Primus Wind Power Air X User manual

OWNER’S MANUAL
Installation •Operation •Maintenance
All Rights Reserved
Air X
Primus Wind Power
938 Quail Street
Lakewood, CO 80215
303-242-5820

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 nd it easy to install your AIR and are condent 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
ve-year warranty is eective 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 [e-mail].
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.
AIR, AIR Breeze, AIR 40 and AIR 30 are trademarks of Primus Wind Power  2013 Primus Wind Power Inc.
Enter the serial and model numbers below
Serial Number ________________________________________
Model Number ________________________________________
Air X Owner’s Manual
3-CMLT-1004, Revision: F
The CE marking is a mandatory compliance requirement in EMEA and the UK
and although it is self-certied, testing and evidence to support that testing
are third party tested and full all the relevant provisions of the following
Directives:
Machinery Directive 2006/42/EC, Low Voltage Directive 2004/95/EC,
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 specic Primus Wind Power product. This product is considered
compliant to CE.
Air X Owner’s Manual 3

4 Air X Owner’s Manual
1) SAVE THESE INSTRUCTIONS. This manual contains important instructions that must
be followed during assembly, installation and maintenance.
2) Read, understand and respect all warnings.
3) Do not install Air X on a windy day.
4) If unusual or operation is experienced, turn off machine and perform an inspection.
5) During assembly and installation properly torque all fasteners.
6) Use only proper grounding techniques as established by the NEC.
7) Properly complete and return the Warranty Registration Card.
8) Air X must be installed in accordance with this manual and local and national build-
ing codes. Failure to comply with this manual and local codes may affect and possibly
void your warranty.
9) Rotating blades are a serious mechanical hazard. Install Air X so no one can come into
contact with blades.
10) Observe wire size and fuse recommendations listed in the Wiring Section of this manual.
TIP: Indicates instruction or advice
that may simplify or ease task or
operation.
IMPORTANT: Indicates instruction
or advice that is critical for correct
assembly or operation. Damage
to equipment may result if not
heeded.
In this manual you will see the
following icons:
One - Important Safety Instructions
READ THESE INSTRUCTIONS IN THEIR ENTIRETY BEFORE ASSEMBLING, INSTALLING OR OPERATING YOUR AIR
LAND USE: Specific to Land Use.
MARINE USE: Specific to Marine
Use.
WARNING: Indicates risk of severe
injury or death or possible severe
damage to equipment - proceed
with caution and follow instructions.
Review this manual to verify that proper assembly and installation procedures have been
followed. Contact Primus Wind Power for further assistance.
sound the
X

Air X Owner’s Manual 5
Contents
1) IMPORTANT SAFETY INSTRUCTIONS__________________ 4
WARRANTY _________________________________________ 6
TECHNICAL SPECIFICATIONS ________________________ 7
2) TURBINE ASSEMBLY ________________________________ 8
3) SITING______________________________________________ 9
4) TOWERS ____________________________________________ 10-13
4-1 Tower Options___________________________________ 10
4-1-1 27 ft (8.3 m) Tower Kit_______________________ 11
4-1-2 29 ft (8.8 m) Tower Kit_______________________ 11
4-1-3 45 ft (13.7 m) Tower Kit _____________________ 12
4-1-4 Marine Tower Kit ___________________________ 12
5) WIRING OPTIONS____________________________________ 13-20
5-1 Hybrid System Wiring_____________________________ 15
5-2 Multiple Air X Wiring______________________________ 16
5-3 Wire Size _______________________________________ 17-18
5-4 Stop Switch _____________________________________ 18
5-5 Fuses, Circuit Breakers, Ammeter___________________ 19
5-6 Batteries _______________________________________ 19
5-7 Turbine Grounding _______________________________ 19-20
5-8 Tower Grounding ________________________________ 20
5-8-1 Electrodes Driven in Soil______________________ 20
6) INSTALLATION ______________________________________ 21
6-1 Wire Connections ________________________________ 21
6-2 Mounting on Tower_______________________________ 22
6-3 Final Connections ________________________________ 22
7) AIR BREEZE OPERATION _____________________________ 23-25
7-1 Operational Summary _____________________________ 23
7-2 Operating Modes ________________________________ 23
7-3 Voltage Regulation _______________________________ 24
7-3-1 Adjusting Regulation Voltage__________________ 24
7-3-2 Using an Alternate Charge Controller ___________ 24-25
8) MAINTENANCE ______________________________________ 25
9) TROUBLE SHOOTING ________________________________ 26
10) EXPLODED VIEWS & PARTS LIST ____________________ 27-28

6Air X Owner’s Manual
What is Covered
Primus Wind Power, Inc. (“Primus Wind Power”) warrants the AIR Wind Turbine against
defects in factory-supplied materials and/or factory workmanship under normal
authorized use consistent with the Wind Turbine’s Owner’s Manual, except for the
limitations set forth in this Limited Warranty. Installation of AIR Breeze Wind Turbine
constitutes acceptance of the terms and conditionsof this Warranty.
How Long Coverage Lasts
of installation of the Wind Turbine, or (ii) ninety (90) days after the date the original
end-user purchaser (“Customer”) purchased the Wind Turbine. The customer is
encouraged to return the warranty registration document included with this Limited
Warranty within sixty (60) days of the start of the Warranty Period. While submission
of the warranty registration document does not reduce your eligibility to receive
warranty service, you willbe requested to provide proof of ownership satisfactory
to Primus Wind Power prior to receiving warranty services. You may alsovisit www.
primuswindpower.com/warranty to register your wind turbine online.
(i)date of installation of the Wind Turbine, or (ii) ninety (90) days after the date the
Customer purchased the Wind Turbine, or (iii) up to one year after the product is
no longer manufactured. ThisLimited Warranty applies to the wind turbine only
provided the owner follows the maintenance procedures outlined in the owner’s
manual. Should the product prove to be irreparable, Primus Wind Power reserves the
right to substitute anequivalent product if available. This Limited Warranty extends
to the original Customer and may not be transferred if the wind turbine is sold.
How to Register a Claim Against Warranty
If a defect arises with regard to any Wind Turbine part and a valid claim is received
withinthe Warranty Period, Customer’s sole and exclusive remedy andthe entire
Limited Warranty is, at Primus Wind Power’s sole option, either (i) to repair free of
charge the defective part, or (ii) exchange free of charge the defective part with a
newor remanufactured part orwind turbine that is new or equivalent to newin
performance and reliability and is at least functionallyequivalent to the original wind
turbine part. Repaired or exchangedwind turbine parts will be warranted for the
remainderof the Warranty Period.
If you experience any problemwith your AIR Wind Turbine, please contact an authorized
service dealer or Primus Wind Power directly. Retain all information and documents
until the problem is resolved. Your authorized service dealer can provide you with a
solution and start the claims process. For best possible service, we strongly recommend
registration of your product with the warranty registration materials provided with your
AIR Breeze Wind Turbine. You MUST demonstrate ownership with a copy of the original
receipt indicating that you are the primary owner of the wind turbine.
claim to technical support, call Primus Wind Power at [phone] Monday-Friday
8:00AM –5:00 PM Mountain standard time.
number of the Wind Turbine at issue, and the original purchase date in addition to
the name, address, and telephone number of the party requesting warranty service
the nature of the problem to determine whetherany part is defective for purposes
of coverage under this Limited Warranty. Other than normal communication carrier
charges, there is no charge for such diagnosis. Any repair or replacement will be
provided only after Primus Wind Power’s diagnosis and its agreement to the defective
condition. Certain diagnosticchecks may be required to be performed by the end-
user ordesignee at Primus Wind Power representatives’ request. All claims for defect
shall be deemed waived unless made inwriting and delivered to your Wind Turbine
dealer during the Warranty Period and not later than thirty (30) days after discovery
of the defect. If Primus Wind Power representatives determine that the Wind Turbine
requires service and that Customer’s service request constitutes a valid claim under
this Warranty, Primus Wind Power will provide warranty service, at Primus Wind
Power’s sole option, either (i) through an authorized dealer, with service to be
performed at the servicer’s location; (ii) by sending replacement Wind Turbine or
parts to the Customer or (iii) by providing the Customer with a Return Merchandise
Authorization(“RMA”) number to authorize the Customer to ship the defective Wind
Turbine or Wind Turbine parts to Primus Wind Power for service. Any Wind Turbine
part(s) requiring warranty repairshall be transported at the expense and risk of the
party requiring warranty service, including butnotlimited to proper packaging of
the part(s). Primus Wind Power will return to sender any Wind Turbine and/orpart(s)
that do nothave a valid RMA number. Primus Wind Power will use all reasonable
replaced wind turbines and replacement parts will be delivered to the Customer at
Primus Wind Power’s expense. If a warranty claim is invalid for any reason, Customer
may be charged at Primus Wind Power’s and/or the authorized service dealer’s
then current rate for repair services performed. In such event, the Customer willbe
informed of the repair charges for prior approval, and, upon approval, will be charged
for the approved repairs and return freight. If the Customer refuses to approve repair
charges, return freight charges may apply. When a Wind Turbine part is replaced for a
new or remanufactured part, such new or remanufactured part becomes Customer’s
property and the replaced part becomes Primus Wind Power’s property. Customer
property remaining at Primus Wind Power’s repair facilities for more thanninety (90)
days without required Customer approval of return freight charges, becomes the
property of Primus Wind Power.
AIR Wind Turbine Limited Warranty
(continued)

Exclusions and Limitations
Primus Wind Power does not warrant that the operation of the Wind Turbine will be
energy productionunder any conditions.
This Limited Warranty does not apply to claims arising from installation of your AIR
Turbine’s Owner’s Manual. ThisLimited Warranty does not cover any part that was
notmanufactured by Primus Wind Power, nor doesit cover the costs of any repairs
or adjustments to your Wind Turbine that might be needed because of the use of
non-Primus Wind Power parts, components, equipment, ormaterials. This Limited
Warranty does not apply to: (i) consumable parts; (ii) cosmeticdamage, including
scratchesor dents unless such damage compromisesthe product’s function; (iii)
damage caused by overload, surges, use with any unsuitable power source, voltage
irregularities or utility system failures that enter the Wind Turbine through the output
or other cyclonic windstorms), misuse, negligence, accident, abuse, or vandalism; (v)
damage due to afailure to service and maintain, and/or operate the Wind Turbine
in accordance with its Owner’s Manual or provided instructions; (vi)a Wind Turbine
the written permission of Primus Wind Power; (vii) any Wind Turbine part whose
serial numberhas been removed or defaced; (viii) damage or loss to any items or
products not manufactured by Primus Wind Power that are connected to, powered
by, or otherwise attached to, the Wind Turbine; (ix)any expensesincurred from travel
to andfrom the repair location, troubleshooting, diagnostic and repair services,
equipment expenses, or; (x)damage due to improper installation of the Wind Turbine
that is not inaccordance to the owner’ s manual or, (xi) use of the wind turbine in
wind regimes withan annual average of 18 mph (8 m/s) or greater.
Disclaimer of Warranty
rights which vary from state to state. TO THE EXTENT PERMITTED BY LAW, THIS
EXPRESS LIMITED WARRANTY AND THE REMEDIES SET FORTH ABOVE ARE EXCLUSIVE
AND IN LIEU OF ALL OTHER WARRANTIES, REMEDIES AND CONDITIONS, WHETHER
ORAL, WRITTEN, STATUTORY, EXPRESSOR IMPLIED. AS PERMITTED BY APPLICABLE
LAW, Primus Wind Power DISCLAIMSANY AND ALL STATUTORY ORIMPLIED
WARRANTIES, INCLUDING, WITHOUTLIMITATION, THE IMPLIED WARRANTIES OF
FITNESS FOR A PARTICULAR PURPOSE, MERCHANTABILITY, NON-INFRINGEMENT AND
WARRANTIES AGAINST HIDDEN OR LATENT DEFECTS. IF Primus Wind Power CANNOT
LAWFULLY DISCLAIM STATUTORY OR IMPLIED WARRANTIES THEN, TO THE EXTENT
PERMITTED BY LAW, ALL SUCH WARRANTIES SHALL BE LIMITED IN DURATION TO THE
DURATION OF THISEXPRESS LIMITED WARRANTY. Primus Wind Power does not grant
the authority to create for it any obligation or liability in connection with your Wind
Turbine.
Limitation of Liability
EXCEPT AS PROVIDED IN THIS EXPRESS LIMITED WARRANTY AND TO THE MAXIMUM
EXTENTPERMITTED BY LAW, UNDER NO CIRCUMSTANCES WILL Primus Wind Power,
OR ITS AFFILIATES, SUPPLIERS, DEALERS, DIRECTORS, OFFICERS, EMPLOYEES, OR
AGENTS (THE “RELEASED PARTIES”) BE LIABLE OR RESPONSIBLE FOR, EVEN IF SUCH
RELEASED PARTY HASBEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGE, ANY
DIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES RESULTING FROM
ANY BREACH OF WARRANTY OR CONDITION, ORUNDER ANY OTHER LEGAL THEORY
OR FORM OF ACTION (WHETHER IN CONTRACT, TORT (INCLUDING NEGLIGENCE),
STRICT LIABILITY OR OTHERWISE), INCLUDING, BUTNOT LIMITED TO, ANY LOSS OF
USE, INTERRUPTION OF OR LOSSOF BUSINESS, LOST OF ACTUAL ORANTICIPATED
PROFITS (INCLUDING LOSS OF PROFITS ON CONTRACTS), LOSS OF REVENUE, LOSS
OF THE USE OF MONEY, LOSS OF ANTICIPATED SAVINGS, LOSS OF OPPORTUNITY,
LOSS OF GOODWILL, LOSSOF REPUTATION, LOSS OF, DAMAGE TO OR CORRUPTION
OF DATA, OR ANY INDIRECT ORCONSEQUENTIAL DAMAGES HOWEVER CAUSED,
INCLUDING THE REPLACEMENT OFEQUIPMENT AND PROPERTY, BODILY INJURY
OR DEATH. (Note: some states do not allow the exclusion orlimitation of incidental
or consequential damages, so these limitationsmay notapply to you.) The total
cumulative liability to Customer, from allcauses of actionandall theories of liability,
will be limited to and will not exceed the purchase price of the Wind Turbine paid by
Customer.
Product Changes
Primus Wind Power reserves the right to make changes, improvements or additions
to its products in the future without incurring obligations to make suchchanges,
improvements, or additions to its products previouslymanufactured. Occasionally, a
product change, improvement or addition will be made that eitherprevents future
failure of a product orpart oreliminates a safety hazard. Primus Wind Power willthen
or thisLimited Warranty will be void should failure occuras a result of not installing
said parts. Primus Wind Power reserves the right to change the terms of this Limited
Warranty in the future without incurring any obligations to make the changed terms
applicable to products previously manufactured.
AIR Wind Turbine Limited Warranty (continued)
(continued)
Air X Owner’s Manual 7

Additional Terms that Govern thisLimited Warranty
Each of us (i) agrees that all actions and proceedings relating directly or indirectly to
County, Colorado; (ii) consents to the jurisdiction and venue of any such court and
consents to service of process in any such action orproceeding by personal delivery
or any othermethod permitted by law; and (iii) waives any and all rights either of
us may have to object to the jurisdiction of any such court, or to transfer or change
the venue of any such action or proceeding. WE FURTHER EACH WAIVE THE RIGHT
TO TRIAL BY JURY IN ANY ACTION OR PROCEEDING BASED UPON, ARISING OUT OF,
OR IN ANY WAY RELATING TO, THESE TERMS AND CONDITIONS. We further agree
that this Limited Warranty may not be extended, altered or waived except in writing
HEREUNDERMUST BE COMMENCED WITHIN ONE YEAR AFTER THE CAUSE OF ACTION
HAS ACCRUED. Primus Wind Power shall be entitled to recover legal fees, costs and
expenses in defending and enforcing this Limited Warranty against Customer and
others. This Limited Warranty shall be construed andenforced in accordance with the
AIR Wind Turbine Limited Warranty (continued)
8Air X Owner’s Manual

Air X Technical Specifications
Model Air X
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 38 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: CE
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
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)
Air X Owner’s Manual
9

Your Air X is delivered partially assembled. Assembly requires mounting
the blades on the blade hub, securing the hub to the turbine body and
installing the nosecone on the blade hub. The necessary hex key (Allen)
wrenches are furnished with Air X.
Torque Specifications:
Blade to hub bolts, 1/4-20 x 1.25 inch, Socket Head Bolt, 7.0 lb-ft (9.4 N·m)
Hub to rotor nut, 5/8 -18 inch, Jam nut, 50 lb-ft (68 N·m)
Yaw Clamp Bolts, M5 x 35 mm, Socket Head Bolt, 4.0 lb-ft (5.4 N·m)
Start the assembly by examining how the blades mount to the hub, refer to
Fig 1. Using the Tef-Gel supplied with the Air X, apply a coat of Tef-Gel to
the blade root and hub. The use of Tef-Gel is recommended for all installa-
tions but is mandatory in marine environments.
The goal is to provide a coating of Tef-Gel between the blade root and
blade hub so that the blade material does not directly contact the alumi-
num hub. This is particularly important for marine installations since the
blades and hub may severely deteriorate in high moisture (particularly
marine) environments.
After coating the hub and blades with Tef-Gel place a nylock nut (Item 4)
in the detent on the back of the blade hub while positioning a blade on
the hub. Pass a bolt through the blade and screw it into the nylock nut –
do not fully tighten the bolt yet. Install the second bolt and nylock nut and
torque both bolts to
If Air X is to be installed on a “tilt-up” tower, mount the blade/hub assem-
bly to the turbine now. Start the 5/8-18 hub nut on shaft threads and
“spin” the hub completely onto the turbine
alternator shaft. Fully tighten the hub to
50 ft-lbs (68 Nm) by inserting a 5/16 inch
hex key wrench in the turbine alternator
shaft and turning the shaft while turning
the blades. Caution - blades are sharp!
If Air X is to be installed after the tower is erected, it will be safer and
easier to first install the turbine body on the tower and then install the
hub/blade assembly. This will avoid attempting to mount the turbine while
the blades are spinning – a dangerous condition.
Snap the nosecone into position over the outside edges of the blade hub.
Make sure all three edges of the nosecone snap over the edge of the
blade hub. After installation tug on the nosecone to make sure it is secure-
ly attached.
Two - Air X Turbine Assembly
IMPORTANT: Tef-Gel is a corrosion inhibitor and
is especially important in marine applications.
WARNING: Don’t
attempt to mount the
turbine while blades
are spinning.
Air X Owner’s Manual
Fig. 1 Air X Blade Attachment Detail.
1- Air X Blade Hub
2- Air X Blade
3- 1/4 - 20 Socket Head Cap Screw (2)
4- 1/4 - Nylock Nut (2)
5- Apply Tef-gel here
lightly temporarily hold the blade in place. Install the
.
remaining two blades following the same procedure. Measure tip to tip to
tip distance between the three blades and align as needed to measure as
equal a distance apart as possible. Torque all blade bolts to 7 ft-lbs. (9.4 Nm).
10
5
3
1
4
2