Southwest Windpower 30 FOOT (9 Meter) TOWER KIT for WHISPER 500 User manual

Whisper 500 Battery Charging ManualDocument #0023 Rev C
SOUTHWEST WINDPOWER April 2006 1
Owners Manual
Installation, Operation and Maintenance
For Battery Charging Applications
Southwest Windpower, Inc.
1801 W Route 66
Flagstaff, Arizona 86001
Phone: [phone]
Fax: [phone]
Email: [e-mail]
Web page: http://www.windenergy.com
© 1 April 2006 Southwest Windpower , Inc
All Right Reserved
WIND GENERATOR SERIAL NUMBER ________________
Southwest Windpower, Inc.
Renewable Energy Made Simple
Whisper 500
Battery Charging
Wind Generator

Whisper 500 Battery Charging Manual Document #0023 Rev C
SOUTHWEST WINDPOWERApril 2006
2
BEFORE YOU BEGIN:
Read this entire manual. Following the instructions and recommendations in this manual will help
assure safe and enjoyable use of your new renewable energy system.
SAFETY INFORMATION: These systems present mechanical, electrical and chemical (battery)
hazards that can be life threatening. The tower or support structure could fall and cause injury
or death and property destruction. A component of the wind generator could come loose
causing injury or death and property destruction. Contact with the high speed propeller can
result in severe injury or death. High voltage from the wind generator or the inverter can cause
injury or electrocution. A burn injury can result from an electrical short. A severe chemical burn
including blinding can occur from a battery explosion or contact with the sulfuric acid in a lead-
acid battery.
These conditions are addressed in the following safety messages:
STOP! DANGER! It is your responsibility to obtain all required permits and engineering certifications for
your tower and tower location. Soil and wind conditions vary and towers and tower foundations must be
designed for your specific location. Tower must not be able to fall on occupied buildings, neighbor's
property or power lines. Tower climbing is dangerous and should be attempted only by experienced
personnel using proper safety equipment. A fold-over tower can eliminate climbing. Locate your
mounting mast (tower) well away from occupied buildings and power lines; a minimum of 100m (300 ft)
is recommended.
STOP! DANGER! If the generator appears or sounds loose in the tower or is making an unusual sound,
the condition must be corrected immediately. A loose generator or component will soon damage itself
further and may fall from the tower or lose parts that could be lethal. Never stand in line with an
operating propeller.
STOP! DANGER! Provide climbing protection against all unauthorized persons or children. Never allow
an untrained person or someone without the proper safety equipment to climb the tower. Always stop
the propeller before climbing the tower. Both falling from the tower and contact with the operating
propeller can be lethal.
STOP! DANGER! High voltage systems (that is, systems with battery voltages of 64 volts and above or
the primary side of any system with a transformer) represent a dangerous shock hazard and could be
lethal. All high voltage systems should be wired and maintained by a qualified and licensed electrician.
STOP! DANGER! Batteries may emit explosive and irritating gas while charging. Never turn on a light
switch or make any other electrical connection or light a match or make any type of spark near a
recently-charged battery. Use protective gloves and eyeglasses when working around a battery. Turn
off all loads, wear safety glasses, and look away when making a final battery connection.
STOP! DANGER! NEVER place objects on top or near the Whisper Controller enclosure, diversion load,
transformer, Aurora Wind Interface or inverter, when applicable. These devices must dissipate heat as
part of normal operation. FIRE AND FAILURE can result if airflow is blocked.

Whisper 500 Battery Charging ManualDocument #0023 Rev C
SOUTHWEST WINDPOWER April 2006 3
Section Page
1. Introduction 4
2. Controller and Diversion Load Installation 6
3. Wire Connections 7
Controller to Battery Connections 7
Controller to Wind Generator Wiring 8
Brake Switch 10
Diversion Load Wiring and Configuration 11
Transformer 11
4. Wind Generator Installation 13
Electrical Tests 13
Install Tower Insert 14
Install Tail Fin 17
Install Tail Boom 19
Install Blades and Nosecone 20
5. Whisper Controller 22
Printed Circuit Board Switch Settings 22
Optional Equipment 24
Controller Operation 26
6. Maintenance 32
7. Troubleshooting 35
Mechanical repairs and parts replacement 38
TABLE OF CONTENTS

Whisper 500 Battery Charging Manual Document #0023 Rev C
SOUTHWEST WINDPOWERApril 2006
4
1. Introduction
System Voltage
All system components, Wind Generator, Whisper Controller, diversion load, transformer and inverter ( if
applicable), must be configured to the correct system voltage.
The Whisper 500 Low Voltage (LV) Wind Generator is factory set at 48 volts, and the Whisper 500 High
Voltage (HV) Wind Generator is factory set at 240volts. The Whisper 500 Controller is also factory set at
48 volts. for the See TROUBLE SHOOTING AND REPAIR section to change the Whisper 500 voltage
from the standard voltage. Refer to the appropriate sections in this manual to configure the Wind Gen-
erator or Controller to different voltages.
Battery Bank Size
Southwest Windpower recommends a 48 volt Whisper 500 have a battery bank with a minimum of 400
amp-hours of capacity, and a 24 volt Whisper 500 should have a battery bank with a minimum of 800
amp-hours of capacity.
Tower
The Whisper 500 Wind Generator is designed to fit on a 5-inch schedule 40 steel pipe. The minimum
recommended tower height is 7 meters (20 feet) above trees or obstacles within 100m (300ft).
The lateral thrust load produced by the Whisper 500 at a wind speed of 45 m/s (100 mph) is 3.6 kN (800
lbs).
The highest point on your property is generally best location to site the wind generator but the distance
to the batteries and the system voltage will figure in the determining the correct installation location.
Wiring and Wire Sizes
The Battery Charging schematic on the following page depicts the wire runs and connections required to
install a typical Battery Charging system. Note not all systems require the voltage transformer or optional
external brake switch.
Wire sizes depend largely on the length of wire, system voltage and power transmitted. Wire is expen-
sive. Site your wind generator accordingly.

Whisper 500 Battery Charging ManualDocument #0023 Rev C
SOUTHWEST WINDPOWER April 2006 5
Whisper 500 Battery Charging Schematic
You will need to make the electrical connections as shown below.
Whisper Controller
Diversion Load
+ -
Battery Bank
Transformer
(HVLV only)
External Brake
Switch
Optional Extra
External Brake
Switch
Whisper 500
Wind Generator
Fuse
Note: Size the DC wire between the Whisper Controller and Diversion Load using the “DC Wire Size Table” on page XX
Note: Size the three phase wire be-
tween the turbine and Whisper Control-
ler using the “Wire Size: Mast top to
Whisper Controller table on page XX

Whisper 500 Battery Charging Manual Document #0023 Rev C
SOUTHWEST WINDPOWERApril 2006
6
2. Controller and Diversion Load Installation
Whisper 500 Controller and 4600 Diversion Load
The Whisper 500 Controller MUST be mounted vertically on a wall as shown below. Even though the
Whisper 500 Controller does not contain a diversion load, this mounting position is necessary to provide
adequate cooling for the electronics and rectifier heat sink.
The 4600 Diversion Load MUST be mounted against a wall to provide adequate heat transfer. The control-
ler must be mounted within 5 feet (1.5 meter) of the diversion load due to the precut wire length.
Do not mount the diversion load within 10 feet ( 3 meters) of flammable materials or near heat sensitive
components. Do not mount the controller above the diversion load since the heat from the diversion load
may overheat the controller.

Whisper 500 Battery Charging ManualDocument #0023 Rev C
SOUTHWEST WINDPOWER April 2006 7
3. Wire Connections
Controller to Battery Connections
Remove the Whisper Controller Electronic Cover and connect the battery and ground wires as shown in
the accompanying figures. Caution: Southwest Windpower strongly recommends connecting the
Controller to the batteries BEFORE making the wind turbine connections.
Refer to the following sections to select the correct gauge wire to connect the controller to the batteries.
Use caution when connecting the battery leads to avoid shorting them together. Correct polarity MUST
be observed when connecting the battery cables.
Depending on your system voltage, wire the controller to the battery system by select the appropriate
size wire from the list below:
24 Volt Systems — Use 2 AWG wire or larger
48 Volt Systems — Use 6 AWG wire or larger
Optional Whisper Controller
LCD Display Panel
Remove Electronic Cover to
make Electrical Connections
Whisper Controller
Printed Circuit Board
Battery Connections
Terminal Block under cover .
Anemometer
Connection
(optional)
Earth Ground
LED’s and Diversion Switch
Wind Generator Connections

Whisper 500 Battery Charging Manual Document #0023 Rev C
SOUTHWEST WINDPOWERApril 2006
8
Controller to Wind Generator Wiring
Southwest Windpower strongly recommends connecting the controller to the batteries prior to connecting the
wind generator to the controller.
After connecting the controller to the batteries proceed by connecting the three wires from the wind generator
to the controller as shown below. Note that the order of the wires is not important. Any wire from the wind
generator may be installed in any of the wind generator input terminals.
Note: Refer to the following section to install the Brake Switch in parallel with the
Whisper 500 and the Whisper Controller.
The size of the wire required to connect the Whisper Controller to the wind generator is determined by the
power produced by the generator, system voltage and the distance between the generator and controller.
Distances are one way and should include the height of the tower.
Refer to the accompanying charts to determine the correct wire size for your system. The wire sizes listed in
the charts provide a 95% transmission efficiency in an area with a 12 mph average wind speed.
To use the charts measure distance from Whisper Controller to wind generator. Find the closest distance
listed in the column for your system voltage and read the wire size to the left of the distance.
Note if your measured distance is nearly midway between two distances on the chart it is probably best to
select the larger size wire. This is particularly true in areas with higher wind speeds. Distances are listed in
both feet and meters.
Wind Generator Input Terminals
Connect three wires from wind generator to
terminals. Order of connection is not important.

Whisper 500 Battery Charging ManualDocument #0023 Rev C
SOUTHWEST WINDPOWER April 2006 9
Whisper 500 — Controller to Wind Generator Wire Size Table
Wire
Size
System Voltage Wire Size System Voltage
▼24 36 48 240** ▼24 36 48 240**
14 AWG xx xx xx
903 14 AWG xx xx xx xx
12 xx xx xx 1442 12 xx xx xx xx
10 xx xx xx 2296 10 xx xx xx 56
8 xx xx 145 3637 8 xx xx 44 89
6 xx 113 226 5653 6 xx 34 69 138
4 90 181 361 9037 4 28 55 110 220
3 114 227 455 11363 3 35 69 139 277
2 143 287 573 14330 2 44 87 175 349
1 183 366 732 1 56 112 223 447
0 227 455 909 0 69 139 277 554
2/0 288 577 1154 2/0 88 176 352 703
3/0 363 726 1452 3/0 111 221 442 885
4/0 459 918 1837 4/0 140 280 560 1120
▲Distance (Feet) ▲Distance (Meters)
** Note: The Whisper 500 High Voltage cannot be wired directly to the Whisper Controller. A step
down voltage transformer is required to reduce the voltage to 24, 36 or 48 volts before connection
to the Whisper Controller.
AWG to Metric Wire Size Conversion Chart
The following chart may be used to convert from American Wire Gauge (AWG) to metric wire size.
AWG gauge Diameter (mm) AWG gauge Diameter (mm)
0000 (4/0) 11.68 mm 4 5.19 mm
000 (3/0) 10.40 mm 6 4.11 mm
00 (2/0) 9.27 mm 8 3.26 mm
0 (1/0) 8.25 mm 10 2.59 mm
1 7.34 mm 12 2.05 mm
2 6.54 mm 14 1.63 mm
3 5.83 mm 16 1.29 mm
AWG to Metric Wire Size Conversion Chart

Whisper 500 Battery Charging Manual Document #0023 Rev C
SOUTHWEST WINDPOWERApril 2006
10
Install Brake Switch
Mount the brake switch next to the Whisper
Controller on 500LV applications or near the
transformer with the 500HVLV. The brake switch
should be connected in parallel with the three
transmission wires between the wind generator and
the Whisper Controller (or transformer for HVLV
systems). The brake switch operates simply by
shorting all three wires together to generate
braking torque on the propellers.
Note:
Disregard the original “on” and “off” marking
on the switch. Moving the switch up is “brake
on”, and moving it down is “normal operation”.
Use three #6 AWG wires to connect a wire in
parallel with each of the three phases from the
Whisper Controller. The three wires are connected
to the three different terminals indicated on the
figure to the right. The order of the three wires
does not matter.
IMPORTANT: be certain the switch is between the
turbine and transformer, and not between the
transformer and Whisper Controller (ie brake
switch is on primary side of step-down
transformer).
Connect first wire
Connect second wire
Connect third wire
To Whisper
Controller
Brake Switch
To Stop the Wind Turbine
Move brake switch handle up.
If the wind turbine blades do not stop in
30 seconds. Move handle down, wait for
wind speed to decrease and retry.
# 6 AWG
Brake Switch

Whisper 500 Battery Charging ManualDocument #0023 Rev C
SOUTHWEST WINDPOWER April 2006 11
48 Volt System
Diversion Load Wiring and Configuration
The Whisper 4600 Diversion Load includes four 8 AWG wires ( labeled Red, Red 1, Black and Black 1) for
connection to the terminal block in the Whisper Controller. To access the terminal block remove the left
side controller cover and connect the wires as shown in the below depictions of the terminal block. Be sure
to wire the terminal block for your system voltage - either 24 or 48 volts.
Transformer ( High Voltage Only)
Install transformer on heat resistant surface with adequate ventilation. The Whisper 500 voltage is
“stepped” down to 24, 36 or 48 volts with utilizing the transformer. Refer to the chart on the following page
for specific directions for configuring the transformer voltage.
Wires from Controller Circuit
Board, do not disconnect.
24 Volt System
No wire in
center terminal.
Red 1
Black 1
Red 1
Black
Red
Red
Black 1
Black 1

Whisper 500 Battery Charging Manual Document #0023 Rev C
SOUTHWEST WINDPOWERApril 2006
12
Transformer (Continued - High Voltage Only)
Install transformer on heat resistant surface with adequate ventilation. The Whisper 500 voltage is
“stepped” down to 24, 36 or 48 volts with utilizing the transformer. Refer to the chart below for spe-
cific wiring directions for configuring the transformer voltage.
ABC
H1 H1 H1
H2 H2 H2
Secondary - to Controller (See Below) Large Wires
x1
x2
x3
x4
x3x3 x1 x1
x2 x4x2x4
AB
C
x1 x2 x3 x4 x1 x2 x3 x4 x1 x2 x3 x4
AB
C
x1 x2 x3 x4 x1 x2 x3 x4 x1 x2 x3 x4
ABC
x1 x2 x3 x4 x1 x2 x3 x4 x1 x2 x3 x4
AB
C
x1 x2 x3 x4 x1 x2 x3 x4 x1 x2 x3 x4
To Blue Wires of Controller
12 Volt Battery
To Blue Wires of Controller
24 Volt Battery
To Blue Wires of Controller
30-36 Volt Battery
To Blue Wires of Controller
48 Volt Battery
Primary to Wind Generator and Brake Switch
Secondary to Whisper Controller (See Be- low) Large Wires
To Wind Terminals of
Whisper Controller
12 Volt Battery
To Wind Terminals of
Whisper Controller
24 Volt Battery
To Wind Terminals of
Whisper Controller
30-36 Volt Battery
To Wind Terminals of
Whisper Controller
48 Volt Battery

Whisper 500 Battery Charging ManualDocument #0023 Rev C
SOUTHWEST WINDPOWER April 2006 13
GROUND TEST OPEN CIRCUIT TEST
When the wires are open
the wind generator rotor
should spin freely.
When the wires are
shorted together the
generator rotor should
turn hard and smooth.
Check resistance to
ground on each wire.
Resistance must
exceed 10,000 ohms.
Drill Tower top Holes
Drill the six 1/2” (12.7mm) holes in the top of the tower using the foldout template at the end of this man-
ual. You must use a sharp drill bit and a powerful drill to make these holes in steel pipe. Applying a cut-
ting fluid at the tip of the drill bit can improve the performance and longevity of the bit. Debur the six
holes, and then check the fit of the tower insert in the top of the tower The six holes in the insert should
match the six holes you just drilled.
4. Wind Generator Installation
Electrical Tests
Complete these tests before mounting blades to rotor, and before installing turbine to top of tower.
These tests confirm that the wind generator is functional and ready to install on the tower.
SHORT CIRCUIT TEST

Whisper 500 Battery Charging Manual Document #0023 Rev C
SOUTHWEST WINDPOWERApril 2006
14
Install Tower Insert on Yaw Shaft
Part # Part Description Qty
IAC14A 5” tower insert 1
IAR98 M10x55 Grade 10.9 zinc bolt 3
IAR99 M10 zinc lockwasher 3
IAR43 M8x30 SS set screw 3
IAR17 M8 SS nylock hex nut 3
IAR29 4mm short arm allen wrench 1
IAR41 M10x25 SS hex bolt 6
IAR40 M10 SS lockwasher 6
Mounting Instructions
A) Check the fit and hole alignment of the tower
insert inside tower, before installing it on the
yaw shaft. The six holes you just drilled in the
tower pipe should line up with the six holes in
the tower insert. A maximum of 1.5mm
(1/16in) play is allowed. Tower Pipe or tube
must be tight against insert when the mount-
ing bolts are tightened.
B) Install the tower insert onto the yaw shaft.
Place the three M10x55 screws into the tower
insert and thread them into the yaw shaft. Be
sure to use the three M10 zinc lock washers
on these screws. Tighten with a 17mm
socket.
C) Finger-tighten the nylock nuts over the three
M8x30 set screws. Tighten the three M8x30
set screws on the upper holes using the sup-
plied allen wrench. After the set-screw is
tightened with the allen wrench, tighten the
nylock nut over the set-screw using a 13mm
deep socket. You must use a deep socket
with this nut because a regular socket will slip
off the nut before the nut is fully tight, and re-
sult in an unsafe attachment between the tur-
bine and tower.
Use 13mm
deep socket

Whisper 500 Battery Charging ManualDocument #0023 Rev C
SOUTHWEST WINDPOWER April 2006 15
Connect Wires and Mount Wind Generator To Tower
Mounting Instructions
A) Use split bolts to make the electrical connec-
tion between the yaw wires and the transmis-
sion wires inside the tower. Any of the three
yaw wires can go to any of the three transmis-
sion wires. Use heat-shrink and electrical
tape to fully insulate these connections from
each other and any surrounding metal.
B) Attach some type of strain relief inside the
tower to support the weight of the wires. See
figure on the right. It is important that the full
weight of the wires is not being supported by
the slip rings on the yaw shaft.
C) Install the turbine, without the blades, onto to
the tower top. Be careful not to pinch or short
any of the wires. Rotate the tower insert so
the six holes in the tower match the corre-
sponding threaded holes in the tower insert.
D) Tighten the six M10x25 screws through the
holes on the outside of the tower pipe into the
tower insert. Be sure to use the lockwasher
on each of these screws. Tighten these six
screws with a 17mm socket.
E) The turbine should now be fully attached to
the tower top.
Test Wind Generator to Whisper Controller Wiring
Repeat WIND GENERATOR ELECTRICAL TESTS. This time use the brake switch to short the wires,
and measure the resistance between the phase and ground at the connection to the Whisper Controller.
Short Circuit Test = Brake handle up
Open Circuit Test = Brake handle down
Do not install the blades until each of these test OK.

SOUTHWEST WINDPOWER April 2006 16
Whisper 500 Battery Charging Manual
Document #0023 Rev C
Hardware
Lay out the hardware contained in the Whisper 500 Hardware Kit and separate as appropriate. You will
need metric sockets and wrenches to complete the installation.
Item Part # Part Description Qty Place used
1 IAR15 M8x 24 SS flatwasher 10 Tail strap to tail fin & Tail strap to tail
boom & Tail boom through-bolt & Nose
cone
2 IAR16 M8x31 nylon flatwasher 16 Tail fin to tail boom & Tail strap to tail
fin
3 IAR52 M8x24 nylon flatwasher 2 Nose cone
4 IAR07 M8x20 SS hex screw 2 Nose cone
5 IAR35 M8x30 SS bolt 7 Tail fin to tail boom & Tail boom to
lower weldment
6 IAR42 M8x90 SS bolt 1 Tail boom through-bolt
7 IAR59 M10x80 zinc bolt 8 Blades
8 IAR31 M8x80 SS bolt 1 Tail strap to tail boom
9 IAR30 M8x40 SS bolt 2 Tail strap to tail fin
10 IAR14 M8 SS lockwasher 2 Nose cone
11 IAQ13 3/4” tube spacer 2 Tail strap
12 IAR17 M8 SS nylock 11 Tail strap to tail fin & Tail strap to tail
boom & Tail fin to tail boom & Tail
boom through-bolt & Tail boom to lower
weldment
13 IAR50 M10 SS nylock 8 Blades
Whisper 500 Hardware Kit

Whisper 500 Battery Charging Manual Document #0023 Rev C
SOUTHWEST WINDPOWERApril 200617
Install Tail Fin and Strap
Before installing the tail boom into the lower weldment,
install the Tail fin and Tail strap as shown in the follow-
ing pictures. The numbers with arrows refer to the item
number in the table from Step 15.
Mounting Instructions
A) Connect one of the fins to the tail boom with a ny-
lon washer sandwiched between the metal tabs on
the tail boom and the tail fin. Repeat so the fin is
secured with three bolts
B) Repeat the above step for the second fin, but use
only two of the three holes so the fin looks like the
picture below (minus the tail strap).
C) Attach the through-bolt as show with SS washers
outside the tail strap. The 3/4” tube spacer is be-
tween the tail strap and the tabs on the tail boom.
The nylon flatwashers are between the tail boom
tabs and the tail fin. At this point, only finger
tighten the nylock nut.
11 2
8
1
2
12
5

SOUTHWEST WINDPOWER April 2006 18
Whisper 500 Battery Charging Manual
Document #0023 Rev C
D) Note how one side of the tail strap has a hole and
the other is a slot. Attach the side with the hole to
the tail fin as show to the right. A stainless steel
washer is used on the outside of the tail strap. A
nylon washer is sandwiched between the tail strap
and tail fin. At this point, only finger tighten the
nylock nut.
E) Then place the bolt in the side of the strap with the
slot. Finger tighten the nylock nut.
F) Use a 13mm socket and a wrench to tighten all
three bolts connecting the tail strap to the tail fin.
G) The tail fin should now be securely fasten to the
tail boom and should look like the last picture on
this page.
9
1 2

Whisper 500 Battery Charging Manual Document #0023 Rev C
SOUTHWEST WINDPOWERApril 200619
61
5
Install Tail Boom to Lower Weldment
The numbers with arrows refer to the item number in the
table from Step 15.
Mounting Instructions
Insert the tail boom into the lower weldment. Be sure the
tail fins will be vertical when the tower is raised. You
may need to tap the tail boom into the weldment with a
rubber mallet or a piece of wood and a sledgehammer.
Insert the tail boom into the lower weldment until the
hole in the lower weldment matches the through-hole in
the tail boom. If the holes are nearly lined up, but not
perfect, then you may want to run a drill through the tail
boom so the through-bolt will go through (if it was diffi-
cult to get the tail boom inserted into the lower weld-
ment).
Install the long through-bolt with stainless steel washers
and a nylock nut and tighten with a socket and wrench.
Install the two compression bolts to the lower weldment,
and tighten with a socket and wrench.
The tail boom should now be securely attached to the
lower weldment.

SOUTHWEST WINDPOWER April 2006 20
Whisper 500 Battery Charging Manual
Document #0023 Rev C
It is very important the blades are installed properly and
not backwards. When looking at the front of the tur-
bine from an upwind position, the leading edge tape
should be as shown in the picture to the right. When
looking at the blades from an upwind position, they will
rotate in a clockwise direction.
Install the blade bolts with the head of the bolt against
the hub plate as shown in the figure to the right. It is
important that the threads of the bolts are pointing into
the wind.
Place the blade straps across the front of the blades, and
tighten the nuts to 18 foot-lbs of torque.
Leading edge tape
Blade close-up view
Blades as viewed from
upwind direction
Leading edge tape
Leading edge tape
7
13
Install Blades, Blade Strap and Nosecone