The New 400 watt turbine! Owner’s Manual Wind Turbine Serial Number ___________________________________
AIR-X Land Manual Document #0056 REV D 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.
AIR-X Land Manual Document #0056 REV D 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-X; 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 five years, over 45,000 AIRs have been sold throughout the world.
AIR-X Land Manual Document #0056 REV D New Features of the AIR-X The AIR-X is the latest evolution of the AIR series of wind turbines from Southwest Windpower. From the outside, the AIR-X looks almost identical to the AIR 303 and AIR 403. The improvements are almost all inside the turbine. The AIR-X Features: • New Electronics: The AIR-X incorporates an entirely new rectifier and controller.
AIR-X Land Manual Document #0056 REV D Table of Contents 1. Safety Precautions……………………………………………………….. 6 1.1 Mechanical Hazards 6 1.2 Electrical Hazards 6 1.3 Installation 7 1.4 Operation 7 2. Package Contents………………………………………………………… 8 3. Wiring and Installation Procedures……………………………………. 9 3.1 Wiring………………………………………………………………….. 9 3.1.1 Electrical Connections 9 3.1.2 Wire Size 10 3.1.3 Grounding 11 3.1.4 Fusing 12 3.1.5 Stop Switch 12 3.1.6 System Wiring Diagrams 13 3.
AIR-X Land Manual Document #0056 REV D 1. SAFETY PRECAUTIONS The AIR-X 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.
AIR-X Land Manual Document #0056 REV D 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-X UPSIDE DOWN. Please follow these precautions during the installation process: • Choose a calm day. • THINK SAFETY! Have someone available to help during the installation process. • Disconnect batteries from turbine wiring.
AIR-X Land Manual Document #0056 REV D 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.
AIR-X Land Manual Document #0056 REV D 3. WIRING AND INSTALLATION PROCEDURES Your AIR-X is shipped partially disassembled. Refer to Figure 7 on page 19 for assembly instructions. Please completely read all procedures before beginning installation.
AIR-X Land Manual Document #0056 REV D AWG SIZE X-Section Area [in2] 14 12 10 0.004 0.005 0.008 8 0.013 6 0.021 4 0.033 3 0.041 2 0.052 1 0.069 0 0.083 2/0 0.105 3/0 0.132 4/0 0.166 X-Section Area [mm2] 2.68 8.37 13.3 21.1 26.7 33.6 44.2 53.5 67.4 85.0 107 3.31 5.26 Wire Color Codes RED = positive BLACK = negative GREEN = earth ground 3.1.
AIR-X Land Manual Document #0056 REV D 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: Average Wind Speed 9mph / 4m/s 10mph / 4.5 m/s 11mph /4.9 m/s 12mph / 5.4 m/s 13mph / 5.8 m/s 14mph / 6.3 m/s Multiplier for Wire LENGTHS 2 1.5 1.25 1 0.8 0.
AIR-X Land Manual Document #0056 REV D 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) 2671000 Fax (915) 267-1035 or your dealer for more information. 3.1.4 Fusing The AIR-X 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.
AIR-X Land Manual Document #0056 REV D If you need a code compliant switch and the voltage of your turbine is 12V, or you have a 12V turbine being used in a very high wind application, then please contact Southwest Windpower for an appropriate switch. Southwest Windpower will be able to recommend the best switch for this application. 3.1.
AIR-X Land Manual Document #0056 REV D Choose the appropriate suggested wiring diagram below for proper wiring information. A.
AIR-X Land Manual Document #0056 REV D B.
AIR-X Land Manual Document #0056 REV D C.
AIR-X Land Manual Document #0056 REV D D.
AIR-X Land Manual Document #0056 REV D 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 damage the circuit inside the turbine and void your warranty. 3.2 Mounting To Tower The AIR-X is designed to be mounted on tubing or pipe with a 1.875 inch (48mm) outside diameter. This is equivalent to 1 ½ inch SCH 40 pipe, which can be used in some tower applications.
AIR-X Land Manual Document #0056 REV D 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/hub assembly on the turbine until the turbine is mounted on the tower. Regulation Set Point Adjustment Screw Figure 7 NOTE: DO NOT PRESS THE ROTOR SHAFT INTO THE TURBINE WHEN MOUNTING THE BLADE ASSEMBLY. 3.3.
AIR-X Land Manual Document #0056 REV D Please note that over-torque of blades may cause damage to the blade and compromise the safety of the product. NOTE: TORQUE THE BLADE BOLTS TO 8 – 10 FOOT-LBS (10.8 – 13.6 Nm). DO NOT OVER-TORQUE. NOTE: You may need to “thread” the screws through the hub with the hex wrench. 3.3.2 Mounting the Hub and Rotor CAUTION: THE BLADES ARE SHARP. USE CAUTION WHILE HANDLING THE BLADES. Remove the 5/8” nut from the alternator shaft.
AIR-X Land Manual Document #0056 REV D CAUTION: IF THE WIRES ARE HOOKED-UP BACKWARDS YOU WILL DAMAGE THE AIR-X’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-X, gently pull the wires down through the tower sliding the yaw shaft over the 1 1/2“, Schedule 40 steel pipe (Actual OD 1.875 inches, 48mm). Do not use plastic pipe.
AIR-X Land Manual Document #0056 REV D 4. TESTING 4.1 General Discussion of Operation The available energy in the wind scales with 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-X is such that it can take full advantage of the power in the wind. The efficiencies of other wind turbines are usually linear and cannot take advantage of the cube effect of the wind.
AIR-X Land Manual Document #0056 REV D 4.1.3 Over-speed Protection All wind turbines must have some form of over-speed protection in order to survive high winds. Most small wind turbines rely on a mechanical method of bending or tilting out of the wind. The AIR 403 was unique in using aero-elastic twist or blade “flutter” for over-speed protection. The flutter design had the advantage of simplicity and reliability, but had the strong disadvantage of noise.
AIR-X Land Manual Document #0056 REV D In regulation mode, the AIR-X controller will blink the LED 10 times each second (fast blink). d) Stall Mode Stall mode is the over-speed condition described in section 4.1.3. In stall mode, the RPM will drop between 500 and 700 RPM, depending on the exact wind speed. Above 50 mph, the turbine will shut off completely and the RPM will slow to almost zero. In stall mode, the AIR-X controller will blink the LED two times each second (slow blink).
AIR-X Land Manual Document #0056 REV D 2. Below 500 RPM, the rotor should spin freely and the LED should remain off. 3. At 500 RPM and above, the AIR-X should be charging the battery. You should begin to feel some resistance on the rotor shaft and the LED should turn on. The shaft should have a slight resistance to rotation, but should still rotate fairly easily. If the shaft is cogging (difficult to rotate), contact your turbine dealer or Southwest Windpower.
AIR-X Land Manual Document #0056 REV D AIR-X Adjustable Voltage Range 12v 13.6v to 17.0v preset to 14.1v 24v 27.2v to 34.0v preset to 28.2v READ THIS BEFORE YOU CONSIDER ADJUSTING THE REGULATION SETPOINT Turning “up” the regulation set point adjustment will NOT increase the AIR-X’s output voltage or amperage. It simply adjusts the “shut down” point for the generators’ voltage regulator.
AIR-X Land Manual Document #0056 REV D 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.
AIR-X Land Manual Document #0056 REV D 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.
AIR-X Land Manual Document #0056 REV D 7. SPECIFICATIONS 7.1 TECHNICAL SPECIFICATIONS Rotor Diameter: Weight: Start up wind speed: Rated Power: Regulator Set Range: Recommended Fuse Size: Yaw Wire Size: Pole Dimensions: SOUTHWEST WINDPOWER 46 inches (1.17 meters) 13 lb. (6kg) 7 mph (3.0 m/s) 400 watts at 28 mph (12.5 m/s) 12v 13.6V – 17.0V preset to 14.1v 24v 27.2V – 34.0V preset to 28.2v 12v - 50 amps slow-blow 24v - 30 amps slow-blow #10 AWG (American Wire Gage) stranded.
AIR-X Land Manual Document #0056 REV D 7.2 PERFORMANCE SPECIFICATIONS The following curve shows the performance you should expect from your AIR-X wind turbine. The AIR-X is rated with a “band-width” of power for a given wind speed. This is an attempt to cover the variability in turbine output due to different levels of wind turbulence. During smooth, steady wind, you should expect to see outputs along the upper curve. During turbulent wind conditions, the power output could drop towards the lower curve.
AIR-X Land Manual Document #0056 REV D 7.3 Sphere of Operation 7.
AIR-X Land Manual Document #0056 REV D 8. MAINTENANCE Although your AIR-X 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.
AIR-X Land Manual Document #0056 REV D Flooded 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. Absorbed Glass Mat or AGM batteries utilize a fiberglass mat saturated with sulfuric acid.
AIR-X Land Manual Document #0056 REV D 9.2 Regulator Options The internal electronics protect you and your batteries from excess voltage from the AIR-X, they control the turbine rotor RPM, and serve as a sophisticated 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 “stop” the turbine from charging.
AIR-X Land Manual Document #0056 REV D for extended periods of time. 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-X 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.
AIR-X Land Manual Document #0056 REV D Figure 9 SOUTHWEST WINDPOWER 10/09/2002 36
AIR-X Land Manual Document #0056 REV D 11. TOWERS There are 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.
AIR-X Land Manual Document #0056 REV D 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.
AIR-X Land Manual Document #0056 REV D 12. FREQUENTLY ASKED QUESTIONS These frequently asked questions are subdivided into six categories for ease of reference: General Operation, Installation, Accessories, Wiring, Batteries, and Radio Interference. Please take the time to read through ALL of the questions, and you will have a better understanding of the features and operation of your AIR 403.
AIR-X Land Manual Document #0056 REV D The microprocessor in the AIR-X constantly monitors turbine RPM, and is programmed to stall the blades in high winds. The blades are put into a low efficient region which drops the turbine to roughly ¼ of its peak RPM. This allows the turbine to survive high wind events with low mechanical stresses.
AIR-X Land Manual Document #0056 REV D batteries BEFORE being connected to negative. It is important that your stop switch be of the type that opens the circuit between positions. This is commonly referred to as a “break-before-make” switch. Be sure to install a fuse in any case. #11 How do I know the AIR is charging? For a precise indication of charge current you will need to install an amp meter in your system. The meter or meter shunt should be installed in-line on the positive wire.
AIR-X Land Manual Document #0056 REV D are used. If your turbines are at various distances from the batteries, make sure turbines with longer wire runs have bigger wires. There will be some variation at what voltage turbines will enter into regulation based on the relative wind to which each turbine is exposed. Small differences in line loss can be significant in strong winds.
AIR-X Land Manual Document #0056 REV D output power drops off to about 75 watts. The wiring could be sized for the maximum current output of the turbine, but this output is seen primarily in gusty conditions. We have recommended wire sizes that are intentionally small to save the customer from spending a lot of money on wiring, while still experiencing no more than a 5% annual energy loss due to resistive line losses.
AIR-X Land Manual Document #0056 REV D in amp-hours and have some indication of the number of charge-discharge cycles that are available. Beware of the dubious claims of “deep-cycle” claimed by the manufacturers of inexpensive batteries. #27 Why shouldn’t I use automotive batteries in my DC system? Automotive batteries are meant to discharge a large amount of current in a very brief time. The lead plates are thinner and often porous to allow rapid discharge.
AIR-X Land Manual Document #0056 REV D 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. A stop switch is not necessary, but most customers find it very useful.
AIR-X Land Manual Document #0056 REV D Guyed tower Kits We offer 27’ (8.2 m) and 45’ (13.7 m) guyed towers. These towers are relatively low cost and easy to install. Contact your dealer or Southwest Windpower for pricing and product information. You can call Southwest Windpower toll free at (866) 805-9463 or visit our website at http://www.windenergy.com.
AIR-X Land Manual Document #0056 REV D 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, PA Batteries The Battery Book R. Perez Home Power Magazine P.O. Box 520 Ashland, OR 97520 (970) 475-0830 Websites http://www.batterycouncil.org http://www.
AIR-X Land Manual Document #0056 REV D 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 Renewable Energy Lab (NREL) 1617 Cole Blvd Golden, CO 80401-3393 (303) 275-3000 http://www.nrel.gov National Technical Information Service United States Department of Commerce 5285 Port Royal Rd.
