Rutland 500 Windcharger Owners Manual
Contents
1. 10m x 2 5mm including battery clips CA 10 11 20m x 2 5mm including battery clips CA 10 12 ELECTRICAL CONNECTION 1 Run the cable selected see Table 1 down the inside of the pole 2 Connect the wind generator flying leads to the cable using the connector block supplied taking care to observe polarity Red is Positive Black is Negative Wrap the connection with insulation tape to secure protect from environment Alternatively join the cable using a latching type plug and socket 3 Reposition and secure the wind generator to the tower using the screws and shakeproof washers provided 4 Final Electrical Connection Select one of the following 2 basic systems and follow the manual provided with the SR60 or RWS60 10 SR60 Regulator and Fuse WG500 WIND GENERATOR SR60 SHUNT REGULATOR BATTERY RWS60 Controller WG500 WIND GENERATOR BATTERY 11 UP AND RUNNING e Before raising and securing the wind generator check that All final mechanical checks have been made The cable is not trapped 3 All electrical connections are secure and safe N HE e The wind generator can now be raised into position Take care to avoid all moving parts when raising and lowering the wind generator e When raised secure the structure firmly in an upright position The performance of your Windcharger can be impaired if the pole is not vertical SPECIFICATION AND PERFORMANCE Charge into 122. Rutland 500 Windcharger Owners Manual N JJ RON u a ee Er gt eS a a 2 P DAA C Document No SM 110 Issue B Contents INTRODUCTION a og O Ana eee 2 CHECK YOU HAVE RECEIVED aoiococsocioisinicicio corona roo ni ninbacadades 3 WHAT YOU WILL NEE Dina 3 SITING THE WINDCHARGER eee 4 General Considerations ccscceeseececeeneeeeenteeeees 4 On Board SY Ste Menea clubs 5 Land based Systems ass sesaeka ds 6 ASSEMBLY amp INSTALLATION eee eee een 7 Tail Assembler 7 Fitting Generator to the Tower 8 Final Mechanical Check 8 BATTERIES oa sachsen p ee Bas a 9 CABLE SPECIFICATION ee elf 10 ELECTRICAL CONNECTION aa aos 10 BASIC WIRING DIAGRAM6 eee eee eee een 11 UPANDRUNNIN Eee Re 12 SPECIFICATION AND PERFORMANCE 12 INSPECTION AND MAINTENANCE eee 13 TROUBLESHOOTING ass 14 INTRODUCTION This manual contains important information concerning your Rutland 500 Windcharger and its installation and operation It is strongly recommended that you read this manual and familiarise yourself with its contents before installing and operating the Windcharger system The Rutland 500 Windcharger is designed to provide a direct current DC power supply via a battery bank for 12V equipment lighting etc It is ideal for leisure applications which require battery charging on non mains sites WARNING e When turning the Win
3. d the Electrical Connection page 10 and Up and Running page 12 and be satisfied that your system complies 2 If your Rutland 500 fails to turn or produces low output check the following e Is there sufficient wind The Rutland 500 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 mast head anemometer or weather reports e Is the battery in good condition Check the voltage and electrolyte level of each battery e Check electrical continuity throughout the system especially corrosion and poor connections in cable joins and connector blocks e Check the brushes and slipring for wear or damage To inspect the brushes remove the round plastic cap on the front of the main casting The brushes can be inspected by removing the caps from the brush holders amp withdrawing the brushes Damage to the brushes 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 e Remove the SR60 RWS60 from the charging circuit and connect the Windcharger direct to the battery via an ammeter If no charge current is measured and there is sufficient wind contact your dealer or manufacturer If cha
4. dcharger is capable of generating voltages in excess of the nominal voltage Caution must be exercised at all times to avoid electric shock e No attempt to repair the system should be made until the wind generator is restrained from turning 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 fuse supplied must be fitted to protect the system e If in doubt refer to your dealer a competent electrical engineer or the manufacturer CHECK YOU HAVE RECEIVED 1 x fuse and fuse holder 1 x main generator assembly 2 x M8 x 12 Hex Head Bolts 1 x Tail Fin 1 x 2 way terminal block In the event of loss or damage consult your dealer or the manufacturer WHAT YOU WILL NEED Tools Suitable wire stripper Small terminal screwdriver Large flat blade screwdriver 13mm spanner 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 SR60 Regulator or RWS60 Charge Controller Inter connect unit Cable kit Rutland 500 mounting kit Voltmeter amp Amm
5. eter 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 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 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 On Board Systems The wind generator should be mounted in a safe position a minimum of 2 metres 6 5 feet above the deck and away from other obstacles which could interfere with the blades or tail assembly Fig 2 The Rutland 500 Mounting Kit PartNo CA 12 01 is available for deck mounting The Rutland 500 is designed to fit inside an aluminium tube with an internal diameter of 31 7mm 1 4 Suitab
6. le tubes Aluminium 1 10 SWG We suggest the following mountings according to preference and site conditions e Pushpit 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 500 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 river boats as the Windcharger can easily be raised and lowered Centre pivoted pole Base pivoted with gin pole Land Based Systems The Rutland 500 is designed to fit inside an aluminium tube with an internal diameter of 31 7mm 1 A suitable mounting pole can be erected using a 6 5 metre 21 feet Aluminium 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 3mm in diameter e The shackles should be a minimum of 5mm in diameter e Rigging screws should be a minimum of 5mm 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 t
7. rge current is normal the battery is fully charged or regulator is faulty If in doubt refer to your dealer or manufacturer 14 Notes Notes 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 as having been in his opinion defective and are so found by Marlec upon inspection Defective parts must be returned by prepaid post to 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 or natural disasters and does not extend to support posts inverters or batteries No responsibility is assumed for incidental or consequential damage or loss damage caused by the use of any unauthorised components No responsibility is assumed for non furling versions of the Rutland Windcharger ie the Standard and Marine generators where Marlec or one of its authorised agents finds that a generator incorporating a furling device should have been used Serial Number
8. se the Windcharger at this stage the turbine must be connected to the battery before the blades are allowed to turn in the wind Total 12v 120Ah 1440Wh Total 24v 60Ah 1440Wh 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 SR60 or RWS60 is fitted to prevent battery overcharging in strong winds and is essential with gel sealed batteries Batteries may be linked as follows e In parallel to increase amp hours Fig 10 e In series to increase voltage Fig 11 Red is Positive Black is Negative Cable Run m Cable Size mm 12 Volt Table 1 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 kits are available from your dealer or the manufacturer
9. v Battery Amperes 4 0 3 5 WINDSPEED CONVERSION 3 0 MPH Knots x 1 15 2 5 M S Knots x 0 515 2 0 1 5 1 0 0 5 0 5 10 15 20 25 30 35 40 Windspeed Knots 12 INSPECTION AND MAINTENANCE The Rutland 500 requires no scheduled maintenance but an annual 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 proceed as follows 1 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 eventually slow down 2 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 all nuts bolts and screws for tightness 2 Check the yaw axis for free rotation 3 Check tower assembly for condition 4 Check the tension of the guy wires if applicable The tension of guy wires should be checked frequently during the first year 5 The unit can be wiped with a mild detergent and rinsed with water to remove dirt and debris 13 TROUBLESHOOTING In the unlikely event that your Rutland 500 should develop a defect the turbine should either be lowered to the ground or tied to prevent the blades from turning before the following inspection is carried out 1 Rea
10. ype 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 ASSEMBLY AND INSTALLATION OF THE WINDCHARGER Tail Assembly Fig 8 L Place the generator assembly on a flat soft surface Nose Cone down Remove the 2 x M5 Pan head screws washers and nut one from the tail nut and the other from the support casting Slot the tail into position in the tail nut ensuring the hole in the tail nut and the hole in the support casting align with the corresponding holes in the tail fin Replace the screws washers and nut and secure in position Check tightness of all screws Do not over tighten Fitting Generator to the Tower Fig 9 1 The post adapter fitted to the 500 is designed to fit inside a standard 31 7mm internal diameter tube 2 Mark and centre punch two positions diametrically opposite at 90 to the pipe seam if necessary 40mm from top of the tube 3 Drill two holes 8 5mm in diameter on centre punch positions 4 Position the Windcharger on the tower Two M8 x 12mm screws and shakeproof washers are provided for securing once the cables are installed Note When using the Rutland 500 Mounting Kit items 2 and 3 can be ignored as the unit is pre drilled Final Mechanical Check 1 Check the tightness of Tail screws 2 Check the free rotation of the hub and yaw axis Do not rai
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