Marlec Rutland Furlmatic 910-3 User manual

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Document No: SM124 Issue D 30.01.07
Rutland Furlmatic 910-3 Windcharger
Owners Manual

Marlec Eng Co Ltd Installation Instructions
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Document No: SM124 Issue D 30.01.07 1
Page
INTRODUCTION……………………………………………………. 2
GENERAL GUIDELINES & WARNINGS………………………….. 2
CHECK YOU HAVE RECEIVED…………………………………… 4
WHAT YOU WILL NEED…………………………………………… 4
SITING THE WINDCHARGER…………………………………….. 5
PRINCIPLE OF OPERATION………………………………………. 6
TOWER CONSTRUCTION…………………………………………. 7
ASSEMBLY & INSTALLATION…………………………………… 8
Blade Assembly…………………………………. 8
Furlmatic Tail Assembly………………………… 9
Tower Preparation……………………………….. 10
BATTERIES…………………………………………………………. 11
CABLE SPECIFICATION…………………………………………… 12
ELECTRICAL CONNECTIONS & FITTING TO TOWER………… 12
Final Mechanical Check…………………………. 13
BASIC WIRING DIAGRAMS………………………………………. 14
UP & RUNNING…………………………………………………. 15
SPECIFICATION & PERFORMANCE……………………………… 15
INSPECTION & MAINTENANCE…………………………….. 16
TROUBLESHOOTING…………………………………………….. 17

Marlec Eng Co Ltd Installation Instructions
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Document No: SM124 Issue D 30.01.07 2
INTRODUCTION
This manual contains important information concerning your Rutland 910-3
Windcharger and its installation and operation.
It is strongly recommended that you read this manual and familiarise yourself
with its contents before installing and operating the Windcharger system.
The Rutland 910-3 Windcharger is designed to provide a direct current (DC)
power supply via a battery bank for 12/24V equipment, lighting, etc. It is
robustly constructed and designed to give many years of trouble free service
with the minimum of maintenance. Please take notice of our General Guidelines
for the user and Inspection and Maintenance sections.
GENERAL GUIDELINES & WARNINGS!
• Observe the mounting pole diameters recommended in this manual. It is
essential to the effective operation of the furling tail system that the mounting
pole is vertical. An unsupported tower will experience lateral movement
particularly in high winds and furling will be adversely affected will potential
damage to the wind turbine.
• 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. Avoid applying a short
circuit to the Windcharger particularly in high winds. If a short circuit is
necessary first slow the turbine as described below. 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
windspeed 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. The optional HRDX
Controller incorporates a shutdown switch.
• No attempt to repair the system should be made until the Windcharger is
restrained from turning.

Marlec Eng Co Ltd Installation Instructions
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Document No: SM124 Issue D 30.01.07 3
• 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.
• The fuse supplied must be fitted to protect the system unless used in
conjunction with a controller that is already fitted with a charge fuse.
• High winds – in high winds the Windcharger’s built-in thermostat may
operate to prevent the generator overheating. In this mode the output will
cease and the turbine will temporarily slow down until such time as the lower
level temperature is reached and the generator is once again connected and
charging. This may be seen to cycle in prolonged high winds particularly in
high ambient temperatures. Further the furling tail mechanism of the
Furlmatic model will operate in high winds orienting the turbine out of the
prevailing wind direction to slow the turbine down. It will return to face the
wind as windspeeds fall and will be seen to cycle during high wind speeds.
• If in doubt, refer to your dealer, a competent electrical engineer or the
manufacturer.

Marlec Eng Co Ltd Installation Instructions
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Document No: SM124 Issue D 30.01.07 4
CHECK YOU HAVE RECEIVED
• 1 x main generator assembly
• 1 x tail assembly
• 24 x No. 10x25mm special self-tapping screws
• 6 x aerofoil blades
• 1 x fuse and fuse holder
• 1 x 2-way terminal block
• 2 x M10 buttoncap screws
• 2 x M10 shakeproof washers
• 1 x 6mm Allen key
In the event of loss or damage, consult your dealer or the manufacturer.
WHAT YOU WILL NEED
Tools
• Suitable wire stripper
• Small terminal screwdriver
• Large flat blade screwdriver
• Crosshead screwdriver
• 10mm Spanner
Other Items You Will Need
• Tower/Mounting pole
• Batteries
• Battery terminals
• Cable
• Connector blocks (as determined by your total system)
Other Items You May Have Selected from Marlec
• HRS913 Regulator or HRDX Controller
• Land Tower and Rigging Kit (Part Nos. CA-12/08 & CA-12/07)
• Voltmeter & Ammeter
SITING THE WINDCHARGER

Marlec Eng Co Ltd Installation Instructions
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Document No: SM124 Issue D 30.01.07 5
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 trees and
buildings.
Both wind sheer and turbulence diminish with height and can be overcome
simply by putting the machine sufficiently high above them as shown in Fig 1.
Wind speed decreases and turbulence increases where obstructions exist.
Consider also that downwind obstructions can be as detrimental to performance
as upwind obstructions.
WIND DIRECTION
A
REA OF TURBULENCE
20H2H
2H
H
Fig.1

Marlec Eng Co Ltd Installation Instructions
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Document No: SM124 Issue D 30.01.07 6
PRINCIPLE OF OPERATION
Generator
The 3 phase ac generator is driven directly by the aerofoil blades, rotating
permanent magnets around the fixed stator winding. The variable
frequency alternating current is rectified within the generator housing, and
the resulting rectified current is transmitted via the sliprings and brushes at
the yaw axis to the output cable.
Winding Over-Temperature Protection
The generator stator winding incorporates embedded thermal protection to
protect the winding from damage due to over temperature during extreme
winds. On reaching the thermal protection limit, the device will reduce
generator output current to allow the winding to cool, whereupon normal
performance will be resumed. If the thermal protection is active, the
turbine may reduce to a slow rotational speed with a corresponding
reduction in charge current, this is normal.
Furling Tail System
The tail assembly is designed to direct the turbine into the main direction of
the wind at windspeeds up to approx 15m/s. Above this the automatic
“furling” mechanism is activated to turn the generator at an angle to the
wind to protect the turbine, generator and supporting structure from severe
electrical and mechanical loads due to high winds. When the wind speed
subsides, the tail assembly will automatically return the turbine to normal
operation. In prolonged gusty & turbulent conditions, the system may be
seen to repeat this cycle many times. Power will be reduced during furling.
For effective operation of the furling system the wind turbine must be sited
to ensure it is as free as possible from turbulence and in a stable upright
position.

Marlec Eng Co Ltd Installation Instructions
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TOWER CONSTRUCTION
The Furlmatic 910-3 is designed to fit inside an aluminium, stainless or
steel tube with an internal diameter of 41mm with a minimum wall
thickness of 5mm.
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 in diameter.
• The shackles should be a minimum of 5mm in diameter.
• Rigging screws should be a minimum of 5mm 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.
Centre pivoted pole
Base pivoted with gin pole
Pivot type towers are recommended as these allow for easier installation
and lowering for access to the wind generator. Two forms of pivot tower
are suggested in Figs 2 & 3. Non-guyed pivoting towers are available, for
further details contact the dealer or manufacturer.
Note: See the warnings section regarding the tower. It is essential that the
tower is maintained vertically to minimise lateral movement which
interferes with the effective operation of the furling tail.
Fig.3
Fig.2

Marlec Eng Co Ltd Installation Instructions
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Document No: SM124 Issue D 30.01.07 8
ASSEMBLY AND INSTALLATION OF THE WINDCHARGER
Blade Assembly (Fig. 4)
1. Place the generator assembly on a flat surface hub-side down.
2. Position blade as shown. The blades will only fit one way round.
Insert the protrusion at the trailing edge of the blade root fixing first into
socket to align with the corresponding recess in the blade socket. The
blade can then be easily inserted with a lever action. Gentle assistance with
a soft faced mallet may be required.
3. Four screws are required for each blade. First secure each blade with
two of the special self-tapping screws provided.
4. Fit the remaining 2 blade screws from the front of the generator hub.
5. Check tightness of all screws. (Do not over-tighten).
NB. IT IS IMPORTANT THAT 4 SCREWS PER BLADE ARE
FITTED.
Fig.4

Marlec Eng Co Ltd Installation Instructions
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Document No: SM124 Issue D 30.01.07 9
Furlmatic Tail Assembly (Fig. 5)
1. Remove the cover from the main housing.
2. Remove the M6 nut, washers and bolt from the tail boom.
3. Insert the tail boom into the saddle on the underside front of the housing.
Ensure the tail assembly is the correct way up. (refer to pictures in this
manual & the text on the tail label).
4. Re-fit bolt washers & nut removed in 2, passing the bolt through the tail
boom and windshaft housing. Tighten all fasteners.
5. Replace cover.
Note: Do not remove the silicone protectors from the tail stops!
Tail Boom
Fasteners
NB. The tail fin is set at an angle of 15°
from vertical. Check that the tail fin is
positioned as shown in the diagram (as
viewed from rear of the Windcharger)
Fi
g
. 5