AIR403 Land Manual
Contents
1. ete 3 1 1 Electrical Connections 9 3 1 2 Wire Size 3 1 3 Grounding 11 3 1 4 Fusing 12 3 1 5 Stop Switch 12 3 1 6 System Wiring Diagrams 3 2 Mounting to es 15 3 2 1 Attaching to Pole 3 3 and Rotor Assembly eee 3 3 1 Mounting Blades 3 3 2 Mounting Hub and Rotor 3 3 3 Attaching Nose Cone 18 4 1 1 Alternator 4 1 2 Regulator 4 1 3 Blades 20 4 1 4 Four Spinning Conditions 4 2 Bench Testing ecciesie eter nenne 4 3 Performance Testing eee 4 4 Adjusting the Internal Regulator 5 Trouble 5 1 Assembly 23 ana AENA ENEE ENEEIER NAE RAAEN ARREA 5 2 Electrical System oiei sce cacceaveetscctys ana npani aii 5 3 Flev Onirin ALAKA EEA AA ATER AANA 6 Warranty 7 Sp cificationS sses aaeeea E 7 1 Technical Specifications 26 7 2 Sphere of Operation 7 3 Exploded View of AIR 403 CARET CIE ae e T T E crecer 9 System Requirements and Considerations 28 9 1 Batteries 28 9 2 Regulator Options 29 10 Siting 4 niii SN T1 TOWeES erecti Deo Deuce T N TT 33 11 1 Guyed Towers 33 11 2 R2. New 400 watt turbine Owner s Manual Version 3 2 NOTICES This information is believed to be reliable however Southwest Windpower Inc 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 Wind generators like other sources of electrical power must be installed following the guidelines established by state and local regulations Consult a local electrical contractor for details and regulations Made in the USA by Southwest Windpower Inc 2131 First Street Flagstaff Arizona 86004 Toll Free Phone 800 946 3313 Phone 520 779 9463 Fax 520 779 1485 E mail info windenergy com Web www windenergy com AIR AIR 403 and AIR Wind Module are trademarks of Southwest Windpower 1999 Southwest Windpower Inc 4 CONGRATULATIONS You have just purchased the most advanced battery charging wind turbine in the world We believe you will find it easy to install your AIR 403 however it is important that you read this entire manual thoroughly prior to installation to assure proper performance and safety Southwest Windpower has over 12 years of experience in designing and manufacturing small wind generators In just four years over 20 000 A Rs have been sold throughout the world What makes the AIR 403 unique in comparison to other turbines is the use o
3. 0 5 10 15 20 25 30 35 40 45 50 55 60 Windspeed Sea Level Miles Per Hour 26 7 2 Sphere of Operation fre rhe wheat iex pga gt TAS un 7 3 Exploded View of AIR 403 27 28 Body Poirier 1 Anse E ae uy i d r Hagi nx Cone a enm M T n EISE ee Lo Ufa Beasng amp iM 2 ey Een Ring Arenas i dia Us Sig Regs San Face 2 PHP PA Sweat Yaw Ds Peg Seal Sarra 8 Although your AIR 403 has been designed to run for long periods without requiring any maintenance reliability and performance will be enhanced if you periodically inspect your system Before performing any inspection be sure to shut down the turbine CAUTION NEVER APPROACH THE TURBINE DURING OPERATION CAUTION THE ROTOR BLADES ARE SHARP PLEASE HANDLE WITH CARE During periodic inspection you should Check blades for chips or nicks Replace blades if necessary Do not operate the turbine with chipped or unbalanced blades This can cause severe wear damage and possible failure Do not install individual blades The blades are balanced as sets Check the blade bolts and the hub nut Make sure the yaw clamp bolts securing your AIR 403 are tight I
4. earth ground 3 1 2 Wire Size To select the appropriate size wire measure the distance from the batteries to your AIR 403 then refer to the following wire sizing chart as minimum sizes If cost is not an issue a larger sized wire will improve the performance of your AIR electrical systems lose energy from the resistance of the wires used Larger wiring sizes have smaller losses but can be considerably more costly The following wiring sizes provide a maximum annual energy losses of 5 or less for sites with a 12mph average wind speed assuming the standard Rayleigh distribution of wind speeds which is sufficient for most sites If you know your average wind speed to be different compensate the wiring LENGTHS given in the charts using the factors given at the end of this section Table entries with a denote cases which should use additional bus lines We recommend these as the minimal wire sizes for optimal performance you should use the largest wires that are practical and affordable Local state and national electrical codes supercede these recommendations and should be followed to insure the safety of your system 12V AIR 403 Wire Size Considering 12mph Wind Average and 95 Energy Transmission Eniiciency 3 3 ag log loo0g 10004 Eco E ELT Fuse 100 Amp Slow Blow per turbine If your system requires this length of wire consider using additional bus line s 24V AIR 403 Wire Size Considering
5. stop the turbine from charging In high winds there may still be a trickle charge It is important to keep in mind that battery charge efficiency varies in extreme temperatures If these conditions exist an external regulator with a temperature compensation sensor should be used to optimize the charge rate There are several regulators available that adjust the charge rate based on ambient battery temperature There are some conditions in which the AIR 4035 internal regulator is not appropriate as the primary regulator These conditions include systems where battery temperature varies widely if batteries are extremely sensitive to charge voltage multiple turbines used with a bus system where turbine to bus wire lengths or types vary systems with a very small battery bank contact Southwest Windpower for low power wiring information The AIR 403 offers you three basic regulation choices 1 Use the AIR 403 at its factory settings AIR 403 Adjustable Voltage Range 12v 13 8 17 8v preset to 14 1v 24v 27 6 35 6v preset to 28 2v 36v 41 4v 53 4 preset to 42 3v 30 48v 55 2v 71 2 preset to 56 4v 2 Adjust the regulator to your systems requirements The voltage adjustment is external as indicated in Figure 7 on page 17 This allows you to adjust AIR 4035 internal regulator to the exact voltage specified by the battery manufacturer Refer to Section 4 4 on page 22 for regulator adjustment instructions NOTE Refe
6. with the Battery 1 post to the battery positive the Battery 2 post to the turbine battery negative and the third post to the turbine positive 3 1 6 System Wiring Diagrams Before deciding how to wire your AIR 403 it is important to understand how your existing system is wired and how the AIR 403 internal regulator operates Refer to the General Discussion of Operation in Section 4 1 2 on page 20 for information on the AIR 403 s internal regulator The recommended way to connect the turbine to your battery bank is to wire the turbine directly to the battery bank to its own set of battery posts This will allow the turbine to operate independently The AIR 403 s internal regulator will independently monitor the battery and charge as necessary You can wire the AIR 403 through most power centers However if you experience interference or pre regulation you must bypass it and wire the turbine directly to the battery bank Some external charging sources i e solar panels fuel powered generators additional wind generators etc can interfere with the turbines electronics and cause pre regulation If there is external interference it will not harm the turbine it will just cause the turbine to spin slowly as if braked or in the stop position If this occurs test the possible interference by disconnecting the other charge sources to determine the possible interference source Choose the appropriate wiring diagram be
7. 12mph Wind Average and 95 Energy Transmission Efficienc 1 120 100 80 69 49 49 49 29 2 129 86 6g 49 4g 2g 2 lig 09 3 00 86 6g 4g 29 04 009 Fuse 50 Amp Slow Blow turbine 36V 403 Wire Size Considering 12mph Wind Average 95 Energy Transmission Efticiency 4g 4 20 100 100 80 CE om EE 1 8g 69 69 49 49 84 100 124 144 2 14g 00 86 60 69 4 144 29 2g Fuse 35 Amp Slow Blow per turbine 10 48 AIR 403 Wire Size Considering 12mph Wind Average 95 Energy Transmission Efficienc 1 4 4 14g 129 hog 09 100 80 2 4 20 00 1009 8 lag 6 60 3 14 14 20 00 89 89 60 l4g Fuse 25 Amp Slow Blow per turbine Wiring Compensation for Average Wind Speed For different average wind speeds the wire LENGTHS in the charts should be compensated Compensating by changing wire gauge can lead to safety problems For the average wind speed of your site multiply each wire length in the chart by the factor shown 9mph 2 10mh 15 11mph 1 25 12mph 1 13mph 0 8 14mph 0 6 Wiring Resistance and Regulation Wiring resistance can affect the regulation set point of the turbine Higher wiring resistance smaller wires will lower the voltage at which the turbine enters regulation and stops charging The recommended wiring sizes should provide little ef
8. 5 8 nut from the alternator shaft Carefully slide the blade assembly onto the alternator shaft Place the nut on the shaft and thread the nut on by spinning the blade assembly Insert the 5 16 hex key torque wrench into the alternator shaft and tighten the nut by holding the hub set and tightening the shaft with the torque wrench The nut should be tightened to 50 65 foot pounds 68 88 Nm When the blade set assembly is tightened spin it to be sure it turns freely 3 3 3 Attaching Nose Cone Carefully place the nose cone over the center of the hub and the blades Snap the nose cone into place Be sure all three edges catch Check to see that the nose cone is secure by firmly pulling on it The nose cone does not affect the performance of the turbine and may be left off if desired 3 4 Step By Step Instructions The following Step By Step Installation Procedures provides you with an outline of the AIR 403 installation process This consolidated reference should only be used as an outline during installation Refer to the appropriate sections for further details 1 Run the wires from the battery do not connect to the battery through the pole to the top of the tower Be sure not to connect the wires to the battery until everything else has been completed 2 Strip the insulation back from each set of wires 3 Mark both ends of all the wires with tape to identify which is negative positive and earth ground AIR 403 color c
9. also adds stability in high winds Why is the LED Light Emitting Diode located where it is Both the AIR 403 and the AIR marine have the LED located on the belly near the yaw This location allows for easy viewing Will the LED burn out The LED is a solid state device with a much longer life than conventional bulbs or fluorescent lights It should last a lifetime Your unit will work fine even if the LED fails How long will the bearings or other wearing parts last According to engineering calculations the bearings should have a 10 year life in 12 mph 6 m s average wind speed sites Bearing life will vary from one application to another however you should expect at least a five year performance in adverse conditions and 10 years in normal conditions The copper brushes should last a lifetime The yaw shaft has been tested to over 100 000 revolutions with no visible wear on the brushes or slip rings What is the maximum wind speed the AIR 403 will survive and do I need to take it down in a storm NEVER approach the AIR 403 or any turbine in strong wind conditions The AIR 403 is designed to run without attention in storm conditions If you wish to shutdown the turbine you can do so remotely as described in Section 3 1 5 on page 12 The AIR 403 is rated to 100 mph 45 m s If you expect higher winds contact the factory for information on the AIR Industrial How do know the turbine is charging For a precise indication of char
10. multiple turbines it is possible to reduce your wiring costs by using a bus bar system NOTE Do NOT accidentally connect the turbine backwards to the battery for even a second i e turbine positive to battery negative and turbine negative to battery positive Doing this will instantly destroy the circuit inside the turbine and void your warranty 3 2 Mounting To Tower The AIR 403 is designed to be mounted on a 1 1 2 SCH 40 steel or aluminum pipe do not use plastic The outside diameter of the pipe should be 1 875 48 mm There is a soft coupling inside the yaw shaft mount that is designed to provide a secure fit and to dampen some of the noise transmitted down the tower The pole must be mounted with hardware specifically designed for small wind turbines Southwest Windpower offers a complete 15 stand alone tower package and a Roof Mount Kit for mounting to structures which provides secure mounting and superior noise isolation Contact your dealer for details CAUTION Only use properly sized metal pipe for towers 3 2 1 Attaching to Pole While attaching the turbine to the tower be careful not to pinch the yaw wires Slide the yaw all the way down over the end of pole After the yaw is seated on the pole move it back up a 1 8th inch 2mm to prevent the bottom of the yaw from contacting the top of the pole This way the only contact between the tower and yaw is through the rubber pad which will reduce noise transm
11. to alter the open circuit voltage Changing the regulation set point will have no affect on the open circuit voltage 4 3 Performance Test 1 Isolate the turbine from the system Connect red positive turbine wire to the battery positive post Connect the black negative turbine wire to the negative battery post Make sure no other system charging components are connected Also make sure that switches diodes regulators or meters are not connected 2 Connect amp meter Connect your non averaging amp meter in line the positive red wire according to the manufacturer s recommendations 3 Monitor wind speed vs output Record the data and compare to the power curve Use an anemometer located within 5 feet 1 5 m of the turbine to get accurate wind speed information An anemometer located in a higher location will not provide correct information for power curve assessment Also refer to the elevation vs output chart in Section 5 3 on Page 24 for information on elevations effect on output Small differences in the wind can have substantial effects on output 4 Check results If the turbine has very poor or no output when compared to power curve refer to the Trouble Shooting section 4 4 Adjusting the Internal Regulator It is important to understand how to use the AIR 4035 internal electronics to ensure proper charging of your batteries Refer to Figure 7 on page 17 for the location of the regulator adjusting screw In the following parag
12. 500 1000 ft 150 300 97 1000 2000 ft 300 600 m 94 2000 3000 ft 600 900 m 9196 3000 4000 ft 900 1200 m 8896 4000 5000 ft 1200 1500 m 8596 5000 6000 ft 1500 1800 m 8296 6000 7000 ft 1800 2100 m 7996 7000 8000 ft 2100 2400 m 76 8000 9000 ft 2400 2700 m 7396 9000 10 000 ft 2700 3000 m 7096 SUMMARY OF TIPS e sure there are no diodes in the line between the AIR 403 and the battery e sure the amp meter is hooked up properly and that it is the proper type e Digital hand held meters work best for testing They usually have a 10 or 20 amp DC scale which is adequate unless high winds are present e Make sure your amp meter is not an averaging style e lf you are using an external regulator be sure that the adjustment screw the AIR 403 is turned all the way clockwise e Make sure you are measuring the current through the positive wire If you measure the current through the negative wire you may only measure part of the current the other part may travel through the ground connection e External regulators should be diversion load types e Use accurate wind speed information Small differences in wind speed will have large effects on output e sure your stop switch is properly installed e Make sure you do not have any electrical shorts in the system 6 WARRANTY POLICY 24 What Is Covered For How Long For turbine
13. ECTRONICS INCLUDE INTERNAL DIODES DO NOT PUT ADDITIONAL BLOCKING DIODES IN BETWEEN THE AIR 403 S WIRES AND THE BATTERIES ANY DIODES BETWEEN THE TURBINE AND THE BATTERIES WILL PREVENT THE TURBINE FROM PROPERLY SENSING THE BATTERIES While you are conducting output tests make sure no other devices such as alternators or photovoltaic panels are charging the batteries at the same time The total voltage from other charging sources could increase the battery voltage causing the AIR 403 s regulator to think the batteries are charged and prematurely stop charging 23 It is a good idea to connect the wires from the AIR 40310 separate battery terminals on the battery bank to ensure the turbine reads the battery voltage instead of output voltages from other charging sources Higher input voltages from solar panels can trick the AIR 403 into thinking the battery is charged Also check the condition of each individual battery One bad battery can create high voltages 16 18 volts and stop the turbine from charging Consult the battery manufacturer for testing individual batteries or cells 5 3 Elevation An important fact to keep in mind is elevation The higher a wind generator is from sea level the lower the air density Air density is directly proportional to the output of your turbine Here are some general numbers to keep in mind when determining the maximum output that can be expected from a wind turbine 1 500 ft 0 150 m 100
14. PA Batteries Siting The Battery Book R Perez Home Power Magazine P O Box 520 Ashland OR 97520 970 475 0830 A Siting Handbook for Small Wind Energy Conversion Systems H L Wegley J V Ramsdell NM Orgill and R L Drake National Technical Information Service 1980 703 487 4600 Tower Construction 40 Uniform Building Code Section 2311 Wind Design UBC International Conference of Building Officials May 1985 Lightning Protection Lightning Protection R H Golde Chemical Publishing Co Inc 1975 New York Lightning Code Section 78 National Fire Codes Volume 7 1978 National Fire Protection Association Available at your Library Resources National Technical Information Service United States Department of Commerce 5285 Port Royal Rd Springfield VA 22161 703 487 4600 The American Wind Energy Association AWEA 122 C Street NW Fourth Floor Washington D C 20001 202 408 8988 NRG Systems Monitoring Equipment Manufacturer 110 Commerce Street Hinesburg VT 05461 802 482 2255 National Electrical Codes 41 National Electrical Code NEC National Fire Protection Association
15. aner in the sense that they do not vent gasses like lead acid batteries However gel cells are more sensitive to charge voltage since they can not vent except in emergencies which may cause irreversible damage Therefore the charge on gel cells must be regulated properly If using gel cells follow the manufacturers recommended regulation set points Gel cell batteries may require an external battery temperature compensated regulator Consult your manufacturer for specific recommendations Nickel Cadmium or Nickel Iron batteries are generally used in extreme conditions These batteries will perform at temperatures less than 40 C 40 F They are capable of delivering higher current and cycle deeper and more often than lead acid and gel batteries Nickel iron batteries can have a 20 year life Nickel iron is one of the most environmentally friendly batteries however nickel cadmium batteries contain heavy metals The disadvantages of this type of battery are its high cost and its low efficiency charge Consult your manufacturer for specific recommendations 9 2 Regulator Options The internal electronics protect you and your batteries from excess voltage from the AIR 403 they control the turbine rotor RPM and serve as a flexible battery charge regulator The internal regulator senses the voltage from the battery and determines whether or not to continue charging Once the battery voltage matches the regulation set point the regulator will
16. ar and can not take advantage of the cube effect of the wind These turbines are efficient at only one or two points along the power curve The AIR 403 s efficiency curve matches the available energy in the wind making it efficient all along the curve This is an important reason why the AIR 40315 able to provide you with such a large amount of power from a small turbine 4 1 1 Alternator The AIR 403 uses a three phase brushless permanent magnet alternator that internally rectifies the power to D C The rotor is comprised of 12 Neodymium Iron Boron arced magnets the most powerful magnet material available The stator is hand wound for maximum output 4 1 2 Regulator When the battery voltage matches the regulation set point the turbine will shut off The new 403 includes the new Autobreak electronics which now stop the blades to a slow silent spin when the batteries are full Normal charging will resume when the battery voltage drops slightly below the fully charged level For 12v turbines the turbine will resume charging at 12 6v 25 2 for 24v turbines NOTE Bad connections undersized wires and inline diodes will cause the internal regulator to not work properly It is very important that the AIR 403 can sense the proper battery voltage 4 1 3 Blades The blades consist of an injection molded high strength all carbon fiber reinforced engineering thermoplastic that results in strong lightweight blades The blades are co
17. cated electronics control the voltage The turbine will become louder when it is disconnected especially in higher wind speeds Not recommended for extended periods Is it possible to short my AIR 403 Yes you can short your AIR 403 without causing any damage however be sure you do not short your batteries Shorting batteries can cause serious damage First disconnect the turbine from the battery and then connect the turbine positive wire to the turbine negative wire Doing this will stop the turbine from spinning Refer to the Four Spinning Conditions of the AIR 403 in Section 4 1 4 on page 21 Also refer to the section on Stop Switches in Section 3 1 5 on page 12 The stop switch can be used to stop the turbine by disconnecting the battery and shorting the turbine wires Can the turbine be hooked up backwards to the battery without causing any damage NO If you hook the turbine up backwards to the battery you will damage the turbine and void your warranty Make sure to hook the positive red wire to the positive post on the battery and hook the negative black wire to the negative battery post Where can locate tubing to make a tower The AIR 403 uses 1 1 2 schedule 40 steel or aluminum pipe Actual outside diameter O D of the pipe is 1 875 inches 48 mm Steel pipe is available at any hardware or plumbing store Aluminum pipe can be found at most electrical hardware stores Ask for electrical aluminum conduit Whe
18. es an exclusive power rectifier that sinks excess heat directly to the body The regulation electronics have been enhanced for more robust control and reliability in the most extreme operating conditions New Alternator A more powerful alternator has been built into the new AIR 403 The stronger permanent magnet rotor can be felt in rotating the blade shaft a slight catch can be felt when spinning the shaft with your fingers This is normal and is quickly overcome when the blades begin spinning New Blades The rotor blades have been redesigned with a new highly efficient true airfoil An all new precision injection mold produces blades of exceptional consistency resulting in quieter performance and minimal vibration In high winds the enhanced over speed mode flutter drops power output and machine RPM for longer life lower noise and even greater survivability in the harshest winds New Body New Hub The AIR 403 body is made from a precision casting process that not only enhances fit and finish but also leads to a stiffer more durable body The die cast aluminum hub design has been engineered to be the strongest stiffest hub we have ever produced Table of Contents 1 Safety 5 1 1 Mechanical Hazards 1 2 Electrical Hazards 1 3 Installation 1 4 Operation 2 Package 1 1 ea as 3 Wiring and Installation Procedures eese eee 31
19. f state of the art technology like Iron Boron Neodymium magnets carbon reinforced engineering thermoplastics high quality aluminum stainless steel hardware and integrated electronics The turbines come standard with built in regulators self governing mechanisms and the best global warranty program in the industry The AIR 403 is for use in applications where salt corrosion is not expected to be a concern The AIR marine is designed for offshore and or land based coastal applications If you have any questions after thoroughly reading the manual please contact your authorized distributor dealer or Southwest Windpower Inc Enjoy New Features of the AIR 403 Hysteresis The AIR 403 regulation control circuitry now incorporates hysteresis This will lock the turbine in a silent regulation mode once the batteries are fully charged The turbine begins producing power again when it senses the battery voltage slightly below fully charged This means for a factory set 12V turbine the turbine will regulate shut down when the batteries have reached 14 1V and will resume charging when the voltage drops to 12 6V which is slightly below fully charged Minimal output is wasted as non charging battery voltages above 12 6V represent mostly a surface charge with very little energy This feature prevents the turbine from fluctuating in and out of regulation mode resulting in a quieter better behaved machine New Electronics The AIR 403 incorporat
20. fect on the regulation set point but all installations should be observed over time to ensure that the batteries are charged to the proper voltage 3 1 3 Grounding Properly grounding the turbine is very important in protecting the electronics for long term operation Grounding procedures must be followed along with any local electrical codes IMPORTANT SEVERE TURBINE DAMAGE CAN RESULT FROM IMPROPER GROUNDING FAILURE TO PROPERLY GROUND WILL VOID YOUR WARRANTY It is very important to ground your battery bank and ground your tower for lightning and static protection The green lead wire provides grounding for the body of the turbine This wire must be connected to the system earth ground This is usually done by connecting a wire from a ground rod near the base of the tower to the green turbine lead wire For additional lightning and static protection another wire should connect this ground rod to the tower pipe The negative wire of your system should also be connected to a ground This is usually done by connecting a wire from the negative battery terminal to a nearby ground rod Wires with the same ratings as the positive and negative wires must connect all system grounds see Wire Size Section 3 1 2 A ground electrode can be made for systems without an existing system ground from an 8 ft 2 4 m section of 3 4 19 mm galvanized pipe or conduit or an 8 ft 2 4 m section of 5 8 16 mm iron or steel rod This ground electrode m
21. ge current you will need to install an amp meter in your system Why is the AIR 403 so powerful for its size weight and cost Almost every part of the turbine has been developed from the ground up using 3 D computer models to help analyze every element of the design As a result this state of the art turbine features the following 37 AIR 403 is the only turbine that uses a permanent magnet PM alternator that matches the cubic power of the wind All other PM alternators are linear in their output and either stall or unload the rotor blades making them very inefficient AIR 403 uses 12 Neodymium Iron Boron magnets which are the strongest magnets available in the world This is the first wind turbine to use blades with advanced airfoils made of injection molded carbon composite materials that meet the strength to weight ratio requirements of this computer assisted design The blades have aeroelastic twist that provides durability and simplicity The electronic circuit alternator allows the turbine to self regulate Most important has been the conviction and passion of our team While overcoming seemingly insurmountable obstacles together we maintain our desire to help change the world by providing quality renewable energy innovations 38 13 ACCESSORIES Southwest Windpower offers a line of accessories for your turbine Some of these accessories are difficult to find due to the high DC outp
22. ill only increase the probability of overcharging your batteries 5 TROUBLE SHOOTING If the turbine does not work properly after following the installation instructions then read this chapter and carefully compare your installation with each section 5 1 Assembly Make sure the blade assembly is on tight You can check by placing the 5 16 hex key in the shaft holding it and attempting to turn the blade assembly If you can turn the blade retighten the blade assembly To minimize noise make sure that you have loosened the four mounting screws and moved the turbine up 1 8 inch 2mm and then re tighten the screws This will prevent the top of the pole from touching the hard plastic in the yaw shaft assembly 5 2 Electrical System Your battery bank should be a minimum 400 amp hours for 12v systems and 200 amp hours for 24v system If your battery bank is smaller than the recommended size battery voltage could quickly rise while the turbine is charging and cause the internal regulator to prematurely stop charging The AIR 403 s trickle charge could potentially over charge the smaller battery Measure the voltage at the battery terminals to which the AIR 403 is connected For the factory regulation set point if the voltage for a 12v system reads 14 1 or higher 24v 28 2 then the turbine will sense the battery is charged and stop producing power n high winds there will still be a trickle charge NOTE THE A R 403 EL
23. installation NOTE Do not install the blade assembly until the turbine is mounted on the tower 1 4 Operation Check support structures blades and electrical systems on a regular basis The rotor blades are very strong however if they come in contact with a solid object they can break Use common sense about safety when locating the turbine When performing periodic inspections or at anytime when you must approach the path of the blades disconnect the power leads from the battery and tie the wind turbine output leads together to stop slow down the blades from rotating The turbine can also be shut down through the use of a stop switch Please refer to Figure 2 on page 13 on how to install a stop switch in your system CAUTION NEVER APPROACH THE TURBINE DURING OPERATION USE COMMON SENSE AND PLEASE BE CAREFUL 2 5 Compare the parts shown Figure 1 to ensure that the contents of the box contain all necessary parts CAUTION THE EDGES OF THE ROTOR BLADES ARE SHARP PLEASE HANDLE WITH CARE Alternator Shaft Hub 5 8 Nut Nose Cone Yaw Shaft E 9 5 16 Hex Key 1 4 Socket Head Cap Screw 6 f Oum f 3 16 Hex Key f 1 4 20 Nut 6 5 32 Key f Omm L AIR 403 Rotor Blades 3 Owners Manual Figure 1 3 WIRING AND INSTALLATION PROCEDURES Your AIR 403 is shipped partially disassembled Refer to Figure 7 on page 17 for assembly
24. instructions Please completely read all procedures before beginning installation NOTE Do not install the blade assembly until the turbine is mounted on the tower Required Tools 5 16 hex key wrench included 3 16 hex key wrench included 5 32 hex key wrench included Torque wrench with 5 16 3 16 and 5 32 hex drives optional Soldering iron or propane torch Rosin core solder Electrical tape or 1 4 6 7mm heat shrink Wire strippers Wire crimpers 3 1 Wiring 3 1 1 Electrical Connections NOTE Refer To All Local and National Codes Before Installation CAUTION MAKE SURE THE TURBINE IS DISCONNECTED FROM THE BATTERIES DURING INSTALLATION Avoid connecting different metals together i e copper and aluminum This will cause a galvanic cell that will erode one of the metals When such connections can not be avoided consult your dealer or an electrical supply house for anti oxidant compounds If possible solder wire termination ends CAUTION CONNECTIONS SHOULD BE INSPECTED PERIODICALLY FOR SIGNS OF CORROSION AND CLEANED WHEN NECESSARY NOTE All electrical power cables should be physically protected Run the wires inside the tower or conduit for maximum protection NOTE The yaw can support a total of 150 Ibs 68 kg in wire weight For higher wire weights you must install a strain relief to minimize the stress put on the hanging wires Wire Color Codes RED positive BLACK negative GREEN
25. ission Tighten all mounting fasteners Make sure that your tower allows for proper clearance of the blades A minimum 2 inch 20 mm clearance must be given between the blade tips and any obstructions Refer to Figure 6 below and the Sphere of Operation drawing in Section 7 2 on page 27 for proper clearances Figure 6 Proper Blade to Tower Clearances rS Lumens Reeve tight Hight 16 3 3 Hub And Rotor Assembly Before assembling the hub and rotor refer to Figure 7 below and the following detailed instructions NOTE To avoid damage to the blades during installation do not put the blade assembly on the turbine until the turbine is mounted on the tower Figure 7 3 3 1 Mounting the Blades CAUTION THE EDGES OF THE ROTOR BLADES ARE SHARP PLEASE HANDLE WITH CARE Notice that the screw holes in the blades are counter bored for the socket head cap screws Place one of the blades with the counter bore facing up and align the screw holes Insert one of the socket head cap screws through the blades and hub Place a nut on the end of the screw and tighten the screw with the 3 16 hex key wrench to 10 12 foot Ibs 13 6 16 3 Nm Repeat this procedure on all three blades NOTE You may need to thread the screws through the hub with the hex wrench 17 3 3 2 Mounting the Hub and Rotor CAUTION THE BLADES ARE SHARP USE CAUTION WHILE HANDLING THE BLADES Remove the
26. l disconnect the turbine from the battery and then short the positive and negative leads from the generator together The blades could still spin slowly but will not charge the battery 4 2 Bench Testing Two quick bench tests can verify if your AIR 40315 providing output Test 1 1 Remove blade assembly from turbine and place in a safe location Do not stand the blade assembly against a wall 2 Spin rotor shaft with your fingers or the allen wrench provided while at the same time connecting and disconnecting the Red and Black yaw wires 3 With the yaw wires connected the rotor shaft should become more difficult to rotate and feel lumpy With the yaw wires disconnected it should spin freely If these conditions do not exist you should contact your turbine dealer or Southwest Windpower Test 2 1 Remove blade assembly from turbine and place in a safe location Do not stand the blade assembly against a wall 21 2 Connect voltmeter across the Red and Black yaw wires 3 With a 5 16 hex drive in an electric drill spin the rotor shaft while observing the voltmeter Cut a small piece off of the Hex Key provided if necessary 4 Rated voltage should be achieved at a minimum of 950 RPM NOTE Do not be alarmed if the open circuit voltage goes above the regulation set point voltage The open circuit voltage will not change if you adjust the regulation set point DO NOT adjust the regulation set point in an attempt
27. lar design This allows for the use of multiple turbines to achieve the desired power production Roof top mounts offer relatively easy multiple turbine installations if the site allows 34 Basic aerodynamics show that as wind moves over or around objects the wind compresses and accelerates It is possible to use a building rooftop to increase the turbine s output using this accelerated wind The amount of acceleration will vary greatly with house design wind direction local obstructions and terrain There are considerable differences in acceleration due to the angle and height of a structure and nearby obstructions However a location of 5 feet 1 5 m to 8 feet 2 5 m above the structure produces substantial acceleration in average situations and is tolerant of different wind directions For ideal sites where the prevailing wind is perpendicular to the roof ridge line the AIR 403s may be mounted fairly close together 9 feet 2 75 m center to center However if your wind primarily comes from a direction along the roof ridge line then the AIR 403s must be spaced to minimize interference 12 to 15 feet 3 6 to 4 5 m and mounted as high as possible 8 feet 2 5 m maximum unsupported pipe Less acceleration occurs when the wind is parallel to the roof line When the prevailing wind is perpendicular to the roof edge mount your first AIR 403 in the center of the roof ridge and add modules to either side along the roof ridge Where the p
28. low for proper wiring information A Single AIR 403 Wiring Figure 3 13 Figure 3 B AIR 403 In System With Solar Panels Hybrid System PV Solar Array Figure 4 NOTE In this drawing the Meter rjj AIR 4035 E i E internal Battery Controller regulator IS Disconnect eu used A diversion type optional Meter external E Load regulator can also be used Resistive Load Ground Ground 14 Multiple AIR Installation ere FT Gg Stop Stop Stop Stop Stop Switch Switch Switch Switch Switch 4 E Fuse Fuse Fuse Fuse Battery Disconnect Amp Meter E Ly Battery Ground Figure 5 There are two methods to wire multiple AIR 403s a Each Turbine Wired Directly To Battery Each turbine operates as an independent system separate from other solar panels gas generators or any other battery charging sources If the turbine has its own fuse stop switch optional and wires the turbine is able to individually communicate and charge the battery b Each Turbine Wired To A Bus Bar If you plan to wire two or more turbines to a bus and then run one set of wires from the bus to the battery you can use each turbine s internal regulator or install an external regulator If you use an external regulator use a diversion style regulator that turns excess power into heat for heating a room water etc When wiring
29. mbled hub and blades to the rotor shaft 12 Run all wires from the turbine to the battery do not connect wires to the battery Be sure to crimp and solder the connections using the appropriate sized connectors If you plan to connect an amp meter into your system see Figure 4 on page 14 13 Attach your positive RED wire to a fuse Refer to Section 3 1 4 for fusing information 14 Make sure that your system is properly grounded before proceeding Refer to the Grounding Section 3 1 3 on page 11 IMPORTANT SEVERE UNIT DAMAGE WILL RESULT FROM IMPROPER GROUNDING FAILURE TO PROPERLY GROUND THE TURBINE WILL VOID YOUR WARRANTY 15 Before attaching the wiring to the battery make sure that all circuit breakers are in the off position the stop switch is in the stop or shorted position if installed 16 Attach wires to the battery Red wire to positive Black wire to Negative 17 Turn on the circuit breakers and or stop switch 18 When the blades are rotating very quickly in the wind you should see the red LED illuminate 19 You have now completed the installation process 19 4 TESTING 4 1 General Discussion of Operation The available energy in the wind is the cube of the wind speed This means that each time you double the wind speed you get eight times the power The unique design of the AIR 403 is such that it can take full advantage of the power in the wind The efficiencies of other wind turbines are usually line
30. mputer designed to efficiently extract the most power out of the wind The blade design also provides over speed protection in high winds All wind generators need some type of high wind over speed protection The AIR 403 s blades feature aeroelastic twist In winds moving above approximately 40 mph 17 9 m s the blade tips will dump excess wind off and prevent the turbine from over speeding The benefit is that the turbine is able to maintain output providing you with the most possible power It also reduces the number of parts resulting in increased reliability The only disadvantage of this type of governor is that in high winds the turbine may produce a loud noise Other turbines have complex mechanisms that either mechanically break the turbine or turn it out of the wind This can reduce reliability due to increased complexity and reduce output by as much as 90 4 1 4 Four Spinning Conditions of the AIR 403 a Open Circuit 20 When the turbine is disconnected from the batteries it will free spin In this mode the generator can spin unloaded with the wind At approximately 40 mph 17 9 m s wind speed the blades will begin to go into an aeroelastic stall to prevent the rotor from over speeding In addition the internal regulator has a high speed regulation to protect the circuit from high voltage conditions Operating the turbine in open circuit for a brief period of time will not damage the turbine However
31. nspect the tower Dirt or debris build up on the blades body may cause a decrease performance of the turbine and or long term damage that is not covered by the warranty Wash off any build up with clean soap and water Check all electrical connections to make sure they are tight and free from corrosion As with all charging systems check your battery water levels and add distilled water if necessary e Check the nose cone 9 SYSTEM REQUIREMENTS AND CONSIDERATIONS 9 1 Batteries The following is a brief description of three common batteries There are many grades sizes voltages and chemistries available Battery life can vary from less than one year to more then ten years It is important to consult your dealer for the most up to date information and for help in selecting the appropriate battery NOTE Never use automotive batteries or any non deep cycle battery NOTE Refer to battery manufacture for specific recommendations regarding installation maintenance charging and operation Lead Acid Wet Lead Acid or flooded lead acid batteries are the most commonly used batteries to store electrical power These are available in vented types most common where water can be added and also in sealed types where water cannot be added 29 GEL Cell sealed batteries are frequently selected in applications where batteries cannot be vented or cannot be mounted in an upright position Gel cells are cle
32. odes RED Positive BLACK Negative GREEN Ground 4 Insulate the connections using either heat shrink tubing or a quality electrical tape 5 Connect the wires from the AIR 403 to the wires running to the battery CAUTION IF THE WIRES ARE HOOKED UP BACKWARDS YOU WILL DAMAGE THE AIR 403 S ELECTRONICS IF YOU ARE UNCERTAIN OF THE POLARITY OF THE WIRES SIMPLY SPIN THE ROTOR SHAFT AND MEASURE THE VOLTAGE DIRECTION WITH A VOLT METER 6 Once the wires are attached to the AIR 403 gently pull the wires down through the tower sliding the yaw shaft over the 1 1 2 Schedule 40 steel or aluminum pipe Actual OD 1 875 inches 48mm Do not use plastic pipe 18 7 Slide the yaw shaft all the way down over the end of pole being careful not to pinch the yaw wires Be sure to leave enough slack in the wires so that if necessary the turbine can be removed 8 After the yaw is all the way onto the pole move it back up 1 8th inch 2 mm to prevent the bottom of the yaw from contacting the top of the pole The only contact between the tower and yaw is through the rubber pad which will reduce the transmission of noise down the tower 9 Once the yaw shaft is on the tower firmly tighten the yaw clamp screws with the 5 32 hex key The AIR 403 should yaw freely without restrictions 10 Check your AIR 403 to be sure that it is securely attached to the mounts Remember that this attachment will have to hold in high winds 11 Attach the asse
33. olts for 24 volt systems Heat in wiring systems is often a result of too much current flowing through an undersized wire or through a bad connection It is important to follow the wire sizing chart in Section 3 1 2 on page 10 to insure a safe electrical system CAUTION FOLLOW THE WIRE SIZING CHART IN SECTION 3 1 2 ON PAGE 10 TO HELP AVOID THE RISK OF AN ELECTRICAL FIRE Batteries can deliver a dangerous amount of current If a short occurs in the wiring from the batteries a fire can result In order to avoid this threat a properly sized fuse or circuit breaker is required in the lines connecting to the battery Refer to Section 3 1 4 on page 12 for fuse sizing information CAUTION FUSE ALL CONNECTIONS FOLLOW THE FUSE SIZING GUIDELINES IN SECTION 3 1 4 ON PAGE 12 TO MINIMIZE THE RISK OF AN ELECTRICAL FAILURE 1 3 Installation CAUTION INSTALLATION PROCEDURES SHOULD BE PERFORMED AT GROUND LEVEL CAUTION MAKE SURE THAT ALL BATTERIES ARE DISCONNECTED THROUGHOUT THE INSTALLATION PROCESS CAUTION NEVER INSTALL THE AIR 403 UPSIDE DOWN Please follow these precautions during the installation process Choose calm day THINK SAFETY Have someone available to help during the installation process Disconnect batteries from turbine wiring Prior to attaching the wires to the battery tie the wind turbine output lead wires positive red negative black together near the battery to be sure that the rotor will not spin up during
34. oof Top Mounting 33 12 Frequently Asked Questions ecce 13 Accessorles e tueur 14 Heferences icgull tre i a O 13 16 17 17 18 18 20 20 20 20 21 21 22 22 23 23 23 24 25 26 27 27 28 30 35 38 1 SAFETY PRECAUTIONS The AIR 403 has been designed with your safety in mind However there are inherent dangers involved with any electrical and or mechanical equipment Safety must be the primary concern as you plan the location installation and operation of the turbine At all times be aware of electrical mechanical and rotor blade hazards 1 1 Mechanical Hazard Rotating blades present the most serious mechanical hazard The AIR 403 s rotor blades are made of very strong thermoplastic At the tip the blades may be moving at velocities over 300 miles per hour At this speed the tip of a blade is nearly invisible and can cause serious injury Under no circumstances should you install the turbine where a person could come in contact with moving rotor blades CAUTION DO NOT INSTALL THE TURBINE WHERE ANYONE CAN APPROACH THE PATH OF THE BLADES 1 2 Electrical Hazards The AIR 403 is equipped with sophisticated electronics designed to provide protection from electrical dangers The internal electronics of the AIR 403 prevent open circuit voltages from rising above 23 volts for 12 volt systems or above 45 v
35. operating the turbine in open circuit for a long period of time can cause excessive wear to the turbine and is NOT recommended We recommend that during long periods of operation the turbine should be connected to a battery or the turbine wires should be shorted Shorting the turbine will minimize wear to the bearings and prolong turbine life and is quieter than running open circuit b Normal Operation Charge When the generator is connected to a battery bank in need of a charge the turbine blades will spin normally with the wind The turbine will charge the battery bank as necessary until the battery voltage matches the regulation set point NOTE When switched from open circuit to charge you may notice a reduction in RPM as the generator is now under load If the batteries are fully charged the turbine blades will slow to a silent spin c Regulation When the battery voltage matches the regulation set point the turbine will go into regulation Blade RPM will lower dramatically and output will stop In very high winds there may still be a trickle charge Normal charging operation will resume when the battery voltage drops slightly below the fully charged level This regulation feature called Hysteresis is explained in more detail in the New Features section see page 4 d Braking Braking can be accomplished by directly shorting the turbine negative and positive wires or through the use of a Stop Switch The Stop Switch wil
36. ows how tower height can dramatically affect output This shows how tower height can affect output Figure 8 is only an example of how tower height affects output not actual outputs of the AIR 403 Figure 8 32 PREMAN AMIE WEHI t Y A NO F 0 BRUSHINE MIS DEFORMITY rit AMD SUGHT amp FLAGGING lil LIGHT MODERATE FLACGING EX i COMPLETE PARTIAL amp FLAGGING ENT EE COMPLETE COMPLE fei THROWING ee AA uu WIND SPEED RATING SCALE BASED ON THE SHADE E THE GEO AMD BEGGS TWIGS BRANCHES TRUNK BENT GRIGGS PLITMAM INDEX WADE AND BAKER i877 MEAM WD SPELD VERSUS THE INDEX GEIS PUTHAM IDES Fi l Li Wi PROSABLE MEAN ANNUAL WIND SPEED RANGE mph 0 2 Teg del 11e13 15 16 15 18 16 21 WIND SPEED RANGE m e 0 5 5 4 4 3 5 5 6 8 7 8 8 10 POWER DENSITY 200 Figure 9 33 11 TOWERS There a few things to consider when choosing the correct tower for your turbine site and budget The following is a list of considerations Site trees hills buildings tower budget space for tower guyed freestanding rooftop number of turbines to be installed ease of use It is important to mount the turbine in the best winds while being balanced by the cost and effort of the installation The higher the tower the greater the output However the talle
37. r tower also involves greater tower cost and effort If purchasing a taller tower will provide significantly more power it might offset the additional cost and effort The AIR 403 has been designed to be mounted on 1 1 2 SCH 40 outside diameter 1 875 inch 48mm steel or aluminum pipe If you have a tower with a larger size pipe that is reduced just before the turbine for mounting make sure that the 1 1 2 SCH 40 pipe stub is at least 26 66 cm long Larger pipes will reduce the blade tip clearance and cause damage to the blades Refer to Figure 6 on page 16 CAUTION PROPER ENGINEERING SAFETY CONSIDERATIONS AND LOCAL CODES SHOULD BE ADDRESSED BEFORE ATTEMPTING ANY INSTALLATION NOTE The yaw wires can support loads up to a total of 150 Ibs 68 kg in wire weight For higher wire weights you must install a strain relief to minimize the stress put on the hanging wires NOTE No more than 8 feet 2 5 m of pipe should extend from the last support NOTE Towers should be capable of withstanding 150 Ib 68 kg of load in the horizontal direction at the turbine 11 1 Guyed Towers Guyed and freestanding towers are the most common way to install a wind generator These towers are available in all shapes sizes and costs As with all towers you must first evaluate your site to determine the appropriate tower height available space and reasonable cost 11 2 Roof Top One of the revolutionary features of the AIR 403 is its modu
38. r to the battery manufacturers specifications for exact regulation set points 3 Use an external regulator A standard diversion load regulator like that used with solar panels will work fine If you choose to use this option you must turn off the internal regulator by gently turning the adjustment screw all the way clockwise Types Of Regulators The three types of regulators available are shunt Pulse Width Modulated PWM and diversion style regulators The first two types charge the battery at full turbine output and reduce the output as the battery becomes full A diversion style regulator charges the battery and as the batteries become charged the excess power is diverted to a resistive load This allows you to capture full output of the turbine even when the battery is full The most common use for this excess power is heating water NOTE If you elect to use an external regulator do not use one that will open circuit the turbine as a means of regulation Most solar controllers will open the solar panel when the batteries are full and this is perfectly acceptable for solar panels However this type of regulation may damage your AIR 403 by causing it to freewheel when the batteries are full If you choose to use an external regulator be sure to use a diversion style regulator 10 SITING In any location the closer you get to the surface of the earth the slower the wind speed This is a result of the friction of the ear
39. raphs 24 volt settings are in Italics The voltage regulator is factory set at 14 1 28 2 volts The factory setting is marked on the casting with a small indentation aligned with the screw slot To change the setting on the voltage regulator rotate the adjusting screw 1 8 of a turn for each 0 7 1 4 volts change desired For example if you want to set your voltage regulator to 14 8 29 6 volts turn the adjusting screw clockwise by 1 8 turn from the 14 1 28 2 volt setting The adjustment screw will provide regulation settings for voltage ranges at least as wide as those listed below The actual voltage set point at the extreme counter clockwise position 22 may as much as 10 lower than the value listed and at the extreme clockwise position may be up to 10 higher than the value listed AIR Adjustable Voltage Range 12v 13 8 to 17 8v preset to 14 1 24v 27 6v to 35 6v preset to 28 2v 36v 414 to 53 4 preset to 42 3v 48v 55 2v to 712v preset to 56 4v READ THIS BEFORE YOU CONSIDER ADJUSTING THE REGULATION SETPOINT Turning up the regulation set point adjustment will NOT increase the AIR 403 s output voltage or amperage It simply adjusts the shut down point for the generators voltage regulator When the battery voltage reaches the regulation set point voltage the turbine will slow down and stop charging the batteries Turning the screw completely clockwise will NOT increase the voltage or power output and w
40. rbine causing the turbine to stop spinning in high winds the blades will spin slowly Shorting the turbine will not cause any damage or additional wear Your dealer distributor should be able to supply the stop switch or you can contact Southwest Windpower directly They can also be found at some automotive electrical stores NOTE The center post must be positive from the turbine Outside posts can be swapped as either positive or negative Figure 2 Stop Switch Wiring Some installations of the AIR 403 may require a high current rated stop switch such as 12V systems in very high wind applications or in cases where local electrical codes require it Switches used in these applications must be single pole double throw rated for the maximum voltages and currents that the system may experience Many battery bank selector switches for RV s can NOT be used as they include a BOTH position which will short your battery bank 12 High current switches are more costly but there are some reasonably priced quality switches available from industrial supply stores One good choice is a battery selector switch manufactured by Cole Hersee model number 75502 This switch is available from several sources including Specialty Electric Supply in Homer AK phone 907 235 9020 and also from Industrial Sales and Service in Portland OR phone 503 239 0754 To use this switch connections are the same as the switch described above
41. re can locate a stop switch If you want to install a stop switch it must be a 50 amp or greater DC Single Pole Double Throw toggle switch see Section 3 1 5 on page 12 This can be purchased from most automotive electrical repair shops your dealer or from Southwest Windpower What type of regulator do need to use You may use AIR 4035 internal regulator or any other type of Dump Load regulator that is intended for use with solar panels See Sections 9 2 on page 29 for more details How adjust the regulator Refer to Section 4 4 on page 22 36 How does the AIR 403 control power and RPM high winds The AIR 403 uses a unique rotor blade made of carbon fiber reinforced thermoplastic As the wind reaches approximately 40 mph 17 9 m s aerodynamic forces cause the blades to twist and the rotor to stall This is a passive function that slows the rotor to protect it Why do hear an unusual noise when wind speed nears 40 mph This noise occurs when the aeroelastic twisting blades reach a deep stall The noise is normal and protects your AIR 403 in high winds If this high wind noise is undesirable stop the turbine by shorting the turbine wires or through the use of a stop switch Why is the casting made of aluminum why not a cheaper or lighter material The aluminum body provides a functional structure and also acts as a heat sink that cools the alternator and electronics at high power levels The weight of the aluminum
42. revailing wind parallels the roof ridge line mount your first AIR 403 on the end of the structure closest to the wind and about 3 feet 1 meter from the edge Although a rooftop can be used to accelerate the wind flowing past a house a tower that is much taller will experience higher winds and greater output The advantages of rooftop mounting are ease of mounting low tower cost and multiple installations The disadvantages are lower wind speeds increased turbulence and noise NOTE Uniform building code requires that a structure must support the wind load it creates by the area presented to the wind The structural load applied by the wind increases with wind speed Any additional loads that increase area during serious storms must be compensated for NOTE Any wind generator can create vibration Always use some type of vibration isolator when attaching the turbine to a structure If available it is always better to mount a wind generator on an unoccupied building CAUTION DO NOT INSTALL THE TURBINE WHERE THE PATH OF THE BLADES CAN BE REACHED DURING NORMAL OPERATION 35 12 FREQUENTLY ASKED QUESTIONS These frequently asked questions are in no particular order Please take the time to read through all the questions you will have a better understanding of the features and operation of your AIR 403 Can disconnect my AIR 403 without damaging it You can disconnect your AIR 403 without causing any damage The AIR 403 s sophisti
43. roblem With Your Southwest Windpower Product Contact your nearest authorized service center or Southwest Windpower to determine the nature of the problem Either Southwest Windpower or the Authorized Service Center will issue a return authorization number to return the turbine or send you the replacement parts needed to repair the machine Southwest Windpower or the Service Center will pay return shipping back to the customer 7 SPECIFICATIONS 7 1 TECHNICAL SPECIFICATIONS Rotor Diameter 46 inches 1 17 meters Weight 13 Ib 6kg Start up wind speed 7 mph 3 0 m s Rated Power 400 watts at 28 mph 12 5 m s Regulator Set Range 12v 13 8v 17 8v preset to 14 1v 24v 27 6 35 6 preset to 28 2v 36v 41 4 53 4 preset to 42 3v 25 48 55 2v 71 2v preset to 56 4 Recommended Fuse Size 12 100 amps slow blow 24v 50 amps slow blow 36v 35 amps slow blow 48v 25 amps slow blow Yaw Wire Size 10 AWG American Wire Gage stranded Pole Dimensions 1_ Schedule 40 pipe outside diameter 1 875 inch 48mm Minimum Battery Bank 400 amp hours 12 200 amp hours 24v 1 BG Ue 4h UE 3 4c 29 5 Md 4 E W 127 14 15 5 zz Annual Average Wind spocd mph Monthly Energy Output kWh AIR 403 Power Curve 900 00 800 00 rdi 700 00 1 600 00 E 2 500 00 400 00 300 00 E 200 00 100 00 0 00 1
44. s that are three years old or less from date of original purchase or three years and three months from date of build any defective part will be replaced at no charge Either a Southwest Windpower technician or an Authorized Service Center determines a defective part What Is Not Covered e Damage due to lightning e Damage due to extreme winds 110 MPH 60 m s e Damage due to improper installation including to but not limited to poor tower design amp inverted hanging e Damage due to improperly wiring to batteries e Damage from flying debris causing blade damage Limitations And Exclusions 1 No one has the authority to add to or vary this limited warranty or to create any other obligation in connection to Southwest Windpower and its products 2 ANY IMPLIED WARRANTY APPLICABLE TO SOUTHWEST WINDPOWER S PRODUCTS IS LIMITED INDURATION TO THE SAME PERIOD OF TIME AS THIS WRITTEN WARRANTY 3 SOUTHWEST WINDPOWER SHALL NOT BE LIABLE FOR INCIDENTAL CONSEQUENTIAL SPECIAL OR CONTINGENT DAMAGES THAT ANY PERSON OR PROPERTY MIGHT SUFFER AS A RESULT OF ITS BREACH TO THIS WRITTEN AND OR IMPLIED WARRANTY 4 This warranty applies to the original purchaser and may be transferred The Customer s Responsibilities All of Southwest Windpower s products must be installed and operated in accordance to the owner s manual and local codes You should keep a copy of the invoice or canceled check to verify the purchase date If You Experience A P
45. th and obstacles on the surface Turbulence caused by obstacles will reduce the efficiency of any wind turbine Therefore locate the turbine in a site that has the cleanest free flowing wind possible Power in the wind is the cubic function of the wind speed This means that small changes in wind speed can have dramatic changes in output Each time the wind speed doubles the AIR 403 is capable of increasing power by eight times Even slight changes have dramatic effects The AIR 403 should be mounted on a tower a minimum of 25 8 meters above any surrounding objects within a 500 150 m radius If this is not possible then place it as high as you can If this is a roof top installation it is important there are no objects around the structure that may block the wind CAUTION DO NOT INSTALL THE TURBINE WHERE THE PATH OF THE BLADES CAN BE REACHED CAUTION DO NOT APPROACH THE TURBINE FOR ANY REASON UNLESS ROTOR BLADES ARE STOPPED 31 You get fairly good estimate of the local average wind speed by looking at the local vegetation Look at the following drawings for information on estimating your local average wind speed m Height TIE Power Hb KWH Morth Average bind T2 of 30 feet Surface Rough v Height BA faat S Power 66 y Jj Height a fem T Power BO 12 AY AW Y 1 H ALLE PP OG MORAG ROARS The first figure sh
46. ust be buried completely beneath the soil at no more than 45 degrees from vertical or horizontally at least 2 1 2 ft 75 cm beneath the 11 surface It is recommended that the ground electrode be installed as close as possible to the batteries for maximum lightning protection The base of the tower is also a good location for an appropriate surge arrestor Delta manufactures surge arrestors for lightning protection such as their model LA 302 RG Contact Delta Lighting Arrestors P O Box 750 Big Springs TX 79721 Phone 915 267 1000 Fax 915 267 1035 or your dealer for more information 3 1 4 Fusing The AIR 403 is capable of producing high amperages As with all electrical installations you must protect each of your turbines with a properly sized fuse or circuit breaker The AIR 403 should be wired with an appropriately sized slow blow type fuse between itself and the batteries If a stop switch is used the fuse should be placed between the switch and the batteries Recommended Size for Circuit Breakers or Slow Blow Fuses 12 volt model 100 amps D C 24 volt model 50 amps D C 36 volt model 35 amps D C 48 volt model 25 amps D C 3 1 5 Stop Switch A stop switch must be used with your AIR 403 to provide a convenient method for shutting down the turbine The stop switch is a 50 amp D C single pole double throw switch that is used to shut the turbine off The switch disconnects the battery and then shorts the tu
47. uts We offer them as a convenience to you They may be available at an automotive parts store Otherwise you can purchase them from your dealer distributor or directly from Southwest Windpower Stop Switch The 50 amp DC Stop Switch can be used to stop the turbine for service or any other reason Refer to the Stop Switch wiring diagram in Section 3 1 5 on page 12 Amp Meter The Amp Meter allows you to monitor the output of your turbine Place it in between your turbine and the battery on the positive lead It will give you instantaneous readings of output in amps Circuit Breaker A Circuit Breaker is required with any electrical installation In the event of a system or turbine failure the circuit breaker disconnects the battery and prevents the possibility of further damage Make sure to purchase the proper size DC breaker 12 volt 100 amp 24 volt 50 amp Circuit Breaker Stop Switch Amp Meter Guyed tower Kits We offer 25 7 5 m 47 14 guyed towers These towers are relatively low cost and easy to install Contact your dealer for pricing and product information 39 14 REFERENCES Wind Energy The Wind Power Book J Park Hackleman Cheshire Books 1981 Palo Alto CA The Home Built Wind Generated Electricity Handbook M Hackleman Peace Press 1975 Culver CA Wind Energy How To Use It P Gipe Stackpole Books 1983 Wind Power For The Home Owner D Marier Rodale Press Emmaus
Download Pdf Manuals
Related Search