Southwest Windpower Air X User manual

Southwest Windpower, Inc.
1801 West Route 66
Flagstaff, Arizona 86001
Toll Free Phone: [phone]
Phone: [phone]
Fax: [phone]
www.windenergy.com
OWNER’S MANUAL
Installation • Operation • Maintenance
 October 2008 Southwest Windpower, Inc.
All Rights Reserved
Air x

Air X Owner’s Manual 3
Southwest Windpower
Congratulations on your purchase and welcome to our family!
Dear Air X Owner,
Thank you for your purchase of Air X. You have purchased the most advanced battery charging wind turbine in the world! We believe you will find it easy
to install your Air X and are confident you will experience years of dependable service from it.
Before going any further, please complete and return the Warranty Registration Card. Note - Southwest Windpower does not sell or distribute your per-
sonal 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 Arizona
Standard Time). Our numbers are 928-779-9463, toll-free 866-805-9463.
Again, welcome to our family and thank you for investing in the future of wind energy with Air X.
Sincerely,
Southwest Windpower
Enter the serial and model numbers below
Serial Number __________________________________
Model Number __________________________________
Air X Owner’s Manual
Document No. 3-CMLT-1004
Revision: E
AIR, AIR 403, Air X, AIR Wind Module are trademarks of Southwest Windpower  2007 Southwest Windpower, Inc.

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 noise or operation is experienced, turn off machine and contact authorized
service personnel.
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 BREEZE
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.

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
11) CSA CERTIFICATE OF COMPLIANCE _________________ 29-30

Hardware Warranty
Southwest Windpower, Inc., (“Southwest Windpower”) will repair or replace free of
charge any part or parts of the Southwest Windpower Air X (Land or Marine) Wind Tur-
bine determined by Southwest Windpower to be defective in materials and/or workman-
ship under normal authorized use consistent with product instructions for a period of
three years from the date the original purchaser (“Customer”) receives the Wind Turbine
(“Start Date”). This warranty extends only to the original purchaser. The Customer’s sole
and exclusive remedy and the entire liability of Southwest Windpower, its suppliers and
affiliates under the warranty is, at Southwest Windpower’s option, either (i) to replace
the Wind Turbine with new or reconditioned Wind Turbine; (ii) to correct the reported
problem; or (iii) to refund the purchase price of the Wind Turbine. Repaired or replaced
products are warranted for the remainder of the original warranty period.
Restrictions
Problems with the Wind Turbine Products can be due to improper use, improper main-
tenance, non-Southwest Windpower additions or modifications or other problems not
due to defects in Southwest Windpower’s workmanship or materials. No warranty will
apply if the Wind Turbine (i) has been altered or modified except by Southwest Wind-
power; (ii) has not been installed, operated, repaired, or maintained in accordance with
instructions supplied by Southwest Windpower; (iii) or (iv) has been exposed to winds
exceeding 120 mph (54 m/s), or has been subjected to abnormal physical, thermal
or electrical stress, misuse, negligence, or accident. If Southwest Windpower’s repair
facility determines that the problem with the Wind Turbine is not due to a defect in
Southwest Windpower’s workmanship or materials, then the party requesting warranty
service will be responsible for the costs of all necessary repairs and expenses incurred
by Southwest Windpower.
Warranty Claims & Return Procedures
In order to be eligible for service under this warranty, the Customer must submit a
service request for Wind Turbine covered by this warranty within the warranty period by
contacting Southwest Windpower in writing or via telephone and obtaining a Return
Authorization (“RA”) number. This RA must be obtained before returning any product
under this warranty.
Notification must include a description of the alleged defect, the manner in which the
Wind Turbine was used, the serial number, and the original purchase date in addition
to the name, address, and telephone number of the party requesting warranty service.
Within 3 business days of the date of notification, Southwest Windpower will provide
the Customer with an RA number and the location to which the Customer must return
the defective Wind Turbine. Any Wind Turbine requiring warranty shall be transported
at the expense and risk of the party requiring warranty service, including but not limited
to proper packaging of the Product. The Customer must return the entire Wind Turbine
kit within 30 days after issuance of the RA number. Southwest Windpower will be
under no obligation to accept any returned Wind Turbine that does not have a valid RA
number. Customer’s failure to return the Wind Turbine within 30 days of its receipt of
an RA number may result in cancellation of the RA. All parts that Southwest Wind-
power replaces shall become Southwest Windpower’s property on the date Southwest
Windpower ships the repaired Wind Turbine or part back to the Customer. Southwest
Windpower will use all reasonable efforts within five days of receipt of the defective
Wind Turbine to repair or replace such Wind Turbine. If a warranty claim is invalid for
any reason, the Customer will be charged at Southwest Windpower’s then-current
rates for services performed and will be charged for all necessary repairs and expense
incurred by Southwest Windpower.
Disclaimer
EXCEPT FOR THE EXPRESSED WARRANTY SET FORTH ABOVE, SOUTHWEST
WINDPOWER DISCLAIMS ALL OTHER EXPRESSED AND IMPLIED WARRAN-
TIES, INCLUDING THE IMPLIED WARRANTIES OR FITNESS FOR A PARTICULAR
PURPOSE, MERCHANTABILITY AND NON-INFRINGEMENT. NO OTHER WAR-
RANTY, EXPRESSED OR IMPLIED, WHETHER OR NOT SIMILAR IN NATURE TO
ANY OTHER WARRANTY PROVIDED HEREIN, SHALL EXIST WITH RESPECT TO
THE PRODUCT SOLD UNDER THE PROVISIONS OF THESE TERMS AND CON-
DITIONS. SOUTHWEST WINDPOWER EXPRESSLY DISCLAIMS ALL LIABILITY
FOR BODILY INJURIES OR DEATH THAT MAY OCCUR, DIRECTLY OR INDIRECT-
LY, BY USE OF THE PRODUCT BY ANY PERSON. ALL OTHER WARRANTIES ARE
EXPRESSLY WAIVED BY THE CUSTOMER.
Limitation of Liability
UNDER NO CIRCUMSTANCES WILL SOUTHWEST WINDPOWER OR ITS AFFIL-
IATES OR SUPPLIERS BE LIABLE OR RESPONSIBLE FOR ANY LOSS OF USE,
INTERRUPTION OF BUSINESS, LOST PROFITS, LOST DATA, OR INDIRECT, SPE-
CIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES OF ANY KIND REGARD-
LESS OF THE FORM OF ACTION, WHETHER IN CONTRACT, TORT (INCLUDING
NEGLIGENCE), STRICT LIABILITY OR OTHERWISE, RESULTING FROM THE DE-
FECT, REPAIR, REPLACEMENT, SHIPMENT OR OTHERWISE, EVEN IF SOUTH-
WEST WINDPOWER OR ITS AFFILIATE OR SUPPLIER HAS BEEN ADVISED
OF THE POSSIBILITY OF SUCH DAMAGE. (Note: some states and provinces
do not allow the exclusion or limitation of incidental or consequential damages, so
these limitations may not apply to you.) Neither Southwest Windpower nor its affiliates
or suppliers will be held liable or responsible for any damage or loss to any items or
products connected to, powered by or otherwise attached to the hardware. The total
cumulative liability to Customer, from all causes of action and all theories of liability, will
be limited to and will not exceed the purchase price of the Product paid by Customer.
This warranty gives the Customer specific legal rights and the Customer may also have
other legal rights that vary from state to state or province to province.
Air X 3-Year Limited Warranty
3-CMLT-1331 REV NC 10-07
WIND TURBINE WARRANTY AGREEMENT
6 Air 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: CSA (certificate 1954979), CE
12 volt and 24 volt Air X 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.
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. SWWP 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 7

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 7 ft – lbs (9.4 Nm). Install the remaining two blades
following the same procedure.
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.
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.
8 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)

Small changes in wind speed can have a dramatic effect on power produc-
tion. The siting of your wind turbine should be carefully considered. Each
installation is different and is often a compromise among tower height, dis-
tance from the battery bank, local zoning requirements and obstacles such
as buildings and trees.
In general the higher the tower, the greater the wind speed and ultimately
power production. However, towers are expensive and can easily exceed
the cost of the turbine.
The minimum recommended tower height is 25 ft (7.6 m) on open ground
or 20 ft (6 m) above nearby obstructions. (Fig. 2) Try to locate the wind
turbine in the “cleanest” turbulent free air as possible. Turbulence will
reduce the efficiency of the wind turbine and may accelerate wear on rotat-
ing components.
Safety must be the primary concern when selecting the mounting location. Install
Air X so there is no possibility of accidental contact with rotating blades even if it
requires installing the wind turbine in a less than ideal location. Safety has prece-
dence over efficiency.
Three - Air X Siting
WARNING: Install Air X so there is no possibility
of accidental contact with rotating blades even if
it requires installing the wind turbine in a less than
ideal location.
20 feet (6 m)
Prevailing wind
Fig. 2 Optimal Air X location.
Air X Owner’s Manual 9

10 Air X Owner’s Manual
The Air X is designed to mount on tubing or pipe with a nominal 1.875
– 1.900 inch outside diameter. This dimension enables constructing a
tower from a range of readily available materials including 1 1/2 inch
Schedule 40 steel pipe and 2 inch SS-20 galvanized fence tubing (0.090
inch wall thickness). Under no circumstances should plastic pipe be used
to construct a tower.
Four - Air X Towers
WARNING: Plastic pipe should NEVER be used to construct a tower.
Fig. 3. Tower Options
29 ft (8.8 m) Tower
27 ft (8.3 m) Tower
4-1 Tower Options
Southwest Windpower offers a number of tower choices for Air X. The
following section provides a summary of the available towers. 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. See Fig. 3.
IMPORTANT: User manuals for towers and tower kits
are available online at www.windenergy.com. Southwest
Windpower recommends reviewing them to make an
appropriate tower selection for your Air X.
45 ft (13.7 m) Tower

Air X Owner’s Manual 11
Fig. 5. 29 ft (8.8 m) Tower Kit
4x
4x
4x
x8
29'EZ TOWER KIT
x16
Fig. 4. 27 ft (8.3 m) Tower Kit
x8
27' AIR TOWER
x4
x2
4-1-1 27 ft (8.3 m) Tower Kit
(Southwest Windpower part number 1-TWA-10-01)
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. 4.
Note: Anchors and pipe or tubing are not furnished with the kit so
you have the flexibility to use the most appropriate components
for the installation.
4-1-2 29 ft (8.8 m) EZ – Tower
(Southwest Windpower part number 1-TWA-11-01)
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, galva-
nized steel tubing and all fasteners are included with the kit. See Fig. 5.

4-1-4 Marine Tower Kit
(Southwest Windpower part number 1-TWA-20-02)
The Marine Tower Kit is specifically 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. 7.
12 Air X Owner’s Manual
3x
8x
45' AIR TOWER
16x
x2
Fig. 6. 45 ft (13.7 m) Tower Kit
4-1-3 45 ft (13.7 m) Tower Kit
(Southwest Windpower part number 1-TWA-10-02)
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. 6.
IMPORTANT: User manuals for towers and tower kits are available online
at www.windenergy.com. Southwest Windpower recommends reviewing them
to make an appropriate tower selection for your Air X.
Fig. 7. Marine Tower Kit
Note: Anchors and pipe or tubing are not furnished with the kit so you have
the flexibility to use the most appropriate components for the installation.

Air X Owner’s Manual 13
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
Five - Air X 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. This will
allow the turbine to operate independently. The Air X’s internal regu-
lator will monitor the battery and maintain the charge as necessary.
Figs. 9 and 10 represent typical single turbine installations. Fig. 10
includes an up-tower junction box for National Electric Code compli-
ance. Contact Southwest Windpower for more information about this
configuration.
TIP: Wire turbine directly to
battery bank to its own set of
battery posts.
Fig. 9. Single Turbine Installation
Air X

14 Air X Owner’s Manual
User Power
Red Lead
Disconnect
Battery
Green Lead
Switch
Earth Ground
Stop
Turbine Ground
Amp
Meter
Black Lead
Turbine Negative
Earth Ground
Battery Bank
Box
Lightning Arrestor
Turbine Positive
Junction Box
Center Junction
Up-Tower
Tower
Chassis
Ground
AIR BREEZE
Wind Turbine
Generator
Fuse or
Breaker
Fig. 10. Single Turbine Installation with Up-Tower Junction Box
Fig. 10 represents a system with an Up Tower Junction
Box. The junction box may be installed close to the top of
the tower to ease installing a Lightning Arrestor. Typically
installing the box will require drilling holes in the tower to
install the box – be careful not to compromise the tower
strength.
Air X

Air X Owner’s Manual 15
Stop
Breaker
Wind Turbine Generato
r
Switch
Black Lead
Turbine Negative
Red Lead
Turbine Positive
Battery
Disconnect
Fuse or
User Power
Box
Center Junction
Turbine Ground
Green Lead
Earth Ground
Battery Bank
Tower Ground
Ground
Chassis
Rod
Ground
Disconnect
Battery
Meter
Amp
Controller
Diversion Load
Load
(Optional)
Resistive
Meter
Amp
Controller
PV Solar Array
PV Charge
AIR BREEZE
Tower
Fuse or
Breaker
Fig. 11. Hybrid System with Solar Panels
5-1 Hybrid System Wiring
Fig. 11 represents a typical “hybrid”
system with solar panels. Some charg-
ing sources (solar panels, fuel-powered
generators, additional wind generators,
etc.) connected to the same system
may cause interference with the Air X
internal electronics and result in pre-
regulation. The interference will not
harm the turbine; it will just cause it to
spin slowly as if “braked” or it may stop
the turbine. If this occurs, test for pos-
sible interference by disconnecting the
other charging sources to determine
the possible cause. If possible wire the
turbine and PV panels to their own set
of battery posts.
TIP: In this figure the Air X
internal regulator is used. A
diversion type external regulator
could also have been used.
TIP: Voltage “pre-regulation”
may be prevented by increasing
the regulation set point. See
section 7-3-2.
Air X

16 Air X Owner’s Manual
Switch
Stop
Battery Bank
Earth
Ground
Generator
Green Lead
Tower Ground
Turbine Ground
Black Lead
Turbine Negative
Red Lead
Turbine Positive
AIR BREEZE
Wind Turbine
Tower
Ground
Rod
Fuse
or
Breaker
Red Lead
Turbine Negative
Black Lead
Green Lead
Turbine Positive
Generator
Stop
Switch
Turbine Ground
AIR BREEZE
Wind Turbine
Tower Tower Ground
Fuse
or
Breaker
Turbine Positive
Meter
Generator
Tower Ground
Stop
Green Lead
Switch
Red Lead
Turbine Ground
Amp
Black Lead
Turbine Negative
AIR BREEZE
Wind Turbine
Tower
Battery
Disconnect
Fuse
or
Breaker
Fuse
or
Breaker
Fig. 12. Multiple Air X Wiring
5-2 Multiple Air X Wiring
Method One:
Each Air X is treated sepa-
rately. Each turbine will
have its own wires, stop
switch and fuse and will
connect directly to the
battery using the internal
regulator to control
charging.
Method Two:
Wire each turbine to a
“bus” and then run one set
of wires from the bus to
the battery. Each turbine’s
internal regulator or an
external diversion type
regulator may be utilized.
A “bus” system typically
results in reduced wire
costs.
It is possible to wire multiple
Air X turbines together. A
typical multi-turbine system
is depicted in Fig. 12.
There are two methods used
to accomplish this task.
Air X Air X Air X

Air X Owner’s Manual 17
5-3 Wire Size
All electrical systems lose energy due to resistance in conductors.
• Large wires have less resistance but can be considerably more costly.
• Resistance losses will also increase with increasing current, therefore, if
yours is a high wind site, it may be worthwhile to go with a larger size wire
to take advantage of the greater energy production potential of your site.
• Conversely, in low wind sites it may not be cost effective to increase the
wire size since power production will be low.
The following wiring sizes provide maximum annual energy losses of 5% or
less for sites with a 12 mph average wind speed (assuming the standard
Rayleigh distribution of wind speeds) which is sufficient for most sites.
To determine the size wire, measure the distance from the batteries to your
Air X. Be sure to include height of the tower. Refer to the appropriate chart
for your system voltage and number of turbines and select the wire size.
We recommend these as the minimum wire sizes; for optimal performance
use the largest wires that are practical and affordable. Local, state, and na-
tional electrical codes have precedence over these recommendations and
must be followed to ensure the safety of your system.
Note: Wiring Resistance and Regulation
Depending on your exact system configuration including other charging
sources in your system, wiring resistance may affect the regulation set point
of the turbine. Higher wiring resistance (smaller wires) will tend to 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.
TIP: Smaller wires will lower the voltage at which
the Air X enters regulation and stops charging.
Number of
Turbines:
0-30 ft
(0-9 m)
30 ft-60 ft
(9-18 m)
60 ft-90 ft
(18-27 m)
90 ft-150 ft
(27-46 m)
150 ft-190 ft
(46-58 m)
190 ft-250 ft
(58-76 m)
250 ft-310 ft
(76-95 m)
310 ft-390 ft
(95-119 m)
390 ft-500 ft
(119-152 m)
18/10 mm26/16 mm24/25 mm22/35 mm21/50 mm20/50 mm200/70 mm2000/90 mm2000/90 mm2
26/16 mm24/25 mm21/50 mm200/70 mm2000/90 mm20000/120 mm2*** *** ***
34/25 mm22/35 mm20/50 mm2000/90 mm20000/120 mm2*** *** *** ***
12 Volt Systems, AWG / Metric Wire Size mm2
*** If your system requires this length of wire, consider using parallel wires.
Number of
Turbines:
0-30 ft
(0-9 m)
30 ft-60 ft
(9-18 m)
60 ft-90 ft
(18-27 m)
90 ft-150 ft
(27-46 m)
150 ft-190 ft
(46-58 m)
190 ft-250 ft
(58-76 m)
250 ft-310 ft
(76-95 m)
310 ft-390 ft
(95-119 m)
390 ft-500 ft
(119-152 m)
114/2.5 mm212/4 mm210/6 mm28/10 mm26/16 mm24/90 mm24/90 mm2000/90 mm2000/90 mm2
212/4 mm28/10 mm26/16 mm24/25 mm24/25 mm22/35 mm22/35 mm21/50 mm20/50 mm2
310/6 mm28/10 mm26/16 mm24/25 mm22/35 mm22/35 mm21/50 mm20/50 mm200/70 mm2
24 Volt Systems, AWG / Metric Wire Size mm2

18 Air X Owner’s Manual
12mm
2
1
3
4
5-4 Stop Switch (Southwest Windpower part number 2-ARAC-101)
MARINE USE:
A Stop Switch is
standard equip-
ment with the Air X
Marine.
Fig. 14. Stop Switch Assembly
Southwest Windpower recommends the use of a stop switch to provide
a convenient and safe method for shutting down your Air X. A switch is
supplied with each Air X Marine as standard equipment and is available for
purchase from Southwest Windpower for the Air X Land.
Install the switch as shown in Fig. 13. A “break then make” switch MUST be
used or severe damage may occur. When wired as shown, Air X will operate
normally with the switch in the “up” position and will be “off” in the “down” po-
sition. Do not leave switch in “middle” position; this will place Air X in an open
circuit condition – see the Operating Modes section of this manual.
The stop switch model offered by Southwest Windpower is sufficient for most
systems, but it should not be used in applications where a code compliant
switch is necessary.
48 Volt Systems, AWG / Metric Wire Size mm2
1. Use either the rubber sleeved nut or the knurled nut but do not use both.
2. Drill 12 mm (0.4725 in) hole in panel.
3. The backing jam nut may be adjusted to allow the switch to mount flush
with the panel.
4. No larger then 8 gauge wire should be connected directly to switch. Short
lengths (a few inches) of 8 gauge wire may be used as a transition to larger
gauge wire. Eye connectors are recommended.
5. Wires should be supported. Provide strain relief – the switch terminals are
not designed to support lengths of wire.
BATTERY
BLACK
FUSE
WIRE
SWITCH
TURBINE
STOP
RED
WIRE
Stop Switch Assembly
NOTE: The center post
must be positive from the
turbine. Outside posts can
be swapped as either
battery positive or battery/
turbine negative.
Number of Turbines: 0-90 ft (0-27 m) 90 -250 ft (27-76 m) 250 -310 ft (76-95 m) 310 -500 ft (95-152 m)
1 14/2.5 mm212/4 mm210/6 mm28/10 mm2
2 12/4 mm28/10 mm26/16 mm24/25 mm2
3 10/6 mm28/10 mm26/16 mm24/25 mm2
Fig. 13. Stop Switch Wiring

Air X Owner’s Manual 19
5-5 Fuses, Circuit Breakers and Ammeter
Air X is capable of producing high amperages. As with all electrical installa-
tions, you must protect each of your turbines with a fuse or circuit breaker.
Wire Air X with an appropriate size “slow-blow” fuse or circuit breaker
between it and the batteries. Refer to installation figures at the start of Sec-
tion 5. If a stop switch is used, the fuse or circuit breaker should be placed
between the switch and the batteries.
Recommended Sizes for Circuit Breakers or Slow-Blow Fuses
• 12-volt model: 40 amp DC, part number 3-ELOT-1147-04
• 24-volt model: 20 amp DC, part number 3-ELOT-1147-03
• 48-volt model: 10 amp DC, part number 3-ELOT-1147-02
Circuit Breakers are available from Southwest Windpower. Part numbers are
listed above.
5-6 Batteries
There are many battery choices available – flooded lead acid, absorbed
glass mat (AGM), gel cell and NiCad. The type of battery utilized will de-
pend largely on the battery bank location and cost. For battery installations
where fumes can be safely ventilated and the potential for acid leakage
accommodated, the flooded lead acid battery is typically the most economi-
cal choice.
Minimum recommended battery bank size:
• 12-volt systems – 400 Amp-hours
• 24-volt systems – 200 Amp-hours
• 48-volt systems – 200 Amp-hours
There are several informative web sites with battery information including:
• www.batterycouncil.org
• www.windsun.com/Batteries/Battery_FAQ.htm
Fig. 16 Ammeter
(Amp Meter)
PN 2-ARAC-102
Fig. 15 Circuit Breaker
IMPORTANT: Never use “automotive” batteries or any battery
other than a “deep-cycle” battery.
5-7 Turbine Grounding
Proper grounding of the Air X provides protection to individuals and equip-
ment by eliminating the possibility of dangerous voltage potentials.
There are two aspects to grounding any electrical system – grounding one of
the conductors of the electrical system and grounding all metal structures in
the system that may have a voltage potential caused by an electrical failure.
In a typical Air X installation grounding one of the conductors is accom-
plished by connecting the Air X negative (black) conductor to an “earth”
ground close to the battery bank. Installation and connection to grounding
rods is described in the following section on Tower Grounding.
Grounding the metal structures in the system – typically this includes the
tower and turbine – is accomplished by connecting the structures together
using conductors of the same size as the positive and negative conductors
and then routing a conductor to an earth ground.
While not necessary, an ammeter (sometimes called an Amp Meter) is an
excellent addition to any system. The Amp Meter allows you to monitor the
current output of your turbine. Place it in between your turbine and the bat-
tery on the positive lead. It will give you instantaneous readings of output in
amps.

20 Air X Owner’s Manual
The following section (5-8) describes grounding the tower in detail. To
ground the Air X turbine body, connect the Air X ground (green) conductor
to the tower ground rod. Alternately the ground (green) conductor may be
connected to the negative (black) conductor in which case it will be ground-
ed through the battery bank ground rod. Refer to figures 9 through 12.
Note that all system grounds should be connected using conductors of the
same size as the positive and negative wires.
If you choose to not set up an earth ground system (not required for
systems under 50 volts), the Air X green and black conductors MUST be
connected to each other or severe damage to Air X may result and void
your warranty.
Southwest Windpower strongly recommends that boat installations be
grounded according to American Boat and Yacht Council recommenda-
tions. There are special grounding requirements for boats, in particular
boats that connect to shore AC power, that MUST be observed or a
serious shock hazard may result. Contact the American Boat and Yacht
Council at 410.990.4460 or visit their website at www.abyc.com.
5-8 Tower Grounding
Every wind turbine and turbine tower should be grounded at the tower base
even though the system may be grounded at the battery bank or service
panel by means of the yaw ground lead. Grounding the tower at its base
may prevent shocks to persons touching the tower due to lightning or
electrical faults.
The following sections are provided as a guide to properly grounding the
tower and should not be considered completely comprehensive. You are
encouraged to reference the National Electrical Code (NEC) and local
building and zoning regulations for complete requirements. Relevant sec-
tions of the National Electrical Code are referenced.
Tower grounding may be accomplished in several ways; the most common
method is a copper clad steel electrode(s) driven into the soil and con-
nected to the tower using a wire conductor.
5-8-1 Electrodes Driven in Soil
Electrodes should be a minimum of 8 ft (2.5 m) in length and free of non-
conductive coatings such as paint. Hollow electrodes of pipe or conduit
should not be smaller than trade size 3/4 (metric designator 21) and must
be galvanized or otherwise protected from corrosion. Solid rod electrodes
must be at least 5/8 inch (16 mm) diameter. Stainless steel rods less than
5/8 inch diameter, nonferrous rods or their equivalent less than 1/2 inch
diameter shall be “listed” by an organization having jurisdiction in the area.
For example: UL in the USA and CSA in Canada.
Electrodes shall be installed such that 8 ft (2.5 m) is in contact with the soil.
They should be driven into undisturbed soil within 1 ft of the tower founda-
tion. Electrodes should be driven to a depth of 8 ft (2.5 m) except where
rock is encountered; then the electrode may be driven at an angle not to
exceed 45 degrees from vertical. Some local authorities permit burial of
the electrode in a trench that is a minimum of 30 inch (76 cm) deep.
The upper end of the electrode and its connection to the grounding con-
ductor should be below grade or if above ground, must be protected from
damage.
Bonding the grounding conductor to the electrode and to the tower may
be accomplished by exothermic weld or by a “listed” mechanical connec-
tor. Solder connections are not permitted. Most local authorities require a
minimum grounding conductor size of 6 AWG for copper and 4 AWG for
aluminum (if aluminum is permitted).
The grounding conductor may be buried directly or contained in conduit;
in either case it is important that it have no sharp bends to keep its induc-
tance low.
The accompanying figure depicts a typical tower grounding technique and
the following sections of the NEC are listed for reference.