Owner`s Manual - ENERGY FOREVER sro
Contents
1. Solar Array Am AIR BREEDE Moler PO Charge Wind Turbine Generator Controller s Am Meter 3 User Power ower Center Junction Battery Fuse Disconnect Breaker fr Tower Ground Battery Fuse or Disconnect Breaker Turbine Positive Red Lead Turbine Ground Green Lead Chassis OoOptionan Ground T Earth Ground Turbine Negative Diversion Load Black Lead Controller Battery Bank Ground Rod Resistive Load Fig 11 Hybrid System with Solar Panels Air Breeze Owner s Manual 15 5 2 Multiple Air Breeze Wiring It is possible to wire multiple Air Breeze turbines together A typical multi turbine system is depicted in Fig 12 There are two methods used to accomplish this task Method One Each Air Breeze is treated separately Each turbine will have its own wires stop switch and fuse and will connect directly to the battery using the internal regulator to control charging Method Two Wire each turbine to a bus and then run one set of wires from the bus to the battery Each turbine s inter nal regulator or an external diversion type regulator may be utilized A bus system typically results in reduced wire costs Tower AIR BREEZE Wind Turbine Generator Tower Ground Tower AIR BREEZE Wind Turbine Generator Tower Ground Tower2. pue 23 86 2002 66 M Aq 23 922 68 OWI eui Adwo Ajnj M SsjueuJeJinbeJ pue esiou JO 93 88 6002 2 L9 031 5 pum jews 34 09 26 86 eui M SMOJ OJ Se pue uBisep Aq uoun ueedoJnz jenuesse y sjeauJ SUIGUN jews ezeaJg YIV y Hed dMMS Agr ezeeJg F2 0L INgsV L dMMS Sunen ezeeJg HIY ZL 0L INgsV L Hed dMMS AZ Suey ezeeJg YIV 87 01 19 Hed dMMS pueg ezeeJg 01 19 Hed dMMS pue ezeeJg ZL OL TavV 1L Hed dMMS AZ pueg ezeeJg adh 7 MIV Ajuo 104 s Ja juJ0JUO2 JO 30 Air Breeze Owner s Manual c I PERT Southwest Windpower Inc 1801 West Route 66 Flagstaff Arizona 86001 Toll Free Phone 866 805 9463 Phone 928 779 9463 Fax 928 779 1485 E mail info windenergy com Web www airbreeze com
3. AIR BREEZE Wind Turbine Generator Tower Ground Green Lead FIN LT Green Lead FIN Green Lead olo olo Turbine Ground olo olo Turbine Ground olo olo Turbine Ground 2105 210 215 2105 215 2 5 o9 ale 55 EE Em 9 2 D D cp 9 E 2 25 ge Fuse 5 ex Fuse E Fuse Ua 8 soo 8 S Stop geo 8 S Break ene 5 switch corse 5 switch Preager 5 switch Preager O LO FN FN Fuse Amp Breaker mele N Battery Battery Bank ERES Ee Fig 12 Multiple Air Breeze Wiring Ground Tl 16 Air Breeze Owner s Manual 5 3 Wire Size All electrical systems lose energy due to resistance in conductors the wires We recommend these as the minimum wire sizes for optimal performance use the largest wires that are practical and affordable Local state and na tional electrical codes have precedence over these recommendations and Resistance losses will also increase with increasing current therefore if must be followed to ensure the safety of your system yours is a high wind site it may be worthwhile to go with a larger size wire to take advantage of the greater power production potential of your site Large wires have less resistance but can be considerably more costly Note Wiring Resistance and Regulation Depending on your exact system configuration including
4. AIR AIR 403 AIR X AIR Wind Module are trademarks of Southwest Windpower 2007 Southwest Windpower Inc Air Breeze Owner s Manual 3 One Important Safety Instructions READ THESE INSTRUCTIONS IN THEIR ENTIRETY BEFORE ASSEMBLING INSTALLING OR OPERATING YOUR AIR BREEZE 1 2 3 4 5 6 7 8 9 10 SAVE THESE INSTRUCTIONS This manual contains important instructions that must be followed during assembly installation and maintenance Read understand and respect all warnings Do not install Air Breeze on a windy day If unusual noise or operation is experienced turn off machine and contact authorized service personnel During assembly and installation properly torque all fasteners Use only proper grounding techniques as established by the NEC Properly complete the Warranty Registration Card Breeze must be installed in accordance with this manual and local and national build ing codes Failure to comply with this manual and local codes may affect and possibly void your warranty Rotating blades are a serious mechanical hazard Install Air Breeze so no one can come into contact with blades Observe wire size and fuse recommendations listed in the Wiring Section of this manual 4 Air Breeze Owner s Manual In this manual you will see the following icons 9 9 IMPORTANT Indicates instruction or advice that is critical for correct assembly or operation Damage to equipment may res
5. FACE ASSEMBLY AIR LAND CMBP 2020 02 CIRCUIT AND RECTIFIER TOTAL ASSEMBLY 24V 8 3 HDBT 1000 577 SCREW SOCKET HEAD 10 24 X 1 1 2 CMBP 2020 01 CIRCUIT AND RECTIFIER TOTAL ASSEMBLY 12V 18 FACE ASSEMBLY AIR MARINE CIRCUIT AND RECTIFIER TOTAL ASSEMBLY 48V STATOR AIR FOR 12V BREEZE 11 STATOR AIR FOR 24V BREEZE BODY ASSEMBLY AIR LAND STATOR AIR FOR 48V BREEZE BODY ASSEMBLY I AIR MARINE 3 CMBP 1313 3 HDNT 101 12 NUT JAM SAE SS Air Breeze Owner s Manual 29 Eleven EC Declaration of Conformity woo MMM 2976 641 826 YSN 10098 ZY HeIsbe 4 OOL eins 99 ISOM 1081 JowodpulM Bojouuoe 1149 pue juepisaJd 200 ez paa sii se jou 3 JO Jeuueuu e ui JO pesn si y Jo juesuoo u9juw ayy Aue ui si J 32 e oqe 94 ewy edoun3 uodxe x1euu 32 oy BuiA dde ase eAoqe y uo peseg 2002 OE 1snBny
6. Tower Grounding Tower Grounding Grounding Electrode Installation Grounding Conductor Routing and Placement Grounding Conductor Size Bonding of Grounding Conductor Six Air Breeze Installation The following are general guidelines for the installation of Air Breeze Be cause each wind turbine installation is unique specific step by step instal lation instructions cannot be provided However before attempting final installation the following basic steps should be completed Completely review Air Breeze Owner s Manual Assemble Air Breeze Blades and hub may be left off depending on tower type see Section 2 0 Turbine Assembly Select tower and tower site and install tower See Sections 3 0 and 4 0 Determine wire size See Section 5 3 Design system including batteries switches circuit breakers and ammeter Draw wiring diagram Obtain required components batteries switches circuit breakers wire tools etc Once these steps are completed final assembly is fairly simple and consists primarily of making good electrical connections according to the wiring dia gram and mounting Air Breeze on the tower 6 1 Wire Connections to Air Breeze until all electrical connections are completed WARNING Do not connect wires to batteries Connect wire leads from Air Breeze to wires to be run down the tower using split bolt or solder connectors Follow good practice and use color coded wires red f
7. or iv has been exposed to winds exceeding 120 mph 54 m s or has been subjected to abnormal physical thermal or electrical stress misuse negligence or accident If Southwest Windpower s repair facility determines that the problem with the Wind Turbine is not due to a defect in Southwest Windpower s workmanship or materials then the party requesting warranty service will be responsible for the costs of all necessary repairs and expenses incurred by Southwest Windpower Warranty Claims amp Return Procedures In order to be eligible for service under this warranty the Customer must submit a service request for Wind Turbine covered by this warranty within the warranty period by contacting Southwest Windpower in writing or via telephone and obtaining a Return Authorization RA number This RA must be obtained before returning any product under this warranty Notification must include a description of the alleged defect the manner in which the Wind Turbine was used the serial number and the original purchase date in addition to the name address and telephone number of the party requesting warranty service Within 3 business days of the date of notification Southwest Windpower will provide the Customer with an RA number and the location to which the Customer must return the defective Wind Turbine Any Wind Turbine requiring warranty shall be transported at the expense and risk of the party requiring warranty service including but not l
8. 1 50 mm 0 50 mm 00 10 mm 000 90 mm 000 90 mm If your system requires this length of wire consider using parallel wires 2 6 16mm 4 25mm2 1 50 2 00 70mm2 000 90mm 0000 190 mm ek 24 Volt Systems AWG Metric Wire Size mm Number of 0 30 ft 30 ft 60 ft 60 ft 90 ft 90 ft 150 ft 150 ft 190 ft 190 ft 250 ft 250 ft 310 ft 310 ft 390 ft 390 ft 500 ft Turbines 0 9 m 9 18 m 18 27 m 27 46 m 46 58 m 58 76 m 76 95 m 95 119 m 119 152 m 14 2 5 mm 19 4 mm 10 6 mm 8 10 mm 6 16 mm 4 50 mm 4 10 mm 4 90 mm 2 90 mm 2 12 4 mm 8 10mm _ 6 6 4 2bmm 4 25mm 2 35 2 35 mm 1 50 _ 0 50 mm 3 10 6 8 10mm _ 6 16 4 2bmm 2 35mm _ 2 35 _ 1 50 0 50mm _ 00 10 mm Air Breeze Owner s Manual 17 48 Volt Systems AWG Metric Wire Size mm Number of Turbines 0 90 ft 0 27 m 90 250 ft 27 76 m 250 310 ft 76 95 m 310 500 ft 95 152 m 1 __________ 1472 5 mm 12 4 mm 10 6 mm 8 10 mm 2d 12 4 mm 8 10 mm 6 16 mm 4 25 mm 3 10 6 mm 8 10 mm 6 16 mm 4 25 mm 5 4 Stop Switch Southwest Windpower part number 2 ARAC 101 Southwest Windpower recommends the use of a stop switch to provide a convenient method for shutting down your Air Breeze A switch is supplied with each Marine Breeze as standard equipment and is available for purchase from Southwest Windpower for the Land Breeze Install and wire the switch
9. 230 N 45 m s Value does not include safety factor SWWP recommends safety factor of 1 5 Air Breeze Owner s Manual 7 Two Air Breeze Turbine Assembly Your Air Breeze is delivered partially assembled Assembly requires mount ing 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 Breeze Torque Specifications Blade to hub screw 1 4 20 x 1 25 socket head screw 10 ft lbs 13 6 Nm Hub to rotor nut 5 8 18 50 ft lbs 68 Nm Yaw clamp bolts M5 0 8 x 35 mm 6 ft lbs 8 Nm Start the assembly by mounting the blades Item1 to the blade hub as shown in Fig 1 Place a nylock nut Item 4 in the hexagonal detent on the back of the blade hub while positioning the blade on the hub The blades must be tilted into position on the hub and can only be installed in one orientation Place a washer Item 2 on a 1 4 20 socket head screw Item 3 and coat the screw threads with Tef Gel Pass the screw through the base of the blade and screw it into the nylock nut Tighten the screw to 10 ft lbs 18 6 Nm Repeat for the remaining two blades Nylock nuts may only be used one time replace after each use Q IMPORTANT Tef Gel is a corrosion inhibitor and is especially important in marine applications If Air Breeze is to be installed on a tilt up tower mount the blade hub assembly to the turb
10. EXPRESSLY DISCLAIMS ALL LIABILITY FOR BODILY INJURIES OR DEATH THAT MAY OCCUR DIRECTLY OR INDIRECT LY BY USE OF THE PRODUCT BY ANY PERSON ALL OTHER WARRANTIES ARE EXPRESSLY WAIVED BY THE CUSTOMER Limitation of Liability UNDER NO CIRCUMSTANCES WILL SOUTHWEST WINDPOWER OR ITS AFFIL IATES OR SUPPLIERS BE LIABLE OR RESPONSIBLE FOR ANY LOSS OF USE INTERRUPTION OF BUSINESS LOST PROFITS LOST DATA OR INDIRECT SPE CIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES OF ANY KIND REGARD LESS OF THE FORM OF ACTION WHETHER IN CONTRACT TORT INCLUDING NEGLIGENCE STRICT LIABILITY OR OTHERWISE RESULTING FROM THE DE FECT REPAIR REPLACEMENT SHIPMENT OR OTHERWISE EVEN IF SOUTH WEST WINDPOWER OR ITS AFFILIATE OR SUPPLIER HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGE Note some states and provinces do not allow the exclusion or limitation of incidental or consequential damages so these limitations may not apply to you Neither Southwest Windpower nor its affiliates or suppliers will be held liable or responsible for any damage or loss to any items or products connected to powered by or otherwise attached to the hardware The total cumulative liability to Customer from all causes of action and all theories of liability will be limited to and will not exceed the purchase price of the Product paid by Customer This warranty gives the Customer specific legal rights and the Customer may also have other legal rights that vary from state to state or p
11. This adjustment changes the point at which the turbine stops charging the batteries By setting the voltage too high you may increase the probability of overcharging and dam aging the batteries 7 3 2 Using an Alternate Charge Controller There are some conditions under which the Air Breeze internal regulator is not appropriate as the primary regulator These conditions include Systems where battery temperature varies widely Battery charge efficiency varies in extreme temperatures If these condi tions 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 Batteries that are extremely sensitive to charge voltage Follow the recommendations of the battery manufacturer For most battery systems the Air Breeze internal voltage regulator is completely adequate Multiple turbines with a bus system Multiple turbine installations will typically function best using a single volt age regulator close to the battery bank This is particularly true if the wire lengths connecting each turbine to the bus vary by distance or wire gauge The Air Breeze 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 Breeze internal regu lator may be virtually eli
12. WARRANTY AGREEMENT Hardware Warranty Southwest Windpower Inc Southwest Windpower will repair or replace free of charge any part or parts of the Southwest Windpower Air Breeze Land or Marine Wind Turbine determined by Southwest Windpower to be defective in materials and or work manship under normal authorized use consistent with product instructions for a period of three years from the date the original purchaser Customer receives the Wind Turbine Start Date This warranty extends only to the original purchaser The Customer s sole and exclusive remedy and the entire liability of Southwest Windpower its suppliers and affiliates under the warranty is at Southwest Windpower s option either i to replace the Wind Turbine with new or reconditioned Wind Turbine ii to correct the reported problem or iii to refund the purchase price of the Wind Turbine Repaired or replaced products are warranted for the remainder of the original warranty period Restrictions Problems with the Wind Turbine Products can be due to improper use improper main tenance non Southwest Windpower additions or modifications or other problems not due to defects in Southwest Windpower s workmanship or materials No warranty will apply if the Wind Turbine i has been altered or modified except by Southwest Wind power ii has not been installed operated repaired or maintained in accordance with instructions supplied by Southwest Windpower iii
13. are not furnished with the kit so you have the flexibility to use the most appropriate components for the installation 29 EZ TOWER KIT Fig 4 27 ft 8 3 m Tower Kit Fig 5 29 ft 8 8 m Tower Kit Air Breeze Owner s Manual 11 4 1 3 45 ft 13 7 m Tower Kit Southwest Windpower part number 1 TWA 10 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 Note Anchors and pipe or tubing are not furnished with the kit so you have the flexibility to use the most appropriate components for the installation Fig 6 45 ft 13 7 m Tower Kit IMPORTANT User manuals for towers and tower kits are available online at www windenergy com Southwest Windpower recommends reviewing them to make an appropriate tower selection for your Air Breeze 12 Air Breeze Owner s Manual 4 1 4 Marine Tower Kit Southwest Windpower part number 1 TWA 20 02 I The Marine Tower Kit is specifically designed to aid mounting the turbine on a boat deck Kit includes powdercoated alu minum mast and stays vibration damping mounts and all necessary marine grade hardware to install the kit See Fig 7 Fig 7 Marine Tower Kit Five Air Breeze Wiring Options The recommended way to connec
14. as shown in Fig 13 A break then make switch must be used The switch first disconnects the battery and then shorts the turbine output wires together causing the turbine to stop spinning in high winds the blades may spin slowly Shorting the turbine does not cause any damage or additional wear on the unit The stop switch model offered by Southwest Windpower is sufficient for most systems but it should not be used in applications where a code compliant switch is necessary NOTE The center post must be positive from the turbine Outside posts can BLACK RED be swapped as either WIRE WIRE battery positive battery turbine negative TURBINE FUSE STOP SWITCH MARINE USE A Stop Switch is standard equipment with the Marine Breeze BATTERY 18 Air Breeze Owner s Manual Fig 13 Stop Switch Wiring Stop Switch Assembly 1 Use either the rubber sleeved nut or the knurled nut but do not use both 2 Drill 12 mm 0 4725 in hole in panel 3 The backing jam nut may be adjusted to allow the switch to mount flush with the panel 4 No larger then 8 gauge wire should be connected directly to switch Short lengths inches of 8 gauge wire may be used as a transition to larger gauge wire Eye connectors are recommended 5 Large gauge wire should be supported The switch terminals are not to bear the weight of the wire 5 5 Fuses Circuit Breakers and Ammeter Air Breeze is capable of pr
15. point voltage Air Breeze will go into regulation At that point it stops producing power and the blade rpm will lower dramati cally almost stopping Air Breeze will remain in regulation until the battery voltage drops slightly below the regulation set point this is often referred to as the cut in voltage When the cut in voltage is reached the blades will resume spinning in response to the available wind Regulation mode is indicated by the Air Breeze LED blinking at a rate of approximately twice a second Stall Mode Stall mode is marked by a dramatic reduction in turbine speed to approximately 500 700 rpm Air Breeze will enter stall mode when a wind speed of 35 mph 15 6 m s is sensed and it will remain in stall mode until the speed drops to 32 mph 14 m s If a wind speed of 50 mph 22 m s is detected the turbine will completely shut down for 5 minutes When in stall mode the Air Breeze LED will blink quickly approximately 10 times per second Braking Mode Air Breeze may be placed in braking mode by directly shorting the turbine positive and negative wires together or by the use of a stop switch The stop switch first disconnects the turbine from the bat tery 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 Breeze will spin freely if disconnected from an electrical load This res
16. c 9 OWNER S MANUAL Installation Operation Maintenance MARINE FOR LAND USE Southwest Windpower Inc 1801 West Route 66 Flagstaff Arizona 86001 Toll Free Phone 866 805 9463 Phone 928 779 9463 Fax 928 779 1485 www airbreeze com MADE IN THE USA September 2008 Southwest Windpower Inc All Rights Reserved Southwest Windpower Congratulations on your purchase and welcome to our family Dear Air Breeze Owner Thank you for your purchase of Air Breeze You have purchased the most advanced battery charging wind turbine in the world We believe you will find it easy to install your Air Breeze and are confident you will experience years of dependable service from it Before going any further please complete and return the Warranty Registration Card Note Southwest Windpower does not sell or distribute your per sonal information to any third party We understand and respect your privacy If you have any questions or comments we would like to hear from you Please call during working hours Monday Friday 8 00am to 5 00pm Arizona Standard Time Our numbers are 928 779 9463 toll free 866 805 9463 Again welcome to our family and thank you for investing in the future of wind energy with Air Breeze Sincerely Southwest Windpower Air Breeze Installation Manual Enter the serial and model numbers below Noe OMe ee Revision B Serial Number Model Number
17. d performance will be enhanced if you periodically inspect your system CAUTION Never approach the turbine during operation After one month and every six months thereafter Check blades for chips or nicks Replace blades if damaged 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 for tightness Check nosecone for cracks and proper fit Wash off any built up dirt or debris from the blades 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 in accordance with manufacturer s recommendation Southwest Windpower suggests replacing the blades and bearings every five years for optimal performance Air Breeze Owner s Manual 25 Nine Air Breeze Trouble Shooting Three quick bench tests can verify if your Air Breeze 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 1 Remove the blade hub assembly from the turbine and place in a safe location Replace the rotor hub nut on the rotor shaft 2 Attempt to quickly spin the rotor shaft with your fingers while connect ing and disconnecting the red and black wires turbine must not be connected t
18. dings 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 The minimum recommended tower height is 25 ft 7 6 m on open ground or 20 ft 6 m above nearby obstructions Fig 2 Try to locate the wind turbine in the cleanest turbulent free air as possible Turbulence will reduce the efficiency of the wind turbine and may accelerate wear on rotat ing components Prevailing wind Safety must be the primary concern when selecting the mounting location Install Air Breeze so there is no possibility of accidental contact with rotating blades even if it requires installing the wind turbine in a less than ideal location Safety has pre cedence over efficiency 9 WARNING Install Air Breeze so there is possibility of accidental contact with rotating blades even if it requires installing the wind turbine in a less than ideal location 7 20 feet 6 m Fig 2 Optimal Air Breeze location Air Breeze Owner s Manual 9 Four Air Breeze Towers The Air Breeze 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
19. hex key wrench in the turbine alternator shaft and attempting to turn the shaft while holding the blades Snap the nosecone into position over the outside edges of the blade hub Make sure all three edges of the nosecone snap over the edge of the blade hub After installation tug on the nosecone to make sure it is securely at tached Q IMPORTANT Tef Gel is a corrosion inhibitor and is especially important in marine applications 22 Air Breeze Owner s Manual 6 3 Final Connections Before making final connections to the batteries make sure circuit break ers and stop switch are in the OFF position Attach wires to battery red to positive battery terminal and black to negative battery terminal WARNING If the battery connections are reversed Air Breeze s electronics will be damaged The polarity of Air Breeze s wires may be checked by con necting a voltmeter to the wires and spinning the rotor by hand 9 Complete battery connections and switch on circuit breakers and stop switch When power is first switched on the Breeze LEDs will blink twice to indicate that the internal controller is functioning properly If there is avail able wind and Air Breeze starts charging the batteries the LED remains illuminated The installation is now complete Seven Air Breeze Operation 7 1 Operational Summary Wind turbines operate by capturing the kinetic energy of moving air the wind They convert it to rotational motion t
20. hing the tower due to lightning or electrical faults The following sections are provided as a guide to properly grounding the tower and should not be considered completely comprehensive You are encouraged to reference the National Electrical Code NEC and local building and zoning regulations for complete requirements Relevant sec tions of the National Electrical Code are referenced Tower grounding may be accomplished in several ways the most common method is a copper clad steel electrode s driven into the soil and con nected to the tower using a wire conductor 20 Air Breeze Owner s Manual 5 8 1 Electrodes Driven in Soil Electrodes should be a minimum of 8 ft 2 5 m in length and free of non conductive coatings such as paint Hollow electrodes of pipe or conduit should 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 Stainless steel rods less than 5 8 inch diameter nonferrous rods or their equivalent less than 1 2 inch diameter shall be listed by an organization having jurisdiction in the area For example UL in the USA and CSA in Canada Electrodes shall be installed such that 8 ft 2 5 m is in contact with the soil They should be driven into undisturbed soil within 1 ft of the tower founda tion Electrodes should be driven to a depth of 8 ft 2 5 m except where rock is encounte
21. imited to proper packaging of the Product The Customer must return the entire Wind Turbine kit within 30 days after issuance of the RA number Southwest Windpower will be 6 Air Breeze Owner s Manual under no obligation to accept any returned Wind Turbine that does not have a valid RA number Customer s failure to return the Wind Turbine within 30 days of its receipt of an RA number may result in cancellation of the RA All parts that Southwest Wind power replaces shall become Southwest Windpower s property on the date Southwest Windpower ships the repaired Wind Turbine or part back to the Customer Southwest Windpower will use all reasonable efforts within five days of receipt of the defective Wind Turbine to repair or replace such Wind Turbine If a warranty claim is invalid for any reason the Customer will be charged at Southwest Windpower s then current rates for services performed and will be charged for all necessary repairs and expense incurred by Southwest Windpower Disclaimer EXCEPT FOR THE EXPRESSED WARRANTY SET FORTH ABOVE SOUTHWEST WINDPOWER DISCLAIMS ALL OTHER EXPRESSED AND IMPLIED WARRAN TIES INCLUDING THE IMPLIED WARRANTIES OR FITNESS FOR A PARTICULAR PURPOSE MERCHANTABILITY AND NON INFRINGEMENT NO OTHER WAR RANTY EXPRESSED OR IMPLIED WHETHER OR NOT SIMILAR IN NATURE TO ANY OTHER WARRANTY PROVIDED HEREIN SHALL EXIST WITH RESPECT TO THE PRODUCT SOLD UNDER THE PROVISIONS OF THESE TERMS AND CON DITIONS SOUTHWEST WINDPOWER
22. ind Turbine Generator Amp User Power Meter Center Junction Battery Fuse or Stop Disconnect Breaker Switch oo gfe Turbine Positive Red Lead Turbine Ground Green Lead EUM Chassis Ground I Earth Ground 1 Hc Turbine Negative Black Lead Battery Bank T Earth Ground Fig 10 Single Turbine Installation with Up Tower Junction Box 14 Air Breeze Owner s Manual 5 1 Hybrid System Wiring Fig 11 represents a typical hybrid system with solar panels Some charg ing sources solar panels fuel powered generators additional wind generators etc connected to the same system may cause interference with the Air Breeze internal electronics and result in pre regulation The interference will not harm the turbine it will just cause it to spin slowly as if braked or it may stop the turbine If this occurs test for possible interference by disconnecting the other charging sources to determine the possible cause If possible wire the turbine and PV panels to their own set of battery posts fe TIP In this figure the Air Breeze internal regulator is used A diversion type external regulator could also have been used J TIP Voltage pre regulation may be prevented by increasing the regulation set point See section 7 3 2 J
23. ine now Coat the alternator rotor shaft threads and blade hub bore with Tef Gel and slide the hub onto the shaft Start the 5 8 18 hub nut on shaft threads and spin the hub completely onto the turbine alternator shaft Fully tighten the hub to 50 ft lbs 68 Nm by inserting a 5 16 inch hex key wrench in the turbine alternator shaft and turning the shaft while turning the blades 8 Air Breeze Owner s Manual If Air Breeze is to be installed after the tower is erected it will be safer and easier to first install the turbine body on the tower and then install the hub blade assembly This will avoid attempting to mount the turbine while the blades are spinning a dangerous condition Q WARNING Don t attempt to mount the turbine while blades are spinning Snap the nosecone into position over the outside edges of the blade hub Make sure all three edges of the nosecone snap over the edge of the blade hub After installation tug on the nosecone to make sure it is secure ly attached 1 blades 2 washer 3 1 4 20 socket head screw 4 nylock nut Fig 1 Air Breeze Blade Attachment Detail Three Air Breeze Siting Small changes in wind speed can have a dramatic effect on power produc tion The siting of your wind turbine should be carefully considered Each installation is different and is often a compromise among tower height dis tance from the battery bank local zoning requirements and obstacles such as buil
24. minated from the battery charging system If a charge controller other than the Air Breeze internal controller is uti lized it must be a diversion style regulator A diversion style regulator charges the batteries and as the batteries become charged the excess power is diverted to a resistive load This technique allows for the capture of full turbine power even after the batteries are charged Do not use a pulse width modulated PWM or shunt style control ler Air Breeze is not designed to work with these types of controllers Additionally most controllers designed to work with solar panels are not suitable for use with Air Breeze These controllers disconnect the solar panels or in this case Air Breeze from the battery bank when the bat teries are charged allowing Air Breeze to spin free which is not recom mended CAUTION Do not use pulse width modulated PWM shunt Q style controller Air Breeze is not designed to work with these types of controllers Additionally most controllers designed to work with solar panels are not suitable for use with Air Breeze These con trollers disconnect the solar panels or in this case Air Breeze from the battery bank when the batteries are charged allowing Air Breeze to spin free which is not recommended Eight Air Breeze Maintenance Although your Air Breeze has been designed to run for long periods with out requiring any maintenance reliability an
25. nductor to an earth ground Air Breeze Owner s Manual 19 The following section 5 8 describes grounding the tower in detail To ground the Air Breeze turbine body connect the Air Breeze ground green conductor to the tower ground rod Alternately the ground green conduc tor 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 If you choose to not set up an earth ground system not required for sys tems under 50 volts the Air Breeze green and black conductors MUST be connected to each other or severe damage to Air Breeze may result and void your warranty Southwest Windpower strongly recommends that boat installations be grounded according to American Boat and Yacht Council recommenda tions There are special grounding requirements for boats in particular boats that connect to shore AC power that MUST be observed or a serious shock hazard may result Contact the American Boat and Yacht Council at 410 990 4460 or visit their website at www abyc com 5 8 Tower Grounding Every wind turbine and turbine tower should be grounded at the tower base even though the system may be grounded at the battery bank or service panel by means of the yaw ground lead Grounding the tower at its base may prevent shocks to persons touc
26. ntial for acid leakage accommodated the flooded lead acid battery is typically the most economi cal choice Minimum recommended battery bank size 12 volt systems 400 Amp hours 24 volt systems 200 Amp hours 48 volt systems 200 Amp hours There are several informative web sites with battery information including www batterycouncil org e www windsun com Batteries Battery FAO htm IMPORTANT Never use automotive batteries or any battery other than a deep cycle battery 5 7 Turbine Grounding Proper grounding of the Air Breeze provides protection to individuals and equipment by eliminating the possibility of dangerous voltage potentials There are two aspects to grounding any electrical system grounding one of the conductors of the electrical system and grounding all metal structures in the system that may have a voltage potential caused by an electrical failure In a typical Air Breeze installation grounding one of the conductors is ac complished by connecting the Air Breeze negative black conductor to an earth ground close to the battery bank Installation and connection to grounding rods is described in the following section on Tower Grounding Grounding the metal structures in the system typically this includes the tower and turbine is accomplished by connecting the structures together using conductors of the same size as the positive and negative conductors and then routing a co
27. o batteries A second person may be helpful to perform this test 3 With the red and black wires connected to each other the shaft should be more difficult to turn Replace the rotor hub nut on the rotor shaft With the yaw wires disconnected it should spin freely Spinning the shaft quickly makes difference easier to detect If these conditions do not exist you should contact your turbine dealer or Southwest Windpower TEST 2 1 Remove blade hub assembly from turbine and place in a safe location 2 Connect the turbine power wires to the appropriate terminals on your battery RED Positive BLACK Negative 3 Each time the Air Breeze is connected to a battery the LED will blink two times to indicate that the controller is running properly You may need to wait 10 seconds between iterations of this test in order to let the microprocessor reset If the LED does not blink when the Air Breeze is connected to a battery you should contact your turbine dealer or Southwest Windpower 26 Air Breeze Owner s Manual TEST 3 1 With Air Breeze connected to your battery bank use an electric drill to spin the rotor shaft while observing the LED A short length cut from the 5 16 inch hex key wrench can serve as a drive if necessary 2 Below 500 RPM the rotor should spin freely and the LED should remain off 3 At 500 RPM and above the Air Breeze should be charging the bat tery There should be resistance on the rotor shaft and the LED
28. o turn an alternator that produc es electrical power The electrical power must be regulated to a voltage to charge the system batteries and there must be a system to prevent over charging 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 The Air Breeze accomplishes all these goals by incorporating a three phase brushless permanent magnet alternator and microprocessor con trolled electronics to optimize its power production capability The micro processor continuously adjusts the loading of the alternator to keep the blades operating at their optimal angle of attack The result high power production high blade efficiency and lower blade noise 7 2 Operating Modes Charging With Air Breeze connected to batteries with the voltage below the voltage regulation set point the blades will spin in response to the wind With an available wind the blades will continue to spin until the bat tery voltage matches the regulation set point Note that Air Breeze requires a minimum battery bank voltage approxi mately 10 5 volts on a 12 volt system or the controller will behave as if an open circuit condition exists Refer to Open Circuit Free Spinning section When charging the batteries the Air Breeze LED will be continu ously illuminated Regulation As Air Breeze produces power and the battery voltage rises to the regulation set
29. oducing high amperages As with all electrical installations you must protect each of your turbines with a fuse or circuit breaker Wire Air Breeze 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 Recommended Sizes for Circuit Breakers or Slow Blow Fuses e 12 volt model 20 amps DC part number 3 ELOT 1 147 03 24 volt model 10 amps DC part number 3 ELOT 1 147 02 48 volt model 5 amps DC part number S3 ELOT 1 147 01 Circuit Breakers are available from Southwest Windpower Part numbers are listed above Fig 15 Circuit Breaker Fig 16 Ammeter Amp Meter PN 2 ARAC 102 While not necessary an ammeter sometimes called an Amp Meter is an excellent addition to any system The Amp Meter allows you to monitor the current output of your turbine Place it in between your turbine and the bat tery on the positive lead It will give you instantaneous readings of output in amps 5 6 Batteries There are many battery choices available flooded lead acid absorbed glass mat AGM gel cell and NiCad The type of battery utilized will de pend largely on the battery bank location and cost For battery installations where fumes can be safely ventilated and the pote
30. or battery positive black for battery negative and green for earth ground Wires must be sized based on turbine to battery bank distance Refer to Section 5 Insulate connections with heat shrink tubing or good quality electrical tape Leave sufficient service loop in the wires to accommodate removal of the turbine from the tower Air Breeze Owner s Manual 21 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 Breeze route the wires down the tower and slide the turbine yaw over tower top After the yaw is completely low ered onto tower top lift the yaw approximately 1 8 inch 3 mm to 1 4 inch 6 mm so that the only contact between the yaw and tower top is through the rubber isolation pad This will reduce noise and vibration transmission to the tower Once the yaw is positioned on the tower secure the yaw clamp screws us ing the supplied 5 32 inch hex key wrench Torque to 5 ft Ibs 6 8 Nm If blade hub assembly is not already installed on turbine it may be installed now Position the 5 8 18 nut in the hexagonal detent at the center of the hub Coat the shaft threads and blade hub bore with Tef Gel and spin the hub completely onto the turbine alternator shaft Fully tighten hub to 50 lb ft by inserting a 5 16 inch
31. other charging sources in your system wiring resistance may affect the regulation set point of the turbine Higher wiring resistance smaller wires will tend to lower T j the voltage at which the turbine enters regulation and stops charging The The following wiring sizes provide maximum annual Energy losses of 5 or recommended wiring sizes should provide little effect on the regulation set less for sites with a 12 mph average wind speed assuming the standard point but all installations should be observed over time to ensure that the Rayleigh distribution of wind speeds which is sufficient for most sites batteries are charged to the proper voltage e Conversely in low wind sites it may not be cost effective to increase the wire size since power production will be low To determine the size wire measure the distance from the batteries to your d 3 Ref TIP Smaller wires will lower the voltage at which Air Breeze Be sure to include height of the tower efer to the appropriate the Air Breeze enters regulation and stops charging chart for your system voltage and number of turbines and select the wire size 12 Volt Systems AWG Metric Wire Size mm Number of 0 30 ft 30 ft 60 ft 60 ft 90 ft 90 ft 150 ft 150 ft 190 ft 190 ft 250 ft 250 ft 310 ft 310 ft 390 ft 390 ft 500 ft Turbines 0 9 m 9 18 m 18 27 m 27 46 m 46 58 m 58 76 m 76 95 m 95 119 m 119 152 m 8 10 mm 6 16 mm 4 24 mm 2 35 mm
32. panying caution before attempting to adjust the voltage regulation set point The most accurate method of setting the regulation voltage is to discon nect the turbine the batteries and use an adjustable voltage source and multi meter to apply the desired voltage across the positive and nega tive turbine leads With the target voltage applied turn the potentiometer fully clockwise and then slowly turn the potentiometer counter clockwise until the LED just illuminates The regulation set point will then be set to the voltage applied across the turbine leads Alternatively the regulation set point voltage may be adjusted using a trial and error method Use the accompanying chart as a guide to increase or decrease the voltage regulation set point Monitor the battery voltage over a period of time and make small adjustments until the regulation set point voltage is at the desired level 24 Air Breeze Owner s Manual Voltage Change due to 1 8 Turn of Potentiometer System Voltage Voltage Regulation Set Point Adjustment Range 12 Volt 13 6 17 0 Volts 0 56 Volts 24 Volt 27 2 34 0 Volts 1 12 Volts 48 Volt 54 4 68 0 Volts 2 24 Volts Adjustment ranges are approximate actual ranges may be greater Turn clockwise to increase voltage counter clockwise to decrease voltage CAUTION Increasing the voltage regulation set point above the initial factory Q setting will NOT increase the power output of Air Breeze
33. plastic pipe be used to construct a tower WARNING Plastic pipe should NEVER be used to construct a IMPORTANT User manuals for towers and tower kits are available online at www windenergy com Southwest Windpower recommends reviewing them to make an appropriate tower selection for your Air Breeze Fig 3 Tower Options Y 27 ft 8 3 m Tower 29 ft 8 8 Tower 10 Air Breeze Owner s Manual 4 1 Tower Options Southwest Windpower offers a number of tower choices for Air Breeze The following section provides a summary of the available towers User manuals for the towers and tower kits are available online and you are encouraged to review them in order to make the most informed tower selection See Fig 3 45 ft 13 7 m Tower 4 1 1 27 ft 8 3 m Tower Kit 4 1 2 29 ft 8 8 m EZ Tower Southwest Windpower part number 1 TWA 10 01 Southwest Windpower part number 1 TWA 11 01 The 27 ft 8 3 m Tower Kit includes a tower clamp guy wire assembly The 29 ft 8 8 m EZ Tower is a complete kit that includes all materials required and all necessary hardware and fasteners to erect a 27 ft tilt up tower to assemble a 29 ft guy wire tilt up tower Anchors guy wire assemblies galva using Schedule 40 steel pipe or tubing with an outside diameter of nized steel tubing and all fasteners are included with the kit See Fig 5 1 875 inch See Fig 4 Note Anchors and pipe or tubing
34. red then the electrode may be driven at an angle not to exceed 45 degrees from vertical Some local authorities permit burial of the electrode in a trench that is a minimum of 30 inch 76 cm deep The upper end of the electrode and its connection to the grounding con ductor should be below grade or if above ground must be protected from damage Bonding the grounding conductor to the electrode and to the tower may be accomplished by exothermic weld or by a listed mechanical connec tor Solder connections are not permitted Most local authorities require a minimum grounding conductor size of 6 AWG for copper and 4 AWG for aluminum if aluminum is permitted The grounding conductor may be buried directly or contained in conduit in either case it is important that it have no sharp bends to keep its induc tance low The accompanying figure depicts a typical tower grounding technique and the following sections of the NEC are listed for reference B N Tower Cable ClamP Grounding Conductor 6 AWG Min Must be secured and buried for protection Grounding Wire Clamp Foundation 2005 NEC Section Article 250 52 item 5 Article 250 53 item Article 250 53 item G Article 250 64 Article 250 66 item A Article 270 70 N Grounding Rod Existing Grade x j KG 02 NS Z LONG T Topic
35. rovince to province 3 CMLT 1331 REV NC 10 07 Air Breeze Technical Specifications Model Air Breeze Weight 13 lb 6 kg P ME Rotor Diameter 46 in 1 17 m ut x 7 N Start Up Wind Speed 6 mph 2 7 m s 1 Kilowatt Hours month 38 kWh month 12 mph 5 4 m s avg wind speed Maximum Wind Speed 110 mph 24 5 in radius 61 cm 1 Rated Power 160 watts 28 mph 12 5 m s wind speed 1 1 Certifications CSA certificate 1954979 x Operating Temperature Range Air Breeze is certified under IEC requirements applying to gt Pi d the temperature range 14 F 10 C to 104 F 40 C DCUM ES 12 volt and 24 volt Air Breeze wind turbines are eligible to bear the CSA mark with C and US indicators The and US indicators signify that the product has been evaluated to the applicable CSA and ANSI UL standards for use in Canada and the US Voltage Regulation Set Point factory setting 12 Volt Systems 14 1 Volts 24 Volt Systems 28 2 Volts 48 Volt Systems 56 4 Volts Regulator Adjustment Range 12 Volt Systems 13 6 to 17 0 Volts approximately 24 Volt Systems 27 2 to 34 0 Volts approximately 48 Volt Systems 54 4 to 68 0 Volts approximately Recommended Fuse Size 12 Volt Systems 20 amp slow blow 24 Volt Systems 10 amp slow blow 22 5 in 56 cm minimum safe pole length above obstructions 48 Volt Systems 5 amp slow blow Tower Loads Shaft Thrust 52 Ib 100 mph wind speed
36. should turn on If the shaft is cogging difficult to rotate contact your turbine dealer or Southwest Windpower Be sure your battery voltage is not high enough to activate the regulation mode during this test Air Breeze Owner s Manual 27 Ten Air Breeze Exploded Views amp Parts List 14 see view 2 Bly 28 Air Breeze Owner s Manual VIEW 2 20 BODY ASSSEMBLY 52 EXPLODED VIEW item item number 13 3 CAOT 1002 3 2015 01 LAND 3 CMBP 2019 01 BODY ASSEMBLY AIR BREEZE LAND 12V SEE VIEW 2 14 CMBP 2019 02 BODY ASSEMBLY AIR BREEZE LAND 24V SEE VIEW 2 3 CMBP 2015 02 NOSECONE MARINE 2 3 HDBT 1000 06 SCREW SOCKET HEAD 1 4 20 X 1 1 4 SS 3 CMBP 2019 03 BODY ASSEMBLY AIR BREEZE LAND 48V SEE VIEW 2 2019 04 BODY ASSEMBLY II AIR BREEZE MARINE 12V SEE VIEW 2 2 3 HDWA 919 WASHER AIR BREEZE SPECIAL 3 HDNT 100 13 NUT JAM SAE 5 8 18 ZINC CMBP 2019 05 BODY ASSEMBLY AIR BREEZE MARINE 24V SEE VIEW 2 BLADE AIR BREEZE LAND CMBP 2019 06 BODY ASSEMBLY AIR BREEZE MARINE 48V SEE VIEW 2 BLADE AIR BREEZE MARINE NET HUB AIR BREEZE LAND 16 YAW SHAFT AIR LAND 34 WIRES HUB AIR BREEZE MARINE 3 1004 04 YAW AIR MARINE 34 WIRES 3 3 CMBP 1013 01
37. t 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 Breeze s internal regulator will monitor the battery and maintain the charge as neces sary Figs 9 and 10 represent typical single turbine installations Fig 10 includes an up tower junction box for UL Underwriters Laboratory compliance Contact Southwest Windpower for more information about this configuration Wind Turbine Generator US TIP Wire turbine directly to battery bank to its own set of battery posts Tower Amp Meter User Power Center Junction K Box Tower Ground Battery Fuse or Stop Disconnect Breaker Switch fre Turbine Positive Red Lead Turbine Ground Green Lead i Chassis Ground hM Earth Ground H 1 Turbine Negative Black Lead Battery Bank Fig 9 Single Turbine Installation Ground Rod Air Breeze Owner s Manual 13 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 or it may be mounted close to the tower base and incorporate the stop switch Typically installing the box will require drilling holes in the tower to install the box be careful not to compromise the tower strength Up Tower AIR BREEZE W
38. ult if not heeded TIP Indicates instruction or advice that may simplify or ease task or operation WARNING Indicates risk of severe injury or death or possible severe damage to equipment proceed with caution and follow instructions LAND USE Specific to Land Use MARINE USE Specific to Marine Use 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 9 7 3 1 Adjusting Regulation Voltage 24 4 TOWERS 10 7 3 2 Using an Alternate Charge Controller 24 25 4 1 Tower Options 10 8 MAINTENANCE 25 4 1 1 27 ft 8 3 m Tower Kit 11 9 TROUBLE SHOOTING 26 4 1 2 29 ft 8 8 m Tower Kit 11 10 EXPLODED VIEWS amp PARTS LIST 28 29 4 1 3 45 ft 13 7 m Tower Kit 12 11 EC DECLARATION OF CONFORMITY 30 4 1 4 Marine Tower Kit 12 5 WIRING OPTIONS 13 14 5 1 Hybrid System Wiring 15 5 2 Multiple Air Breeze Wiring 16 5 3 Wire Size 17 18 5 4 Stop Switch 18 5 5 Fuses Circuit Breakers Ammeter 19 5 6 Batteries 19 5 7 Turbine Grounding 19 20 5 8 Tower Grounding 20 5 8 1 Electrodes Driven in Soil 20 6 INSTALLATION 21 6 1 Wire Connections 21 6 2 Mounting on Tower 22 6 3 Final Connections 22 Air Breeze Owner s Manual 5 Air Breeze 3 Year Limited Warranty WIND TURBINE
39. ults in a cycle of rapid blade speed followed by rapid braking this mode of operation may accelerate wear of the turbine and is also non productive To turn Air Breeze off for short periods of time Southwest Windpower recommends using a properly installed switch If your Air Breeze will be shut down for an extended period of time Southwest Windpower recommends lowering the turbine completely or securing the blades to prevent rotation Air Breeze Owner s Manual 23 7 3 Voltage Regulation Air Breeze 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 Breeze enters regu lation mode effectively switching off and waiting for the battery voltage to drop to the cut in voltage The cut in voltage is slightly lower than the voltage regulation set point The difference between the two values is referred to as hysteresis and is purposely done so the turbine does not bounce in and out of a single regulation set point Refer to specifications for specific voltage cut in values 7 3 1 Adjusting Regulation Voltage The voltage regulation set point is adjustable using the potentiometer on the side of Air Breeze body Please read the accom
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