Rutland 500 Windcharger Owners Manual
Rutland 500 Windcharger
Owners Manual
Document No. SM-110 Issue B
Contents
Page
INTRODUCTION................................................................................ 2
CHECK YOU HAVE RECEIVED....................................................... 3
WHAT YOU WILL NEED.................................................................. 3
SITING THE WINDCHARGER.......................................................... 4
General Considerations........................................... 4
On Board Systems.................................................. 5
Land based Systems................................................ 6
ASSEMBLY & INSTALLATION........................................................ 7
Tail Assembly......................................................... 7
Fitting Generator to the Tower................................ 8
Final Mechanical Check.......................................... 8
BATTERIES........................................................................................
9
CABLE SPECIFICATION................................................................... 10
ELECTRICAL CONNECTION........................................................... 10
BASIC WIRING DIAGRAMS............................................................ 11
UP AND RUNNING...........................................................................
12
SPECIFICATION AND PERFORMANCE......................................... 12
INSPECTION AND MAINTENANCE............................................... 13
TROUBLESHOOTING....................................................................... 14
1
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!
• When turning, the Windcharger is capable of generating voltages in excess of
the nominal voltage. 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.
• The fuse supplied must be fitted to protect the system.
• If in doubt, refer to your dealer, a competent electrical engineer or the
manufacturer.
2
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
•
•
•
•
•
Mounting pole
Cable
Batteries
Battery terminals
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 & Ammeter
3
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
Fig.1
WIND DIRECTION
2H
H
2H
20H
4
On Board Systems
Fig.2
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.
Fig.3
The Rutland 500 is designed to fit inside an
aluminium tube with an internal diameter of
31.7mm (11/4”).
Suitable tubes: Aluminium 11/2“ 10 SWG
We suggest the following mountings
according to preference and site
conditions:• Pushpit (Fig.3)
Fig.4
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.
• Mizzen (Fig.4)
Fig.5
Mizzen mounting is suitable on larger
yachts, taking advantage of greater wind
flow the higher the wind turbine is
mounted.
• River Boats (Fig.5)
A pivot pole is ideal for river boats as the
Windcharger can easily be raised and
lowered
5
Land Based Systems
Fig.6
The Rutland 500 is designed to fit inside an
aluminium tube with an internal diameter of
31.7mm (11/4”).
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.
Centre pivoted pole
Fig.7
Base pivoted with gin pole
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
3mm 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.
We suggest pivot type 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 & 7.
6
Fig.8
ASSEMBLY AND INSTALLATION OF
THE WINDCHARGER
Tail Assembly (Fig.8)
1. Place the generator assembly on a flat
soft surface, Nose Cone down.
2. Remove the 2 x M5 Pan head screws,
washers and nut, one from the tail nut
and the other from the support casting.
3. 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.
4. Replace the screws, washers and nut and
secure in position.
5. Check tightness of all screws. (Do not
over-tighten).
7
Fitting Generator to the Tower (Fig.9)
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 raise the Windcharger at this stage,
the turbine must be connected to the battery
before the blades are allowed to turn in the
wind.
8
BATTERIES
Fig.10
Total = 12v
120Ah
1440Wh
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.
12v
60Ah
12v
60Ah
Fig.11
Total = 24v
60Ah
1440Wh
12v
60Ah
12v
60Ah
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:
• In parallel to increase amp hours
(Fig.10).
• In series to increase voltage (Fig.11).
Red is + Positive
Black is - Negative
9
CABLE SPECIFICATION
Cable
Run (m)
0-20
21-30
31-45
46-80
Cable Size
(mm²)
12 Volt
2.5
4
6
10
Table.1
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.
10m x 2.5mm² including battery clips
(CA-10/11)
20m x 2.5mm² 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
RED
BROWN
BLACK
BLACK
RED
CHARGE FUSE
BATTERY
RWS60 Controller
WG500 WIND
GENERATOR
RED
BLACK
BATTERY
11
UP AND RUNNING
• 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.
• 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. The
performance of your Windcharger can be impaired if the pole is not vertical .
SPECIFICATION AND PERFORMANCE
Charge into 12v 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
0
5
10
15
20
25
Windspeed (Knots)
12
30
35
40
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.
• 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.
• 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. Read 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:
• 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.
• 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.
• 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 & withdrawing the
brushes. Damage to the brushes and reduced power indicate a possible reverse
connection to the battery (see Page 10).
• 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.
• 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
charge 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.
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