Southwest Windpower AIR MARINE - V3.2 User manual

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