Superwind SW 350-II User manual

Operation Manual
SW 350-II
January 2022

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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 6
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 Recommended 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 Wiring diagram of a 48 Volt system with charge regulator SCR 48 V 12
5.3 System components 13
5.3.1 Wires 13
5.3.2 Battery 14
5.3.3 Charge regulator 15
5.3.4 Fuses 15
5.3.5 Stop switch 15
5.4 Earthing 16
6. Wind generator assembly 17
6.1 Precautions 17
6.2 Mast mounting 18
6.2.1 Mounting on a 60.3mm or 60.0mm mast tube 18
6.2.2 Mounting on other mast tubes 20
6.3 Mounting of the wind vane 20
6.4 Rotor assembly 21
6.4.1 Fastening the rotor blades to the hub 21
6.4.2 Mounting the hub to the generator shaft 23
7. Commissioning 24
7.1 Check list 24
8. Operation 25
8.1 Safety instructions 25
8.2 RUN and STOP 25
8.3 Power control 25
8.4 Overspeed protection 26
8.5 Annual power production 27
9. Inspections, maintenance 28
9.1 Periodic inspections 28
9.1.1 Rotor blades 28
9.1.2 Bolted connections 28
9.1.3 Bearings, seals 28

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9.1.4 Slip rings 29
9.1.5 Corrosion protection 29
9.1.6 Mast 29
9.1.7 Electrical system 29
9.2 Maintenance 30
10. Trouble shooting 30
10.1 Wind generator does not start 30
10.2 No power output 31
10.3 Unsufficient power output 31
10.4 Battery is not fully charged 31
10.5 Checking the open circuit voltage 32
11. Repairs, spare parts 33
11.1 Repairs 33
11.2 Spare parts list 33
12. Warranty 34
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.

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Thank you for purchasing a SW 350-II.
The SW 350-II 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 SW 350-II
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
You will find the label with the serial number and the nominal voltage of your SW 350-II at the rear of the
generator unit (see drawing).
generator unit
Type: SW 350-II
Nominal Voltage: 12 VDC
Nominal Power: 350 W
Serial No.: 9999353
superwind GmbH, Brühl / Germany
Made in Germany
type label

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1.2 Range of application
The electric power generated by the SW 350-II charges batteries and can directly be used for 12 VDC or
24 VDC or 48 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 or 48V 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 SW 350-II 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 SW 350-II 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 SW 350-II – 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 SW 350-II 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: In situations where there is a risk of objects getting into the spinning rotor no persons are
allowed to stay in the hazard zone of the wind generator. Otherwise the wind generator
has to be shut down. On sailing yachts the wind generator should not be operated during
any maneuvers as well as in bad weather conditions. The owner must be aware of the
dangers and ensure that no persons can be injured by the operation.
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.

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2.1.2 Electrical dangers
The generator can produce dangerous open circuit voltages up to 52 VDC (12 V version) ,105 VDC (24 V
version) 210 VDC (48 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) or 7,5
Ampere (48 V version). The cabling, all electrical components and connectors must be suitable for 40
Ampere (12 V version) or 20 Ampere (24 V version) or 10 Ampere (48 V version). For correct
dimensioning refer to Section 5.3.
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.

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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
operation range 3,5 m/s - 35 m/s (in production mode)
survival wind speed 50 m/s (in shutdown mode)
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 or 48 VDC
speed regulation rotor blade pitch
power regulation rotor blade pitch
brake generator short-circuit
weight 12,0 kg
rotor thrust (operation) 70 N
rotor thrust (extreme wind speed) 220 N
view on top
(space required)
Ø1263
168 556
superwind
530
136
fits for:
stainless steel tube (Ø60.3 x 2.0)
steel tube (Ø60.3 x 2.3)
aluminium tube (Ø60 x 2.5)
dimensions in mm
Ø1220
71
Ø54,5
... 55,7

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3.3 Functional description / special features
The SW 350-II, 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 SW 350-II 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 SW 350-II 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 SW 350-II 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. The patented, fully synchronised rotor hub ensures very
high turbulence resistance, stability and endurance.

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4. Preparations for assembly
4.1 Packing list
Please check your delivery for completeness and transport damage.
Packing list:
1
pcs
generator unit
Pos.
1
1
pcs
hub
Pos.
2
1
pcs
wind vane
Pos.
3
3
pcs
rotor blades
Pos.
4
1
pcs
wind vane mounting plate
Pos.
5
1
pcs
socket cap screw
M8 x 90 (TUFLOK)
Pos.
6
2
pcs
socket cap screw
M8 x 20 (TUFLOK)
Pos.
7
6
pcs
socket cap screw
M6 x 25 (TUFLOK)
Pos.
8
2
pcs
hexagon socket button head screw
M6 x 12
Pos.
9
1
pcs
allen key
6 mm
Pos.
10
1
pcs
allen key
5 mm
Pos.
11
1
pcs
allen key
4 mm
Pos.
12
1
pcs
operation manual
Pos.
13
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
4
4
4
1
3
2
10
SW 350-II
Operation
Manual
13
12
11
5
9
8
6
7

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4.2 Tools
For installation of your SW 350-II a set of allen keys is supplied.It is recommended to prepare some
additional tools as follows:
set of 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 Recommended accessories
mast-sets:
mast mounting set for yachts (without tubes)
mast tube set, mirror polished AISI 316 consisting of:
1 pc. 60,3 x 2 mm / 3,0 m long
2 pcs. 21,3 x 2 mm / 3,0 m long
mizzen bracket, mirror polished AISI 316
electrical components:
charge regulator SCR Marine 12 V or 24 V incl. power resistor IP 54
charge regulator SCR 48 V incl. power resistor IP 54
remote temperature sensor for SCR Marine 12 V / 24 V
fuses: 40 Ampere, slow-blow / 20 Ampere, slow-blow / 10 Ampere, slow blow
fuse holder
stop-switch