Rutland Furlmatic 910-3 Windcharger Owners Manual
Contents
1. 3 Bare small amount of wire from the ends of the cable twist Fig 1 YN ss AAA UIII 77271 Fig 2 Note When fully assembled please ensure the electrical connections make direct contact with the fuse Document No SM124 Issue C 03 11 03 12 SA gt lt Marlec Eng Co Ltd Installation Instructions Regulator and Fuse Wiring Diagram REGULATOR FM910 3 WIND GENERATOR CHARGE FUSE BATTERY Charge Controller Wiring Diagram FM910 3 WIND GENERATOR BATTERY Document No SM124 Issue C 05 11 03 13 Marlec Eng Co Ltd Installation Instructions FITTING GENERATOR TO THE TOWER 1 The post adapter fitted to the FM910 3 is designed to fit inside a standard 41mm internal diameter tube The adapter is provided with a flat on one side to clear the weld seam on seamed pipe 2 Mark and centre punch two positions diametrically opposite at 90 to the pipe seam if necessary 20mm from the top of the tube 3 Drill 2 holes 10 5mm in diameter on centre punch positions 4 Connect the wind generator flying leads to the cable using the connector block supplied taking care to observe polarity Redis Positive Blackis Negative 5 Wrap the connection with insulation tape to secure protect from environment Alternatively join the cable using a latchin2. 12 Volt 24 Volt 0 20 2 5 1 5 21 30 4 2 5 31 45 6 4 46 80 10 6 Table 1 ELECTRICAL CONNECTION Run the cable selected see Table 1 down the inside of the pole 2 Select one of the following 2 basic systems and follow the manual provided with the charge regulator selected e If the basic regulator is selected a convenient Interconnect Unit CA 11 24 is available to provide a simple amp neat junction box for interconnection of the separate system components The unit is internally pre wired amp can accommodate the charge fuse e Follow the instructions below to fit the in line fuse Document No SM124 Issue C 05 11 03 11 Marlec Eng Co Ltd Installation Instructions HOW TO ASSEMBLE THE IN LINE FUSE HOLDER Select a suitable position to mount the in line fuse this should be in the positive lead between the regulator and the battery Each Pack consists of Item 1 amp 2 One Plastic Holder the copper wire crimp and solder the electrical connections 3 onto the ends 4 Insert the fuse and twist the two halves of the holder together to complete the electrical circuit See fig 2 C9 Item 3 Two Electrical Connections Item 4 One Spring 3 1 Item 5 One Fuse 1 Insert the positive wire from the battery and regulator into each half of the plastic holder 1 amp 2 See fig 1 2 Place the spring over the cable inside the longer 1 of the two plastic holders See fig 1
3. and operating the Windcharger system The Rutland 913 Windcharger 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 for the user and Inspection and Maintenance sections GENERAL GUIDELINES amp WARNINGS e Observe the mounting pole diameters recommended in this manua It is essential to the effective operation of the furling tail system that the mounting pole is vertical An unsupported tower will experience lateral movement particularly in high winds and furling will be adversely affected will potential damage to the wind turbine e 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 Avoid applying a short circuit to the windcharger particularly in high winds If a short circuit is necessary first slow the turbine as described below Caution must be exercised at all times to avoid electric shock e 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 i
4. 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 gen and the meter to the wind gen 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 gen directly to the battery Set the digital multimeter to DC Amps and measure power between the wind gen and the battery If a 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 No SM124 Issue C 05 11 03 17 Marlec Eng Co Ltd Installation Instructions 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 Remo
5. Rutland Furlmatic 910 3 Windcharger Owners Manual C Document No SM124 Issue C 05 11 03 Marlec Eng Co Ltd Installation Instructions Page INTRODUCTION kaka es 2 GENERAL GUIDELINES amp WARNINGS pp 2 CHECK YOU HAVE RECEIVED pp 4 WHAT YOU WILLNEED pp 4 SITING THE WINDCHARGER ppp 5 PRINCIPLE OF OPERATION 2283 S ssi daar a 6 TOWER CONSTRUCTION RN 7 ASSEMBLY amp INSTALLATION ppp 8 Blade Assembly pp 8 Furlmatic Tail Assembly 9 BATTERIES d asus nde que teen Uode 10 CABLE SPECIBICA TION Se en conexa etur dede Ed 11 ELECTRICAL CONNECTION edes cus rta otn 11 HOW TO ASSEMBLE THE IN LINE FUSE HOLDER 12 BASIC WIRING DIAGRAMS sni s 13 FITTING GENERATOR TO THE 14 Final Mechanical CRECK assa gi 14 UPAND RUNNING a nn 15 SPECIFICATION AND 15 INSPECTION AND 16 FROUB ESHOOTINES ppp 17 Document No 5 124 Issue C 05 11 03 1 Marlec Eng Co Ltd Installation Instructions INTRODUCTION This manual contains important information concerning your Rutland 913 Windcharger and its installation and operation It is strongly recommended that you read this manual and familiarise yourself with its contents before installing
6. al inspection should be carried out to monitor the general condition of the system e 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 follow one of the procedures below 1 Lower the windcharger on its tower to the ground coming to rest on a structure that will prevent the windcharger from striking the ground Take care that all persons are clear ofthe area The turbine will eventually slow down Tie a blade to the mounting pole to prevent it from rotating 2 If the tail boom is safely accessible using the tail boom rotate the generator out of the wind the turbine will eventually slow down Tie a blade to the mounting pole to prevent it from rotating e Whilst the generator is stationary the following routine checks should be performed 1 Check the blade screws for tightness 2 Check all other nuts bolts and screws for tightness 3 Check the yaw axis for free rotation 4 Check the tail fin moves freely 5 Check tower assembly for condition 6 Check the tension of the guy wires if applicable The tension of guy wires should be checked frequently during the first year 7 The unit can be wiped with a mild detergent and rinsed with water to remove dirt and debris Document No SM124 Issue C 05 11 03 16 Marlec Eng Co Ltd Installation Instructions TROUBLESHOOTING In the unlikely event that your Rutland Furlmati
7. c 910 3 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 page 11 and Up and Running page 13 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 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 gen 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
8. d by a minimum of four guy lines The attachment points for the guy lines to the tower should be securely fixed to the tower The guy wires should be a minimum of 4mm in diameter The shackles should be a minimum of 5mm in diameter Rigging screws should be a minimum of 5mm in diameter 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 Centre pivoted pole Base pivoted with gin pole Pivot type towers are recommended as these allow for easier installation and lowering for access to the wind generator Two forms of pivot tower are suggested in Figs 2 amp 3 Non guyed pivoting towers are available for further details contact the dealer or manufacturer Note See the warnings section regarding the tower It is essential that the tower is maintained vertically to minimise lateral movement which interferes with the effective operation of the furling tail Document No SM124 Issue C 05 11 03 7 Marlec Eng Co Ltd Installation Instructions ASSEMBLY AND INSTALLATION OF THE WINDCHARGER Blade Assembly Fig 4 1 Place the generator assembly 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 firs
9. enting the turbine out of the prevailing wind direction to slow the turbine down It will return to face the wind as windspeeds fall and will be seen to cycle during high wind speeds If in doubt refer to your dealer a competent electrical engineer or the manufacturer Document No 5 124 Issue C 05 11 03 3 Marlec Eng Co Ltd Installation Instructions CHECK YOU HAVE RECEIVED x main generator assembly 1 x tail assembly 24 x No 10x25mm special self tapping screws 6 x aerofoil blades x fuse and fuse holder x 2 way terminal block 2x M10 buttoncap screws 2 x shakeproof washers 1 x 6mm Allen key In the event of loss or damage consult your dealer or the manufacturer WHAT YOU WILL NEED Tools e Suitable wire stripper e Small terminal screwdriver e Large flat blade screwdriver e Pozi drive or Philips cross head screwdriver No2 Other Items You Will Need Tower Mounting pole Batteries Battery terminals Cable Connector blocks as determined by your total system Other Items You May Have Selected from Marlec e Voltage Regulator or Charge Controller e Land Tower and Rigging Kit Document No SM124 Issue C 05 11 03 4 Marlec Eng Co Ltd Installation Instructions 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 la
10. g Co Ltd Installation Instructions 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 the use of a charger regulator to prevent battery overcharging in strong winds and one is essential with gel sealed batteries Batteries may be linked as follows e In parallel to increase amp hours Fig 6 e series to increase voltage Fig 7 Redis Positive Blackis Negative Total 12v Total 24v 120Ah 60Ah 1440Wh 1440Wh Document No SM124 Issue C 05 11 03 10 Marlec Eng Co Ltd Installation Instructions 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 amp battery connectors are available from your dealer or the manufacturer Cable Run Cable Size Cable Size m mm mm
11. g type plug and socket 6 Position the windcharger on the tower ensuring the flat on the post adapter aligns with the pipe seam if necessary Use the 2 MIO x 16mm screws and shakeproof washers provided to secure the windcharger to the tower Final Mechanical Check Ensure the system is properly assembled 1 Check the tightness of the 4 screws per blade 2 Check the free rotation of the hub and yaw axis 3 Check the tail fin for free movement Document No SM124 Issue C 05 11 03 14 Marlec Eng Co Ltd Installation Instructions UP AND RUNNING e Before raising and securing the wind generator check that 1 All final mechanical checks have been made 2 The cable is not trapped 3 All electrical connections are secure and safe e 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 performance of your Windcharger can be impaired if the pole is not vertical SPECIFICATION AND PERFORMANCE WINDSPEED CONVERSION MPH M S x 2 23 Knots M S x 1 94 CHARGE CURRENT INTO 12v BATTERY AMPS CHARGE CURRENT INTO 24v BATTERY AMPS 0 5 10 15 20 25 30 35 WINDSPEED M S Document No SM124 Issue C 05 11 03 15 Marlec Eng Co Ltd Installation Instructions INSPECTION AND MAINTENANCE The Rutland Furlmatic 910 3 requires no scheduled maintenance but an annu
12. hermal protection limit the device will reduce generator output current to allow the winding to cool whereupon normal performance will be resumed If the thermal protection is active the turbine may reduce to a slow rotational speed with a corresponding reduction in charge current this is normal Furling Tail System The tail assembly is designed to direct the turbine into the main direction of the wind at windspeeds up to approx 15m s Above this the automatic furling mechanism is activated to turn the generator at an angle to the wind to protect the turbine generator and supporting structure from severe electrical and mechanical loads due to high winds When the wind speed subsides the tail assembly will automatically return the turbine to normal operation In prolonged gusty amp turbulent conditions the system may be seen to repeat this cycle many times Power will be reduced during furling For effective operation of the furling system the wind turbine must be sited to ensure it is as free as possible from turbulence and in a stable upright position Document No SM124 Issue C 05 11 03 6 Marlec Eng Co Ltd Installation Instructions TOWER CONSTRUCTION The Furlmatic 910 3 is designed to fit inside an aluminium stainless or steel tube with an internal diameter of 41mm with a minimum wall thickness of 5mm A suitable mounting pole can be erected using a 6 5 metre 21 feet galvanised medium tube The tube must be supporte
13. ll 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 responsibility is assumed for consequential damage No responsibility is assumed for damage caused by 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 Tel 353 21 4371328 or john gprsmodems co uk Document No SM124 Issue C 05 11 03 21
14. nd 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 speed as one gets closer to the ground Turbulence is caused by the wind passing over obstructions such as trees and buildings Both wind sheer and turbulence diminish with height and can be overcome simply by putting the machine sufficiently high above them It is therefore essential that the wind generator should be located in an area as free as possible from disturbed wind flow Bear in mind that downwind obstructions can be as detrimental to performance as upwind obstructions Fig 1 AREA OF TURBULENCE WIND DIRECTION Document No 5 124 Issue C 05 11 03 5 Marlec Eng Co Ltd Installation Instructions PRINCIPLE OF OPERATION Generator The 3 phase ac generator is driven directly by the aerofoil blades rotating permanent magnets around the fixed stator winding The variable frequency alternating current is rectified within the generator housing and the resulting rectified current 1s transmitted via the sliprings and brushes at the yaw axis to the output cable Winding Over Temperature Protection The generator stator winding incorporates embedded thermal protection to protect the winding from damage due to over temperature during extreme winds On reaching the t
15. t 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 First secure each blade with two of the special self tapping screws provided 4 Fit the remaining 2 blade screws from the front of the generator hub 5 Check tightness of all screws Do not over tighten NB IT IS IMPORTANT THAT 4 SCREWS PER BLADE ARE FITTED Document No SM124 Issue C 05 11 03 8 Marlec Eng Co Ltd Installation Instructions Furlmatic Tail Assembly Fig 5 1 Remove the cover from the main housing 2 Remove the M6 nut washers and bolt from the tail boom 3 Insert the tail boom into the saddle on the underside front of the housing Ensure the tail assembly is the correct way up refer to pictures in this manual amp the text on the tail label 4 Re fit bolt washers amp nut removed in 2 passing the bolt through the tail boom and windshaft housing Tighten all fasteners 5 Replace cover Note Do not remove the silicone protectors from the tail stops Tail Boom Fasteners NB The tail fin is set at an angle of 15 from vertical Check that the tail fin is I positioned as shown in the diagram as viewed from rear of the Windcharger Figure 5 Document No SM124 Issue C 05 11 03 9 Marlec En
16. t 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 e No attempt to repair the system should be made until the wind generator is restrained from turning Document No 5 124 Issue C 05 11 03 2 Marlec Eng Co Ltd Installation Instructions 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 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 The fuse supplied must be fitted to protect the system unless used in conjunction with a controller that is already fitted with a charge fuse 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 slow down 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 Further the furling tail mechanism of the Furlmatic model will operate in high winds ori
17. ve 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 company from whom the product was originally purchased If in doubt refer to your dealer or manufacturer Document No SM124 Issue C 05 11 03 18 Marlec Eng Co Ltd Installation Instructions Notes Document No SM124 Issue C 05 11 03 19 Marlec Eng Co Ltd Installation Instructions Notes Document No SM124 Issue C 05 11 03 20 Marlec Eng Co Ltd Installation Instructions 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 wi
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