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Southwest Windpower AIR MARINE - V3.2 Manual

400 watt battery charging wind turbine
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Summary of Contents for Southwest Windpower AIR MARINE - V3.2

  • Page 2 The New 400 watt turbine! Owner’s Manual Version 3.2...
  • Page 3 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.
  • Page 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 marine; however, it is important that you read this entire manual thoroughly prior to installation to assure proper performance and safety.
  • Page 5 New Features of the AIR marine Hysteresis: The AIR marine 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.

  • Page 6: Table Of Contents

    1. Safety Precautions………………………………………………………... 1.1 Mechanical Hazards 1.2 Electrical Hazards 1.3 Installation 1.4 Operation 2. Package Contents………………………………………………………… 3. Wiring and Installation Procedures……………………………………. 3.1 Wiring………………………………………………………………….. 3.1.1 Electrical Connections 3.1.2 Wire Size 3.1.3 Grounding 3.1.4 Fusing 3.1.5 Stop Switch 3.1.6 System Wiring Diagrams 3.2 Mounting to Tower……………………………………………………16 3.2.1 Attaching to Pole 3.3 Hub and Rotor Assembly……………………………………………...

  • Page 7: Safety Precautions

    1. SAFETY PRECAUTIONS The AIR marine 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.

  • Page 8: Installation

    1.3 Installation CAUTION: ALL INSTALLATION PROCEDURES SHOULD BE PERFORMED AT DECK LEVEL. CAUTION: MAKE SURE THAT ALL BATTERIES ARE DISCONNECTED THROUGHOUT THE INSTALLATION PROCESS. CAUTION: NEVER INSTALL THE AIR MARINE UPSIDE DOWN. Please follow these precautions during the installation process: Choose a calm day.

  • Page 9: Package Contents

    2. PACKAGE CONTENTS Compare the parts shown in 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. Figure 1...

  • Page 10: Wiring And Installation Procedures

    3. WIRING AND INSTALLATION PROCEDURES Your AIR marine is shipped partially disassembled. Refer to Figure 7 on page 17 for assembly 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”...

  • Page 11: Wire Size

    To select the appropriate size wire, measure the distance from the batteries to your AIR marine, 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 marine. All electrical systems lose energy from the resistance of the wires used.

  • Page 12: Grounding

    48V AIR marine: Wire Size, Considering 12mph Wind Average and 95% Energy Transmission Efficiency # Turbines 0-30ft 31ft-60ft 61ft-90ft 91ft-150ft 151ft-190ft 191ft-250ft 251ft-310ft 311ft-390ft 391ft-500ft 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.

  • Page 13: Fusing

    The reference section in the appendix lists two books that provide you detailed information on proper grounding in marine applications. Delta manufactures surge arrestors for lightning protection. An example is their model LA 302-RG surge protector. 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.

  • Page 14: System Wiring Diagrams

    To use this switch, connections are the same as the switch described above, 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 marine it is important to understand how your existing system is wired and how the AIR marine’s internal regulator operates.
  • Page 15 Figure 3 Figure 3 B. AIR marine In System With Solar Panels (Hybrid System) Figure 4 NOTE: In this drawing the AIR marine’s internal regulator is used. A diversion type external regulator can also be used.
  • Page 16 C. Multiple AIR marine Installation Figure 5 There are two methods to wire multiple AIR marines. 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. Since the turbine has its own fuse, stop switch (optional), and wires, the turbine is able to individually operate and charge the battery.

  • Page 17: Mounting To Tower

    The AIR marine 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.

  • Page 18: 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.

  • Page 19: Mounting Hub And Rotor

    CAUTION: THE BLADES ARE SHARP. USE CAUTION WHILE HANDLING THE BLADES. Remove the 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.
  • Page 20 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.

  • Page 21: Testing

    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 marine is such that it can take full advantage of the power in the wind.

  • Page 22: Bench Testing

    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.

  • Page 23: Performance Testing

    2. Connect a 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.

  • Page 24: Trouble Shooting

    AIR marine Adjustable Voltage Range 13.8v to 17.8v preset to 14.1v 27.6v to 35.6v preset to 28.2v 41.4v to 53.4v preset to 42.3v 55.2v to 71.2v 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 marine’s output voltage or amperage.
  • Page 25 It is a good idea to connect the wires from the AIR marine to 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 marine into thinking the battery is charged.

  • Page 26: Warranty Policy

    6. WARRANTY POLICY What Is Covered And For How Long For turbines 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.

  • Page 27: Specifications

    7. SPECIFICATIONS 7.1 Technical Specifications Rotor Diameter: 46 inches (1.17 meters) Weight: 13 lb. (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: 13.8v - 17.8v preset to 14.1v 27.6v - 35.6v preset to 28.2v 41.4v - 53.4v preset to 42.3v 55.2v - 71.2v preset to 56.4v...

  • Page 28: Exploded View Of Air Marine

    7.3 Exploded View of the AIR marine...

  • Page 29: Maintenance

    8. MAINTENANCE Although your AIR marine 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.

  • Page 30: Regulator Options

    GEL Cell or sealed batteries are frequently selected in applications where batteries cannot be vented or cannot be mounted in an upright position. Gel cells are cleaner 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).

  • Page 31: Siting

    55.2v 71.2v 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 marine’s internal regulator to the exact voltage specified by the battery manufacturer. Refer to Section 4.4 on page 22 for regulator adjustment instructions.

  • Page 32: Towers

    CAUTION: DO NOT APPROACH THE TURBINE FOR ANY REASON UNLESS THE ROTOR BLADES HAVE BEEN STOPPED. 11. TOWERS When determining the best location for your AIR marine keep safety and structural requirements in mind. Discuss the location with your dealer and any structural concerns with the boat manufacturer.

  • Page 33: Frequently Asked Questions

    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 marine. Can I disconnect my AIR marine without damaging it? You can disconnect your AIR marine turbine without causing any damage.
  • Page 34 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 I 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 marine in high winds.
  • Page 35 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: The AIR marine is the only turbine that uses a permanent magnet (PM) alternator that matches the cubic power of the wind.

  • Page 36: Accessories

    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 outputs. 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.

  • Page 37: References

    24 volt = 50 amp Marine Tower kits The marine tower kit is available for mounting the AIR marine on boats. The Stay Base and the Tilting Mast Base incorporate three rubber isolation mounts to reduce transmitted vibration. Contact your dealer for pricing and information.
  • Page 38 The Battery Book R. Perez Home Power Magazine P.O. Box 520 Ashland, OR 97520 (970) 475-0830 Marine Applications Boat Owners Mechanical and Electrical Manual Nigel Calder International Marine Publications, 1996 (800) 722-4726 Boat Owners Illustrated Handbook of Wiring Charlie Wing International Marine Publications (800) 722-4726 ABYC (American Boat and Yacht Council)
  • Page 39 National Electrical Codes National Electrical Code (NEC) National Fire Protection Association...

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