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Wind-generators

The AIR 403 Marine has been fully protected against harsh, corrosive, salt-water environments. The entire exterior of the Marine body is powder-coated with a UV and corrosion resistant coating. The unit is completely sealed to prevent water entry, and stainless steel hardware is used throughout the machine. In addition, a Teflon corrosion inhibitor is used on all fasteners
What kind of batteries should I use with my AIR 403?
Only batteries intended for power system applications should be used. This means "deep cycle" type batteries, and not the Marine deep cycle type as these are not intended for the same application. Typically "true" deep-cycle batteries will be rated in amp-hours and have some indication of the number of charge-discharge cycles that are available. Beware of the dubious claims of "deep-cycle" claimed by the manufacturers of inexpensive batteries.

Will it hurt my AIR 403 to short-circuit the output?
No, the AIR 403 is designed to be short-circuited as a normal shutdown procedure. The function of the stop switch is to both disconnect the turbine from the batteries as well as short-circuit the output of the turbine. BE SURE NOT TO SHORT YOUR BATTERIES!

Can the output of my AIR 403 be changed by the potentiometer?
The Air 403 produces 100% of the power of which it is capable according to the wind speed. The potentiometer only changes the voltage setting at which the Autobrake engages. Changing this setting will not increase the ampere output of the machine but may overcharge your batteries.

How does the AIR 403 regulate my batteries?
The internal circuitry monitors the voltage at the output of the turbine. When the maximum charging voltage is reached (adjustable by the potentiometer on the side of the turbine) the Autobrake is engaged. This cuts off the turbine output, and the blades are braked to a slow rotation. The Autobrake remains on until the voltage drops to a level slightly below that of a fully charged battery (12.6V for 12V, 25.2V for 24V, etc.) At this point the Autobrake releases and the turbine resumes charging.

Can I use an external charge controller to regulate my 403?
We recommend using only diversion load type charge regulators with the AIR 403. These regulators divert excess power to a heating element or power resistor when the batteries are full. This excess power can be used to assist in hot water or room heating. PV type regulators should never be used. Series type regulators that disconnect the power source when batteries are full will often give undesirable results such as causing the Autobrake to fluctuate on and off when the batteries become full.

The open-circuit voltage of my AIR 403 is far above my batteries. Is this normal?
When connected to batteries, the AIR 403 spins freely until it reaches the battery voltage. When the voltage of the turbine rises above battery voltage, current (amps) begins to flow, as current is a function of a difference in voltage. The greater the difference in voltage, the greater the current is.

If no battery is connected, then the turbine will continue to increase in voltage (provided there is sufficient wind) until almost double the rated voltage is reached. At this point the Autobrake is engaged and the turbine slows down. For a 12V turbine this happens at about 23V.

It should be noted that, when the turbine is open circuit (not connected to batteries), the Autobrake will slow the blades, and the voltage from the turbine will drop. The Autobrake will release until the blades spin up again, and then re-engage. This leads to an oscillation that is more strenuous on the turbine than normal operation. For this reason you must short the positive turbine output wire to the turbine negative wire whenever it is not connected to a load to achieve the maximum life from your turbine.

If you observe your turbine oscillating in the manner described above, check the fuse or breaker for the turbine as it may be expired.

Why does my AIR 403 regulate before my batteries are fully charged?
This will happen if your wires are too small. This can also happen if the AIR is connected in parallel with another charging source, and there is some distance between this connection and the batteries. The other charging source can create a voltage drop because of its own current output, which will raise the voltage that the turbine sees".

Be sure to check ALL of your wire connections. All connections should be soldered, split bolted, or secured in a terminal block. CRIMP-ON TYPE CONNECTORS MUST NEVER BE USED! These are poor connection for high currents and will almost always have some resistance at the male/female connection that will increase your voltage drop and line loss.

How does wire sizing or voltage drop affect the regulation of my AIR 403?
When current (amps) passes across a resistance (ohms), it creates a voltage difference (voltage drop). Higher current or higher resistance causes a greater voltage drop. All wire has some resistance to it; the smaller the wire the greater the resistance. If you use undersized wire, then the turbine will see a higher voltage than the batteries as it''s output increases, even though the battery voltage may remain the same. If the voltage at the machine exceeds the regulation set point of the control circuit, then the turbine will regulate even though the batteries are not fully charged.

Example: A 12V AIR 403 is connected to a very large battery bank via 75 feet of 10g stranded wire. The battery bank is at 12.0V.

The resistance of the wire is 75ft x 0.00129 ohms/ft = 0.097 ohms, multiplied by 2 conductors for the positive and negative = 0.194 ohms. When the turbine is producing 1 amp, the voltage drop across the wires is 1 x 0.194 = 0.194 volts, which isn''t that much. But at 15 amps, the voltage drop becomes 15 x 0.194 = 2.91 volts. This means that while the battery bank is at 12.0V, the turbine thinks it is at 14.91V. If your turbine is set for 14.1V (the factory setting), the Autobrake will engage. There will then be no voltage drop, the turbine will see 12.0V, and will begin charging again until the output climbs again. The turbine thus cycles in and out of regulation, even though the battery is not fully charged.

What effect does radio interference have on my AIR 403?
The internal circuitry of the AIR 403 is shielded and filtered to prevent radio interference, and has been tested to insure electro-magnetic compatibility.

What effect does my AIR 403 have on radio transmissions?
The AIR 403 normally does not affect radio transmitters. Care should be taken, however, to route power lines from the AIR away from the power and antenna lines of a radio transmitter. An old ham radio operator''s trick is to twist positive and negative wires together to provide an even distribution of EMF noise across both wires, which serves to cancel out the electrical noise created. This technique can be used on the AIR power lines, on the radio''s power lines, and on transmission wires. Transmission lines should always be kept as far from power lines as is practically possible. Proper grounding of the AIR and other system components must also be observed.

Will it affect the regulation of my AIR 403 to install an RF (radio frequency) filter?
Any electronic devices placed in line with the AIR must be rated for the proper current and voltage. The filter will not have any significant effect on regulation UNLESS the filter is between the AIR and the batteries. If the filter has any internal resistance, the regulation of the turbine will be affected in the same manner as undersized power lines (that being increased line loss and voltage drop, leading to pre-regulation.) It is best to place any line filters on the power lines for the load device (transmitter) that requires it, and as close to the device as possible.