Southwest Windpower Whisper 200 Quick start guide

Owners Manual
Installation, Operation and Maintenance
Southwest Windpower, Inc.
1801 West Route 66
Flagstaff, Arizona 86001
Phone: [phone]
Fax: [phone]
Email: [e-mail]
Web page: http://www.windenergy.com
© January 2005 Southwest Windpower ,Inc
All Right Reserved
WIND GENERATOR SERIAL NUMBER ________________
WHISPER WIND GENERATORS
MODEL Whisper 200
For the *NEW* Whisper Controller
Southwest Windpower, Inc.
Renewable Energy Made Simple

0157 REV NC - Southwest Windpower Warranty Policy.doc
Warranty policy for Whisper and AIR Wind turbines
What Is Covered and For How Long
AIR Wind turbines: Three years from the date of purchase, or:
Whisper: Two years from the date of purchase, or:
Windseeker: Two years from the date of purchase, or:
Two years and three months from date of build, any defective part will be replaced at no charge. Either a Southwest
Windpower technician or an Authorized Service Center determines a defective part.
WHAT IS NOT COVERED
• Damage due to lightning
• Damage due to extreme winds (110 MPH+; 60 m/s)
• Damage due to improper installation & operation (Including but not limited to – Poor tower design)
• Damage due to improperly wiring to batteries
• Damage resulting from contact with flying debris
LIMITATIONS AND EXCLUSIONS
1) NO ONE HAS THE AUTHORITY TO ADD TO OR VARY THIS LIMITED WARRANTY, OR TO CREATE ANY OTHER
OBLIGATION IN CONNECTION TO SOUTHWEST WINDPOWER AND ITS PRODUCTS UNLESS SPECIFICALLY
ISSUED BY SOUTHWEST WINDPOWER.
2) ANY IMPLIED WARRANTY APPLICABLE TO SOUTHWEST WINDPOWER’S PRODUCTS IS LIMITED IN DURATION
TO THE SAME PERIOD OF TIME AS THIS WRITTEN WARRANTY.
3) SOUTHWEST WINDPOWER IS NOT AND SHALL NOT BE LIABLE FOR INCIDENTAL, CONSEQUENTIAL,
SPECIAL, OR CONTINGENT DAMAGES THAT ANY PERSON OR PROPERTY MIGHT SUFFER AS A RESULT OF ITS
BREACH TO THIS WRITTEN AND OR IMPLIED WARRANTY.
4) THIS WARRANTY APPLIES TO THE ORIGINAL PURCHASER AND MAY BE TRANSFERRED.
The Customer’s Responsibilities
All of Southwest Windpower’s products must be installed and operated in accordance to this owner’s manual and local
codes. Any modifications to the turbine system design will void the warranty and compromise the safety of the machine.
You should keep a copy of the invoice or canceled check to verify the purchase date. You will be responsible for removing
the machine from the tower shipping the turbine to the repair center and re-installing.
If You Experience A Problem With Your Southwest Windpower Product
Contact your nearest authorized service center or Southwest Windpower (928-779-9463) to determine the nature of the
problem. Either Southwest Windpower or the Authorized Service Center will issue a return authorization number (RA
number) before you return the turbine or send you the replacement parts needed to repair the machine. (Southwest
Windpower or the Service Center will pay least cost return shipping back to the customer. If express is required, the
customer will be required to pay the difference in freight charges.)

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Owners Manual
Installation, Operation and Maintenance
Southwest Windpower, Inc.
1801 W Route 66
Flagstaff, Arizona 86001
Phone: [phone]
Fax: [phone]
Email: [e-mail]
Web page: http://www.windenergy.com
© January 2005 Southwest Windpower ,Inc
All Right Reserved
WIND GENERATOR SERIAL NUMBER ________________
WHISPER WIND GENERATORS
MODEL 200
For the *NEW* Whisper Controller
Southwest Windpower, Inc.
Renewable Energy Made Simple

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Table of Contents
INTRODUCTION 3
1. INSTALLATION 7
2. PURCHASE BATTERIES OF PROPER SIZE 7
3. SETTING TURBINE VOLTAGE 8
4. CHOOSE BATTERY LOCATION 10
5. WIND GENERATOR ELECTRICAL TESTS 11
6. MOUNT WIND GENERATOR ON TOWER 12
7. WHISPER CONTROLLER - MOUNTING 13
8. WHISPER CONTROLLER - WIRING 13
9. WHISPER CONTROLLER DISPLAY INSTALLATION 15
10. INSTALL TAIL ASSEMBLY 16
11. INSTALL BLADES AND NOSE CONE 17
12. BECOMING FAMILIAR WITH THE WHISPER CONTROLLER 18
13. MAINTENANCE - MONTHLY 23
14. MAINTENANCE - ANNUAL 24
15. TROUBLESHOOTING AND REPAIR 26
16. MECHANICAL REPAIR AND REPLACEMENT 31
Table of Contents
FOLLOW STEP-BY-STEP INSTALLATION
LOOK FOR THE SHADED BOXES AND FOLLOW THE STEPS IN ORDER. CHECK
THE PROVIDED BOX WHEN COMPLETE.
SUGGESTED TOOLS AND EQUIPMENT YOU WILL NEED
Round or Half Round File Pliers
Carpenters Level (optional) Metric Wrenches and Sockets
Torque Wrench w/ 9/16” socket Large Adjustable Wrench
Blue Loctite 242 Tubing or Pipe for Tower
Sawhorse Hex Wrenches (metric and standard)
Electrical Wire (see p. 6) Ground Rod and Clamp
Wire Connectors (preferably copper split bolts) Soldering Iron and Solder
Pipe Insulation (to prevent wire “rattle” inside pole) Electrical tape
3/8” Drill Motor 3/8” or 10mm Metal Cutting Drill Bit

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WELCOME TO YOUR RENEWABLE ENERGY SYSTEM!
ELECTRICITY FROM THE WIND AND SUN:
Renewable electric power systems provide independent (no utility grid!) electric power for boats, homeowners, farms,
villages and commercial applications such as telecommunications. If utility power is available, your renewable energy
system can reduce the electric bill and with a battery system provide back up electricity during storms or line failure. The
most common sources of renewable electric power in these systems are small wind powered generators and solar photovoltaic
(PV) modules that convert sunlight directly to electricity. Renewable means power sources that do not deplete the world's
finite fossil fuel resources, do not pollute or warm the atmosphere and do not generate hazardous waste. Electricity means
your children can study at night for a better future and you can benefit from appliances, power tools and communication
technologies that make life easier and more rewarding. Nearly three billion people in the world do not have electricity and by
necessity most will ultimately get their electricity from renewable resources to the benefit of everybody. You are a pioneer
and part of the solution!
BEFORE YOU BEGIN:
Read this entire manual. Identify and note your model wind generator where it appears in this 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 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 spinning 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 spinning 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. These devices must dissipate heat
as part of normal operation. FAILURE AND FIRE can result if airflow is blocked.
Introduction

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DESCRIPTION OF SYSTEMS
The illustration below depicts a typical installation. For more information regarding specifications of wind, wind/solar and
inverter systems, contact Southwest Windpower. Note that the illustration below is for information purposes only. See the
appropriate section to properly wire your own wind system.
Whisper Wind Generators (Whisper 100 and 200) include the Whisper Controller System Center. The user supplies the
battery, tower, inverter and wiring. During windless periods, solar panels may supplement your usage of renewable energy.
Solar PV (photovoltaic) panels make electricity directly from sunlight. Batteries store electricity so you have power during
windless and sunless periods as well as periods of high demand. A deep cycle type of battery must be used. If you have the
wind generator only, use this manual to help size the battery and inverter.
Introduction

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Overview of Wind Generator
Whisper 200 Shown
Tail Stalk
Assembled Generator
Blade
Nose Cone
Tower Insert
Tail Fin
Tower
Blade Extender
What you should have with your Whisper wind generator
Assembled Generator 1
Blades 3
Tail Fin 1
Tail Stalk 1
Nose Cone 1
Tower Insert Kit 1
Hardware Kit 1
Whisper Controller (if ordered with a controller) 1
100 amp Fuse 1
Introduction

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Introduction
VOLTS 12 24 30-36 48 60-72 120 240
COPPER All
WIRE SIZE HVLV
AWG 14 xx xx xx 108 217 678 2710
12 xx xx 87 173 346 1082 4327
10 xx 69 138 276 551 1722 6888
8 xx 109 218 436 879 2730 10910
6 42 170 339 678 1357 4241 16960
4 68 271 542 1084 2169 6779 27110
3 85 341 682 1364 2727 8525 34090
2 108 430 860 1720 3439 10750 42990
1 137 549 1098 2195 4390 13723
0 171 682 1364 2727 5455 17050
2/0 217 865 1731 3462 6923 12860
3/0 273 1088 2177 4355 8710 27230
4/0 345 1378 2755 5510 11020
250 402 1607 3214 6429 12860
300 482 1929 3857 7714 15430
350 563 2250 4500 9000
400 650 2596 5192 10390
500 805 3214 6429
VOLTS 12 24 32-36 48 64-72 120 240
COPPER All
WIRE SIZE HVLV
AWG 14 xx xx xx 33 66 207 826
12 xx xx 27 53 105 330 1319
10 xx 21 42 84 168 525 2099
8 xx 33 66 133 268 831 3320
6 13 52 103 207 414 1293 5170
4 21 83 165 330 661 2066 8260
3 26 104 208 416 831 2598 10390
2 33 131 262 524 1048 3277 13100
1 41 167 335 669 1340 4183
0 52 208 416 831 1663 5200
2/0 66 264 528 1055 2110 6600
3/0 83 332 664 1327 2655 8300
4/0 105 420 840 1679 3360
250 123 490 980 1960 3919
300 147 588 1180 2351 4700
350 172 686 1370 2740
400 198 791 1580 3160
500 245 980 1960
AWG
SIZE 14 12 10 8 6 4 3 2 1 0 2/0 3/0
Diam
inches 0.064 0.081 0.102 0.129 0.162 0.204 0.229 0.258 0.289 0.325 0.365 0.409
Diam
mm 1.628 2.057 2.591 3.277 4.115 5.182 5.817 6.553 7.341 8.255 9.271 10.389
Inch to Metric Conversion — AWG
Typical Renewable Energy System Wiring
You will need to make the electrical connections as shown below.
WIRE SIZE FROM WIND GENERATOR TO
WHISPER CONTROLLER
The following tables are used to determine the wire size based on
your system voltage and the distance required to connect your
Whisper 200 to the WHISPER Controller. Distances are one way
distances from the turbine connection to Whisper Controller
terminals.
WHISPER Controller
See wire size
table below.
10 Feet or 3
Meters Maxi-
mum Distance
See the
Whisper
Controller
installation
section for
complete
wiring de-
tails
Fuse Included
Battery Bank
-
+
Ground
Lug

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Tower
Tower height minimum: 7m (20 ft) above trees or obsta-
cles within 100m (300 ft).
100m (300 ft)
1. TOWER LOCATION/TYPE AND
HEIGHT. INSTALL TOWER
(Install tower following manufacturer’s instructions.)
Tower height minimum is 7 meters (20 feet) above trees
or obstacles within 100m (300ft). The highest point on
your property is generally best, but wind generator dis-
tance to battery and the battery voltage determine the cor-
rect wire size (Refer to wire size table pg. 6). A self sup-
porting tower occupies less ground area than a guyed
tower but is more expensive. A tilt-up design permits
easy installation and maintenance on the ground and
eliminates the need for climbing.
The Whisper Model 200 is suitable for side-of-building
mounting on unoccupied buildings such as garage or
barn. Some vibration transmission will be noticeable from
mounts to structure.
Foundations must be designed and approved for local
wind/soil conditions.
Consult with a professional engineer to determine
proper type and location of tower installation.
Side of Building Mount
Mounting
Bracket
Wind Generator Model
Whisper 200
Battery System Volts
12, 24, 36, 48
Minimum Amp x Hours
(20 hour rate)
200
Min. kwh (Volts x Amps x Hours/1000)
4
MINIMUM BATTERY SIZES
2. PURCHASE BATTERIES OF PROPER SIZE.
See Table below for minimum battery size.
1. INSTALLATION
Installation

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3. SETTING TURBINE VOLTAGE
Introduction
The Whisper 200 Wind Generator must be configured for the correct systemvoltage - 12, 24,
36 or 48 volts. All Whisper Wind Generators are shipped from the factory configured for 24
volt operation unless specially ordered.
To check the voltage configuration or to change the configuration, refer to the following notes
and wiring table. Your Whisper Dealer may also be of assistance configuring your Wind Gen-
erator to the voltage for your application if different from 24 volts.
Wiring and Assembly Notes
The correct Whisper 200voltage isset byalteringthe 12stator wireand 3 brush wire connec-
tions. The wire connections are made using appropriate size wire nut connectors.
To access the wire nuts remove the metal cover on the side of the Whisper turbine housing. Re-
fer to the following Voltage Configuration Wiring Table for specific stator and brush wire con-
nections.
Observe the following notes when changing the voltage configuration:
•The three brush wires are interchangeable and are not labeled. The brush wires are easily
identifiable as they are larger multi-strand wires and stator wires are solid wire. ( 8 awg
compared to 20 awg).
•Stator wires are numbered and color coded with a wire sleeve. For example stator wire
“Red 3” has a red sleeve with the number “3” printed on it. Wire “Red - “ has a red sleeve
with no number. The “-” indicates there is no number. There is a” Red - “, “White - “, and
“Black -” stator wire.
•When changing the voltage configuration cut off the twisted ends of the wires (stator wires
only) and strip off approximately 25mm (1 inch) of insulation.
Important Note:
In addition to the PVC insulation, the stator wires are also coated with varnish that MUST be
removed to make a good connection. The varnish can be removed by scraping with sharp edge or
lightly sandpapering the wire.
•Hold the stripped ends of the wires to be joined parallel to each other and twist together with
pliers before installing the wire nut. The wires should be twisted in a clockwise direction.
•Cut of the “untwisted” ends of the wires and twist on the appropriate color wire nut. Push
hard on the wire nut while twisting clockwise.
•Coat wire nuts and terminal strip connections with dielectric grease to protect wires against
corrosion. Atube of dielectric grease is supplied with each Whisper 200.

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12 Volt
Red Wire Nuts
Brush Wire Brush Wire Brush Wire White 1 Red - Black 1 White 3 White - Red 1 Black - White 2 Red 3 Black 2 Red 2 Black 3
24 Volt
Yellow Wire Nuts
Brush Wire Brush Wire Brush Wire White - White 2 White 1 Red - Black 1 Red 3 Red 1 White 3 Red 2 Black 3 Black - Black 2
36 Volt
Yellow Wire Nuts Orange Wire Nuts
Brush Wire Brush Wire Brush Wire Black 2 Red 2 White 2 White 1 Red - Black 1 Black 3 Red 3 White 3 Black - White - Red 1
48 Volt
Yellow Wire Nuts Orange Wire Nuts
Brush Wire Brush Wire Brush Wire White - Red 2 White 2 Black 2 White 1 Red - Black 1 Red 1 Red 3 White 3 Black 3 Black -
Reference the following table to determine the correct brush and stator wire connections for your voltage configuration. Note the correct color (size) wire nut is indicated for each connection. See the preceding page for specific wiring directions.
9
Voltage Configuration Wiring Table

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Locate battery in moderately stable room temperature, dry
unoccupied building. Battery performance is optimal at room
temperatures. Run AC power from inverter to house or load.
If battery is in an occupied building, an enclosure with vent
to outside is required. Follow code. See the following
diagrams for package system series/parallel arrangement.
Determine series/parallel arrangement and construct a rack
or mount from heavy, treated lumber, or other suitable
material. Allow 5 cm (2 in) on all sides for ventilation.
Allow 60 cm (2 ft) vertical clearance for access to terminals
and checking water.
Coat all connections with grease or corrosion protector
available at auto parts store. Install Whisper Controller and
Inverter fuse (if used) at battery positive. To minimize the
possibility of EMI (electromagnetic interference), the line
from the battery to the Whisper Controller should be less
than 10 feet (3 meters).
12 Volt Configuration
Inverter
Inverter
Whisper Controller
Whisper Controller
24 Volt Configuration
Inverter
Inverter
Whisper
Controller
Whisper
Controller
Inverter
Whisper
Controller
48 Volt Configuration
Inverter
Whisper
Controller
Nut and Bolt
Battery Positive
Drill one end of fuse to fit
battery post, if necessary.
JJN-100 IR 200kA
Use the diagrams below to determine the
series/parallel arrangement for your system
voltage (typical 6 volt battery arrangement
shown).
Recommended Battery Fuse Installation
(Consult local electrical codes)
Fuse Included
4. CHOOSE BATTERY LOCATION
Installation

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Complete these tests before mounting blades to rotor.
These tests confirm that the wind generator was not damaged in shipment and is ready to install on the
tower.
GROUND TEST
Check resistance
to ground on any
wire. Resistance
must exceed
10,000 ohms.
When the wires
are uncon-
nected the wind
generator rotor
should spin
freely.
OPEN CIRCUIT TEST
SHORT CIRCUIT TEST
When all the wires
are shorted together
the
generator rotor
should turn hard and
smooth.
5. WIND GENERATOR ELECTRICAL TESTS
PHASE TO PHASE TEST
When two wires are
shorted together the
generator rotor
should turn lumpy
as though there are
smooth and bumpy
portions of the rotor
Installation

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Mounting Instructions
Check fit of insert by placing it inside the tower. A maximum of 1.5 mm (1/16 in) play is allowed. You must be able to
pull pipe or tube tight against insert with mounting bolts. Next, using the template supplied on the last page of this man-
ual, drill holes in the tower tube. Check to see that the holes in the tower line up with the threaded holes in the insert.
Install insert on yaw shaft with slot facing down. The slot is used for tower cable grip strain relief. Use medium-strength
thread locking compound on all fasteners. M6 X 20 Allen head set-screws must engage both engagement holes in yaw
shaft.
Solder or use split bolts to make electrical connections. A good wire connection is crucial. Any wind generator wire can
go to any tower wire. Wrap connections thoroughly with electrical tape to prevent shorts to tower. Support wires to avoid
weight on slip ring wires and wire connections. Slide generator without propeller into tower and install mounting hard-
ware as shown. Make sure the top flange of the tower insert is resting on the top end of the tower pipe. Insert and torque
all four insert mounting bolts (M8 x 35mm) to 10-11 ft-lb. (12-14 N-m) repeating any tightening sequence used at least
four times. As an option, the tower tube may be insulated with pipe insulation to prevent the wires from rattling.
Tower Insert Kit
For
2.5 Schedule 40 Pipe (2.875 O.D. x .20Wall)
Item Description 2.5”
QTY
1 Set Screw (M6 X 20) 2
2 Bolt M8 X 35 4
3 M8 SS Nylock Nut 4
2
2.5” Insert
1
3
Engagement Hole
Solder or
Split Bolt
Connector
Cable Grip
Strain Relief
Tower
Wires to Whisper
Controller Wire
System
Wires From
Turbine
Tower Insert Support Wires
by Attaching
to the Tower
Insert
6. CONNECT WIRES AND MOUNT WIND GENERATOR TO
TOWER
Installation

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Installation
PRELIMINARY MOUNTING INSTRUCTIONS FOR WHISPER CONTROLLER
Please note that for preliminary turbine to controller tests, it may be convenient to temporarily mount the
Whisper Controller close to the Wind Turbine. This will allow the user easy access to the controls and displays
while testing the turbine and controller functionality. Please observe the following recommendations for
mounting the controller.
The tests should be performed prior to mounting the blades.
Mounting
The Whisper Controller should be mounted against a vertical wall with the LEDs and Diversion Switch to the top.
Vertical mounting is required to provide good heat convection for the resistor bank (dump load). Since the dump load
side of the controller may get very hot, do not mount the unit near anything flammable or heat sensitive.
Conduit knockouts on the bottom of controller unit accommodate 0.75”, 1.25”, and 1.5” nominal size conduit. An
earth ground connection terminal is provided inside the controller between the turbine and battery mounting blocks.
7. WHISPER CONTROLLER - MOUNTING
Connecting
Connect the battery and grounding wires as shown in the schematic on the next page. Caution: connect the Control-
ler to the batteries BEFORE connecting to the turbine, otherwise the Controller will be damaged. Please use
caution when connecting the battery leads to avoid shorting them together. After connecting the battery, check that the
microprocessor is energized correctly by flipping the Diversion Switch to the stop position. The red LED should illu-
minate. If not, disconnect the battery and reconnect it. Return the diversion switch to the battery position and observe
the red LED to turn off. Try not to allow the connection to “bounce” causing the microprocessor to power up and then
power down quickly. This kind of quick on-off cycle can cause the microprocessor to latch up. If it latches and the
Red LED is unresponsive, contact Southwest Windpower for instructions on resetting the microprocessor.
8. WHISPER CONTROLLER - WIRING
Knockouts (on bottom
of controller)
Earth Ground
Connection
Battery Outputs
Turbine Inputs
LED’s and Diversion
Switch
Dump Load Side/Hot Side
Suggested Mounting Configuration
Anemometer
Connection
(optional)
+ -

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InstallationInstallation
14
Whisper Controller Wiring Diagram
Optional Anemometer Connection
The Whisper Controller has been designed to accommodate a Model #40 anemometer, manufactured by NRG. Other
equivalent anemometers may work; refer to manufacturers specifications. Terminal blocks on the circuit board are the
connection points for the two anemometer signal wires. A ground shield (if applicable) may be connected to the control-
ler’s grounding terminal. Either wire from the anemometer may connect to either terminal on the terminal block.
For best results the anemometer should be mounted on the turbine tower as near as possible to the turbine without entering
the turbine’s sphere of operation. See the manufacturer’s recommended installation instructions.
Diversion Switch
Once startup is successful and the red LED can be cycled by toggling the Diversion Switch, then set the switch to
“Stop” (Red LED on) and connect the turbine wires to the controller (order of the turbine wires is not important). If the
Red LED is on, the turbine will not spin as long as at least two of its wires are connected. For further operational informa-
tion refer to Whisper Operation on page 16.
WHISPER Controller
Optional
Anemometer
NRG #40
Ground
Lug
Fuse
Included
Battery Bank
-
+
Wire size for wiring to the battery (3 meters each way):
12V system: 1/0 gauge or larger
24V system: 2 gauge or larger
48V system: 6 gauge or larger
Dump Load Wiring
Make sure the Controller is
wired correctly for the volt-
age of your turbine.
24v & 36v 12v 48v

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InstallationInstallation
Whisper Controller Components
The optional display was designed to be mounted either on the Whisper Controller base unit, or in a wall type switch re-
ceptacle. Hardware is provided with the display. There is a short ethernet CAT5 cable provided for Controller base instal-
lation.
Local Display Installation
If the display is to be mounted directly on the Whisper Controller you will need to remove the electronics cover and knock
out the sheet metal insert where the display will mount. There are pre-drilled holes to mount the display. Use the provided
8-32 x 3/8”, black oxide, stainless steel screws, and 8-32 nuts with captive star washers to mount the display to the elec-
tronics cover.
Connect the display cable to the CAT5 jack located nearest the diversion switch. This will indicate to the display that it is
locally mounted and it will disable its LED features, since these are redundant to those mounted on the Whisper Controller
base. Leave the cover off until the display function is verified.
Remote Display Installation
The display may up to 300 meters (1000 ft) from the Whisper Controller. An appropriate length of Category 5 (CAT5)
cable will have to be purchased. Install the display in the desired location and connect the ethernet cable.
Remove the electronics cover on the Whisper Controller. If necessary, knock out one of the sheet metal plugs in the Whis-
per Controller base unit and route the ethernet cable inside the unit. Plug the ethernet cable into the jack in the lower right
corner of the controller board. Leave the cover off until the display function is verified.
Display Function Verification
Once the display is plugged into the controller base and the batteries are connected to the controller there should be text
displayed on the LCD display. If the display is blank there is a contrast adjusting potentiometer that can be adjusted to
brighten the display. Insert a bladed screwdriver into the hole on the display between the buttons and the LEDs. Turn the
potentiometer to adjust the brightness. If a display is still not visible disconnect and reconnect the cable to the display to
reset the display. Once display function is verified re-install the electronics cover on the controller base.
The system wiring is now complete. Proceed to assembling the turbine and mounting blades to rotor.
Whisper Controller Display
Whisper Controller Resistive
Loadbank (Dumpload)
Whisper Controller
Electronic Cover
Whisper Controller Electronics
Diversion Switch and
LED’s (Far Side)
Whisper Controller Regulation
Potentiometer
9. DISPLAY INSTALLATION—OPTIONAL

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Item Number Description Quantity
1 Assembled Generator 1
2 Tail Stalk 1
3 Tail Fin 1
4 Hex Bolts, M8 x 55 2
5 Nylon Washer, M8 X 31 2
6 SSTL Washer, M8 x 24 2
7 Nylock Nut, M8 4
8 Hex Bolt, M8 x 25 1
9 Hex Bolt, M8 x 70 1
2
1
5
4
3
6
7
9
8
7
10. INSTALL TAIL
Installation

17
Whisper H-80 Manual Document #0212 REV B
11/22/2004SOUTHWEST WINDPOWER
INSTALL BLADE AND NOSE CONE. DIVERSION SWITCH IN “STOP” POSITION.
1. Bolt down Blade Extension (#1) to rotor using only the one bolt (#3) and lock washer (#2) nearest center of rotor. In-
sure remaining Extension bolt-hole lines up with rotor by loosely inserting bolt in outer hole and tighten inner bolt
securely. Repeat for each Blade Extension.
2. Line up bolts (#3) through Nose Cone (#4) using Flat Washers (#5), and lock washers (#2). Tighten to 18 Ft-lbs
(24Nm) torque.
3. Install blade (#6), rounded edge advancing clock-wise, on Extension (#1) using cut washer (#10) on outside mounting
bolt. Using bolts (#11), Washers (#9 and #10), and Nuts (#7), tighten all bolts to 18 Ft-lbs (24Nm) torque. Repeat for
remaining Blades. Note: Tapered ground end of extensions faces towards blades.
Item Description Quantity
1 SS Blade Extension 3
2 SS Lock Washer, M10 6
3 SS Hex Bolt M10 x 40 6
4 Nose Cone 1
5 SS Flat Washer M10 x 20
(Thin)
3
6 Blade 3
7 SS Nylock Nut M10 6
9 SS Flat Washer M10 x 30
(Thick)
3
10 SS Shaved Flat Washer
M10 x 30
3
11 SS Hex Bolt, M10 x 50 6
4
1
Ground Edge
2
3
3
5
2
6
9
11
10
Leading Edge
Rounded
Trailing Edge Sharp
7
WHISPER 200
Blade Installation
11. INSTALL BLADES AND NOSE CONE.
Installation
Important Assembly Note !
Each turbine blade has a dot of paint on the
“front “ of the blade between the blade
mounting holes. The blades should be bolted
to the “front” of the blade extensions (item
1) as shown in the above figure so that the
paint dot is VISIBLE after the blades are
mounted.
Paint Dot
See Assembly Note Below

18
Whisper 200 Operators Manual Document #0212 REV B
SOUTHWEST WINDPOWER 11/22/2004
1. Normal Operation – Whisper Controller Overview
The Whisper Controller is a one or two part system specifically designed to control the operation and convert the power of
a Southwest Windpower Whisper 100 or 200. Its basic functions are rectification, regulation, and resistive power dump-
ing. However, to best accommodate many individual customers, the Whisper Controller offers many features and adjust-
able operation parameters.
The main Whisper Controller block (hereafter the “Controller”) is a functionally autonomous unit. The Controller contains
all of the Whisper turbine’s power electronics including rectification and load diversion. Additionally, it continuously
monitors voltage, current, energy production, and wind speed (if equipped). These parameters are measured to ascertain
system parameters (i.e. battery voltage) and turbine state (i.e. whether power is being generated).
The auxiliary Whisper Controller Display block (hereafter the “Display”) offers an interface to the many operational pa-
rameters and system measurements of which the Controller is capable. It can be mounted at the Controller or in a remote
location or (with two Displays) both places. From the Display, instant and easy access is gained to voltage, current, power,
energy, charge, peak power, and wind speed.
2. Normal Operation – Whisper Controller
The Whisper Controller provides all of the necessary functions and displays for safe and productive turbine operation. It
includes interface features for setting the regulation voltage, monitoring the state of the system, and manually disabling bat-
tery charging. The interface mechanisms of the Whisper Controller are the LED Display, the Diversion Switch, and the
Regulation Adjustment.
3. Diversion Switch
The diversion switch is located on the top of the controller to the left of the LEDs. This switch will divert turbine power to
the dumpload to keep the batteries from being charged. While this switch does not necessarily stop a spinning turbine,
once the turbine has stopped, this switch will keep it from spinning.Therefore, it should be noted that in most situations
this switch can be used as a stop switch; however, spinning blades with an activated diversion switch is a normal and safe
operational state.
Whisper Controller with
Display
Turbine
Battery
Remote Display
12. BECOMING FAMILIAR WITH THE WHISPER
CONTROLLER
Normal Operation—Whisper Controller