Superwind 350 User manual

Superwind 350 / 48 Volt
Operation Manual
North, Central, South America and the Caribbean Regions
Version 1-2019
www.superwind.com

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Thank you for purchasing a
Superwind 350/48V
The Superwind 350/48V is an advanced wind generator of the highest quality that will reliably
generate power for many years. Reliable operation depends not only on product quality however, but
also on correct assembly and installation. Please read this manual in its entirety before starting your
installation, paying particular attention to all safety instructions and warning notices. Your safety is our
highest priority!
MEANING OF SYMBOLS USED IN THIS MANUAL
Indicates critical information regarding a hazardous situation that
could lead to serious personal injury or death if ignored.
Indicates a potentially hazardous situation that could lead to
serious personal injury or death if ignored.
Indicates pertinent or otherwise useful information on a given topic
or procedure.
INSTALLATION
PLEASE DO NOT PROCEED
UNTIL YOU HAVE READ
ALL INSTRUCTIONS
AND SAFETY INFORMATION
All information provided in this manual is believed to be accurate at time of publication,
however superwind GmbH assumes no responsibility for errors or omissions.
The user of this information and product assumes full responsibility and risk.
All specifications are subject to change without notice.
Member of:
KEEP THIS MANUAL ACCESSIBLE FOR FUTURE REFERENCE
© 2018 superwind GmbH.
Superwind is a Registered Trade Mark of superwind GmbH, Germany
VERSION 1-2019
(Please visit www.missioncriticalenergy.com to verify the latest manual version)

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Table of Contents
Section Description Page No.
OVERVIEW................................................................................................................. 2
TABLE OF CONTENTS.............................................................................................. 3
1. GENERAL INFORMATION AND REFERENCES ..................................................... 6
1.1 Company Profile.......................................................................................................... 6
1.2 Labeling....................................................................................................................... 6
1.3 Range of Application................................................................................................... 7
2. WARRANTY .............................................................................................................. 7
2.1 Warranty...................................................................................................................... 7
2.2 Warranty period........................................................................................................... 7
2.3 To obtain warranty service.......................................................................................... 7
2.4 Limitations................................................................................................................... 8
2.5 Others ......................................................................................................................... 8
2.6 Expenses and Responsibilities ................................................................................... 8
2.7 Claims ......................................................................................................................... 9
3. SAFETY INSTRUCTIONS.......................................................................................... 9
3.1 Potential hazards ........................................................................................................ 9
3.1.1 Mechanical hazards..........................................................................................9
3.1.2 Electrical hazards .............................................................................................9
3.1.3 Hazards when mounting the wind turbine ......................................................10
3.1.4 General safety precautions.............................................................................10
4. TECHNICAL SPECIFICATIONS ..............................................................................11
4.1 Operational free space required ................................................................................11
4.1.1 Main dimensions.............................................................................................11
4.2 Technical data............................................................................................................11
4.3 Functional description / Special features...................................................................12
5. PREPARATIONS FOR ASSEMBLY ........................................................................13
5.1 Inspection and Unpacking..........................................................................................13
5.1.1 Inspection .......................................................................................................13
5.1.2 Unpacking.......................................................................................................13
5.1.3 Packing List ....................................................................................................13
5.2 Tools ..........................................................................................................................14
5.3 Available accessories.................................................................................................14
5.4 Electrical components................................................................................................14
5.5 Shipping .....................................................................................................................15
5.5.1 Measurements................................................................................................15
5.5.2 Weight.............................................................................................................15
5.5.3 Shipping Class and HB Number.....................................................................15
6. ELECTRICAL COMPONENTS AND CONNECTIONS ............................................15
6.1 General information....................................................................................................15
6.2 Wiring Diagram ..........................................................................................................15
6.3 System components...................................................................................................16

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6.3.1 Wires...............................................................................................................16
AWG Wire Size Chart Table No. 6.3.1...........................................................17
6.3.2 Strain relief......................................................................................................17
6.3.3 Polarity............................................................................................................18
6.3.4 Batteries..........................................................................................................18
6.3.4.1 Charging the batteries......................................................................18
6.3.4.2 Selecting the batteries .....................................................................18
6.3.4.2.1 Battery Capacity ..............................................................19
6.3.4.3 Protection ........................................................................................19
6.3.5 Charge Regulator SCR 48 V..........................................................................20
6.3.5.1 Technical data..................................................................................20
6.3.5.2 Functional description......................................................................21
6.3.5.3 Installation location ..........................................................................21
6.3.5.4 Connecting the Charge Regulator ...................................................21
6.3.5.5 Wiring diagrams...............................................................................23
6.3.6 Fuses..............................................................................................................23
6.3.7 Stop Switch.....................................................................................................24
6.3.7.1 Mounting ..........................................................................................24
6.3.7.2 Dimensions ......................................................................................24
6.3.7.3 Electrical Connection.......................................................................25
6.3.7.4 Switch Terminals..............................................................................26
6.3.7.5 Component locations .......................................................................27
6.3.8 Diversion Load Power Resistor......................................................................27
6.3.9 Temperature Sensor.......................................................................................27
6.4 Grounding ..................................................................................................................27
7. SUPERWIND 350/48V GENERATOR ASSEMBLY ................................................28
7.1 Precautions ................................................................................................................28
7.1.1 Short Circuit....................................................................................................28
7.2 Delrin®Bushings ........................................................................................................29
7.2.1 Bushing Basics...............................................................................................29
7.2.2 Bushing Types................................................................................................29
Bushing Quick Guide Chart ..........................................................................31
7.2.2.1 American Delrin®White ...................................................................31
7.2.2.2 American Delrin®Black ...................................................................32
7.3 Mast mounting............................................................................................................32
7.3.1 Mounting on a 60.3 mm or 60.0 mm mast tube .............................................33
7.3.1.1 Preparations at the mast head.........................................................33
7.3.2 Mounting on a 48.3 mast tube........................................................................35
7.3.2.1 Preparations at the mast head.........................................................35
7.3.3 Mounting on other mast tubes........................................................................35
7.3.3.1 Preparations at mast head...............................................................36
7.3.4 Mast Tube Specifications ...............................................................................36
7.4 Rotor Blades ..............................................................................................................36
7.4.1 Mounting on the wind vane.............................................................................37
7.5 Rotor Assembly..........................................................................................................37
7.5.1 Attaching the rotor blades to the hub .............................................................38
7.5.2 Mounting the hub to the generator shaft ........................................................39

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8. COMMISSIONING ...................................................................................................40
8.1 Check list....................................................................................................................40
9. OPERATION .............................................................................................................41
9.1 Safety Instructions......................................................................................................41
9.2 RUN and STOP..........................................................................................................41
9.3 Power Control ............................................................................................................41
9.4 Over-Speed Protection ..............................................................................................42
9.5 Annual Power Production ..........................................................................................42
10. INSPECTIONS AND MAINTENANCE .....................................................................43
10.1 Periodic Inspections...................................................................................................43
10.1.1 Rotor Blades...................................................................................................43
10.1.2 Bolted Connections ........................................................................................43
10.1.3 Bearings..........................................................................................................43
10.1.4 Slip Rings........................................................................................................44
10.1.5 Corrosion Protection.......................................................................................44
10.1.6 Mast................................................................................................................44
10.1.7 Electrical system.............................................................................................44
10.2 Maintenance...............................................................................................................45
11. TROUBLE SHOOTING ............................................................................................45
11.1 Wind Generator does not start...................................................................................45
11.2 No power output.........................................................................................................46
11.3 Low power output.......................................................................................................46
11.4 Battery fails to (fully) charge ......................................................................................47
11.5 Checking open circuit voltage....................................................................................47
12. REPAIRS AND RECOMMENDED SPARE PARTS ................................................47
12.1 Repairs.......................................................................................................................47
12.2 Spare parts list...........................................................................................................48
13. FREQUENTLY ASKED QUESTIONS ........................................................................48
13.1 Basic use....................................................................................................................48
13.2 Installation..................................................................................................................48
13.3 Operation ...................................................................................................................49
13.4 Trouble shooting ........................................................................................................50
14. ABBREVIATIONS ......................................................................................................51
15. SCOPE OF CHANGES...............................................................................................52

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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, Superwind 353 and
Superwind 1250 turbines have been quietly providing reliable, autonomous wind
generated electricity to users in remote locations under harsh conditions on both land
and sea world-wide.
As your satisfaction is as important as our reputation, we thank you in advance for
reading this Superwind manual in its entirety prior to installing (or even 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 accurately predict how a Superwind
turbine can 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, real-world proven wind turbines.
1.2 Labeling
This manual refers to our Superwind 350/48V wind generator.
Manufacturer:
superwind GmbH
Am Rankewerk 2-4
D-50321 Brühl
Germany
Tel.: +49 / 2232 / 577357
Fax: +49 / 2232 / 577368
E-Mail: [e-mail]
Internet: www.superwind.com
The data tag listing the serial number and
nominal voltage of your the Superwind
350/48V is located on the yaw shaft. (Fig
No. 1.2).
The Intent of this manual is to assist
technicians with the professional
installation of the Superwind 350/48V
in order to ensure the system is both installed correctly and operational as quickly as
possible.
For future reference, please record the Serial Number of your Superwind 350/48V in
the space provided below prior to installation. Once the yaw shaft is inserted into the
bushing and into the mast, this information will not be visible.
Type........................................................Superwind 350/48V
Serial Number........................................___________________

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1.3 Range of application
The electrical power generated by the Superwind 350/48V is used primarily to charge
batteries and/or directly power 48 VDC appliances. AC appliances can be powered via
an optional inverter. There is a wide range of high quality, 48 VDC equipment
available. Examples include energy saving lamps, refrigerators, deep-freezers, water
pumps, ventilators, consumer electronics, TV, radio and navigation equipment, etc.
Ideal applications for the Superwind 350/48V range from commercial and government
needs (navigational aids, traffic management systems, monitoring stations and
transmitters) to private sector use, such as mountaintop cabins or other remote, off-
grid locations.
The Superwind 350/48V is also fully compatible with installations utilizing solar
arrays. At many locations, wind and solar energy complement each other. A hybrid
wind / solar dual charging system featuring the Superwind 350/48V allows you to
optimise available energy sources, while requiring minimal battery capacity.
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.
Warranty covered repairs may be obtained only upon presentation of the warranty
card and the original invoice issued to the customer by the retailer. The warranty card
must state the buyer’s name, the retailer’s name and address, the serial number and
purchase date 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 by the purchaser from the retailer.
2.2 Warranty period
The warranty period is three years from the date of purchase, as provided by the
above mentioned documents.
2.3 To obtain warranty service
Warranty service is available at superwind GmbH and all Superwind authorized
service partners. All costs associated with transportation of the product to and from
superwind GmbH or Superwind authorized service partners will be borne by the
customer.

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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 express written
approval.
Defects caused by improper use, handling or operation and in particular defects
caused by improper installation or installation on inadequate masts or support
structures.
To obtain warranty service, the purchaser must provide evidence upon request
that the product has been installed on an adequate mast or support structure.
Accidents, disasters or any cause beyond the control of superwind GmbH,
including but not limited to lightning, flooding, fire, acts of war, vandalism, 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 of the
original Superwind system shall be repaired or replaced. Should repair or replacement
by superwind GmbH not be possible, the original purchaser will be entitled to a full
refund from the manufacturer; superwind GmbH. This refund is limited to the
purchase price of the product only and does not include any associated expenses,
such as shipping, installation, bank fees, etc.
This warranty does not affect the purchaser’s statutory rights under applicable national
legislation in force, nor the buyer’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.
In addition to the above warranty coverage, the GENERAL CONDITIONS FOR THE
SUPPLY OF PRODUCTS AND SERVICES OF THE ELECTRICAL AND
ELECTRONICS INDUSTRY produced by the German Federation of the Electric and
Electronic Industry (ZVEI) also applies.
2.6 Expenses and Responsibilities
All associated expenses (shipping 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:
Inspect the outside of the shipping package or container for any damage (dents,
scratches, etc,). Document any damage noted on the Bill of Lading before signing
and keep a copy. Documenting damage with photos is also highly recommended.
Open the crate and inspect the contents immediately for any damage.
Unpack the unit immediately 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.

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2.7 Claims
Claims that occur during transportation must be filed by the consignee (the buyer) with
the freight company, as shipping terms are FOB EX-WORKS (our distribution point as
contracted).
THE BUYER IS RESPONSIBLE FOR ALL SHIPPING EXPENSES, INCLUDING
CUSTOMS DUTIES AND VAT (IMPORT DUTIES).
3
SAFETY INSTRUCTIONS
Please read this manual thoroughly prior to assembly and installation of your Superwind
350/48V. The information provided is to ensure your safety during assembly, mounting and
operation, as well as during maintenance and troubleshooting. If you have any additional
questions please contact your dealer, a Superwind service partner or the manufacturer.
3.1 Potential Hazards
There are a number of potential physical and electrical hazards associated with the
installation and operation of a wind turbine. Familiarity with safety practices and
procedures beforehand is crucial, both in avoiding injury to personnel and damage to
the Superwind 350/48V wind turbine.
3.1.1 Mechanical Hazards
The main physical hazard is contact with a spinning rotor. The rotor blades can cause
serious injury, even at very low speed.
Never touch the rotor blades while moving!
Never try to stop the rotor by hand!
Never mount the rotor in a location where it can accidentally come into contact
with personnel!
The rotor blades are constructed of glass fibre and carbon fibre reinforced plastic.
This material is extremely durable (which enables your Superwind 350/48V to cope
with heavy storms) however it can break if objects strike the rotor at higher rotational
speeds.
Never allow objects to come in contact with the rotor while in operation!
3.1.2 Electrical Hazards
Even at low wind speeds, the generator can produce dangerous open circuit voltages
(up to 210 VDC) at no-load operation (i.e. with the electric connection to the battery
disconnected).
Charging currents can reach up to 7.5 Amps DC. As such, all cabling, electrical
components and connectors must be rated to 10 Amps. For correct wiring
dimensioning refer to Section 6.3.
The use of undersized cabling can result in overheating and failure, possibly
creating fire and shock hazards!

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Fuses are installed to protect the wiring of the system and must be installed as close
to the battery as possible. For details see Section 6.3.6.
Never short-circuit the battery, which can result in fire or explosion of
the battery, along with release of acid and toxic gases.
Unsealed lead-acid batteries produce and vent flammable hydrogen gas during
charging. This creates an explosive mixture that can easily be detonated by even the
smallest of sparks (those produced by an electrical switch for example).
To reduce the possibility of explosion, always ensure battery installations are provided
adequate ventilation.
Never install batteries in locations where the danger of sparks exist.
Provide sufficient ventilation for battery storage areas at all times.
The diversion load power resistor for the charge regulator can become hot. To
prevent the possibility of fire, never mount the power resistor on a flammable
surface or close to flammable materials.
Never mount the power resistor on a flammable surface.
Mount the power resistor at least 40mm (1.57”) away from any flammable
materials
3.1.3 Hazards when mounting the wind turbine
These instructions also apply to future disassembly, inspections or other
work carried out on your wind generator.
Use only mast and support designs capable of safely handling the loads associated
with the installation of your Superwind 350/48V. The mast not only has to support
your wind generator’s weight, but also the considerable thrust generated by high wind
speeds. For details see Section 7.3.
3.1.4. General safety precautions
Conduct all work on the mast or wind generator only on a calm, windless day.
Do not allow personnel to walk or stand beneath hanging loads or potential drop
hazards (such as a tilted mast).
Disconnect all batteries from the system prior to beginning any work.
To prevent your wind generator from starting unintentionally, place the stop switch
into the STOP position or short circuit the generator output wires (Red and Black)
before mounting the rotor blades.
Do not install the wind generator in areas where it can be easily reached or
approached by anyone walking by or working around the turbine structure.

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4.
TECHNICAL SPECIFICATIONS
4.1 Operational free space required
4.1.1 Main dimensions
Dimensions
Table No. 4.1.1
mm
inches
a
Distance between centre of mast and blade tip
168
6.61”
b
Distance between centre of mast and extreme upper part of wind vane
556
21.9”
c
Distance from mast-top to centre of rotor
136
5.35”
d
Distance from the centre of hub and extreme upper part of the wind vane
530
20.9”
e
Length of yaw shaft
76
2.99”
f
Rotor diameter including blades
1220
48”
g
Outside diameter (OD) of yaw shaft with damping rings
44
1.73”
h
High for Plastic Bushing to be inserted into mast
71
2.79”
i
Required space for yawing
1263
49.72”
4.2 Technical Data
Nominal power .....................................................350 W
Nominal wind speed.............................................12.5 m/s (24.29 knots)
Cut in wind speed.................................................3.5 m/s (6.80 knots)
Cut off wind speed................................................None
Rotor diameter......................................................1,20 m (47.24”)
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....................................................48 V DC
Speed regulation..................................................Rotor blade pitch
Power regulation ..................................................Rotor blade pitch
Brake....................................................................Generator short circuit
Weight..................................................................11.5 kg (25.35 lb)
Rotor thrust (operation)........................................70 N (15.7 lbf)
Rotor thrust (extreme wind speed).......................220 N (49.5 lbf)

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4.3 Functional description / special features
Like all wind turbines, the Superwind 350/48V uses the kinetic energy of the wind to
generate electricity. The power generated is approximately proportional to the cube of
the wind speed (i.e. doubling the wind speed results in eight times the power output).
This means that relatively little energy can be generated during the varying wind
speeds of a moderate breeze. A heavy storm however, contains such a high quantity
of energy that the wind generator must be protected against overstress and damage.
The Superwind 350/48V has been designed to achieve optimum power output for a
wide range of wind speeds while providing maximum safety and survivability during
storm conditions.
a) The rotor blades were developed using modern computerized calculation and
simulation methods. The airfoil has been wind tunnel tested and specifically
developed for small size rotors. Relatively broad rotor blades combined with a
special pitch angle produces a high start-up torque, enabling the rotor to start
turning at only 3.5 m/s (7.8 mph) of wind speed.
Optimum start-up performance will be reached after a break-in
period of the bearings and their seals. The duration of the break-in
period can vary depending on site wind conditions
When using the Superwind 350/48V for battery charging, do not confuse the initial rotor
start-up voltage for the output charging voltage. The wind speed required to start
charging depends on the battery’s state of charge and may be slightly higher than the
rotor start-up wind speed.
b) A key innovation of the Superwind 350/48V is its patented aerodynamic rotor
control system, which (similar to large wind turbines) automatically adjusts the
pitch angle of the rotor blades based on wind speed. The mechanical controller is
fully integrated into the hub and works without expensive, failure-prone electrical
or hydraulic components. Instead, the controller is actuated by forces arising
from operation of the wind turbine itself. These forces are affected by the
geometric and kinematic lay-out of the rotor controller mechanism.
Aerodynamic forces act as control variables to automatically adjust the rotor blades for
power regulation above the nominal operating wind speed of the unit. Simultaneously,
centrifugal forces (the second control variable of the rotor blade adjustment) are
introduced and as both the wind force and rotor speed decrease or increase, the
controller automatically limits rotor speed. This occurs even at extreme wind velocities.
This unique system is crucial in protecting the wind turbine from over-speed conditions,
even during no-load operation. As a result, the controller limits the mechanical loads at
high wind speeds and enables smooth operation under all weather conditions.

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5.
PREPARATIONS FOR ASSEMBLY
5.1 Inspection and Unpacking
5.1.1 Inspection
Visually inspect each shipping container immediately upon delivery for damage that
may have occurred during transportation. If damage is found, request a complete
inspection by the carrier’s driver and have him acknowledge the type and extent of
damage in writing on the Bill of Lading. If a claim needs to be filed with the carrier, it
must be filed within 24 hours of arrival. Claims for damage that occur during transit are
the sole responsibility of the buyer.
5.1.2 Unpacking
Upon opening the shipping container(s), visually inspect all system components for
signs of physical damage that may have occurred during shipping (scratches, loose
hardware, broken parts, etc).
5.1.3 Packing list:
PACKING LIST
Table 5.1.3
ITEM
DESCRIPTION
SIZE
QTY

1
Generator unit
48V
1
2
Hub
1
3
Wind vane
1
4
Rotor blade
3
5
Wind vane mounting plate
1
6
Plastic bushing (optional stainless steel bushing)
1
7
Socket cap bolt –[Rotor Hub Mounting Bolt]
M8 x 80
1
8
Socket cap bolt
M8 x 20
2
9
Socket cap bolt
M6x 25 (TUFLOK)
6
10
Socket cap screw with rubber ring
M6 x 8 (TUFLOK)
3
11
Hexagon socket button head screw
M6 x 12
2
12
Hexagon socket button head screw
M6 x 6
2
13
Allen key
6 mm
1
14
Allen key
5 mm
1
15
Allen key
4 mm
1
16
SCR 48V Charge Regulator
1
17
Stop Switch
1
18
Power resistor
5.6 Ohm, 400 Watt
1
19
Temp-Sensor
1
20
Operation manual
1

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The trailing edges of the rotor blades are very thin and sharp. Use caution
when unpacking, both to avoid injury and damage to the blades.
5.2 Tools
A set of Allen wrenches is supplied to assist with the installation of your Superwind
350/48V.
The following additional tools will also be required:
Screw drivers
Set of wrenches
Wire strippers
Wire crimpers
Heat shrink or electrical tape
Multi-meter
Torque wrench
Tools for the mast installation are not listed here. Refer to applicable mast installation
instructions.
5.3 Available accessories
Mast-Sets:
Mast kit for guyed tubular mast 6 m (19.68 FT) [other heights on request]
Mast kit for self-supporting tubular mast 7.5 m (24.60 FT).
5.4 Electrical Components:
Superwind SCR 48V Charge Regulator with diversion load power resistor
10 amp slow-blow fuse and holder
Stop-switch
Temperature Sensor

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5.5 Shipping
5.5.1 Measurements:
Superwind 350/48V
Box: 23” x 13” x 9” - 1.55 Cubic Feet
5.5.2 Weight
Superwind 350/48V
Box: 38 lbs (17.2 Kg)
Add 1 lb if optional Stainless Steel Bushing is included
5.5.3 Shipping Class and Commodity or HB Number
Shipping Class: 77.5
HS Code: 85023100
6.
Electrical Components and Connections
6.1 General information
Always use caution and follow all industry accepted practices and safety procedures when
working on your Superwind 350/48V unit or installation system. Electrical system installation,
maintenance and repairs should only be carried out by competent personnel who have studied
and are familiar with the information and instructions provided in this manual. Contact
Superwind for clarification if any questions arise.
All electrical components should be mounted at their respective locations
prior to making any electrical connections.
Ensure batteries remain disconnected until the installation is complete.
Do not connect the battery / battery bank to the system until installation
of the turbine is complete!
6.2 Wiring diagram
Figure 6.2 shows the wiring diagram for a typical Superwind 350/48V system.

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6.3 System components
6.3.1 Wires
The cross section (also known as diameter or gauge) of the wires to be used will
depend on the length of the wire run and the rated voltage of your wind generator.
After deciding on a location, measure the distance from the top of the mast to the
battery and select the minimum cross section required as provided in the table below.
In order to keep power loss to a minimum and maintain safety, never use wires with
under-sized cross sections.
Cables with insufficient cross sections can heat up and cause a fire!
All values given in the tables below are based on a voltage drop of 3%.

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AWG Wire Size Chart for Superwind 350/48V
Table No. 6.3.1
Distance from mast top to the battery
From:
To:
up to
19.8 m
19.9 m
31.7 m
31.8 m
47.6 m
47.7 m
79.3 m
79.4 m
126.8 m
126.9 m
198.2 m
Up to
64 ft
65 ft
104 ft
105 ft
156 ft
157 ft
260 ft
261 ft
416 ft
417 ft
650 ft
Minimum gauge
(cross section)
2.5 mm²
4 mm²
6 mm²
10 mm²
16 mm²
25 mm²
Recommended per wire
AWG 14
AWG 12
AWG 10
AWG 8
AWG 6
AWG 4
See Fig. No. 6.3.1b
The use of multi-strand, marine grade wire is recommended.
Solid wire is not recommended!
Tinned multi-strand, marine grade wiring is recommended for all marine insulations to
reduce corrosion issues.
For underground installations, the cable must be installed in conduit or be suitable for
direct bury applications. All cables and materials (heat shrink, insulating tape, etc)
should be ultraviolet resistant.
Chafe protection should be provided for the entire cable run. All penetrations into the
mast, electronics enclosures, etc, should be de-burred and the cable protected against
chafe using rubber sleeves, grommets, etc.
All wire terminations and connections must be made using suitable (preferably marine
grade) crimp on connectors.
6.3.2 Strain Relief
Depending on mast length and cable cross section,
the weight of the cable inside the mast can be
considerable. If the cable weighs more than 5 kg
(11 lbs) strain relief must be provided inside the
mast to prevent damage to the internal connection
point of your Superwind 350/48V (Fig. No. 6.3.2)

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6.3.3. Polarity
Always pay attention to the correct polarity of the wires.
Reversing polarity at the battery connections or anywhere in
the system will destroy the electronic rectifier of your
Superwind 350/48V. During installation or when changing
out batteries, clearly mark all wire ends as POSITIVE (+) or
NEGATIVE (-) to prevent connection errors. Fig. No. 6.3.3.
Marking of the connecting wires at the Superwind 350/48V:
POSITIVE Line (+) RED
NEGATIVE Line (-) BLACK
The internal electronic rectifier of the Superwind 350/48V will be
destroyed by the application of reverse polarity anywhere within the
system.
Rectifiers damaged due to reverse polarity are not covered under
warranty!
6.3.4 Batteries
6.3.4.1 Charging the batteries
The Superwind 350/48V is primarily used to charge batteries. For
proper battery protection, installation of the provided Superwind SCR 48V
Charge regulator and diversion load power resistor is mandatory.
The SCR 48V Charge Regulator allows the Superwind 350/48V to
operate automatically and completely unsupervised. The SCR 48V
Charge Regulator is suitable for use with all battery types and its use
ensures batteries are charged optimally and protected against overcharging
and damage.
6.3.4.2 Selecting the batteries
When selecting batteries, always ensure their voltage matches the rated
voltage of the system (48 volts in this case). The rated voltage of your
Superwind is specified on the data label located on the yaw shaft.
Flooded lead-acid batteries are the most commonly used battery type world-
wide. They work well in a wide variety of applications and are very cost
effective, however they require periodic maintenance (electrolyte level checks,
etc).
The use of AGM (Absorbent Glass Matt) batteries has many advantages.
AGM batteries are sealed, virtually maintenance free, have a long service life
and can better survive the occasional deep discharge.
All batteries should be ‘deep cycle’ rated. Automobile type ‘starting batteries’
are not suitable for use as storage batteries and will fail rapidly due to the
cyclic operations associated with renewable energy-based charging.

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6.3.4.2.1 Battery Capacity
Another important factor of battery selection is capacity, which is expressed in
amp hours (Ah). This value represents the quantity of energy a battery can
store. The required battery capacity depends on individual site requirements
and factors such as location, wind availability, power consumption, power
generating systems, etc. Consult your battery supplier for assistance with
questions regarding load support, battery selection and installation.
Follow all manufacturer recommendations when selecting a location for your
battery installation. Charging flooded lead-acid batteries generates flammable
and potentially explosive hydrogen gas. Unsealed lead-acid batteries have
vent caps to release this gas, which can detonate if it is mixed with air and a
spark is present (from an electrical switch for example) or other ignition source
(open hot exhaust).
Never install batteries in a location where the danger of spark
formation exists. Ensure battery installations are provided adequate
ventilation at all times.
Batteries store a large quantity of energy, which can be suddenly discharged
in the event a battery is accidentally shorted. This sudden discharge can
destroy the battery (resulting in the release of battery acid and gas) and even
set the battery and cabling on fire. To protect against accidental short-
circuiting, do not attach battery terminal connections until all work on the
electric system has been completed.
Never short-circuit the battery or terminals across a bank of
batteries!
Connect cabling to battery terminals only after all work on the
electrical system has been completed.
6.3.4.3 Protection
Fuses (or appropriate circuit breakers) must be installed in the positive (+)
wires to the battery to protect the system against excessive current and/or
short-circuits. For fuse installation requirements, refer to the wiring diagrams
provided in Section 6.2 and Section 6.3.5.5. As a fuse can cause an electrical
spark when failing (blowing) do not install fuse holders in the same area as
the battery or bank.
Use caution when handling battery acid, adding distilled water or performing
other battery maintenance. Follow all battery manufacturer instructions and
wear protective clothing and suitable eye protection.
Use caution when conducting battery maintenance.
Wear protective clothing and suitable eye protection.