Primus Wind Power Air 30, Owner'S Manual

Page 1: ...nc AIR Owner s Manual 3 CMLT 2020 A OWNER S MANUAL Installation Operation Maintenance 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 Manual Release Date October 2020 ...

Page 2: ...Tower Kit 17 Marine Tower Kit 17 Roof Mounting Kit 18 WIRING OPTIONS WIRE SIZING 19 27 Single Turbine Installation 19 Single Turbine w Up Tower Junction Box 20 Hybrid System Installation 21 WIRE SIZING CONTINUED Multiple Systems Turbine Installation 22 Wire Size 23 25 Stop Switch 26 Fuses Circuit Breakers Ammeter 27 Turbine Grounding 28 Electrodes Driven in Soil 29 AIR WIND TURBINE OPERATION 30 32...

Page 3: ...m Mountain Standard Time Our number is 303 242 5820 You can also email our Customer Service Department at info primuswindpower com Again welcome to our family and thank you for investing in the future of wind energy with a Primus Wind Power AIR turbine Sincerely Primus Wind Power Inc Enter the serial and model numbers below Serial Number Model Number The CE marking is a mandatory compliance requir...

Page 4: ...nding 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 Properly complete the Warranty Registration Card or register your product online at www primuswindpower com warranty Rotating blades are a serious mechanical hazard Install AIR wind turbines so no one can come i...

Page 5: ...kg 46 in 1 17 m 8 mph 3 59 m s 30 kWh month 12 mph 5 5 m s 110 mph 49 2 m s 400 watts 28 mph 12 5 m s CSA IEC CE AIR 30 wind turbines are eligible to bear the CSA mark with C and US indicators The C 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 ...

Page 6: ... AIR 30 AIR X MARINE and AIR SILENT X are trademarks of Primus Wind Power 2013 Primus Wind Power Inc AIR Owner s Manual 3 CMLT 2020 A 6 Please NOTE AC loads require an inverter EXAMPLE OF AN OFF GRID HYBRID INSTALLATION ...

Page 7: ...a prepared by E W Hewson J E Wade and R W Baker of Oregon State University EXCESSIVE TURBULENCE Fatigue Damage Shorter Turbine Life Prevailing wind 1 2 Excess 76 m 250 ft Turbine should be a minimum of 76m 250 ft away from and 6m 20 ft above obstacles ATYPICAL SITING CONSIDERATIONS Coastal or Lakeside Trees and taller structures can be down wind Ridge Tops Wind compresses as it blows over the top ...

Page 8: ...event tower climbing by unauthor ized persons or children Never climb without proper safety equipment Always stop the blades before climbing the tower Both falling from the tower and contact with the spinning blades can be lethal Tower height THE POWER OF THE WIND Cube of Wind Speed The wind speed is extremely important for the amount of energy a wind turbine can convert to elec tricity The energy...

Page 9: ...pplications a 25 DoD will extend battery life significantly TEMPERATURE Standard for most battery rating is 25 C 77 F Cold temperatures reduced battery capacity High temperatures shortened battery life RECOMMENDATION Keep the number of parallel strings of batteries to three or fewer one is preferred and considered best practice More than three strings of batteries risks shortening battery life due...

Page 10: ...a yaw clamp bolts 5 6 hex wrench 1 4 20 1 3 8 socket head bolts 4 3 16 hex wrench 1 4 20 Nylock nuts 4 5 32 hex wrench Flat washers 4 Tef Gel Applicator Rotor Nut 1 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 All marine AIR wind turbines contain a stop switch as part of the hardware ki...

Page 11: ...ons depicted See Figure 1 for AIR Breeze AIR 40 procedure and Figure 2 for AIR 30 procedure WARNING Nylock nuts and greased blade bolts may only be used one time replace after each use 1 AIR 30 blade hub 2 AIR 30 AIR X blade 3 1 4 20 socket head cap bolt 2 4 1 4 Nylock nut 2 Fig 2 AIR 30 AIR X Marine and AIR Silent X wind turbine Blade Attachment Detail Torque Specifications Blade to hub bolts 1 4...

Page 12: ... units it is recommended to perform tip to tip measurment of blades prior to properly securing hub to avoid vibration The hub blade root allows for adjustment of the blade position There fore it is recommended to adjust the distance between each blade tip The blades should have a distance from blade tip to blade tip approxi mately equal between all three blades and AIR X Marine IMPORTANT Tef Gel i...

Page 13: ... lbs 55 Nm 3 Start 5 8 18 jam nut on rotor shaft 4 Carefully and slowly spin the blades to begin tightening the nut IMPORTANT Observe torque specs NOTE When The Shaft and Face are exposed apply a liberal amount of synthetic grease to the gap around Shaft and Bearing on the Face of the turbine this should be performed as a regular maintenance event every 12 months See FAQ section on storage kit rec...

Page 14: ...p over the edge of the hub 2 Tug on nose cone to ensure it is secure Nose cone 3 Turbine assembly is now complete NOTE See AIR Silent X Blade Set Instructions and Further Installation Recommendations under Appendix B NOTE If the nose cone is not securely in place tabs snapping over edge of hub you may experience a clicking sound as the blades turn If this occurs you will need to press down firmly ...

Page 15: ...is is especially important when installed on boats or structures 1 Insert yaw pad into yaw pivot point clamp assembly 2 NOT SHOWN Complete turbine wiring connections 3 After assembling the yaw clamp insert yaw wires into the tower lift the yaw clamp assembly 1 8 to secure the yaw onto yaw pad to prevent metal to metal contact and reduce vibration down tower This is espe cially important when mount...

Page 16: ...ower kits are available online and you are encouraged to review them in order to make the most informed tower selection 27 ft 8 3 m Tower Kit The 27 ft 8 3 m Tower Kit includes a tower clamp guy wire assembly and all neces sary 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 3 Note Anchors and tubing are no...

Page 17: ...rnished MARINE TOWER KIT The Marine Tower Kit is specifically designed to aid mounting the turbine on a boat deck Kit includes powder coated alumi num mast and stays vibration damping mounts and all neces sary marine grade hardware to install the kit See Fig 6 Marine towers components are sold in two kits 1 Marine grade Pole and Mast Set Stay Kit 2 Marine grade hardware and mounting brackets SS Fi...

Page 18: ...ed via penetrating hole we recom mend purchasing the roof mount kit with seal See Fig 7 Fig 7 Roof Mounting Kit TOWER LEVELING 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 In addition to power output being affected there is the potential the blades could rotate in the opposite di...

Page 19: ... Ground Green Lead Earth Ground Fig 8 Single Turbine Installation 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 nec essary Figs 8 and 9 represent typic...

Page 20: ... Manual 3 CMLT 2020 A 20 TIP It is recommended for longer wire runs to utilize the 24V or 48V tur bines due to reduced wire size All AIR turbines are voltage specific and not field adjustable TIP It is recommended to include a lighting arrestor with your installation See FAQ section at www primuswindpower com for recommendations ...

Page 21: ...e regula tion process This will not harm the turbine however it may spin slowly as if braked or may stop completely Test for possible interference by dis connecting the other charging sources to determine the possible cause Contact Primus Wind Power Customer Service for guidance TIP In this figure the AIR wind turbine internal regulator is used A diversion type external regula tor could also have ...

Page 22: ... 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 Each individual turbine should have its own stop switch and breaker or Wind Control Panel Method Two Each AIR wind turbine is treated sepa rately to the breaker or wind con...

Page 23: ... practical and affordable Wire con nections e g splices etc also contribute additional resistance in the overall wire run Care should be taken to insure all connections are se cure It is recommended that turbines installed in corrosive environments e g marine saltwater should use tinned copper wiring It is also recommend ed to use stranded wire for all AIR installations green ground wire can be so...

Page 24: ... 8 10 mm2 8 10 mm2 6 16 mm2 6 16 mm2 4 25 mm2 4 25 mm2 2 12 4 mm2 10 6 mm2 8 10 mm2 6 16 mm2 4 25 mm2 2 35 mm2 2 35 mm2 1 50 mm2 0 50 mm2 3 10 6 mm2 8 10 mm2 6 16 mm2 4 25 mm2 2 35 mm2 2 35 mm2 1 50 mm2 0 50 mm2 00 70 mm2 Number of Turbines 0 30 ft 0 9 m 30ft 60ft 9 18 m 60ft 90ft 18 27 m 90ft 150 ft 27 46 m 150ft 190ft 46 58 m 190 ft 250 ft 58 76 m 250 ft 310 ft 76 95 m 310ft 390 ft 95 119 m 390f...

Page 25: ...8 10 mm2 6 16 mm2 4 25 mm2 4 25 mm2 2 35 mm2 1 50 mm2 0 50 mm2 2 10 6 mm2 6 16 mm2 4 25 mm2 2 35 mm2 2 35 mm2 1 50 mm2 0 50 mm2 00 70 mm2 00 95 mm2 3 8 10 mm2 4 25 mm2 2 35 mm2 1 50 mm2 0 50 mm2 00 70 mm2 000 95 mm2 0000 120 mm2 Number of Turbines 0 30 ft 0 9 m 30ft 60ft 9 18 m 60ft 90ft 18 27 m 90ft 150 ft 27 46 m 150ft 190ft 46 58 m 190 ft 250 ft 58 76 m 250 ft 310 ft 76 95 m 310ft 390 ft 95 119...

Page 26: ...AIR 40 AIR Breeze AIR 30 AIR X MARINE and AIR SILENT X are trademarks of Primus Wind Power 2013 Primus Wind Power Inc AIR Owner s Manual 3 CMLT 2020 A 26 2 ARAC 101 ...

Page 27: ...p Meter NOTE An optional ammeter sometimes called an Amp Meter is an excellent addition to any system It allows you to monitor the instantaneous current output of your turbine IMPORTANT Place it between your turbine and the battery on the positive lead NOTE Primus Wind Power Inc offers a combination of the above in the Wind Control Panel WCP available in both analog and digital versions These prod...

Page 28: ...ing and zoning regulations for complete requirements Relevant sections of the National Electrical Code are referenced ELECTRODES DRIVEN IN SOIL Electrodes must be a minimum of 8 ft 2 5 m in length and free of non conductive 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 corrosi...

Page 29: ...e battery connections and switch ON circuit breakers and stop switch When power is switched on the turbine LED will illuminate for two seconds go off for two seconds and illuminate for four seconds This indi cates the internal controller is functioning The LED remains illuminated if the turbine is charging the battery The installation is now complete WARNING Do not connect wires to batteries until...

Page 30: ...urbine RPM s diminish below 420 LED will turn off OVERSPEED PROTECTION In gusty or sustained high winds greater than 16 m s 35 mph AIR enters overspeed protection where the blades come to a near stop approximately two revolutions per second Depend ing on the code revision level for your turbine the turbine stops the blades near stop until restart is initiated If the wind is still high or gusty the...

Page 31: ...age 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 approxi mately 3 times per second After a short time the turbine will shift to REGULATION STOP or back to POWER MODE depending on the battery voltage readings OPEN CIRCUIT CONDITIONS AIR spins freely if disconnected from an...

Page 32: ...crease voltage USING AN ALTERNATE CHARGE CONTROLLER There are some conditions under which the AIR wind turbine s internal regu lator is not optimal as the primary regulator and instead an external diver sion load controller can be substituted These conditions include Systems where battery temperature varies widely Battery charge effi ciency varies in extreme temperatures If these conditions exist ...

Page 33: ...lace blades if damaged Do not operate the turbine with chipped or unbalanced blades This will cause severe wear dam age and possible failure Operating the wind turbine with unbalanced blades may void your warranty Do not install individual blades as they are balanced as a set Check blade bolts and hub nut for proper tightness Refer to installation sec tion for proper specifications Check nosecone ...

Page 34: ...hly two revolutions per second in any position of the stop switch i e no change in behavior between different positions of the stop switch the circuit card or possibly the stator is likely compromised 4 With the turbine spinning and the LED on solid monitor current output or battery voltage as the wind resource fluctuates If monitoring battery voltage disconnect all loads if practical to insure th...

Page 35: ...e measured using an appropriate meter measure in milli amps in addition to volts note only small amounts of current will be present until higher RPM s approximately 700 RPM are attained There should be resistance on the rotor shaft and the LED should turn on If the shaft is cogging intermittent resistance or the turbine is consuming power contact your turbine deal er or Primus Wind Power Be sure y...

Page 36: ...AIR 40 AIR Breeze AIR 30 AIR X MARINE and AIR SILENT X are trademarks of Primus Wind Power 2013 Primus Wind Power Inc AIR Owner s Manual 3 CMLT 2020 A 36 Exploded Views Parts List AIR 40 and AIR BREEZE ...

Page 37: ...ING 44MM INTERNAL 3 CAOT 1005 1 11 BEARING 6203 RLBZD SEALED SHIELDED 3 CABR 1002 1 12 WASHER WAVE SPRING 3 CAOT 1012 2 13 SPACER BEARING 3 CAOT 1010 1 14 BEARING 6203 ZZ SHIELDED 3 CABR 1001 1 15 ISOLATOR STATOR 3 CMBP 1341 1 STATOR 16 AWG 17 TURNS 3 CMBP 1019 02 16 STATOR 18 AWG 34 TURNS 3 CMBP 1019 03 1 STATOR 21 AWG 60 TURNS 3 CMBP 1019 05 17 ROTOR HP 3 CMBP 1313 1 18 SCREW TAPTITE 8 32 X 1 3 ...

Page 38: ...D MARINE FACE AND YAW BEARING KIT 10 11 12 13 14 21 23 24 25 3 CMBP 1003 01 AIR FACE ASSEMBLY 9 3 CMBP 1019 02 AIR 40 AND AIR BREEZE 12V STATOR 16 3 CMBP 1019 03 AIR 40 AND AIR BREEZE 24V STATOR 16 3 CMBP 1019 05 AIR 40 AND AIR BREEZE 48V STATOR 16 3 CMBP 1313 AIR 40 AND AIR BREEZE ROTOR SHAFT 17 2 ARCT 103 01 AIR 40 AND AIR BREEZE CIRCUIT KIT 12V BOLTS 18 19 20 21 2 ARCT 103 02 AIR 40 AND AIR BRE...

Page 39: ...40 AIR Breeze AIR 30 AIR X MARINE and AIR SILENT X are trademarks of Primus Wind Power 2013 Primus Wind Power Inc AIR Owner s Manual 3 CMLT 2020 A 39 Exploded Views Parts List AIR 30 AIR X AND AIR SILENT X ...

Page 40: ...AOT 1005 1 10 BEARING 6203 RLBZD SEALED SHIELDED 3 CABR 1002 1 11 WASHER WAVE SPRING 3 CAOT 1012 2 12 WASHER BEARING 3 CAOT 1227 2 13 BEARING 6203 ZZ SHIELDED 3 CABR 1001 1 14 ISOLATOR STATOR 3 CMBP 1341 1 15 STATOR 16 AWG 10 TURNS 3 CMBP 1019 01 1 STATOR 16 AWG 17 TURNS 3 CMBP 1019 02 STATOR 18 AWG 34 TURNS 3 CMBP 1019 03 16 ROTOR HP 3 CMBP 1313 1 17 SCREW TAPTITE 8 32 X 1 3 HDBT 9000 2 18 CIRCUI...

Page 41: ...RINE SILENT X 12V STATOR 15 3 CMBP 1019 02 AIR 30 AIR X MARINE SILENT X 24V STATOR 15 3 CMBP 1019 03 AIR 30 AIR X MARINE SILENT X 48V STATOR 15 3 CMBP 1313 AIR 30 AIR X MARINE SILENT X ROTOR SHAFT 16 2 ARCT 101 03 AIR 30 AIR X MARINE SILENT X CIRCUIT KIT 12V BOLTS 17 18 19 20 2 ARCT 101 05 AIR 30 AIR X MARINE SILENT X CIRCUIT KIT 24V BOLTS 17 18 19 20 2 ARCT 101 06 AIR 30 AIR X MARIINE SILENT X CI...

Page 42: ...ion document does not reduce a Customer s eligibility to receive warranty service the Customer will be required to provide proof of own ership and original purchase including a copy of the original receipt and date of purchase or installation satisfactory to Primus Wind Power prior to receiving warranty services All Customer warranty claims must be received by Primus Wind Power during the Warranty...

Page 43: ...itable power source voltage irregularities or utility system failures that enter the Wind Tur bine through the output side vi damage caused by acts of God including flood fire earthquake lightning hail damage flying de bris wind speeds in excess of 120 mph tornadoes hurricanes or other cyclonic windstorms abnormal physical stress abnormal thermal stress misuse negligence accident abuse or vandalis...

Page 44: ...DURA TION AND SCOPE TO THE DURATION AND SCOPE OF THE APPLICABLE EXPRESS LIMITED WARRANTIES HEREIN Primus Wind Power does not grant to any person or entity including its field representatives dealers or distributors including the ASDs the authority to create for Primus Wind Power any obligation or liability in connection with any Wind Turbine Limitation of Liability EXCEPT AS PROVIDED IN THIS EXPRE...

Page 45: ...e are intended to be mandatory PRIMUS WIND POWER AND CUSTOMER FURTHER EACH WAIVE THE RIGHT TO TRIAL BY JURY IN ANY ACTION OR PROCEEDING BASED UPON ARISING OUT OF OR IN ANY WAY RELAT ING TO THE SALE OF PRIMUS WIND POWER PRODUCTS OR THIS LIMITED WARRANTY This Limited War ranty may not be extended altered or waived except in writing signed by an authorized officer of Primus Wind Power ANY ACTION FOR ...

Page 46: ... per the battery manual utilized The AIR turbines will function properly using all battery types if the above considerations are taken into account Adjustments to the regulation voltage set point may be avoided considering the following the larger the battery bank and more consistent voltage load the less likely the need for any adjustments to the regulation voltage set point All LI Batteries have...

Page 47: ...y off turn the potentiometer screw fully clockwise Then turn on the power supply verify two 2 blinks of the LED on the turbine and then turn the potentiometer screw counterclockwise very slowly until the LED begins blinking The regulation set point is now fixed to the voltage applied across the turbine leads Alternatively the regulation set point voltage may be adjusted using a trial and error met...

Page 48: ...ful Links for Blade Nose Cone and Hub install www primuswndpower com info primuswindpower com 303 242 5820 Primus Support Under Support tab Service and Repair Affixing Blades continued The recommended torque on the screws is 7 8 Nm 62 71 in lbs This is equiv alent to a weight of 7 8 kg 15 432 17 637 lbs on a 10 cm 3 94 in long lever arm applied perpendicular to the lever arm If the fastening torqu...

Page 49: ...AIR 40 AIR Breeze AIR 30 AIR X MARINE and AIR SILENT X are trademarks of Primus Wind Power 2013 Primus Wind Power Inc AIR Owner s Manual 3 CMLT 2020 A 49 APPENDIX B continued Silent Blade Assembly ...

Page 50: ...new hub eliminates the need to any tip to tip measurements of the blade Included with each blade set is a washer for behind hub and rotor shaft This washer is an optional install and only should be used if there is rubbing from hub to AIR turbine Face that impedes free movement of rotor hub Most AIR installs will not require this washer NOTE In addition to the washer you will find Tef Gel and appl...

Page 51: ...ved there is a high probability that water infiltration will occur and the nacelle interior will rust causing damage This will not be covered un der the Primus Wind Power warranty To avoid this potential issue Pri mus Wind Power offers the AIR Storage Kit INSTRUCTIONS When storing your turbine remove the Blade Hub Nose Cone Assembly and store in safe location to not damage blade set When The Shaft...

Page 52: ... 5 models specific to the AIR Wind Turbine voltage and type The WCP D controls and monitors the wind turbine It is equipped with a power On Off circuit breaker digital meter and a Stop Run switch for direct con trol of the turbine The digital meter equipped with a 50 amp shunt provides critical operational information real time battery voltage current in amps power in Watts and accumulated energy ...

Page 53: ...rsion that will support 12 volt systems for AIR Breeze or AIR 40 Wind Turbines The WCP controls and monitors the wind turbine It is equipped with a power On Off circuit breaker analog ammeter indicating wind turbine current pro duction and a Stop Run switch for direct control of the turbine A clearly marked rear terminal block is provided for easy interconnect of the two turbine wires and two batt...

Page 54: ... Primus Wind Power 2013 Primus Wind Power Inc AIR Owner s Manual 3 CMLT 2020 A 54 MADE IN THE USA 2013 Primus Wind Power Inc Primus Wind Power Inc 938 Quail Street Lakewood CO 80215 USA Phone 303 242 5820 info primuswindpower com www primuswindpower com All Rights Reserved ...