Marlec Rutland FM1803-2 Furlmatic Operating instructions

Document No: SM-146 IssueG 01.11.20
Rutland FM1803-2 Furlmatic
Windcharger
Turbine & MPC2 Controller
Installation & Owner’s Manual

Rutland FM1803-2 Installation& Operation
Document No: SM-146 IssueG 01.11.20 MarlecEngineeringCoLtd
1
GENERAL SCHEMATIC
Note: The schematic also shows an optional solar panel charging system connected in parallel to
the same batterybank.

Rutland FM1803-2 Installation& Operation
Document No: SM-146 IssueG 01.11.20 MarlecEngineeringCoLtd
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CONTENTS Page
GENERAL SCHEMATIC 1
INTRODUCTION AND GENERAL GUIDELINES & WARNINGS 3
CHECK YOU HAVE RECEIVED 4
WHAT YOU WILL NEED – Tools, Other Items 4
SITING THE WINDCHARGER 5
SYSTEM DESCRIPTION AND PRINCIPLE OF OPERATION 6
AerofoilBlades & Rotor 6
Generator 6
Yaw System 6
Tail Assembly 6
Control Unit – Connection features list 7
MOUNTING TOWER 9
ASSEMBLY AND INSTALLATION OF THE TURBINE 10
Blade &Hub Assembly 10
Tail Assembly 12
Tower Preparation 13
Control Unit Installation 14
BATTERIES 15
CABLE SPECIFICATION 16
FUSES 16
ELECTRICAL CONNECTION 17
CONTROL UNITWIRING 18
FITTING THEGENERATOR TOTHE TOWER 20
FinalMechanicalcheck 20
UP AND RUNNING 21
LCD Display Features Explained 21
OPERATION EXPLAINED 22
Backlight 22
Low/High Wind Modes 22
ManualShutdown 22
Batteries Fully Charged 22
Awaiting Re-set V 23
Other Modes/Messages 23
Run/Stop Switch – supplied separately 23
SPECIFICATIONAND PERFORMANCE 24
INSPECTION AND MAINTENANCE 25
TROUBLESHOOTING 26
FM1803-2 MAINTENANCE SCHEDULE 1-12 MONTHS 27
FM1803-2 ONGOING MAINTENANCESCHEDULE TEMPLATE 28

Rutland FM1803-2 Installation& Operation
Document No: SM-146 IssueG 01.11.20 MarlecEngineeringCoLtd
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INTRODUCTION
Congratulations and thank you for purchasing your Rutland 1803-2 Wind Turbine with MPC2
Charge Controller. Our range of Rutland Wind Turbines are renowned for reliable, quiet and
efficient service and have been used worldwide by sailors and off-grid power specialists since
1978. The utmost of care goes into the manufacture of all our products in our ISO9001
approved UK factory.
It is essential that the turbine and controller are installed in accordance with these instructions
and failure to comply invalidates the warranty. To ensure you get the very best out of the
Rutland 1803-2 please read and understand this manual before commencing installation and
operating the wind turbine and charging system.
The FM1803-2 Furlmatic turbine is designed to provide a direct current (DC) power supply via a
battery bank for low voltage equipment, inverters etc in professional and off grid applications.
It is essential to the turbine’s operation that it is installed on a stable vertical pole on land to
ensure that the furling mechanism efficacy is maintained in service.
Note: The selected turbine must matchthe battery voltage of the system.
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 keysafetyrisk factors to be assessed are:
The rotating turbine – Risk of injury to persons
•Install the turbine at a location and height where persons cannot interferewith the path of
the blades. No attempt to access theturbine should be made until it hasbeen restrained
from turning, if possiblelower the tower to ground level.
•Never allow the turbine to run disconnected from the controller and batteries. Usethe
RUN/STOP switch if fitted or built in stall switch to stop power production of the turbine. The
turbine speed will eventually reduce to an idle for safer access to theturbine or batteries.
•Do not allow the turbine to run with damaged blades, replacement partsare available at
www.marlec.co.uk
Handling DC voltages and batteries – Risk of electric shock
•Never make live connections to the controller. Eg: High open circuit voltagesgenerated by a
rotating turbine will permanently damage electronics. Lower orstop the turbine to prevent
operation. Similarly, batterycables must be wiredinto the controller without being
connected to the battery.
•Observe correct polarity to avoid permanent damage to equipment.
•Do not open electronic equipment duringlive operation.
•Alwaysuse cable suitable forcarrying the expected currents and ensure good quality
electrical connectionsto avoid arcing and fire risks. The use of smaller cables will cause
system overload and damage the generator. See Table 1.
•Damages asa consequence of failure to follow these guidelines will invalidatethe warranty.

Rutland FM1803-2 Installation& Operation
Document No: SM-146 IssueG 01.11.20 MarlecEngineeringCoLtd
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General warnings
•The generator is fitted with rare earth magnets which can be damaged by heavyhandling.
The main generator assembly should betreated with care during transit and assembly.
•Do not adjust the settings on the controller without reference to the manufacturer.
Working at height—use suitable equipment. Effect asmuch of the installation at ground level
as possible and choose a calm day toinstall the turbine.
If in doubt refer to your dealer, a competent electrical engineer or the manufacturer.
CHECK YOU HAVE RECEIVED
Three (3) Aerofoil Blades and 9 nuts and bolts
Main GeneratorAssembly
Tail Fin assembly and Fixings
Nose Cone and fixing screws
Control Unit – Check that thevoltage indicated onthe connection label and theside of the
housing corresponds with your batteryvoltage.
Temperature Sensor – packed with control unit
3 Way Connector Block
In the event of loss or damage, consult your dealer or the manufacturer.
WHAT YOU WILL NEED
Tools
Suitable wire stripper
Small terminal screwdriver
Phillips (cross-head) screwdriver
2 x 13mm spanners or sockets
36mm spanner or socket
17mm spanner or socket
8mm Socket key
Other Items You Will Need
Run/Stop Switch supplied separately from Marlec (optional)
Mounting tower & winch or other suitable lifting/pulling equipment
Cables
Batteries & terminals
Connector blocks (as determined by your total system)
Suitable fixings for wall mounting the control unit.
Sensor cables (optional)
Please complete the system details and serial numbers in the maintenance schedule (Appendix
A). This information is important & should be kept safe & available if contacting the
manufacturer for advice or technical information.

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Document No: SM-146 IssueG 01.11.20 MarlecEngineeringCoLtd
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SITING THE WINDCHARGER
The location and height of the tower for the wind turbine will be a major factor in the overall
performance, energy yield and lifetime of the system. The smooth flow of wind over land is
often interrupted by a multitude of obstructions causing wind sheer and turbulence.
Wind sheer describes the interference between the fast-moving upper air and the slow-moving
air close to the ground and the resulting decrease in average wind speed as one gets closer to
the ground. Turbulence is caused by the wind passing over obstructions such as trees and
buildings.
Both wind sheer and turbulence diminish with height and can be overcome simply by locating
the turbine high above them in an area as free as possible from disturbed wind flow. Bear in
mind that downwind obstructions can be as detrimental to performance as upwind
obstructions (Fig.1).
Fig.1

Rutland FM1803-2 Installation& Operation
Document No: SM-146 IssueG 01.11.20 MarlecEngineeringCoLtd
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SYSTEM DESCRIPTION AND PRINCIPLE OF OPERATION
Aerofoil Blades & Rotor
The 1803rotorconsists of 3aerofoil blades rigidlyfixed toa hub. The blades are at an optimum
fixed pitch for variable speed operation over a wide wind speed range. A nose cone attaches to
the rotor plate and directs the flow of wind.
Generator
The rotor is rigidly attached to the
generator shaft providing direct drive
to the 3-phase brushless permanent
magnet ac generator, producing
variable frequency ac at approx. 120v
L-L under normal conditions. Note: the
generator must not be allowed to run
open circuit since high voltages can be
generated.
Yaw System
The complete wind generator assembly
is mounted on yaw bearings allowing
free rotation on its vertical axis to
enable it to respond to changes in wind
direction. The yaw assembly also
includes a slipring & brush system to
transmit the generated current to the
fixed transmission cable while allowing
free 360° yaw rotation. The post
adaptor is designed to be fixed to the mounting pole and the cable exits to the inside of the
mounting pole.
Tail Assembly
The inclined tail fin is hinged to the rigid tail boom on durable sleeve bearings. It must be
installed and maintained at the 15° inclination for effective furling.
The tail is designed to direct the turbine into the main direction of wind at wind speeds up to
approx. 35mph. Above this the automatic ‘furling’ mechanism will turn the turbine at an angle
to the wind to protect the generator, turbine & supporting structure from severe winds. During
furling the output power will be reduced. When the high wind subsides, the tail assembly will
automatically return the turbine to normal operation. In turbulent conditions the system may
be seen to repeat this cycle many times.

Rutland FM1803-2 Installation & Operation
Document No: SM-146 IssueG 01.11.20 MarlecEngineeringCoLtd
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Control Unit
The 1803MPC2control unit controls the operationof the FM1803-2 wind generator & protects
the battery bank from overcharge. Key features of the controller are:
•The 3-phase transformer and full wave
bridge rectifier convert the raw generated 3
phase ac to dc at a level corresponding to
the battery voltage.
•The microcontroller based electronic control
unit monitors the battery voltage, charge
current & temperature.
•Low and High wind modes to optimise
performance depending on windspeed - at
pre-set levels the controller will switch the
generator between these modes.
•When the battery voltage reaches a level
indicating fully charged, the controller
switches the generator to ‘stalled’ mode
causing the generator RPM to reduce to a slow idle, preventing further power being
generated into the battery bank. When the battery voltage falls to a lower pre-set limit,
the control unit will automatically switchback to ‘charge’ mode. Note:Unless otherwise
specified at the time of order, the limits will be set for lead acid batteries (upper limit
2.4v/cell & lower limit 2.08v/cell @ 25°C). If other types of battery are to be used or
other settings are required, contact Marlec for advice on factory setting or the interface
cable and PC app.
•Remote NTC Temperature Sensor – Temperature compensation ensures that the
battery voltage switching points are automatically adjusted for ambient temperature to
maintain optimum battery performance. A sensor is supplied and can be connected at
the control unit with the tip positioned at the batteries. Temperature compensation is
applied only when the sensor is connected.
•A push button switches between Run and Stall when held for >3 seconds. When in any
stalled mode the turbine runs at a slow idle preventing power from being produced.
When MANUAL SHUTDOWN is selected the LCD built-in backlight will be permanently
on to alert the user.
•A digital LCD display shows battery voltage, charge current, generatedpower, operating
mode & warnings. The built-in backlight remains on for 1 minute when the button is
pressed once.
•If a battery is not connected, the control unit will default to stall mode and will not be
operational.

Rutland FM1803-2 Installation & Operation
Document No: SM-146 IssueG 01.11.20 MarlecEngineeringCoLtd
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Pin 1
Pin6
•Remote Voltage Sensing feature – enables the user to connect fine wires to the battery
terminals over the distance to a battery located more than 2m cable distance away. See
Table 1. This senses actual battery voltage and the controller charges and regulates
based on this reading overcoming any voltage drop that may occur in the battery cables.
Note:Do not undersize longer battery cables’ current carrying capacity.
•Remote Shutdown Connection feature – volt free contacts e.g. switch or relay contacts
connected across these terminals, provide a method of remotely shutting down the
turbine. Closed contacts to shut down the turbine, open contacts to run the turbine.
The LCD displays “REMOTE SHUTDOWN” when activated.
•The control unit has a built-in cooling fan which will only operate when the internal
temperature of the control unit exceeds a pre-set level. This will only normally operate
during periods of high generated power levels.
•A RJ11 Serial Data output is provided for connection of other devices e.g. Computer
which can read serial data. This requires a special interface cable and PC app. Some
operating parameters can be changed using bespoke PC app, contact the manufacturer.
The pins are configured as follows:
Please Note: The output signal level is 5V, to interface with RS232 levels, eg for a PC, a
line driver may be required.
•Baud Rate 115200
•8 data Bits
•No parity
•1 stop bit
Battery Voltage: Text string "Batv" immediately followed by Integer value of voltage x
100 (*)
WG Current : Text String "Amps" immediately followed by integer value of current x
100 (*)
Mode : Text String “Mode" immediately followed by integer value.
0= Run
1 = Manual Shutdown
2 = Over Voltage
3 = Rectifier Over Temperature
4 = Transformer Over Temperature
5 = Remote Shutdown
* ie 12.42 volts is output as 1242
Pin Function
1Do not use
2TX
3GND
4 RX
5+5v 100mA Output
6Do Not Use

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Document No: SM-146 IssueG 01.11.20 MarlecEngineeringCoLtd
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MOUNTING TOWER
The Rutland 1803-2 is designed to fit inside a round tube with an internal diameter of 81mm.
A suitable mounting pole can be erected using 80mm (3“) galvanised (medium) tube to BS1387
a minimum height of 6.5m, 10m or greater is recommended. The tube must be supported by a
minimum of 2 sets of four guy lines.
The attachment points for the guy lines to the tower should be securely fixed to the tower.
•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 ground conditions.
Pivot type towers are recommended as these allow for easier installation and lowering for
access to the wind generator for maintenance. A form of pivoting tower is suggested in Fig 2.
Non-guyed lattice and pole type pivoting towers are available, for further details contact the
dealer or manufacturer.
Fig 2. Typical Tower

Rutland FM1803-2 Installation & Operation
Document No: SM-146 IssueG 01.11.20 MarlecEngineeringCoLtd
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ASSEMBLY AND INSTALLATION OF THE TURBINE
Blade & Hub Assembly
Fig 3. BladeHub Assembly
Correct position of front
hub plate tolocate nose
cone fixi
n
g holes
Nose cone fixing
boss – 3 fixings
FlatSide of Blade
faces the wind
Front Hub Plate
Rear
HubPla
te
Windshaft – note socket at
end to place 8mm Allenkey
toholdduring as
se
mbly

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Blade & Hub Assembly continued
1. Preparethe rotor assembly - assemble the 3 turbine blades between the hub front and
rear plates, inserting the bolts through the rear plate, ensuring the flat side of the blade
faces the front plate. Fit all 9 bolts, washers & Ny lock nuts provided & secure tightly.
Ensure the 3 cut outs around the edge of the front plate align with the nose cone fixing
bosses.
2. Fit the rotor assembly onto the windshaft.
3. Put the spring washer over the end of the windshaft, it will pass through the hexagonal
hole in the front plate.
4. Thread the M24 nut onto the threaded end of the windshaft, until it just comes up
against the front plate.
5. Pull the rotor assembly forward slightly & rotate as necessary to align the hexagonal
hole in the front plate over the M24 nut.
6. Rotate the whole rotor assembly clockwise to thread the nut onto the windshaft. The
windshaft can be held using an 8mm Allen key in the socket in the end of the windshaft.
Alternatively hold the rotor assembly still & rotate the windshaft anticlockwise using the
8mm Allen key in the socket in the end of the windshaft.
7. Tighten the rotor onto the shaft to a torque of 30 - 50Nm, until the spring washer is
compressed, the rotor is secure & the rear plate is located against the shoulder on the
windshaft. Check the rotor for free rotation.
8. Fit the nose cone in position on the front of the rotor and secure in place with the 3
No10 x 9.5mm screws provided.
Alternatively, the turbine and nosecone can be fitted after mounting the generator assembly to
the tower.

Rutland FM1803-2 Installation & Operation
Document No: SM-146 IssueG 01.11.20 MarlecEngineeringCoLtd
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Tail Assembly
Insert the tail fin assembly into the end of the tail boom, aligning the threaded holes in the tail
mounting with the clearance holes in the tail boom. Insert the two M10 x 14 Hex Head and Tab
Washers, to secure the tab washers bend and press the short tab against a flat on each screw
head. Bend the long tab so that it follows the circumference of the pole, tap lightly with a
mallet to maintain the curve, this prevent screws from working loose in service. Tighten to a
torque of 20Nm.
Note: When fitted, the tail fin will be inclined 15° to the vertical. This must be maintained to
ensure effectiveoperation ofthe furling mechanism in high winds.
.
Fig 4. Tail Assembly
Tail Fin –setat 15˚from
vertical. Caution - do not
adjust angle, it is essential
to effectivefurling.
M10 x 14HEX Head
and Tab Washer
Tail Boom

Rutland FM1803-2 Installation & Operation
Document No: SM-146 IssueG 01.11.20 MarlecEngineeringCoLtd
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Tower Preparation
The post adaptor fitted to the 1803-2 is designed to fit inside a standard 81mm (3”) internal
diameter tube. The adaptor is provided with a flat on one side to clear the weld seam on
seamed pipe.
1. Mark and centre-punch four positions diametrically opposite, at 45° to the pipe seam if
necessary, 20mm from the top of the tube.
2. Drill four holes 12.5mm in diameter on centre-punch positions & remove burrs.
3. Ensure that the top section of the mounting pole is no more than 90mm outside
diameter. This is essential to ensure that blade running clearance is achieved. This top
section may then be securely attached to a wider supporting structure.
Fig 5. Tower Preparation
Turbine Post
Adaptor
Pipe Seam
M12 x 25Button CapScrews
& Shakeproof Washers
Top of Tower
20mm

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Control Unit Installation
Mount the unit as shown below securely to a wall or other vertical surface, using the mounting
holes provided (hole centres are 285mm W x 205mm H), in a suitable location allowing for
cable entries in the base ofthe unit. The cable entries are fitted with blanking grommets, these
can be pierced or replaced with 20mm gland fittings. Follow these guidance notes:
•Install the control unit as close as possible to the batteries, 2m length of the main
battery leads is recommended as a maximum.
•The unit should be protected from battery fumes from vented batteries.
•The control unit is fan cooled and ventilation of a minimum of 10cm is required above
and below the unit. These vents must not be covered or obstructed.
•The unit is not weatherproof and therefore must be suitably protected indoors.
If selected, position and install the RUN/STOP Switch at a convenient location for shutting down
the turbine in the event the control unit needs to be isolated.
Fig 6. ControlUnit
Run / Stall
Push
Button
LCD Display with rear
ribbon fixing. Unplug at
PCB to remove cover
Mounting
Holes
Mounting
Holes
Vent
4 x Panel
Front fixing
screws
4 x PanelSide
fixing screws

Rutland FM1803-2 Installation & Operation
Document No: SM-146 IssueG 01.11.20 MarlecEngineeringCoLtd
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BATTERIES
Ensure the voltage indicated on your controller corresponds with your battery voltage!
Batteries are the most important part of a battery charging system and capacity should be sized
according to the load requirements and provide at least 3 days reserve. This will reduce cycling,
prolong the life of the battery and ensure system reliability during periods of low wind. Ifin
doubt about batterysizing, contact your dealer or the manufacturer.
Follow these guidelines:
•Deep Cycle batteries which are specifically designed for good performance in terms of
charge/discharge cycles must be used.
•Suitable battery chemistries include lead acid sealed, non-sealed, Absorbed Glass Mat or
Gel. Other types can be used but may require different regulating voltage settings.
These can be factory set when ordering or using a Marlec interface cable and PC app.
•Minimum battery capacities recommended: 400Ah @12v, 200Ah @24v, 100Ah @48V.
•Only batteries of similar type, capacity and ideally the same manufacturer should be
connected in series or parallel.
•Permanent connections should always be made to the battery terminals. Never use
crocodile clips or similar devices. Battery terminals should be well greased with
petroleum jelly or similar.
Batteries may be linked as follows:
•In parallel to increase amp hours (Fig.7).
•In series toincrease voltage (Fig.8).
•A combination of series & parallel to achieve desired voltage & capacity.
Fig.7
Fig.8

Rutland FM1803-2 Installation & Operation
Document No: SM-146 IssueG 01.11.20 MarlecEngineeringCoLtd
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CABLE SPECIFICATION
Follow the guidelines for cable sizes in the table below. The type of cable is dependent on the
type ofinstallationandnational orlocal wiring regulations. All cables must be suitably
protected from mechanical damage.
All cables & installation should be in accordance with IEE Wiring regulations
Turbine to Controller
Type 4 equally sized stranded cores. Note the FM1803 is 3 phase AC
output and the connection sequence is in any orderand colour.
The earth connects to the earthing point in the controller.
Specification Cable Run Minimum Cable Size
(m) (mm²) AWG
Up to 50 1.5 16
Up to 100 2.5 14
Up to 150 4 12
Up to 250 6 10
Controller to Battery
Type & Specification 2 separate cores black - and red +, stranded
cable. Minimum 10mm² and ≤1.5m length.
Remote Temperature
Sensor 1.5m cable supplied with controller
Remote Voltage Sensing
Wires A pair of conductors 0.5 to 0.75mm from the battery terminals to the controller. Optional to
fit where >1.5m battery cables are used.
Caution! System performance and safety are compromised if smaller cable
sizes are installed and there is risk of electrical damage in high winds.
FUSES
A suitably rated fuse may be fitted in the battery “+” line to protect the cables against damage
arising from any accidental reverse polarity connection at the battery.
WARNING! – This fuse will not protect the control unit’s electronics from the high currents that
flow from a reverse polarity event, permanent damage is likely. Note also that a blown fuse will
cause the turbine to run open circuit resulting in further damage to the control unit and
turbine. Place this warning at the fuse: DO NOT REMOVE FUSE UNLESS THE TURBINE IS STALLED.
Table 2.
System Voltage Minimum Fuse Rating
12V 100A
24V 50A
48V 25A
Table.1

Rutland FM1803-2 Installation & Operation
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ELECTRICAL CONNECTION
1. Using the cable selected (see Table 1), pass the cable through the inside of the tower &
route to the control unit. Leave enough length of cable protruding from the top of the tower
to enable easy connection to the wind generator.
2. If selected install the separately supplied Run/Stop Switch following the wiring diagram Fig 9
at a suitable location close to the control unit or convenient for shutting down the turbine in
the event the control unit needs to be isolated. Set it at the STOP position.
3. Remove the fixing screws from the control unit front panel, see Fig 6. As the panel lifts away
unplug the LCD connection ribbon cable from the PCB in the main housing.
4. Using the cables selected pass each through the grommeted holes in the base of the control
unit. The grommets can be replaced by M20 glands if preferred. Ensure the battery cables
are not yet connected to the battery, i.e. DO NOT MAKE LIVE CONNECTIONS
5. Make the connections following Figs. 10 and 11. Note that some connections are optional.
It is vital to observe correct polarity when connecting the battery cables otherwise serious
damage will result.
6. Offer up the front panel to the main unit and re-connect the display ribbon cable. Re-fit the
control unit front panel.
7. Proceed to joining the turbine fitted cables to the connecting cable at the top of the tower.
Fig 9. Run/Stop Switch Connections(optional)

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CONTROL UNIT WIRING
Fig 10. 12v, 24v& 48v Control Unit ConnectionsLabel
Wind Generator
Connections – 3 phase AC.
No polarity or colour
sequence required
Battery Connections
CAUTION – Do not
reverse or allow contact
to cross over
Remote Sensor (optional) –
connect required length to
battery – and+
Remote Shutdown –
(optional volt free contact)
connect
RJ11 Serial Dataport
(optional) See page 8
for pin outs.
Remote Temperature
Sensor – supplied.
Installation
recommended
Voltage Identification
label according to unit
supplied
Earth connection
point

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Fig 11. Control Unit Connections