Air X OWNER’S MANUAL Installation • Operation • Maintenance Primus Wind Power 938 Quail Street Lakewood, CO 80215 303-242-5820 All Rights Reserved
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.
One - Important Safety Instructions REAd ThESE INSTRuCTIONS IN ThEIR ENTIRETy bEfORE ASSEMblINg, INSTAllINg OR OPERATINg yOuR AIR X 1) SAVE THESE INSTRUCTIONS. This manual contains important instructions that must be followed during assembly, installation and maintenance. 2) Read, understand and respect all warnings. 3) Do not install Air X on a windy day. 4) If unusual sound or operation is experienced, turn off the machine and perform an inspection.
Contents 1) IMPORTANT SAfETy INSTRuCTIONS __________________ 4 7) AIR bREEzE OPERATION _____________________________ 23-25 WARRANTy _________________________________________ 6 7-1 Operational Summary _____________________________ 23 TEChNICAl SPECIfICATIONS ________________________ 7 7-2 Operating Modes ________________________________ 23 2) TuRbINE ASSEMbly ________________________________ 8 7-3 Voltage Regulation _______________________________ 24 3) SITINg_________________________________________
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 energy production under any conditions. This Limited Warranty does not apply to claims arising from installation of your AIR 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 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 rights either of us may have to object to the jurisdiction of any such court, or to tran
Air X Technical Specifications Model Air X 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 38 kWh/month @ 12 mph / 5.4 m/s avg. wind speed Maximum Wind Speed 110 mph Rated Power 400 watts @ 28 mph / 12.5 m/s wind speed Certifications: CE 24.5 in radius (61 cm) Voltage Regulation Set Point (factory setting) 12 Volt Systems 14.1 Volts 24 Volt Systems 28.2 Volts 48 Volt Systems 56.
Two - Air X Turbine Assembly Your Air X is delivered partially assembled. Assembly requires mounting the blades on the blade hub, securing the hub to the turbine body and installing the nosecone on the blade hub. The necessary hex key (Allen) wrenches are furnished with Air X. Torque Specifications: Blade to hub bolts, 1/4-20 x 1.25 inch, Socket Head Bolt, 7.0 lb-ft (9.4 N·m) Hub to rotor nut, 5/8 -18 inch, Jam nut, 50 lb-ft (68 N·m) Yaw Clamp Bolts, M5 x 35 mm, Socket Head Bolt, 4.0 lb-ft (5.
Three - Air X Siting Small changes in wind speed can have a dramatic effect on power production. The siting of your wind turbine should be carefully considered. Each installation is different and is often a compromise among tower height, distance from the battery bank, local zoning requirements and obstacles such as buildings and trees. In general the higher the tower, the greater the wind speed and ultimately power production. However, towers are expensive and can easily exceed the cost of the turbine.
Four - Air X Towers The Air X is designed to mount on tubing or pipe with a nominal 1.875 – 1.900 inch outside diameter. This dimension enables constructing a tower from a range of readily available materials including 1 1/2 inch Schedule 40 steel pipe and 2 inch SS-20 galvanized fence tubing (0.090 inch wall thickness). Under no circumstances should plastic pipe be used to construct a tower. 4-1 Tower Options Primus Wind Power offers a number of tower choices for Air X.
4-1-1 27 ft (8.3 m) Tower Kit 4-1-2 29 ft (8.8 m) Ez – Tower The 27 ft (8.3 m) Tower Kit includes a tower clamp/guy wire assembly and all necessary hardware and fasteners to erect a 27 ft tilt-up tower using Schedule 40 steel pipe or tubing with an outside diameter of 1.875 inch. See fig. 4. The 29 ft (8.8 m) EZ Tower is a complete kit that includes all materials required to assemble a 29 ft guy wire tilt-up tower.
4-1-3 45 ft (13.7 m) Tower Kit 4-1-4 Marine Tower (Primus Wind Power marine aluminium pole set kit, part number 1-TWA-20-02 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. 6.
Five - Air X 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. This will allow the turbine to operate independently. The Air X’s internal regulator will monitor the battery and maintain the charge as necessary. Figs. 9 and 10 represent typical single turbine installations. Fig. 10 includes an up-tower junction box for National Electric Code compliance.
Fig. 10 represents a system with an Up Tower Junction Box. The junction box may be installed close to the top of the tower to ease installing a Lightning Arrestor. Typically installing the box will require drilling holes in the tower to install the box – be careful not to compromise the tower strength.
5-1 Hybrid System Wiring PV Solar Array Fig. 11 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 cause interference with the Air X internal electronics and result in preregulation. The interference will not harm the turbine; it will just cause it to spin slowly as if “braked” or it may stop the turbine.
5-2 Multiple Air X Wiring It is possible to wire multiple Air X turbines together. A typical multi-turbine system is depicted in Fig. 12. Air XBREEZE AIR Wind Turbine Generator Air XBREEZE AIR Wind Turbine Generator There are two methods used to accomplish this task.
5-3 Wire Size All electrical systems lose energy due to resistance in conductors. We recommend these as the minimum wire sizes; for optimal performance use the largest wires that are practical and affordable. Local, state, and national electrical codes have precedence over these recommendations and must be followed to ensure the safety of your system. • Large wires have less resistance but can be considerably more costly.
Volt Systems, AWG / Metric Wire Size mm2 Number of Turbines: 0- 0 ft (0-2 m) 0 -2 0 ft (2 - m) 2 0 - 10 ft ( - m) 10 - 00 ft ( -1 2 m) 1 14/2.5 mm 12/4 mm 2 10/6 mm 8/10 mm2 2 12/4 mm2 8/10 mm2 6/16 mm2 4/25 mm2 10/6 mm2 8/10 mm2 6/16 mm2 4/25 mm2 2 2 5-4 Stop Switch 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 X.
5-5 Fuses, Circuit Breakers and Ammeter 5-6 Batteries Air X is capable of producing high amperages. As with all electrical installations, you must protect each of your turbines with a fuse or circuit breaker. Wire Air X with an appropriate size “slow-blow” fuse or circuit breaker between it and the batteries. Refer to installation figures at the start of Section 5. If a stop switch is used, the fuse or circuit breaker should be placed between the switch and the batteries.
The following section (5-8) describes grounding the tower in detail. To ground the Air X turbine body, connect the Air X ground (green) conductor to the tower ground rod. Alternately the ground (green) conductor may be connected to the negative (black) conductor in which case it will be grounded through the battery bank ground rod. Refer to figures 9 through 12. Note that all system grounds should be connected using conductors of the same size as the positive and negative wires.
Six - Air X Installation The following are general guidelines for the installation of Air X. Because each wind turbine installation is unique, specific step-by-step installation instructions cannot be provided. However, before attempting final installation the following basic steps should be completed: • Completely review Air X Owner’s Manual. • Select tower and site and install tower. See sections 3.0 and 4.0. • Determine wire size. See Section 5.3.
6-3 Final Connections Follow system wiring diagram and run wires to disconnect switch, fuse or circuit breaker and ammeter. If a stop switch is utilized (highly recommended) turn switch to OFF until all connections are completed. 6-2 Mounting on Tower After wires are connected to Air X, route the wires down the tower and slide the turbine yaw over tower top.
Seven - Air X Operation 7-1 Operational Summary Wind turbines operate by capturing the kinetic energy of moving air: the wind. They convert it to rotational motion to turn an alternator that produces electrical power. The electrical power must be regulated to a voltage to charge the system batteries, and there must be a system to prevent overcharging the batteries and resume charging as the battery voltage drops. A means to protect the wind turbine from extreme wind damage must also be provided.
7-3 Voltage Regulation Air X continually monitors the battery voltage and compares it to the voltage regulation set point. Refer to specifications for voltage regulation set points. The voltage regulation set points are factory set to the values listed in the specifications. These values may be adjusted to suit individual applications. When the voltage regulation set point is achieved, Air X enters regulation mode – effectively switching off and waiting for the battery voltage to drop to the cut-in voltage.
The Air X internal voltage regulator cannot be completely turned off; however, by setting the voltage regulation set-point to its highest value (potentiometer turned completely clockwise), the Air X internal regulator may be virtually eliminated from the battery charging system. If a charge controller other than the Air X internal controller is utilized, it must be a diversion style regulator.
Nine - Air X Trouble Shooting Three quick bench tests can verify if your Air X 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. These tests are to be performed with the turbine off the tower, using only the turbine wire leads, so that no other connections or components are present. 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.
AIR X AIR 40 AIR X Exploded Views & Parts List 22 21 21 20 22 21 20 19 18 19 20 19 23 22 24 2X 1211 2 X 6 3X 6 11 10 10 9 3X 5 5 3X 5 23 12 2 X2 X 12 13 14 13 13 11 17 14 16 10 4 15 2 2 9 2 8 8 7 4 1 1 3 1 3X 3 6 3X 4 14 15 2X 24 25 24 2X 18 17 17 16 18 23 2X 25 26 25 26 16 15 9 3X 3X 7 8 3X 6X 3X 7 3X 3X 3X 3 6X Air X Owner’s Manual 29
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