Rutland FM910-4 Windcharger

Rutland FM910-4 Windcharger
Rutland FM910-4 Windcharger
Rutland Furlmatic 910-4 Windcharger
Installation & Operation
(12V or 24V)
Owners Manual
Installation and Operation
Doc No: SM-138 Iss. B 29.01.13
Doc No: SM-138 Iss. B 29.01.13
Marlec Eng Co Ltd
Rutland Furlmatic 910-4 Windcharger
Installation & Operation
Contents
Page
Introduction
Summary of Features and Uses
Check you have received
Other Items
Principle of Operation
Siting the Windcharger
Tower Construction
3
4
5
6
7
8
Assembly & Installation
Blade Assembly
Furlmatic Tail Assembly
Tower Preparation
Batteries
Cable Specification
Electrical Connection and Fitting to the Tower
Up and Running
9
10
11
12
12
13
13
Typical wiring diagrams
14
Specification & Performance
15
Inspection and Maintenance
16
Troubleshooting
16
Notes
18
Warranty
19
Doc No: SM-138 Iss. B 29.01.13
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Marlec Eng Co Ltd
Rutland Furlmatic 910-4 Windcharger
Installation & Operation
INTRODUCTION
Introduction
Congratulations and thank you for purchasing your Rutland FM-910-4
Windcharger. The utmost of care goes into the manufacture of all our products in
our ISO9001 approved factory. To ensure you get the very best out of the
Rutland FM-910-4 it is vital that you read this manual and familiarise yourself
with its contents before installing and operating the Windcharger system.
Summary of Features and Uses
Automatic “furling” tail fin directs turbine out wind above 15m/s for gale
protection.
Low wind speed start up maximises power generation in low winds.
High grade construction materials for durability in the harshest environments.
Provides a D.C. power supply to charge 12 or 24 V battery banks.
Designed for use on permanent land based applications where low power is
needed for professional and domestic devices.
Ideally mounted on the Rutland Land Tower and Rigging Kit – see product
catalogue.
General Guidelines & Warnings
Observe the mounting pole diameters recommended in this manual. It is
essential for 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 could be adversely affected with potential
damage to the Windcharger.
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 an 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 wind speed
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. We recommend the use of a Marlec charge
regulator that includes a shutdown switch.
Doc No: SM-138 Iss. B 29.01.13
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Marlec Eng Co Ltd
Rutland Furlmatic 910-4 Windcharger
Installation & Operation
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.
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.
High winds – The furling tail mechanism of the Furlmatic model will operate in
high winds orienting 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. As a secondary safety feature the Windcharger
has a built-in thermostat which may operate in extreme conditions to prevent the
generator overheating. In this mode the output will cease and the turbine will
temporarily slow down until such time as a lower 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.
It is essential to observe the correct polarity when connecting the Windcharger
and all other components into an electrical circuit. Reverse polarity connection
could damage the Windcharger and/or regulator and incorrect installation will
invalidate the warranty.
The fuse supplied must be fitted to protect the system if Marlec regulator is not
used. (HRSi and HRDi regulators have fuses fitted).
If in doubt, refer to your dealer, a competent electrical engineer or the
manufacturer.
Check You Have Received
In the event of loss or damage, consult your dealer or the
manufacturer.
2 x M10 buttoncap screws
2 x M10 shakeproof washers
1 x 6mm Allen key
1 x Main generator assembly
1 x Tail Fin assembly
6 x aerofoil blades
24 x No. 10x25mm special selftapping screws
1 x fuse and fuse holder
1 x 2-way terminal block
Doc No: SM-138 Iss. B 29.01.13
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Marlec Eng Co Ltd
Rutland Furlmatic 910-4 Windcharger
Installation & Operation
Tools That You Will Need:
Suitable wire stripper
Small terminal screwdriver
Large flat blade screwdriver
Crosshead screwdriver
10mm Spanner
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:
HRSi or HRDi Charge Regulator.
Land Tower and Rigging Kit
Doc No: SM-138 Iss. B 29.01.13
(Part Nos. CA-11/46 & CA-11/44)
(Part Nos. CA-12/08 & CA-12/07).
5
Marlec Eng Co Ltd
Rutland Furlmatic 910-4 Windcharger
Installation & Operation
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 is transmitted via the sliprings and brushes at the yaw axis to
the output cable.
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 & 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.
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 thermal protection limit, the device will cut generator output
current to allow the winding to cool, whereupon normal performance will be
resumed. If the thermal protection is active, the turbine will reduce to a slow
rotational speed, this is normal.
Doc No: SM-138 Iss. B 29.01.13
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Marlec Eng Co Ltd
Rutland Furlmatic 910-4 Windcharger
Installation & Operation
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 trees and
buildings.
Both wind sheer and turbulence diminish with height and can be overcome
simply by putting the machine sufficiently high above them as shown.
Wind speed decreases and turbulence increases where obstructions exist.
Consider also that downwind obstructions can be as detrimental to performance
as upwind obstructions.
Figure 1
Doc No: SM-138 Iss. B 29.01.13
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Marlec Eng Co Ltd
Rutland Furlmatic 910-4 Windcharger
Installation & Operation
Tower Construction
The Furlmatic 910-4 is designed to fit inside an aluminium, stainless or steel
tube with an internal diameter of 41mm with a minimum wall thickness of 3mm.
Maximum outside diameter of 50mm.
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.
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.
Where guy lines are looped, the loop must incorporate a thimble and be fitted
with a minimum of three rope grips.
All ground fixings must be made suitable according to the terrain.
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 & 3. Non-guyed pivoting towers are available, for further
details contact the dealer or manufacturer.
Centre pivoted pole
Base pivoted with gin pole
Figure 2
Figure 3
NB: 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.
Doc No: SM-138 Iss. B 29.01.13
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Marlec Eng Co Ltd
Rutland Furlmatic 910-4 Windcharger
Installation & Operation
Assembly & Installation of the Windcharger
Blade Assembly
1. Place the generator assembly on a flat surface hub-side down.
2. Position the blade as shown in Figure 4. The blade 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 easily be inserted with a lever action. Gentle assistance with a
soft faced mallet may be required.
Figure 4
3. Four screws are required for each blade. First secure each blade with
two of the special self-tapping screws provided to the rear of each blade by
inserting each in turn through the moulded slot in the nacelle (Figure 5a).
4. Fit the remaining two screws at the front of the generator hub (Figure 5b).
5. Check the tightness of all screws (Do not over-tighten). Recheck again in a
few weeks time as loosening is possible.
NB. IT IS VITAL THAT 4 SCREWS/BLADE ARE FITTED.
Figure 5a
Figure 5b
Doc No: SM-138 Iss. B 29.01.13
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Marlec Eng Co Ltd
Rutland Furlmatic 910-4 Windcharger
Installation & Operation
Furlmatic Tail Assembly
Fit the tail fin on to the hinge assembly using the screws and washers already
present (Figure 6a and 6b):Do not remove the silicone protectors from the tail stops!
Figure 6a
NB. The tail fin is set at an angle of 15° from vertical. This is vital to the
furling mechanism. For the 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.
Figure 6b
Doc No: SM-138 Iss. B 29.01.13
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Marlec Eng Co Ltd
Rutland Furlmatic 910-4 Windcharger
Installation & Operation
Tower Preparation
Having selected a suitable pole from the guidelines.
1. The post adaptor fitted to the FM910-4 is designed to fit inside a standard
41mm (1 ") internal diameter tube. The adaptor 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 (NOTE: Use metric measurements for this
operation) from the top of the tube.
3. Drill two holes 10.5mm (NOTE: Use metric measurements for this operation)
in diameter on centre-punch positions. (Figure 7.)
Note: When using the Rutland Land Tower Kit, items 2 and 3 can be ignored as
the unit is pre-drilled.
Figure 7
Doc No: SM-138 Iss. B 29.01.13
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Marlec Eng Co Ltd
Rutland Furlmatic 910-4 Windcharger
Installation & Operation
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 follows:
In parallel to increase amp hours (Fig 8) In series to increase voltage (Fig 9)
Figure 8
Figure 9
Red is positive (+)
Black is negative (-)
12V System
24V System
Cable Specification
The cable used for connection of the Windcharger to the batteries should be in
accordance with table below. The use of a smaller cable than recommended will
reduce the performance of the charging system. Cable and connectors are
available from your dealer or the manufacturer.
Cable Run(m)
Cable Size(mm²)
12V system
Cable Size(mm²)
24V system
0-20
2.5
1.5
21-30
4
2.5
31-45
6
4
46-80
10
6
Doc No: SM-138 Iss. B 29.01.13
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Marlec Eng Co Ltd
Rutland Furlmatic 910-4 Windcharger
Installation & Operation
Electrical Connection and Fitting To The Tower
1. Run the cable selected (see table) down the inside of the pole.
2. Select one of the 2 basic systems on page 14 and follow the manual
provided with the charge regulator selected.
3. Connect the Windcharger flying lead to the cable protruding from the top of
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 (-)
4. Wrap the connection with insulation tape to secure/protect from the
environment. Alternatively join the cables using a latching type plug and
socket.
5. Locate the Windcharger into the tower whilst gently easing the cable from
the tower base to ensure the cable is not trapped. Secure the Windcharger to
the tower using the button cap screws and shake-proof washers provided.
Tighten using the 6mm Allen key supplied.
Up and Running
Four Point Final Checklist
Before raising and securing the wind generator:
1. Check the tightness of the blade & tail fixing screws and generator
mounting screws.
2. Check free rotation of the hub and yaw axis.
3. Check that the cable is not trapped.
4. Check that all electrical connections are secure and safe.
The Windcharger 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.
Caution-The performance of your Windcharger will be impaired if the pole is
not vertical.
Doc No: SM-138 Iss. B 29.01.13
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Marlec Eng Co Ltd
Rutland Furlmatic 910-4 Windcharger
Installation & Operation
Typical Wiring Diagrams For The Rutland FM910-4 Windcharger
Optional
Solar Panel(s)
Rutland FM 910-4 with HRSi Charge
Regulator Wiring Diagram.
Optional
Solar Panel(s)
Rutland FM 910-4 with HRDi Charge
Regulator Wiring Diagram
Optional 2nd
Battery
Doc No: SM-138 Iss. B 29.01.13
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Marlec Eng Co Ltd
Rutland Furlmatic 910-4 Windcharger
Installation & Operation
14
7
12
6
10
5
8
4
6
3
Windspeed Conversion
MPH=m/s x 2.23
Knots=m/s x 1.94
4
2
1
2
CHARGE CURRENT INTO 24v BATTERY (AMPS)
CHARGE CURRENT INTO 12v BATTERY (AMPS)
Specification and Performance
Guideline performance curve
0
0
0
5
10
15
20
25
30
35
40
WINDSPEED M/S
Doc No: SM-138 Iss. B 29.01.13
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Marlec Eng Co Ltd
Rutland Furlmatic 910-4 Windcharger
Installation & Operation
Inspection and Maintenance
The Rutland Furlmatic 910-4 requires no scheduled maintenance but an
annual inspection should be carried out to monitor the general condition of the
system.
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:
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 of the area. The turbine will eventually slow down.
Tie a blade to the mounting pole to prevent it from rotating.
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.
Whilst the generator is stationary, the following routine checks should be
performed:
Check the blade screws for tightness.
Check all other nuts, bolts and screws for tightness.
Check the yaw axis for free rotation.
Check the tail fin moves freely.
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.
The unit can be wiped with a mild detergent and rinsed with water to
remove dirt and debris.
Troubleshooting
In the unlikely event that your Rutland Furlmatic 910-4 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.
Doc No: SM-138 Iss. B 29.01.13
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Marlec Eng Co Ltd
Rutland Furlmatic 910-4 Windcharger
Installation & Operation
1. Read the Electrical Connection and Up & Running sections and be
satisfied that your system complies.
2. Is there sufficient wind? The Rutland 910-4 needs approximately 4-5
knots wind speed to start charging. The wind speed across the turbine
blades may be greatly reduced in built-up area compared with weather
reports for example.
3. Static Tests: Is the battery in good condition? Check the voltage and
electrolyte level of each battery. Check electrical continuity throughout
the system, especially corrosion and poor connections in cable joins and
connector blocks.
4. Running Tests: Check for power output from the Windcharger,
following this procedure:
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
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.
Doc No: SM-138 Iss. B 29.01.13
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Marlec Eng Co Ltd
Rutland Furlmatic 910-4 Windcharger
Installation & Operation
5. Mechanical inspection. It will be necessary to remove the Windcharger
from its pole for the following tests.
6. Check the brushes and slipring for wear or damage. To inspect the
brushes, remove the 6 screws joining the nacelle halves together and
remove top half of nacelle. Remove the 4 screws connecting the bottom half
of nacelle to the post adaptor and remove bottom half of nacelle. This
now gives access to the 2 sets of brush holders (2 brushes in each). The
brushes and slipring can then be inspected by removing the four selftapping screws holding the brush holder assemblies in place. Remove any
black deposits from slipring with fine emery paper. Heavy deposits and
reduced power indicate a possible reverse connection to the battery. Check
brushes for undue wear and replace if necessary.
7. Check hub for free rotation with generator disconnected from battery.
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.
Notes
Doc No: SM-138 Iss. B 29.01.13
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Marlec Eng Co Ltd
Rutland Furlmatic 910-4 Windcharger
Installation & Operation
LIMITED WARRANTY
The Marlec Engineering Company Limited Warranty provides free
replacement cover for all defects in parts and workmanship for 24 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 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.
Manufactured in the UK by
Marlec Engineering Co Ltd
Rutland House, Trevithick Rd, Corby, Northants,
NN17 5XY UK
Tel: +44 (0)1536 201588 Fax: +44 (0)1536 400211
[email protected] www.marlec.co.uk
Doc No: SM-138 Iss. B 29.01.13
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Marlec Eng Co Ltd
Rutland Furlmatic 910-4 Windcharger
Installation & Operation
Did you know ...
Marlec also offer
Solar Energy
Systems!
Solar power to keep your
batteries topped up on-board
Energy saving solar
panels for your home
Solar power that works with your
Rutland Windcharger
Doc No: SM-138 Iss. B 29.01.13
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Marlec Eng Co Ltd
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