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Marlec Rutland 1200 Owner's manual

Rutland 1200 Wind Turbine
& Hybrid MPPT Controller
Installation and Operation
Part 1—Turbine Installation
12V and 24V Models
6mm Allen
Key 3 x Aerofoil
Blades
Post Adaptor &
Yaw Axis
Fix with 2 x M10 Set
Screws & Shake-Proof
Washers
2 x Pole Fairing. Fix with
4 x No3.5x10 Screws
3 Core 2.5mm Tinned
Output Cable and 3
Way Connector Block
Rotor Hub
Plate &
9 x M6 Hex
Head Blade
Nose Cone.
Fix with
3 x No3x10
Plastech Screws
9 x M6 Nylock-
Blade Nuts &
1 x M16 Nylock
Nut
Nacelle & Tail Fin
Generator
Hub
Wind Shaft
Check you have received:
1 x Rutland 1200 Wind turbinewith fixings
1 x Hybrid MPPT Charge Controller with External Temperature Sensor
In the event ofloss or damage consult yourdealer or themanufacturer.
Tools Required
10mm & 17mm Spanner
PZ1 & PZ2 Crosshead
Screwdrivers
Terminal Screwdriver
Wire Strippers
Multi-meter (useful)
Other items you may
require
Tower / MountingPole
Connection Cables &
Connector Blocks
Deep Cycle Batteries &
Terminals
ControllerFixing Screws
Solar PV Panels & Diodes
Introduction
Congratulations and thank you for purchasing your Rutland 1200 Wind Turbine and Hybrid MPPT Charge
Controller. Our range of Rutland Wind Turbines are renowned as reliable, quiet and efficient in service and have
been used worldwide by sailors and many off-grid power specialists since 1979.
The utmost of care goes into the manufacture of all our products in our ISO9001 approved factory. Toensure you
get the very bestout of the Rutland1200we recommend that you read this manual and familiarise yourself with
its contents before installing and operating the wind turbine and charging system.
How to Use This Manual
There are 2 parts to this manual, we recommend installing the controller and wiring followed by the turbine
before final commissioning. Visit www.marlec.co.uk/support to seeuseful video installation andoperating guides.
General Guidelines and Warnings
Safety is the primary concern during both installation and operation of your wind turbine. You should familiarise
yourself with the risks associated with electrical and mechanical installation and if in doubt seek professional
advice. The keysafety risk factors tobe assessed are:
The rotating turbine
•Install the turbine ata locationand height where persons cannot interfere withthepath of the blades. No
attempt toaccess the turbineshouldbe made until it has beenrestrained from turning, if possible lower the
tower to ground level.
•Use the electronicstall switches to stop powerproduction of both the turbine and solar panel. The turbine
speed will eventually reduce toan idle for saferaccess.
•Caution: The aerofoilblades are very sharp, gloves are recommended for handling and every precautionmust
be made to avoid them inrotation as there is risk of harm to persons if struck.
Handling DC voltages and batteries
• Never allow the wind turbine or asolar paneltogenerate electricity without connection to a battery. Cover
solar panelsand lower or stop the turbine, short circuit them to prevent operation.
• Do not make live connections to controllers or batteries as high open circuit voltages will permanently damage
electronics.
• Observe correctpolarity to avoid permanent damage to equipment.
• Do not openelectronic equipment during liveoperation.
• Always usecablesuitable for carrying the expected currents and ensure goodquality electrical connections to
avoid arcing andfire risks.
• Damagesas a consequence of failure to followthese guidelines will invalidate the warranty.
Working at height—use suitable equipment. Effectas much of theinstallation at ground level as possible and
choose a calm day to install the turbine.
If in doubt refer toyour dealer, a competent electrical engineeror the manufacturer.
Inspection and Maintenance
The Rutland Wind Turbine requires no scheduled maintenance. An annual inspection should be undertaken to
monitor the general condition of the system to ensure the electrical and mechanical integrity and safety of the
system. For advice and troubleshooting visit www.marlec.co.uk or watch our videos at YouTube/MarlecTV
For Your Records—you will need this if you contact us
Read in conjunction with Part 2 Rutland 1200 ControllerInstallation manual. Find more information at www.marlec.co.uk
Doc No: SM-469 Iss D Part1 20.03.17
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 so found by Marlec upon inspection. A
validproof ofpurchaseis requiredif makinga warranty claim.
Defective parts must be returned by prepaid post to the manufacturer
Marlec Engineering Co Ltd, Rutland House, Trevithick Rd, Corby,
Northamptonshire, NN17 5XY, England orto an authorised Marlec agent.
This Warranty is invalid in the event of improper installation, owner
neglect, mis-use, damage caused by flying debris or natural disasters
including lightning strike and hurricane force winds. This Warranty does
not extend tosupport 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 or loss. No responsibility is assumed
for damage caused by user modification to the product or the use of
unauthorised components.
Manufactured in the UK by
Marlec Eng CoLtd
Rutland House, Trevithick Rd, Corby, NN17 5XY
www.marlec.co.uk sales@marlec.co.uk
Serial Number of Rutland 1200 Turbine
Serial Number of Rutland 1200 Controller
Date of Purchase and Sellers Name
Date of Installation
On Board Systems
Land Based Systems
The smooth flow of wind over land and water is often interrupted by a multitude of obstructions causing wind sheer and turbulence. The location and height
of the mounting pole or tower for the wind turbine will be the major factor in the overallperformance and lifetime of the system.Wind speeds decrease and
turbulence increases where obstructions exist so the siting of the turbine is very important to ensure good yields and turbine lifetime. On yachts, the open
water will deliver better yields than in typically sheltered marinas.
The Wind Turbine should be mounted in a safe
position, a minimumof 2.7 metres above the deck
and away from other obstacles which could
interfere with the blades or tail assembly.
The pole should be supported to maintain it in the
upright position against lateral movement in high
winds.
The Rutland Marine Mounting Kit & Stays Kits are
available for deck mounting. We suggest the
following mountings according to preference:
Tower Selection
River Boats
A pivot pole is ideal for riverboats as this enables
the turbine to be easily raised and lowered. Rigid
stays are required to support the upright pole.
Push Pit
A suitable pole mounted to the deck with deck
plates and stays is the most popular method of
mounting the wind turbine on yachts, eg. Rutland
Marine Mounting & Stays Kit
For good performance mount the Rutland 1200 at
a minimum of 6m above ground level following the
siting guidelines.
Pivot type towers are suggested for ease of raise
and lowering. Performance is impaired if the
tower is not maintained vertical in operation.
Lattice or other types of freestanding columns can
be selected. Ensure that all loadings are calculated.
Freestanding Tower
A tower can be erectedusing a 6.5metre (21 feet)
galvanised (medium) tube and must be supported
by a minimum of two sets of four guy lines. The
Marlec Land Tower & Tower Rigging Kit are
available at www.marlec.co.uk
Rotor Blade Assembly
1.Place a M6Nylock nutinto the nut recess in the
aerofoil blade.
2.Align with a hole inthe Rotor HubPlate and
partly tighten a M6screw infrom the back of the
plate. Repeat with 3fasteners on all 3blades.
Caution - All 9 screws must be fitted!
Fit the Main Shaft Nut
1.Fit the M16 Nylock nut (supplied pre-greased)
into the recess created by the 3 blades.
2.Finish tightening the M6 blade screws using a
10mm spanner from the back of the Rotor Hub
Plate. Hold the blades near theroot to avoid
damaging the aerofoils. Check tightness of all
screws but do not over-tighten.
Assemble and Install the Turbine
Fitting the Rutland 1200to the Tower
Select an aluminium or stainless steel tube.
Internal diameter 41mm (1⅝”). For blade
clearance the pole must not exceed 48.5mm(2’’)
outside diameter for the top 0.6m.
Drill 2 holes diametrically opposite as shown.
Connect the Cables - See table in Manual Part 2
1.Thread the 3 core turbine cable through the pole
allowing at least 1m of extra cable for lifting the
turbine on and off.
2.Strip back 10mm of the wind turbine and tower
cables. Join them using the 3-way connector block.
Wrap the connection with insulation tape to
secure and protect from the environment.
Alternativelyjoin the cables using a latching plug
andsocket. Loop back the cable and secure witha
cable tie to provide strainrelief to the joint.
3.Coat the post adaptor with petroleum jelly to
protect it.
4.Carefully push the cables down the pole as you
slide the post adaptor into position, lining up the
screw holes.
5. Secure in place with the M10screws and shake-
proof washers using a 17mm spanner. Tighten up
to the shake-proof washer finishing with the head
in either of the positions shown ready for fitting
the pole fairing.
20mm
Fit the Turbine to the Generator
1. Offer up the rotor blade assembly to the
generator and place thegreased M16 Nylock nut at
the centre over the windshaft.`
Hold the blades near the root to avoid damaging
the aerofoils. CAUTION: The blades are sharp.
2. Carefully start to screw the rotor blade assembly
onto the windshaft by turning it clockwise. When
engaged place the 6mm Allen key provided at the
centre of the shaft and hold this firmly as you
continue to screw the rotor to full tightness.
IMPORTANT: Ensure the turbine hub plate is
squarely located on the shaft’s shoulder.
At this time you should restrain the turbine from
turning or keep the mounting pole lowered. If the
cable is already connected to the controller the
turbine will be prevented from turning.
Fit the Nose Cone
1.Locate the nose cone over the rib on the rotor
blade assembly and align the 3 screw holes.
2 . Secure nose cone using the 3 No3x10 Plastech
screws and a PZ1 screwdriver.
Fit the Pole Fairing
Note: For thick wall poles the tab on the inside of
the fairings should be trimmed back to the step as
indicated.
1. Push the Pole Fairing over the M10 Hexhead.
This also acts as a locking device.
2. Screw together the pole fairing using the 4
No3.5x10 Plastech screws and a PZ2 screwdriver.
Before raising the tower or allowing the turbine to
rotate follow the Commissioning section inthe
Manual Part 2
Commissioning
Turbine Dimensions
Turbine Orientation
The Rutland 1200 is designed
for use in the orientation
shown in this manual it
should not be installed and
operated upside down.
48.5mm
41mm
11mm
Siting the Turbine
Base Pivot Tower

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