Rutland FM910-3 Windcharger Fault Finding Guide

Rutland FM910-3 Windcharger Fault Finding Guide
Rutland FM910-3 Windcharger
Fault Finding Guide
Document No. SM-127 Issue B
FM910-3 Fault Finding Guide
INTRODUCTION
This manual contains important information concerning fault
finding on your Rutland FM910-3 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 finding guide, open out this flow chart, select
the symptom in the left hand column & follow the arrows &
instructions.
WARNING!
• When turning, the Windcharger is capable of generating
voltages in excess of the nominal voltage, therefore it should
not be allowed to rotate without connection to the battery or
regulator. Caution must be exercised at all times to avoid
electric shock.
• 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.
• 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.
• If in doubt, refer to your dealer, a competent electrical
engineer or the manufacturer.
Document SM-127 Issue B
Marlec Engineering Co Ltd
FM910-3 Fault Finding Guide
Notes:
1. Insufficient Wind / Turbulence
Please see page 4 of the WG910-3 Owners Manual “Siting the Windcharger”Document No SM-124 supplied with the FM910-3.
2. Turbine Not Turning
A. Check for a short circuit in the system. Ensure there are 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 it
does not, it could be due to a mechanical defect inside the hub. If the hub produces
a rumbling sound, this could be due to faulty bearings which should be replaced.
3. Check Brushes and Slipring
• Remove the generator from it’s mounting & place it face down on a suitable flat
surface.
• Remove the 4 screws which secure windshaft housing cover in place, remove the
cover to expose the rectifier assembly.
• Remove the 4 self tapping screws which secure the brush holder assembly in place.
• Withdraw the brush assembly and inspect the brushes and slipring surface.
The slipring can be cleaned using fine emery cloth, applying light pressure to the
slipring while rotating the post adaptor.
Check the brushes for signs of damage or overheating, overheating indicates that at
some time the battery has been connected with reverse polarity.
• Replace brushes if necessary.
4. Check Battery Condition.
• Check that the battery voltage is correct for the system.
• Check the battery terminal voltage.
• Check electrolyte level if a non-sealed battery is fitted.
5. Check Regulator.
This section applies to the SR200 regulator. If you have a RWS200 or other regulator,
please refer to the regulator manual.
Before attempting to bench test the regulator, disconnect it from the system & reconnect the wind generator directly to the battery, if the system now charges as
expected this indicates that the regulator is at fault, if the symptoms are still
unchanged then this indicates the fault is elsewhere.
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 returned to the manufacturer.
• 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 13.8v (27.6v on 24v unit) is
reached, at this point the regulator will begin to draw current and the red LED will
Document SM-127 Issue B
Marlec Engineering Co Ltd
FM910-3 Fault Finding Guide
light, a further increase of the power supply voltage will cause the Regulator to
draw more current & the voltage will rise to a max of 14.4v (28.8v on 24v unit).
• The built in blocking diode can 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 returned to the
manufacturer or replaced.
6. Check Rectifiers.
• Remove the connections from both rectifiers
• Using a multimeter on Ohms range, the rectifier can be tested as follows.
a.c
+ve
-ve
a.c
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 terminal, Black lead to each a.c terminal - Continuity
Black lead to -ve rectifier terminal, Red lead to each a.c terminal - No Continuity
• If the rectifiers do not check out as above they should be replaced.
7. Check Winding.
• Disconnect the 3 generator leads from the rectifiers.
• Using a multimeter on Ohms range or an Ohmeter, measure the resistance between
2 of the 3 leads, the reading should be approx 1.6Ω for a 12v machine, 6.4Ω for a
24v machine, at 20°C.
• Repeat the process for each combination of 2 leads, in each case the readings
should be approximately the same.
• If the resistance measured is greatly different from above, the winding should be
replaced.
• Disconnect the 2 thermostat leads from the rectifier, using a multimeter on Ohms
range, check the continuity of the thermostat between these 2 leads, at room
temperature the thermostat should be open indicated by no continuity reading, if
continuity is measured the winding should be replaced.
8. Check System Wiring
• Check all wiring & connections between the wind generator, regulator and
battery for damage, corrosion & open circuit or poor/loose connections.
Document SM-127 Issue B
Marlec Engineering Co Ltd
FM910-3 Fault Finding Guide
TOP BRUSH IS +VE
GENERATOR SHAFT
4
3
5
1
RECTIFIERS
2
6
BRUSH HOLDER
7
No
1
2
3
4
5
6
7
Description
Red cable
Black cable
Thermostat lead
Thermostat lead
Winding output lead
Winding output lead
Winding output lead
Internal Wiring Diagram
Document SM-127 Issue B
Marlec Engineering Co Ltd
FM910-3 Fault Finding Guide
Exploded View 1. Main assemblies.
Item No
Description
1
Aerofoil Blade
2
Hub assembly (Exploded view 2)
Including:
Front Hub Moulding (Item 9)
Rear Hub Moulding (Item 10)
6202 2RS Bearing (Items 11 & 12)
Stator Winding (Item 13)
3
Windshaft Housing Assembly (Exploded view 3)
Including:
Windshaft Housing (Item 14)
Baseplate (Item15)
Gasket (Item 16)
Grommet (Item 17)
4
Post casting Assembly
(Exploded view 4)
Including:
Slipring (Item 18)
Carbon Brush (item 19)
5
Windshaft Casting Assembly
6
Bridge Rectifier
7
Tail assembly
Marlec Part No
01-100
SA-02/07 (12v)
SA-02/08 (24v)
SA-09/02
SA-05/05
SA-04/03
913-001
SA-08/01
Items above with Part Nos prefixed ‘SA’ are supplied ready assembled.
Components of assemblies with Item numbers are available separately.
Document SM-127 Issue B
Marlec Engineering Co Ltd
FM910-3 Fault Finding Guide
Exploded view 2. Hub assembly
Item No
Description
9
Hub Moulding (Front) MK III
10
Hub Moulding (Rear) MK III
11
6202 2RS bearing (Hub Front)
12
6202 2RS bearing (Hub Rear)
13
Stator MKIII 12V (FM910-3)
Stator MKIII 24V (FM910-3)
Document SM-127 Issue B
Marlec Part No
SA-01/05
SA-05/04
921-013
921-013
SA-06/09
SA-06/10
Marlec Engineering Co Ltd
FM910-3 Fault Finding Guide
Exploded view 3. Wind shaft housing assembly
Item No
Description
14
Windshaft Housing
15
Baseplate
16
Gasket
17
Grommet
Marlec Part No
SA-09/02
01-046
01-062
931-001
Exploded view 4. Post adaptor assembly.
Item No
Description
18
Slipring
19
Carbon Brush (Qty 2 Required)
Marlec Part No
919-003
917-003
Document SM-127 Issue B
Marlec Engineering Co Ltd
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