Marlec 910 Series User manual

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Document No:SM-412 Issue C 28.01.21 Marlec Engineering Co Ltd
Land Tower & Rigging Kit
Installation Instructions
Rutland Windcharger
910 and 1200 Series Turbines

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Document No:SM-412 Issue C 28.01.21 Marlec Engineering Co Ltd
CONTENTS
Page
INTRODUCTION 2
CHECK YOU HAVE RECEIVED 3
WHAT YOU WILL NEED 3
SITING 4
FOUNDATIONS 5
Tower base 6
Guy Anchors 7
TOWER PREPARATION 8
ASSEMBLY 9
ERECTION 10
APPENDIX A – TUBE DRILLING DETAIL 11
APPENDIX B – SECTIONED TUBE KIT 12

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Document No:SM-412 Issue C 28.01.21 Marlec Engineering Co Ltd
INTRODUCTION
This manualcontains important information concerningyour turbine towerand its
installation. It is strongly recommended that you read this manual and familiarise
yourself with its contents before installing and operatingthe Windcharger system.
Thecomplete kitis a base pivoted 6.5mhightwinguyed tower, for easy installation &
erection by2 people. The design complies with IEC1400-2.
The tower and rigging kits are available separately to allow the use of a single length of
tube (supplied bythe user) with the rigging kit. The customers own towershould be
40mmnominal medium (3.2mm wall) galvanisedtube. Inside diameter 41.7mm,
outside diameter 48.1mm. Single length 6.5m.
WARNING!
•Itis recommended thaterection of the tower isonly attempted in light winds.
•Standard Health and Safety working practices and appropriate personalprotective
equipmentshould be adopted duringthe followingprocedures.
•When using the Rutland 914i or Rutland 1200 Windchargers, mounting pole outside
diameter MUST NOT exceed 48.5mm. 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 theWindcharger by allowing the blade to come into contact with the
mounting pole.
WHAT YOU WILL NEED
•Tape Measure, Spade, Concrete forfoundations, 13mm AF Spanner, 17mmAF
Spanner, 8mm AF Spanner, SpiritLevel
Other Items you will need if not using Sectioned Tower Kit
•6.5m length of 40mm Medium(3.2 wall) galvanised tube.
•Electric Drill
•10.5mm Drill
•8.5mm Drill

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Document No:SM-412 Issue C 28.01.21 Marlec Engineering Co Ltd
CHECK YOU HAVE RECEIVED
Rigging kit CA-12/07
2 x Tower Base brackets
2 x Base Foundation ‘U’ bolts, washers & nuts
4 xGuy Ground Anchors (Lshaped,notas shown above)
2 x Guy Tower Brackets
2 x M8 x 65 Hex Head Bolts, Flat washers & Lock Nuts
1 x M10 x 70 Hex Head Bolts, Flat washers & Lock Nuts
4 x 6.5m Wire Rope Guys with Shackles fitted to a looped end
4 x 4.5m Wire Rope Guys with Shackles fitted to a looped end
8 x Rigging Screws
24 x Wire Rope Grips
Sectioned Tower kit CA-12/08 (optional)

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Document No:SM-412 Issue C 28.01.21 Marlec Engineering Co Ltd
SITING
General Considerations
The location and height of the mounting pole or tower for your wind turbine will be the major factor
in the overall performance of your system.
The smooth flow of wind over land and water is often interrupted by a multitude of obstructions
causing wind sheer and turbulence.
Wind sheer describes the interference between the fast moving upper air and the slow moving air
close to the ground and the resulting decrease in average wind speed as one gets closer to the
ground.
Turbulence is caused by the wind passing over obstructions such as moored boats, trees and
buildings. Both wind sheer and turbulence diminish with height and can be overcome simply by
putting the machine sufficiently high above them.
It is therefore essential that the wind generator should be located in an area as free as possible from
disturbed wind flow. Bear in mind that downwind obstructions can be detrimental to performance as
upwind obstructions (Fig.1).

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Document No:SM-412 Issue C 28.01.21 Marlec Engineering Co Ltd
FOUNDATIONS
Note: The foundation dimensions given below are minimum based on normal compacted cohesive
soil, for other soil types the foundations should be designed accordingly. If in doubt consult a civil
engineer.
Mark out & dig holes for the tower base and four guy anchor points as shown in the diagram below:
For added security, slope the sides of the holes outwards as shown in Fig 3
3.5m
Tower Base.
300mm x
300mm x
400mm deep.
Guy Anchors.
500mm x
500mm x
500mm deep.
Fig 2
Fig 3

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Document No:SM-412 Issue C 28.01.21 Marlec Engineering Co Ltd
Tower base
Suspend the ‘U’ bolts centrally in the hole in the correct position and orientation. This can be
achieved using a suitable piece of wood which will span the hole, drill four holes Ø12 using the tower
base as a guide, insert the 2 base foundation ‘U’ bolts through the holes and fit the 4 nuts ensuring
that approx 30mm of thread protrudes above the concrete
Fig 3a. Foundation bolt spacing is 131 x 113mm.
Check for correct spacing of the foundation bolts by positioning tower base brackets on the
protruding threads and laying tower tube between the brackets prior to mixing concrete.
Fig 4
Fig 3a

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Document No:SM-412 Issue C 28.01.21 Marlec Engineering Co Ltd
Guy Anchors
Select a suitable piece of wood which will span the hole, drill 1 hole Ø10.5 mm through and secure
the ground anchor to the wood at an angle of 45° using a suitable bolt as shown in fig 5, suspend in
the hole as shown ensuring they are in the correct position & orientation.
Mix approx 0.5m³ of concrete and fill the five holes ensuring the concrete is well packed down and air
removed. Ensure all inserts are correctly positioned & allow to harden for 2 days.
Note: The holes can be filled with concrete first and the foundation bolts and ground anchors pushed
in immediately afterwards if this is found to be easier.
Fig 5

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Document No:SM-412 Issue C 28.01.21 Marlec Engineering Co Ltd
TOWER PREPARATION
Using single 6.5m length of tube (not supplied) (Appendix A)
•Drill tube as shown on drawing in Appendix A.
•Insert 1 M8 x 65 bolt through the 8.5 hole at the lower guying position, fit and tighten an M8 lock
nut, orientate the nut and bolt so that the flats face the ends of the tube.
•Slide one of the guy plates over the top of the tube with the angled corners pointing down, until it
stops against the M8 nut and bolt.
•Repeat the procedure for the upper guying point.
Using sectioned tower kit CA-12/08 (Appendix B)
See Appendix B for correct orientation of the tube sections.
•Insert M8 x 65 bolts through the 8.5 holes in the top and middle sections of tube, orientate the
nut and bolt so that the flats face the ends of the tube.
•Slide guy plates over the top of the top and middle sections of tube with the angled corners
pointing down, until they stop against the M8 nuts & bolts.
•Join the 3 sections of tube using the joiners provided.
Fig 6

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Document No:SM-412 Issue C 28.01.21 Marlec Engineering Co Ltd
ASSEMBLY
Place the Tower Base over the four threads protruding from the concrete foundation, ensuring the
pivot is orientated correctly. Fit the nuts and washers, and securely tighten.
Lay the tower tube in position on the ground with its bottom end in the tower base and insert the
M10 x 70 bolt, secure with the washer and nut ensuring the tube is free to pivot.
Attach the guys to the guy plates with the shackles through the looped ends of the guys, the 6.5m
guys are fittedtowards the top of the tube, the 4.5mguys towards the bottom.
Fit the remaining 4 shackles to the guy ground anchors. Place the hooked ends of 2 of the rigging
screws through the shackles on the side anchor points. Open the rigging screws to approx ¾ their
maximum length.
Take the 2 upper side guys and pass the free ends through the looped ends of the rigging screws and
around the thimbles pulling the cables to remove the slack, secure in position using 3 rope grips on
each guy. Repeat the procedure with the fore and aft guys by laying them alongside the side guys to
achieve the same length.
Note: Ifthe groundis uneven or not level, the guy lengthsmay differ.
The first rope grip must be placed immediately against the thimble. The grips must be placed so that
they are separated by a minimum distance of 30mm. The ‘U’ bolt must always be placed on the tail
end of the rope i.e. non load bearing end.
Hook the rigging screw into the shackle on the anchor point for the rear guy, i.e. the anchor point
coveredby the tower.
Fig 7

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Document No:SM-412 Issue C 28.01.21 Marlec Engineering Co Ltd
ERECTION
Erection should only be attempted in light winds.
The tower should first be erected without the wind generator fitted. Raise the tower to it’s working
position by pivoting about it’s base fixing. Ensure the rear rigging screw does not become detached
from it’s anchor point. Attach the free guy to it’s anchor point to secure the tower in it’s vertical
position.
With the aid of a spirit level, adjust the rigging screws until the tower is vertical and the guys are
suitably tensioned. Attach the 4 lower guys to their rigging screws by looping the free end through
the eye of the rigging screw and thimble and secure using 3 rope grips. Tension as for the upper
guys. Ensure the tube is straight and vertical.
The tower can now be lowered by reversing the procedure for raising. It may be necessary to slightly
slacken the side guys during this procedure.
The wind generator cable can now be installed down the centre of the tower and the wind generator
fitted to the tower top. The tower can be raised in the same previous manner; the guys tensioned
ensuring the tower is straight and vertical.
After tensioning of the guys, the rope grip nuts should be checked for tightness, this should be
repeated after 24 hours. Further periodic checking and tightening of the nuts is essential during
service, more frequently during early stages of operation to ensure long term reliability of the
structure.

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Document No:SM-412 Issue C 28.01.21 Marlec Engineering Co Ltd
THROUGH HOLE 10.5
THROUGH HOLES 8.5
THROUGH HOLE 10.5
20
1000
20
2700
6500
TOP BOTTOM
UPPER GUYING POINT
LOWER GUYING POINT
Appendix A
Tube Drilling Detail

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Document No:SM-412 Issue C 28.01.21 Marlec Engineering Co Ltd
10.5 HOLE
8.5 HOLE
8.5 HOLE
10.5 HOLE
TOP SECTION
MIDDLE SECTION
BOTTOM SECTION
UPPEREND
LOWEREND
Appendix B
Sectioned tube kit