Superwind 350 Installation manual

Operation Manual
Superwind 350
December 2007

2
Table of Contents: Page
1. General information and references 4
1.1 Labelling 4
1.2 Range of application 5
2. Safety instructions 5
2.1 Potential sources of danger 5
2.1.1 Mechanical dangers 5
2.1.2 Electrical dangers 5
2.1.3 Dangers when mounting 6
3. Technical characteristics, required space 7
3.1 Required space 7
3.2 Technical data 7
3.3 Functional description / special features 8
4. Preparations for assembly 9
4.1 Packing list 9
4.2 Tools 10
4.3 Optional accessories 10
5. Electrical components and electrical connection 11
5.1 General information 11
5.2 Wiring diagrams 11
5.2.1 Wiring diagram of a 12 Volt system with charge regulator SCR 12 Marine 11
5.2.2 Wiring diagram of a 24 Volt system with charge regulator SCR 24 Marine 12
5.2.3 Alternative charge regulators 12
5.3 System components 13
5.3.1 Wires 13
5.3.2 Battery 13
5.3.3 Charge regulator 14
5.3.4 Fuses 15
5.3.5 Stop switch 15
5.4 Earthing 16
6. Wind generator assembly 16
6.1 Precautions 16
6.2 Mast mounting 17
6.2.1 Mounting on a 60.3mm or 60.0mm mast tube 17
6.2.2 Mounting on a 48.3mm mast tube 18
6.2.3 Mounting on other mast tubes 19
6.3 Mounting of the wind vane 20
6.4 Rotor assembly 20
6.4.1 Fastening the rotor blades to the hub 20
6.4.2 Mounting the hub to the generator shaft 22
7. Commissioning 23
7.1 Check list 23
8. Operation 24
8.1 Safety instructions 24
8.2 RUN and STOP 24
8.3 Power control 25
8.4 Overspeed protection 25
8.5 Annual power production 26
9. Inspections, maintenance 27
9.1 Periodic inspections 27
9.1.1 Rotor blades 27
9.1.2 Bolted connections 27

3
9.1.3 Bearings, seals 27
9.1.4 Slip rings 27
9.1.5 Corrosion protection 28
9.1.6 Mast 28
9.1.7 Electrical system 28
9.2 Maintenance 28
10. Trouble shooting 29
10.1 Wind generator does not start 29
10.2 No power output 29
10.3 Unsufficient power output 30
10.4 Battery is not fully charged 30
10.5 Checking the open circuit voltage 30
11. Repairs, spare parts 31
11.1 Repairs 31
11.2 Spare parts list 31
12. Warranty 32
Notices:
This information is believed to be correct and reliable. However, superwind GmbH assumes no
responsibility for inaccuracies or omissions. The user of this information and product assumes full
responsibility and risk.
All specifications are subject to change without notice.

4
Thank you for purchasing a Superwind 350.
The Superwind 350 is a wind generator of highest quality and will reliably generate power for many
years. However, reliable operation not only will depend on product quality but also on accurate
assembling and proper wiring. Please read this manual carefully before you start the installation. Please
also keep in mind our safety instructions and warning notices. Our main concern is with your safety.
1. General information and references
1.1 Labelling
This manual refers to the wind generator Superwind 350
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
You will find the label with the serial number and the nominal voltage of your Superwind at the yaw shaft
(see drawing).
label
yaw shaft
Type: superwind 350
Nominal Voltage: 12 VDC
Nominal Power: 350 W
Serial No.: 9999350
superwind GmbH, Brühl / Germany
Made in Germany

5
1.2 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.
Ideal fields of application for example are sailing yachts, campers, summer cottages, mountain shelters,
as well as industrial applications, like navigational aids, traffic management systems, environmental
monitoring stations or transmitters. For rural electrification the Superwind supplies basic power to
families, schools, small health care centres etc.
The combination with solar arrays is without problems. At many places, energy supplies from sun and
wind complement each other. That is why the Superwind is used in wind / solar hybrid systems to
optimise the availability of power (at minimised battery capacity).
2. 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.
2.1 Potential sources of danger
Wind turbines in general – including small wind generators like the Superwind – are electrical machines
and thus potential sources of hazards.
2.1.1 Mechanical dangers
The main danger is the spinning rotor. The rotor blades are sharp and can cause very serious injuries
even at very low speed.
WARNING: Never touch the running rotor.
Never try to stop the rotor by hand.
Do not mount the rotor at places where any persons can reach the area swept by the
rotor.
The rotor blades are made of carbon fibre reinforced plastic. The material is extremely sturdy and enables
your Superwind to cope with heavy storms. However the material can break if any objects, e.g. ropes,
battens falling down, branches etc. get into the running rotor. The fragments of the blades are sharp and
can be thrown off the rotor at very high speed.
WARNING: Avoid any objects touching the running rotor.
For aerodynamic reasons the rotor blades´ trailing edges are very thin and sharp. Unpacking the parts
you should be careful, in order to avoid injuries.
2.1.2 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 the consumers would be
interrupted. This open circuit voltage will be reached at a wind speed of approx. 35 m/s.
The charging current reaches up to 30 Ampere DC (12 V version) or 15 Ampere DC (24 V version). The
cabling, all electrical components and connectors must be suitable for 40 Ampere (12 V version) and 20
Ampere (24 V version). For correct dimensioning refer to Section 5.3.

6
WARNING: Cables with insufficiently dimensioned cross sections can heat up extremely and
cause electrical fire.
In order to protect the cabling, fuses must be installed as close to the battery as possible. For details see
Section 5.3.
The battery must never be short-circuited. There is serious danger of setting the battery and the cabling
on fire. The battery would be destroyed furthermore and acid and gases would be released.
WARNING: You must be extremely cautious never to short-circuit the battery.
Charging lead-acid batteries produces inflammable hydrogen gas. Unsealed lead-acid batteries have vent
holes releasing hydrogen which forms detonating gas with the ambient air. A small spark e.g. of an
electrical switch can detonate the explosive gas mixture. For explosion prevention therefore always
provide sufficient ventilation.
WARNING: Never install the batteries at places with danger of spark formation.
Provide sufficient ventilation at all times.
The dump loads (power resistors) of the optional charge regulators can become very hot. For fire
protection they must not be mounted on inflammable surfaces or close to inflammable materials.
WARNING: Never install the power resistors on inflammable surfaces.
2.1.3 Dangers when mounting
These instructions also apply for potential disassembling, checks or other work carried out on your wind
generator.
Only use mast and support designs capable safely to withstand the loads of your wind generator. The
mast not only has to withstand your wind generator´s weight and mass moment of inertia (e.g. on a sailing
yacht) but also the considerable thrust caused by high wind speed. Details see Sections 3.2 and 6.1.
Work on the mast or on your wind generator only at a calm and windless day.
Do not step under hanging loads and also prevent other persons from staying underneath e.g. a tilted
mast.
Make sure that during all work your batteries are disconnected from the system.
Prevent your wind generator from unintended starting. For this short-circuit the two generator lines
(caution: disconnect the battery beforehand !) or tie one of the rotor blades to the mast.
WARNING: Never approach the running rotor.

7
3. Technical characteristics, required space
3.1 Required space
(see drawing)
3.2 Technical data
nominal power 350 W
nominal wind speed 12,5 m/s
cut in wind speed 3,5 m/s
cut off wind speed none
rotor diameter 1,20 m
number of blades 3
blade material carbon fibre reinforced plastics
rotor speed 500 – 1300 rpm
generator permanent magnet, 3-phase with rectifier
Neodymium magnets
nominal voltage 12 V DC or 24 V DC
speed regulation rotor blade pitch
power regulation rotor blade pitch
brake generator short-circuit
weight 11,5 kg
rotor thrust (operation) 70 N
rotor thrust (extreme wind speed) 220 N
superwind
Ø1220
136
168 556
530
... 55,7
71
Ø 54,5
76
Ø 44
Ø1263
dimensions in mm
fits for:
stainless steel tube (Ø 60.3 x 2.0)
steel tube (Ø 60.3 x 2.3)
aluminium tube (Ø 60 x 2.5)
fits for:
stainless steel tube (Ø 48,3 x 2,0)
view on top
(space required)

8
3.3 Functional description / special features
The Superwind , like all other wind turbines, uses a part of the kinetic energy of the wind and converts it
into electricity. The power is approximately proportional to the cube of the wind speed, i.e. doubling the
wind speed results to eight times higher power output. With the wind speed varying this means that only
relatively little energy can be generated from a moderate breeze. On the other hand a heavy storm
contains such a high quantity of energy that the wind generator must be protected against overstressing
and damage. Designing the Superwind special technologies have been developed in order to achieve
optimum power output for a wide wind speed range as well as maximum safety at storm conditions.
a) The rotor blades were developed using modern computerized calculation and simulation methods.
The airfoil had been wind tunnel tested and was specifically developed for small size rotors.
Relatively broad rotor blades combined with their special pitch angle produce a high start-up torque
enabling the rotor to start at only 3.5 m/s wind speed. Annotation: Optimum start-up performance will be
reached after a certain running-in period of the bearings and their seals. Using the Superwind for battery
charging please do not mistake the rotor start-up for the start of charging. The wind speed required to
start charging depends on the battery´s state of charge and might be slightly higher than the rotor start-up
wind speed.
b) The basic innovation of Superwind is its novel aerodynamic rotor control system. Similarly to large
wind turbines it adjusts the pitch angle of the rotor blades. The mechanical controller is fully integrated
into the hub and works without expensive electrical or hydraulic components. Instead, the controller is
actuated by forces arising at operation of the wind turbine itself. The forces are effected by the geometric
and kinematic lay-out of the rotor and controller mechanism.
Aerodynamic forces act as control variable to adjust the rotor blades for power regulation above the
nominal wind speed. Centrifugal forces are the second control variable for the rotor blade adjustment. By
the special arrangement of both force components, the controller limits the rotor speed even at extreme
wind velocities automatically, and protects the wind turbine from over speed, even at no-load operation.
As a result the controller limits the mechanical loads at high wind speed significantly and guarantees
smooth operation under all weather conditions.

9
4. Preparations for assembly
4.1 Packing list
Please check your delivery for completeness and transport damage.
Packing list:
1 pcs generator Pos. 1
1 pcs hub Pos. 2
1 pcs wind vane Pos. 3
3 pcs rotor blade Pos. 4
1 pcs wind vane mounting plate Pos. 5
1 pcs plastic bushing Pos. 6
1 pcs socket cap screw M8 x 80 Pos. 7
2 pcs socket cap screw M8 x 20 Pos. 8
6 pcs socket cap screw M6 x 25 (TUFLOK) Pos. 9
2 pcs hexagon socket button head screw M6 x 12 Pos. 10
2 pcs hexagon socket button head screw M6 x 6 Pos. 11
1 pcs allen key 6 mm Pos. 12
1 pcs allen key 5 mm Pos. 13
1 pcs allen key 4 mm Pos. 14
1 pcs operation manual Pos. 15
NOTE: For aerodynamic reasons the rotor blades´ trailing edges are very thin and sharp.
When unpacking the parts you should be careful, in order to avoid injuries.
superwind
125
7
8
9
10
11
12
13
14
15
4
4
4
3
6
superwind
350
operation
manual

10
4.2 Tools
For installation of your Superwind a set of allen keys is supplied.It is recommended to prepare some
additional tools as follows:
screw drivers
set of spanners
wire strippers
wire crimpers
heat shrink or electrical tape
multimeter
For correct tightening of the screws a torque wrench is recommended.
Tools for the mast installation are not listed here. See respective instructions.
4.3 Optional accessories
mast-sets:
mast-set for yachts
mast-set for land installation / guyed tubular mast 6 m (other heights on request)
mast-set for land installation / self supporting tubular mast 7,5 m
electrical components:
charge regulator SCR Marine incl. power resistors
fuses 40 Ampere, slow-blow / 20 Ampere, slow-blow
fuse holder
stop-switch
ammeter

11
5. Electrical components and electrical connection
5.1 General information
Always abide by the acknowledged rules of technology and the rules for accident prevention when
working on your Superwind or the electrical system.
Take care that works on the electrical system like installation, maintenance and repair is carried out by
qualified persons only. These persons must also have studied the instructions before given in this manual.
NOTE: After careful planning first the electrical components should be installed at their
respective places. The electrical connection should be made in a second step.
NOTE: Make sure that the batteries are disconnected until installation is complete.
5.2 Wiring diagrams
5.2.1 Wiring diagram of a 12 Volt system with charge regulator SCR 12 Marine
Please pay attention to the parallel connection of the power resistors in 12 Volt systems.
+
superwind
- + -
blackred
fuses:
40 A
battery set 1
12 V
fuse fuse fuse
power resistors
(parallel connection)
charge regulator
SCR 12 Marine
12 Volt-system
battery set 2
12 V
option STOP
switch

12
5.2.2 Wiring diagram of a 24 Volt system with charge regulator SCR 24 Marine
Please pay attention to the series connection of the power resistors in 24 Volt systems.
5.2.3 Alternative charge regulators
Alternatively the follwing charge regulators can be used:
•superwind CRM 12 V, respectively superwind CRM 24 V
•LVM 6TB12 V, respectively LVM 6TB24 V
For wiring diagrams of these charge regulator types please refer to the respective manuals.
+
superwind
- + -
blackred
fuses:
20 A
fuse fuse fuse
power resistors
(series connection)
charge regulator
SCR 24 Marine
24 Volt-system
battery set 1
24 V battery set 2 24 V
option STOP
switch

13
5.3 System components
5.3.1 Wires
The cross sections of the wires to be used depend on their length and the rated voltage of your wind
generator. After you decided where to set up the mast measure the distance from the mast top to the
battery and then select the minimum cross section required on the basis of the following tables. In order to
keep the losses of power in the lines as small as possible, you should not use lines with under-sized cross
sections.
For the 12 Volt version applies:
distance from mast top
to the battery up to 10,6 m 10,7 – 17,6 m 17,7 – 28,2 m 28,3 – 44,1 m 44,2 – 68,1 m 68,1m – 110 m
minimum cross section
recommended per cable 6 mm²
(= AWG 10) 10 mm² (= AWG 8) 16 mm² (= AWG 6) 25 mm² (= AWG 4) 35 mm² (= AWG 2) 50 mm² (= AWG 1)
For the 24 Volt version applies:
distance from mast top
to the battery up to 10,6 m 10,7 – 17,6 m 17,7 – 28,2 m 28,3 – 42,4 m 42,3 – 70,6 m 70,7 – 112,9 m
minimum cross section
recommended per cable 2,5 mm²
(= AWG 14) 4 mm² (= AWG 12) 6 mm² (= AWG 10) 10 mm² (= AWG 8) 16 mm² (= AWG 6) 25 mm² (= AWG 4)
WARNING: Cables with insufficiently dimensioned cross sections can heat up extremely and cause
electrical fire.
For applications on board a boat or at offshore locations, cables with tinned braids are recommended, in
order to prevent corrosion by salty air.
If the cable is to be laid into the ground, a special ground cable must be used, and / or it must be led
through a tube.
In any case an ultraviolet resistant cable should be used, so that it is protected against environmental
influences. Same applies to the isolation (heat shrink sleeves, insulating tape) at the junction points.
For protection of the cable against chafing the hole at the bottom of the mast must be properly deburred.
If necessary pull a piece of rubber tube over the cables.
For connecting to the terminals the cable ends are to be stripped and suitable wire end ferrules or lugs
must be crimped.
Depending on the mast length and the cross section the cable in the mast might be quite heavy. If the
cable hanging in the mast weighs more than 5 kg, a strain relief must be attached in the mast top, so that
the internal junction point at the slip rings of your Superwind will not be damaged.
Always pay attention to the correct polarity of the lines. Connecting to the batteries with interchanged
polarity will destroy the electric rectifier of your Superwind. In general you should mark all line ends by
POSITIVE (+) and NEGATIVE (-), in order to prevent errors with the connection.
Marking of the connecting cables at the Superwind :
POSITIVE Line (+) : RED
NEGATIVE Line (-) : BLACK
WARNING: The internal electric rectifier of the Superwind will be destroyed by connecting with
interchanged polarity. (loss of warranty!)
5.3.2 Battery
The most common application of the Superwind is charging batteries. For special applications it is
possible to operate the system without charge regulator. This would require however the continuous
monitoring of the state of charge of the batteries by the operator and a stop switch for shutting down the

14
Superwind in case of fully charged batteries. We therefore generally recommend to install a suitable
charge regulator. The charge regulator allows operating the Superwind completely unsupervised and
automatically; the batteries are charged optimally and protected against overcharging and benefit from a
substantially longer life span.
When selecting the batteries pay attention to the correct rated voltage (12 V or 24 V). The rated voltage of
your Superwind is specified on the type label.
Lead-acid batteries are most commonly used. The charge regulators recommended in the accessory list
are suitable for all types of batteries. We recommend batteries for stationary use. Solar batteries are well
suitable, because they have a long life span. They usually are maintenance-free and better survive
occasional deep discharge. Car batteries are less suitable because they wear out very fast by cyclic
operation, which probably will be the normal case for your system.
Another important criterion for battery selection is the capacity, expressed in ampere-hours (Ah). This
value represents the quantity of storable energy. The required capacity depends on your individual
situation (wind location, consumption structure, combination with other generators like PV etc.). Your
battery dealer surely will assist you selecting the suitable battery.
When selecting the place of installation for the battery refer to the instructions of the battery manufacturer.
Charging lead-acid batteries produce inflammable hydrogen gas. Unsealed lead-acid batteries have vent
holes releasing hydrogen, which forms detonating gas with the ambient air. A small spark e.g. of an
electrical switch can detonate the explosive gas mixture. For explosion prevention therefore always
provide sufficient ventilation.
WARNING: Never install the batteries at places with danger of spark formation.
Provide sufficient ventilation at any time.
Batteries store a large quantity of energy, which suddenly is discharged in the case of a short-circuit. This
can destroy the battery (emission of battery acid and gas), can set the battery and the cabling on fire and
therefore must be avoided in all cases. For this reason the battery terminals may be only connected after
all work on the electric system has been completed.
WARNING: Never short-circuit the battery.
NOTE: The battery terminals may be connected only after all work on the electric system has
been completed.
For protection against too high currents and or short-circuit, fuses must be installed in the positive (+)
wires to the battery. See the connection diagram in Section 5.2 and the references in Section 5.3.5.
Since blowing a fuse or releasing an automatic circuit breaker can cause an electrical spark, these may
not be installed in the same area as the battery.
Act with extreme caution while handling corrosive battery acid, refilling of distilled water or performing
other maintenance on the batteries. Follow the instructions of the battery manufacturer and wear
protective clothing and suitable eye protection.
WARNING: Act with extreme caution while handling corrosive battery acid.
Wear protective clothing and suitable eye protection.
5.3.3 Charge regulator
We recommend to install the charge regulator SCR Marine. These regulators are adapted optimally to the
Superwind 350 and ensure effective charging of the batteries. The SCR-series is particularly suitable for
applications on yachts and is available in versions for 12 V and 24 V.
Before installing the charge regulator please read the respective operating instructions. Also follow the
instructions concerning the point of installation. The charge regulator should be placed close to the battery
as it also detects the ambient temperature. For optimum adjustment of the charging voltage an external
temperatur sensor is available.

15
The resistance of the lines between the charge regulator and the battery affects the charging voltage
detected by the regulator. Therefore the lines must be as short as possible (max. 1 meter).
The charge regulators are not protected agianst interchanged polarity of the lines and would be damaged.
WARNING: Do not interchange the polarity of the cables.
If you want to use another charge regulator than described here, make sure that it is a shunt-regulator.
Series controllers as often used in photovoltaic systems are unsuitable, since they interrupt the electric
circuit for voltage regulation and thus the wind generator would run in no-load operation. Futhermore the
charge regulator must be laid out for currents of at least 30 A (12 V version) or 15 A (24 V version).
5.3.4 Fuses
To protect the battery against short-circuit fuses must be installed in the POSITIVE line between the wind
generator and the battery and in the POSITIVE line between the battery and the charge regulator. The
fuses are of 40 ampere slow-blow type (12 V-system) or 20 ampere slow-blow type (24 V-system) or
appropriate automatic circuit breakers.
The fuses must be placed as close to the battery as possible, however not with it in the same
compartment. Unsealed lead-acid batteries have vent holes releasing hydrogen which forms detonating
gas with the ambient air. A spark when blowing the fuse (or releasing an automatic circuit breaker) can
detonate the explosive gas mixture.
5.3.5 Stop switch
A stop switch (option) is not obligatory if a charge regulator has been installed. The stop switch is used to
shut down the wind generator if it is not to be operated or to prevent starting of the rotor when working on
it.
When using the Superwind on a boat or a sailing yacht the stop switch is strongly recommended
to shut the wind turbine down in heavy weather at sea. Spray and waves, parts detached from the
rigg or from the sails etc. could touch the rotor. Furthermore in such situations the restricted
mobility on board increases the risk of accidentially touching the running rotor.
If you run the system without charge regulator, a stop switch is obligatory. In this case the state of charge
must be continuously supervised by the operator and terminated when the battery is fully charged. The
stop switch disconnects the Superwind from the battery and simultaneously shuts down the rotor. The
stop switch must be installed in the line between the wind generator and the battery (see connection
diagram in Section 5.2) as close to the wind generator as possible. In this line between wind generator
and stop switch fuses or circuit breakers must not be installed.
The stop switch has two positions:
a) RUN The positive line from the generator is connected to the battery.
The negative line from the generator is connected to the battery.
b) STOP The positive line and the negative line from the wind generator are short-circuited
(generator short circuit brakes the rotor).
The positive and the negative lines from the battery are both open and disconnected from
the wind generator.
For further information concerning the connection of the stop switch refer to the respective installation
manual.
WARNING: Do not use a stop switch from an other manufacturer. The switch must be of such type of
construction that in no case the battery is short-circuited when switching.

16
5.4 Earthing
In order to protect your system against damage by lightning or over voltage, you should earth it
adequately. The design of the earthing system depends on the local conditions, like place of installation,
type of soil, groundwater table or an earthing bus already excisting. If you are in doubt, consult an
electrician close-by. He knows the local conditions and regulations.
When installing the Superwind on a yacht we recommend to connect its mast or support to the ship´s
earthing system.
6. Wind generator assembly
6.1 Precautions
Before you start installing your wind generator please keep in mind the potential dangers and act with
caution.
Only use a mast and support construction capable safely to withstand the loads of your wind generator.
The mast not only has to withstand the weight of the wind generator and its mass moment of inertia (e.g.
on a sailing yacht) but also a considerable thrust caused by high wind speed. The maximum thrust by
wind at operation will be approx. 70 N. In an extreme gust ( wind speed of 49 m/s ) the thrust can rise up
to 220 N.
Only work on the mast or on your wind generator on a calm and windless day.
Do not step under hanging loads and also prevent other persons from standing underneath e.g. a tilted
mast.
Make sure that during all work your batteries are disconnected from the system.
Prevent your wind generator from unintended starting. For this connect the two generator cables together
(caution: disconnect the battery before !) or tie one of the rotor blades to the mast.
WARNING: Do not approach the running rotor.
Never try to stop the rotor by hand.
Do not install the wind generator at places where the rotor area could be approached by
persons.
6.2 Mast mounting
Before your Superwind is finally installed on the mast or support, the electric cables must be led through
the mast tube and be connected to the generator with correct polarity (also see Section 5.3 ).
NOTE: The following applies to any kind of mast or support:
Before assembling the wind generator make sure that from the mast top to a point 650
mm below there are no out-standing fittings or ropes which could obstruct the rotor. This
is important because the rotor controller pitches the blades at high wind velocities and by
this their distance from the mast will be reduced.

17
6.2.1 Mounting on a 60.3mm or 60.0mm mast tube
The yaw shaft of your Superwind fits for various sizes of mast tubes:
outer-∅thickness inner-∅material
60.3 mm 2.3 mm 55.7 mm steel, welded
60.3 mm 2.0 mm 56.3 mm stainless steel, welded
60.0 mm 2.5 mm 55.0 mm aluminium, seamless
With welded tubes pay attention that the welding seam does not obstruct the insertion of the yaw shaft. If
necessary, an out-standing seam must be smoothed with a round file or the like.
Preparations at the mast head:
Deburr the end of the tube carefully (inside and outside)
File off the welding seam if necessary
Drill the two holes ∅7 mm (distance to the mast top: 35 mm)
First of all the attached plastic bushing has to be mounted onto the yaw shaft of the generator unit. For
this the two elastomer damping rings as well as the inner surface of the plastic bushing have to lubricated
with Vaseline or grease. Now push the plastic bushing with the collar ahead onto the damping rings until
limit stop at the O-ring seal 40x3. Please take care not to damage the damping rings during feeding in.
For mounting in mast tubes with inner diameter 55.0 mm the two adjusting rings have to be removed from
the plastic bushing before the next working step can be carried out.
Insert the yaw shaft of the Superwind with the plastic bushing until limit stop (collar) and align the tap
holes with the drilled holes of the mast. Screw down the two hexagon socket button head screws M6 x 12
for axial fixation. The screws now extend into the groove of the yaw shaft, but will not touch it.
Drawing:
35
Ø 7
O-ring-seal 40 x 3
elastomer damping ring
adjusting ring
plastic bushing
hexagon socket button head screw
M6 x 12
yaw shaft
mast tube Ø 60.3 x 2.0
dimensions in mm
elastomer damping ring
adjusting ring

18
6.2.2 Mounting on a 48.3mm mast tube
Occasionally some sailing yachts have an existing 48.3 mm mast which has been used for an other type
of wind generator before. This stainless steel tube with 2.0 mm wall thickness also fits for the Superwind
if the inner diameter is not smaller than 44.0 mm.
Preparations at the mast head:
Deburr the end of the tube carefully (inside and outside)
File off the welding seam if necessary.
Drill the two holes ∅5 mm and tap M6. (distance to the mast top: 40 mm)
Drawing:
With this configuration the attached plastic bushing is not needed. For easy assembling the two damping
rings of the yaw shaft and the inside of the mast tube should be lubricated with Vaseline or grease. Now
insert the yaw shaft into the tube and push it until the O-ring seal 40x3 seats solidly at the face side of the
tube. Please take care not to damage the damping rings during feeding in.
After this screw in the two hexagon socket button head screws M6 x 6 provided for axial fixation. The
screws now extend into the groove of the yaw shaft, but will not touch it. That way you will benefit from
your Superwind´s vibration and impact sound absorber, too.
40
M 6
dimensions in mm
mast tube Ø 48.3 x 2.0
yaw shaft
hexagon socket button head screw
M6 x 12
elastomer damping ring
O-ring-seal 40 x 3
elastomer damping ring

19
6.2.3 Mounting on other mast tubes
As the Superwind´s yaw shaft is inserted into the mast tube the inner diameter must be appropriate. The
outer diameter may be not greater than 70 mm, so that there is sufficient space between the mast and
rotor blades. There also must be no out-standing fittings or ropes which could obstruct the rotor.
Drawing:
Preparations at the mast head:
Deburr the end of the tube carefully (inside and outside)
File off the welding seam if necessary.
Drill the two holes ∅7 mm .
Depending on the size of your tube the two hexagon socket button head screws M6 x 12 provided for
axial fixation may be too short. In this case appropriate screws must be used. The screws however should
not be too long and must not touch the inner aluminium part of the yaw shaft. Otherwise the vibration and
impact sound absorber would be without effect.
650
max. Ø 70
dimensions in mm

20
6.3 Mounting of the wind vane
The wind vane is fastened to the rear cover of the generator. Insert the wind vane and the mounting plate
into the groove. From the back-view the mounting sheet must be on the right side. Now insert the two
socket cap screws M8 x 20 and screw them down firmly.
Drawing:
6.4 Rotor assembly
There are two methods to assemble the rotor of your Superwind:
a) first the hub is fixed to the generator shaft and the rotor blades are fixed to the hub later.
b) the rotor blades are fixed to the hub first and after that the completed rotor is fixed to the generator.
We recommend method b), since it is in most cases easier, first to pre-mount the rotor completely at a
convenient place and afterwards to take it to the wind generator.
6.4.1 Fastening the rotor blades to the hub
NOTE: For aerodynamic reasons the rotor blades´ trailing edges are very thin and sharp. When
unpacking the parts you should be careful, in order to avoid injuries.
The rotor blades were arranged at the factory to sets with three rotor blades of same mass. Therefore the
rotor blades can be fixed to the hub in arbitrary order. It is not permissible however to mount rotor blades
from different sets to the hub since then the rotor could be out of balance. This also applies in the case of
a damaged single rotor blade. It is obligatory always to exchange the entire rotor blade set.
wind vane
mounting plate
socket cap screw M8 x 20
socket cap screw M8 x 20