OWNER’S MANUAL Installation • Operation • Maintenance Primus Wind Power, Inc. 938 Quail Street Lakewood, CO 80215 USA Phone: 303.242.5820 www.primuswindpower.com 2013 Primus Wind Power, Inc.
Primus Wind Power, Inc. Congratulations on your purchase and welcome to our family! Dear AIR Owner, Thank you for your purchase of an AIR wind turbine. You have purchased the most advanced battery charging wind turbine in the world! We believe you will find it easy to install your AIR and are confident you will experience years of dependable service from it. Before going any further, please complete and return the Warranty Registration Card or register on-line at wwww.primuswindpower.com/warranty.
IMPORTANT SAFETY INSTRUCTIONS Read these instructions in their entirety before installing or operating. SAVE THESE INSTRUCTIONS. Enclosed are important instructions that must be followed during installation and maintenance. Properly torque all fasteners. Turn AIR “OFF” and contact Primus Wind Power Customer Service Department if unusual noise or operation is observed. Use grounding techniques as established by the NEC. Install turbine in accordance with this manual and local and national building codes.
Contents IMPORTANT SAFETY INSTRUCTIONS_________________________ 4 WIRING OPTIONS _________________________________________ 20-28 TECHNICAL SPECIFICATIONS_______________________________ 7 Single Turbine Installation _____________________________ 20 SITING ________________________________________________ 9 Up-Tower Junction Box________________________________ 21 TIPS FOR BATTERY BANK SIZING _____________________________ 11 Hybrid System_______________________________________ 22 Multiple Systems________
Notes __________________________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________________________ _________________________________________________________________________________________________________________
AIR Technical Specifications Model AIR 30 Weight 13 lb / 6 kg Rotor Diameter 46 in / 1.17 m Start Up Wind Speed 8 mph / 3.6 m/s Kilowatt Hours/month 30 kWh/month @ 12 mph / 5.4 m/s avg. wind speed 110 mph Maximum Wind Speed 110 mph Rated Power 160 watts @ 28 mph / 12.5 m/s wind speed Rated Power Operating Temperature Range AIR Breeze and AIR 40 are certified under IEC requirements applying to the temperature range 14º F (-10º C) to 104º F (40º C). AIR 40 is CSA certified.
EXAMPLE OF AN OFF-GRID HYBRID INSTALLATION Please Note: AC loads require an inverter AIR Owner’s Manual 8
1 1 2 2 3 3 PRIOR TO INSTALLATION Siting Tips for Permanent Installations PROPER SITING = Better Performance & Increased Longevity Look at vegetation deformation to determine best area and prevailling wind direction. Prevailing wind ATYPICAL SITING CONSIDERATIONS Prevailing wind Prevailing wind Prevailing wind 1 2 1 Coastal or Lakeside 3 1 Trees and taller structures can be down-wind.
Tower Selection and Installation Tower Selection Soil and wind conditions vary; towers and tower foundations must be designed for your specific location. Prevent tower climbing by unauthorized persons or children. Never climb without proper safety equipment. 150’ 46m 16 mph 7.3m/s 120’ 37m 15.5 mph 7 m/s 90’ 27m 14.7 mph 6.6 m/s 60’ 18m 13.5 mph 6 m/s 45‘ 14m 12.8 mph 5.7 m/s 33’ 10m 12 mph 5.4 m/s 0 0 20% 41% 75% 100% Always stop the blades before climbing the tower.
Simple Tips for Deep Cycle Battery Bank Sizing In preparation for battery sizing, know: ELECTRICAL USAGE - the amount of energy consumed 1 day in Watt-hours (Wh) DAYS OF AUTONOMY - days of battery back-up required if unable to charge the batteries by any means. DEPTH OF DISCHARGE - limit of energy withdrawal to which you will subject the deep cycle battery bank. *Deeper discharge = Shortened battery life.
ARRIVAL KIT Foam packing Nose cone & blade hub in foam packing Blades Nose cone in foam packing Hardware kit Blades Turbine DIFFERENCES FOR AIR 30: • Different blades and hub Nose cone Yaw pad Tef gel 1. 7. 2. 5. 3. Owner’s Manual 6. Blade hub 4. Hub to rotor nut 5/8-18 • 1/4-20 7/8 socket head bolts (7) • 1/4-20 Nylock nuts (7) • No flat washers 1. Extra yaw clamp bolts 2. 1/4-20 socket head bolts (4) 3. 1/4-20 Nylock nuts (4) 4. Flat washers 5. 5/16 hex wrench 6. 3/16 hex wrench 7.
TURBINE ASSEMBLY Your AIR wind turbine is delivered partially assembled. Assembly requires: 1. Mounting the blades on the blade hub. 2. Securing the hub to the turbine body. 3. Installing the nosecone on the blade hub. The necessary hex (Allen) wrenches are furnished with your AIR wind turbine. WARNING: Nylock nuts may only be used one time; replace after each use. Step 1: Blade to Hub Assembly Attach all blades to the blade hub.
Blade to Hub Assembly Assembled blade hub 3/16” 14 AIR Owner’s Manual
TURBINE ASSEMBLY Step 2: Mount Blade Hub to Turbine 5/16” Hex wrench Jam nut Blade hub Assembled blade hub Rotor shaft 1.) Coat rotor shaft threads and blade hub with Tef Gel. 1.) Insert 5/16” hex wrench in rotor shaft. 2.) Carefully and slowly “spin” the blades to completely secure the blade hub to the turbine. 2.) Slide blade hub onto rotor shaft. IMPORTANT: Tef-Gel is a corrosion inhibitor and WARNING: Don’t attempt to mount the turbine while blades are spinning.
Nose cone Yaw pivot & clamp Tower tubing Turbine assembly is now complete. 1.) Insert tower into yaw assembly. Step 4: Attach Turbine to Tower 2.) Ensure yaw pad is in place. M5 Socket head screw 5/32” (comes imbedded in yaw assembly) Hex wrench 3.) Tighten screws to secure turbine to tower. IMPORTANT: Observe torque specs. Yaw pivot & clamp Yaw pad Turbine wires 1.) Insert yaw pad into yaw pivot point/clamp assembly. 2.) NOT SHOWN: Complete turbine wiring connections.
27' AIR TOWER AIR Wind Turbine Towers 1. 2. 3. The AIR wind turbine mounts on tubing with a nominal 1.875 – 1.900 inch outside diameter. Typical tower construction use: 1 1/2 inch Schedule 40 steel pipe or 2 inch SS-20 galvanized fence tubing (0.090 inch wall thickness). DO NOT use plastic pipe to construct a tower. Tower Options Primus Wind Power offers a number of tower choices for your AIR wind turbine. The following section provides a summary of the available tower kits.
45 ft (13.7 m) Tower Kit Marine Tower Kit The 45 ft (13.7 m) Tower Kit includes tower clamp/guy wire assemblies and all necessary hardware and fasteners to erect a 45 ft tilt-up tower using Schedule 40 steel pipe or tubing with an outside diameter of 1.875 inch. See Fig. 5. The Marine Tower Kit is specifically designed to aid mounting the turbine on a boat deck. Kit includes powdercoated aluminum mast and stays, vibration damping mounts and all necessary marine grade hardware to install the kit. See Fig.
Roof Mounting Kit The Roof Mount Kit allows the pole for your AIR wind turbine to be mounted to the wall or roof truss of a structure and extend above its roofline. The kit includes isolators, base plates and all hardware, clamps and straps. Your AIR can be mounted flush to the side of the structure or via a penetrating hole through the roof or eaves. If mounted via penetrating hole, we recommend purchasing the roof mount kit with seal. See Fig. 7. Fig. 7.
AIR Wind Turbine Wiring Options The recommended way to connect the turbine to your battery bank is to wire the turbine directly to its own set of battery posts; allowing the turbine to operate independently. The AIR turbine’s internal regulator will monitor the battery and maintain the charge as necessary. AIR BREEZE Wind Turbine Generator Figs. 8 and 9 represent typical single turbine installations. Fig. 9 includes an up-tower junction box for UL (Underwriters Laboratory) compliance.
Fig. 9 represents a system with an Up Tower Junction Box. 1. Install close to the top of the tower to ease installing a Lightning Arrestor or 2. Mount close to the tower base to incorporate the stop switch. WARNING: Typically installing the box requires drilling holes in the tower – be careful not to compromise the tower strength.
Hybrid System Wiring PV Solar Array Fig. 10 represents a typical “hybrid” system with solar panels. Some charging sources (solar panels, fuel-powered generators, additional wind generators, etc.) connected to the same system may interfere with the AIR turbine’s internal charge regulation process. This will not harm the turbine, however it may spin slowly as if “braked” or may stop completley. Test for possible interference by disconnecting the other charging sources to determine the possible cause.
Multiple AIR wind turbine wiring It is possible to wire multiple AIR wind turbines together. A typical multi-turbine system is depicted in Fig. 11. AIR BREEZE Wind Turbine Generator There are two methods used to accomplish this task. AIR BREEZE Wind Turbine Generator AIR BREEZE Wind Turbine Generator Method One: (Fig. 11) Wire each turbine to a “bus” and then run one set of wires from the bus to the battery. Each turbine’s internal regulator or an external diversion type regulator may be utilized.
Wire Size All electrical systems lose energy due to resistance in the wires. • Large wires have less resistance but are more costly. • Resistance losses increase with increasing current. High wind sites will benefit from using a larger size wire to take advantage of the greater power production potential. We recommend these as the minimum wire sizes; for optimal performance use the largest wires that are practical and affordable.
12 Volt Systems, AWG / Metric Wire Size mm2 Number of Turbines: 0-30 ft (0-9 m) 30 ft-60 ft (9-18 m) 60 ft-90 ft (18-27 m) 90 ft-150 ft (27-46 m) 150 ft-190 ft (46-58 m) 190 ft-250 ft (58-76 m) 1 8/10 mm2 6/16 mm2 4/25 mm2 2/35 mm2 1/50 mm2 0/50 mm2 2 6/16 mm 4/25 mm 1/50 mm 00/70 mm 000/90 mm 0000/120 mm 3 4/25 mm2 2/35 mm2 0/50 mm2 000/90 mm2 0000/120 mm2 *** 2 2 2 2 2 250 ft-310 ft (76-95 m) 310 ft-390 ft (95-119 m) 390 ft-500 ft (119-152 m) 000/90 mm2 000/90 mm2 **
Stop Switch (Switch Kit part number 2-ARAC-101) Stop Switch Assembly Primus Wind Power recommends the use of a stop switch to provide a convenient and safe method for shutting down your AIR turbine. 1. Drill a 12 mm (0.47 inch) hole to mount the switch. 2. Screw the jam nut fully onto the switch. Item 3 in Fig. 13. 3. Place the switch in the panel and secure from the back of the panel with the rubber sleeved nut or the knurled nut. 4. Use mounting nuts to adjust the height of the switch in the panel. 5.
Fuses, Circuit Breakers and Ammeter Batteries AIR can produce high amperages. Protect your turbine with fuses or circuit breakers. Wire with an appropriate size “slow-blow” fuse or circuit breaker between AIR and the batteries. If a stop switch is used, the fuse or circuit breaker should be placed between the switch and the batteries. Deep cycle batteries are required. Types include: flooded lead acid, absorbed glass mat (AGM), gel cell and NiCad. See Simple Sizing Tips for guidelines on battery sizing.
Turbine Grounding Electrodes Driven in Soil Proper grounding of the AIR wind turbine protects people and equipment by eliminating dangerous voltage potentials. Electrodes must be a minimum of 8 ft (2.5 m) in length and free of nonconductive coatings such as paint. Hollow (pipe or conduit) electrodes must not be smaller than trade size 3/4 (metric designator 21) and must be galvanized or otherwise protected from corrosion. Solid rod electrodes must be at least 5/8 inch (16 mm) diameter.
Wire Connections to AIR wind turbine WARNING: Do not connect wires to batteries until all electrical connections are completed. Secure connections using “split bolt” or solder connectors. Use color coded wires – red for battery positive, black for battery negative, and green for earth ground. Size wiring based on wiring tables provided. Insulate connections with heat shrink tubing or good quality electrical tape.
AIR Wind Turbine Operation Operational Summary AIR converts wind to rotational motion which turns the alternator and produces electrical power. The voltage is regulated for battery charging and integrated controls prevent overcharging the batteries, allowing the turbine to continue charging as battery voltage drops. AIR also uses integrated controls to protect the wind turbine from extreme wind damage.
Braking Mode: AIR may be placed in braking mode by directly shorting the turbine positive and negative wires together or by using a stop switch. The stop switch first disconnects the turbine from the battery and then shorts the positive and negative wires. In very strong winds the blades may rotate slowly even with the switch activated. No Load Operation /Open Circuit /Free Spinning: AIR spins freely if disconnected from an electrical load.
AIR Wind Turbine Maintenance The turbine’s internal voltage regulator cannot be completely turned off; however, by setting the voltage regulation set-point to its highest value the internal regulator is virtually nullified. If an external charge controller is utilized, it must be a diversion style regulator which diverts the excess power to a resistive load. Do not use a pulse width modulated (PWM) or shunt style controller; the AIR wind turbine is not designed to work with these types of controllers.
AIR Wind Turbine Trouble Shooting Three quick bench tests can verify if your AIR wind turbine is working correctly. Test 1 does not require any equipment. For tests 2 and 3 you will need a battery bank and a power drill. TEST 1 TEST 3 1) Remove the blade/hub assembly from the turbine and place in a safe location. Replace the rotor hub nut on the rotor shaft. 1) With the AIR wind turbine connected to your battery bank, use an electric drill to spin the rotor shaft while observing the LED.
22 22 AIR AIRBreeze 40 AIR 40 AIR wind turbine Exploded Views & Parts List 21 21 20 20 AIR 40 19 19 23 23 12 12 66 33XX 11 11 24 24 22XX 13 13 14 14 18 18 22XX 25 25 10 10 55 17 17 26 26 16 16 15 15 22 99 88 77 44 11 33 33XX 33XX 33XX 33XX AIR Owner’s Manual 34
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AIR40 30 AIR AIR 40 AIR 30 Exploded Views & Parts List 22 21 21 20 22 21 20 19 18 19 20 19 23 22 24 1211 2 2X X 6 3X 6 5 5 4 3X 11 10 10 9 3X 5 23 12 2 2 XX 12 13 14 13 13 11 17 14 16 10 15 2 2 9 2 8 8 1 1 3 1 4 3X 3X 4 3 6 7 14 15 18 17 17 16 2X 2X 18 23 24 25 24 2X 25 26 25 26 16 15 9 3X 3X 7 8 3X 6X 3X 7 3X 3X 3X 3 6X AIR Owner’s Manual 36
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AIR Wind Turbine Limited Warranty What is Covered Primus Wind Power, Inc. (“Primus Wind Power”) warrants the AIR Wind Turbine against defects in factory-supplied materials and/or factory workmanship under normal authorized use consistent with the Wind Turbine’s Owner’s Manual, except for the limitations set forth in this Limited Warranty. Installation of AIR Breeze Wind Turbine constitutes acceptance of the terms and conditions of this Warranty.
AIR Wind Turbine Limited Warranty (continued) Exclusions and Limitations Primus Wind Power does not warrant that the operation of the Wind Turbine will be uninterrupted, nor does this Limited Warranty guarantee specific performance or energy production under any conditions. This Limited Warranty does not apply to claims arising from installation of your AIR Breeze Wind Turbine at improper or deficient site locations as described in the Wind Turbine’s Owner’s Manual.
AIR Wind Turbine Limited Warranty (continued) Additional Terms that Govern this Limited Warranty Each of us (i) agrees that all actions and proceedings relating directly or indirectly to this Limited Warranty shall be litigated in state or federal courts located in Jefferson County, Colorado; (ii) consents to the jurisdiction and venue of any such court and consents to service of process in any such action or proceeding by personal delivery or any other method permitted by law; and (iii) waives any and all
AIR Owner’s Manual
Primus Wind Power, Inc. 938 Quail Street Lakewood, CO 80215 USA Tel: 303.242.5820 www.primuswindpower.
