Superwind 350 12V & 24V Manual

North, Central, & South American Regions

09-2016

www.superwind.com
 Table of Contents
Section Page No.

OVERVIEW ............................................................................................................................ 4

1. GENERAL INFORMATION AND REFERENCES

1.1. Company profile ............................................................................................... 5
1.2. Labelling ........................................................................................................... 5
1.3. Range of application.......................................................................................... 6

2. WARRANTY
2.1. Warranty ............................................................................................................ 7
2.2. Warranty period ................................................................................................. 7
2.3. To obtain warranty service ................................................................................ 7
2.4. Limitations ......................................................................................................... 7
2.5. Others ................................................................................................................ 7
2.6. Expenses and Responsibilities ......................................................................... 8
2.7. Claims ............................................................................................................... 8

3. SAFETY INSTRUCTIONS
3.1. Potential sources of danger ............................................................................. ..9
3.1.1. Mechanical dangers ............................................................................. ..9
3.1.2. Electrical dangers ................................................................................ ..9
3.1.3. Dangers when mounting ...................................................................... 10

4. SPECIFICATIONS
4.1. Operational free space required ....................................................................... 12
4.1.1. Dimensions .......................................................................................... 12
4.2. Technical data .................................................................................................. 13
4.3. Functional description / Special features ......................................................... 13

5. PREPARATIONS FOR ASSEMBLY

5.1. Packing list ....................................................................................................... 15
5.2. Tools ................................................................................................................. 16
5.3. Optional accessories ....................................................................................... 16
5.4. Electrical components ...................................................................................... 16

6. ELECTRICAL COMPONENTS AND CONNECTIONS

6.1. General information .......................................................................................... 17
6.2. Wiring diagrams ............................................................................................... 17
6.2.1. Recommended charge regulator......................................................... 17
6.2.1.1. SCR Marine Charge Regulator .......................................... 17
6.2.1.2. Diversion Load Resistor ...................................................... 19
6.3. System components ........................................................................................ 19
6.3.1. Wires ................................................................................................... 19
6.3.2. Strain relief .......................................................................................... 21
6.3.3. Polarity ................................................................................................ 22
6.3.4. Batteries .............................................................................................. 22
6.3.4.1. Charging batteries ............................................................... 22
6.3.4.2. SCR Marine charge regulator (with diversion load control) 24
6.3.4.3. Diversion load resistor ........................................................ 25
6.3.5. Fuses ................................................................................................... 25
6.3.6. Stop switch .......................................................................................... 25
6.4. Grounding ......................................................................................................... 26

7. SUPERWIND 350 GENERATOR ASSEMBLY

7.1. Precautions during mounting ........................................................................... 27
7.2. Mast mounting .................................................................................................. 28
7.2.1. Mast tube specifications ...................................................................... 28
7.2.2. Mounting the turbine on the mast ......................................................... 29

V 09 – 2016 2
 7.2.3. Preparations at the mast head .............................................................. 29
7.3. Mounting of the wind vane .............................................................................. 31
7.4. Rotor assembly ............................................................................................... 31
7.4.1. Rotor blade hub assembly ................................................................... 31
7.4.2. Mounting the hub to the generator shaft ............................................... 33

8. COMMISSIONING
8.1. Verification chart ............................................................................................... 35

9. OPERATION
9.1. Safety instructions ........................................................................................... 36
9.2. RUN and STOP ............................................................................................... 36
9.3. Power control ................................................................................................. 36
9.4. Over-speed protection ..................................................................................... 37
9.5. Annual power production ................................................................................. 38

10. INSPECTIONS, MAINTENANCE

10.1. Periodic inspections ........................................................................................ 39
10.1.1. Rotor blades ..................................................................................... 39
10.1.2. Bolted connections ............................................................................ 39
10.1.3. Bearings, seals .................................................................................. 39
10.1.4. Slip rings ............................................................................................ 40
10.1.5. Corrosion protection ......................................................................... 40
10.1.6. Mast .................................................................................................. 40
10.1.7. Electrical system ................................................................................ 40
10.2. Maintenance ................................................................................................... 41

11. TROUBLESHOOTING
11.1. Wind generator does not start....................................................................... 42
11.2. No power output ........................................................................................... 43
11.3. Insufficient power output ............................................................................... 43
11.4. Battery is not fully charged ............................................................................ 44
11.5. Checking the open circuit voltage ................................................................. 44

12. REPAIRS, SPARE PARTS

12.1. Repairs .......................................................................................................... 45
12.2. Spare parts list .............................................................................................. 45

13. FREQUENTLY ASKED QUESTIONS

13.1 Basic use ....................................................................................................... 46
13.2 Installation ..................................................................................................... 46
13.3 Operation ...................................................................................................... 47
13.4 Troubleshooting ............................................................................................ 47

14. ABBREVIATIONS USED ON THIS MANUAL ........................................................ 49

ATTACHMENT A – STOP-SWITCH MANUAL

ATTACHMENT B – SUPERWIND CHARGE CONTROLLER 12V MANUAL

ATTACHMENT C – SUPERWIND CHARGE CONTROLLER 24V MANUAL

V 09 – 2016 3
 Thank you for purchasing a

Superwind 350.

Like all specialized commercial electrical generating equipment, it is important to

protect your investment by reviewing this manual in its entirety, paying particular
attention to all precautions and warnings.

Superwind micro-wind turbines are constructed of the highest quality materials

and have been designed for autonomous use in harsh conditions – but no matter
how well we construct the product, damage can be done to the turbine and/or
related systems (batteries, wiring, loads etc) if the integration is not well planned
and more importantly, installed correcty – as directed in this full version manual.
Should you have any questions regarding the installation or use of a Superwind
350 after reading this manual, PLEASE contact your closest Superwind installer,
distributor or superwind (the manufacturer) directly.

Your Superwind has been designed to provide many years of autonomous

service when properly installed.

INSTALLATION

PLEASE DO NOT PROCEED UNTIL

YOU HAVE READ
ALL INSTRUCTIONS
AND
SAFETY INFORMATION

© 2016 superwind GmbH.

Superwind is a Registered Trade Mark of superwind GmbH, Germany

MANUAL VERSION 09-2016

V 09 – 2016 4
 1. GENERAL INFORMATION AND REFERENCES

1.1 Company Profile

superwind GmbH was established in 2004 after four years of successful research, design
and testing of its now internationally patented micro-turbine technology. Since then,
thousands of commercially rated Superwind 350 (and new Superwind 1250) turbines
have been quietly providing reliable, autonomous wind generated electricity to users in
remote, harsh conditions on both land and at sea world-wide.

As our reputation is as important as your satisfaction, we thank you in advance for

reading the Superwind manual in full – even before purchasing our wind generating
equipment. We also wish to remind you that wind turbines work best when installed
where there is sufficient wind, so please research your planned wind turbine site or vessel
installation to help predict how a Superwind 350 might help with you power needs.

On behalf of our superwind staff and world joint venture partners, we thank you for your
interest in our cutting edge and real world proven wind turbines.

1.2 Labelling

This manual refers to the Superwind 350 wind generator.

Manufacturer:

superwind GmbH
Am Rankewerk 2-4
D-50321 Brühl
Germany
Tel.: +49 / 2232 / 577357
Fax: +49 / 2232 / 577368
E-Mail: [email protected]
Internet: www.superwind.com

The label providing the serial number and nominal voltage of your Superwind is located
at the yaw shaft (See Graphic No. 1.2).

V 09 – 2016 5
 For future reference please record the serial number of your
Superwind 350 in the space provided below prior to
installation. Once the yaw shaft is inserted into the mast this
information will not be visible.

Type .................................................Superwind 350

Serial Number..................................._____________

1.3 Range of application

The electric power generated by the Superwind charges batteries and can directly be
used for 12 VDC or 24 VDC-appliances (depending on the system voltage). AC-
appliances are supplied via an optional inverter. There is a wide range of high quality 12
VDC or 24 VDC equipment available like energy saving lamps, refrigerators, deep-
freezers, water pumps, ventilators, consumer electronics, TV, radio and navigation
equipment, etc.
Examples of ideal applications include sailing yachts, campers, summer cottages,
mountain shelters, and industrial applications such as navigational aids, security systems,
environmental monitoring stations and communications. For rural electrification the
Superwind supplies basic power to families, schools, small health care facilities, etc.
In many integration sites, energy supplies from sun and wind complement each other.
That is why the Superwind is used in wind / solar and in combination with other charging
systems to optimize the availability of power (at minimized battery capacity).

V 09 – 2016 6
 2 WARRANTY

2.1 Warranty

superwind GmbH warrants this product to be in good working order during the warranty
period. In the event that the product is found to be defective within the warranty period,
repair service will be provided free of charge by superwind GmbH or an authorized
service partner.

Free repair service may only be obtained by providing the warranty card and original
purchase invoice issued to the customer by the retailer. The warranty card must state the
purchaser ́s name, the retailer ́s name and address, the serial number and the date of
purchase of the product. superwind GmbH reserves the right to refuse warranty service if
this information is not complete or has been removed or changed after the original
purchase of the product from the retailer.

2.2 Warranty period

The warranty is valid for three years from the date of purchase by the purchaser, as
evidenced by the above mentioned documents.

2.3 To obtain warranty service

Warranty service is available at superwind GmbH and Superwind authorized service

partners. Any costs of secure transportation of the product to and from superwind GmbH /
Superwind authorized service partners will be borne by the customer.

2.4 Limitations

superwind GmbH does not warrant the following:

Periodic check-ups, maintenance and repair or replacement of parts due to

normal wear and tear.
Defects caused by modifications carried out without superwind ́s approval.
o Includes damage caused by improper use, handling or operation, in particular
defects caused by improper installation and installation on inadequate masts or
support structures.
Installation on inadequate masts or support structures (to obtain warranty service
the purchaser has to provide evidence that masts or support structures are as
recommended in the Superwind 350 manual).
Accidents or disasters or any cause beyond the control of superwind GmbH,
including but not limited to lightning, flooding, fire etc.
Costs for disassembly and reassembly of the product to enable shipment for
warranty reasons.

2.5 Others

Superwind GmbH reserves the right to decide whether the product or parts thereof shall
be repaired or replaced under warranty. Should neither repair nor replacement by
superwind GmbH be possible, the purchaser solely will be entitled to a full or partial
refund (prorated when returned to the manufacture after more than 1 year of use).

This warranty does not affect the purchaser ́s statutory rights under applicable national
legislation in force, nor the purchaser ́s right against the retailer arising from the sales /
purchase contract. In the absence of applicable national legislation, this warranty will be
the purchaser ́s sole and exclusive remedy, and superwind GmbH shall not be liable for
any incidental or consequential damages for breach of any expressed or implied warranty
of this product.

V 09 – 2016 7
 THE GENERAL CONDITIONS FOR THE SUPPLY OF PRODUCTS AND SERVICES OF
THE ELECTRICAL AND ELECTRONICS INDUSTRY APPLY WITH APPROPRIATE
LIMITS AND STANDARDS.

2.6 Expenses and Responsibilities

All associated expenses (shiping to and from the repair facility, insurance, etc) are the full
responsibility of the buyer or his shipping agent, unless the buyer is notified otherwise by
the manufacturer.

Upon receipt of your unit:

The crate should be opened and inspected immediately for damage.

Note any damage to the outside of the package (dents, scratches, etc.) and
document it on the Bill of Lading before signing and keep a copy. Documenting
damage with photos is also highly recommended.
Unpack the unit at once and perform a visual inspection to determine if it is
dented, bent or scratched.
If for any reason the unit should need to be returned, the original crate is the best
way to ship it back to the manufacturer.

2.7 Claims

Claims that occur during transportation must be filed by the consignee (the buyer) as
shipping terms are FOB-EX-WORKS (our distribution point as contracted).

BUYER IS RESPONSIBLE FOR ALL SHIPPING EXPENSES INCLUDING CUSTOMS

DUTIES AND VAT (IMPORT DUTIES).

V 09 – 2016 8
 3 SAFETY INSTRUCTIONS
Please carefully study this manual before starting assembly and installation. The
information provided is to ensure your safety during mounting, operation, and in case of
trouble. If you have any additional questions please contact your dealer, a Superwind
service partner, or the manufacturer.

3.1 Potential sources of danger

Wind turbines in general – including small wind generators like the Superwind – are
electrical machines and thus potential sources of hazards.

3.1.1 Mechanical dangers

The main danger is the spinning rotor. The rotor blades are sharp and can cause
serious injuries, even at very low speed.

Never touch a spinning rotor.

Never try to stop the rotor by hand.
Do not mount the unit where personnel can come in contact
with the spinning rotor.

The rotor blades are made of carbon fiber reinforced plastic. This material is
extremely sturdy and enables your Superwind to cope with heavy storms;
however the rotor blades can break if any objects (e.g. ropes, loose sail battens,
branches etc.) come in contact with a spinning rotor. The fragments of broken
blades are sharp and can be thrown off of the rotor at very high speed.

Protect the spinning rotor from impact with foreign objects.

For aerodynamic reasons the trailing edges of the rotor blades are very thin and
sharp.

NOTE:

Be careful when unpacking and handling in order to avoid injuries as well as damage to
the blades.

3.1.2 Electrical dangers

The generator can produce dangerous open circuit voltages up to 52 VDC (12 V
version) and 105 VDC (24 V version) at no-load operation if the electrical
connection to the battery or consumer (load) is interrupted. This open circuit
voltage will be reached at a wind speed of approximately 35 m/s.

The charging current will reach up to 30 Ampere DC (12 V version) or 15 Ampere

DC (24 V version)! All wires, electrical components and connectors must be rated
for 40 Amps (12 V version) or 20 Amps (24 V version). For correct dimensioning
(gauge) refer to Section 6, Tables 6.3.1.1 and 6.3.1.2 on page 19.

V 09 – 2016 9
 Smaller gauged wires with insufficient cross section
(diameter) will get extremely hot and can cause an electrical
fire.

To reduce installation problems, keep wire runs as short as practical and mount
all system components as close to the battery as possible. For details see
Section 6.2 on page 17

NEVER SHORT-CIRCUIT THE BATTERY. Doing so can cause serious damage

to the battery and wiring, such as fire, explosion, and the release of acid toxic
gases.

Be extremely careful to never short-circuit the battery.

Charging lead-acid batteries can produce dangerous
flammable gas. Unsealed lead-acid batteries have vent holes
releasing hydrogen during charging, which can form
potentially explosive gases in enclosed areas. A small spark
(such as from an electrical switch) can detonate this
explosive gas mixture. To prevent such explosions always
provide sufficient ventilation in battery storage areas.

Never install batteries in locations where the danger of

sparks exist.
Provide sufficient ventilation for batteries at all times.

The diversion load (power resistor) of the Superwind 350 charge regulator (SCR
type) can become very hot.
This device requires adequate space and ventilation to prevent the resistor from
overheating. To prevent damage to the device and to protect against fire, never
mount the power resistor on flammable surfaces or close to flammable materials.

Never install the power resistors on a flammable surface.

3.1.3 Dangers when mounting

These instructions also apply during disassembly, when conducting checks or

other work carried out on your wind generator.

Only use mast and support designs capable of safely withstanding the loads of
your wind generator. The mast not only has to withstand your wind generator’s
weight and mass moment of inertia (e.g. on a sailing yacht) but also the
considerable thrust caused by high wind speed. Details see Section 7 on page
27.

Work on the mast or on your wind generator only on a calm and windless day.
Do not step beneath or stand under hanging loads (e.g. a tilted mast) and prevent
other persons from doing so.

V 09 – 2016 10
 Ensure that all batteries are disconnected from the system prior to conducting
any work.

Prevent your wind generator from starting unintentionally (turning in a direct wind)
during mounting by turning off the safety switch or short circuiting the generator
output wires (Red and Black).

Disconnect the battery before INSTALLATION! Short-circuit

the two generator OUTPUT WIRES (Caution: Do this only
AFTER disconnecting the battery!) and/or loosely tie one
blade to the mast without pressure to prevent the blade
from spinning during installation.

Never tie a rotor blade to the mast for long periods of time
as this will distort the aerodynamic design of the blade,
resulting in vibrations during operation which could damage
the generator.

Never approach a spinning rotor.

Never try to stop a spinning rotor by hand.
Never install the wind generator in areas where it can be
easily reached or approached by anyone while walking or
working around the turbine structure.

V 09 – 2016 11
 4. SPECIFICATIONS

4.1 Operational Free Space Required

The area where the Superwind turbine will be installed must be considered carefully.
Operational space for the turbine itself, as well as the working area (including the mast
and support) must be free from obstructions such as nearby trees, walls or buildings,
sailing equipment, etc. It is imperative that the turbine operational area is completely
unobscured and open to the wind to achieve maximum energy production.

Wind turbine operations and safety are both optimized by careful preinstallation planning.
Clear, open air space provides the best air flow and performance, but even ideal locations
can be impacted by future changes to the area. Wind power is dramatically affected by
nearby structures, obstacles (growing trees, ship bimini covers, etc), and even the
turbine’s own mast structure. As such, it is important for the installation to be designed
with the end result and proper integration in mind – such as including the highest practical
mast top with the clearest safety zone possible.

4.1.1 Dimensions

Dimensions
mm
Table No. 4.1.1
a Distance between center of mast and blade tip 168
b Distance between center of mast and extreme upper part of wind vane 556
c Distance from mast-top to center of rotor 136
d Distance from the center of hub and extreme upper part of the wind vane 530
e Length of yaw shaft 76
f Rotor diameter including blades 1220
g Outside diameter (OD) of yaw shaft with damping rings 44
h High for Plastic Bushing to be inserted into mast 71
i Required space for yawing 1263

V 09 – 2016 12
 4.2 Technical data

nominal power .........................................350 W

nominal wind speed .................................12,5 m/s
cut in wind speed .....................................3,5 m/s
cut off wind speed ...................................none
rotor diameter ..........................................1,20 m
number of blades .....................................3
blade material ..........................................carbon fibre reinforced plastics
rotor speed ..............................................500 – 1300 rpm
generator ................................................permanent magnet 3-phase with rectifier
magnets Neodymium
nominal voltage .......................................12 V DC or 24 V DC
speed regulation ......................................rotor blade pitch
power regulation ......................................rotor blade pitch
brake........................................................dynamic, short circuit
weight ......................................................11,5 kg
rotor thrust (operation) .............................70 N (15.7 lbf)
rotor thrust (extreme wind speed) ...........220 N (49.5 lbf)

4.3 Functional description / Special features

The Superwind, like all wind turbines, uses part of the kinetic energy of the wind and
converts it into electricity.

The power is approximately proportional to the cube of the wind speed - i.e. doubling the
wind speed results in eight times higher power output. Therefore, power from the wind at
low wind speeds produces very little energy. However, as the wind speed increases
exponentially, high pressure suddenly impacts the turbine and all of its mechanical
components. During high wind events, conventional wind turbine technology resulted in
the turbine going into an “over-speed” condition, damaging both internal electrical
components as well as the blades themselves.

To design the Superwind, special technologies were developed in order to achieve

optimum power output for a wide wind speed range, as well as maintain maximum safety
in high wind or storm conditions. The following technology has been incorporated into the
Superwind to achieve this performance.

a) The rotor blades were developed using modern computerized calculation and
simulation methods. The airfoil had been wind tunnel tested and was specifically
developed for small size rotors.

Relatively broad rotor blades combined with a special pitch angle produces a high
start-up torque, enabling the rotor to start at only 3.5 m/s wind speed.

NOTE:

Optimum start-up performance will be reached after a mechanical run-in period of the
bearings and their seals. This ‘break-in’ period will vary depending on the winds speed
and hours the turbine is left “on” in windy conditions.

When using the Superwind for battery charging, do not mistake rotor start-up for the
start of charging. The wind speed required to start charging the battery depends on
the battery charge load at the time and might be slightly higher than the rotor start-
up wind speed.

The term ‘cut in speed’ describes when the turbine can start producing power to
charge your batteries. This is a higher wind speed than the ‘start up wind speed’, a
lower wind value where your turbine may spin, but will not be producing power. At
superwind, we focus on power production and not just turning blades. As such, keep

V 09 – 2016 13
 in mind that the wind speed required to start charging the battery depends on the
battery state of charge (load) and other basic electrical system factors.

NOTE:
Your turbine has extremely high quality bearing sets to provied a long, nearly
maintenance free service life. These special bearings require a “ break in period“ of
weeks or possibly months to achieve the highest charging levels at lower wind
speed conditions. Leaving the Superwind turbine in the autonomous “Run” position
through all types of weather, including high winds and storms, will help shorten this
break in period.

b) The basic innovation of Superwind is its novel aerodynamic rotor control system.
Similarly to large wind turbines, it adjusts the pitch angle of the rotor blades.

The mechanical controller is fully integrated into the hub and works without expensive
electrical or hydraulic components. Instead, the controller is actuated by forces
arising at operation of the wind turbine itself.

The forces are affected by the geometric and kinematic lay-out of the rotor and
controller mechanism.

Aerodynamic forces act as a control variable to adjust the rotor blades for power
regulation above the nominal wind speed. Centrifugal forces are the second control
variable for the rotor blade adjustment. By the special arrangement of both force
components, the controller limits rotor speed automatically (even at extreme wind
velocities) and protects the wind turbine from over-speed, even during no-load
operation. As a result, the controller limits the mechanical loads at high wind speed,
providing smooth operation under all weather conditions.

V 09 – 2016 14
 5. PREPARATIONS FOR ASSEMBLY

5.1 Packing list

Please check your delivery for completeness and transport damage.

PACKING LIST
Table 5.1
ITEM DESCRIPTIOM SIZE QUANTITY 
1 Generator unit 1
2 Hub 1
3 Wind vane 1
4 Rotor blade 3
5 Wind vane mounting plate 1
6 Plastic bushing (optional stainless 1
steel bushing)
7 Socket cap screw M8 x 80 1
8 Socket cap screw M8 x 20 2
9 Socket cap screw M6 x 25 (TUFLOK) 6
10 Socket cap screw with rubber ring M6 x 8 (TUFLOK) 3
11 Hexagon socket button head screw M6 x 12 2
12 Hexagon socket button head screw M6 x 6 2
13 Allen key 6 mm 1
14 Allen key 5 mm 1
15 Allen key 4 mm 1
16 Operation’s manual 1

NOTE:

For aerodynamic reasons the rotor blades trailing edges are very thin and sharp. Use
caution when unpacking, both to avoid injury and damage to the blades.

V 09 – 2016 15
 5.2 Tools

A set of allen keys is included to assist with the installation of your Superwind. The
following is a list of additional recommended tools:

1. screw drivers
2. set of spanners
3. wire strippers
4. wire crimpers
5. heat shrink or electrical tape
6. multimeter

For correct tightening of the screws, a torque wrench is recommended.

Tools for the mast installation are not listed here. See respective instructions.

5.3 Optional accessories

Mast-sets:

Mast-set for yachts

Mast-set for land installation / guyed tubular mast 6 m (other heights on request)
Mast-set for land installation / self-supporting tubular mast 7,5 m

5.4 Electrical components:

Charge regulator SCR Marine incl. power resistor

20 Amps (24 V System) or 40 Amps (12 V System), slow-blow fuses or breaker
Fuse holder
Stop-switch
Ammeter

V 09 – 2016 16
 6. ELECTRICAL COMPONENTS AND CONNECTIONS

6.1 General information

Ensure that any installation or repair work on the electrical system is carried out by
qualified technicians only. These technicians must also read these instructions prior to
starting the installation!

NOTE:

Careful pre-installation planning is a crucial first step in the installation of your

new Superwind, as well as other system components that are also part of your
project.
The actual electrical connection should be made during the lasts steps of the
installation.

Make sure that the batteries and other charging sources

(such as grid or shore power) are disconnected until the
installation is complete.

6.2 Wiring diagrams

6.2.1 Recommended charge regulator

6.2.1.1 SCR Marine Charge Regulator (12V or 24V, depending on

turbine and system voltage, Graphic No. 6.2.1.1)

The SCR Marine charge regulator has been especially designed for use
with the Superwind 350 wind generator. It allows the user to fully charge
batteries, while also protecting battery banks from overcharging via a
diversion load control, as well as temperature compensation.

Wind charge controllers are very different from solar charge controllers in
that they are designed to electrically maintain the load correlation with
the battery bank while simultaneously producing power above the ever
changing battery state of charge. This allows the batteries to be properly
charged based on ideal temperature-compensated charging rates and
consumer demands.

The Diversion mode initiates when the batteries have reached their
maximum charging voltage; the SCR Marine´s PWM circuit automatically
diverts the wind turbine´s surplus power to the diversion resistor block.
With this technology, even when batteries are fully charged, the wind
turbine continues operating (provides useable power generated when
there is ample wind) providing real time power to other electric
consumers (loads) as they come online automatically or when switched
on manually.

This ‘Diversion State’ (dumping generated power) is indicated by an LED

illuminating (turning on) on the SCR Controller when the battery bank is
full – indicating that electric power (above and beyond the battery bank
charging needs) is available to be used rather than dumped.

V 09 – 2016 17
 The SCR Marine Charge Controller is suitable for charging lead acid
batteries, gel batteries and AGM batteries (AGM = Absorbed Glass Mat)
and some Lithium Ion batteries (NOTE: consult your Superwind
Customer Service Contact and the battery manufacturer for important
specific details before trying to charge Lithium Ion Batteries!). For special
applications, the maximum charging voltage can be adjusted to customer
requirements by superwind.


The SCR Marine charge regulator is completely sealed and protected

against moisture (such as found in a marine environment) however it is
not waterproof and should be installed in a suitable weather proof
outdoor control panel or located in an appropriate dry space aboard ship.

The SCR Marine charge regulator has the ability to charge two separate
battery banks independently, yet still work in diversion mode when both
battery banks are in a full state of charge (eg. starter battery set and the
house battery bank on a yacht).

IMPORTANT:

An advantage of using the SCR Charge Controller is that it can work alongside
other charging technologies such as solar panels, diesel generators, fuel cells,

V 09 – 2016 18
 engine power (from the alternator), and even shore power (aboard ship or at a
site) without affecting other operations. Please contact your Superwind customer
service contact for special configuration information or more details.

6.2.1.2 Diversion Load Resistor

The resistance of the cable that connects the load resistor with the
charge regulator can affect the charging voltage. Therefore, the
connecting resistor wire run should not exceed 1 meter with the
recommended wire gauge. If you would like to extend the resistor wire
beyond 1 meter, please refer to the AWG Wire Size Chart (Table No.
6.3.1.1 and 6.3.1.2).

NOTE: Charge regulators are not protected against reversed polarity of

the wires (“+” & “-“), and will be damaged if connected incorrectly!
Connecting the wrong wire (line) polarity to your Charge Controller will
void the warranty!

Do not reverse the polarity of the wires.

If you want to use a different charge regulator than what is recommended

for use with your Superwind 350 (the SCR Marine charge controller: 12v
or 24v), make sure that it is a suitable shunt-regulator based device with
full time diversion load control. To insure you are not voiding the warranty
on your Superwind turbine, please ask your Superwind customer service
contact as many other charge controllers - especially those used for solar
photovoltaic systems - are unsuitable, since they interrupt the electric
circuit for voltage regulation and can render the wind generator into a
dangerous no-load operation!

6.3 System components

6.3.1 Wires

The cross sections (gauge) of the wires required depends on their length
and the rated voltage of your wind generator. After selecting the location
of the mast, measure the distance from the mast top to the battery and
then select the minimum cross section required on the basis of the
following tables. In order to keep the power loss of the lines as small as
possible, do not use lines with under-sized cross sections.

It is always recommended to use

stranded (braided) wire.

Solid wire should be avoided.

V 09 – 2016 19
 For the 12 Volt version:

AWG Wire Size Chart for 12 Volt Version

Table No. 6.3.1.1
Distance from mast top to the battery
From: up to 5,3 m 8,8 m 14,1 m 21,9 m 30,7 m
To: 5,2 m 8,7 m 14 m 21,8 m 30,6 m 43,7 m
Minimum gauge
6 mm² 10 mm² 16 mm² 25 mm² 35 mm² 50 mm²
(cross section)
Recommended per wire AWG 10 AWG 8 AWG 6 AWG 4 AWG 2 AWG 1
Refer to Graphic No. 6.3.1.2 to better understand cross section

For the 24 Volt version:

AWG Wire Size Chart for 24 Volt Version

Table No. 6.3.1.2
Distance from mast top to the battery
From: up to 8,8 – 14,1 – 21,1 – 35 – 56 –
To: 8,7 m 14 m 21 m 34,9 m 55,9 m 87,3 m
Minimum gauge
2,5 mm² 4 mm² 6 mm² 10 mm² 16 mm² 25 mm²
(cross section)
Recommended per wire AWG 14 AWG 12 AWG 10 AWG 8 AWG 6 AWG 4
See Graphic No. 6.3.1.2

NOTE:

The cross sections of the above two tables refer to a maximum voltage drop of 5% when
using copper wires

Installations using a smaller than recommended wire gauge

can get dangerously hot, resulting in damage to the system
and possibly cause an electrical fire. Plan and install your
system correctly!

For applications on board a boat or in marine (i.e. salt water) environments,

wiring with tinned braids is recommended, in order to prevent corrosion.

V 09 – 2016 20
 If the wire is to be buried (installed underground), a special underground rated
wire must be used, and / or the wire run must be led through an underground
rated conduit.

In all applications, ultraviolet (UV) resistant wire should be used, so that it is

protected against environmental influences. The same applies to the insulation
covering, including heat shrink sleeves, and electrical tape at connection points.

For protection of the wire against chafing, the hole at the bottom of the mast must
be properly de-burred. If necessary, install a piece of rubber tube over the wires
to prevent wear from sharp metal at contact points.

For connecting to the terminals,

wire ends must be stripped and
suitable wire end ferrules or lugs
must be crimped in place.
(Graphic No. 6.3.1.4).

6.3.2 Strain Relief

Wires that connect to the turbine and travel

down through the mast have weight. Depending
on mast length, the length of the wire run,
coupled with the selected wire size (AWG
profile) can result in a significant amount of
weight. This weight can cause strain on both the
mast wiring connections and wires coming out of
the turbine if not relieved.

It is recommended that for

mobile wind turbine integrations
- as well as any application with
tall masts - that the wire be
hung from the Strain Relief Bar
located in the Yaw Shaft
(Graphic No. 6.3.2.2). This is
especially true if the wire
hanging in the mast weighs
more than 5 kg; a strain relief
must be attached in the mast
top or via the internal Strain
Relief Bar located within the
Yaw Shaft. This ensures that
the internal junction point at the
slip rings of your Superwind will
not be damaged. The Yaw Shaft strain relief bar is composed of a cylinder pin 3 mm OD
x 40 mm which is shown in the drawing in Graphic 6.3.2.2 on page 21.

V 09 – 2016 21
 6.3.3 Polarity

Always pay attention to the correct polarity of

the lines. Connecting to the batteries with
reversed polarity will destroy the electric
rectifier of your Superwind. In general, you
should mark all line ends by POSITIVE (+)
and NEGATIVE (-), in order to prevent errors
with the connection.

Marking of the connecting wires at the

Superwind:

POSITIVE Line (+): RED

NEGATIVE Line (-): BLACK

The internal electric rectifier of the Superwind will be

destroyed by connecting the wires with reversed polarity.
Loss of warranty will result!

6.3.4 Batteries

6.3.4.1 Charging batteries

The most common use of the Superwind is charging batteries.

Our diversion charge regulator allows the Superwind operation to be
autonomous.
Autonomous operation allows the batteries to be brought to a full state of charge
(SOC) and still be protected against overcharging, resulting in longer battery life
and maintaining the battery manufacturer warranty.

When selecting batteries, pay particular attention to the correct rated voltage (12
V or 24 V). The rated voltage of your Superwind is specified on the yaw serial
number label. (See Section 1 on Page No. 5).

Lead-acid batteries are most commonly used. The Superwind SCR Charge
regulators (Section 6.2 on Page No. 18) are suitable for all types of batteries,
although (depending on the battery manufacturing specs) the charge controller
may need to be adjusted to the battery manufacturer recommendations. We
recommend batteries designed for stationary use (not starting batteries).
Stationary or deep cycle batteries are more suitable because they are designed
for deeper discharge and rapid recharge cycling, resulting in a longer service life.

Many deep cycle batteries are maintenance-free and better survive occasional
deep (below manufacturer’s recommended SOC) discharges than do starter type
batteries.
Car batteries (starting batteries) should be avoided as house span batteries
because they wear out very fast when exposed to the repeated
discharge/charging cycles that will normally occur in your system.

Another important criteria for battery selection is the ‘capacity’, expressed in

ampere-hours (Ah). This value represents the quantity of storable energy. The
required capacity depends on your individual situation (wind location,
consumption structure, combination with other generators sources like diesel,
solar etc.). Your battery dealer can assist you in selecting a suitable battery.

V 09 – 2016 22
 When selecting battery location for an installation, refer to the battery
manufacturer’s instructions.
Charging lead-acid batteries produce potentially flammable hydrogen gas.
Unsealed lead-acid batteries have vent holes that also release hydrogen, which
forms potentially explosive gas in the surrounding environment. A small spark
(e.g. an electrical switch) can detonate this explosive gas mixture. For explosion
and fire prevention, always provide sufficient ventilation for your battery bank.

Never install the batteries in places with a danger of flame or

spark formation.
Provide sufficient ventilation at all times.

Batteries store a large quantity of energy potential, which when suddenly

discharged (in the case of a short-circuit) can destroy the battery (releasing
battery acid and gas) and/or set the battery and wiring on fire! Short-circuiting
wires or batteries must be avoided in all cases. For this reason battery terminal
connections must only be made after all work on the electric system has been
completed.

NEVER SHORT-CIRCUIT THE BATTERY.

NOTE:

The battery terminals may be connected only after all work on the electric system has
been completed.

For protection against high voltage spikes and/or an accidental short-circuit

event, fuses must be installed in the positive (+) wires to the battery. See Section
6.3.5 on page 25 for fuses. See Graphic 6.2.1.1 for connection diagram on page
18.

Since blowing a fuse or releasing an automatic circuit breaker can cause an

electrical spark, fuses and breakers must not be installed in the same area as the
battery.

Use extreme caution while handling battery acid, refilling with distilled water or
performing other maintenance on the batteries. Follow the instructions of the
battery manufacturer and wear protective clothing and suitable eye protection.

Act with extreme caution while handling battery acid.

Wear protective clothing and suitable eye protection.

6.3.4.2 SCR Marine Charge Regulator (with diversion load control)

The 12 volt or 24 volt SCR Marine charge regulator has been especially designed
for use with the Superwind 350 wind generator, allowing the user to fully charge
batteries while also protecting battery bank from overcharging via a diversion

V 09 – 2016 23
 load control, as well as temperature compensation. The SCR marine charge
regulator has a self-contained temperature sensor that allows the unit to sense
the proximate temperature of the controller. If the charge controller is to be
installed in an area with a significantly different temperature than the battery
storage area, an optional external sensor is available.

Wind charge controllers are very different from solar charge controllers in that
they are designed to electrically maintain the load correlation with the battery
bank while simultaneously producing power above the ever changing battery
state of charge. This allows the batteries to be properly charged based on ideal
temperature compensated charging rates and consumer loads. The Diversion
mode engages when the batteries have reached their maximum charging
voltage, and the SCR Marine´s PWM circuit automatically diverts the wind
turbine´s surplus power to the diversion resistor block. With this technology, even
when batteries are fully charged, the wind turbine continues operating
(generating useable power when there is ample wind) providing real time power
to other electric consumers (loads) when they come on automatically or are
switched on manually. This ‘Diversion State of Charge’ is indicated by an LED
illuminating (turning on) at the SCR Controller when the battery bank is full –
indicating that electric power above and beyond the battery bank charging needs
is available to be used rather than dumped.

The SCR Marine Charge Controller is suitable for charging lead acid batteries,
gel batteries and AGM batteries (AGM = Absorbed Glass Mat) and some Lithium
Ion batteries (NOTE: consult your Superwind Customer Service Contact and the
battery manufacturer for important specific details before trying to charge Lithium
Ion Batteries!). For special applications, the maximum charging voltage can be
adjusted to customer requirements by superwind.

The SCR Marine charge regulator is completely sealed and effectively protected
against moisture (such as in the marine environment) however it is not waterproof
and should be installed in a suitable weather-proof outdoor control panel or
located in an appropriate dry space aboard ship.

The SCR Marine charge regulator has the ability to charge two separate battery banks
independently (Graphic No. 6.3.4.2), yet still work in diversion mode when both battery
banks are in a full state of
charge (eg. starter battery set
and the house battery bank on
a yacht).
Important: An advantage of
using the SCR Charge
Controller is that it can work
alongside other charging
technologies such as solar
panels, Diesel Generators, fuel
cells, engine power (from the
alternator) and even shore
power (aboard ship or at a site)
without affecting those other
operations. Please contact
your Superwind customer service contact for special configuration information or more
details.

V 09 – 2016 24
 The charge regulators are not protected against
interchanged polarity of the lines (wires) and would be
damaged in a reversed polarity situation.
If you want to use a different charge regulator other than the
one described here, make sure that it is a shunt-regulator.

6.3.4.3 Diversion Load Resistor

The resistance of the cable that connects the

load resistor with the charge regulator can
affect the charging voltage. Therefore, the
connecting resistor wire run should not
exceed 1 meter with the recommended wire
gauge. If you would like to extend the resistor
wire beyond 1 meter, please refer to the
AWG Wire Size Chart (Table No. 6.3.1.1 and
6.3.1.2).

NOTE:

The series controllers (sometimes called Solar Charge Controllers/Regulators) often

used in photovoltaic systems are unsuitable. They interrupt the electric circuit for voltage
regulation, which would allow the wind generator to run in no-load operation. Additionally,
the charge regulator must be laid out for electric flows of at least 40 A (12 V version) or
20 A (24 V version).

6.3.5 Fuses

To protect the battery against short-circuits, fuses must be installed in the

POSITIVE line between the wind generator and the battery and in the POSITIVE
line between the battery and the charge regulator. (See Graphic No. 6.2.1.1 on
Page 18). The fuses are 40 ampere slow-blow type (12 V-system), 20 ampere
slow-blow type (24 V-system), or appropriate automatic circuit breakers.

Fuses must be placed as close to the battery as possible, however they cannot
be installed within the same compartment. Unsealed lead-acid batteries have
vent holes which release hydrogen that mixes with the ambient air to create a
potentially explosive mixture. The spark generated by a blowing fuse (or release
of an automatic circuit breaker) can detonate this explosive gas mixture.

6.3.6 Stop switch

Graphic No. 6.3.6

The stop switch is used to shut down the

wind generator operation or to prevent
starting of the rotor during maintenance,
repairs, or when working in the turbine
operational area.

When using the Superwind on a boat or

a sailing yacht, installation of a stop
switch is strongly recommended to

V 09 – 2016 25
 shut the wind turbine down in heavy weather at sea. Spray and waves,
parts detached from the rigs or from the sails or other equipment could
strike and damage the spinning rotor. Reduced mobility under such
conditions could also increase the risk of accidental contact with the
spinning rotor by personnel

If you run the system without a charge regulator (Not Recommended!) a stop switch is
mandatory and in this case the battery’s state of charge must be continuously supervised
by the operator and stopped when the battery is fully charged or if the system is going to
be left unattended for any reason. The stop switch disconnects the Superwind from the
battery and simultaneously shuts down the rotor.
The stop switch must be installed in the line between the wind generator and the battery
as close to the wind generator as possible (see Wiring Diagrams in Section 6.2.1.1 on
Page 18).

NEVER PUT A CIRCUIT BREAKER OR FUSE BETWEEN

THE STOP SWITCH AND THE WIND TURBINE.

The stop switch has two positions:

a) RUN The positive wire from the generator is connected to the battery.
The negative wire from the generator is connected to the battery.

b) STOP The positive and the negative wires from the wind generator
are short-circuited (generator short-circuit brakes the rotor). The
positive and the negative lines from the battery are both open
and disconnected from the wind generator.

For further information concerning the connection of the stop switch refer to the
respective installation manual.

ONLY USE A STOP SWITCH PROVIDED BY SUPERWIND!

SUPERWIND SPECIFICATIONS REQUIRE THE BATTERY
TO BE DISCONNECTED AND NOT SHORT-CIRCUITED
WHEN THE SWITCH IS OPERATED.

6.4 Grounding

In order to protect your system against damage by lightning or over voltage, it should be
properly grounded. The design of the grounding system depends on the local conditions,
place of installation, type of soil, groundwater table, or the availability of a pre-existing
grounding bus. If you are in doubt, consult an experienced electrician or an electrical
systems technician.

When installing the Superwind on a yacht we recommend connecting the mast or

support to the ship´s grounding system whenever possible.

V 09 – 2016 26
 7. SUPERWIND 350 GENERATOR ASSEMBLY

7.1 Precautions during the mounting

Before starting the installation of your wind generator, please keep in mind the potential
dangers and proceed with caution.
Only use a mast and a support construction capable of safely withstanding the loads of
your wind generator. The mast not only has to withstand the weight of the wind generator
and its mass moment of inertia (e.g. on a sailing yacht) but also the considerable thrust
caused by high wind speed. The maximum wind thrust by wind during operation will be
approx. 70 N (15.7 lbf). In an extreme gust (wind speed of 49 m/s) the thrust can rise up
to 220 N (49.5 lbf).

Only work on the mast or your wind generator on a calm,

windless day.
Do not step or stand under hanging loads (e.g. a tilted
mast) and prevent other personnel from doing so.
Make sure that batteries are disconnected from the
system during all work.

TO PREVENT THE GENERATOR FROM

UNINTENDED STARTING, “SHORT-
CIRCUIT”
THE GENERATOR BY CONNECTING
THE TWO GENERATOR CABLES
TOGETHER.

Graphic No. 7.1.1

IF THE WIRE RUN – INCLUDING STOP

SWITCH – IS ALREADY INSTALLED,
THE STOP SWITCH CAN BE PLACED IN
THE ‘STOP’ POSITION FOR THE SAME
PURPOSE AS GRAPHIC NO.7.1.1

DISCONNECT THE BATTERY BEFORE SHORTING

THE TWO CABLES TOGETHER!

Do not approach a spinning rotor.

Never try to stop the rotor by hand.
Never tie any blade to the mast - the aerodynamic design
will be distorted and/or damaged and will affect the
performance of the turbine.

Do not install the wind generator where personnel could

come into contact with the rotor.

V 09 – 2016 27
 7.2 Mast mounting

Before your Superwind can be

installed on the mast or support, the
electric cables must be led through the
mast tube and connected to the
generator with the correct polarity
(Section 6.3.3 on page 22).

NOTE:

The following applies to any type of mast or support:

Before assembling the wind

generator, make sure that, from
the mast top to a point 650 mm
below, there are no projecting
fittings or ropes which could
obstruct the rotor (Graphic No.
7.2.1.2).

This is important because the

rotor controller pitches the
blades at high wind velocities,
which will reduce the distance
from the mast.

7.2.1 Mast Tube Specifications

The yaw shaft of your Superwind fits into the following mast materials with the
appropriate integration bushing:

Common North American Mast Materials

Table No. 7.2.1.1
Mast Type Inner Diameter Outer Diameter Wall Thickness
Stainless Steel Pipe
52.46 mm 60.3 mm 3.92 mm
(2” sch 40)
Stainless Steel Tube
52.50 mm 57.15 mm 2.325 mm
(2 ¼”, 316L, 16 Gauge)
Aluminum Pipe
52.50 mm 60.325 mm 3.912 mm
(2” sch 40)

NOTE:

When using any of the above mast materials, use a North American Delrin® bushing for
integration on ships, in salt water applications or mobile trailers.

The North American Stainless steel integration bushing is used on tall towers and
historically high wind areas.

See below for common EU size masts and appropriate bushing sizes.

V 09 – 2016 28
 North American Delrin® bushing specification fits pipe with an ID ranging from 2.05” –
2.15” (this bushing OD is 2.16” and can be sanded down to spec).

North American Stainless Steel bushing – use only on high towers or in higher than
average wind areas; not aboard ships. This bushing cannot be sanded, and is specified
for immediate use.

Bushings
Table No. 7.2.1.3
BUSHING TYPE INNER DIAMETER OUTER DIAMETER
mm inches mm inches
North American
Stainless Steel 42.2 1.66 52.1 2.05

North American 47.9

44.2 1.74 2.08
Delrin® 52.9
44.2 1.74 Bands
56 2.2
EU Delrin®
No bands
54.6 2.15

7.2.2 Mounting the Turbine on the Mast

With welded tubes, ensure that

the welding seam does not
obstruct the insertion of the yaw
shaft. If necessary, an out-
standing seam must be smoothed
with a round file or the like.

7.2.3 Preparations at the mast

head:

Deburr or smooth the end of the

tube carefully (inside and
outside).File off the welding seam
if necessary.
Drill the two holes 7 mm (distance
to the mast top: 35 mm) Graphic
No. 7.2.2.3 on Page 30.

The included plastic (Delrin®)

bushing needs to be mounted
onto the yaw shaft of the generator unit. The two elastomer damping rings of the
yaw shaft as well as the inner surface of the plastic bushing have to be lubricated
with Vaseline®. Graphic No. 7.2.2.1 (showing North American Delrin® bushing).

Be careful not to damage the damping rings while pushing the yaw shaft into the
plastic bushing. (Graphic No. 7.2.2.1)

Before the plastic bushing is installed on the yaw shaft, align the three 16 mm
holes of the bushing concentrically with the respective threads M6 of the yaw
shaft. Now push the plastic bushing with the collar ahead onto the elastomer
damping rings to the limit stop at the O-ring seal 40x3.

Be careful not to damage the damping rings during installation.

Next, screw the three socket cap screws (M6 x 8) together with the rubber rings
on their head in each of the threads. These bolts have a TUFLOK (blue color)

V 09 – 2016 29
 thread lock, and they can be a bit stiff. Screw until the screw heads are tight to
the yaw shaft. If everything is correct and the screw heads do not protrude, they
will not obstruct the insertion into the mast tube (the face of the screw will be
flush with the OD of the bushing).

Graphic No. 7.2.2.2 (Shown with EU style bushing with adapter bands)

Insert the yaw shaft of the Superwind with the plastic bushing to the limit stop
(collar), and align the tap holes with the drilled holes of the mast. Screw down the
two hexagon socket button head screws (M6 x 12) for axial fixation. The screws
now extend into the groove of the yaw shaft, but will not touch it.

Next, screw in the two hexagon socket button head screws (M6 x 6) provided for
the axial fixation of the bushing in the mast head. The screws now extend into the
groove of the yaw shaft, but will not touch it. This entire assembly, when installed
correctly, provides sound and vibration dampening.

V 09 – 2016 30
 7.3 Mounting of the wind vane

The wind vane is fastened to the rear cover of the generator. Insert the wind vane and the
mounting plate into the groove. As viewed from the rear (Graphic No. 7.3), the mounting
sheet must be on the right side. Next, insert the two socket cap screws M8 x 20 and
screw them down firmly.

7.4 Rotor assembly

There are two methods to assemble the rotor of your Superwind:

a) The hub is attached to the generator shaft and the rotor blades are fitted to the hub
later.

b) The rotor blades are fitted to the hub first, and then the completed rotor is attached
to the generator.

We recommend method b) since in most cases it is easier to assemble the rotor

completely at a convenient place and take it to the wind generator for attachment
afterwards.

7.4.1 Rotor Blade Hub Assembly

NOTE:

For aerodynamic reasons the rotor blades trailing edges are very thin and sharp. Use
care when unpacking the blades to avoid injury.

Superwind rotor blades are manufactured

as sets of three, balanced by weight and
axial runout. These 3 blades can be fixed
to the hub in any order. However, do not
mix and match blades from different
Superwind 350 blades sets as this could

V 09 – 2016 31
 cause the rotor to become out of balance. This means that if a single Superwind
350 blade is damaged, the entire blade set needs to be replaced - not just one
blade.

Accurate positioning of the rotor blades onto the hub is insured by a special
fitting. The flat area of the three axles extending from the hub have two cylindrical
counter bores each. The rotor blades have rectangular recesses with two
‘cylindrical tenons’ (see Graphic No 7.4.1.2), which fit into the cylindrical counter
bores of the axle with light force.

The rotor blades are fixed by two socket cap screws (M6 x 25), which are
TUFLOK-coated to prevent loosening once installed and during operation
(Graphic No. 7.4.1).

When screwing in you will sense a slight drag torque due to the coating.

Place the hub with the flat side on a soft surface.

1- The three flat axles should point upward (Graphic No. 7.4.1.2).
2- Attach the first rotor blade with its rectangular recess to one of the axles to fit
both cylindrical tenons into the counter bores of the axle with light pressure.
Do not use excessive force, as the threads could be damaged. Stainless
steel threads are very soft, so make sure the screws are started by hand and
not cross threaded.
Once both tenons are aligned correctly with the counter bores, screw in the
two socket cap screws M6 x 25 (Graphic No. 7.4.1.2). If mounting the blade
for the first time, place in the screws a half turn each, alternately until the
tenons are completely pressed into the counter bores.
3- When the rotor blade is attached to the axle correctly, do not simply tighten
the screws, since excessive tightening could damage the blade material. For
the correct initial tension, a torque of 4.5 Nm (3.3 ft. lbs.) is required. If a
suitable torque wrench is not available, the following method is
recommended:
a. Ensure the contact surface on each blade face and adjoining axle fits
properly. Insert both screws slowly, with offset pressure – alternating
between each screw while tightening - until snug. Once properly positioned,
tighten each screw slightly until it starts to feel tight.

V 09 – 2016 32
 b. At this point, screw down exactly one quarter turn in order to adjust to the
correct final tension.
c. Continue mounting the other two blades the same way.

NOTE:

Make sure, that the cylindrical tenons on each blades are correctly inserted into the
axles counter bores.
Do not use force.
Do not over-tighten the screws.

7.4.2 Mounting the hub to the generator shaft

NOTE:

In order to prevent the rotor from unintended starting, it is recommended to short circuit
the two generator cables (See Graphic No. 7.1.1 on Page No. 27) or turn your stop switch
into STOP position before beginning with the assembling.

DISCONNECT THE BATTERIES BEFOREHAND!

Once the rotor hub blade assembly has been completed, align the center to the
generator (paying close attention to the alignment with the keyed generator shaft)
and connect the hub to the generator.

NOTE:

Remember to hold the rotor at the hub only (not by the blades) as the sharp
edges of the rotor blades could cause injuries or the blades could be damaged.

V 09 – 2016 33
 Also remember, once the turbine is completely assembled, carry the completed
wind turbine by the generator unit (nacelle) only - never by the blades. Graphic
No. 7.4.2.1.

Take care not to push the generator shaft into the housing of the generator unit!
Insert the socket cap screw M8 x 80 through the hub and tighten it until you
cannot feel any axial play (the generator shaft should now be flush inside the
rotor assembly). Now tighten the screw at 18 Nm (13.3 ft. lbs.). Graphic No.
7.4.2.2.

To avoid damage inside the generator, do not push the

generator shaft into the generator housing.
This could void the Warranty!

V 09 – 2016 34
 8. COMMISSIONING
Before initial operation verify correct installation of your new Superwind using the below
check list.

Verification Chart
Table No. 8.1
DONE Look
 also
Section:
Mast
Assembled and erected in accordance with the respective manuals.
Bolts, joints, anchors and braces checked. Mast vertically adjusted.

Grounding / lightning protection:

Mast / support grounded 6.4
Ground wire connected to the grounding bus 6.4

Electrical system:
Batteries correctly installed and electrolyte level o.k. 6.3.4
Charge regulator has been set correctly and connected 6.3.4.2
Power resistor has been set correctly and connected. Installation point 6.3.4.3
provides adequate heat dissipation
Fuse holders has been set and connected 6.3.5
fuses 40 A (12 V system) or 20 A (24 V system) prepared
Stop switch (optional) correctly installed and connected 6.3.6
Ammeter (optional) correctly installed and connected
Cabling in accordance to wiring diagram and correctly connected 6.2.1.1
Correct polarity of all cables and connections 6.3.3

Wind Generator:
Cables connected with correct polarity 6.3.3
Strain relief for cables provided (if necessary) 6.3.2.2
Yaw shaft correctly inserted and set with screws 7.2.1.1
Wind vane correctly tightened with mounting plate, screws tightened 7.3
Rotor blades correctly tightened 7.4.1
Rotor blade screws tightened at 4.5 Nm (3.3 ft. lbs.) 7.4.1
Hub mounted on the generator shaft and tightened at 18 Nm (13.3 ft. 7.4.2
lbs.)

After the installation has been completed correctly and everything has been checked,
disconnect the generator lines from each other and connect them with correct polarity to
the battery. Insert the fuses and if you have a stop switch turn it into RUN-position.

Now your new Superwind is ready for operation. CONGRATULATIONS!

V 09 – 2016 35
 9. OPERATION

9.1 Safety instructions

 Do not run your Superwind unless you have confirmed that no persons can
touch the spinning rotor.

 Do not run your Superwind without an electrical load. (e.g. no load connected at
all or battery fully charged without charge regulator connected).

9.2 RUN and STOP

NOTE:

RUN (autonomous operation – making

power when there is wind or waiting for wind
to start).

STOP (Shut-down)

The Superwind turbine is designed for unattended

automatic operation (autonomous use) in all weather
conditions. Nevertheless, there might be situations when you would like to stop it. For that
purpose, the use of a stop switch is recommended. See Section 6.3.6 on Page 26

For wiring, see Section 6.3.1 on page 20

In RUN-position, the wind generator supplies power to the battery and to the appliances
connected to it when there is sufficient wind power.

By manually turning the safety switch to the STOP-position, the wind generator will be
disconnected from the battery and the generator output wires will be short-circuited
simultaneously. The generator short circuit also prevents the rotor from turning at
operational speeds.

NOTE: In very high wind conditions the rotor may not stop completely, but will continue
running at very low revolutions and will still be disconnected from the battery completely.

Never try to stop the spinning rotor by hand. Even slowed

down by the stop switch, the slowly running rotor can cause
serious injuries.
If there is no stop switch wired, the only way to slow down
your Superwind is to disconnect the generator from the
battery and then connect the generator leads to each other.
(Short Circuit Section 7.1 on Page 27) Be extremely careful
to avoid short- circuiting the battery by mistake.

9.3 Power control

As described earlier in Section 4.3.b (Page 14) the Superwind is equipped with a unique
aerodynamic, feathering rotor control system. This over-speed control also helps ensure
known electrical output in high wind speeds, adding to the unit’s autonomous operation
and safety.

V 09 – 2016 36
 Function:

The rotor blades are pivoted and can adjust their pitch angle to leeward. Below nominal
wind speed, the controller keeps the pitch angle in normal position. Above nominal wind
speed, the rotor control system adjusts the blade pitch exactly to the specific angle that
keeps the power output constant.

9.4 Over-speed Protection

The Superwind is equipped with an automatic rotor control system which incorporates an
Over-speed Control mechanism. The over-speed controller system works in all wind
speeds, even without an electrical load on the turbine. Although it is not a normal
operation mode, an unloaded turbine (meaning the turbine is disconnected from the
batteries) could occur under certain conditions (e.g. blown fuses, malfunction of the
charge regulator or electrical failures caused by overvoltage or a lightning strike). It is
important to try to avoid an unloaded turbine condition at all times.

Function:

The rotor control system responds to both aerodynamic and centrifugal forces affecting
the rotor blades. Due to the special geometric rotor blade layout and the matched rotor
controller mechanism, the rotor at no-load operation first accelerates to an increased idle-
speed. The idle-speed will be kept on a nearly constant level, only slightly speeding up if
the wind speed increases. That way, during no-load operation, the rotor control system
provides extra safety against high centrifugal forces and guarantees a very high level of
safety.

V 09 – 2016 37
 9.5 Annual power production

In DC-systems, the electrical power is the product of voltage and current. Actual output,
however, is a function of the generator speed and the load connected, including the
battery state of charge (i.e. the electric resistance of the consumers, including the
battery). Therefore, the actual annual power produced is a function of the wind conditions
at your site, in combination with what is being powered and/or the battery bank being
charged.
The diagram below shows the annual power production versus Rayleigh distributed
annual mean wind speeds.

V 09 – 2016 38
 10. INSPECTIONS, MAINTENANCE

10.1 Periodic inspections

Your Superwind has been designed to run for years without maintenance, but simple
periodic inspections are required for reliability, safety and peace of mind.

Before performing any inspection, disconnect the Superwind from the batteries and shut
down the rotor as described in Section 9.2 on Page 37.

Do not approach a spinning rotor.

Never try to stop the rotor by hand.

PRECAUTIONS:

 Only work on the mast or wind generator on a calm and windless day.
 Do not step under hanging loads (potentially free-falling equipment) and also
prevent other persons from standing underneath the same (e.g. a tilted mast).

The inspections described below should be performed every 12 months.

NOTE:

In some turbine applications (such as operations on a sail boat, for example), daily
inspections in and around the working area of a turbine is recommended. Look for
equipment or rigging that may have been moved by others that could impact the turbines
use and operation. Keep the working area of the turbine free and clear!

10.1.1 Rotor blades

Check the rotor blades for damage (e.g. cracks, broken edges, unusual
discolouring etc.). If you see any damage, your Superwind must be put out of
operation and the complete rotor blade set NEEDS to be replaced at once.

superwind GmbH does not authorize or allow mounting of rotor blades from
different sets to the hub, since then the rotor could become out of balance.
Dirt on the blades spoils the airfoil performance and reduces the power output. If
necessary, clean the blades with a sponge using only soap and water. Do not
use abrasive or chemical cleaners.

10.1.2 Bolted connections

Check all accessible bolted connections, making sure they are tightened to the
correct torque. This applies especially to the bolts of the rotor blades, the hub,
and the wind vane. Also check the bolts securing the yaw shaft. Refer to Section
7 on Page 27.

10.1.3 Bearings, Seals

The generator bearings and the yaw shaft bearings are sealed and lifetime
lubricated. Check the bearings for smooth running, clearance, and leak tightness.
Defective bearings must be replaced at an authorized service facility.

V 09 – 2016 39
 10.1.4 Slip rings

The electrical power is transmitted from the yawing nacelle to the stationary mast
via slip rings. The carbon brushes are designed for a lifetime of use. However, a
periodical check for unusual wear or loss of contact material is recommended (for
example, after a lightning strike or any other damage to the mast). Unscrew the
two black cylindrical screw caps (see Graphic No. 10.1.4 below) and pull out the
carbon brushes. Worn or damaged carbon brushes must be replaced. The
carbon brush does not need to be replaced until it reaches a length of 7mm or
less. Before you screw on the caps again, also check the O-ring seals.

10.1.5 Corrosion protection

The housing, as well as the wind vane, are made of a sea water-proof aluminium
alloy and are additionally protected by a powder coating. This coating however
can only adhere optimally to the housing surface if it is not damaged. Therefore,
check for damage and touch up the coating with suitable lacquer.

All steel parts (e.g. ball bearings, shafts, axles and bolts) are made of stainless
steel and need no special corrosion protection.

10.1.6 Mast

Check your mast or support. Refer to the respective instruction.

10.1.7 Electrical system

Inspections of the electrical system shall only be performed by qualified persons.

Before performing any inspection, make sure that all lines are safe and that the
wind generator will not start unintentionally.

Check all electrical connections, making sure that they are tight and free from
corrosion. Pay particularly attention to battery terminals, since they are especially
prone to corrosion. If corroded, clean and cover them with battery terminal
grease.

Check the battery fluid level and add distilled water when necessary. Refer to the
instructions of the battery manufacturer

V 09 – 2016 40
 10.2 Maintenance

There is no special maintenance required however the periodic inspections noted

previously must be performed every 12 months.

V 09 – 2016 41
 11. TROUBLESHOOTING
If problems occur after installation of your new Superwind, most can be solved using the
below troubleshooting list.

At all times be aware of electrical and mechanical hazards:

Do not approach a spinning rotor.

Never try to stop the rotor by hand.

Be careful when doing work on the electrical system, since

most of the lines are live.

Never short-circuit the batteries.

Useful tools for troubleshooting are:

A multimeter (voltage, current, electrical resistance) and

An anemometer (wind speed).

11.1 Wind generator does not start

Wind generator does not start

Table 11.1
Possible source
Test Solution
of errors
Wait for more wind.
Not enough wind Measure wind speed Annotation: start-up wind speed 3,5
m/s (during running-in period
slightly higher)
Stop switch in STOP
Switch to RUN
position
Wrong connection of Check stop switch and
Connect correctly
the stop switch connection
Debris between
Remove the hub from the generator
generator housing and Find the debris
shaft and eliminate debris
hub

V 09 – 2016 42
 Turn generator shaft by
hand. For this test the
Generator shaft is stiff generator must not be Repair by authorized service station
short-circuited (turned
off)
Yaw bearing is stiff,
wind generator does
Move by hand Repair by authorized service station
not follow the wind
direction

11.2 No power output

No power output
Table 11.2
Possible source
Test Solution
of errors
Wait for more wind
Annotation: Charging possibly will
Not enough wind Measure wind speed start only with 4,5 to 5,5 m/s.
(depending on the battery state of
charge)
Current linkage is
Check the cabling Replace defective line or devices
interrupted
Fuse is blown Check the fuse Replace the fuse
Carbon brushes are Check the carbon
Replace the carbon brushes
without contact brushes and the springs
No increased torque
Build-in rectifier is sensible when generator
Repair by authorized service station
defective cables have been short-
circuited.

11.3 Insufficient power output

Insufficient power output

Table 11.3
Possible source
Test Solution
of errors
Measure the electric
Bad electrical Replace defective lines or devices,
resistance of the cabling
connection clean connectors and terminals
and devices
Check the cable cross
Cable resistance too Use cables with higher cross
sections and cable
high sections
lengths

V 09 – 2016 43
 11.4 Battery is not fully charged

Battery is not fully charged

Table 11.4
Possible source
Test Solution
of errors
Battery is too old or Fill up with distilled water, replace
Check fluid level
defective defective battery
Fuse is blown Check the fuse(s) Replace the fuse
Check connection
Charge regulator is not Connect the charge regulator
referring to the wiring
connected correctly correctly
diagram
Charge regulator For troubleshooting see
Repair by authorized service station
defective respective manual

11.5 Checking the open circuit voltage

A simple test to detect an internal defect of the generator is measuring the open circuit
voltage. Disconnect the cables from the generator and connect a voltmeter to the positive
and negative line. To avoid injury, dismantle the rotor blades beforehand. Now turn the
hub by hand. Count the revolutions within a certain period (e.g. 30 revs within 10 seconds
= 180 rpm). Watch the voltage. The voltage and the speed should correspond to the
following diagram:

V 09 – 2016 44
 12. REPAIRS, SPARE PARTS

12.1 Repairs

If your Superwind should be defective, you may replace all parts accessible from the
outside by yourself (e.g. rotor blades, carbon brushes, damping rings). In case of any
other defects, please consult your dealer, an authorized service partner, or the
manufacturer.

Do not open the hub housing

The hub is a safety relevant component. For repair, specialized knowledge and tools are
required. To ensure safe operation, repairs of the hub may only be performed by
authorized service partners or by the manufacturer.

12.2 Spare parts list

Spare Parts
Table No. 12.2
Item
Description Part No.
No
1 set of rotor blades incl. socket cap screw M6 x 25 TUFLOK 0300.05.00.00
2 set of carbon brushes incl. screw caps 0300.01.03.03
3 rectifier (incl. capacitors) 0300.01.04.01
4 generator bearing front 0300.03.02.03
5 generator bearing rear 0300.03.02.04
6 set of damping rings incl. O-ring 40 x 3 0300.02.01.02
7 socket cap screw M8 x 80 V4A DIN 912 0300.04.01.10
8 hexagon socket button head screw M6 x 6 V4A ISO 7380 0300.02.01.12
9 hexagon socket button head screw M6 x 12 V4A ISO 7380 0300.02.01.10

V 09 – 2016 45
 13. FREQUENTLY ASKED QUESTIONS

13.1 Basic use

Q. Can I mount a wind turbine on top my house?

A. The Superwind 350 is not for residential, grid-tied applications. This unit
was designed to charge batteries in off-grid environments only.
In situations where sufficient wind exists - such as farms, cabins, structures on
cliff edges, bluffs, or near the ocean – the Superwind 350 can be an asset.
Unless architecturally engineered to be part of the structure, no wind turbine
should be mounted to the roof of a house.

Q. Other than sailboats, what is the Superwind 350 used for?

A. The Superwind 350 was designed to be a commercial-grade micro wind

generator that has the ability to withstand extreme environmental conditions for
many years. Its applications are numerous, and it has been successfully utilized
by governments, militaries, disaster preparedness & response agencies,
aquaculture, and agriculture industries throughout the world.

Q. Is my boat large enough for a Superwind 350?

A. It is recommended that a Superwind 350 be mounted on a boat 30’ or

larger.

13.2 Installation

Q. How large should my battery bank be?

A. Battery capacity specifications are unique to each individual situation, and

therefore cannot be easily determined by Superwind without more details.
However, even the smallest battery banks that work efficiently with our turbines
typically consist of a minimum of 400Ah (3-4 large batteries).

Q. Do I need a charge controller, stop-switch, and resistor?

A. It is highly recommended that a charge controller be installed to protect

your batteries and turbine. A diversion load resistor (part of the Superwind charge
controlling system) will shed excess loads to avoid overcharging when the
batteries are completely full. The safety-stop switch will allow you to be able to
safely perform maintenance near or around your unit.
The use of a Superwind 12V or 24V SRC marine charge controller is what
enables your system to be completely autonomous and helps ensure full state of
charge and long battery life.

Q. What size wire do I run to the Superwind and the charge controller?

A. The Superwind manual specifies wire sizing for various distances (the
wire run). The proper wire size is important to optimize charging and eliminate the
risk of fire. Refer to page 20 -21 for wiring specifications. Please do not hesitate
to contact us for recommendations regarding your specific project.

V 09 – 2016 46
 Q. Can I hook up to my hot water tank and avoid overcharging?
A. The internal electrical components in hot water tanks will not withstand
overcharging, and will fail. This will, in turn, shed power to your batteries, which
can be very dangerous. Your water tank was not designed as a diversion load,
but our commercial resistor is.

13.3 Operation

Q. Can the Superwind be left ON while unattended (when I am not on

my boat)?

A. The Superwind 350 kit (in 12V or 24V) allows for safe autonomous
operation 24/7 when installed properly with the SRC marine charge controller
and diversion load resistor (included in the kit).
The Superwind 350 is a commercial turbine designed for off-grid use in remote
areas. When installed properly, it is maintenance-free and can be left unattended.
While you can always use the safety-stop switch to temporarily shut down the
unit, it is not required.

Q. Do I need to tie down the Superwind in high winds or storms?

A. No. Tying down a Superwind 350 blade or vane can actually damage the
unit. You can, however, choose to utilize the safety-stop switch to enable the
dynamic (magnetic) brake. The Superwind 350 is designed to operate in wind
conditions nearing hurricane force speeds. In most circumstances, the unit can be
left on without endangering the turbine or the batteries.

Q. How long do the bearings last?

A. The Superwind 350 ‘auto-feathers’ during high wind conditions, which

prevents over speed of the turbine and lessens the wear on the bearings. This
technology allows Superwind units to have a long life – many have been in the
field for over a decade and are still going strong.

Q. If one blade breaks do I replace just one?

A. Superwind rotor blades are manufactured as sets of three balanced by

weight and axial runout. These 3 blades can be fixed to the hub in any order.
However, do not mix and match blades from different Superwind blades sets as
this could cause the rotor to be out of balance. This means that if a single
Superwind blade is damaged, the entire blade set needs to be replaced - not just
one blade.

13.4 Troubleshooting

Q. The Superwind 350 is not producing power.

A. A common installation oversight preventing power production is related to

the safety-stop switch. Ensure all screws on the safety-stop switch are tightened
down securely – even the screws that are not in use. Loose screws can prevent a
closed circuit, and deny power throughout the system. Refer to the manual for
specific stop-switch procedures, if necessary. Again, two of the screws with no

V 09 – 2016 47
 wire attached are actually forming a jumper within the switch; ensure they are
tight.

Q. How can I test to ensure the Superwind unit is producing power?

A. A clamp-on DC amp meter is an inexpensive tool that can be used to test

the power output from the unit. Make sure the amp meter that you purchase is
capable of reading DC amps.
If the batteries are fully charged and the unit is still working in efficient wind, the
charge controller will display an indicator light. When lit, a solid LED light
represents a full state of charge and indicates power is being diverted to the
resistor.
The use of calibrated shunts – when in combination with other charging sources -
is NOT recommended for monitoring power output from the wind turbine.
Calibrated shunts often negatively affect the charge controller, causing
significantly reduced charging and incorrect readings. An amp coil sensor (often
an option with many battery monitoring systems) is recommended instead.

Q. The Superwind 350 is not producing the expected power

A. The Superwind 350 turbine has extremely high quality bearing sets to
allow for a long, nearly maintenance free, service life. These special bearings do
require some weeks or months of a “break in period” to achieve the highest
charging levels at lower wind speed conditions. Leaving the Superwind turbine in
the autonomous “Run” position through all types of weather, including high winds
and storms, will help shorten this break in period.
Please read safety-switch notation above
Do you have a calibrated shunt in your system? If yes, please read
troubleshooting step above.

V 09 – 2016 48
 14. ABBREVIATIONS USED ON THIS MANUAL

AGM ................ Absorbed Glass Mat

AWG ................ America Wire Gauge
DC ................... Direct Current
e.g. ................... For example
EU .................... European Union
ID ..................... Inside Diameter
Kg .................... Kilograms
lbf .....................
LED .................. Light-Emitting Diode
M ...................... Meter or Meters
m/s ................... Meters per second
mm ................... Millimetre or Millimeter
mm2 ................. Square millimetres
OD ................... Outside Diameter
PWM ................ Pulse Width Modulation
Revs ................ Revolutions
rpm .................. Revolutions per minute
Sch .................. Schedule
SCR ................. Superwind Charge Regulator
SOC ................. State of charge
V ...................... Volt (s)
VDC ................. Volt Direct Current
W ..................... Watt (s)

V 09 – 2016 49
 Attachment A
Stop-Switch Mounting Guidelines
09-2016

V 09 – 2016 50
 INSTALLATION

PLEASE DO NOT PROCEED UNTIL

YOU HAVE READ
ALL INSTRUCTIONS
AND
SAFETY INFORMATION

© 2016 superwind GmbH.

Superwind is a Registered Trade Mark of superwind GmbH, Germany

MANUAL VERSION 09-2016

V 09 – 2016 51
 1. GENERAL INFORMATION

1.2 General Information

In stop-position, the switch connects the wires (+) and (-) of your Superwind 350 to short-
circuit its generator to effect substantial reduction of the rotor speed. In stop-position, the
switch also disconnects the shorted generator from the battery circuit.

1.2 Mounting

The stop-switch is only designed for indoor panel mounting. For easy adaption to panels
up to 22 mm thickness, the shaft is adjustable.

Before installing the switch, adjust the shaft to the length required and fix it by means of
the screw (see picture).

Note: For very thin panels, it might be necessary to cut off the screw’s head afterwards for
proper mounting.

1.3 Electrical Connection

Any electrical work may be accomplished only by authorize

and skilled persons!

During any connection work, the related electrical circuit

must be disconnected from the battery terminals!

For optimum brake efficiency, the wires between the Superwind generator and the stop-
switch should be as short as possible. For appropriate conductor cross-section, see
owner’s manual.

It is obligatory to install a fuse of 40 A in the (+) wire

between the stop-switch and the battery!
No fuse must be installed between the stop-switch and the
Superwind generator!

V 09 – 2016 52
 There are 8 wiring posts on the stop-switch. Only those
utilized in Table 1.3.1 should be used.
However, all screws must be tightened down. If this step is
not done, your Superwind unit may not perform correctly.
Remember, part of your annual Superwind inspection is to
ensure all screw connections on the stop-switch are still
tight.

V 09 – 2016 53
 Attachment B
Superwind Charge Regulator 12V (Marine)
Manual
09-2016

V 09 – 2016 54
 INSTALLATION

PLEASE DO NOT PROCEED UNTIL

YOU HAVE READ
ALL INSTRUCTIONS
AND
SAFETY INFORMATION

© 2016 superwind GmbH.

Superwind is a Registered Trade Mark of superwind GmbH, Germany

MANUAL VERSION 09-2016

V 09 – 2016 55
 1. GENERAL INFORMATION

1.1 General Information

The Superwind Charge Regulator (SCR) 12V (Marine) is a charge regulator of the highest
quality and will perfectly and reliably charge your batteries for many years.

However, reliable operation not only will depend on product quality but also on accurate
assembly and proper wiring. Please read this manual carefully before you start the
installation. Please also keep in mind our safety instructions and warning notices. Our
main concern is with your safety.

1.2 Labelling

This manual refers to the Superwind Charge Regulator (SCR) 12V (Marine).

Manufacturer:

superwind GmbH
Am Rankewerk 2-4
D-50321 Brühl
Germany
Tel.: +49 / 2232 / 577357
Fax: +49 / 2232 / 577368
E-Mail: [email protected]
Internet: www.superwind.com

You will find the label with the serial number and the nominal voltage on the side of the
housing.

1.3 Intended use and range of application

The SCR 12V (Marine) is designed to sense and limit the output voltage of a Superwind
350 12V wind generator and thus to prevent batteries from becoming overcharged.

It is suitable for lead acid batteries, gel batteries, and AGM (Absorbed Glass Mat)
batteries, and has two battery charging outputs isolated by Schottky blocking diodes. This
allows the wind turbine to charge two batteries totally independent of each other.

The SCR 12V (Marine) is not influenced by other power sources connected to the
batteries like alternators, gensets, solar arrays, and battery chargers. For that reason, it
can be used very well in complex systems and hybrid systems.

The regulator is fully potted to protect the electronics against humidity and vibration.

Fields of application can be sailing yachts, campers, summer cottages, mountain shelters,
as well as industrial applications like navigational aids, traffic management systems,
environmental monitoring stations, or transmitters.

2 WARRANTY

2.1 Warranty

superwind GmbH warrants this product to be in good working order during the warranty
period. In the event that the product is found to be defective within the warranty period,
repair service will be provided free of charge by superwind GmbH or an authorized
service partner.

V 09 – 2016 56
 Free repair service may only be obtained by providing the warranty card and original
purchase invoice issued to the customer by the retailer. The warranty card must state the
purchaser ́s name, the retailer ́s name and address, the serial number and the date of
purchase of the product. superwind GmbH reserves the right to refuse warranty service if
this information is not complete or has been removed or changed after the original
purchase of the product from the retailer.

2.2 Warranty period

The warranty is valid for three years from the date of purchase by the purchaser, as
evidenced by the above mentioned documents.

2.3 To obtain warranty service

Warranty service is available at superwind GmbH and Superwind authorized service

partners. Any costs of secure transportation of the product to and from superwind GmbH /
Superwind authorized service partners will be borne by the customer.

2.4 Limitations

superwind GmbH does not warrant the following:

Periodic check-ups, maintenance and repair or replacement of parts due to

normal wear and tear.
Defects caused by modifications carried out without superwind ́s approval.
o Includes damage caused by improper use, handling or operation, in particular
defects caused by improper installation and installation on inadequate masts or
support structures.
Installation on inadequate masts or support structures (to obtain warranty service
the purchaser has to provide evidence that masts or support structures are as
recommended in the Superwind 350 manual).
Accidents or disasters or any cause beyond the control of superwind GmbH,
including but not limited to lightning, flooding, fire etc.
Costs for disassembly and reassembly of the product to enable shipment for
warranty reasons.

2.5 Others

Superwind GmbH reserves the right to decide whether the product or parts thereof shall
be repaired or replaced under warranty. Should neither repair nor replacement by
superwind GmbH be possible, the purchaser solely will be entitled to a full or partial
refund (prorated when returned to the manufacture after more than 1 year of use).

This warranty does not affect the purchaser ́s statutory rights under applicable national
legislation in force, nor the purchaser ́s right against the retailer arising from the sales /
purchase contract. In the absence of applicable national legislation, this warranty will be
the purchaser ́s sole and exclusive remedy, and superwind GmbH shall not be liable for
any incidental or consequential damages for breach of any expressed or implied warranty
of this product.

THE GENERAL CONDITIONS FOR THE SUPPLY OF PRODUCTS AND SERVICES OF

THE ELECTRICAL AND ELECTRONICS INDUSTRY APPLY WITH APPROPRIATE
LIMITS AND STANDARDS.

2.6 Expenses and Responsibilities

All associated expenses (shiping to and from the repair facility, insurance, etc) are the full
responsibility of the buyer or his shipping agent, unless the buyer is notified otherwise by
the manufacturer.

V 09 – 2016 57
 Upon receipt of your unit:

The crate should be opened and inspected immediately for damage.

Note any damage to the outside of the package (dents, scratches, etc.) and
document it on the Bill of Lading before signing and keep a copy. Documenting
damage with photos is also highly recommended.
Unpack the unit at once and perform a visual inspection to determine if it is
dented, bent or scratched.
If for any reason the unit should need to be returned, the original crate is the best
way to ship it back to the manufacturer.

2.7 Claims

Claims that occur during transportation must be filed by the consignee (the buyer) as
shipping terms are FOB-EX-WORKS (our distribution point as contracted).

BUYER IS RESPONSIBLE FOR ALL SHIPPING EXPENSES INCLUDING CUSTOMS

DUTIES AND VAT (IMPORT DUTIES).

2.8 Exclusion of liability

The manufacturer shall not be liable for damages caused by use other than as intended or
mentioned in this manual, or if the recommendations of the battery manufacturer were
neglected. The manufacturer shall also not be liable if there has been service or repair
carried out by any unauthorized person, unusual use, incorrect installation, or
inappropriate system design. Opening the charge regulator voids the warranty.

3 SAFETY INSTRUCTIONS
Please carefully study this manual before starting assembly and installation. The
information provided is to ensure your safety during mounting, operation, and in case of
trouble. If you have any additional questions please contact your dealer, a Superwind
service partner, or the manufacturer.

3.1 General safety recommendations

Always abide by the acknowledged rules of any technology

and the rules for accident prevention when working on the
electrical system!

Take care that work on the electrical system like installation,

maintenance, and repair is carried out by qualified persons
only. These persons must also have studied the instructions
given in this manual.

Batteries store a large amount of energy. In any circumstance, avoid short-circuiting the
battery. For your safety, connect a fuse to each of the battery cables.

Charging lead-acid batteries produces inflammable hydrogen gas. Unsealed lead-acid

batteries have vent holes, releasing hydrogen, which forms detonating gas when mixed
with ambient air. A small spark (e.g. from an electrical switch) can detonate the explosive
gas mixture. For prevention, always provide sufficient ventialtion.

Avoid touching and short-circuiting wires or terminals. Be aware that the voltage on
specific terminals or wires can be significantly higher than the nominal battery voltage.
Only use isolated tools, stand on dry grounds, and keep your hands dry.

V 09 – 2016 58
 Please also follow the instructions of the wind turbine operation manual and the safety
recommendations provided by the battery manufacturer.

4. SPECIFICATIONS

4.1 Technical Data

Nominal voltage 12V

Max charging voltage (20° C) 14.4V
Temperature compensation 30 mV / °C
Max. current 40 A
Total resistance of power resistor 0.35 Ohm
Number of charging outputs 2
Method of voltage regulation PWM
Connectors M4

LED indicating that max. charging voltage has been

achieved (batteries are fully charged).

Option to connect external temperature sensor.

The default setting for the maximum charging

voltage can be adapted to special customer
requirements. Since special devices are needed,
proper calibration can only be performed by the
manufacturer.

4.2 Description of functions

The SCR 12V (Marine) has been especially designed for the Superwind 350 12V wind
generator and guarantees optimum charging of the batteries. The secondary function of
the SCR 12V (Marine) is to electronically keep the wind generator under load. When the
batteries have reached their maximum charging voltage, the SCR 12V (Marine) PWM
circuit automatically diverts the wind turbine’s surplus power the the power resistor. Thus,
with batteries even fully charged, the wind turbine continues operation and provides
useable power as soon as electric consumers are switched on. This state of charge is
indicated by the LED and the resistor will make a very slight buzzing sound when
operating and dissipating power.

5. Assembly

5.1 Choosing the position

The charge regulator and the power resistor are designed for indoor use and shall be
mounted at a place well protected from the effects of weather. As the charge regulator
has a temperature sensor in order to adapt the charging voltage to the battery
temperature, it should be placed in the same room with the batteries or in a room with the
same temperature level. If this is not possible, an external temperature sensor is available
which then replaces the standard sensor mounted at the regulator housing.

The distance between the regulator and the battery should be a minimum of 30 cm but not
exceed 200 cm. The distance between the regulator and the power resistor should not

V 09 – 2016 59
 exceed 200 cm. The power resisor must be ventilated properly. Never mount the power
resistor on a flammable surface and take care that no flammable items will be close to the
resistor. Consider the resistor will dissipate all the wind turbine’s power into heat when the
batteries are fully charged.

As a note: if installing on a yacht, a good place for the power resistor is the engine
compartment.

5.2 Connecting the charge regulator

Before connecting the charge regulator, prevent your wind

turbine from unintended starting. Connect the two generator
cables together (CAUTION: make sure to disconnect the
battery before!) or tie one of the rotor blades loosely to the
mast (if accessible).

Slide the regulator’s black cover sidewards and take it off.

Mount the regulator and the power resistor to a dry, plain, and non-flammable surface.
Use appropriate mounting holes.

For connecting the cables to the charge regulator, use the yellow solderless terminals.
The solderless terminals provided are suitable for cable cross-sections from 2.5 mm2 to
6.0 mm2 (AWG 13 to AWG 10).

Use a crimping tool suitable for insulated terminals and check that the terminal has been
securely crimped to the bared part of the cable.

Connect the regulator as shown in Diagram 1.8.1 below.

To prevent your system from damages, the cables must be

connected in the order described below.

1. Connecting the power resistor

Connect the power resistor to the terminals labeled ‘Resistor’ on the charge
regulator. The cross-section of the cables must be a minimum of 4 mm 2 (AWG
12).

2. Connecting the wind generator

Connect the wind generator to the terminals labeled ‘Gen +‘ and ‘Gen –‘ on the
charge regulator.

Never interchange the polarity of the cables. Interchanged

polarity would destroy the charge regulator and void the
warranty.

V 09 – 2016 60
 Marking of the connecting cables at the Superwind 350:

POSITIVE (+): RED

NEGATIVE (-): BLACK

If you are not sure of the polarity of the cables led down from the wind generator,
you can identify POSITIVE (+) and NEGATIVE (-) easily by means of a simple
multimeter before connecting the cables to the charge regulator.

Select DC (range 10 VDC) on your multimeter. There is normally a red measuring

line connected to the V plug and black line to the COM plug. Connect the
measuring lines to the cables coming from the wind turbine. Ask an assistant to
turn the rotor of the wind turbine slowly by hand (avoid touching the blades). The
wind turbine will produce low voltage that is measurable by the multimeter. If the
voltage is indicated by (+) or without prefix, the red measuring line is connected to
the POSITIVE (+) cable. If the voltage is indicated by (-), the red measurement
line is connected to the NEGATIVE (-) cable of the wind turbine.

3. Connecting the batteries

You may connect one or two batteries to the SCR 12V (Marine). Use the
terminals ‘+ Batt. 1‘ and ‘- Batt. 1‘ to connect your first battery and use the
terminals ‘+ Batt. 2‘ and ‘- Batt. 2‘ to connect to your second battery. If two
batteries are connected, they are charged independently and are protected from
discharging each other by the regulator’s internal Schottky blocking diodes.

In order to avoid accidentally short-circuiting, first connect

the cables to the charge regulator and then to the battery

V 09 – 2016 61
V 09 – 2016 62
 Attachment C
Superwind Charge Regulator 24V (Marine)
Manual
09-2016

V 09 – 2016 63
 INSTALLATION

PLEASE DO NOT PROCEED UNTIL

YOU HAVE READ
ALL INSTRUCTIONS
AND
SAFETY INFORMATION

© 2016 superwind GmbH.

Superwind is a Registered Trade Mark of superwind GmbH, Germany

MANUAL VERSION 09-2016

V 09 – 2016 64
 1. GENERAL INFORMATION

1.1 General Information

The Superwind Charge Regulator (SCR) 24V (Marine) is a charge regulator of the highest
quality and will perfectly and reliably charge your batteries for many years.

However, reliable operation not only will depend on product quality but also on accurate
assembly and proper wiring. Please read this manual carefully before you start the
installation. Please also keep in mind our safety instructions and warning notices. Our
main concern is with your safety.

1.2 Labelling

This manual refers to the Superwind Charge Regulator (SCR) 24V (Marine).

Manufacturer:

superwind GmbH
Am Rankewerk 2-4
D-50321 Brühl
Germany
Tel.: +49 / 2232 / 577357
Fax: +49 / 2232 / 577368
E-Mail: [email protected]
Internet: www.superwind.com

You will find the label with the serial number and the nominal voltage on the side of the
housing.

1.3 Intended use and range of application

The SCR 24V (Marine) is designed to sense and limit the output voltage of a Superwind
350 24V wind generator and thus to prevent batteries from becoming overcharged.

It is suitable for lead acid batteries, gel batteries, and AGM (Absorbed Glass Mat)
batteries, and has two battery charging outputs isolated by Schottky blocking diodes. This
allows the wind turbine to charge two batteries totally independent of each other.

The SCR 24V (Marine) is not influenced by other power sources connected to the
batteries like alternators, gensets, solar arrays, and battery chargers. For that reason, it
can be used very well in complex systems and hybrid systems.

The regulator is fully potted to protect the electronics against humidity and vibration.

Fields of application can be sailing yachts, campers, summer cottages, mountain shelters,
as well as industrial applications like navigational aids, traffic management systems,
environmental monitoring stations, or transmitters.

2 WARRANTY

2.1 Warranty

superwind GmbH warrants this product to be in good working order during the warranty
period. In the event that the product is found to be defective within the warranty period,
repair service will be provided free of charge by superwind GmbH or an authorized
service partner.

V 09 – 2016 65
 Free repair service may only be obtained by providing the warranty card and original
purchase invoice issued to the customer by the retailer. The warranty card must state the
purchaser ́s name, the retailer ́s name and address, the serial number and the date of
purchase of the product. superwind GmbH reserves the right to refuse warranty service if
this information is not complete or has been removed or changed after the original
purchase of the product from the retailer.

2.2 Warranty period

The warranty is valid for three years from the date of purchase by the purchaser, as
evidenced by the above mentioned documents.

2.3 To obtain warranty service

Warranty service is available at superwind GmbH and Superwind authorized service

partners. Any costs of secure transportation of the product to and from superwind GmbH /
Superwind authorized service partners will be borne by the customer.

2.4 Limitations

superwind GmbH does not warrant the following:

Periodic check-ups, maintenance and repair or replacement of parts due to

normal wear and tear.
Defects caused by modifications carried out without superwind ́s approval.
o Includes damage caused by improper use, handling or operation, in particular
defects caused by improper installation and installation on inadequate masts or
support structures.
Installation on inadequate masts or support structures (to obtain warranty service
the purchaser has to provide evidence that masts or support structures are as
recommended in the Superwind 350 manual).
Accidents or disasters or any cause beyond the control of superwind GmbH,
including but not limited to lightning, flooding, fire etc.
Costs for disassembly and reassembly of the product to enable shipment for
warranty reasons.

2.5 Others

Superwind GmbH reserves the right to decide whether the product or parts thereof shall
be repaired or replaced under warranty. Should neither repair nor replacement by
superwind GmbH be possible, the purchaser solely will be entitled to a full or partial
refund (prorated when returned to the manufacture after more than 1 year of use).

This warranty does not affect the purchaser ́s statutory rights under applicable national
legislation in force, nor the purchaser ́s right against the retailer arising from the sales /
purchase contract. In the absence of applicable national legislation, this warranty will be
the purchaser ́s sole and exclusive remedy, and superwind GmbH shall not be liable for
any incidental or consequential damages for breach of any expressed or implied warranty
of this product.

THE GENERAL CONDITIONS FOR THE SUPPLY OF PRODUCTS AND SERVICES OF

THE ELECTRICAL AND ELECTRONICS INDUSTRY APPLY WITH APPROPRIATE
LIMITS AND STANDARDS.

2.6 Expenses and Responsibilities

All associated expenses (shiping to and from the repair facility, insurance, etc) are the full
responsibility of the buyer or his shipping agent, unless the buyer is notified otherwise by
the manufacturer.

V 09 – 2016 66
 Upon receipt of your unit:

The crate should be opened and inspected immediately for damage.

Note any damage to the outside of the package (dents, scratches, etc.) and
document it on the Bill of Lading before signing and keep a copy. Documenting
damage with photos is also highly recommended.
Unpack the unit at once and perform a visual inspection to determine if it is
dented, bent or scratched.
If for any reason the unit should need to be returned, the original crate is the best
way to ship it back to the manufacturer.

2.7 Claims

Claims that occur during transportation must be filed by the consignee (the buyer) as
shipping terms are FOB-EX-WORKS (our distribution point as contracted).

BUYER IS RESPONSIBLE FOR ALL SHIPPING EXPENSES INCLUDING CUSTOMS

DUTIES AND VAT (IMPORT DUTIES).

2.8 Exclusion of liability

The manufacturer shall not be liable for damages caused by use other than as intended or
mentioned in this manual, or if the recommendations of the battery manufacturer were
neglected. The manufacturer shall also not be liable if there has been service or repair
carried out by any unauthorized person, unusual use, incorrect installation, or
inappropriate system design. Opening the charge regulator voids the warranty.

3 SAFETY INSTRUCTIONS
Please carefully study this manual before starting assembly and installation. The
information provided is to ensure your safety during mounting, operation, and in case of
trouble. If you have any additional questions please contact your dealer, a Superwind
service partner, or the manufacturer.

3.1 General safety recommendations

Always abide by the acknowledged rules of any technology

and the rules for accident prevention when working on the
electrical system!

Take care that work on the electrical system like installation,

maintenance, and repair is carried out by qualified persons
only. These persons must also have studied the instructions
given in this manual.

Batteries store a large amount of energy. In any circumstance, avoid short-circuiting the
battery. For your safety, connect a fuse to each of the battery cables.

Charging lead-acid batteries produces inflammable hydrogen gas. Unsealed lead-acid

batteries have vent holes, releasing hydrogen, which forms detonating gas when mixed
with ambient air. A small spark (e.g. from an electrical switch) can detonate the explosive
gas mixture. For prevention, always provide sufficient ventialtion.

Avoid touching and short-circuiting wires or terminals. Be aware that the voltage on
specific terminals or wires can be significantly higher than the nominal battery voltage.
Only use isolated tools, stand on dry grounds, and keep your hands dry.

V 09 – 2016 67
 Please also follow the instructions of the wind turbine operation manual and the safety
recommendations provided by the battery manufacturer.

4. SPECIFICATIONS

4.1 Technical Data

Nominal voltage 24V

Max charging voltage (20° C) 28.8V
Temperature compensation 30 mV / °C
Max. current 40 A
Total resistance of power resistor 1.4 Ohm
Number of charging outputs 2
Method of voltage regulation PWM
Connectors M4

LED indicating that max. charging voltage has been

achieved (batteries are fully charged).

Option to connect external temperature sensor.

The default setting for the maximum charging

voltage can be adapted to special customer
requirements. Since special devices are needed,
proper calibration can only be performed by the
manufacturer.

4.2 Description of functions

The SCR 24V (Marine) has been especially designed for the Superwind 350 24V wind
generator and guarantees optimum charging of the batteries. The secondary function of
the SCR 24V (Marine) is to electronically keep the wind generator under load. When the
batteries have reached their maximum charging voltage, the SCR 24V (Marine) PWM
circuit automatically diverts the wind turbine’s surplus power the the power resistor. Thus,
with batteries even fully charged, the wind turbine continues operation and provides
useable power as soon as electric consumers are switched on. This state of charge is
indicated by the LED and the resistor will make a very slight buzzing sound when
operating and dissipating power.

5. Assembly

5.1 Choosing the position

The charge regulator and the power resistor are designed for indoor use and shall be
mounted at a place well protected from the effects of weather. As the charge regulator
has a temperature sensor in order to adapt the charging voltage to the battery
temperature, it should be placed in the same room with the batteries or in a room with the
same temperature level. If this is not possible, an external temperature sensor is available
which then replaces the standard sensor mounted at the regulator housing.

The distance between the regulator and the battery should be a minimum of 30 cm but not
exceed 200 cm. The distance between the regulator and the power resistor should not
exceed 200 cm. The power resisor must be ventilated properly. Never mount the power
resistor on a flammable surface and take care that no flammable items will be close to the

V 09 – 2016 68
 resistor. Consider the resistor will dissipate all the wind turbine’s power into heat when the
batteries are fully charged.

As a note: if installing on a yacht, a good place for the power resistor is the engine
compartment.

5.2 Connecting the charge regulator

Before connecting the charge regulator, prevent your wind

turbine from unintended starting. Connect the two generator
cables together (CAUTION: make sure to disconnect the
battery before!) or tie one of the rotor blades loosely to the
mast (if accessible).

Slide the regulator’s black cover sidewards and take it off.

Mount the regulator and the power resistor to a dry, plain, and non-flammable surface.
Use appropriate mounting holes.

For connecting the cables to the charge regulator, use the yellow solderless terminals.
The solderless terminals provided are suitable for cable cross-sections from 2.5 mm2 to
6.0 mm2 (AWG 13 to AWG 10).

Use a crimping tool suitable for insulated terminals and check that the terminal has been
securely crimped to the bare part of the cable.

Connect the regulator as shown in Diagram 1.8.1 below.

To prevent your system from damages, the cables must be

connected in the order described below.

1. Connecting the power resistor

Connect the power resistor to the terminals labeled ‘Resistor’ on the charge
regulator. The cross-section of the cables must be a minimum of 2.5 mm 2 (AWG
13).

2. Connecting the wind generator

Connect the wind generator to the terminals labeled ‘Gen +‘ and ‘Gen –‘ on the
charge regulator.

Never interchange the polarity of the cables. Interchanged

polarity would destroy the charge regulator and void the
warranty.

V 09 – 2016 69
 Marking of the connecting cables at the Superwind 350:

POSITIVE (+): RED

NEGATIVE (-): BLACK

If you are not sure of the polarity of the cables led down from the wind generator,
you can identify POSITIVE (+) and NEGATIVE (-) easily by means of a simple
multimeter before connecting the cables to the charge regulator.

Select DC (range 10 VDC) on your multimeter. There is normally a red measuring

line connected to the V plug and black line to the COM plug. Connect the
measuring lines to the cables coming from the wind turbine. Ask an assistant to
turn the rotor of the wind turbine slowly by hand (avoid touching the blades). The
wind turbine will produce low voltage that is measurable by the multimeter. If the
voltage is indicated by (+) or without prefix, the red measuring line is connected to
the POSITIVE (+) cable. If the voltage is indicated by (-), the red measurement
line is connected to the NEGATIVE (-) cable of the wind turbine.

3. Connecting the batteries

You may connect one or two batteries to the SCR 24V (Marine). Use the
terminals ‘+ Batt. 1‘ and ‘- Batt. 1‘ to connect your first battery and use the
terminals ‘+ Batt. 2‘ and ‘- Batt. 2‘ to connect to your second battery. If two
batteries are connected, they are charged independently and are protected from
discharging each other by the regulator’s internal Schottky blocking diodes.

In order to avoid accidentally short-circuiting, first connect

the cables to the charge regulator and then to the battery

V 09 – 2016 70
V 09 – 2016 71