Southwest windpower Air 40 User manual

Southwest Windpower, Inc.

1801 West Route 66

Flagstaff, Arizona 86001

Toll Free Phone: 866.805.9463

Phone: 928.779.9463

Fax: 928.779.1485

www.windenergy.com

Owner’s Manual

Installation • Operation • Maintenance

 2012 Southwest Windpower, Inc.

4 AIR 40 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 wind turbines 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 the Warranty Registration Card or register your product on-line.

8) AIR wind turbines must be installed in accordance with this manual and local and

national building 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 wind turbines 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 40

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 40 Owner’s Manual 5

Contents

1) IMPORTANT SAFETY INSTRUCTIONS _________________ 4

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 Mounting 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

11) WARRANTY ________________________________________ 29-31

6 AIR 40 Owner’s Manual

Notes

__________________________________________________________________________________________________________________________________

AIR 40 Owner’s Manual 7

AIR 40 Technical Specifications

Model AIR 40

Weight 13 lb / 6 kg

Rotor Diameter 46 in / 1.17 m

Start Up Wind Speed 7 mph / 3.1 m/s

Kilowatt Hours/month 38 kWh/month @ 12 mph / 5.4 m/s avg. wind speed

Maximum Wind Speed 110 mph

Rated Power 160 watts @ 28 mph / 12.5 m/s wind speed

Certifications CSA (certificate 1954979), CE

Operating Temperature Range AIR 40 are certified under IEC requirements

applying to the temperature range 14º F (-10º C) to

104º F (40º C)

12 volt, 24 volt and 48 volt AIR 40 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 20 amp (slow blow)

24 Volt Systems 10 amp (slow blow)

48 Volt Systems 5 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)

8 AIR 40 Owner’s Manual

Your AIR wind turbine 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 your AIR wind turbine.

Torque Specifications:

Blade to hub screw, 1/4 - 20 x 1.375, socket head screw 72 in-lb (8.0 N·m)

Hub to rotor nut, 5/8-18, 40 lb-ft (55 N·m)

Yaw clamp bolts, M5-0.8 x 35 mm 48 in-lb (5.5 N·m)

Start the assembly by mounting the blades (Item1) to the blade hub as

shown in Fig. 1. Place a nylock nut (Item 4) in the hexagonal detent on the

back of the blade hub while positioning the blade on the hub.

The blades must be “tilted” into position on the hub and can only be

installed in one orientation.

Place a washer (Item 2) on a 1/4 - 20 socket head screw (Item 3).

Tighten the screw to 72 in-lb (8.0 N·m). Repeat for the remaining two

blades. Nylock nuts may only be used one time; replace after each use.

If your AIR wind turbine is to be installed on a “tilt-up” tower, mount the

blade/hub assembly to the turbine now. Coat the alternator rotor shaft

threads and blade hub bore with Tef-Gel and slide the hub onto the shaft.

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 lb-ft (55 N·m)

by inserting a 5/16 inch hex key wrench in the turbine alternator shaft and

turning the shaft while turning the blades.

If your AIR wind turbine is to be installed

after the tower is erected, it is safer and

easier to first install the turbine body on the

tower and then install the hub/blade assem-

bly. 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.

3

1

2

4

1- blades

2- washer

3- 1/4 - 20 socket head screw

4- nylock nut

Two - AIR Turbine Assembly

IMPORTANT: Tef-Gel is a corrosion inhibitor.

WARNING: Don’t

attempt to mount the

turbine while blades

are spinning.

Fig. 1 AIR wind turbine Blade Attachment Detail.

AIR 40 Owner’s Manual 9

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 your 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.

20 feet

Prevailing wind

Fig. 2 Optimal AIR 40 location.

(6 m)

10 AIR 40 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 40 Owner’s Manual 11

Fig. 5. 29 ft (8.8 m) Tower Kit

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.

Southwest Windpower AIR 40 User manual

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