Superwind 350 12V User manual

www.superwind.com
Superwind 350 12V & 24V Manual
North, Central, and South America regions
01-2017

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Thank you for purchasing a
Superwind 350.
Like all specialized commercial electrical generating equipment, it is important to
protect your investment by reviewing this manual in its entirety, paying particular
attention to all precautions and warnings.
Superwind micro-wind turbines are constructed of the highest quality materials
and have been designed for autonomous use in harsh conditions – but no matter
how well we construct the product, damage can be done to the turbine and/or
related systems (batteries, wiring, loads etc) if the integration is not well planned
and more importantly, installed correcty – as directed in this full version manual.
Should you have any questions regarding the installation or use of a Superwind
350 after reading this manual, PLEASE contact your closest Superwind installer,
distributor or superwind (the manufacturer) directly.
Your Superwind has been designed to provide many years of autonomous
service when properly installed.
INSTALLATION
PLEASE DO NOT PROCEED UNTIL
YOU HAVE READ
ALL INSTRUCTIONS
AND
SAFETY INFORMATION
© 2016 superwind GmbH.
Superwind is a Registered Trade Mark of superwind GmbH, Germany
MANUAL VERSION 01-2017
Replace previous version 10-2016

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Table of Contents
Section Description Page No.
OVERVIEW............................................................................................................... 2
Table of Contents.................................................................................................... 3
1. GENERAL INFORMATION AND REFERENCES
1.1. Company profile ............................................................................................ 5
1.2. Labelling ........................................................................................................ 5
1.3. Range of application ...................................................................................... 6
2. WARRANTY
2.1. Warranty......................................................................................................... 7
2.2. Warranty period ............................................................................................. 7
2.3. To obtain warranty service............................................................................. 7
2.4. Limitations...................................................................................................... 7
2.5. Others ............................................................................................................ 7
2.6. Expenses and Responsibilities ...................................................................... 8
2.7. Claims ............................................................................................................ 8
3. SAFETY INSTRUCTIONS
3.1. Potential sources of danger ........................................................................... 9
3.1.1. Mechanical dangers ....................................................................... 9
3.1.2. Electrical dangers........................................................................... 9
3.1.3. Dangers when mounting ...............................................................10
4. SPECIFICATIONS
4.1. Operational free space required ...................................................................12
4.1.1. Dimensions....................................................................................12
4.2. Technical data...............................................................................................13
4.3. Functional description / Special features ......................................................13
5. PREPARATIONS FOR ASSEMBLY
5.1. Packing list....................................................................................................15
5.2. Tools .............................................................................................................16
5.3. Optional accessories ....................................................................................16
5.4. Electrical components...................................................................................16
6. ELECTRICAL COMPONENTS AND CONNECTIONS
6.1. General information ......................................................................................17
6.2. Wiring diagrams ............................................................................................17
6.2.1. Recommended charge regulator....................................................17
6.2.1.1. SCR Marine Charge Regulator .......................................17
6.2.1.2. Diversion Load Resistor...................................................19
6.3. System components ....................................................................................19
6.3.1. Wires ..............................................................................................19
6.3.1.1 WAG Wire size chart for 12 Volt version .........................20
6.3.1.2 WAG Wire size chart for 24 Volt version .........................20
6.3.2. Strain relief ....................................................................................21
6.3.3. Polarity............................................................................................22
6.3.4. Batteries .........................................................................................22
6.3.4.1. Charging batteries ...........................................................22
6.3.4.2. SCR Marine charge regulator (with diversion load control). 24
6.3.4.3. Diversion load resistor .....................................................25
6.3.5. Fuses..............................................................................................25
6.3.6. Stop switch .....................................................................................25
6.4. Grounding .....................................................................................................26
7. SUPERWIND 350 GENERATOR ASSEMBLY
7.1. Precautions during mounting ........................................................................27

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7.2. Mast mounting ..............................................................................................28
7.2.1. Mast tube specifications ................................................................29
7.2.1.1 Common North American Mast Materials.......................29
7.2.1.2 Bushings .........................................................................29
7.2.2 Mounting the turbine on the mast ......................................................29
7.2.3 Preparations at the mast head...........................................................29
7.3 Mounting of the wind vane ...........................................................................31
7.4 Rotor assembly ............................................................................................32
7.4.1 Rotor blade hub assembly ................................................................32
7.4.2 Mounting the hub to the generator shaft............................................34
8 COMMISSIONING
8.1 Verification chart ...................................................................................................36
9 OPERATION
9.1 Safety instructions ........................................................................................37
9.2 RUN and STOP ...........................................................................................37
9.3 Power control ..............................................................................................38
9.4 Over-speed protection .................................................................................38
9.5 Annual power production ..............................................................................39
10 INSPECTIONS, MAINTENANCE
10.1 Periodic inspections ......................................................................................40
10.1.1 Rotor blades ..................................................................................40
10.1.2 Bolted connections .........................................................................40
10.1.3 Bearings, seals...............................................................................40
10.1.4 Slip rings.........................................................................................41
10.1.5 Corrosion protection ......................................................................42
10.1.6 Mast ...............................................................................................42
10.1.7 Electrical system ............................................................................42
10.2 Maintenance..................................................................................................42
11 TROUBLESHOOTING
11.1 Wind generator does not start.......................................................................43
11.2 No power output ...........................................................................................44
11.3 Insufficient power output ...............................................................................44
11.4 Battery is not fully charged............................................................................44
11.5 Checking the open circuit voltage.................................................................45
12 REPAIRS, SPARE PARTS
12.1 Repairs..........................................................................................................46
12.2 Spare parts list ..............................................................................................46
13 FREQUENTLY ASKED QUESTIONS
13.1 Basic use.......................................................................................................47
13.2 Installation .....................................................................................................47
13.3 Operation ......................................................................................................48
13.4 Troubleshooting ............................................................................................49
14 Abbreviations used in this manual ...............................................................................50
ATTACHMENT A – SUPERWIND STOP-SWITCH MOUNTING GUIDELINES..................51
ATTACHMENT B – SUPERWIND CHARGE CONTROLLER 12V (MARINE) SYSTEM....59
ATTACHMENT C – SUPERWIND CHARGE CONTROLLER 24V (MARINE) SYSTEM....69

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1. GENERAL INFORMATION AND REFERENCES
1.1 Company Profile
superwind GmbH was established in 2004 after four years of successful
research, design and testing of its now internationally patented micro-turbine
technology. Since then, thousands of commercially rated Superwind 350 (and
new Superwind 1250) turbines have been quietly providing reliable, autonomous
wind generated electricity to users in remote, harsh conditions on both land and
at sea world-wide.
As our reputation is as important as your satisfaction, we thank you in advance
for reading the Superwind manual in full – even before purchasing our wind
generating equipment. We also wish to remind you that wind turbines work best
when installed where there is sufficient wind, so please research your planned
wind turbine site or vessel installation to help predict how a Superwind 350 might
help with you power needs.
On behalf of our superwind staff and world joint venture partners, we thank you
for your interest in our cutting edge and real world proven wind turbines.
1.2 Labelling
This manual refers to the Superwind 350 wind generator.
Manufacturer:
superwind GmbH
Am Rankewerk 2-4
D-50321 Brühl
Germany
Tel.: +49 / 2232 / 577357
Fax: +49 / 2232 / 577368
E-Mail:[email protected]
Internet: www.superwind.com
The label providing the serial number and nominal voltage of your Superwind is
located at the yaw shaft (See Graphic No. 1.2).

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For future reference please record the serial number
of your Superwind 350 in the space provided below
prior to installation. Once the yaw shaft is inserted
into the mast this information will not be visible.
Type..................................................Superwind 350
Serial Number ..................................._____________
1.3 Range of application
The electric power generated by the Superwind charges batteries and can
directly be used for 12 VDC or 24 VDC-appliances (depending on the system
voltage). AC-appliances are supplied via an optional inverter. There is a wide
range of high quality 12 VDC or 24 VDC equipment available like energy saving
lamps, refrigerators, deep-freezers, water pumps, ventilators, consumer
electronics, TV, radio and navigation equipment, etc.
Examples of ideal applications include sailing yachts, campers, summer cottages,
mountain shelters, and industrial applications such as navigational aids, security
systems, environmental monitoring stations and communications. For rural
electrification the Superwind supplies basic power to families, schools, small
health care facilities, etc.
In many integration sites, energy supplies from sun and wind complement each
other. That is why the Superwind is used in wind / solar and in combination with
other charging systems to optimize the availability of power (at minimized battery
capacity).

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2 WARRANTY
2.1 Warranty
superwind GmbH warrants this product to be in good working order during the
warranty period. In the event that the product is found to be defective within the
warranty period, repair service will be provided free of charge by superwind
GmbH or an authorized service partner.
Free repair service may only be obtained by providing the warranty card and
original purchase invoice issued to the customer by the retailer. The warranty
card must state the purchaser s name, the retailer s name and address, the serial
number and the date of purchase of the product. superwind GmbH reserves the
right to refuse warranty service if this information is not complete or has been
removed or changed after the original purchase of the product from the retailer.
2.2 Warranty period
The warranty is valid for three years from the date of purchase by the purchaser,
as evidenced by the above mentioned documents.
2.3 To obtain warranty service
Warranty service is available at superwind GmbH and Superwind authorized
service partners. Any costs of secure transportation of the product to and from
superwind GmbH / Superwind authorized service partners will be borne by the
customer.
2.4 Limitations
superwind GmbH does not warrant the following:
Periodic check-ups, maintenance and repair or replacement of parts due to
normal wear and tear.
Defects caused by modifications carried out without superwind’s approval.
o Includes damage caused by improper use, handling or operation, in
particular defects caused by improper installation and installation on
inadequate masts or support structures.
Installation on inadequate masts or support structures (to obtain warranty
service the purchaser has to provide evidence that masts or support
structures are as recommended in the Superwind 350 manual).
Accidents or disasters or any cause beyond the control of superwind GmbH,
including but not limited to lightning, flooding, fire etc.
Costs for disassembly and reassembly of the product to enable shipment for
warranty reasons.
2.5 Others
Superwind GmbH reserves the right to decide whether the product or parts
thereof shall be repaired or replaced under warranty. Should neither repair nor
replacement by superwind GmbH be possible, the purchaser solely will be
entitled to a full or partial refund (prorated when returned to the manufacture after
more than 1 year of use).
This warranty does not affect the purchaser s statutory rights under applicable
national legislation in force, nor the purchaser s right against the retailer arising
from the sales / purchase contract. In the absence of applicable national
legislation, this warranty will be the purchaser s sole and exclusive remedy, and
superwind GmbH shall not be liable for any incidental or consequential damages
for breach of any expressed or implied warranty of this product.

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THE GENERAL CONDITIONS FOR THE SUPPLY OF PRODUCTS AND
SERVICES OF THE ELECTRICAL AND ELECTRONICS INDUSTRY APPLY
WITH APPROPRIATE LIMITS AND STANDARDS.
2.6 Expenses and Responsibilities
All associated expenses (shiping to and from the repair facility, insurance, etc)
are the full responsibility of the buyer or his shipping agent, unless the buyer is
notified otherwise by the manufacturer.
Upon receipt of your unit:
The crate should be opened and inspected immediately for damage.
Note any damage to the outside of the package (dents, scratches, etc.) and
document it on the Bill of Lading before signing and keep a copy.
Documenting damage with photos is also highly recommended.
Unpack the unit at once and perform a visual inspection to determine if it is
dented, bent or scratched.
If for any reason the unit should need to be returned, the original crate is the
best way to ship it back to the manufacturer.
2.7 Claims
Claims that occur during transportation must be filed by the consignee (the buyer)
as shipping terms are FOB-EX-WORKS (our distribution point as contracted).
BUYER IS RESPONSIBLE FOR ALL SHIPPING EXPENSES INCLUDING
CUSTOMS DUTIES AND VAT (IMPORT DUTIES).

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3 SAFETY INSTRUCTIONS
Please carefully study this manual before starting assembly and installation. The
information provided is to ensure your safety during mounting, operation, and in case of
trouble. If you have any additional questions please contact your dealer, a Superwind
service partner, or the manufacturer.
3.1 Potential sources of danger
Wind turbines in general – including small wind generators like the Superwind –
are electrical machines and thus potential sources of hazards.
3.1.1 Mechanical dangers
The main danger is the spinning rotor. The rotor blades are sharp and
can cause serious injuries, even at very low speed.
Never touch a spinning rotor.
Never try to stop the rotor by hand.
Do not mount the unit where personnel can come in contact with
the spinning rotor.
The rotor blades are made of carbon fiber reinforced plastic. This
material is extremely sturdy and enables your Superwind to cope with
heavy storms; however the rotor blades can break if any objects (e.g.
ropes, loose sail battens, branches etc.) come in contact with a spinning
rotor. The fragments of broken blades are sharp and can be thrown off of
the rotor at very high speed.
Protect the spinning rotor from impact with foreign objects.
For aerodynamic reasons the trailing edges of the rotor blades are very
thin and sharp.
Be careful when unpacking and handling in order to avoid injuries
as well as damage to the blades.
3.1.2 Electrical dangers
The generator can produce dangerous open circuit voltages up to 52
VDC (12 V version) and 105 VDC (24 V version) at no-load operation if
the electrical connection to the battery or consumer (load) is interrupted.
This open circuit voltage will be reached at a wind speed of
approximately 35 m/s.
The charging current will reach up to 30 Ampere DC (12 V version) or 15
Ampere DC (24 V version)! All wires, electrical components and
connectors must be rated for 40 Amps (12 V version) or 20 Amps (24 V
version). For correct dimensioning (gauge) refer to Section 6, Tables
6.3.1.1 and 6.3.1.2 on page 19.