OWNER’S MANUAL Installation · Operation · Maintenance Ma Primus Wind Power, Inc. 938 Quail Street Lakewood, CO 80215 USA Phone: 303.242.5820 info@primuswindpower.com www.primuswindpower.com MADE IN THE USA 2013 Primus Wind Power, Inc. All Rights Reserved Silent AIR 40, AIR Breeze, AIR 30, AIR MaX, AIR X MARINE and AIR SILENT-X are trademarks of Primus Wind Power 2013 Primus Wind Power Inc.
CONTENT: WIRE SIZING (CONTINUED) IMPORTANT SAFETY INSTRUCTIONS…………………………….………….4 Multiple Systems Turbine Installation……………………………...22 TECHNICAL SPECIFICATIONS…………………………………………………….5 Wire Size…………………………………………………………………………..23-25 EXAMPLE OF HYBRID OFF-GRID INSTALL ………………………..……….6 Stop Switch……………………………………………………………………….26 SITING ……………………………………………………………………………..……..7 Fuses, Circuit Breakers, Ammeter …………………………………….27 TOWER HEIGHT / SAFETY TIPS ………………………………………...……..
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 AND STORAGE INSTRUCTIONS Apply Tef-Gel using applicator provided in the hardware kit to all bolts for both land and marine units. Properly torque all fasteners. Read these instructions in their entirety before installing or operating. Use grounding techniques as established by the NEC. Install turbine in accordance with this manual and local and national building codes. Failure to comply may affect and possibly void your warranty. SAVE THESE INSTRUCTIONS.
AIR Technical Specifications Model AIR 40 and AIR Breeze Weight 13 lb. / 5.9 kg Rotor Diameter 46 in / 1.17 m Start Up Wind Speed 7 mph (3.13 m/s) Kilowatt Hours/month 40 kWh/month @ 12 mph ( 5.5 m/s) Max. Wind Speed 110 mph (49.2 m/s) Rated Power 160 watts @ 28 mph (12.5 m/s) Operating Temperature Range: AIR Breeze and AIR 40 are certified under Model AIR 30, AIR X Marine and AIR Silent X Weight 13 lb. / 5.9 kg Rotor Diameter 46 in / 1.17 m Start Up Wind 8 mph (3.
EXAMPLE OF AN OFF-GRID HYBRID INSTALLATION Please NOTE: AC loads require an inverter AIR 40, AIR Breeze, AIR 30, AIR MaX, AIR X MARINE and AIR SILENT-X are trademarks of Primus Wind Power 2013 Primus Wind Power Inc.
PRIOR TO INSTALLATION Siting Tips for Permanent Installations PROPER SITING: Better Performance & In creased Longevity Look at vegeta- ATYPICAL SITING CONSIDERATIONS tion deformation to determine best area and prevailing wind direction. Coastal or Lakeside Trees and taller structures can be down-wind. VI IV Griggs-Putnam Index. *Probable mean annual windspeed. Data prepared by E.W. Hewson, J.E. Wade, and R.W.
TOWER SELECTION AND INSTALLATION Tower Selection Soil and wind conditions vary; towers and tower foundations must be designed for your specific location. Wind speed increases with height. Higher towers also raise generators above the air turbulence that can exist close to the ground. Prevent tower climbing by unauthorized persons or children. Never climb without proper safety equipment. Always stop the blades before climbing the tower.
SIMPLE TIPS FOR DEEP CYCLE BATTERY BANK SIZINING In preparation for battery sizing, know: CALCULATIONS: calculate battery bank size, use example below: ELECTRICAL USAGE - the amount of energy consumed 1 day in Watt- • A system load of 6,000 Watt-hours per day • 3 Days of Autonomy (back-up) needed • Planned Depth of Discharge (DoD): 40% • Battery bank ambient average low 15.6 °C (60 ° F) hours (Wh) DAYS OF AUTONOMY - days of battery back-up required if unable to charge the batteries by any means.
ARRIVAL KIT/PACKAGING Foam packing Nose cone & blade hub in Blades Nose cone in foam packing Hardware kit DIFFERENCES IN HARDWARE FOR AIR 30, AIR X Marine and AIR Silent X: Different blades and hub 1/4-20 7/8 socket head bolts (7) 1/4-20 Nylock nuts (7) No flat washers Hardware Kit Content for AIR 40 / AIR Breeze: • Extra yaw clamp bolts • 1/4-20 (1 3/8) socket head bolts (4) • 1/4-20 Nylock nuts (4) • Flat washers (4) • Rotor Nut (1) • • • • 5/6 hex wrench 3/16 hex wrench 5/32 hex wrench A
TURBINE ASSEMBLY WARNING: Nylock nuts and greased blade bolts may only be Your AIR wind turbine is delivered partially assembled. Assembly requires: used one time; replace after each use. 1. Mounting the blades on the blade hub 2. Securing the hub to the turbine body. and AIR X (see Appendix A for AIR Silent X installation 3. Installing the nosecone on the blade hub. The necessary hex (Allen) wrenches are furnished with your AIR wind turbine.
Blade to Hub Assembly (STEP 1) IMPORTANT: Tef-Gel is a corrosion inhibitor and is especially important in marine applications. Tef-Gel should be applied to all blade bolts and yaw bolts using the applicator and Tef-Gel provided with your hardware kit. Tef-Gel helps to prevent corrosion and lubricates threads (recommended for both land and marine usage). Tef-Gel has been applied to the top of yaw bolt threads upon pre-assembly of the yaw at the factory.
TURBINE ASSEMBLY STEP 2: Mount Blade Hub to Turbine Assembled blade hub Rotor shaft 1.) Coat rotor shaft threads and blade hub with Tef Gel. 5.) Insert 5/16” hex wrench in rotor shaft. 2.) Slide blade hub onto rotor shaft. 6.) Carefully and slowly “spin” the blades to completely secure the blade hub to the turbine. 7.) Apply the following torque when tightening the Rotor Jam Nut using torque wrench at 40 ft.lbs. / 55 Nm.
STEP 3: Attach Nose Nose cone 1.) Attach nose cone to blade hub. You will feel it snap into place. Take additional care to assure all three “tabs” of nose cone are secure and snap over the edge of the hub. 3.) Turbine assembly is now complete. 2.) Tug on nose cone to ensure it is secure. NOTE : See AIR Silent X Blade Set Instructions and Further Installation Recommendations under Appendix B WARNING: Don’t attempt to mount the turbine while blades are spinning.
STEP 4: Attach Turbine to Tower WARNING: The yaw pad is critical to ensuring proper and secure turbine mounting to the tower; however, in some instances it makes it difficult to tell if the tower is properly inserted into the yaw assembly. Check this carefully before raising the tower. IMPORTANT: Apply Tef-Gel to yaw bolts prior to assembly. Observe torque specs during assembly. A small amount of Tef-Gel has been applied to the top of yaw bolt threads for pre-assembly of the yaw at the factory. 1.
AIR WIND TURBINE TOWERS 1. The AIR wind turbine mounts on tubing with a nominal 1.875 – 1.900 inch outside diameter. 2. 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) or equivalent. 3. DO NOT use plastic pipe to construct a tower or electrical conduit. LAND 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.
AIR WIND TURBINE TOWERS (continued) 45 ft (13.7 m) 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. Note: Anchors and pipe or tubing are not furnished. MARINE TOWER KIT The Marine Tower Kit is specifically designed to aid mounting the turbine on a boat deck.
ROOF MOUNT KIT TOWER LEVELING 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. When installing a tower it is important that both the tower and turbine are properly level. If not properly leveled this can affect both performance and power output.
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 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.
TIP: It is recommended to include a lighting arrestor with your installation. See FAQ section at www.primuswindpower.com for recommendations. TIP: It is recommended for longer wire runs to utilize the 24V or 48V turbines due to reduced wire size. All AIR turbines are voltage specific and not field adjustable. AIR 40, AIR Breeze, AIR 30, AIR MaX, AIR X MARINE and AIR SILENT-X are trademarks of Primus Wind Power 2013 Primus Wind Power Inc.
HYBRID SYSTEM WIRING Fig. 10 represents a typical “hybrid” system with solar panels. Some charging sources (solar panels, fuelpowered 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 completely. 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 multiturbine system is depicted in Fig. 11 There are two methods used to accomplish this task see below: Method One (Recommended) Fig. 11: Wire each turbine as a “home run” to the bus-bar. The wire size between the bus bar and battery must be sized for the full output of ALL turbines added together. Wire sizing chart should be referenced, a ”home run” bus system typically results in reduced wire costs.
AIR WIRE SIZING All electrical systems lose energy due to resistance in the wires. • • Large wires have less resistance but are more costly. • Conversely, in low wind sites it may not be cost effective to increase the wire size. 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.
Refer back to page 22 for multiple turbine install options. It is recommended that each turbine is installed on a “home“ run per option one for best practice installation.
Refer back to page 22 for multiple turbine install options. It is recommended that each turbine is installed on a “home” run per option one for best practice installation.
(2-ARAC-101) AIR 40, AIR Breeze, AIR 30, AIR MaX, AIR X MARINE and AIR SILENT-X are trademarks of Primus Wind Power 2013 Primus Wind Power Inc.
FUSES, CIRCUIT BREAKERS AND AMPMETER 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. BATTERIES Deep cycle batteries are required. Types include: flooded lead acid, absorbed glass mat (AGM), gel cell, NiCad and Lithium Ion batteries.
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.
Tower WIRE CONNECTIONS TO AIR WIND TURBINE Cable Clamp Grounding Conductor 6 AWG minimum. Must be secured and 1 ft. (0.3 m) Grounding Wire Clamp Grounding Rod Existing Grade 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.
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 of the batteries, allowing the turbine to continue charging until the battery reaches a full state of charge. AIR also uses integrated controls to protect the wind turbine from extreme wind damage.
OPERATION SUMMARY (REGULATION MODES—continued) REGULATION FLOAT: When the battery voltage set point has been reached, the turbine enters a temporary mode called REGULATION FLOAT where the voltage is briefly monitored to confirm the high voltage readings. Depending on the code revision, the LED will either blink erratically (quick blinks followed by long blinks) or blink approximately 3 times per second.
ADJUSTING REGULATION VOLTAGE The voltage regulation set point is adjustable using the potentiometer on the side of the AIR turbine body. To accurately set the regulation voltage, disconnect the turbine from the batteries and use an adjustable voltage source (i.e. power supply) and or multi -meter to apply the desired voltage across the positive and negative turbine leads.
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.
AIR WIND TURBINE TROUBLE SHOOTING ON TOWER TROUBLE SHOOTING: With the turbine on the tower, observe the behavior of the turbine during different states of the stop switch. On a moderate to strong wind day (winds 15 mph or greater): 1.) Place the stop switch in the STOP position (or RED and BLACK wires disconnected from the battery and crossed), the turbine should spin approximately 2 revolutions per second in moderate to high winds.
BENCH TEST (continued): TEST 2 Power Up Test 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 wind turbine is connected to a battery, the LED will blink twice. The Air 40/Air Breeze LED will come on for two seconds, go off for two seconds and come back on for four seconds to indicate that the controller is running properly.
Exploded Views & Parts List AIR 40 and AIR BREEZE AIR 40, AIR Breeze, AIR 30, AIR MaX, AIR X MARINE and AIR SILENT-X are trademarks of Primus Wind Power 2013 Primus Wind Power Inc.
Exploded View Parts List—Numeric Designation ITEM NO. AIR 40 and AIR BREEZE DESCRIPTION 1 NOSE CONE 2 3 4 5 JAM NUT 5/8-18 - SS SCREW - SOCKET HEAD - 1/4-20 X 1-3/8 - SS WASHER - FLAT -1/4"- SS MACHINED - HUB - AIR 6 7 PART NUMBER QTY.
AIR 40 AND AIR BREEZE SPARE PARTS LIST (not all parts are available individually – see kits) PART NUMBER KIT DESCRIPTION EXPLOADED VIEW 3-CMBP-2015-01 NOSE CONE AIR 40 - LAND (1) 3-CMBP-2015-02 NOSE CONE BREEZE - MARINE (1) 2-ARBR-101 AIR 40 AND AIR BREEZE BLADE SET AND HARDWARE (2,3,4,6 & 7 3-CMBP-1023-06 AIR 40 AND AIR BREEZE HARDWARE KIT (2,3 & 6) 3-HDNT-912 AIR – JAM NUT – NOT SOLD INDIVIDUALLY (2) 3-CMBP-2016-01 AIR 40 HUB – LAND (5) 3-CMBP-2016-02 AIR X BREEZE MARINE HUB – MARIN
Exploded Views & Parts List AIR 30, AIR MaX, AIR X AND AIR SILENT X AIR 40, AIR Breeze, AIR 30, AIR MaX, AIR X MARINE and AIR SILENT-X are trademarks of Primus Wind Power 2013 Primus Wind Power Inc.
Exploded View Parts List - Numeric Designation ITEM NO.
AIR 30,AIR Max, AIR X MARINE AND SILENT- X MARINE SPARE PARTS LIST (not all parts are available individually – see kits) PART NUMBER KIT DESCRIPTION EXPLOADED VIEW 3-CMBP-1007-01 NOSE CONE AIR 30 - LAND (1) 3-CMBP-1007-02 NOSE CONE AIR X / SILENT X - MARINE (1) 2-ARBL-101-01 AIR 30 AND AIR X MARINE BLADE SET AND HARDWARE (2,3,5 & 6) 2-ARBL-102-01 AIR SILENT X BLADE SET AND HARDWARE KIT (2,3,5 & 6) 3-CMBP-1023-01 AIR 30, AIR X MARINE /SILENT X HARDWARE KIT (2,3 & 6) 3-HDNT-912 AIR – JAM NU
AIR WIND TURBINE FIVE YEAR (5 YR.) - LIMITED WARRANTY Length of Limited Warranty and What is Covered Primus Wind Power Inc.
AIR Wind Turbine Five Year (5 Yr.) - Limited Warranty (continued) If a warranty claim is invalid for any reason, the Customer may be charged at Primus Wind Power's and/ or the ASD's then current rate for repair services performed. In such event, the Customer will be informed of the repair charges for prior approval, and, upon approval, will be charged for the approved repairs and return freight. If the Customer refuses to approve repair charges, return freight charges may apply.
AIR Wind Turbine Five Year (5 Yr.) - Limited Warranty (continued) The In-House Repair Service Limited Warranty provides a six-month limited warranty on parts and labor quoted within the repair (warranty is only applicable with a full pre-qualification of repair needs, parts required and labor outlined within a company quote process). The In-House Repair Service Limited Warranty does not include or cover other non-authorized repairs by third party repair services.
AIR Wind Turbine Five Year (5 Yr.
APPENDIX: A Lithium Ion Battery Technical Bulletin FROM: Primus Wind Power Engineering Department RE: Potentiometer Adjustment of the Regulation Voltage for all AIR Wind Turbines and all Battery Types (including Lithium Ion batteries) The AIR turbine continually monitors battery voltage (as a bulk charging source) and compares it to the voltage regulation set point. The voltage regulation settings are preset at the factory to the values illustrated within the table in this document.
APPENDIX A (continued) Lithium Ion Battery Technical Bulletin ADJUSTING REGULATION VOLTAGE The AIR turbine enters a regulation mode when the voltage set point is reached and remains in place until the battery voltage drops to the “cut-in” voltage (which is slightly lower than voltage set point). The difference between these two (2) values is called “hysteresis” which prevents the turbine from “bouncing” in and out regulation. The hysteresis is approximately 0.6V for 12V turbines, 1.
APPENDINIX: B AIR Silent X AND AIR MaX – Multi-Color BLADE INSTALL GUIDE (Part #: 2-ARBR-103), SAFETY NOTES AND SAFETY: Wind turbine blades spin at a potentially dangerous speed. This must be respected. Danger - Never approach a turbine in motion. Utilize the stop-switch to shut down turbine and exercise caution as blade edges are sharp and pose a safety hazard. Affixing Blades: 1.) When attaching the blades, one should be aware of the torque applied to the screws. Blade edges are sharp – exercise caution.
APPENDIX B (continued) Silent Blade Assembly (for AIR MaX and AIR Silent X) AIR 40, AIR Breeze, AIR 30, AIR MaX, AIR X MARINE and AIR SILENT-X are trademarks of Primus Wind Power 2013 Primus Wind Power Inc.
APPENDIX B (continued) SILENT X and AIR MaX BLADE KIT COMPONENTS ROTOR BLADES Check if the blades show damages ( e . g . broken edges, damaged surface or cracks). you notice any damage, the generator must not be used any longer. Check blade bolt tightness one day after mounting and after that every 3-6 months. Eventually then can go to a longer NOTE: The Silent X Blade Kit (Upgrade Kit) can be retrofitted to all Primus Wind Power wind turbine models.
APPENDIX: C AIR Storage Kit, P/N 2-ARAL-ST-100 PARTS INCLUDED (in caption below): AIR 30 Hub – 3-CMBP-1005-01 AIR X Marine Nose cone – 3-CMBP-1007-02 CAUTION - When the AIR turbine is stored outdoors for an extended period, it is critical the nose cone and hub remain in place, as this prevents water infiltration through the shaft/bearing gap and into the turbine body (nacelle).
APPENDIX: D Wind Control Panel -DIGITAL (WCP-D) Primus Wind Power is pleased to offer a digital wind control panel for use with all AIR Wind Turbines (see chart below). The panel is easy to install and will result in a professional operator station enhancing the beauty and value of the Hybrid system installation. WCP-D includes a full indoor only, black plastic enclosure. Dimensions are: L - 6.5 inch / W - 4.25 inch / D - 2.5 inches.
APPENDIX D (continued) Wind Control Panel - Analog Primus Wind Power is pleased to offer a low cost analog control panel for use with AIR Breeze and AIR 40 12 VDC wind turbines. The panel is easy to install and will result in a professional operator station enhancing the beauty and value of your vessel or home installation. It helps to reduce installation costs and makes wiring a snap with just 4 wires to connect.
Primus Wind Power, Inc. 938 Quail Street Lakewood, CO 80215 USA Phone: 303-242-5820 MADE IN THE USA © 2013 Primus Wind Power, Inc. All Rights Reserved info@primuswindpower.com www.primuswindpower.com AIR 40, AIR Breeze, AIR 30, AIR MaX, AIR X MARINE and AIR SILENT-X are trademarks of Primus Wind Power 2013 Primus Wind Power Inc.
