913 Owners Manual G
Contents
1. Static Tests e Is the battery in good condition Check the voltage and electrolyte level of 4 each battery Check electrical continuity throughout the system especially corrosion and poor connections in cable joins and connector blocks Running Tests Check for power output from the windcharger following this procedure A Set a digital multimeter to DC Amps scale of between 5 and 10 if possible Connect the meter positive probe to the wind generator output positive cable and the meter negative to the regulator input positive Provided there is sufficient wind there should be a current reading This establishes that power is being delivered Using the same multimeter setting as above measure between the regulator to battery and the battery Provided there is sufficient wind there should be a current reading This establishes if power is passing through the regulator If both above are unsuccessful set the multimeter to DC Volts Disconnect the wind generator from the regulator and connect the meter to the wind generator and the meter to the wind generator Provided there is sufficient wind there should be a variable voltage reading according to the speed of the wind seen at the wind turbine This will establish if the wind generator is able to deliver power or not If tests A and C are successful but test B fails to produce results connect the wind generator directly to the battery Set the digita2. 0 16 in diameter e The shackles should be a minimum of 5mm 0 20 in diameter e Rigging screws should be a minimum of 5mm 0 20 in diameter e All items should be galvanised or stainless steel for protection against corrosion e Where guy lines are looped the loop must incorporate a thimble and be fitted with a minimum of three rope grips e All ground fixings must be made suitable according to the terrain We suggest pivot type towers as these allow for easier installation and lowering for access to the wind generator Two forms of pivot tower are suggested in Figs 6 amp 7 A base hinged 6 4m tall Land Tower Kit Part No CA 12 08 and Rigging Kit Part No CA 12 07 are available from Marlec 7 Marlec Engineering Co Ltd Rutland 913 Windcharger Owner s Manual ASSEMBLY AND INSTALLATION OF THE WINDCHARGER Blade Assembly Fig 8 1 Place the generator assembly on a flat surface hub side down 2 Position blade as shown The blades will only fit one way round Insert the protrusion at the trailing edge of the blade root fixing first into socket to align with the corresponding recess in the blade socket The blade can then be easily inserted with a lever action Gentle assistance with a soft faced mallet may be required 3 Four screws are required for each blade Secure each blade with two special self tapping screws provided by inserting each in turn through the cutout in the nacelle rotating
3. Stainless Steel 1 16 SWG Aluminium 17 10 SWG We suggest the following mountings according to preference and site conditions e Push pit Fig 3 A suitable pole mounted to the deck with deck plates and guy ropes is the most popular method of mounting the Windcharger on yachts eg Rutland 913 Mounting Kit e Mizzen Fig 4 Mizzen mounting is suitable on larger yachts taking advantage of greater wind flow the higher the wind turbine is mounted e River Boats Fig 5 A pivot pole is ideal for riverboats as the Windcharger can easily be raised and lowered 6 Marlec Engineering Co Ltd Rutland 913 Windcharger Centre pivoted pole Base pivoted with gin pole Document SM 130 Issue G 26 10 06 Owner s Manual Land Based Systems The Rutland 913 is suitable for some land based temporary and leisure applications We recommend the Furlmatic model windchargers for land based remote and exposed locations The Rutland 913 is designed to fit inside aluminium stainless or steel tube with an internal diameter of 41mm 1 IMPORTANT The external diameter MUST NOT exceed 48 5mm 1 see Warning in Introduction A suitable mounting pole can be erected using a 6 5 metre 21 feet galvanised medium tube The tube must be supported by a minimum of four guy lines The attachment points for the guy lines to the tower should be securely fixed to the tower e The guy wires should be a minimum of 4mm
4. fuse supplied must be fitted to protect the system unless used in conjunction with a controller that is already fitted with a charge fuse e High winds in high winds the windcharger s built in thermostat may operate to prevent the generator overheating In this mode the output will cease and the turbine will temporarily speed up until such time as the lower level temperature is reached and the generator is once again connected and charging This may be seen to cycle in prolonged high winds particularly in high ambient temperatures If safely accessible you may prefer to temporarily secure the turbine e The Rutland 913 Windcharger is suitable for sailing boats and some land based applications When storm winds are forecast the turbine can be restrained to minimise wear and tear particularly when installed on land based applications where Furlmatic model windchargers are normally recommended Note that where the manufacturer recommends a furling type windcharger should have been used the warranty is invalidated in cases of storm damage e If in doubt refer to your dealer a competent electrical engineer or the manufacturer Document SM 130 Issue G 26 10 06 3 Marlec Engineering Co Ltd Rutland 913 Windcharger Owner s Manual CHECK YOU HAVE RECEIVED 24 x No 10x25mm special self tapping screws 1 x fuse and fuse holder 1 x main generator assembly 6 x aerofoil blades 1 x nose cone 3 x nylon fixing screws 1 x 6mm Allen key 1
5. or the manufacturer 10 Marlec Engineering Co Ltd Rutland 913 Windcharger Owner s Manual ELECTRICAL CONNECTION amp FITTING TO THE TOWER 1 2 poa Nn as Run the cable selected see Table 1 down the inside of the pole Select one of the 2 basic wiring systems on page 12 and follow the manual provided with the voltage controller Fit the in line fuse and fuse holder in the circuit where the HRS type or no regulator is used t is essential that a charge fuse is fitted but note that some Marlec controllers incorporate one negating the need for a separate fuse Cut the fuse holder cable and strip back the ends to allow connection in the circuit es I Fig 12 20A Fuse and Fuse holder Connect the wind generator flying leads to the cable protruding from the tower using the connector block supplied taking care to observe polarity Connect the windcharger to cable and windcharger to cable Red is Positive Black is Negative Wrap the connection with insulation tape to secure protect from environment Alternatively join the cables using a latching type plug and socket Locate the wind generator into the tower whilst gently easing the cable from the tower base to ensure the cable is not trapped Secure the wind generator to the tower using the button cap screws and shake proof washers provided tighten using the 6mm Allen key provided FINAL MECHANICAL CHECK l Ch
6. speed as one gets closer to the ground Turbulence is caused by the wind passing over obstructions such as moored boats trees and buildings Both wind sheer and turbulence diminish with height and can be overcome simply by putting the turbine sufficiently high above them as shown in Fig 1 Windspeed decreases and turbulence increases where obstructions exist Consider also that downwind obstructions can be as detrimental to performance as upwind obstructions It is therefore essential that the wind generator should be located in an area as free as possible from disturbed wind flow AREA OF TURBULENCE WIND DIRECTION Document SM 130 Issue G 26 10 06 5 Marlec Engineering Co Ltd Rutland 913 Windcharger Document SM 130 Issue G 26 10 06 Owner s Manual On Board Systems The wind generator should be mounted in a safe position a minimum of 2 3 metres 7 6 feet above the deck and away from other obstacles which could interfere with the blades or tail assembly Fig 2 The Rutland 913 Mounting Kit PartNo CA 12 02 is available for deck mounting or short sections of stainless steel tube of 1200mm 47 and 600mm 23 pre drilled are also available for your own fabrication The Rutland 913 is designed to fit inside an aluminium or stainless steel tube with an internal diameter of 41mm _ 1 IMPORTANT The external diameter MUST NOT exceed 48 5mm 17s see Warning in Introduction Suitable tubes
7. Rutland 913 Windcharger Owner s Manual Document No SM 130 Issue G 26 10 06 CE Rutland 913 Windcharger Owner s Manual Contents Page INTRODUCTION sesso creas ico van ae se aaaevon e a R 2 GENERAL GUIDELINES amp WARNINGS ccc eee e ee ene ene es 2 CHECK YOU HAVE RECEIV ED aj ivncassstadesneswendeteadeavea Meseopelacoatnesss 4 WHAT YOU WILL NIB BID 5a race asaava nen op ogeaatena al camuces vohasaen evans 4 SITING THE WINDCHARGER sciccsasncssevessasnanesccotacessteaspaarcddavevoaeveds 5 General CoOnsideranOns siyever csevaateonesae ceatseeeGiaienns 5 On Board SW SUING sesia02sckte dex tecwcebdastaaneeatieecenac es tenes 6 Land based 3S VSLEMIS ae ieciacs adacectarnuepeucacccdseelaaecatess 7 ASSEMBLY amp INSTALLATION ccsccsssscssssssseerssersssnssensesnerenaes 8 Blade FA SSEMDIY vps ceazenuunds contoaessp smcaerausn sy nase sieenarsRs 8 Tower Preparation 44 c cstioetuiartaasia Gechrtenare theres 9 BATTERIES nennti e oeas a aeare R 10 CABLE SPECIFICATION ni eriet ea taia 10 ELECTRICAL CONNECTION amp FITTTING TO THE TOWER 1 FINAL MECHANICAL CHECK ccccscessecssescereeneesnees 11 BASIC WIRING DIAGRAMG ccscssscssscsscsensecnseenseesseeenecenseeneees 12 UPF AND RUNNING Sis ere ee e a ede ese 13 SPECIFICATION AND PERFORMANCE cccecccesteesteeeneeeneeeneeens 13 INSPECTION AND MAINTENANCE ccecccessceseeeeeeeeeeeeeeeneeenees 14 TROUBLESHOOTING per
8. ea np a e ER r Ea TE 15 Document SM 130 Issue G 26 10 06 1 Marlec Engineering Co Ltd Rutland 913 Windcharger Owner s Manual INTRODUCTION Congratulations on your Rutland 913 purchase The utmost of care goes into the manufacture of all our products in our ISO9002 approved factory To ensure you get the very best out of the Rutland 913 Windcharger we recommend that you read this manual and familiarise yourself with its contents before installing and operating the Windcharger system The Rutland 913 is designed to provide a direct current DC power supply via a battery bank for 12 24V equipment lighting etc It is robustly constructed and designed to give many years of trouble free service with the minimum of maintenance Please take notice of our General Guidelines amp Warnings and Inspection amp Maintenance sections GENERAL GUIDELINES amp WARNINGS Mounting pole outside diameter MUST NOT exceed 48 5mm for at least the top 0 5m Larger section poles must not be used as this will reduce the tower to blade clearance In high wind conditions this could cause damage to the windcharger by allowing the blade to come into contact with the mounting pole A broken blade will cause turbine imbalance with consequent damage When turning the Windcharger is capable of generating voltages in excess of the nominal voltage The turbine must never be allowed to rotate unless it is electrically connected to a regulator or batteries Connecting a
9. eck the tightness of the blade fixing screws and generator mounting screws 2 Check free rotation of the hub and yaw axis Document SM 130 Issue G 26 10 06 11 Marlec Engineering Co Ltd Rutland 913 Windcharger Owner s Manual Rutland 913 with HRS913 Regulator Wiring Diagram HRS913 Regulator Rutland 913 sl Se Red Brown Black Black Red O gt lt O _ Charge Fuse Battery Rutland 913 with HRDX Controller HRDX Controller HRDX CHARGE CONTROLLER Rutland 913 Q oO Z X Black Steerer Red ETAPER de Toy Battery Battery ae anaes eee a Document SM 130 Issue G 26 10 06 12 Marlec Engineering Co Ltd Rutland 913 Windcharger Owner s Manual UP AND RUNNING Ww N o Before raising and securing the wind generator check that All final mechanical checks have been made The cable is not trapped All electrical connections are secure and safe The wind generator can now be raised into position Take care to avoid all moving parts when raising and lowering the wind generator When raised secure the structure firmly in an upright position The performance of your Windcharger can be impaired if the pole is not vert
10. esponsibility is assumed for consequential damage No responsibility is assumed for damage caused by user modification to the product or the use of any unauthorised components No responsibility is assumed for use of a non furling versions of the Rutland Windcharger where Marlec or one of its authorised agents finds that a generator incorporating a furling device should have been used Manufactured in the UK by Marlec Engineering Co Ltd Rutland House Trevithick Rd Corby Northants NN175XY UK Tel 44 0 1536 201588 Fax 44 0 1536 400211 Email sales marlec co uk www marlec co uk
11. ical SPECIFICATION AND PERFORMANCE The curve shown below is for ideal non turbulent wind conditions this may not be achieved in some installations Charge into 12v Battery Amperes Charge into 24v Battery Amperes 20 18 16 WINDSPEED CONVERSION 14 MPH Knots x 1 15 M S Knots x 515 12 10 0 5 10 15 20 25 30 35 40 Windspeed Knots Document SM 130 Issue G 26 10 06 13 Marlec Engineering Co Ltd Rutland 913 Windcharger Owner s Manual INSPECTION AND MAINTENANCE The Rutland 913 requires no scheduled maintenance but an annual inspection should be carried out to monitor the general condition of the system to ensure the electrical and mechanical integrity and safety of the system WARNING Before inspection the turbine should either be lowered to the ground or tied to prevent the generator from turning To stop the generator from turning proceed as follows 1 Either rotate the switch to stall mode on the HRDX Controller if used OR turn the wind generator out of the wind 180 using the tail a hole is provided in the tail fin to assist in this The generator will gradually slow down 2 Tie a blade to the mounting pole to prevent it from rotating Whilst the generator is stationary the following routine checks should be performed 1 Check the blades for damage eg chips or nicks Replace any damaged blades The turbine should not be operated with damaged blades as this may cause imbalance resulting in p
12. l multimeter to DC Amps and measure power between the wind generator and the battery Ifa reading is measured providing there is sufficient wind then the regulator is faulty If the wind turbine fails to deliver any current or open circuit V reading undertake the further tests below Document SM 130 Issue G 26 10 06 15 Marlec Engineering Co Ltd Rutland 913 Windcharger Owner s Manual 5 Mechanical inspection It may be necessary to remove the windcharger from its pole for the following tests e Check the brushes and slipring for wear or damage To inspect the brushes remove the nacelle by removing the three fixing screws and slide the nacelle backwards towards the tail fin The brushes and slipring can be inspected by removing the four self tapping screws holding the brush holder assembly in place Remove any black deposits from slipring with emery paper Heavy deposits and reduced power indicate a possible reverse connection to the battery see Page 10 e Check hub for free rotation with generator disconnected from battery If the hub does not rotate freely check for a possible short circuit in the wiring If no wiring fault is found refer to your dealer or manufacturer If the above checks have identified a need for spare parts or failed to identify the problem you should contact Marlec who can advise you of your nearest distributor in their world wide network In the first instance we recommend that you contact the com
13. n open circuit running turbine to the electrical system can cause serious damage to system components owing to excessive voltage Caution must be exercised at all times to avoid electric shock Stopping the turbine this may be necessary to undertake battery maintenance If possible stopping the turbine should be done in low windspeed conditions The turbine can be slowed by rotating or orienting the tail fin upwind this will slow the turbine sufficiently for it to be safely secured to the pole with rope Avoid leaving the turbine tied up for any period of time we recommend that the turbine either be covered to give protection from the weather or removed and stored in a dry location The optional HRDX Controller incorporates a shutdown switch e Choose a calm day to install the equipment and consider other safety aspects No attempt to repair the system should be made until the wind generator is restrained from turning Document SM 130 Issue G 26 10 06 2 Marlec Engineering Co Ltd Rutland 913 Windcharger Owner s Manual e The Windcharger is fitted with ceramic magnets which can be damaged by heavy handling The main generator assembly should be treated with care during transit and assembly e It is essential to observe the correct polarity when connecting the Windcharger and all other components into an electrical circuit Reverse connection will damage the Windcharger and incorrect installation will invalidate the warranty e The
14. pany from whom the product was originally purchased If in doubt refer to your dealer or manufacturer Document SM 130 Issue G 26 10 06 16 Marlec Engineering Co Ltd Rutland 913 Windcharger Owner s Manual For your future reference we recommend you note the following Serial Number Date of Purchase Date of Installation Type of Regulator Lenn Document SM 130 Issue G 26 10 06 17 Marlec Engineering Co Ltd LIMITED WARRANTY The Marlec Engineering Company Limited Warranty provides free replacement cover for all defects in parts and workmanship for 12 months from the date of purchase Marlec s obligation in this respect is limited to replacing parts which have been promptly reported to the seller and are in the seller s opinion defective and are so found by Marlec upon inspection A valid proof of purchase will be required if making a warranty claim Defective parts must be returned by prepaid post to the manufacturer Marlec Engineering Company Limited Rutland House Trevithick Road Corby Northamptonshire NN17 5XY England or to an authorised Marlec agent This Warranty is void in the event of improper installation owner neglect misuse damage caused by flying debris or natural disasters including lightning and hurricane force winds This warranty does not extend to support posts inverters batteries or ancillary equipment not supplied by the manufacturer No responsibility is assumed for incidental damage No r
15. remature wear and possible failure Check the blade screws for tightness Check all other nuts bolts and screws for tightness Check the yaw axis for free rotation Check tower assembly for condition Check the tension of the guy wires if applicable The tension of guy wires should be checked frequently during the first year 6 The unit can be wiped with a mild detergent and rinsed with water to remove dirt and debris MA BW bd Note The Windcharger is designed for continuous running to achieve maximum resistance to water ingress should the unit be restrained for any extended period it is recommended that it be covered Document SM 130 Issue G 26 10 06 14 Marlec Engineering Co Ltd Rutland 913 Windcharger Owner s Manual TROUBLESHOOTING In the unlikely event that your Rutland 913 should develop a defect the turbine should first be tied to prevent the blades from turning to perform the static tests below Follow the procedure described in the Inspection and Maintenance section It will be necessary to let it run for the tests to check for power production l Read the Electrical Connection and Up and Running sections and be satisfied that your system complies Is there sufficient wind The Rutland 913 needs 5 knots wind speed to start charging The wind speed across the turbine blades may be greatly reduced in a marina or built up area compared with the reading on a masthead anemometer or weather reports 3
16. rs Total 24v 60Ah 1440Wh In series to increase voltage mm Cable Size 12V AWG mm 24V AWG 25 13 11 1 5 2 5 4 6 15 13 11 9 Document SM 130 Issue G 26 10 06 Owner s Manual BATTERIES Leisure Deep Cycle batteries are specifically designed for good performance in terms of charge discharge cycles Batteries are the most important part of your battery charging system and should be sized according to your load requirements and provide at least 3 days reserve capacity This will reduce cycling prolong the life of the battery and ensure system reliability during periods of low wind Permanent connections should always be made to the battery terminals Never use crocodile clips or similar devices Battery terminals should be well greased with petroleum jelly or similar We strongly recommend that one of the voltage regulators available from Marlec is fitted to prevent batteries becoming overcharged in strong winds and is essential with gel sealed batteries Batteries may be linked as shown in the figures 10 and 11 It is essential to observe polarity as follows Redis Positive Blackis Negative CABLE SPECIFICATION The cable used for connection of the Windcharger to the batteries should be in accordance with table 1 The use of a smaller cable than recommended will reduce the performance of the charging system Cable and connectors are available from your dealer
17. the generator each time until the holes align Caution It is essential that all 4 screws are fitted 4 Fit the remaining blade screws from the front of the generator hub 5 Check tightness of all screws Do not over tighten 6 Fit the plastic nose dome in position on the front of the generator hub and secure in place with the three nylon screws provided Alternatively the blades and nose dome can be fitted after mounting the generator assembly to the tower Document SM 130 Issue G 26 10 06 8 Marlec Engineering Co Ltd Rutland 913 Windcharger Document SM 130 Issue G 26 10 06 Owner s Manual Tower Preparation Fig 9 Having selected a suitable pole from the guidelines on pages 6 and 7 l The post adapter fitted to the 913 is designed to fit inside a standard 41mm 134 internal diameter tube The adapter is provided with a flat on one side to clear the weld seam on seamed pipe Mark and centre punch two positions diametrically opposite at 90 to the pipe seam if necessary 20mm NOTE Use metric measurements for this operation from top of the tube Drill two holes 10 5mm NOTE Use metric measurements for this operation in diameter on centre punch positions Note When using the Rutland 913 Mounting Kit items 2 and 3 can be ignored as the unit is pre drilled 9 Marlec Engineering Co Ltd Rutland 913 Windcharger Total 12v 120Ah 1440Wh In parallel to increase amp hou
18. x 2 way terminal block 2 x M10 buttoncap screws 2 x shakeproof washers HRS913 Regulator USA Mariner s Package only 600mm 23 2 Stainless Steel Tube USA Mariner s Package only In the event of loss or damage consult your dealer or the manufacturer WHAT YOU WILL NEED Tools e Suitable wire stripper Small terminal screwdriver Large flat blade screwdriver Crosshead screwdriver Other Items You Will Need e Mounting pole e Cable e Batteries e Battery terminals e Connector blocks as determined by your total system Other Items You May Have Selected HRS913 Regulator or HRDX Charge Controller Cable Rutland 913 Marine Mounting Kit Part No CA 12 02 Rutland 913 Land Tower amp Rigging Kit Part Nos CA 12 08 amp CA 12 07 Short section of stainless steel tube to adapt into your own mounting design Voltmeter amp Ammeter Document SM 130 Issue G 26 10 06 4 Marlec Engineering Co Ltd Rutland 913 Windcharger Owner s Manual SITING THE WINDCHARGER General Considerations The location and height of the mounting pole or tower for your wind turbine will be the major factor in the overall performance of your system The smooth flow of wind over land and water is often interrupted by a multitude of obstructions causing wind sheer and turbulence Wind sheer describes the interference between the fast moving upper air and the slow moving air close to the ground and the resulting decrease in average wind
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