Rutland 1200 Wind Turbine & Charge Controller

Rutland 1200 Wind Turbine & Charge Controller
Rutland 1200 Wind Turbine & Charge Controller
Owners Manual
Rutland 1200 Wind Turbine & Charge Controller
Owners Manual
Rutland 1200
Wind Turbine
& Charge Controller
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.
Owners Manual
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.
Installation and Operation
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.
GB
No responsibility is assumed for incidental damage. No responsibility is
assumed for consequential damage. No responsibility is assumed for damage
caused by user modification to the product or the use of any unauthorised
components.
No responsibility is assumed for use of 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
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Rutland 1200 Wind Turbine & Charge Controller
Owners Manual
Contents
4
Rutland 1200 Features and Uses
4
Overview of Rutland 1200
5
Rutland 1200 Dimensions
5
Charge Controller Features and Uses
6
Charge Controller Overview
6
Charge Controller Dimensions
8
General Guidelines and Warnings
8
Check You Have Received
9
Tools Required
9
Other Items
9
Quick Start Guides
10
System Requirements
12
Cable Specification
12
Battery Specification
13
Solar PV Specification
14
Charge Controller Installation
16
Mounting the Charge Controller
16
Connecting the Charge Controller
16
Wind Turbine Assembly
18
Tower Preperation
18
Fitting the Rutland 1200 to the Tower
18
Fitting the Pole Fairing
19
Turbine Assembly
19
Fitting the Turbine to the Generator
20
Fitting the Nose Cone
20
Up and Running
21
5 Point Final Checklist
21
Electrical Connection
21
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Page
Introduction
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Rutland 1200 Wind Turbine & Charge Controller
Owners Manual
Rutland 1200 Wind Turbine & Charge Controller
Owners Manual
For Your Records
For your future reference we recommend you note the following:
Operation
21
Serial Number of Wind Turbine:
Buttons
21
Serial Number of Charge Controller:
LED Indicators
22
Date of Purchase:
Operating Characteristics
22
Purchased from:
Multi stage charging
22
Date of Installation:
Temperature Compensation
23
Electronic High Wind Current Protection
23
Maximum Power Point Tracking
23
Performance and Yield
24
Siting the Wind Turbine
26
Mounting the Wind Turbine
27
Support
On Board Systems
27
Visit www.marlec.co.uk/ for support and spare parts to ensure you get the best out of
your Rutland Wind Turbine. Many repairs are simple enough to carry out yourself, and
require only basic equipment, but we also offer a full testing and repairs service. Contact Marlec for further information.. For maintenance demonstrations and further advice
see www.marlec.co.uk or watch our videos at MarlecTV on YouTube.
Land Based Systems
28
Siting the Solar Array
29
Maintenance and Troubleshooting
30
Inspection and Maintenance
30
Rutland 1200 Troubleshooting
31
Solar Troubleshooting
Charge Controller Troubleshooting
32
For Your Records
Support
34
Contact Details
Limited Warranty
34
Notes:
Contact Details
Address:
Marlec Engineering Co Ltd
Rutland House
Trevithick Road
Corby, Northants
NN17 5XY
UK
Tel:
+44 (0)1536 201 588
Skype:
marlecengineering
Email:
[email protected]
Opening Times:
Mon-Thurs
Fri
08:30-17:00
08:30-15:00
33
34
36
Thank You
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Rutland 1200 Wind Turbine & Charge Controller
Owners Manual
Introduction
Congratulations and thank you for purchasing your Rutland 1200 Wind Turbine and
Hybrid MPPT Charge Controller. Our range of Rutland Wind Turbines are well known
as simple, reliable, quiet and efficient wind turbines that have been used worldwide by
sailors, farmers and off-grid power specialists since 1978.
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 1200 we
recommend that you read this manual and familiarise yourself with its contents before
installing and operating the wind turbine and charging system.
Rutland 1200 Wind Turbine Features and Uses
· The Rutland charge system provides a direct current (DC) to charge a battery
bank and power low voltage equipment connected to the batteries.
· Our Maximum Power Point Tracking (MPPT) technology continuously adjusts the
turbine speed to achieve its optimum power performance. This increases the
genetrator efficiency and delivers more ampere hours to your battery.
· Aerodynamically efficient aerofoil blades for a powerful and quiet turbine.
· Sleek design that ensures a smooth and stable operation.
· Low wind speed start up maximises power generation in the most common winds.
· The Rutland 1200 uses rare earth magnets with an ironless core to create an
efficient axial flux generator with no cogging torque.
· Electronic High Wind Current Protection Mode.
· High grade construction materials for durability in the harshest environments.
· Sealed long life bearings & stainless steel fasteners.
· Designed for domestic uses such as on board sailing yachts, motor caravans,
static caravans and remote living, as well as professional applications such as
navigation, pumping, lighting and sensing equipment, etc, at remote sites where
off grid power is required.
· Ideally mounted on the Rutland Marine Mounting Kit and the Land Tower Kit - see
product catalogues.
Rutland 1200 Wind Turbine & Charge Controller
Owners Manual
Charge Controller Troubleshooting
1. Charge Controller Not Powered - BAT 1 LED dark.
· Check polarity.
· Check all fuses, switches and connections on the battery cables.
· Check battery voltage is sufficient. It must be over 9V for the charge controller to
function.
2. Charge Controller showing BAT 2 not connected. BAT 2 LED dark.
· Check the connection of Battery 2 as above.
· Shutdown the wind and solar using the WG and PV buttons. They show solid red
when shutdown.
· Disconnect, then reconnect Battery 1 to restart the controller. BAT 2 LED will light
with BAT 1 LED. Restart the wind and solar to resume charging.
3. Charge Controller WG and PV buttons Flashing Red
· The controller is in a managed shutdown due to over temperature, or is operating
in High Wind and Solar Current Protection Mode. It will resume charging
automatically when conditions permit. (for Solar current overload manual reset is
necessary)
· Check that the solar array connected is not too large, <20A.
· Check that the charge controller is in a well ventilated area, and that the fan and
the vents on the controller are free from dust or blockage.
4. Charge Controller Constantly Regulating
· Battery capacity is too small for the level of charge current or there is no load.
· If operating a 24V system, the battery may have been discharged below 20V when
the charge controller was connected and automatically detected the system
voltage as 12V. Externally recharge the battery and then reconnect the charge
controller.
· External charge source (e.g. alternator) raising battery voltage. Disconnect
external charge before testing the charge controller.
· Is voltage sensing cable fitted? This will give a the charge controller a more
accurate reading of battery voltage.
· Is the external temperature sensor connected?
6.
·
·
·
No Charge To Batteries
Ensure that the batteries are not fully charged and causing regulation.
Check that there is sufficient wind and/or solar available for charging.
Perform the Rutland 1200 & Solar Troubleshooting steps to ensure the charge
sources are performing correctly.
· Test the charge current by series connecting your multimeter.
If in doubt, refer to your dealer or the manufacturer.
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Rutland 1200 Wind Turbine & Charge Controller
4.
·
·
·
Owners Manual
Open the Nacelle if further inspection is required.
Remove the 4 screws connecting the bottom of the nacelle to the post adaptor.
Remove the 5 larger screws towards the nacelle front.
Then gently prise open nacelle halves, and slide off the generator hub and post
adaptor.
Rutland 1200 Wind Turbine & Charge Controller
Owners Manual
Overview of Rutland 1200
9 x M6 Hex
Head Blade
Screws
Rotor Hub
Plate
9 x M6 Nylock
Blade Nuts
Wind Shaft
Generator Hub
Nacelle
5. Check for a short circuit or damage to the cables inside the nacelle.
6. Check the brushes and slip rings for wear or damage.
· There are 2 sets of black plastic brush holders (3 brushes in each).
· The brushes and slip rings can then be inspected by removing the four selftapping screws holding the black plastic brush holder assemblies in place.
· Remove any black deposits from slip ring 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.
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 on further tests, or
recommend your nearest distributor in their world wide network.
M16 Nylock
Nut
Tail
Nose Cone with
3 x No3x10 Screws
Post Adaptor with
2 x M10 Set Screws &
Shake-Proof Washers
6mm Allen
Key
2 x Pole Fairing fix with
4 x No3.5x10 Screws
3 x Aerofoil Blades
Post Adaptor &
Yaw Axis
3 Core 2.5mm Tinned
Output Cable
Solar Troubleshooting
Warning! Solar panels generate electricity when exposed to light. Always cover the
solar array before changing any connections.
Carry out the these tests with the panel(s) in direct sunlight!
1.
·
·
·
·
·
·
·
2.
·
·
·
Rutland 1200 Dimensions
Test Voc
Disconnect the solar cables from the charge controller.
Clip your multimeter to the cables and set to DC volts. Uncover the solar panel(s).
Check the polarity of the solar panel.
Check the reading is close to the Voc of the panel. (usually found on the label on
the rear)
The reading must be above battery voltage to allow charge.
If the reading is much below Voc there is an internal fault in the solar panel.
If the cables ay the charge controller show no voltage there is a problem with the
module, blocking diodes or the wiring.
Test Isc
Disconnect the solar cables from the charge controller.
Clip your multimeter to the cables and set to DC current. Uncover the solar
panel(s).
Check the reading is close to the Isc of the panel. (only in direct sunlight and at
optimum tilt angle!)
If in doubt, refer to your dealer or the manufacturer.
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Rutland 1200 Wind Turbine & Charge Controller
Owners Manual
Hybrid MPPT Charge Controller Features and Uses
· Hybrid MPPT Charge Controller for Rutland 1200 and up to 20 Amps of Solar
([email protected] or [email protected]).
· Separate MPPT Control of the Wind Turbine and Solar PV increases energy
yields.
· Multi stage battery charging for an optimum charge regime. PWM voltage regulation protects batteries from overcharging and increases lifetime.
Rutland 1200 Wind Turbine & Charge Controller
Owners Manual
Troubleshooting
In the unlikely event that your system develops a defect, the turbine should first be
made safe. If the stall button is not functioning the turbine can be slowed by turning it
into the wind and then tied off, or lowering the tower. Follow the below
troubleshooting in order. Take care that all test equipment used is suitable.
1. Read the Electrical Connection and Up & Running sections and be satisfied that
your system complies. Check for mechanical obstruction to the turbine.
· Temperature compensated for optimum charge with remote sensor.
2. Is there sufficient wind?: The Wind Turbine needs approximately 4-5 knots wind
speed to start charging. The actual wind speed at the turbine blades may be
greatly reduced when compared with weather reports. As a guide the blades will
appear as a blur before charge starts to be delivered.
3. System 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.
· Remote voltage sensing. Negates battery cable volt drop for precise regulation.
Rutland 1200 Troubleshooting
· Designed for use with lead acid batteries, Wet, AGM and Gel.
· Automatic 12 or 24 Volt battery bank detection.
· Built in Charge Splitting for use with single or dual battery banks.
· Built in charge stop switches for independent shutdown of wind or solar.
1. Mechanical Inspection: Lower the Rutland 1200 for the following tests.
· With the tower lowered disconnect the wind turbine from the charge controller.
· The turbine should rotate freely with no noise or vibration.
· Noise or vibration under rotation suggests a bearing change is required.
· If the hub does not rotate freely, check for a possible short-circuit in the wiring
from the charge controller to the turbine.
· Controlled cooling fan for efficient operation.
· Optional remote display via serial cable.
Charge Controller Overview
2. Remove the Rutland 1200 from the pole: for further inspection.
· Remove the Pole Fairing by removing the 4 screws.
· Unscrew the 2 M10 screws with shake-proof washers from the Tower.
· Gently pull the Post Adaptor free from the tower and disconnect from the tower
cable and charge controller.
“Wind” Terminals
“Wind” Button
Battery Terminals
Battery Status LED’s
“PV” Button
“PV” Terminals
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3. Rutland 1200 Tests: Check for power output from the Wind Turbine whilst the
turbine is lowered, follow this procedure:
· With the outputs open-circuit check the turbine wind shaft for free rotation.
Noise or vibration under rotation suggests a bearing change is required.
· If the hub fails to rotate freely with no short-circuit check inside the nacelle.
· Set your multimeter to AC Voltage. Clip between two of the output phases and
turn the generator by hand noting the reading. Make three readings between
the different phases to check there is no open-circuit.
· Set your multimeter to AC Current. Clip between two of the output phases and
turn the generator by hand. You should feel a smooth resistance to rotation.
Make three readings between the different phases.
· Otherwise there is no fault on the Rutland 1200, and the problem is in the
charge controller or the wiring to the controller.
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Rutland 1200 Wind Turbine & Charge Controller
Owners Manual
Rutland 1200 Wind Turbine & Charge Controller
Owners Manual
Maintenance and Troubleshooting
Left Side - Inputs Connections
Inspection and Maintenance
Right Side - Outputs Connections
The Rutland Wind Turbine requires no scheduled maintenance except an annual
inspection to monitor the general condition of the system to ensure the electrical and
mechanical integrity and safety of the system.
For maintenance demonstrations and advice see www.marlec.co.uk or watch our
videos at MarlecTV on YouTube. We also offer a full testing and repairs service,
contact Marlec for further information.
WARNING! Before inspection, the turbine should be stalled and lowered to the ground
or tied to be prevented from turning to avoid injury.
To stop the turbine from turning proceed as follows:
Charge Controller Dimensions
1. Press the shutdown switch on the Charge Controller. The turbine will slow down. It
may turn slowly but will not accelerate with the wind.
2. Tie a blade to the mounting pole to prevent it from rotating.
The following routine checks should be performed whilst the turbine is stationary:
1. Check the blades for damage, eg chips or nicks. Replace any damaged blades. The
turbine should not be operated with damaged blades as this may cause imbalance
resulting in premature wear and possible failure. 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 tower assembly for good condition.
5. Check the tension of any guy wires if applicable. The tension of guy wires should be
checked frequently during the first year.
6. The Rutland 1200 can be wiped with a mild detergent and rinsed with water to
remove dirt and debris.
7. Ensure that the solar array is clean and has not become shaded over time.
8. Check that the charge controller is in a well ventilated area, and that the fan and the
vents on the controller are free from dust or blockage.
Weight 1.3kg
9. Ensure that all terminal connections are secure.
Note: The Rutland 1200 is designed for continuous running to achieve maximum
resistance to water ingress into the bearing and generator.
Should you wish to take the unit out of service for an extended period it is recommend
that the unit be removed from the mounting and stored in a dry location, or well covered
and secured if removal and storage is not possible.
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Rutland 1200 Wind Turbine & Charge Controller
Owners Manual
Rutland 1200 Wind Turbine & Charge Controller
Owners Manual
General Guidelines and Warnings
Siting the Solar Array
·Follow the instructions for the Rutland 1200, Solar Module and Batteries when installing your
PV panels are easy to install, have no moving parts and are virtually maintenance free.
system. Always perform the operations in this manual in the order specified.
·When turning the Wind Turbine 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 the
Charge Controller and the Charge Controller connected to the batteries. Connecting an open
circuit running turbine to the electrical system can cause serious damage to the system
components owing to excessive voltage. Solar PV Panels can also generate voltages in excess
of the nominal voltage whenever they are exposed to light. Always cover panels during
installation. Caution must be excercised at all times to avoid electric shock.
·Stopping the turbine—this may be necessary to undertake battery maintenance for example. If
possible this should be done in low wind speed conditions. Use the shutdown switch on the
Charge Controller to stop the turbine. Alternatively 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 extended period of time. We
recommend that the turbine either be covered to protect from the weather or removed and stored
in a dry location.
·Choose a calm day to install the equipment and consider other safety aspects. No attempt to
repair the system should be made without restraining the turbine from turning and the PV panels
being covered.
·The Wind Turbine is fitted with permanent magnets which can be damaged by heavy handling.
The main generator assembly should be treated with care during transit and handling.
·It is essential to observe the correct polarity when connecting the Wind Turbine, Charge
They are usually mounted on brackets from a pole, wall or a roof which inclines the
module at a fixed angle. They are also suitable for mounting flat, which is often safer
and more convenient on a boat deck or caravan roof .
To provide good year round operation of an off-grid battery system they should be
orientated towards the equator and inclined at an angle relative to latitude.
To provide good year round operation of a fixed inclination off-grid battery system they
should optimised for winter yields with the steeper angle of 65-75° used. In the UK (or
areas of similar latitude) a steeper angle in winter (65-75°) and a flatter angle in
summer (20°) will improve seasonal output. A system where the angle can be manually
altered seasonally will generate more yield through the year.
If panels are mounted at less than 15° they should be cleaned more often as flatter
angles do not take full advantage of the cleansing effect of rainfall.
Careful siting is important to ensure maximum exposure to sunlight for the longest
possible time. If panels are shaded their charge output will be reduced. To compensate
for this loss in charge a larger solar array is required.
As module cell temperature affects the power it is recommended to mount framed
modules so that airflow underneath the backsheet is allowed. Laminated semi-flexible
modules are suitable for mounting flush to a surface.
Conrtoller and all other components into an electrical circuit. Reverse connection will damage the
Wind Turbine and/or the Charge Controller and incorrect installation will invalidate the warranty.
·Do not open the case of the Charge Controller. Do not connect the Charge Controller in the
event of damage. Live components operate at potentially harmful voltages.
·Ensure the area of installation of the Charge Controller is adequately ventilated. Maintain at
least 5cm of clearance around the charge controller to allow air circulation.
·Ensure all connections to the Charge Controller are permanent.
·The Wind Turbine mounting pole outside diameter should not exceed 48.5mm for at least the
top 0.6m to avoid blade strike. Note that an unsupported tower will experience lateral movement,
particularly in high winds, which can cause damage to the Wind Turbine. It is essential for
effective performance that the mounting pole is vertical.
·High winds – The Rutland 1200 Wind Turbine is suitable for marine and land based
applications. When storm winds are forecast the turbine can be restrained to minimise wear and
tear.
If in doubt refer to your dealer, a competent electrical engineer or the
manufacturer.
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Rutland 1200 Wind Turbine & Charge Controller
Owners Manual
Rutland 1200 Wind Turbine & Charge Controller
Land Based Systems
Check You Have Received
For good performance the Rutland 1200 should be mounted a minimum of 6m from the
ground to ensure the affect of wind shear is minimised.
1 x Main Generator Assembly
1 x Hybrid MPPT Charge Controller and
External Temperature Sensor
3 x Aerofoil Blade
1 x Rotor Hub Plate
1 x M16 Nylock Nut
9 x M6x20mm Hex Head Screw
9 x M6 Nylock Nut
2 x M10 Hex Head Screw
2 x M10 Shake Proof Washer
The Marlec Land Tower Kit & Tower Rigging Kit (Part No. CA-12/08 & CA-12/07) are
available for mounting our range of wind turbines on land. They come as a complete kit
ready for assemble and permanent installation with a concrete base.
We also offer a range of non-guyed pivoting towers that can be customised and towers
for a range of professional applications. Please contact Marlec for further details.
Alternatively 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 and loads.
Pivot type towers are recommended as these allow for easier installation and lowering
for access to the wind turbine. Two forms of pivot tower are suggested below.
Owners Manual
2 x Pole Fairing
4 x No3.5x10 Plastech Screw
1 x Nose Cone
3 x No3x10 Plastech Screw
1 x Allen Key 6mm
1 x 3 Way Terminal Block
In the event of loss or damage, consult your dealer or the manufacturer.
Tools Required
· 10mm and 17mm Spanner
· PZ1 Crosshead Screwdriver
· PZ2 Crosshead Screwdriver
· Terminal Screwdriver
· Wire Strippers
· Multimeter (useful)
Other Items you may require
· Tower/Mounting pole
· Connector Blocks
· Tower, Battery and Solar Cables
· Deep Cycle Batteries
· Battery Terminals
· Solar PV Panels
· Blocking Diodes
· Controller Wall Mounting Screws
Other Items available from Marlec
Marlec can provide many quality products to complete your installation, some are listed below.
See www.marlec.co.uk for more details.
Centre pivoted pole
Base pivoted with gin pole
NB:See the warnings section regarding the tower. It is essential that the tower is
maintained vertically to minimise unnecessary yawing which may cause a loss of yield.
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· Optional Remote Display
- (CA-11/121)
· Rutland Marine Mounting and Stays Kit
- Options Available
· Land Tower and Rigging Kit
- (CA-12/08 & CA-12/07)
· Pre-drilled stainless steel tube(1200/600mm) - (CA-12/03 or CA-12/04)
· Cable 3-core 2.5mm² tinned
- (902-037)
· Cable 2-core 2.5mm² tinned
-(902-036)
· Battery Cable
- Options available
· Solar Cable - Single Core 4mm or 6mm
- Options available
· Deep Cycle Batteries
- AGM & Gel options available
· Battery Terminals
- (901-039)
· Plug and Socket Connectors
- Options available
· Solar PV Panels
- Framed or Flexible options available
· Blocking Diodes
- Options available
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Rutland 1200 Wind Turbine & Charge Controller
Owners Manual
Quick Start Guide - Charge Controller
Rutland 1200 Wind Turbine & Charge Controller
Owners Manual
Mounting The Wind Turbine
The sequence of connections is critical to the safe setup of the charge controller. Make
sure no connections are live during installation.
1. Select a covered, dry, flat vertical wall in a ventilated area within 1.5m of the
batteries. Attach the controller to the wall allowing 5cm of clearance for ventilation .
2. Select all cables according to your installation and the Cable Specification
Guidelines (Page 12). You will require:
· Battery Cables and voltage sensing wire(optional)
· 3 core wind turbine tower cable to be threaded through the tower
· Solar cable to connect the solar panel to the controller
The Rutland 1200 is designed to fit inside an aluminium or stainless steel tube with an
internal diameter of 41mm (1⅝”). The external diameter MUST NOT exceed 48.5mm
(2”) for the top 0.6m of the tower to avoid blade strike. Any play between the tower and
the post adaptor must be taken up with a shim.
Suitable tubes: Stainless Steel 13/4”16 SWG, Galvanised Steel 40mm and Aluminium
17/8” 10 SWG.
On Board Systems
The Wind Turbine should be mounted in a safe position, a
minimum of 2.4 metres above the deck and away from other
obstacles which could interfere with the blades or tail
assembly.
3. Do not make live connections to the controller. Before any connections are made
ensure that the battery cables are disconnected from the battery, all other battery
charge sources are off and cover any solar panels.
The Rutland Mounting Kit & Stays Kits are available for deck
mounting, or use our short sections of pre-drilled stainless
steel tube, 1200mm (47”) & 600mm (23”), for your own
fabrication.
4. Strip back the power cable ends to be connected to the charge controller by 10mm.
All power cable terminals should be tightened with a PZ2 Crosshead Screwdriver.
5. Connect the battery cables to the charge controller observing correct polarity. If the
system has only one battery then it must be connected to BAT 1 as this provides the
internal power for the controller. Do not connect to batteries at this stage.
We suggest the following mountings according to preference
and site conditions:-
6. Connect the remote temperature sensor to its port. Connect the voltage sensing wire
(optional) to the REMOTE BAT terminals. Do not connect to batteries at this
stage.
Push Pit
A suitable pole mounted to the deck with deck plates and solid
guys is the most popular method of mounting the Wind
Turbine on yachts, eg. Rutland Marine Mounting & Stays Kit.
7. Connect the 3 core cable from the wind turbine and tower to the WG INPUT.
8. Keeping the solar panels covered. See Solar PV Guidelines (Page 14) for
suitable solar arrays. Observing correct polarity connect the solar panel to PV INPUT
terminals.
Quick Start Guide - Rutland 1200 Wind Turbine
Mizzen
1. Choose an open site that exposes the Wind Turbine to a clear flow of wind and
avoids obstructions. On board mount the Wind Turbine at least 2.4 metres above the
deck and on land at least 6 m high. See Siting the Wind Turbine (Page 26).
Mizzen mounting is suitable on larger yachts, taking
advantage of greater wind flow the higher the wind turbine is
mounted.
2. Choose a mounting pole with an internal diameter of 41mm and external diameter of
no greater than 48.5mm for the top 0.6 m to ensure secure fixing to the tower. See
Mounting the Wind Turbine (Page 27).
3. Drill the mounting pole, if required, in preparation to accept and secure the Wind
Turbine. See Assembly and Installation (Page 18-20).
4. Join the cable threaded through the pole to the Wind Turbine output cable using the
connector block provided and wrap with insulating tape. Alternatively use a latching
plug and socket. We recommend looping back the cable and securing with a cable
tie to provide strain relief to the joint.
River Boats
A pivot pole is ideal for riverboats as the Wind Turbine can
easily be raised and lowered.
5. Carefully push the cables down the pole whilst sliding the Post Adaptor into the pole.
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Rutland 1200 Wind Turbine & Charge Controller
Owners Manual
Siting the Wind Turbine
The location and height of the mounting pole or tower for your wind turbine will be the
major factor in the overall performance and lifetime 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 is the frictional affect of the ground on the wind, the amount that it reduces
wind speed by depends on the terrain and your height above ground. The interference
between the fast moving upper air and the slow moving air closer to the ground can
also creates turbulence and eddy currents.
To negate the effect of wind shear we recommend a minimum mounting height of 6m
above the ground for land based machines. On yachts this is often not practical to
achieve, but as the shear affect of water is much less than land so a lower turbine
height can still give good yields.
Turbulence is the effect of obstructions creating eddy currents, swirling the wind in
different directions and changing the velocities of the air particles, in their wake.
The effects are greatest downstream of the obstruction so the direction of the prevailing
wind needs to be considered for your site, but turbulence also occurs above and in front
of an obstruction. As a general rule a tower can raise a turbine out of the turbulent
wind, but it is often more practical to move the turbine further upstream or downstream
of the obstruction as shown below.
Rutland 1200 Wind Turbine & Charge Controller
Owners Manual
Line up the holes and secure in place with the M10 screws and shake-proof
washers.
6. Fit the Pole Fairing. Cut the tab off to suit your pole diameter, place the Fairing over
the Screw Head and screw together using the No3.5x10 Plastech Screws and PZ2
Screwdriver (Page 19).
7. Assemble the Turbine. Fit the Aerofoil blades to the Rotor Hub Plate, using the M6
fasteners provided. Place the M16 nut in the centre of the blades before you tighten
the fasteners. It is essential that 3 screws are fitted per blade (Page 19).
8. Fit the Turbine to the Generator. Screw the turbine on to the Wind Shaft by turning
the Turbine in a clockwise direction, to tighten hold the Wind Shaft in place using the
6mm Allen Key provided (Page 20).
9. Fit the Nose Cone using the No3x10 Plastech Screws and PZ1 Screwdriver( Page
20).
10.Ensure connections to the charge controller are permanent. The Wind Turbine
should NEVER be operated without a connection to the controller.
11.Raise and secure the Tower and Wind Turbine. The charge controller will hold the
turbine in stall at this stage.
Quick Start Guide - Up and Running
5 Point Final Checklist
1. Check that all cables are secure and safe, and the tower is not trapped.
2. Check that all electrical connections are permanent and safe.
Wind speeds decrease and turbulence increases where obstructions exist so the sitting
of the turbine is very important to avoid unnecessary turbulence in order to ensure good
yields and turbine lifetime.
3. Check for free rotation of the hub and yaw axis. Release the turbine.
Both wind sheer and turbulence diminish with increasing height and can be overcome
simply by putting the turbine sufficiently high above them as shown.
5. The solar array can be uncovered. The controller will prevent any current.
4. The wind turbine can now be raised into position. When raised, secure the structure
firmly in an upright position. The charge controller will hold the turbine in stall.
Electrical Connection
Connect the charge controller to the batteries. If a second battery bank is to be used
connect this first to BAT 2, then connect BAT1.
Connect the voltage sensing wire (if used) to the battery positive.
When connected the battery status LED’s will light and the controller will auto configure
to 12V or 24V. The Wind and PV buttons will light red to show they are shutdown.
To enable charge press the Wind Button to release the turbine and the PV Button to
switch on the solar. The LEDs will light according to the charge status.
The charge controller has now been enabled
and will automatically charge your batteries.
The General Guidelines and Warnings, Cable Specifications, Assembly and
Installation and Operation sections expands on the above points.
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Rutland 1200 Wind Turbine & Charge Controller
Owners Manual
Rutland 1200 Wind Turbine & Charge Controller
Owners Manual
System Requirements
Wind and Solar Yield Prediction
Cable Specification
The cable used for connection of the Wind Turbine to the Charge Controller and to the
batteries should be chosen in accordance with tables shown. The use of a smaller
cable than recommended will reduce the performance of the charging system and is a
potential fire hazard. Always use flexible, stranded, insulated copper cables.
Battery Cables
The battery cable must be rated to 35A DC minimum if the Rutland 1200 is the only
input used. If the full solar input is also used the cable must be rated to 55A DC
minimum. See the table below for recommended battery cable sizes up to 1.5m cable
length.
Charge Source Connected
Minimum Cable Size
mm²
AWG
6
10
10
8
Rutland 1200 Only - 35A DC
Rutland 1200 & 20A Solar - 55A DC
It is recommended that the optional remote voltage sensing should be utilised if the
battery cable exceeds 1.5m. This negates the battery cable volt drop from the voltage
sensing for charge and regulation points. This gives a more precise charge regime.
The voltage sensing cable only requires 1 length of conductor per battery bank. This is
a signal, not a power connection so does not need to be more than 0.75mm².
Wind Turbine Tower Cables
The Rutland 1200 has a 3 phase AC output. A 3 core cable of at least 2.5mm² cross
sectional area is required to connect the Wind Turbine to the Charge Controller.
Tower Cable Run
3 Core Stranded Cable Size
mm²
AWG
2.5
14
4
12
0-50 m
50-100 m
Solar PV Cables
Solar PV generates a DC. This requires a positive and negative conductor that is rated
to the current generated by your array. It is recommended that the volt drop along the
cable does not exceed 5%.
Up to 10A DC Solar - Cable Run
Stranded Cable Size
mm²
AWG
4
12
6
10
Stranded Cable Size
mm²
AWG
6
10
10
8
0-5 m
5-10 m
Up to 20A DC Solar - Cable Run
0-5 m
5-10 m
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Please Note: These predictions are for typical sites with the yields over time. For this
reason sufficient battery backup is needed to guarantee power to your load. It does not
guarantee that this much energy will be produced every day, and for poor sites you
should expect lower yields and design your system accordingly.
We recommend that an average wind speed of 4m/s is used for yield predictions unless
you have accurate wind speed data for your site.
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Rutland 1200 Wind Turbine & Charge Controller
Owners Manual
Rutland 1200 Wind Turbine & Charge Controller
Owners Manual
Performance and Yield
Battery Specification
Wind Performance Curve
Leisure / Deep Cycle batteries are specifically designed for good performance in terms
of charge / discharge cycles. Batteries are the most important part of the renewable
energy battery charging system and should be sized according to the load requirements
to 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 or solar.
· Always use the WG1200 Charge Controller to connect to your batteries. The
controller prevents batteries becoming overcharged and protects your system in
strong winds.
· The controller is designed for use with lead acid batteries. Wet, AGM and Gel.
· Permanent connections should always be made to the battery terminals. Never use
crocodile clips or similar devices. Battery terminals should be clean and well
greased.
· When connecting a 24V battery it must be charged to 20V or higher to be recognised
by the automatic 12 or 24 Volt battery bank detection.
· It is essential to observe correct polarity.
Brown/Red is + Positive & Grey/Black is - Negative
Batteries may be linked as follows:
In parallel to increase amp hours
+
In series to increase voltage
-
+
-
+
160Ah
12V
+
-
+
160Ah
12V
160Ah
12V
Total = 12V, 320Ah, 3840Wh
+
160Ah
12V
Total = 24V, 160Ah, 3840Wh
Battery Bank Capacity
Due to the potentially high charge currents produced by the Rutland 1200 it is
recommended a minimum battery capacity following the table below is used. Smaller
capacities may used but may result in a loss of charging performance as the battery
voltage can quickly rise to the regulation level under the potential rate of charge.
Charge Source
Please Note: The curve shown is for clear, non-turbulent wind conditions; this may not
be achieved for some installations. Refer to Siting the Wind Turbine to optimise
performance at your site. Due to wind shear and turbulence the wind experienced by
the wind turbine will be different to wind speeds measured at the top of a mast or those
reported by the Met. Office.
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Minimum Battery Capacity
12V
24V
175Ah
85Ah
225Ah
110Ah
275Ah
135Ah
Rutland 1200 Only
Rutland 1200 & 10A Solar
Rutland 1200 & 20A Solar
Additional parallel charge sources will also affect the battery capacity required.
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Rutland 1200 Wind Turbine & Charge Controller
Owners Manual
Rutland 1200 Wind Turbine & Charge Controller
Owners Manual
Solar PV Specifications
Temperature Compensation
A maximum solar array charge current of 20Amps can be connected to the charge
controller. This is equal to approx 250W for a 12V system, and 500W for a 24V system.
The charge controller uses temperature compensation to adjust the voltage regulation
settings according to deviation from 25°C. A colder battery requires charging to a higher
voltage level, a warmer battery to a lower voltage level. The external temperature
sensor supplied increases the accuracy of the charge controller and should be fitted as
close to the batteries as possible.
The maximum open circuit voltage (Voc) of the array must not exceed 50V over the
entire operating temperature range.
The operating voltage of the solar array must be greater than battery voltage
throughout the range of expecting operating conditions. A minimum, maximum power
voltage at STC (Vmpp), of 15V/30V in normal operating conditions is recommended for a
12/24V system.
Types of Solar Modules
Off Grid PV modules are designed for battery charging and have nominal voltages of
12V or 24V. Grid connect PV modules have a higher operating voltage and come in
modules of higher nominal power.
· If using multiple 12V modules connect parallel for 12V, or series for 24V operation.
· If using multiple 24V modules connect in parallel.
· Only connect grid connect modules alone or in parallel up to 20A charge current.
Parallel & Series Connection
Most framed 12V panels have an opening IP54 junction box that can be used to wire
panels in series or parallel and allows easy connection of blocking diodes. External
junction boxes can also be used. Always refer to the module instructions.
12V
10A
Connect parallel to increase current
whilst maintaining voltage.
+
Total = 20A at 12V
12V
10A
12V
10A
12V
10A
12V
10A
12V
10A
12V
10A
Electronic PV Over-Current & Temperature Protection
The over-current protection condition should only occur if the current rating of the
system’s PV modules is exceeded (i.e. 20 Amps (Ipm)). If this does occur check the
rating of the PV and downsize if necessary. In this condition the controller needs to be
manually reset with the “Solar Button”. If the over-temperature condition is activated the
charge controller will reset itself. Under both these conditions the “Solar Button” will
flash red.
Maximum Power Point Tracking
Wind
All wind turbines have a characteristic relationship of output power to blade speed.
Our Maximum Power Point Tracking (MPPT) technology continuously adjusts the
turbine speed to achieve its optimum power performance. This increases the
generator efficiency and delivers more ampere hours to your battery.
“Off Grid” PV modules are designed for battery charging and have nominal voltages of
12V or 24V. They are designed so their Vmpp is slightly above battery voltage so that
they are operating near their maximum power. MPPT will still increase their efficiency.
Connect series to increase voltage
whilst maintaining current.
+
-
Total = 10A at 24V
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“Grid Connect” PV modules have a higher Vmpp and so when used on a traditional 12 or
24V system are unable to generate their nominal power as they are limited by the
battery voltage..
MPPT detaches module voltage from battery voltage allowing module operation
towards Vmpp. This has several advantages:
+
-
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This protection mode monitors the charge from the wind turbine. If excessive currents
are reached the turbine is stalled by the charge controller. The turbine will be
automatically released after approximately 5 minutes to resume charging. The charge
controller is also protected against over temperature conditions and should this occur
the wind turbine will be also be temporarily stalled. Under both these conditions the
“Wind Button” will flash red.
Solar
12V
10A
Electronic High Wind Over-Current & Temperature Protection
14
Bot h paral l el and seri es
connections can be used to
match your array to the system
requirements.
· Higher voltage grid connect modules can be used which are often more economical.
· Increased yields as the full I-V curve can be used up to the modules Vmpp.
· Higher voltage on the solar input reduces cable losses.
Total = 20A at 24V
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Rutland 1200 Wind Turbine & Charge Controller
Owners Manual
LED Indicators
The two Battery Status Lights are tri colour LED’s that show the voltage level of each
battery. The BAT 1 LED is always lit if the charge controller is connected to a battery.
Rutland 1200 Wind Turbine & Charge Controller
Owners Manual
Blocking Diodes
Blank
- Battery not connected, (or too low to power the controller)
Blocking diodes must be fitted if connecting solar modules in parallel strings to prevent
backflow of current due to shading. If fitting a single solar module or a single series
string a blocking diode is not needed as this is incorporated in the charge controller.
Flashing Red
- Battery voltage below 11V (22V) - Disconnect loads.
Check the rating (Amps) of blocking diode(s) is suitable for the solar module(s).
Solid Red
- Battery voltage below 12V (24V)
Always connect the blocking diode into the positive conductor.
Amber
- Battery voltage between 12-13V (24-26V)
Green
- Battery voltage above 13V (26V)
Flashing Green
- Battery fully charged. Controller is in regulation mode.
Symbol
Physical
Direction of Current Flow
The Wind WG Button and Solar PV Buttons are also LED’s that show:
Solid Red
- Manual Shutdown.
Voltage and Temperature Relationship
Flashing Red
- Controller Managed Shutdown.
Blank
- No charge source output voltage.
As module cell temperature increases the operating voltage of the solar module drops,
this relationship follows a linear temperature coefficient that is provided in the module
datasheet. It is therefore recommended to check:
Flashing Green
- Standby Mode, currently insufficient output for charging.
· Voc is below 50V at the lowest expected operating temperature.
Solid Green
- Charging by renewable power.
· Vmpp is above battery voltage at the highest expected operating temperature.
Further functionality and system indicators are added with the use of the optional
remote display.
In the UK typical cell operating temperatures are: -10°C min, 50°C typical, 70°C max.
Operating Characteristics
The pre-programmed settings are suitable for lead acid, AGM and most Gel batteries.
If in doubt refer to your dealer or the manufacturer.
Multi-Stage Charging
Bulk Charge Absorption Float Charge -
All available wind and solar power is used to charge the battery as
quickly as possible up to 13.8V.
Constant voltage regulation is used to fully charge up to 14.4V.
Holds the battery up to 13.8V and maintain this with a trickle charge
minimising gassing and prolonging battery life.
If the battery is discharged below 12.5V the charge cycle recommences.
The remote voltage sensing should be used to negate battery cable volt drop for
precise regulation set points. This will improve battery maintenance and rate of charge.
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Owners Manual
Charge Controller Installation
Rutland 1200 Wind Turbine & Charge Controller
Owners Manual
Up and Running
Mounting the Charge Controller
5 Point Final Checklist
1. Select a covered dry flat vertical wall
within 1.5m of the batteries.
Before releasing or raising the wind turbine, uncovering the solar panels or connecting
the link cables to the batteries:
2. Ensure the area of installation is
adequately ventilated. Maintain at least
50mm of clearance around the charge
controller to allow air circulation.
1. Check that all cables are secure and safe, and the tower cable is not trapped.
3. With the screws appropriate
substrate use the 4 mounting
securely attach controller to
with the inputs on the left,
outputs on the right.
4. The wind turbine can now be raised into position. When raised, secure the structure
firmly in an upright position. The charge controller will hold the turbine in stall.
for your
points to
the wall
and the
2. Check that all electrical connections are permanent and safe.
3. Release the turbine and check for free rotation of the wind shaft and yaw axis.
5. The solar array can be uncovered. The controller will prevent any current flowing at
this stage.
Electrical Connection
Connect the charge controller to the batteries via the link cables. If a second battery
bank is to be used connect this first to BAT 2, then connect BAT 1.
When connected the battery status LED’s will light and the controller will auto configure
to 12V or 24V.
Operation
Connecting the Charge Controller
Do not make live connections to the controller. Before any connections are made
restrain the wind turbine from turning and cover any solar panels. Ensure that the
battery cables are disconnected and other battery charge sources are off.
The charge controller will automatically operate a charging regime for your batteries
and display the state of charge via the LED’s. You can manually shutdown the wind and
solar to stall the turbine and independently stop charging from each source. For more
information on the charging regime see Operating Characteristics.
Wind Button
1. For all power cables that are to be connected strip the insulation
back 10mm. All power terminals should be tightened with a PZ2
crosshead screwdriver.
Battery Status LED’s
Buttons
2. Observing correct polarity connect the ends
of the battery link cables to the charge
controller. If a second battery bank is to be
used connect this first to BAT 2 so that it is
recognised by the charge controller.
Please Note: It is essential that there is a
BAT 1 connection as this provides internal
power to the controller.
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PV Button
To Release the Electronic Stall and begin charging press the “Wind Button”. The button
will change from Solid Red to show charging by wind power is enabled, the button be lit
according to the status of the wind turbine input.
To switch on the solar and begin charging press the “PV Button”. The button will
change from Solid Red to show charging by solar power is enabled, the button be lit
according to the status of the solar input.
Note: The charge controller has now been enabled and will automatically charge
your batteries.
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Rutland 1200 Wind Turbine & Charge Controller
Owners Manual
Rutland 1200 Wind Turbine & Charge Controller
Fitting the Turbine to the Generator
Owners Manual
3. Place the end of the remote temperature sensor next, or as
close as possible, to the batteries and secure in place. Plug
the sensor into its port.
1. Place the M16 Nut held in the Turbine over the
Wind Shaft.
Please Note: If the remote temperature sensor is not
connected temperature compensation is disabled.
4. Using a terminal screwdriver connect the sensing wire to the
REMOTE BAT terminals.
2. Screw the Turbine onto the Wind Shaft by turning
the Turbine clockwise, to tighten hold the Wind
Shaft in place using the 6mm Allen key provided.
Hold the blades near the root to avoid damaging
the aerofoil. Ensure that the Rotor Hub Plate is
squarely located on the shoulder of the Wind Shaft.
Please Note: If the remote voltage sensing is not used the
controller will use the voltage of the power cables for all
calculations. This has a volt drop associated which will
reduce the accuracy of the charging regime.
5. Connect the 3 core wind turbine tower cable to the WG
INPUT on the charge controller. The order is not important.
Please Note: The Rutland 1200 must be connected directly
to the charge controller with no switches or fuses.
Fitting the Nose Cone
1. Locate the Nose cone over the rib on the Turbine
and align the 3 screw holes.
6. Ensure the solar array is covered. Observing correct polarity
connect the cables from the solar to the PV INPUT on the
charge controller. Do not uncover the solar array at this
stage.
2. Secure the nose cone using the 3 No3x10 Plastech
Screws (supplied) and a PZ1 Screwdriver.
You have finished your Rutland 1200
Assembly
7. Ensure all connections are permanent and that cable runs
are secure and safe from tripping or any sources of strain or
damage.
You have finished installing your charge controller
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Rutland 1200 Wind Turbine & Charge Controller
Owners Manual
Rutland 1200 Wind Turbine & Charge Controller
Owners Manual
Fitting the Pole Fairing
Wind Turbine Assembly
Tower Preparation
1. Select a suitable pole from the suggested guidelines
in Mounting The Wind Turbine.
Note: The post adapter fitted to the Rutland 1200 is
designed to fit inside a standard 41mm (1⅝”) internal
diameter tube and is provided with a flat on one side to
clear any tube weld seam.
1. For thin wall stainless steel poles proceed to Step 2. For thicker wall galvanised steel
the Tab on the inside of the Pole Fairing will need trimming to the step.
2. Push the Pole Fairing over the M10 Hex Head. This also acts as a locking device.
3. Screw together the pole fairing using the 4 No3.5x10 Plastech Screws (supplied)
and a PZ2 Screwdriver.
Items 2 & 3 can be ignored if using a pre-drilled Marlec
pole.
2. 20mm from the top, mark and centre-punch two
positions diametrically opposite at 90° to any seam.
3. Pilot drill then drill two 10.5mm holes on centre-punch positions.
4. Thread your tower cable through the pole and securely position your tower following
instructions Siting the Wind Turbine & Mounting the Wind Turbine (Page 26/27)
Fitting the Rutland 1200 to the Tower
1. Strip the Wind Turbine and Tower Cables 10mm and
join using the 3-way connector block provided. Wrap
the connection with insulation tape to secure/protect
from environment. We recommend looping back the
cable and securing with a cable tie to provide strain
relief to the joint. Alternatively join the cables using a
plug and socket.
2. Carefully push the cables down the pole then slide
the post adaptor into the pole whilst keeping the
screw holes lined up.
Turbine Assembly
1. Place a M6 Nylock Nut (supplied) into the nut recess in the aerofoil blade.
2. Align with a hole in the Rotor Hub Plate and partly tighten a M6 Screw (supplied) in
from the back of the plate. Repeat with 3 fasteners on all 3 blades. Measure
between the blade tips to check equal spacing.
3. Fit the M16 Nylock Nut (supplied) into the recess created by the 3 blades.
4. Finish tightening the M6 screws using a 10mm spanner from the back of the Rotor
Hub Plate. Hold the blades near the root to avoid damaging the aerofoil. Check
tightness of all screws but do not over-tighten.
Caution - All 9 screws must be fitted!
3. Secure in place with the M10 screws and shake-proof washers (supplied). Using a
17mm spanner tighten the M10 screw against the shake-proof washer ensuring the
head is secured in a upright or horizontal position as shown below. This allows the
fitting of the pole fairing.
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