Primus wind power Air breeze User manual

Primus Wind Power, Inc.

938 Quail Street

Lakewood, CO 80215 USA

Phone: 303.242.5820

www.primuswindpower.com

OWNER’S MANUAL

Installation • Operation • Maintenance

 2013 Primus Wind Power, Inc.

AIR Owner’s Manual 3

Primus Wind Power, Inc.

Congratulations on your purchase and welcome to our family!

Dear AIR Owner,

Thank you for your purchase of an AIR wind turbine. You have purchased the most advanced battery charging wind turbine in the world! We believe you

will find it easy to install your AIR and are confident you will experience years of dependable service from it.

Before going any further, please complete and return the Warranty Registration Card or register on-line at wwww.primuswindpower.com/warranty. The

five-year warranty is effective only after the product has been registered. Note - Primus Wind Power does not sell or distribute your personal 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 Mountain

Standard Time). Our number is (303)-242-5820. You can also email our Customer Service Department at customer.service@primuswindpower.com.

Again, welcome to our family and thank you for investing in the future of wind energy with a Primus Wind Power AIR turbine.

Sincerely,

Primus Wind Power, Inc.

Enter the serial and model numbers below

Serial Number ________________________________________

Model Number ________________________________________

AIR Owner’s Manual

3-CMLT-2001, Revision: A

The CE marking is a mandatory compliance requirement in EMEA and the UK

and although it is self-certified, testing and evidence to support that testing

is preferred from an independent test house. All Primus Wind Power turbines

are third party tested and fulfil all the relevant provisions of the following

Directives:

Machinery Directive 2006/42/EC, Low Voltage Directive 2004/95/EC,

Electromagnetic Compatibility Directive 2004/108/EC. The report and the

declaration of conformity are available for inspection on request.

The serial number stated on the inside front cover of this owner’s manual

refers to a specific Primus Wind Power product. This product is considered

compliant to CE.

4 AIR Owner’s Manual

IMPORTANT SAFETY INSTRUCTIONS

Read these instructions in their entirety before installing or operating.

SAVE THESE INSTRUCTIONS. Enclosed are important instructions

that must be followed during installation and maintenance.

Turn AIR “OFF” and contact Primus Wind Power Customer Service

Department if unusual noise or operation is observed.

Install AIR on a calm day - no wind at ground level.

TIP: Helpful information

WARNING: Risk of injury or death - proceed with extreme caution

In this manual

IMPORTANT: Please take note

MARINE: Information specific to corrosive environments

AIR 30: Information specific to AIR 30 only

Properly torque all fasteners.

Use grounding techniques as established by the NEC. Install

turbine in accordance with this manual and local and national

building codes. Failure to comply may affect and possibly void

your warranty.

Properly complete the Warranty Registration Card or register your

product online at www.primuswindpower.com/warranty.

Rotating blades are a serious mechanical hazard. Install AIR wind

turbines so no one can come into contact with blades.

Observe wire size and fuse recommendations listed in the Wiring

Section of this manual.

AIR Owner’s Manual 5

Contents

IMPORTANT SAFETY INSTRUCTIONS________________________ 4

TECHNICAL SPECIFICATIONS ______________________________ 7

SITING _______________________________________________ 9

TIPS FOR BATTERY BANK SIZING ____________________________ 11

INSTALLATION___________________________________________ 12-16

Arrival Kit ____________________________________________ 12

Blade to Hub Assembly ________________________________ 13-14

Blade Hub to Turbine Assembly __________________________ 15-16

Turbine to Tower Assembly _____________________________ 16

TOWERS _______________________________________________ 17-19

Tower Options __________________________________________ 17

27 ft (8.3 m) Tower Kit _____________________________ 17

29 ft (8.8 m) Tower Kit _____________________________ 17

45 ft (13.7 m) Tower Kit ____________________________ 18

Marine Tower Kit _________________________________ 18

Roof Mounting Kit ________________________________ 19

WIRING OPTIONS ________________________________________ 20-28

Single Turbine Installation ____________________________ 20

Up-Tower Junction Box _______________________________ 21

Hybrid System ______________________________________ 22

Multiple Systems ____________________________________ 23

Wire Size __________________________________________ 24-25

Stop Switch_________________________________________ 26

Fuses, Circuit Breakers, Ammeter _______________________ 27

Turbine Grounding___________________________________ 28

Electrodes Driven in Soil ________________________ 28

AIR WIND TURBINE OPERATION ____________________________ 30-32

Operational Summary ________________________________ 30

Operating Modes ____________________________________ 30

Voltage Regulation___________________________________ 31

Adjusting Regulation Voltage _______________________ 31

Using an Alternate Charge Controller_________________ 31-32

MAINTENANCE __________________________________________ 32

TROUBLE SHOOTING _____________________________________ 33

EXPLODED VIEWS & PARTS LIST_____________________________ 34-37

WARRANTY_____________________________________________ 38-40

6 AIR Breeze Owner’s Manual

Notes

__________________________________________________________________________________________________________________________________

AIR Owner’s Manual 7

AIR Technical Specifications

Model AIR Breeze and AIR 40

Weight 13 lb / 6 kg

Rotor Diameter 46 in / 1.17 m

Start Up Wind Speed 7 mph / 3.1 m/s

Kilowatt Hours/month 38 kWh/month @ 12 mph / 5.4 m/s avg. wind speed

Maximum Wind Speed 110 mph

Rated Power 160 watts @ 28 mph / 12.5 m/s wind speed

Operating Temperature Range AIR Breeze and AIR 40 are certified under IEC

requirements applying to the temperature range 14º F

(-10º C) to 104º F (40º C). AIR 40 is CSA certified.

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 (AIR 40 and AIR Breeze)

12 Volt Systems 20 amp (slow blow)

24 Volt Systems 10 amp (slow blow)

48 Volt Systems 5 amp (slow blow)

Recommended Fuse Size (AIR 30)

12 Volt Systems 40 amp (slow blow)

24 Volt Systems 20 amp (slow blow)

48 Volt Systems 10 amp (slow blow)

Tower Loads

Shaft Thrust* 52 lb @ 100 mph wind speed (230 N @ 45 m/s)

*Value does not include safety factor. Primus Wind Power 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)

Model AIR 30

Weight 13 lb / 6 kg

Rotor Diameter 46 in / 1.17 m

Start Up Wind Speed 8 mph / 3.6 m/s

Kilowatt Hours/month 30 kWh/month @ 12 mph / 5.4 m/s

avg. wind speed

Maximum Wind Speed 110 mph

Rated Power 400 watts @ 28 mph / 12.5 m/s wind

speed

Certifications CSA, CE

AIR 30 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.

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)

AIR Owner’s Manual 8

EXAMPLE OF AN OFFGRID HYBRID INSTALLATION

Please Note: AC loads require an inverter

AIR Owner’s Manual 9

PROPER SITING = Better Performance & Increased Longevity

Look at vegetation deformation to determine best area and

prevailling wind direction.

Griggs-Putnam Index. *Probable mean annual windspeed. Data prepared by E.W.

Hewson, J.E. Wade, and R.W. Baker of Oregon State University

EXCESSIVE TURBULENCE = Fatigue Damage & Shorter Turbine Life

1

2

3

1

2

3

1

2

3

Prevailing wind

123

1

2

3

1

2

3

Plateau/Mesa

Ridge TopsCoastal or Lakeside

Prevailing wind

76 m (250 ft)

ATYPICAL SITING CONSIDERATIONS

0

No Deformity

I

5-9 mph*

Brush & Slight

Flagging

II

8-11 mph*

Slight Flagging

III

10-13 mph*

Moderate

Flagging

IV

12-16 mph*

Complete

Flagging

V

14-18 mph*

Partial Throwing

VI

15-21 mph*

Complete

Throwing

VII

22-higher mph*

Carpeting

1

2

3

1

2

3

1

2

3

Prevailing wind

123

1

2

3

1

2

3

Plateau/Mesa

Ridge TopsCoastal or Lakeside

Prevailing wind

Coastal or Lakeside

Trees and taller structures

can be down-wind.

Ridge Tops

Wind compresses as it

blows over the top of a hill,

increasing the wind speed.

Plateau/Mesa

Site the generator far

enough from the cli to

avoid turbulent wind.

Excess

Turbulence

1

2

3

1

2

3

1

2

3

Prevailing wind

123

1

2

3

1

2

3

Plateau/Mesa

Ridge TopsCoastal or Lakeside

Prevailing wind

1

2

3

1

2

3

1

2

3

Prevailing wind

123

1

2

3

1

2

3

Plateau/Mesa

Ridge TopsCoastal or Lakeside

Prevailing wind

PRIOR TO INSTALLATION

Siting Tips for Permanent Installations

Turbine should be a minimum of 76m (250 ft) away from and 6m (20 ft)

above obstacles.

AIR Owner’s Manual 10

Tower Selection and Installation

Soil and wind conditions vary; towers and tower foundations

must be designed for your specic location.

Prevent tower climbing by unauthorized

persons or children. Never climb

without proper safety equipment.

Tower Selection

150’46m

120’37m

90’27m

60’18m

45‘ 14m

33’10m

0

0 20% 41% 75% 100% 124%

Increase in wind power

16 mph

7.3m/s

15.5 mph

7 m/s

14.7 mph

6.6 m/s

13.5 mph

6 m/s

12.8 mph

5.7 m/s

12 mph

5.4 m/s

Tower height

Wind Speed

Calculations based on Power Law Exponenet 0.02

(In area of tall row crops,hedges,a few trees).

Guyed tower Monopole tower

Always stop the blades before climbing the tower. Both

falling from the tower and contact with the spinning

blades can be lethal.

Wind speed increases with height. Higher towers also raise generators

above the air turbulence that can exist close to the ground.

Calculations are based on Power Law

Exponent 0.02 (in areas of tall row crops,

hedges, a few trees.)

AIR Owner’s Manual 11

Simple Tips for Deep Cycle Battery Bank Sizing

ELECTRICAL USAGE - the amount of energy consumed 1 day

in Watt-hours (Wh)

DAYS OF AUTONOMY - days of battery back-up required if

unable to charge the batteries by any means.

DEPTH OF DISCHARGE - limit of energy withdrawal to which

you will subject the deep cycle battery bank.

*Deeper discharge = Shortened battery life.

• Recommeded: never discharge a deep cycle battery

below 50% of its capacity

• O-grid applications, a 25% DoD will extend battery

life signicantly

TEMPERATURE - Standard for most battery rating is

25 ° C (77 ° F).

Cold temperatures = reduced battery capacity

High temperatures = shortened battery life

CALCULATIONS - calculate battery bank size, use example below:

3.) Identify Depth of Discharge (DoD) and convert to a

decimal value. Divide result of step 2 by this value.

4.) Select the multiplier corresponding to the lowest

average temperature your batteries will be exposed

to. Multiply result from Step 3 by this factor. *Result

is minimum Wh capacity of battery bank:

°C ° F Factor

26.7 80 + 1.00

21.2 70 1.04

15.6 60 1.11

10 50 1.19

4.4 40 1.30

1.1 30 1.40

-6.7 20 1.59

5.) Divide result from Step 4 by system voltage. Result

is the minimum Amp-hour (Ah) capacity of your battery

bank.

EXAMPLE:

40% DoD:

18,000 / 0.4 = 45,000 Wh

15.6 ° C (60 ° F) = 1.11

45,000 x 1.11 = 49,950 Wh

49,950 / 48 = 1,040 Ah

• A system load of 6,000 Watt-hours per day

• 3 Days of Autonomy (back-up) needed

• Planned Depth of Discharge (DoD): 40%

• Battery bank ambient average low 15.6 °C (60 ° F)

• A 48V system

STEPS:

1.) Identify total daily use in Watt-hours (Wh)

2.) Identify Days of Autonomy (back-up days);

multiply Wh/day by this factor.

6,000

Wh/day

3 days of Autonomy:

6,000 x 3 = 18,000 Wh

RECOMMENDATION - Keep the number of parallel strings of bat-

teries to three or fewer. More than three strings of batteries, risks

shortening battery life due to uneven charging.

• Batteries in Series = Voltage is Additive

• Batteries in Parallel = Ah is Additive

*Example: 2 12V 100Ah Battery Bank

Series 24V 100 Ah

Parallel 12V 200 Ah

Temp in degrees

In preparation for battery sizing, know:

AIR Owner’s Manual 12

ARRIVAL KIT

Foam packing Blades

Nose cone

in foam

packing

Nose cone & blade hub

in foam packing

Hardware kit

Turbine

Yaw pad

Blade hub

Nose cone

Hub to rotor

nut 5/8-18

Product registration

Owner’s

Manual

Blades

Tef gel

1. 2.

3.

4.

5.

7.

6.

1. Extra yaw clamp bolts

2. 1/4-20 socket head bolts (4)

3. 1/4-20 Nylock nuts (4)

4. Flat washers

5. 5/16 hex wrench

6. 3/16 hex wrench

7. 5/32 hex wrench

DIFFERENCES FOR AIR 30:

• Different blades and hub

• 1/4-20 7/8 socket head bolts (7)

• 1/4-20 Nylock nuts (7)

• No flat washers

AIR Owner’s Manual 13

Your AIR wind turbine is delivered partially assembled. Assembly requires:

1. Mounting the blades on the blade hub.

2. Securing the hub to the turbine body.

3. Installing the nosecone on the blade hub. The necessary hex (Allen)

wrenches are furnished with your AIR wind turbine.

Step 1: Blade to Hub Assembly

Attach all blades to the blade hub. (See Figure 1 for AIR Breeze and AIR 40

procedure and Figure 2 for AIR 30 procedure.)

Fig. 2 AIR 30 Blade Attachment Detail.

1- AIR 30 blade hub

2- AIR 30 blade

3- 1/4 - 20 socket head cap bolt (2)

4- 1/4 - Nylock nut (2)

TURBINE ASSEMBLY

3

1

2

4

1- blades

2- washer

3- 1/4 - 20 socket head bolt

4- Nylock nut

Torque Specifications:

Blade to hub bolt, 1/4 - 20 x 1.375, socket head bolt 72 in-lb (8.0 N·m)

Hub to rotor nut, 5/8-18, 40 lb-ft (55 N·m)

Fig. 1 AIR Breeze & AIR 40 wind turbine Blade Attachment Detail.

WARNING: Nylock nuts may only be used one time;

replace after each use.

Torque Specifications:

Blade to hub bolts, 1/4-20 x 0.875 inch, Socket Head Bolt,

72 in-lb (8.0 N·m

)

Hub to rotor nut, 5/8-18, 40 lb-ft (55 N·m)

14 AIR Owner’s Manual

3/16”

Assembled

blade hub

Blade to Hub Assembly

AIROwner’s Manual 15

Step 2: Mount Blade Hub to Turbine

TURBINE ASSEMBLY

Step 3: Attach Nose Cone

Assembled

blade hub

Rotor

shaft

1.) Coat rotor shaft threads and blade hub with Tef Gel.

2.) Slide blade hub onto rotor shaft.

1.) Start 5/8-18 jam nut on rotor shaft.

2.) Carefully and slowly “spin” the blades to begin tightening the nut.

IMPORTANT: Tef-Gel is a corrosion inhibitor and

is especially important in marine applications.

5/8-18

Jam nut

Blade

hub

Blade

hub

Jam nut

Rotor

shaft

5/16” Hex

wrench

1.) Insert 5/16” hex wrench in rotor shaft.

2.) Carefully and slowly “spin” the blades to completely secure the

blade hub to the turbine.

1.) Attach nose cone to blade hub. You will feel it snap into place.

2.) Tug on nose cone to ensure it is secure.

WARNING: Don’t attempt to mount the turbine while

blades are spinning.

Nose

cone

AIR Owner’s Manual 16

Nose

cone

Turbine assembly is now complete.

Step 4: Attach Turbine to Tower

IMPORTANT: Observe torque specs.

WARNING: The yaw pad is critical to ensuring secure turbine mounting to tower;

however, it sometimes makes it dicult to tell if the tower is fully inserted into

the yaw assembly. Check this carefully before raising the tower.

1.) Insert yaw pad into yaw pivot point/clamp assembly.

2.) NOT SHOWN: Complete turbine wiring connections.

1.) Insert tower into yaw assembly.

2.) Ensure yaw pad is in place.

3.) Tighten screws to secure turbine to tower.

1.) Ensure turbine is securely attached to tower.

Turbine

wires

Yaw pad

Yaw pivot

& clamp

Yaw pivot

& clamp

M5 Socket head screw

(comes imbedded in

yaw assembly)

Tower

tubing

5/32”

Hex

wrench

29 ft (8.8 m) EZ – Tower

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, galvanized steel tubing and all fasteners. See Fig. 4.

17 AIR Owner’s Manual

Fig. 3. 27 ft (8.3 m) Tower Kit

x8

27' AIR TOWER

x4

x2

27 ft (8.3 m) Tower Kit

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. 3.

Note: Anchors and tubing are not furnished with the kit.

1. The AIR wind turbine mounts on tubing with a nominal 1.875 – 1.900

inch outside diameter.

2. Typical tower construction use: 1 1/2 inch Schedule 40 steel pipe or 2

inch SS-20 galvanized fence tubing (0.090 inch wall thickness).

3. DO NOT use plastic pipe to construct a tower.

AIR Wind Turbine Towers

Tower Options

Primus Wind Power offers a number of tower choices for your AIR wind

turbine. The following section provides a summary of the available tower

kits. 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.

IMPORTANT: User manuals for towers and tower kits are

available online at www.primuswindpower.com. Primus

Wind Power recommends reviewing them to make an

appropriate tower selection for your AIR wind turbine.

Fig. 4. 29 ft (8.8 m) Tower Kit

4x

x8

29'EZ TOWER KIT

x16

AIR Owner’s Manual 18

Marine Tower Kit

The Marine Tower Kit is specically 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. 6.

3x

8x

45' AIR TOWER

16x

x2

Fig. 5. 45 ft (13.7 m) Tower Kit

45 ft (13.7 m) Tower Kit

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. 5.

IMPORTANT: User manuals for towers and tower kits are available online

at www.primuswindpower.com. Primus Wind Power recommends reviewing

them to make an appropriate tower selection for your AIR wind turbine.

Fig. 6. Marine Tower Kit

Note: Anchors and pipe or tubing are not furnished.

19 AIR Owner’s Manual

Roof Mounting Kit

The Roof Mount Kit allows the pole for your AIR wind turbine to be mount-

ed to the wall or roof truss of a structure and extend above its rooine. The

kit includes isolators, base plates and all hardware, clamps and straps. Your

AIR can be mounted ush to the side of the structure or via a penetrating

hole through the roof or eaves. If mounted via penetrating hole, we recom-

mend purchasing the roof mount kit with seal. See Fig. 7.

Fig. 7. Roof Mounting Kit

AIR Owner’s Manual 20

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

AIR Wind Turbine 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;

allowing the turbine to operate independently. The AIR turbine’s

internal regulator will monitor the battery and maintain the charge as

necessary.

Figs. 8 and 9 represent typical single turbine installations. Fig. 9

includes an up-tower junction box for UL (Underwriters Laboratory)

compliance.

Contact Primus Wind Power for more information about this

configuration.

Fig. 8. Single Turbine Installation

Primus Wind Power Air Breeze User manual

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