FM910-3 Manual Issue D
Rutland Furlmatic 910-3 Windcharger
Owners Manual
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Document No: SM124 Issue D 30.01.07
Marlec Eng Co Ltd
Installation Instructions
Page
INTRODUCTION……………………………………………………. 2
GENERAL GUIDELINES & WARNINGS………………………….. 2
CHECK YOU HAVE RECEIVED…………………………………… 4
WHAT YOU WILL NEED…………………………………………… 4
SITING THE WINDCHARGER…………………………………….. 5
PRINCIPLE OF OPERATION………………………………………. 6
TOWER CONSTRUCTION…………………………………………. 7
ASSEMBLY & INSTALLATION…………………………………… 8
Blade Assembly…………………………………. 8
Furlmatic Tail Assembly………………………… 9
Tower Preparation……………………………….. 10
BATTERIES…………………………………………………………. 11
CABLE SPECIFICATION…………………………………………… 12
ELECTRICAL CONNECTIONS & FITTING TO TOWER………… 12
Final Mechanical Check…………………………. 13
BASIC WIRING DIAGRAMS………………………………………. 14
UP & RUNNING………………………………………………….
15
SPECIFICATION & PERFORMANCE……………………………… 15
INSPECTION & MAINTENANCE……………………………..
16
TROUBLESHOOTING……………………………………………..
17
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Installation Instructions
INTRODUCTION
This manual contains important information concerning your Rutland 910-3
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 910-3 Windcharger is designed to provide a direct current (DC)
power supply via a battery bank for 12/24V equipment, lighting, etc. It is
robustly constructed and designed to give many years of trouble free service
with the minimum of maintenance. Please take notice of our General Guidelines
for the user and Inspection and Maintenance sections.
GENERAL GUIDELINES & WARNINGS!
• Observe the mounting pole diameters recommended in this manual. It is
essential to 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 will be adversely affected will potential
damage to the wind turbine.
• 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. Avoid applying a short
circuit to the Windcharger particularly in high winds. If a short circuit is
necessary first slow the turbine as described below. 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
windspeed 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. The optional HRDX
Controller incorporates a shutdown switch.
• No attempt to repair the system should be made until the Windcharger is
restrained from turning.
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• 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 unless used in
conjunction with a controller that is already fitted with a charge fuse.
• High winds – in high winds the Windcharger’s built-in thermostat may
operate to prevent the generator overheating. In this mode the output will
cease and the turbine will temporarily slow down until such time as the lower
level 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. Further 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.
• If in doubt, refer to your dealer, a competent electrical engineer or the
manufacturer.
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CHECK YOU HAVE RECEIVED
•
•
•
•
•
•
•
•
•
1 x main generator assembly
1 x tail assembly
24 x No. 10x25mm special self-tapping screws
6 x aerofoil blades
1 x fuse and fuse holder
1 x 2-way terminal block
2 x M10 buttoncap screws
2 x M10 shakeproof washers
1 x 6mm Allen key
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
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
• HRS913 Regulator or HRDX Controller
• Land Tower and Rigging Kit (Part Nos. CA-12/08 & CA-12/07)
• Voltmeter & Ammeter
SITING THE WINDCHARGER
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Installation Instructions
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 in Fig 1.
Wind speed decreases and turbulence increases where obstructions exist.
Consider also that downwind obstructions can be as detrimental to performance
as upwind obstructions.
AREA OF TURBULENCE
Fig.1
WIND DIRECTION
2H
H
2H
20H
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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.
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 reduce
generator output current to allow the winding to cool, whereupon normal
performance will be resumed. If the thermal protection is active, the
turbine may reduce to a slow rotational speed with a corresponding
reduction in charge current, this is normal.
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.
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TOWER CONSTRUCTION
The Furlmatic 910-3 is designed to fit inside an aluminium, stainless or
steel tube with an internal diameter of 41mm with a minimum wall
thickness of 5mm.
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.
Fig.2
Fig.3
Centre pivoted pole
Base pivoted with gin pole
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.
Note: 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.
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ASSEMBLY AND INSTALLATION OF THE WINDCHARGER
Blade Assembly (Fig. 4)
1. Place the generator assembly on a flat surface hub-side down.
2. Position blade as shown. The blades 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 then be easily inserted with a lever action. Gentle assistance with
a soft faced mallet may be required.
3. Four screws are required for each blade. First secure each blade with
two of the special self-tapping screws provided.
4. Fit the remaining 2 blade screws from the front of the generator hub.
5. Check tightness of all screws. (Do not over-tighten).
Fig.4
NB. IT IS IMPORTANT THAT 4 SCREWS PER BLADE ARE
FITTED.
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Furlmatic Tail Assembly (Fig. 5)
1. Remove the cover from the main housing.
2. Remove the M6 nut, washers and bolt from the tail boom.
3. Insert the tail boom into the saddle on the underside front of the housing.
Ensure the tail assembly is the correct way up. (refer to pictures in this
manual & the text on the tail label).
4. Re-fit bolt washers & nut removed in 2, passing the bolt through the tail
boom and windshaft housing. Tighten all fasteners.
5. Replace cover.
Note: Do not remove the silicone protectors from the tail stops!
Tail Boom
Fasteners
Fig. 5
NB. The tail fin is set at an angle of 15°
from vertical. Check that the tail fin is
positioned as shown in the diagram (as
viewed from rear of the Windcharger)
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Tower Preparation (Fig. 6)
Having selected a suitable pole from the guidelines on page 7:
1. The post adaptor fitted to the FM910-3 is designed to fit inside a
standard 41mm (1⅝") 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.
Note: When using the Rutland Land Tower Kit, items 2 and 3 can be ignored as
the unit is pre-drilled.
Fig.
BATTERIES
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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.6).
• In series to increase voltage (Fig.7).
Red is + Positive
Black is - Negative
Total = 12v
120Ah
1440Wh
Fig.6
Fig.7
Total = 24v
60Ah
1440Wh
12v
60Ah
12v
60Ah
12v
60Ah
12v
60Ah
CABLE SPECIFICATION
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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 and connectors are available from your dealer or the manufacturer.
Cable Run
(m)
0-20
21-30
31-45
46-80
Cable Size
(mm²)
12 Volt
2.5
4
6
10
Cable Size
(mm²)
24 Volt
1.5
2.5
4
6
Table.1
ELECTRICAL CONNECTION & FITTING TO THE TOWER
1. Run the cable selected (see Table 1) 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. Fit the in-line fuse and fuse holder in the circuit where the HRS type or
no regulator is used. It is essential that a charge fuse is fitted but note
that some Marlec controllers incorporate one negating the need for a
separate fuse. Cut the fuse holder cable and strip back the ends to allow
connection in the circuit.
Fig. 8
20A Fuse
and Fuse holder
4. Connect the Wincharger flying lead to the cable protruding from the top
of the tower using the connector block supplied, taking care to observe
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polarity. Connect the Windcharger + to cable + and Windcharger – to
cable –
Red is +Positive
Black is –Negative
5. Wrap the connection with insulation tape to secure/protect from the
environment. Alternatively join the cables using a latching type plug and
socket.
6. 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.
FINAL MECHANICAL CHECK
1. Check the tightness of the blade fixing screws and generator mounting
screws.
2. Check free rotation of the hub and yaw axis.
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Regulator and Fuse
Wiring Diagram
REGULATOR
FM910-3 WIND
GENERATOR
RED
BROWN
BLACK
BLACK
RED
CHARGE FUSE
BATTERY
Charge Controller
Wiring Diagram
FM910-3 WIND
GENERATOR
RED
BLACK
BATTERY
BATTERY
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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.
14
7
12
6
10
5
8
4
6
3
4
WINDSPEED CONVERSION
2
2
MPH = M/S x 2.23
Knots = M/S x 1.94
1
CHARGE CURRENT INTO 24v BATTERY (AMPS)
CHARGE CURRENT INTO 12v BATTERY (AMPS)
SPECIFICATION AND PERFORMANCE
0
0
0
5
10
15
20
25
30
35
40
WINDSPEED M/S
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INSPECTION AND MAINTENANCE
The Rutland Furlmatic 910-3 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:
1) 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.
2) 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:
1) Check the blade screws for tightness.
2) Check all other nuts, bolts and screws for tightness.
3) Check the yaw axis for free rotation.
4) Check the tail fin moves freely.
5) Check tower assembly for condition.
6) Check the tension of the guy wires if applicable. The tension of guy wires
should be checked frequently during the first year.
7) The unit can be wiped with a mild detergent and rinsed with water to remove
dirt and debris.
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TROUBLESHOOTING
In the unlikely event that your Rutland Furlmatic 910-3 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.
1. Read the Electrical Connection (page 12) and Up & Running (page 15)
sections and be satisfied that your system complies.
2. Is there sufficient wind? The Rutland 910-3 needs approximately 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:
A. 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.
B. 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.
C. 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.
D. 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.
E. If the wind turbine fails to deliver any current or open circuit V reading
undertake the further tests below.
5. Mechanical inspection. It may be necessary to remove the Windcharger from
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its pole for the following tests.
• Check the brushes and slipring for wear or damage. To inspect the brushes,
remove the cover from the main housing by removing the four fixing screws.
The brushes and slipring can be then be inspected by removing the four selftapping screws holding the brush holder assembly in place. Remove any black
deposits from slipring with emery paper. Heavy deposits and reduced power
indicate a possible reverse connection to the battery (see Page 11).
• 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.
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.
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Notes
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Notes
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LI M I T E D W A R R A N T Y
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 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: [email protected]
www.marlec.co.uk
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