Rutland 913 Windcharger Fault Finding Guide

Rutland 913 Windcharger Fault Finding Guide
Rutland 913 Windcharger
Fault Finding Guide
Document No. SM1943 Issue A
Notes:
1. Insuflicient Wind / Turbulente
Please see page 4 of the WG9 13 Owners Manual “Siting the Windcharger”Document No SM1913 supplied with the WG913.
2. Turbine Not Turning
A. Check for a short circuit in System. Ensure there arc no wires trapped or shorted to
the supporting pole or other earth on the system- Ensure all wiring is connected
correctly and securely.
B. Check that the generator hub is running freely by rotating the hub by hand. If the
hub does not rotate freely it could be due to a mechanical defect inside the
generator hub. If the generator hub produces a rumbling Sound, this could be due
to faulty bearings which should be replaced.
3. Check Brushes and Slipring
Remove the generator fiom it’s mounting & remove the Front dome to enable the
generator to be placed face down on a suitable flat surface.
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Remove the 3 screws which secure the nacelle in place, & slide the nacelle along
the tail boom towards the tail fin to expose the brush holder assembly.
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Remove the 4 self tapping screws which secure the brush holder assembly to the
casting.
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Withdraw the brush assembly and inspect the brushes and slipring surface.
The slipring tan be cleaned using fine emery cloth, applying light pressure to the
slipring through the hole in the side of the casting while rotating the yaw assembly.
Check the brushes for signs of darnage or overheating, overheating indicates that at
some time the battery has been connected with reverse polarity.
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Replace brushes if necessary.
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4. Check Battery Condition.
Check battery voltage is correct for System.
l Check battery terminal voltage.
l Check electrolyte level if wet battery is fitted.
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5. Check Regulator.
In Order to check the regulator it is necessary to use a variable d.c power supply
together with a Voltmeter and ammeter, if this equipment is not available the regulator
must be retumed to the manufacturer.
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Connect the Black lead of the SR200 to the negative of the power supply.
Connect both the Brown and the Red leads of the SR200 to the positive of the
power supply.
Slowly increase the voltage of the power supply until 13.8~ is reached, at this Point
the regulator will begin to draw current and the Red LED will light, a further
increase of the power supply voltage will Cause the Regulator to draw more
current.
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The built in blocking diode tan be checked using a multimeter set to Ohms range
applied between the Red & Brown leads of the Regulator. Positive lead to Brown,
negative lead to Red should show continuity. Positive lead to Red, negative lead to
Brown should show no continuity.
If the Regulator does not operate as above it should be retumed to the
manufacturer or replaced.
6. Check Rectifiers.
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It is first necessary to remove the generator and it’s nacelle cover as in Note 3.
Remove the connections fiorn both rectiflers, making note of which terminals each
wire is connected to.
Using a multimeter on Ohms range, the rectifier tan be tested as follows.
Red lead to +ve rectifier terminal, Black lead to each a.c terminal - No Continuity
Black lead to +ve rectifier terminal, Red lead to each a.c terminal - Continuity
Red lead to -ve rectifier termmal, Black lead to each a.c terminal - Continuity
Black lead to -ve rectifier terminal, Red lead to each a.c terminal - No Continuity
AC
-VE
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+VE
AC
If the rectifiers do not operate as above they should be replaced.
7. Check Winding.
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It is first necessary to remove the generator and it’s nacelle cover as in Note 3.
Disconnect the 3 generator leads fiom the rectifiers, making note of which
terminals each wire is connected to.
Using a multimeter on Ohms range or an Ohmeter, measure the resistance between
2 of the 3 leads, the reading should be approx 1.8 Ohms for 12v machine, 7.2
Ohms for a 24~ machine, at 20°C.
Repeat the process for each combination of 2 leads, in each case the readings
should be approx the same.
If the resistance measured is greatly different from above, the winding should be
replaced.
Disconnect the 2 thermostat leads fiom the rectifier and brush assembly, making
note of which terminals each wire is connected to.
Using a multimeter on Ohms range, check the continuity of the thermostat between
these 2 leads, at room temperature the thermostat should be closed indicated by a
continuity reading, if no continuity tan be measured the winding should be
replaced.
Spare Parts List
Item No
Description
Marlec Part No
1
2
3
4
5
6
7
8
Aerofoil Blade
Nose Dome
Nacelle Cover
Bridge Rectifier
Carbon Brush
Slipring
620222 Ball Bearing
620322 Ball Bearing
01-100
01-103
01-112
913-001
917-003
919-003
921-001
921-010
Sub Assemblies (SuppIied pre-assembled)
9
10
11
Stator Wirrding 12~
Bearings @em 7)
Including:
Stator Winding 24v
Bearings (Atem 7)
Including:
Hub Moulding (Front)
Hub Moulding (Back)
Hub Assembly 12~
Hub Mauldings (Items IO & 11)
Including:
Stator Winding 12v (Item 9)
Hub Assembly 24v
Hub Mauldings (Atems IO & 11)
Including:
Stator Winding 24v @em 9)
Wind Sh& Casting Assembly
Windshaf? casting @em 12)
Including:
Brush Holder @em 13)
Carbon Brushes (Irem 5)
All related fasteners
Post Adapter Assembly
Post Adapter (Item 14)
Including:
Post Shajt (Item 15)
Slipring (Item 6)
620222 Ball Bearing (Item 7)
620322 Ball Bearing (Item 8)
OSm 2.5mm Cable
All related fateners
Tail Assembly
Tail Fin @em 16)
Including:
Tail Boom @em 17)
All related fasteners
Brush Assembly
Brush Holder (Item 13)
Including:
Carbon Brushes (Item 5)
All related fasteners
SA-06/07
SA-06108
SA-01105
SA-O1106
SA-02107
SA-02/08
SA-04104
SA-OYO4
SA-08102
SA-10/02
h
B
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INTRODUCTION
This manual contains important information conceming fault
fmding on your Rutland 913 Windcharger.
It is strongly recommended that you read this manual and
familiarise yourself with its contents before attempting to
repair the Windcharger System.
To use this fault fmding guide, open out this flow Chart, select
the Symptom in the lefi hand column & follow the arrows &
instructions.
WARNING!
When tuming, the Windcharger is capable of generating
voltages in excess of the nominal voltage. Caution must be
exercised a t all t i m e s t o avoid electric shock.
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No attempt to repair the System should be made until the
wind generator is restrainedfiom turning.
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The Windcharger is jitted with ceramic magnets which tan
be damaged by heavy handling. The main generator assembly
should be treated with care during transit and assembly.
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It is essential to observe the correct [email protected] when
connecting the Windcharger and all other components into an
Reverse connection will darnage the
electrical circuit.
Windcharger and incorrect installation will invalidate the
warranty.
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If in doubt, refer to your dealer, a competent electrical
engineer or the manufacturer.
GENERATOR SHAFI’
4
RECTIFIERS
No
1
2
3
4
5
6
7
8
Description
Black Cable
Red Cable
Black Cable
Thermostat lead
Thermostat lead
Winding Output lead
Winding Output lead
Winding Output lead
6
7
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