Superwind SW 350-II User manual

Operation Manual
SW 350-II
January 2022

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 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.

4
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

5
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.

6
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

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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 SW 350-II 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
power resistor
0,35 Ohm
fuse
fuses:
40 A
STOP
switch
superwind
blackred
12 Volt-system
charge regulator
SCR 12 Marine
battery set 1
12 V
+
fuse -
option
-
battery set 2
12 V
fuse
+

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5.2.2 Wiring diagram of a 24 Volt system with charge regulator SCR 24 Marine
5.2.3 Wiring diagram of a 48 Volt system with charge regulator SCR 48 V
Batt.2
charge regulator
SCR 48 V
+
battery set 1
48 V temp.-
sensor
battery set 2
48 V
fuse
power resistor
5,6 Ohm
Temp.-
Sensor
1
Resistor
23
+
Batt.1
- -
option
fuse
fuse
fuses:
10 A
STOP-
switch
48 Volt-system
red
+
Gen.
-
superwind
black
superwind
fuses:
20 A
STOP
switch
black
red
fuse +
fuse
battery set 1
24 V
-
battery set 2
24 V
+
fuse
-
24 Volt-system
power resistor
1,4 Ohm
charge regulator
SCR 24 Marine option

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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.
Note: The cross sections of the following two tables refer to a maximum voltage drop of 5% when using copper wires.
For the 12 Volt version applies:
distance from mast top
to the battery
up to
5,2 m
5,3 –
8,7 m
8,7 –
14,0 m
14,1 –
21,8 m
21,9 –
30,6 m
30,7 –
43,7 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
8,7 m
8,8 –
14,0 m
14,1 –
21,0 m
21,1 –
34,9 m
35,0 –
55,9 m
56,0 –
87,3 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)
For the 48 Volt version applies:
distance from mast top
to the battery
up to
19,8 m
19,9 –
31,7 m
31,8 –
47,6 m
47,7 –
79,3 m
79,4 –
126,8 m
126,9 –
198,2 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 SW 350-II will not be damaged. For this purpose you
may use the cylinder pin ∅3 x 40 which is shown in the drawing in section 6.2.1.
Always pay attention to the correct polarity of the lines. Connecting to the batteries with interchanged
polarity will destroy the electric rectifier of your SW 350-II. In general you should mark all line ends by
POSITIVE (+) and NEGATIVE (-), in order to prevent errors with the connection.

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Marking of the connecting cables at the SW 350-II:
POSITIVE Line (+) : RED
NEGATIVE Line (-) : BLACK
WARNING: The internal electric rectifier of the SW 350-II will be destroyed by connecting with
interchanged polarity. (loss of warranty!)
5.3.2 Battery
The most common application of the SW 350-II 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 SW 350-II in
case of fully charged batteries. We therefore generally recommend to install a suitable charge regulator.
The charge regulator allows operating the SW 350-II 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 or 48 V). The rated
voltage of your SW 350-II 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.
When using the superwind SCR Marine and the SCR 48V to charge lithium batteries, it should be noted
that the end-of-charge voltage may have to be adjusted accordingly for the respective battery and the
temperature compensation function must be deactivated in most cases to prevent damage to the battery,
the charge controller and the generator. For more information, please consult the operating instructions
for the respective charge controller and your battery.
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.

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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 of the SCR-series. These regulators are adapted optimally
to the SW 350-II and ensure effective charging of the batteries. The charge regulators SCR 12V- and
SCR 24V- Marine are particularly suitable for applications on yachts. For systems with the
SW 350-II / 48 V we recommend the charge regulator SCR 48V.
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.
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.
(Void of warranty!)
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) or 7,5
A (48 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
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 SW 350-II 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.

16
If you run the system without any 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 SW 350-II 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.
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 SW 350-II on a yacht we recommend to connect its mast or support to the ship´s
earthing system.

17
6. Wind generator assembly
6.1 Precautions
Before you start installing your SW 350-II 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 the 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.

18
6.2 Mast mounting
Before your SW 350-II 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.
6.2.1 Mounting on a 60.3mm or 60.0mm mast tube
The yaw shaft of your SW 350-II is equipped with a plastic bushing which 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)
650
max. Ø 70
dimensions in mm
space for rotor blade
pitch must be free of
any obstructions !

19
NOTE: 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 SW 350-II with the plastic bushing until limit stop (collar) into the mast tube 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. Tighten the screws with 2 Nm. We recommend to apply Loctite 243 for
screw locking.
mast tube 60,3 x 2,0
Torque: 2 Nm
plastic bushing
hexagon socket button head
screw M6x12
In the next drawing you can see that the two button head screws M6 x 12 protrude into the groove of the
yaw shaft, but do not touch it. In order to ensure the function of the vibration and impact sound absorber,
it is important that the two holes in the mast tube are carefully drilled.

20
6.2.2 Mounting on other mast tubes
As the SW 350-II ´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 flanges, fittings or ropes which could obstruct the rotor.
Please refer to the drawing in section 6.2.
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 (refer to section 6.2.1).
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.
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 tighten them at 30 Nm. These srcews have a TUFLOK coating against
loosening.
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 Ø60.3 x 2.0
elastomer damping ring
adjusting ring
cylinder pin Ø3 x 40
35
dimensions in mm
Ø 7