Southwest Windpower AIR 30 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 2011 Southwest Windpower, Inc.
All Rights Reserved

AIR 30 Owner’s Manual 3
Southwest Windpower
Congratulations on your purchase and welcome to our family!
Dear AIR 30 Owner,
Thank you for your purchase of AIR 30. You have purchased the most advanced battery charging wind turbine in the world! We believe you will find it
easy to install your AIR 30 and are confident you will experience years of dependable service from it.
Before going any further, please complete and return the Warranty Registration Card or register on-line at wwww.windenergy.com, log-in and create an
account to proceed with registration. The 5-year warranty is effective only after the product has been registered. Note - Southwest Windpower does not
sell or distribute your personal information to any third party. We understand and respect your privacy.
If you have any questions or comments, we would like to hear from you. Please call during working hours (Monday-Friday – 8:00am to 5:00pm 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 30.
Sincerely,
Southwest Windpower
Enter the serial and model numbers below
Serial Number __________________________________
Model Number __________________________________
AIR 30 Owner’s Manual
Document No. 3-CMLT-1007
Revision: A
AIR, AIR 403, AIR 30, AIR Wind Module are trademarks of Southwest Windpower  2007 Southwest Windpower, Inc.

4 AIR 30 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 30 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 or register on-line.
8) AIR 30 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 30 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.
WARNING: Indicates risk of severe
injury or death or possible severe
damage to equipment - proceed
with caution and follow instructions.

AIR 30 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
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 Roof Mount Kit _____________________________ 12
5) WIRING OPTIONS ___________________________________ 13-14
5-1 Hybrid System Wiring _____________________________ 15
5-2 Multiple AIR wind turbine 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 WIND TURBINE 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

Hardware Warranty
Southwest Windpower, Inc., (“Southwest Windpower”) will repair or replace free of
charge any manufacturer defect in part or parts of the Southwest Windpower AIR 30
Wind Turbine determined by Southwest Windpower to be defective in materials and/
or workmanship under normal authorized use consistent with product instructions for
a period of five years from the date the product is registered by the original purchaser
(“Customer”). The customer must register the product within 90 days of purchase. This
warranty extends only to the original purchaser and is non-transferable. The Customer’s
sole and exclusive remedy and the entire liability of Southwest Windpower, its suppli-
ers 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 30 5-Year Limited Warranty
WIND TURBINE WARRANTY AGREEMENT
6 AIR 30 Owner’s Manual

AIR 30 Technical Specifications
Model AIR 30
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 30 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 30 Owner’s Manual 7

Your AIR 30 is delivered partially assembled. Assembly requires mount-
ing 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 30.
Torque Specifications:
Blade to hub bolts, 1/4-20 x 0.875 inch, Socket Head Bolt, 72 in-lb (8.0 N·m )
Hub to rotor nut, 5/8 -18 inch, Jam nut, 40 lb-ft (55 N·m)
Yaw Clamp Bolts, M5 x 35 mm, Socket Head Bolt, 48 in-lb (5.5 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 30, apply a coat of Tef-
Gel to the blade root and hub. The use of Tef-Gel is recommended for all
installations.
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 high moisture 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 72 in – lbs (8.0 Nm). Install the remaining two blades
following the same procedure.
If AIR 30 is to be installed on a “tilt-up” tower, mount the blade/hub
assembly to the turbine prior to mounting on the tower. 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 40 ft-lbs (55 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 30 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
securely attached.
Two - AIR 30 Turbine Assembly
IMPORTANT: Tef-Gel is a corrosion inhibitor.
WARNING: Don’t
attempt to mount the
turbine while blades
are spinning.
8 AIR 30 Owner’s Manual
Fig. 1 AIR 30 Blade Attachment Detail.
1- AIR 30 Blade Hub
2- AIR 30 Blade
3- 1/4 - 20 Socket Head Cap Screw (2)
4- 1/4 - Nylock Nut (2)
3
1
2
4

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 wind turbine 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 precedence over efficiency.
Three - AIR Wind Turbine Siting
WARNING: Install AIR wind turbine so there is
no possibility of accidental contact with rotating
blades even if it requires installing the wind tur-
bine in a less than ideal location.
20 feet (6 m)
Prevailing wind
Fig. 2 Optimal AIR 30 location.
AIR 30 Owner’s Manual 9

10 AIR 30 Owner’s Manual
The AIR wind turbine 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 Wind Turbine 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 your AIR wind
turbine. 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 wind turbine.
45 ft (13.7 m) Tower

AIR 30 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
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.

12 AIR 30 Owner’s Manual
3x
8x
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 wind turbine.
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.
4-1-4 Roof Mounting Kit
(Southwest Windpower part number 1-TWA-19-01)
The Roof Mount Kit allows the pole for your AIR wind turbine to be
mounted to the wall or roof truss of a structure and extend above its roof-
line. The kit includes isolators, base plates and all hardware, clamps and
straps. Your AIR can be mounted flush to the side of the structure or via a
penetrating hole through the roof or eaves. If mounted via penetrating hole,
we recommend purchasing the roof mount kit with seal. See Fig. 7.
Fig. 7. Roof Mounting Kit

AIR 30 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
Wind Turbine
Generator
Five - AIR Wind Turbine 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 wind turbine’s
internal regulator will monitor the battery and maintain the charge as
necessary. Figs. 9 and 10 represent typical single turbine installa-
tions. Fig. 10 includes an up-tower junction box for UL (Underwriters
Laboratory) compliance. 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

14 AIR 30 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
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 or it may
be mounted close to the tower base and incorporate the
stop switch. Typically installing the box will require drilling
holes in the tower to install the box – be careful not to
compromise the tower strength.

AIR 30 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
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
wind turbine internal electronics and
result in pre-regulation. The interfer-
ence 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 possible interference by discon-
necting the other charging sources to
determine the possible cause. If pos-
sible wire the turbine and PV panels to
their own set of battery posts.
TIP: In this figure the AIR wind
turbine internal regulator is used.
A diversion type external regula-
tor could also have been used.
TIP: Voltage “pre-regulation”
may be prevented by increasing
the regulation set point. See
section 7-3-2.

16 AIR 30 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
Wind Turbine
Tower
Ground
Rod
Fuse
or
Breaker
Red Lead
Turbine Negative
Black Lead
Green Lead
Turbine Positive
Generator
Stop
Switch
Turbine Ground
AIR
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
Wind Turbine
Tower
Battery
Disconnect
Fuse
or
Breaker
Fuse
or
Breaker
Fig. 12. Multiple AIR wind turbine Wiring
5-2 Multiple Turbine Wiring
Method One:
Each AIR wind turbine is
treated separately. Each
turbine will have its own
wires, stop switch and fuse
and will connect directly to
the battery using the inter-
nal 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 tur-
bine’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 wind turbines together.
A typical multi-turbine sys-
tem is depicted in Fig. 12.
There are two methods used
to accomplish this task.

AIR 30 Owner’s Manual 17
5-3 Wire Size
All electrical systems lose energy due to resistance in conductors: the wires.
•฀฀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 power 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 wind turbine. Be sure to include height of the tower. Refer to the ap-
propriate 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 wind turbine 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 30 Owner’s Manual
12mm
2
1
3
4
5-4 Stop Switch (Southwest Windpower part number 2-ARAC-101)
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 wind turbine.
A switch is available for purchase from Southwest Windpower for the AIR
wind turbine.
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 wind
turbine will operate normally with the switch in the “up” position and will be
“off” in the “down” position. Do not leave switch in “middle” position; this
will place AIR wind turbine 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 30 Owner’s Manual 19
5-5 Fuses, Circuit Breakers and Ammeter
AIR wind turbine’s are capable of producing high amperages. As with all
electrical installations, you must protect each of your turbines with a fuse or
circuit breaker. Wire your AIR wind turbine with an appropriate size “slow-
blow” fuse or circuit breaker between it and the batteries. Refer to installation
figures at the start of Section 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฀amps฀DC,฀part฀number฀3-ELOT-1147-04฀฀•฀24-volt฀model:฀20฀amps฀DC,฀part฀number฀3-ELOT-1147-03฀฀•฀48-volt฀model:฀฀10฀amps฀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-hoursThere are several informative web sites with battery information including:
฀฀•฀฀www.batterycouncil.org฀฀•฀฀www.windsun.com/Batteries/Battery_FAQ.htmFig. 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 wind turbine provides protection to individuals and
equipment 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 wind turbine installation grounding one of the conductors is
accomplished by connecting the AIR wind turbine 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 30 Owner’s Manual
The following section (5-8) describes grounding the tower in detail. To
ground the AIR wind turbine body, connect the AIR wind turbine 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 grounded 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 wind turbine green and black conductors
MUST be connected to each other or severe damage to AIR wind turbine
may result and void your warranty.
5-8 Tower Grounding (Fig. 16)
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.