5.5 mm28 / 8 mm26 / 14 mm2
5
High battery voltage protection 14.8V
Over charging current protection 20A
Over-speed protection ≤1200 rpm
Overheat protection for generator ≤900 rpm and 70 sec.

2.4 Mechanical Stop Switch
The wind turbine has built-in controller with braking device protection.
Further to this protection we have incorporated a secondary level of
safety and convenience with a mechanical 3-phase AC brake.
During periods of high winds (upwards of 30 mph, 13 m/s) it is strongly
advised to utilize your mechanical stop switch. The use of your
mechanical stop switch will not aff ect the voltage of your battery.
We strongly advise the activation of the mechanical stop switch during
any maintenance of or around your wind turbine. This will prevent the
blades spinning and voltage to be transferred.
Likewise during initial installation please activate the mechanical brake.
The fi nal step in installation of turbine and battery should be release of
this mechanical stop switch.
The mechanical stop switch is pre-wired for your convenience with 8
AWG wire and battery terminal connections. The wire configuration is
explained in the diagram below (page 7). Connect the corresponding
wires of the mechanical stop switch to the turbine. The red (+) wire of
the stop switch should match with the red wire of the turbine. The yellow
wire (BRAKE) of the stop switch should match with the yellow wire of
the turbine. They should match the correct wires from your turbine. This
provides a parallel connection.
Test the connection of your mechanical stop switch at the point of initial
installation. Push the brake “ON”. You should see the turbine stop its
rotation. Continue to apply this brake during the remainder of your
installation.
6

Yellow (BRAKE)
Yellow (BRAKE)
Mechanical
Stop Switch
Turbine
Incorrect connection can damage your wind turbine and
cause dangers.
Should the turbine continue to spin, check your terminal
connections. Do not approach the turbine without activation
of this mechanical stop switch under any circumstance!
NOTES
• It is strongly advised to test mechanical stop switch periodically.
• Your mechanical stop switch is pre-wired with 8 AWG wire, this should
not be altered.
• The mechanical stop switch should be placed close to your turbine in a
dry ventilated environment.
• For multiple turbine applications please use one mechanical stop switch
for each wind turbine.
• This mechanical stop switch has been designed specifically for your
wind turbine; it should not be incorporated into other models.
7

Blade
Base
Generator
Hub
Nose Cone
Tai l
3. PACKAGE CONTENTS
Check the parts listed with the contents of the box and make sure that
you have everything needed for assembly.
8
Caution: The edges of the blades are sharp. Please handle with care.
3.1 Parts List
Name Quantity
Generator (integrated with Tail and Hub) 1
Blade 3
Nose Cone 1
Accessory Pack
Hex Screw (M6XL45) 9
Nut (M6) 11
Washer (M6) 20
Hex Screw (M6XL30) 2
Hex Key No.5 1
10mm Unilateral Open Wrench 1

Please refer to the recommended wire gauge table and
select the appropriate wire size for your system.
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3.2 System Wiring Diagrams
9

4. INSTALLATION PROCEDURE
Step 1 : Open box and ensure all parts are present.
Step 2 : Install the wind turbine to your chosen tower and fasten the bolt
securely by using the hex key (The Yaw Shaft includes a rubber spacer
to ensure the connection is secure).
How to select your tower : The outside diameter of the iron pipe should
be 48.3 mm, the thickness of iron pipe should be at least 1.9 mm.
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Step 3 : Fasten the blades on the hub with nuts by using the hex key and
unilateral open wrench. (Make sure that all of the bolts are secured with
nuts.)
11

Step 4 : Fit the nose cone onto the hub properly.
Step 5 : Final product diagram
12

5. MAINTENANCE
Your wind turbine has been designed to run for long periods without
requiring any maintenance. Performance will be enhanced if you
periodically inspect your system.
Review the following simple maintenance procedures and implement
every six months.
Caution 1 : Do not go near the wind turbine during operation.
Caution 2 : The blades are sharp. Please handle with care.
• Check blades for superfi cial damage. Replace blades if damaged. It is
important to not use blades that are damaged, as you will lose overall
balance, resulting in a decrease in effi ciency. Should you notice
damage to the blades you must replace all 3. The blades are balanced
as sets.
• Check the blade bolts and the hub nut for tightness.
• Check nosecone for cracks and tighten nuts.
• Wipe any excess dirt build-up from the blades.
• Check all electrical connections to make sure they are tight and free
from corrosion.
• Check the voltage of your battery bank with a Multi-meter and clean the
terminals.
• We suggest replacing the blades every fi ve years for optimal
performance.
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6. FAQS
(1) How does the wind turbine control power and RPM in high winds?
Your Turbine’s operation will be halted to reduce the risk of damage due
to overcharge and over spin of the rotor blades. This process of braking
is handled internally through your Turbines electronics.
(2) What is the maximum wind speed the wind turbine will survive, and
do I need to take it down in a storm? Your wind turbine is designed to
operate in most climatic conditions. Should you expect or experience
winds of 110 MPH upwards, please manually activate the brake. Once
the Turbine has stopped it is possible to lay down the Tower to offer
further protection.
(3) How long will the bearings or other wearing parts last?
According to engineering calculations, the bearings should have a 10-
year life span in 12 mph (6 m/s) average wind speed sites. Bearing life
will vary from one application to another; however, you should expect
at least a five-year performance in adverse conditions and 10 years in
normal conditions.
(4) Can the wind turbine be connected in reverse-polarity to the battery
without causing any damage?
Reverse polarity will cause damage to your battery if not quickly
remedied. Always double check any wiring to reduce the risk of reverse
polarity. Your turbine is equipped with polarity protection to reduce the
risk of damage, but it is still possible to degrade your wiring and cause
damage to the overall system.
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(5) Will it hurt my wind turbine to short-circuit the output?
No, the wind turbine is designed to be short-circuited as a normal
shutdown procedure by a fuse. The function of the stop switch is to both
disconnect the turbine from the batteries as well as short-circuit the
output of the turbine.
(6) Where can I locate tubing to make a tower?
Your wind turbine is designed to make mounting as simple and
straightforward as possible. Should you not wish to purchase the custom
tower kit feel free to utilize schedule 40 1.5 inch steel tubing. This should
be available through your local hardware outlet.
(7) What is the diff erence between copper and aluminum wire?
Generally aluminum wire is less conductive, so it must be bigger for the
same amp load and resistive losses as copper. The wind turbine uses
copper or tinned copper for the yaw wires.
(8) What battery should I choose for my wind turbine?
There are multiple battery options in today’s market– fl ooded lead acid,
absorbed Glass mat (AGM), gel cell and NiCad. There is no definitive
choice for your alternative energy needs. Normally the choice of battery
is determined by availability and pricing. Should you have questions
regarding batteries please consult a local battery supplier. Or view: www.
batterycouncil.org. The capacity of your battery bank is determined by
your use. Below is a good guideline.
• 12-volt systems – 400 Amp-hours
Possible Battery Confi gurations (suggested)
15

12V VOLT BATTERIES IN PARALLEL
(9) Is lightning protection necessary?
You should ground your wind turbine. Proper grounding (illustrated
below) provides protection to individuals and equipment by eliminating
the possibility of dangerous voltage. Remember a steel tower is a conduit
for lightning.
Every wind turbine and turbine tower needs to be grounded at the tower
base even though the system may be grounded at the battery bank.
Grounding the tower at its base may help prevent shocks to persons
touching the tower due to lightning or electrical faults. Please take the
time to review the National Electrical Code (NEC) and local building and
zoning regulations for complete requirements. Even in “Off Grid Systems”
there are multiple ways for tower grounding, the most common method
is a copper clad steel electrode(s) driven into the soil. Please view the
following grounding diagram.
(10) What eff ect does radio interference have on my wind turbine?
The internal circuitry of the wind turbine is shielded and fi ltered to prevent
radio interference, and has been tested to insure electro-magnetic
compatibility.
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7. TROUBLESHOOTING
You may require an extra person to assist with these tests.
(1) Remove the blade/hub from the turbine.
(2) Quickly spin the hub manually with your fi ngers while connecting and
disconnecting the red and yellow wires (turbine must not be connected to
batteries).
(3) With the red and yellow wires connected to each other, the shaft
should be more difficult to turn. When the wires are disconnected it
should spin freely. Should this not be true please contact supplier or
manufacturer.
(4) With your wind turbine connected to your battery bank, use an electric
hand drill to spin the rotor shaft.
(5) Below 300 RPM, the rotor should spin freely without friction.
(6) At 300 RPM and above, the wind turbine should be charging the
battery. You should feel resistance on the rotor shaft if the shaft is not
rotating; contact your turbine dealer or manufacturer. Be aware your
battery banks needs to be under 12V for this testing as the Turbine needs
to read a charge.
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8. WARRANTY
We warrant your product to be free from defects in material and/or
workmanship for a period of 1 year from original date of purchase.
Warranty coverage is extended only to customer (original purchaser).
If product proves defective during warranty period, the manufacturer, at
its option will:
1. Replace wind turbine with new or refurbished product.
2. Correct reported problem
Customers warranty continues to be valid on repaired or replaced
product from original warranty date.
Restrictions
This warranty covers defects in manufacturing discovered while using the
product as recommended by the manufacturer. The warranty does not
apply to: (a) equipment, materials, or supplies not manufactured by the
manufacturer. (b) Product that has been modifi ed or altered by other than
manufacturer or without manufacturers prior written approval. (c) Has
been exposed to winds exceeding 112 mph (50 m/s). (d) Windstorms,
lightning and Hail damage. (e) Repairs performed by other than
authorized support staff. (f) All acts of God; misuse, negligence or
accidents. (g) Tower foundation and wire has not been installed,
operated, repaired or maintained in accordance with the instructions
supplied by manufacturer. Any service identified in the above list or
product is found not to have any defect in manufacturers’ workmanship
or materials the customer will be responsible for the costs of all repairs
and expenses incurred by the manufacturer.
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