Southwest Windpower AIR MARINE - V3.2 User manual

The New 400 watt turbine!
Owner’s Manual
Version 3.2
2

NOTICES:
•This information is believed to be reliable; however, Southwest Windpower, Inc.
assumes no responsibility for inaccuracies or omissions. The user of this information
and product assumes full responsibility and risk.
•All specifications are subject to change without notice.
•Wind generators, like other sources of electrical power, must be installed following the
guidelines established by state and local regulations. Consult a local electrical contractor for
details and regulations.
Made in the USA by:
Southwest Windpower, Inc.
2131 N. First Street
Flagstaff, Arizona 86004
Toll Free Phone: [phone]
Phone: [phone]
Fax: [phone]
E-mail: [email protected]
Web: www.windenergy.com
AIR, AIR 403, and AIR marine are trademarks of Southwest Windpower
1999 Southwest Windpower, Inc.
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CONGRATULATIONS!
You have just purchased the most advanced battery charging wind turbine in the world!
We believe you will find it easy to install your AIR marine; however, it is important that you
read this entire manual thoroughly prior to installation to assure proper performance and
safety.
Southwest Windpower has over 12 years of experience in designing and manufacturing
small wind generators. In just four years, over 20,000 AIRs have been sold throughout the
world.
What makes the AIR marine unique in comparison to other turbines is the use of state-of-
the-art technology like Iron Boron Neodymium magnets, carbon reinforced engineering
thermoplastics, high-quality aluminum, stainless steel hardware and integrated electronics.
The turbines come standard with built-in regulators, self-governing mechanisms and the best
global warranty program in the industry.
The AIR marine is designed for off-shore and or land-based coastal applications where salt
corrosion is a concern.
If you have any questions after thoroughly reading the manual, please contact your
authorized distributor/dealer or Southwest Windpower, Inc.
Enjoy.
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New Features of the AIR marine
•Hysteresis: The AIR marine regulation control circuitry now incorporates hysteresis.
This will lock the turbine in a silent regulation mode once the batteries are fully charged.
The turbine begins producing power again when it senses the battery voltage slightly
below fully charged. This means, for a factory set 12V turbine, the turbine will regulate
(shut down) when the batteries have reached 14.1V, and will resume charging when the
voltage drops to 12.6V, which is slightly below fully charged. Minimal output is wasted,
as non-charging battery voltages above 12.6V represent mostly a “surface charge” with
very little energy. This feature prevents the turbine from fluctuating in and out of regulation
mode, resulting in a quieter, better-behaved machine.
•New Electronics: The AIR marine incorporates an exclusive power rectifier that sinks
excess heat directly to the body. The regulation electronics have been enhanced for
more robust control and reliability in the most extreme operating conditions.
•New Alternator: A more powerful alternator has been built into the new AIR marine.
The stronger permanent magnet rotor can be felt in rotating the blade shaft; a slight
“catch” can be felt when spinning the shaft with your fingers. This is normal, and is
quickly overcome when the blades begin spinning.
•New Blades: The rotor blades have been redesigned with a new, highly efficient true
airfoil. An all-new precision injection mold produces blades of exceptional consistency,
resulting in quieter performance and minimal vibration. In high winds the enhanced over-
speed mode (“flutter”) drops power output and machine RPM for longer life, lower noise,
and even greater survivability in the harshest winds.
•New Body, New Hub: The AIR marine body is made from a precision casting process
that not only enhances fit and finish, but also leads to a stiffer, more durable body. The
die cast aluminum hub design has been engineered to be the strongest, stiffest hub we
have ever produced.
Table of Contents
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1. Safety Precautions………………………………………………………... 6
1.1 Mechanical Hazards 6
1.2 Electrical Hazards 6
1.3 Installation 7
1.4 Operation 7
2. Package Contents………………………………………………………… 8
3. Wiring and Installation Procedures……………………………………. 9
3.1 Wiring………………………………………………………………….. 9
3.1.1 Electrical Connections 9
3.1.2 Wire Size 10
3.1.3 Grounding 11
3.1.4 Fusing 12
3.1.5 Stop Switch 12
3.1.6 System Wiring Diagrams 13
3.2 Mounting to Tower……………………………………………………16
3.2.1 Attaching to Pole 16
3.3 Hub and Rotor Assembly…………………………………………… 17
3.3.1 Mounting Blades 17
3.3.2 Mounting Hub and Rotor 18
3.3.3 Attaching Nose Cone 18
3.4 Step By Step Instructions………………………………………….. 18
4. Testing………………………………………………………………………. 20
4.1 General Discussion of Operation…………………………………. 20
4.1.1 Alternator 20
4.1.2 Regulator 20
4.1.3 Blades 20
4.1.4 Four Spinning Conditions 21
4.2 Bench Testing………………………………………………………… 21
4.3 Performance Testing………………………………………………… 22
4.4 Adjusting the Potentiometer (regulator) ………………………… 22
5. Trouble Shooting………………………………………………………….. 23
5.1 Assembly………………………………………………………………. 23
5.2 Electrical System………………………………….…………………. 23
6. Warranty Policy……………………………………………………………. 25
7. Specifications……………………………………………………………… 26
7.1 Technical Specifications 26
7.2 Sphere of Operation 27
7.3 Exploded View of AIR marine 27
8. Maintenance………………………………………………………………... 28
9. System Requirements and Considerations……………………………28
9.1 Batteries 28
9.2 Regulator Options 29
10. Siting……………………………………………………………………….. 30
11. Towers………………………………………………………………………31
12. Frequently Asked Questions…………………………………………... 32
13. Accessories……………………………………………………………….. 35
14. References …………………………………………………………………36
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1. SAFETY PRECAUTIONS
The AIR marine has been designed with your safety in mind. However, there are inherent
dangers involved with any electrical and/or mechanical equipment.
Safety must be the primary concern as you plan the location, installation and
operation of the turbine. At all times be aware of electrical, mechanical and rotor
blade hazards.
1.1 Mechanical Hazard
Rotating blades present the most serious mechanical hazard. The AIR marine’s rotor blades
are made of very strong thermoplastic. At the tip, the blades may be moving at velocities over
300 miles per hour. At this speed, the tip of a blade is nearly invisible and can cause serious
injury. Under no circumstances should you install the turbine where a person could
come in contact with moving rotor blades.
CAUTION: DO NOT INSTALL THE TURBINE WHERE ANYONE CAN APPROACH THE
PATH OF THE BLADES.
1.2 Electrical hazard
The AIR marine is equipped with sophisticated electronics designed to provide protection
from electrical dangers. The internal electronics of the AIR marine prevent open circuit
voltages from rising above 23 volts for 12-volt systems or above 45 volts for 24-volt systems.
Heat in wiring systems is often a result of too much current flowing through an undersized
wire or through a bad connection. It is important to follow the wire-sizing chart in Section
3.1.2 on page 10 to insure a safe electrical system.
CAUTION: FOLLOW THE WIRE SIZING CHART IN SECTION 3.1.2 ON PAGE 10 TO
HELP AVOID THE RISK OF AN ELECTRICAL FIRE.
Batteries can deliver a dangerous amount of current. A short occurs in the wiring from the
batteries can result in a fire. In order to avoid this threat, a properly sized fuse or circuit
breaker is required in the lines connecting to the battery. Refer to Section 3.1.4 on page 12 for
fuse sizing information.
CAUTION: FUSE ALL CONNECTIONS. FOLLOW THE FUSE SIZING GUIDELINES IN
SECTION 3.1.4 ON PAGE 12 TO MINIMIZE THE RISK OF AN ELECTRICAL FAILURE.
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1.3 Installation
CAUTION: ALL INSTALLATION PROCEDURES SHOULD BE PERFORMED AT DECK
LEVEL.
CAUTION: MAKE SURE THAT ALL BATTERIES ARE DISCONNECTED THROUGHOUT
THE INSTALLATION PROCESS.
CAUTION: NEVER INSTALL THE AIR MARINE UPSIDE DOWN.
Please follow these precautions during the installation process:
•Choose a calm day.
•THINK SAFETY! Have someone available to help during the installation process.
•Disconnect batteries from turbine wiring.
•Prior to attaching the wires to the battery, tie the wind turbine output lead wires
(positive = red; negative = black) together near the battery to be sure that the rotor will not
spin-up during installation.
NOTE: Do not install the blade assembly until the turbine is mounted on the tower.
1.4 Operation
Check support structures, blades, and electrical systems on a regular basis.
•The rotor blades are very strong; however, if they come in contact with a solid object,
they can break. Use common sense about safety when locating the turbine.
•When performing periodic inspections, or at anytime when you must approach the
path of the blades, disconnect the power leads from the battery and tie the wind turbine
output leads together to stop (slow down)the blades from rotating. The turbine can also be
shut down through the use of a stop switch. Please refer to Figure 2 on page 12 on how to
install a stop switch in your system.
CAUTION: NEVER APPROACH THE TURBINE DURING OPERATION.
USE COMMON SENSE AND PLEASE BE CAREFUL
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2. PACKAGE CONTENTS
Compare the parts shown in Figure 1 to ensure that the contents of the box contain all
necessary parts.
CAUTION: THE EDGES OF THE ROTOR BLADES ARE SHARP. PLEASE HANDLE WITH
CARE.
Figure 1
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3. WIRING AND INSTALLATION PROCEDURES
Your AIR marine is shipped partially disassembled. Refer to Figure 7 on page 17 for
assembly instructions. Please completely read all procedures before beginning installation.
NOTE: Do not install the blade assembly until the turbine is mounted on the tower.
Required Tools:
•5/16” hex key wrench (included)
•3/16” hex key wrench (included)
•5/32” hex key wrench (included)
•Torque wrench with 5/16”, 3/16”, and 5/32” hex drives (optional)
•Soldering iron or propane torch
•Rosin core solder
•Electrical tape or 1/4” (6-7mm) heat shrink
•Wire strippers
•Wire crimpers
3.1 Wiring
3.1.1 Electrical Connections
NOTE: Refer To All Local and National Codes Before Installation.
CAUTION: MAKE SURE THE TURBINE IS DISCONNECTED FROM THE BATTERIES
DURING INSTALLATION.
Avoid connecting different metals together (i.e., copper and aluminum). This will cause a
galvanic cell that will erode one of the metals. When such connections can not be avoided,
consult your dealer or an electrical supply house for anti-oxidant compounds. If possible
solder wire termination ends.
CAUTION: CONNECTIONS SHOULD BE INSPECTED PERIODICALLY FOR SIGNS OF
CORROSION AND CLEANED WHEN NECESSARY.
NOTE: All electrical power cables should be physically protected. Run the wires inside the
tower or mast for maximum protection.
NOTE: The yaw can support a total of 150 lbs. (68 kg) in wire weight. For higher wire
weights, you must install a strain relief to minimize the stress put on the hanging wires. Due
to the presence of moist salt air(which acts as electrolyte, as in a battery) the marine
environment is very corrosive. Always use tin plated, stranded copper wire for best
protection against corrosion.
Wire Color Codes
RED = positive
BLACK = negative
GREEN = earth ground
3.1.2 Wire Size
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To select the appropriate size wire, measure the distance from the batteries to your AIR
marine, then refer to the following wire sizing chart as minimum sizes. If cost is not an
issue, a larger sized wire will improve the performance of your AIR marine.
All electrical systems lose energy from the resistance of the wires used. Larger wiring sizes
have smaller losses, but can be considerably more costly. The following wiring sizes provide
a maximum annual energy losses of 5% or less for sites with a 12mph average wind speed
(assuming the standard Rayleigh distribution of wind speeds,) which is sufficient for most
sites. If you know your average wind speed to be different, compensate the wiring
LENGTHS given in the charts using the factors given at the end of this section. Table entries
with a “*” denote cases which should use additional bus lines.
We recommend these as the minimal wire sizes; for optimal performance you should use the
largest wires that are practical and affordable. Local, state, and national electrical codes
supercede these recommendations, and should be followed to insure the safety of your
system.
12V AIR marine: Wire Size, Considering 12mph Wind Average and 95% Energy
Transmission Efficiency
# Turbines 0-30ft 31ft-60ft 61ft-90ft 91ft-150ft 151ft-190ft 191ft-250ft 251ft-310ft 311ft-390ft 391ft-500ft
18g 6g 4g 2g 1g 0g 00g 000g 000g
26g 4g 1g 00g 000g 0000g * * *
34g 2g 0g 000g 0000g * * * *
Fuse: 100 Amp Slow-Blow per turbine
* If your system requires this length of wire, consider using additional bus line(s).
24V AIR marine: Wire Size, Considering 12mph Wind Average and 95% Energy
Transmission Efficiency
# Turbines 0-30ft 31ft-60ft 61ft-90ft 91ft-150ft 151ft-190ft 191ft-250ft 251ft-310ft 311ft-390ft 391ft-500ft
114g 12g 10g 8g 6g 4g 4g 4g 2g
212g 8g 6g 4g 4g 2g 2g 1g 0g
310g 8g 6g 4g 2g 2g 1g 0g 00g
Fuse: 50 Amp Slow-Blow per turbine
36V AIR marine:Wire Size, Considering 12mph Wind Average and 95% Energy
Transmission Efficiency
# Turbines 0-30ft 31ft-60ft 61ft-90ft 91ft-150ft 151ft-190ft 191ft-250ft 251ft-310ft 311ft-390ft 391ft-500ft
114g 14g 12g 10g 10g 8g 8g 6g 6g
214g 12g 10g 8g 8g 6g 6g 4g 4g
314g 10g 8g 6g 6g 4g 4g 2g 2g
Fuse: 35 Amp Slow-Blow per turbine
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48V AIR marine: Wire Size, Considering 12mph Wind Average and 95% Energy
Transmission Efficiency
# Turbines 0-30ft 31ft-60ft 61ft-90ft 91ft-150ft 151ft-190ft 191ft-250ft 251ft-310ft 311ft-390ft 391ft-500ft
114g 14g 14g 14g 12g 10g 10g 10g 8g
214g 14g 12g 10g 10g 8g 8g 6g 6g
314g 14g 12g 10g 8g 8g 6g 6g 4g
Fuse: 25 Amp Slow-Blow per turbine
Wiring Compensation for Average Wind Speed
For different average wind speeds, the wire LENGTHS in the charts should be compensated.
Compensating by changing wire gauge can lead to safety problems. For the average wind
speed of your site, multiply each wire length in the chart by the factor shown:
Average Wind Speed Multiplier for Wire LENGTHS
9mph 2
10mph 1.5
11mph 1.25
12mph 1
13mph 0.8
14mph 0.6
Wiring Resistance and Regulation
Wiring resistance can affect the regulation set point of the turbine. Higher wiring resistance
(smaller wires) will lower the voltage at which the turbine enters regulation and stops
charging. The recommended wiring sizes should provide little effect on the regulation set
point, but all installations should be observed over time to ensure that the batteries are
charged to the proper voltage.
3.1.3 Grounding
Properly grounding the turbine is very important in protecting the electronics for long-term
operation. Grounding procedures must be followed along with any local electrical codes.
IMPORTANT: SEVERE TURBINE DAMAGE CAN RESULT FROM IMPROPER GROUNDING!
FAILURE TO PROPERLY GROUND WILL VOID YOUR WARRANTY.
It is very important to ground your battery bank and ground your tower for lightning and static
protection. The green lead wire provides grounding for the body of the turbine. This wire must
be connected to the system earth ground. Assuming you have the battery negative properly
grounded, you can connect the black and green wires together at the turbine and then run the
negative wire to the battery bank.
IMPORTANT: ALL grounds must be connected together to insure a proper
ground.
The AIR marine should be grounded according to the American Boat and Yacht Council
(ABYC). Ph. [phone]
Most boats use the engine block or a submerge plate to carry the ground to the water.
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The reference section in the appendix lists two books that provide you detailed information on
proper grounding in marine applications.
Delta manufactures surge arrestors for lightning protection. An example is their model LA
302-RG surge protector. Contact: Delta Lighting Arrestors P.O. Box 750, Big Springs TX
79721, Phone [phone] Fax [phone] or your dealer for more information.
3.1.4 Fusing
The AIR marine is capable of producing high amperages. As with all electrical installations,
you must protect each of your turbines with a properly sized fuse or circuit breaker. The AIR
marine should be wired with an appropriately sized “slow-blow” type fuse between itself
and the batteries. If a stop switch is used, the fuse should be placed between the switch
and the batteries.
Recommended Size for Circuit Breakers or Slow-Blow Fuses
•12-volt model: 100 amps D.C.
•24-volt model: 50 amps D.C.
•36-volt model: 35 amps D.C.
•48-volt model: 25 amps D.C.
3.1.5 Stop Switch
A stop switch must be used with your AIR marine to provide a convenient method for
shutting down the turbine. The stop switch is a 50-amp D.C. single-pole double-throw switch
that is used to shut the turbine off. The switch disconnects the battery and then shorts the
turbine causing the turbine to stop spinning (in high winds the blades will spin slowly).
Shorting the turbine will not cause any damage or additional wear.
Your dealer/distributor should be able to supply the stop
switch or you can contact Southwest Windpower directly.
They can also be found at some automotive electrical stores.
Figure 2 Stop Switch Wiring
NOTE: The center post must be positive from the turbine.
Outside posts can be swapped as either positive or negative.
Some installations of the AIR marine may require a high
current rated stop switch, such as 12V systems in very high wind applications, or in cases
where local electrical codes require it. Switches used in these applications must be single-
pole, double-throw, rated for the maximum voltages and currents that the system may
experience. Many battery bank selector switches for RV’s can NOT be used, as they include
a “BOTH” position, which will short your battery bank.
High current switches are more costly, but there are some reasonably priced, quality
switches available from industrial supply stores. One good choice is a battery selector
switch manufactured by Cole-Hersee, model number 75502. This switch is available from
several sources, including Specialty Electric Supply in Homer, AK, phone # [phone],
and also from Industrial Sales and Service in Portland, OR, phone # [phone].
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To use this switch, connections are the same as the switch described above, with the
“Battery 1” post to the battery positive, the “Battery 2” post to the turbine/battery negative,
and the third post to the turbine positive.
3.1.6 System Wiring Diagrams
Before deciding how to wire your AIR marine it is important to understand how your existing
system is wired and how the AIR marine’s internal regulator operates. Refer to the General
Discussion of Operation in Section 4.1.2 on page 20 for information on the AIR marine’s
internal regulator.
The recommended way to connect the turbine to your battery bank is to wire the turbine
directly to the battery bank to its own set of battery posts. This will allow the turbine to
operate independently. The AIR marine’s internal regulator will independently monitor the
battery and charge as necessary.
You can wire the AIR marine through most “power centers”. However, if you experience
interference or pre-regulation, you must bypass it and wire the turbine directly to the battery
bank.
Some external charging sources(i.e. solar panels, fuel-powered generators, shore chargers,
additional wind generators etc.) can interfere with the turbines electronics and cause pre-
regulation. If there is external interference, it will not harm the turbine: it will just cause the
turbine to spin slowly as if “braked” or in the stop position. If this occurs test the possible
interference by disconnecting the other charge sources to determine the possible
interference source.
Choose the appropriate wiring diagram below for proper wiring information.
A. Single AIR Wiring
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Figure 3
Figure 3
B. AIR marine In System With Solar Panels (Hybrid System)
Figure 4
NOTE: In this
drawing the
AIR marine’s
internal
regulator is
used. A
diversion type
external
regulator can
also be used.
15

C. Multiple AIR marine Installation
Figure 5
There are two methods to wire multiple AIR marines.
a) Each Turbine Wired Directly To Battery
Each turbine operates as an independent system separate from other solar panels, gas
generators or any other battery charging sources. Since the turbine has its own fuse, stop
switch (optional), and wires, the turbine is able to individually operate and charge the battery.
b) Each Turbine Wired To A Bus Bar
If you plan to wire two or more turbines to a “bus”, and then run one set of wires from the
bus to the battery, you can use each turbine’s internal regulator or install an external
regulator. If you use an external regulator use a diversion style that turns excess current into
heat for heating a room, water etc. When wiring multiple turbines, it is possible to reduce your
wiring costs by using a bus bar system.
NOTE: Do NOT accidentally connect the turbine “backwards” to the battery for
even a second (i.e. turbine positive to battery negative and turbine negative to
battery positive). Doing this will instantly destroy the circuit inside the turbine
and void your warranty.
3.2 Mounting To Tower
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The AIR marine is designed to be mounted on a 1 1/2“, SCH 40 steel or aluminum pipe (do
not use plastic). The outside diameter of the pipe should be 1.875” (48 mm). There is a soft
coupling inside the yaw shaft mount that is designed to provide a secure fit and to dampen
some of the noise transmitted down the tower. The pole must be mounted with hardware
specifically designed for small wind turbines. Southwest Windpower offers a complete
stand-alone marine tower package for sailboats and a “Roof Mount Kit” for mounting to
structures, which provides secure mounting and superior noise isolation. Contact your dealer
for details.
CAUTION: Only use properly sized metal pipe for towers.
3.2.1 Attaching to Pole
While attaching the turbine to the tower, be careful not to pinch the yaw wires. Slide the yaw
all the way down over the end of pole. After the yaw is seated on the pole, move it back up a
1/8th inch (2mm) to prevent the bottom of the yaw from contacting the top of the pole. This
way the only contact between the tower and yaw is through the rubber pad, which will
reduce noise transmission. Tighten all mounting fasteners.
Make sure that your tower allows for proper clearance of the blades. A minimum
2 inch (20 mm) clearance must be given between the blade tips and any obstructions. Refer
to Figure 6 below, and the “Sphere of Operation” drawing in Section 7.2 on page 27 for
proper clearances.
Figure 6 Proper Blade-to-Tower Clearances
3.3 Hub And Rotor Assembly
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Before assembling the hub and rotor refer toFigure 7 below, and the following detailed
instructions.
NOTE: To avoid damage to the blades during installation, do not put the blade assembly on the
turbine until the turbine is mounted on the tower.
Figure 7
3.3.1 Mounting the Blades
CAUTION: THE EDGES OF THE ROTOR BLADES ARE SHARP. PLEASE HANDLE WITH
CARE.
Notice that the screw holes in the blades are counter-bored for the socket head cap screws.
Place one of the blades, with the counter bore facing up and align the screw holes. Insert one
of the socket head cap screws through the blades and hub. Place a small amount of Tef-
Gelanti-seizing agent on the threads of each screw. Place nut on the end of the screw
and tighten the screw with the 3/16” hex key wrench to 10 - 12 foot lbs. (13.6 – 16.3 Nm).
Repeat this procedure on all three blades. You may need to “thread” the screws through the
hub with the hex wrench.
3.3.2 Mounting the Hub and Rotor
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CAUTION: THE BLADES ARE SHARP. USE CAUTION WHILE HANDLING THE BLADES.
Remove the 5/8” nut from the alternator shaft. Carefully slide the blade assembly onto the
alternator shaft. Place the nut on the shaft and thread the nut on by spinning the blade
assembly. Place a small amount of Tef-Gelon the rotor threads before you insert the rotor
nut. Insert the 5/16” hex key torque wrench into the alternator shaft and tighten the nut by
holding the hub set and tightening the shaft with the torque wrench. The nut should be
tightened to 50 - 65 foot pounds (68 – 88 Nm). When the blade set assembly is tightened, spin
it to be sure it turns freely.
3.3.3 Attaching Nose Cone
Carefully place the nose cone over the center of the hub and the blades. Snap the nose cone
into place. Be sure all three edges catch. Check to see that the nose cone is secure by firmly
pulling on it. The nose cone does not affect the performance of the turbine and may be left
off, if desired.
3.4 Step By Step Instructions
The following Step-By-Step-Installation-Procedures provides you with an outline of the AIR
marine installation process. This consolidated reference should only be used as an outline
during installation. Refer to the appropriate sections for further details.
1) Run the wires from the battery (do not connect to the battery), through the pole to the top
of the tower. Be sure not to connect the wires to the battery until everything else
has been completed.
2) Strip the insulation back from each set of wires.
3) Mark both ends of all the wires with tape to identify which is negative, positive and earth
ground.
AIR marine wire color-codes:
RED = Positive
BLACK = Negative
GREEN = Ground.
4) Insulate the connections using either heat shrink tubing or a quality electrical tape.
5) Connect the wires from the AIR marine to the wires running to the battery.
CAUTION: IF THE WIRES ARE HOOKED-UP BACKWARDS YOU WILL DAMAGE THE
AIR MARINE’S ELECTRONICS. (IF YOU ARE UNCERTAIN OF THE POLARITY OF THE
WIRES, SIMPLY SPIN THE ROTOR SHAFT AND MEASURE THE VOLTAGE DIRECTION
WITH A VOLT METER).
6) Once the wires are attached to the AIR marine,gently pull the wires down through the
tower sliding the yaw shaft over the 1 1/2“, Schedule 40 steel or aluminum pipe (Actual OD
1.875 inches, 48mm). Do not use plastic pipe.
19

7) Slide the yaw shaft all the way down over the end of pole being careful not to pinch the
yaw wires. Be sure to leave enough slack in the wires so that if necessary, the turbine can
be removed.
8) After the yaw is all the way onto the pole, move it back up 1/8th inch (2 mm) to prevent the
bottom of the yaw from contacting the top of the pole. The only contact between the tower
and yaw is through the rubber pad which will reduce the transmission of noise down the
tower.
9) Once the yaw shaft is on the tower, firmly tighten the yaw clamp screws with the 5/32
hex key. The AIR marine should yaw freely without restrictions. Be sure to apply Tef-Gel
to the threads of the four yaw screws before you tighten them.
10) Check your AIR marine to be sure that it is securely attached to the mounts. Remember
that this attachment will have to hold in high winds.
11) Attach the assembled hub and blades to the rotor shaft.
12) Run all wires from the turbine to the battery (do not connect wires to the battery). Be sure
to crimp and solder the connections using the appropriate sized connectors. If you plan to
connect an amp meter into your system, see Figure 4, on page 14.
13) Attach your positive (RED) wire to a fuse. Refer to Section 3.1.4 on page 12 for fusing
information.
14) Make sure that your system is properly grounded before proceeding. Refer to the
Grounding Section 3.1.3 on page 11.
IMPORTANT: SEVERE UNIT DAMAGE WILL RESULT FROM IMPROPER GROUNDING.
FAILURE TO PROPERLY GROUND THE TURBINE WILL VOID YOUR WARRANTY.
15) Before attaching the wiring to the battery, make sure that:
- all circuit breakers are in the off position
- the stop switch is in the “stop” or shorted position (if installed)
16) Attach wires to the battery. Red wire to positive, Black wire to Negative.
17) Turn on the circuit breakers and or stop switch.
18) When the blades are rotating very quickly in the wind, you should see the red LED
illuminate.
19) You have now completed the installation process.
20