Rutland 914i Windcharger Owners Manual
Installation & Operation
Rutland 914i Windcharger
(12 or 24 V )
Owners Manual
Installation and Operation
GB, FR, ES & DE
Languages
Doc No:SM-137 Iss. C 13.02.13
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Marlec Eng Co Ltd
Doc No:SM-137 Iss. C 13.02.13
Installation & Operation
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Marlec Eng Co Ltd
Installation & Operation
Contents
Page:
Introduction
4
Summary of Features and Uses
4
Profile and Dimensions
4
General Guidelines and Warnings
5
Check You Have Received
6
Other Items
7
Exploded View of the Rutland 914i
7
Assembly & Installation
Twelve Step Quick Start Guide
8
Tower Preparation
9
Blade Assembly
9
Tail and Nose Assembly
10
Electrical Connection & Fitting to the Tower
11
Up & Running
Four Point Checklist
11
Typical Wiring Diagrams for the Rutland 914i Windcharger
12
Siting the Windcharger
General Considerations
13
Mounting The Windcharger
On Board Systems
14
Land Based Systems
15
16
Cable Specifications
16
Specification & Performance
Guideline Performance Curve
17
Maintenance & Troubleshooting
Inspection & Maintenance
18
Troubleshooting
19
Installation Instructions (abbreviated) - French
21
Installation Instructions (abbreviated) - Spanish
24
Installation Instructions (abbreviated) - German
27
For Your Records
30
Limited Warranty
31
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Installation & Operation
Introduction
Congratulations and thank you for purchasing your Rutland 914i Windcharger.
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 914i we
recommend that you read this manual and familiarise yourself with its contents
before installing and operating the Windcharger system.
Summary of Features and Uses
Aerodynamically improved to maintain good wind flow and stability.
Maximum power point tracking technology yields up to 30% more power than
the Rutland 913.
Low wind speed start up maximises power generation in low winds.
High grade construction materials for durability, U.V. stability and weather
resistance.
Provides a D.C. power supply to charge 12 or 24 V battery banks.
Designed for use on board sailing yachts, motor caravans, static caravans
and sites where low power is needed for domestic devices as well as
navigation equipment etc.
Note: There are other Rutland Windchargers designed for permanent
installations on land - contact Marlec or visit www.marlec.co.uk to find out
more.
Rutland 914i Profile & Dimensions
Fig 1
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General Guidelines & Warnings
Mounting pole outside diameter MUST NOT exceed 48.5mm for at least the
top 0.5m. Larger section poles must not be used as this will reduce the tower
to blade clearance. In high wind conditions this could cause damage to the
Windcharger by allowing the blade to come into contact with the mounting
pole. A broken blade will cause turbine imbalance with consequent damage.
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. Connecting an open circuit
running turbine to the electrical system can cause serious damage to system
components owing to excessive voltage. 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 wind
speed 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. We recommend the use of
Marlec charge regulator that includes a shutdown switch.
Choose a calm day to install the equipment and consider other safety aspects.
No attempt to repair the system should be made until the wind generators
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.
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The fuse supplied must be fitted to protect the system.
The Rutland 914i Windcharger is suitable for sailing boats and some land
based applications. When storm winds are forecast the turbine can be restrained to minimise wear and tear particularly when installed on land based
applications where Furlmatic model windchargers are normally recommended.
Note that where the manufacturer recommends a furling type windcharger
should have been used the warranty is invalidated in cases of storm damage.
If in doubt, refer to your dealer, a competent electrical engineer or the
manufacturer.
Check You Have Received - See Rutland 914i Exploded View
24 x No.10x25mm special self-tapping screws for aerofoil blades
1 x No.4 x 13mm self tapping screw for tail bracket covers
2 x M6 x 16mm hex. Head screws for tail fin
2 x M6 nylock nuts for tail fin
1 x fuse and fuse holder
1 x main generator assembly
6 x aerofoil blades
1 x tail fin
2 x tail bracket covers
1 x nose cone + 3 x nylon fixing screws
1 x 6mm Allen key
1 x 2-way terminal block
2 x M10 buttoncap screws
2 x shakeproof washers
In the event of loss or damage, consult your dealer or the manufacturer.
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Other Items
Other Items You Will Need
Mounting pole
Cable
Batteries
Battery terminals
Connector blocks (as determined
by your total system)
What You Will Need - Tools
Suitable wire stripper
Small terminal screwdriver
Large flat blade screwdriver
Crosshead screwdriver
10mm Spanner or Socket
Other Items You May Have Selected
HRSi or HRDi Charge Regulator
Cable (usually 2.5mm² twin core - Part No: 902-015)
Rutland 914i Marine Mounting Kit and Stays Kit ( CA-12/02 & CA-12/32 )
Rutland 914i Land Tower & Rigging Kit (Part Nos: CA-12/08 & CA-12/07)
Short section of stainless steel tube to adapt into your own mounting design.
Voltmeter & Ammeter
Exploded View of The Rutland 914i
Nacelle Dome
Six Blades with
Twenty Four
Tail fin
Nose Cone
With Three
Screws
Post Adaptor
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Assembly and Installation
Twelve Step Quick Start Guide
1. Choose an open site to expose the Windcharger to a clear flow of wind and avoiding
obstructions. On board mount the Windcharger at least 2.4 metres above the deck and
on land at least 4 - 6 m high. Read the full section on Siting.
2. Choose a mounting pole with an internal diameter of 41.0mm and external
diameter of no greater than 48.5 mm for the top 0.6m minimum to (i) prevent
accidental damage and (ii) meet warranty conditions.
3. Mount a charge regulator, from the Marlec range, to a suitable vertical surface
and close to the battery. Follow instructions supplied with the charge regulator.
4. Drill the mounting pole, if required, in preparation to accept and secure the
Windcharger. See Assembly and Installation section.
5. Choose suitable two core cable to connect from the Windcharger to the regulator. Up
to 20m this should be of at least 2.5mm² cross sectional area. A short section of 4mm²
cross sectional area is required to link the regulator to the battery. For other distances
see the table in Cable Specifications.
6. Position the mounting pole ( this may be done on the ground before raising the
pole ) so that the selected cable can be threaded along it.
7. Fit the blades, tail and nose to the Windcharger using fasteners provided. It is
essential that 4 screws are fitted per blade.
8. Join the cable threaded through the pole to the Windcharger output cable using
the connector block provided. 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.
9. Carefully push the cables down the pole whilst sliding the post adaptor down
the pole. Line up the holes and secure in place with the screws and washers
provided. Tighten with the Allen key. Do not allow the turbine to spin freely.
10.Locate the charge regulator close to the battery and carefully follow ALL the
regulator guidelines and installation sequences for connecting the Windcharger
through to the battery. Note : Install the in-line fuse supplied with the
Windcharger between the battery and charge regulator.
11.Ensure that the battery connections are permanent as the Windcharger should
NEVER be operated without a connection to the battery.
12.Raise and secure the Windcharger. It can now be allowed to rotate. Follow the
“ Up and Running- Four Points Final Checklist” featured later. Also the
“ General Guidelines and Warnings” section expands on the above points.
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Assembly and Installation Detailed Instructions
Tower Preparation (Fig.2)
Fig.2
1. Select a suitable pole from the suggested
guidelines in Mounting the Windcharger.
Note that the post adapter fitted to the 914i
is designed to fit inside a standard 41mm
(1 ”) internal diameter tube.
The adapter 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 from top of the tube
Note: Use metric measurements for this operation
3. Drill two holes 10.5mm in diameter on centre-punch positions.
Note :Use metric measurements for this operation
Note: When using Rutland 914i Mounting Kit , items 2 and 3 can be ignored as
Marlec supplied poles are pre-drilled.
Blade Assembly (Fig.3)
Fig. 3
1.Place the generator assembly on a flat
surface hub-side down. Position blade as
shown. The blades will only fit one way
around.
2. Insert the protrusion at the trailing edge of
the blade root fixing first into the socket to
align with the corresponding recess in the
blade socket. The blade can then be
inserted with a lever action. A soft faced
mallet may be used to tap the end of the
3. First fit each blade with two special self-tapping screws provided to the rear of
each blade by inserting each in turn through the cut out in the nacelle, rotating
the generator each time until the holes align. Fit the remaining blade screws
from the front of the generator hub. Check tightness of all screws but do not
over-tighten. Caution- It is essential that all 4 screws are fitted!
Alternatively the blades, tail and nose dome can be fitted after mounting the
generator assembly to the tower.
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Fitting The Tail and Nose Assembly (Fig.4)
1. Slide the tail fin between the two tail brackets lining up all drilled holes.
2. Locate the two screws provided through the appropriate holes and secure
with nuts.
3. Locate the tail bracket covers into the nacelle grommet whilst positioning
the processes for the fixing screw into the appropriate drilled hole in the
tail.
4. Secure with the self tapping screw provided.
Tail Bracket Covers
Tail Brackets
Tail Fin
Nacelle
Fig.4
4. Fit the plastic nose dome in position on the front of the generator hub and
secure in place with the three nylon screws provided.
5. You may now mount the Rutland 914i on to the tower if you have not
already done so.
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Electrical Connection and 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 wiring systems on page 12 and follow the manual
provided with the voltage controller.
3. Connect the wind generator flying leads to the cable protruding from the
tower using the connector block supplied, taking care to observe polarity.
Connect the Windcharger + to cable + and windcharger – to cable –
Red is + Positive
Black is - Negative
4. Wrap the connection with insulation tape to secure/protect from environment.
Alternatively join the cables using a latching-type plug and socket.
5. Locate the wind generator into the tower whilst gently easing the cable from
the tower base to ensure the cable is not trapped. Secure the wind generator
to the tower using the button cap screws and shake proof washers provided,
tighten using the 6mm Allen key provided.
Up and Running
Four Point Final Checklist
Before raising and securing the wind generator:
1. Check the tightness of the blade & tail fixing screws and generator mounting
screws.
2. Check free rotation of the hub and yaw axis.
3. Check that the cable is not trapped.
4. Check that 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.
Caution-The performance of your Windcharger will be impaired if the pole is
not vertical.
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Typical Wiring Diagrams For The Rutland 914i Windcharger
Solar Panel
Maximum
160 Watts
HRSi Charge
Regulator
12/24 V
Typical Wiring Scheme For A Single Battery Bank
Typical Wiring Scheme For Single or Dual Battery Banks
HRDi Charge
Regulator
12/24 V
Solar Panel
Maximum
160 Watts
Second battery
optional
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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 shear 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 turbine sufficiently high above them as shown in Fig 4.
Wind speed decreases and turbulence increases where obstructions exist.
Consider also that downwind obstructions can be as detrimental to performance
as upwind obstructions.
It is therefore essential that the wind generator should be located in an area as
free as possible from disturbed wind flow.
2H
H
2H
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Mounting The Windcharger
Fig. 5
On Board Systems
The wind generator should be mounted in a safe
position, a minimum of 2.3 metres (7.6 feet) above
the deck and away from other obstacles which
could interfere with the blades or tail assembly (Fig.
5).
Fig. 6
The Rutland 914i Mounting & Stays Kits (Part No.
CA-12/02 & CA-12/32) are available for deck
mounting, or short sections of stainless steel tube
of 1200mm (47”) and 600mm (23”) pre-drilled are
also available for your own fabrication.
The Rutland 914i is designed to fit inside an
aluminium or stainless steel tube with an internal
diameter of 41mm (1 ”). IMPORTANT: The
external diameter MUST NOT exceed 48.5mm
(1 ), see Warning in Introduction.
Suitable tubes: Stainless Steel 13/4”16 SWG and
Aluminium 17/8” 10 SWG
Fig. 7
We suggest the following mountings according to
preference and site conditions:Push pit (Fig.6)
A suitable pole mounted to the deck with deck
plates and solid guys is the most popular method of
mounting the Windcharger on yachts, eg. Rutland
913 Mounting & Stays Kit.
Fig. 8
Mizzen (Fig.7)
Mizzen mounting is suitable on larger yachts,
taking advantage of greater wind flow the higher
the wind turbine is mounted.
River Boats (Fig.8)
A pivot pole is ideal for riverboats as the
Windcharger can easily be raised and lowered.
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Land Based Systems
Fig. 9
The Rutland 914i is suitable for some land based
temporary and leisure applications. The Furlmatic
Windcharger model is recommended for land
based remote and exposed locations.
The Rutland 914i is designed to fit inside
aluminium, stainless or steel tube with an internal
diameter of 41mm. (1 ”).
IMPORTANT: The
external diameter MUST NOT exceed 48.5mm
(1 ), see Warning in Introduction.
Centre pivoted pole
Fig. 10
Base pivoted with gin pole
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
(0.16”) in diameter.
The shackles should be a minimum of 5mm
(0.20”) in diameter.
Rigging screws should be a minimum of 5mm
(0.20”) 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 9 & 10.
A base-hinged 6.4m tall Land Tower Kit (Part
No: CA-12/08) and Rigging Kit (Part No:CA12/07) are available from Marlec.
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Further System Requirements
Batteries
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.
60Ah
12v
60Ah
12v
In parallel to increase amp
Permanent connections should always be made
to the battery terminals. Never use crocodile
clips or similar devices.
Total = 24v
60Ah
1440Wh
60Ah
12v
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.
60Ah
12v
Batteries may be linked as shown in the figures
10 and 11. It is essential to observe polarity as
follows:
Red is + Positive
Black is - Negative
In series to increase voltage
Cable Specification
Cable Size
12V
24V
mm²
AWG
mm²
AWG
2.5
13
1.5
15
21-30
4
11
2.5
13
31-45
6
9
4
11
46-80
10
7
6
9
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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.
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Installation & Operation
Specification and Performance
Guideline Performance Curve
Note : The curve shown below is for clear, non-turbulent wind conditions; this
may not be achieved in some installations. Refer to the section on Siting to
optimise performance at your site. Wind speeds are those flowing across the
turbine of the Windcharger and may not reflect those measured at mast top or
those reported by the Met. Office.
9
8
7
6
5
4
3
2
1
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Charge into 24 V Battery (Amperes)
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Installation & Operation
Maintenance and Troubleshooting
Inspection and Maintenance
The Rutland 914i requires no scheduled maintenance but an annual inspection
should be carried out to monitor the general condition of the system to ensure
the electrical and mechanical integrity and safety of the system.
WARNING! 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. Either rotate the switch to stall mode on the charge regulator if used OR 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 gradually 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 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 condition.
5. Check the tension of the guy wires if applicable. The tension of guy wires
should be checked frequently during the first year.
6. The unit can be wiped with a mild detergent and rinsed with water to remove
dirt and debris.
Note: The Windcharger is designed for continuous running to achieve
maximum resistance to water ingress. 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
covered.
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Troubleshooting
In the unlikely event that your Rutland 914i 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.
Read the Electrical Connection and Up and Running sections and be satisfied
that your system complies.
Is there sufficient wind? The Rutland 914i 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 masthead anemometer
or weather reports.
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.
Running Tests:
Check for power output from the windcharger, following this procedure:
1. 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.
2. 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.
3. 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
generator + and the meter – to the wind generator -. 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.
4. If tests 1 and 3 are successful but test 2 fails to produce results connect the
wind generator directly to the battery. Set the digital multimeter to DC Amps
and measure power between the wind generator + and the battery +. If a
reading is measured, providing there is sufficient wind, then the regulator is
faulty.
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5. If the wind turbine fails to deliver any current or open circuit V reading
undertake the further tests below.
6. Mechanical inspection. It may be necessary to remove the windcharger from
its pole for the following tests.
Check the brushes and slipring for wear or damage. To inspect the brushes,
remove the nacelle by removing the three fixing screws and slide the nacelle
backwards towards the tail fin. The brushes and slipring can be inspected by
removing the four self-tapping 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 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.
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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1 x Haube
1 x Pfosten Adapter
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For Your Records
For your future reference we recommend you note the following:
Serial Number:
Date of Purchase:
Date of Installation:
Type of Regulator:
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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.
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 user modification to the product or 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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