Marlec Rutland FM1803-2 Furlmatic User manual

Document No: SM-146 Issue D 14.03.08
Rutland FM1803-2 Furlmatic
Windcharger
Owners Manual

Rutland FM1803-2 Installation & Operation
Document No: SM-146 Issue D 14.03.08 Marlec Engineering Co Ltd
1

Rutland FM1803-2 Installation & Operation
Document No: SM-146 Issue D 14.03.08 Marlec Engineering Co Ltd
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CONTENTS
Page
INTRODUCTION................................................................................ 3
CHECK YOU HAVE RECEIVED....................................................... 4
WHAT YOU WILL NEED, TOOLS, OTHER..................................... 4
SITING THE WINDCHARGER.......................................................... 5
SYSTEM DESCRIPTION & PRINCIPLE OF OPERATION………. 6
Aerofoil Blades
Generator
Tail Assembly
Control Unit
MOUNTING TOWER ………….……………………………………. 10
ASSEMBLY & INSTALLATION........................................................ 12
Blade & Hub Assembly.......................................... 12
Tail Assembly……………………………………. 14
Tower Preparation..............................……………. 15
Control Unit Installation………………………….. 16
BATTERIES.....................................................................................… 17
CABLE SPECIFICATION................................................................... 18
ELECTRICAL CONNECTION........................................................... 19
FITTING GENERATOR TO THE TOWER………………………… 20
Final Mechanical check…………………………. 20
UP AND RUNNING........................................................................... 21
SPECIFICATION AND PERFORMANCE......................................... 22
INSPECTION AND MAINTENANCE............................................... 23
TROUBLESHOOTING....................................................................... 24

Rutland FM1803-2 Installation & Operation
Document No: SM-146 Issue D 14.03.08 Marlec Engineering Co Ltd
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INTRODUCTION
This manual contains important information concerning your Rutland FM1803
Series 2 Windcharger system and its installation and operational characteristics.
It is strongly recommended that you read this manual and familiarise yourself with
its contents before installing and operating the Windcharger system.
The Rutland FM1803 Series 2 Windcharger is designed to provide a direct current
(DC) power supply via a battery bank for low voltage equipment, lighting,
inverters etc. in domestic and professional applications.
WARNING!
•When turning, the Windcharger is capable of generating voltages in excess of
the nominal voltage Caution must be exercised at all times to avoid electric
shock.
•Never disconnect the batteries from the controller when the turbine is running.
•The wind generator must never be operated on open circuit, (ie without control
unit connected, since hazardous voltages can be generated.
•No attempt to work on the system should be made until the wind generator is
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 system and invalidate the warranty.
.
•Do not adjust the settings on the control unit without reference to the
manufacturer.
•If in doubt, refer to your dealer, a competent electrical engineer or the
manufacturer.

Rutland FM1803-2 Installation & Operation
Document No: SM-146 Issue D 14.03.08 Marlec Engineering Co Ltd
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CHECK YOU HAVE RECEIVED
•Three (3) Aerofoil Blades and 9 nuts and bolts
•Main Generator Assembly
•Tail Fin assembly and Fixings
•Spinner and fixing screws
•Control Unit – Check that the voltage indicated on the connection label and the
side of the housing corresponds with your battery voltage.
•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
•10mm spanner or socket
•8mm Allen key
•6mm Allen key
•4mm Allen key
•Flat blade screwdriver
Other Items You Will Need
•Mounting tower
•Winch or other suitable lifting/pulling equipment
•Cable
•Batteries
•Battery terminals
•Connector blocks (as determined by your total system)
•Suitable fixings for wall mounting control unit.
Please complete the system details in the maintenance schedule (appendix A).
This information is important & should be kept safe & available if contacting the
manufacturer for advice or technical information.

Rutland FM1803-2 Installation & Operation
Document No: SM-146 Issue D 14.03.08 Marlec Engineering Co Ltd
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SITING THE WINDCHARGER
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 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 as detrimental to performance as upwind obstructions (Fig.1).
WIND DIRECTION
A
REA OF TURBULENCE
20H2H
2H
H
Fig.1

Rutland FM1803-2 Installation & Operation
Document No: SM-146 Issue D 14.03.08 Marlec Engineering Co Ltd
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SYSTEM DESCRIPTION & PRINCIPLE OF OPERATION
Aerofoil Blades & Rotor
The 1803 rotor consists of 3 aerofoil blades rigidly fixed to a hub. The blades are at
an optimum fixed pitch for variable speed operation over a wide wind speed range.
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 it’s 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.
Tail assembly
The inclined tail fin is hinged to the rigid tail boom on durable sleeve bearings.
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 generator 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 Issue D 14.03.08 Marlec Engineering Co Ltd
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Control Unit
The 1803 MPC1 control unit controls the operation of the FM1803-2 wind
generator & protects the battery bank from overcharge.
The 3 phase transformer & 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 controller monitors the battery voltage,
charge current & temperature. At pre-set levels, the controller will switch the
generator between Low and High wind modes to ensure optimum performance.
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
switch back to ‘charge’ mode. 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 the manufacturer for advice.
When in ‘stalled’ mode, the system can be manually re-set to ‘charge’ mode by
pressing the reset button on the front panel.
Temperature compensation ensures that the battery voltage switching points are
automatically adjusted for ambient temperature to maintain optimum battery
performance.
A digital LCD display shows battery voltage, charge current, generated power,
operating mode & warnings. Coloured LEDs also indicate operating status &
warnings.
The on/off switch on the front panel allows the control unit to be switched off
which will select ‘stalled’ mode for installation / servicing, stalling the turbine to a
slow idle & preventing power being produced. In this mode the LCD display will
be blank.
If a battery is not connected, the control unit will default to stall mode.
There are 3 continuous operating modes:
Mode Low/High LED Charge/Stall LED LCD Display
Charge Low Wind Green Green Charge Low Wind
Charge High Wind Red Green Charge High Wind
Stalled Red Red Turbine Stalled

Rutland FM1803-2 Installation & Operation
Document No: SM-146 Issue D 14.03.08 Marlec Engineering Co Ltd
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Transitional modes indicated by LEDs:
Charge/Stall LED Flashing Green/Amber – Currently in charge mode, the
battery voltage has reached the fully charged level & a time delay period has
started prior to entering stall mode, the voltage must remain at this level for the
whole of the time period before a mode change will take place. If the voltage falls
again while in this phase, the LED will stop flashing & the controller will stay in
charge mode. This is to prevent unnecessary change of mode during transient
voltage changes.
Charge/Stall LED Red/ pulsing off once per second – The Controller has
switched to stall mode & a time delay period has started to allow the turbine to
stabilize in the new operating mode before re-checking the battery voltage.
Charge/Stall LED Flashing Red/Amber – Currently in stalled mode, the battery
voltage has reached the lower voltage limit & a time delay period has started prior
to entering charge mode, the voltage must remain at this level for the whole of the
time period before a mode change will take place. If the voltage rises again while
in this phase, the LED will stop flashing & the controller will stay in stall mode.
This is to prevent unnecessary change of mode during transient voltage changes.
Charge/Stall LED Green/ pulsing off once per second – The Controller has
switched to charge mode & a time delay period has started to allow the turbine to
stabilize in the new operating mode before re-checking the battery voltage.
Low/High Wind LED Flashing Green/Amber – Currently in Low wind mode,
the charge current has reached the upper limit for low wind mode & a time delay
period has started prior to entering High wind mode, the current must remain at
this level for the whole of the time period before a mode change will take place. If
the current falls again while in this phase, the LED will stop flashing & the
controller will stay in Low wind mode. This is to prevent unnecessary change of
mode during transient current changes.
Low/High Wind LED Red/ pulsing off once per second – The Controller has
switched to High wind mode & has started a time delay period to allow the turbine
to stabilize in the new operating mode before re-checking the charge current.
Low/High Wind LED Flashing Red/Amber – Currently in High wind mode, the
charge current has reached the lower limit for high wind mode & a time delay
period has started prior to entering Low wind mode, the current must remain at this
level for the whole of the time period before a mode change will take place. If the
current increases again while in this phase, the LED will stop flashing & the
controller will stay in High wind mode. This is to prevent unnecessary change of
mode during transient current changes.

Rutland FM1803-2 Installation & Operation
Document No: SM-146 Issue D 14.03.08 Marlec Engineering Co Ltd
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Low/High Wind LED Green/ pulsing off once per second – The Controller has
switched to Low wind mode & has started a time delay period to allow the turbine
to stabilize in the new operating mode before re-checking the charge current.
Note: High/Low wind mode switching is inactive when the controller is in Stall
mode. In Stall mode, high wind mode will also be selected to prevent high transient
currents if the controller switches back to charge mode during high winds.
Warnings
Mode Low/High LED Charge/Stall LED LCD Display
Low Battery Volts Flashing Red Flashing Red Warning: Low Bat
Over Temperature Flashing Red Flashing Red Over Temperature
Both Leds flashing alternately Red & LCD display ‘Warning: Low Bat’ –
Battery voltage is below the minimum recommended level & is therefore seriously
discharged, any loads should be removed & the batteries recharged as soon as
possible to avoid permanent damage to the battery.
Both Leds flashing alternately Red & LCD display ‘Over Temperature’ – The
internal components of the control unit have reached a higher than normal
temperature. The turbine will be stalled and the cooling fan will run until the
temperature has reduced to normal levels when the turbine will resume normal
operation. If this occurs, check that the controller housing vents are not obstructed.
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.

Rutland FM1803-2 Installation & Operation
Document No: SM-146 Issue D 14.03.08 Marlec Engineering Co Ltd
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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 pivoting towers are available, for further
tower details contact the dealer or manufacturer.

Rutland FM1803-2 Installation & Operation
Document No: SM-146 Issue D 14.03.08 Marlec Engineering Co Ltd
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Fig 2. Typical Tower
R4400
1300
2600
2600

Rutland FM1803-2 Installation & Operation
Document No: SM-146 Issue D 14.03.08 Marlec Engineering Co Ltd
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ASSEMBLY AND INSTALLATION OF THE WINDCHARGER
Blade & Hub Assembly
The blade hub rear assy complete with blade bolts is pre-fitted to the
generator shaft, this must not be removed to fit the turbine blades.
Fig 3. Blade Hub Assembly
Turbine Blade
Flat Side of
Blade
M8 Nylock
Nuts
Hub Front Plate
M8
washers
Hub Rear Assy
with protruding
blade bolts
‘D’ washer
Tab washer
M10 x 25
Spinner fixing
boss

Rutland FM1803-2 Installation & Operation
Document No: SM-146 Issue D 14.03.08 Marlec Engineering Co Ltd
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Blade & Hub Assembly continued
Fit the 3 turbine blades to the protruding blade bolts, ensuring the flat surface of
the blades faces the front plate.
Fit the front hub plate to the shaft with the pre-fitted pins protruding outwards.
Ensure alignment with the flats on the shaft, the pins with the holes in the hub
boss, and the cutouts with the spinner fixing holes in the blades.
Fit the nuts & washers to the blade bolts & tighten using 2 x 13mm spanners. If
necessary use a flat blade screwdriver from the back of the hub assembly to push
the bolts through.
Using a suitable hammer, drive the 3 protruding pins into the corresponding holes
in the front plate & boss assy, until the pins are flush with the front plate.
Fit the centre screw, ‘D’ washer & tab washer to the assembly & tighten the screw
securely to push the assembly back against the shoulder on the shaft. Ensure there
is no gap between the rear hub plate & shaft shoulder.
Using a hammer & suitable drift, bend the edges of the tab washer against the flats
on the centre screw to prevent loosening.
Check tightness of all screws. (Do not over-tighten).
Fit the plastic spinner in position on the front of the generator hub and secure in
place with the 3 No10 x 9.5 screws provided.
Alternatively the turbine and spinner can be fitted after mounting the generator
assembly to the tower.
Fig 4. Turbine Assembly Fixing
Insert tab washer into
slot in front hub plate
Bend a corner of the tab
washer against a flat on the
bolt head

Rutland FM1803-2 Installation & Operation
Document No: SM-146 Issue D 14.03.08 Marlec Engineering Co Ltd
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Tail Assembly
Insert the tail 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
16 Button Cap Screws & Shakeproof washers & tighten to a torque of 20Nm.
When fitted, the tail fin will be inclined 15° to the vertical.
Fig 5. Tail Assembly
Tail Assembly
M10 Button Cap
Screws & Shakeproof
washers
Tail Boom

Rutland FM1803-2 Installation & Operation
Document No: SM-146 Issue D 14.03.08 Marlec Engineering Co Ltd
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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.
•Mark and centre-punch four positions diametrically opposite, at 45° to the pipe
seam if necessary, 20mm from the top of the tube.
•Drill four holes 12.5mm in diameter on centre-punch positions & remove burrs.
Fig 6. Tower Preparation
Post Adaptor
Pipe Seam
M12 x 25 Button Cap Screws
& Shakeproof Washers
Top of Tower
20

Rutland FM1803-2 Installation & Operation
Document No: SM-146 Issue D 14.03.08 Marlec Engineering Co Ltd
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Control Unit Installation
The Control unit should be installed as close as possible to the batteries to
minimise the length of the main battery leads, at the same time the unit should be
protected from battery fumes from vented batteries.
Ensure adequate ventilation is provided to allow efficient heat dissipation via the
control unit vents. These vents must not be covered or obstructed.
The unit is not weatherproof & therefore must be suitably protected.
Mount the unit securely to a wall or other vertical surface, using the mounting
holes provided (hole centres are 270mm W x 200mm H), in a suitable location
allowing for cable entries in the base of the unit. The cable entries are fitted with
blanking grommets which need to be pierced or can be removed for attachment of
20mm conduit fittings if required.
Fi
g
7. Control Unit
On / Off
Switch
LED
Indicators
Mounting
Holes
Mounting
Holes
Vents
Manual Re-set
Push button
Vents
Front Panel
fixing screws
Front Panel
fixing screws

Rutland FM1803-2 Installation & Operation
Document No: SM-146 Issue D 14.03.08 Marlec Engineering Co Ltd
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BATTERIES
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. If in
doubt about battery sizing, contact your dealer or the manufacturer.
The minimum battery capacity recommended is 400Ah @ 12v, 200Ah @ 24v
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.8).
•In series to increase voltage (Fig.9).
•A combination of series & parallel to achieve desired voltage & capacity.
Only batteries of similar type & capacity & ideally the same manufacturer should
be connected together in series or parallel.
Ensure the voltage indicated on your controller corresponds with your battery
voltage.
12v
200Ah
12v
200Ah
Total = 12v
400Ah
4800Wh
Fig.8
12v
200Ah
12v
200Ah
Total = 24v
200Ah
4800Wh
Fig.9

Rutland FM1803-2 Installation & Operation
Document No: SM-146 Issue D 14.03.08 Marlec Engineering Co Ltd
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CABLE SPECIFICATION
The cable size used for connection of the Windcharger to the control unit should be
in accordance with table 1 in order to minimise voltage drop and ensure optimum
performance. 3 cores will be required.
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
Up to 450 10 8
Up to 700 16 6
Up to 1000 25 4
The cable size for connection of the control unit to the batteries should be 10mm²
minimum; the use of smaller cables than recommended will reduce the
performance of the charging system.
The type of cable is dependent on the type of installation & national or local wiring
regulations. All cables must be suitably protected from mechanical damage.
All cables & installation should be in accordance with IEE Wiring regulations
The 3 phase cable from the WG is coloured in accordance with amendment 2 to
BS7671: 2001 (IEE wiring Regulations 16th Edition).
Phase 1- Brown
Phase 2 - Black
Phase 3 - Grey
Table.1

Rutland FM1803-2 Installation & Operation
Document No: SM-146 Issue D 14.03.08 Marlec Engineering Co Ltd
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ELECTRICAL CONNECTION
•Remove the four screws from the control unit front panel, carefully remove the
front panel by sliding upwards to release the latches into the main housing,
withdraw until the ribbon cable connecting the front panel to the main housing
can be accessed. Unplug the ribbon cable from the PCB in the main housing &
the front panel can then be removed.
•Using the cable selected (see Table 1), pass the cable through the inside of the
tower & route to the control unit. Leaving sufficient length of cable protruding
from the top of the tower to enable easy connection to the wind generator.
•Pass the cables through the grommet or conduit in the base of the control unit &
connect to the 3 terminals labelled for the wind generator. (The generator output
is 3 phase ac, therefore these connections can be made in any sequence).
•Using the cable selected for connection of the control unit to the batteries. Pass
the cables through the grommet or conduit in the base of the control unit &
connect to the 2 terminals labelled for the battery. It is vital to observe correct
polarity when connecting the battery cables otherwise serious damage will
result.
•Re-connect the ribbon cable & re-fit the control unit front panel. Move the
ON-OFF switch to the ‘OFF’ position.
Fig 10. 12 & 24v Control Unit Connections
Wind Generator
Connections
Battery
Connections
Voltage
Identification label