User manual SOUTHWEST WINDPOWER AIR STERNMOUNT MARINE TOWER KIT REV B

[. . . ] Contents: Step 1: Site Evaluation ___________________________________________ 4 Step 2: Saddle Clamp Installation __________________________________ 5 Step 3: Mast Base Assembly ______________________________________ 6 Step 4: Mast Base Installation _____________________________________ 7 Step 5: Stay Base Installation _____________________________________ 7 Step 6: Wiring and Final Assembly __________________________________ 8 Mast and Stay Specifications ______________________________________ 10 Drill Guide Template For Poles _____________________________________ 11 In this manual you will see the following icon: WARNING: Indicates risk of severe injury or death or possible severe damage to equipment - proceed with caution and follow instructions. 12 AIR Sternmount Marine Tower Owner's Manual AIR Sternmount Marine Tower Owner's Manual 1 Parts List Your new tower kit includes: Quantity: ·Stainlesssteelendcaps __________________________________4 ·Mastvibrationdampeningmount (with bolt, washers, nut and bracket) ________________________1 ·Stayvibrationdampeningmounts __________________________2 ·Staybasebracket _______________________________________2 ·Masthingebaseanglebrackets ___________________________2 ·Mastsaddlestraps ______________________________________4 ·Mastwiringgrommet ____________________________________1 ·3/8inch-16x2inchstainlesssteelsocketheadscrews _______2 ·5/16inch-18x¾inchstainlesssteelsocketheadscrews _____2 ·5/16inch-18x1inchstainlesssteelsocketheadscrews _____4 ·¼inch-20x1-¾inchstainlesssteelsocketheadscrews ______4 ·8-32x½screws ________________________________________2 ·3/8inch-16nylonlocknuts _______________________________2 ·5/16inch-18nylonlocknuts _____________________________6 ·¼inch-20nylonlocknuts ________________________________4 ·3/8inchstainlesssteelextrathickwasher ___________________2 ·3/8inchlockwasher ____________________________________2 ·1/8inchthickrubberadaptersleeve (for stainless steel towers only) ____________________________1 ·Powdercoatedorstainlesssteelmast ______________________1 ·Powdercoatedorstainlesssteelstays ______________________2 Pleaseinspectthecontentswiththeabovelisttofamiliarizeyourself with all parts. See page 10 for kits not including mast or stays for correct preparation information. 2 AIR Sternmount Marine Tower Owner's Manual AIR Sternmount Marine Tower Owner's Manual 11 Mast and Stay Specifications For kits not including mast or stays: If you opted to purchase a hardware kit without the mast and stays, you will need to make your own poles prior to proceeding with the installation. The materials you will need are: Two (2) stays of 9-12 foot (2. 7 m-3. 7 m) lengths of 1 inch (25. 4 mm) outer diameter aluminum pipewithawallthicknessof1/8inch(3. 18 mm). Ifstainlesssteelstaysaredesired, 1inch(25. 4mm)outerdiameter, 0. 095inch(2. 41mm)wallthicknessorthickerpipeisrecommended. · The stays should be long enough to support the tower structure in high wind conditions and short enough to allow for proper blade clearance. [. . . ] You must use your judgment to determine how best to attach the brackets to your boat. Priortoassembly, itisagoodideatogatherallthetoolsnecessaryfor the installation. These include: · Powerdrill · A¼inchdrillbit(6. 4mm) · Hacksawwithacoursetoothblade · Measuringtape · Siliconecaulk · Hexwrenches:7/16inch, ½inch, 9/16inch · Hexkeys:1/8inch, 3/16inch, 7/32inch · Asecondpersontohelpyouwiththeinstallationprocess. Once you have checked all your parts and you have gathered all the necessary tools, you are ready to begin the installation process. Safety and Installation Information The most important factors that must be taken into consideration when installing your tower are SAFETY and performance. WARNING: Any wind turbine has high-speed spinning parts and it can be very dangerous if the turbine is installed improperly! 10 AIR Sternmount Marine Tower Owner's Manual AIR Sternmount Marine Tower Owner's Manual 3 WARNING: The AIR must be installed in a place high enough so that a person cannot come in contact with the spinning blades while the turbine is in operation. Followyourturbinemanual'sinstructionsforattachingtheturbinetothe tower. Permanentlyattachtheendcapstothestaysandboltthebrackettothe deck. Re-assemblethestayvibrationmount(seefigure5). Raise the mast, with turbine attached, and secure the stays to the bracket assembly. Tighten all end cap set screws and saddle clamp hardware. Tighten the bolts at the swivel base from the nut side (see figure 4). The second important rule is to locate the AIR in a place where the turbine is free from obstructions. The more open the area around the turbine, the better performance you will receive, and the less the chance your turbine will hit something. Be especially aware of any overhead obstructions (e. g. your boom or sail rigging). Maintenance Periodicallytightenallscrewsandboltsinthebasebracketstomake sure the tower hardware has not been loosened by vibration or wear. Step 1: Site Evaluation While evaluating your site location, keep in mind that the stays need to be mountedatleast3. 5feet(1. 1m)andnomorethan6. 5feet(2. 0m)away from the turbine mast (see figure 1). The spread angle between the stays shouldbeascloseto90degreesaspossible, plusorminus20degrees (see figure 2). If the stays are to be mounted to a vertical or steeply sloped surface, such as the bulkhead, these guidelines may not apply. Fig. 1 Safe distances from mast to stays. 4 AIR Sternmount Marine Tower Owner's Manual AIR Sternmount Marine Tower Owner's Manual 9 Fig. 2Safeanglesbetweeneachstay. Fig. 5Staymountingbracketassembly. Have your assistant raise the mast while you hold the ends of each stay. As you do this, position each bracket base where they will provide the most rigid assembly. Determine the proper length for each stay and if necessary cut them with a hacksaw to meet the criteria specified in Step 1: Site Evaluation. When each stay is in the correct position, mark the bracket hole location onthedeck. Tightenthesetscrewintheendcap, andusea¼inch(6. 4 mm)bittodrilltheboltholesintothestayonesideatatime. Fastenthe endcapswitha¼inch-20x1-1/2socketheadscrewanda¼inch-20 nut. Drill the three bracket holes and mount the bracket assembly to the deck. Make sure there are no objects below the turbine that would allow someone to step onto and possibly come in contact with the operating turbine. It is also very important to find a secure spot on the deck or transom since the mast and stay bases will be under stress. [. . . ] If the mast slips on the vibration mount, remove the mast base from the deck and repeat steps 3 and 4, making sure to securely attach the mast to the isolator. Fig. 3Saddleclamp, endcapandstayassembly. Step 3: Mast Base Assembly Pushthelargenoiseisolatorintothebottomofthemastandtightenthe bolt securely. If you are using a stainless steel mast instead of an aluminum mast, you must first slip the silicone adapter onto the rubber isolator before you insert the isolator into the bottom of the mast. Tightening the boltwillexpandtherubberisolatorinsidethemast, therebysecuringthe mast to the base. Step 5: Stay Base Installation By now you should have a good idea where the stay brackets will be positioned on the deck. Mounting the stays too far apart or too close together will result in inadequate tower support in high wind or rough seas. [. . . ]