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' Rutland 913 Owners Manual Issue G'


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              Rutland 913 Windcharger
                  Owner's Manual

Document No: SM-130 Issue G 26.10.06
Rutland 913 Windcharger                                                                         Owner's Manual



INTRODUCTION................................................................................ 2

GENERAL GUIDELINES & WARNINGS............................... 2

CHECK YOU HAVE RECEIVED....................................................... 4

WHAT YOU WILL NEED.................................................................. 4

SITING THE WINDCHARGER.......................................................... 5

                           General Considerations........................................... 5
                           On Board Systems................................................... 6
                           Land based Systems................................................ 7

ASSEMBLY & INSTALLATION........................................................ 8

                           Blade Assembly...................................................... 8
                           Tower Preparation ............................................. 9

BATTERIES........................................................................................   10

CABLE SPECIFICATION................................................................... 10


FINAL MECHANICAL CHECK.......................................... 11

BASIC WIRING DIAGRAMS............................................................ 12

UP AND RUNNING...........................................................................           13

SPECIFICATION AND PERFORMANCE......................................... 13

INSPECTION AND MAINTENANCE............................................... 14

TROUBLESHOOTING....................................................................... 15

Document SM-130 Issue G 26.10.06                          1                             Marlec Engineering Co Ltd
Rutland 913 Windcharger                                                 Owner's Manual


Congratulations on your Rutland 913 purchase! The utmost of care goes into
the manufacture of all our products in our ISO9002 approved factory. To ensure
you get the very best out of the Rutland 913 Windcharger we recommend that
you read this manual and familiarise yourself with its contents before installing
and operating the Windcharger system.

The Rutland 913 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 & Warnings and
Inspection & Maintenance sections.


· Mounting pole outside diameter MUST NOT exceed 48.5mm for at least the
  top 0.5m. 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 the
  windcharger by allowing the blade to come into contact with the mounting
  pole. A broken blade will cause turbine imbalance with consequent damage.

· 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. Connecting an open circuit
  running turbine to the electrical system can cause serious damage to system
  components owing to excessive voltage. 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.

· Choose a calm day to install the equipment and consider other safety aspects.
  No attempt to repair the system should be made until the wind generator is
  restrained from turning.

Document SM-130 Issue G 26.10.06           2                      Marlec Engineering Co Ltd
Rutland 913 Windcharger                                           Owner's Manual

· 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 speed up 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. If safely accessible you may prefer to temporarily
  secure the turbine.

· The Rutland 913 Windcharger is suitable for sailing boats and some land
  based applications. When storm winds are forecast the turbine can be
  restrained to minimise wear and tear particularly when installed on land
  based applications where Furlmatic model windchargers are normally
  recommended. Note that where the manufacturer recommends a furling type
  windcharger should have been used the warranty is invalidated in cases of
  storm damage.

· If in doubt, refer to your dealer, a competent electrical engineer or the

Document SM-130 Issue G 26.10.06        3                   Marlec Engineering Co Ltd
Rutland 913 Windcharger                                             Owner's Manual


·   24 x No. 10x25mm special self-tapping screws
·   1 x fuse and fuse holder
·   1 x main generator assembly
·   6 x aerofoil blades
·   1 x nose cone + 3 x nylon fixing screws
·   1 x 6mm Allen key
·   1 x 2-way terminal block
·   2 x M10 buttoncap screws
·   2 x shakeproof washers
·   HRS913 Regulator (USA "Mariner's Package" only)
·   600mm (23 ˝") Stainless Steel Tube (USA "Mariner's Package" only)

In the event of loss or damage, consult your dealer or the manufacturer.


· Suitable wire stripper
· Small terminal screwdriver
· Large flat blade screwdriver
· Crosshead screwdriver

Other Items You Will Need
· Mounting pole
· Cable
· Batteries
· Battery terminals
· Connector blocks (as determined by your total system)

Other Items You May Have Selected
· HRS913 Regulator or HRDX Charge Controller
· Cable
· Rutland 913 Marine Mounting Kit (Part No: CA-12/02)
· Rutland 913 Land Tower & Rigging Kit (Part Nos: CA-12/08 & CA-12/07)
· Short section of stainless steel tube to adapt into your own mounting design.
· Voltmeter & Ammeter

Document SM-130 Issue G 26.10.06         4                    Marlec Engineering Co Ltd
Rutland 913 Windcharger                                                                Owner's Manual


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 turbine sufficiently high above them as shown in Fig 1.
Windspeed decreases and turbulence increases where obstructions exist.
Consider also that downwind obstructions can be as detrimental to performance
as upwind obstructions.

It is therefore essential that the wind generator should be located in an area as
free as possible from disturbed wind flow.

                                                   A REA O F T U RB U L EN C E
      W IN D D IREC T IO N



                   2H                                20H

Document SM-130 Issue G 26.10.06           5                                     Marlec Engineering Co Ltd
Rutland 913 Windcharger                                              Owner's Manual

                                    On Board Systems
                                    The wind generator should be mounted in a safe
                                    position, a minimum of 2.3 metres (7.6 feet)
                                    above the deck and away from other obstacles
                                    which could interfere with the blades or tail
                                    assembly (Fig. 2).

                                    The Rutland 913 Mounting Kit
                                    (PartNo.CA-12/02) is available for deck
                                    mounting, or short sections of stainless steel
                                    tube of 1200mm (47") and 600mm (23") pre-
                                    drilled are also available for your own

                                    The Rutland 913 is designed to fit inside an
                                    aluminium or stainless steel tube with an
                                    internal    diameter    of   41mm      (1").
                                    IMPORTANT: The external diameter MUST
                                    NOT exceed 48.5mm (1), see Warning in
                                    Suitable tubes: Stainless Steel 13/4"16 SWG
                                    Aluminium 17/8" 10 SWG

                                    We suggest the following mountings according
                                    to preference and site conditions:-

                                    · Push pit (Fig.3)
                                    A suitable pole mounted to the deck with deck
                                    plates and guy ropes is the most popular method
                                    of mounting the Windcharger on yachts, eg.
                                    Rutland 913 Mounting Kit.

                                    · Mizzen (Fig.4)
                            Fig.5   Mizzen mounting is suitable on larger yachts,
                                    taking advantage of greater wind flow the
                                    higher the wind turbine is mounted.

                                    · River Boats (Fig.5)
                                    A pivot pole is ideal for riverboats as the
                                    Windcharger can easily be raised and lowered.

Document SM-130 Issue G 26.10.06           6                   Marlec Engineering Co Ltd
Rutland 913 Windcharger                                                Owner's Manual

                                    Land Based Systems
                                    The Rutland 913 is suitable for some land based
                                    temporary and leisure applications.
                                    We recommend the Furlmatic model
                                    windchargers for land based remote and
                                    exposed locations.

                                    The Rutland 913 is designed to fit inside
                                    aluminium, stainless or steel tube with an
                                    internal   diameter   of    41mm.   (1").
                                    IMPORTANT: The external diameter MUST
Centre pivoted pole                 NOT exceed 48.5mm (1), see Warning in

                           Fig.7    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
                                       (0.16") in diameter.
                                    · The shackles should be a minimum of 5mm
                                       (0.20") in diameter.
                                    · Rigging screws should be a minimum of
Base pivoted with gin pole             5mm (0.20") 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.

                                    We suggest pivot type towers as these allow for
                                    easier installation and lowering for access to the
                                    wind generator. Two forms of pivot tower are
                                    suggested in Figs 6 & 7.

                                    A base-hinged 6.4m tall Land Tower Kit (Part
                                    No:CA-12/08) and Rigging Kit
                                    (Part No:CA-12/07) are available from Marlec.

Document SM-130 Issue G 26.10.06           7                     Marlec Engineering Co Ltd
Rutland 913 Windcharger                                                Owner's Manual

                                   ASSEMBLY AND INSTALLATION OF
                                   THE WINDCHARGER

                                   Blade Assembly (Fig.8)

                                   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.
                                      Secure each blade with two special self-
                                      tapping screws provided by inserting each in
                                      turn through the cutout in the nacelle,
                                      rotating the generator each time until the
                                      holes align. Caution!- It is essential that all 4
                                      screws are fitted!

                                   4. Fit the remaining blade screws from the front
                                      of the generator hub.

                                   5. Check tightness of all screws. (Do not over-

                                   6. Fit the plastic nose dome in position on the
                                      front of the generator hub and secure in place
                                      with the three nylon screws provided.

                                   Alternatively the blades and nose dome can be
                                   fitted after mounting the generator assembly to
                                   the tower.

Document SM-130 Issue G 26.10.06          8                      Marlec Engineering Co Ltd
Rutland 913 Windcharger                                              Owner's Manual

                                   Tower Preparation (Fig.9)
                          Fig 9
                                   Having selected a suitable pole from the
                                   guidelines on pages 6 and 7:

                                   1. The post adapter fitted to the 913 is designed
                                      to fit inside a standard 41mm (1") internal
                                      diameter tube. The adapter is provided with a
                                      flat on one side to clear the weld seam on
                                      seamed pipe.

                                   2. Mark and centre-punch two positions
                                      diametrically opposite, at 90° to the pipe
                                      seam if necessary, 20mm (NOTE: Use metric
                                      measurements for this operation) from top of
                                      the tube.

                                   3. Drill two holes 10.5mm (NOTE: Use metric
                                      measurements for this operation) in diameter
                                      on centre-punch positions.

                                   Note: When using the Rutland 913 Mounting
                                   Kit, items 2 and 3 can be ignored as the unit is

Document SM-130 Issue G 26.10.06          9                    Marlec Engineering Co Ltd
        Rutland 913 Windcharger                                                         Owner's Manual

                    Total = 12v
                                                      Leisure/Deep Cycle batteries are specifically
                            1440Wh                    designed for good performance in terms of
                                                      charge/discharge cycles. Batteries are the most
                            12v                       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.

                In parallel to increase               Permanent connections should always be made
                amp hours                             to the battery terminals. Never use crocodile
                                                      clips or similar devices. Battery terminals
                                                      should be well greased with petroleum jelly or

                                                      We strongly recommend that one of the voltage
                    Total = 24v             Fig.11
                            60Ah                      regulators available from Marlec is fitted to
                            1440Wh                    prevent batteries becoming overcharged in
                                                      strong winds and is essential with gel/sealed

                                                      Batteries may be linked as shown in the figures
                                      12v             10 and 11. It is essential to observe polarity as

                                                                   Red is + Positive
                In series to increase                              Black is - Negative
                                                      CABLE SPECIFICATION
Cable                   Cable Size
 Run        12V                  24V                  The cable used for connection of the
 (m)     mm˛ AWG              mm˛ AWG                 Windcharger to the batteries should be in
0-20      2.5       13        1.5           15        accordance with table 1. The use of a smaller
21-30      4        11        2.5           13        cable than recommended will reduce the
31-45      6        9          4            11        performance of the charging system.
46-80     10         7         6             9
                                                      Cable and connectors are available from your
                                                      dealer or the manufacturer.

        Document SM-130 Issue G 26.10.06                     10                   Marlec Engineering Co Ltd
Rutland 913 Windcharger                                                Owner's Manual


1. Run the cable selected (see Table 1) down the inside of the pole.

2. Select one of the 2 basic wiring systems on page 12 and follow the manual
   provided with the voltage controller.

3. Fit the in-line fuse and fuse holder in the circuit where the HRS type or no
   regulator is used. It is essential that a charge fuse is fitted but note that some
   Marlec controllers incorporate one negating the need for a separate fuse. Cut
   the fuse holder cable and strip back the ends to allow connection in the circuit.

                                                            Fig. 12
                                                            20A Fuse
                                                            and Fuse holder

4. Connect the wind generator flying leads to the cable protruding from the tower
   using the connector block supplied, taking care to observe polarity. Connect
   the windcharger + to cable + and windcharger ­ to cable ­

   Red is + Positive
   Black is - Negative
5. Wrap the connection with insulation tape to secure/protect from environment.
   Alternatively join the cables using a latching-type plug and socket.

6. Locate the wind generator into the tower whilst gently easing the cable from
   the tower base to ensure the cable is not trapped. Secure the wind generator to
   the tower using the button cap screws and shake proof washers provided,
   tighten using the 6mm Allen key provided.


1. Check the tightness of the blade fixing screws and generator mounting screws.

2. Check free rotation of the hub and yaw axis.

Document SM-130 Issue G 26.10.06           11                    Marlec Engineering Co Ltd
 Rutland 913 Windcharger                                                              Owner's Manual

 Rutland 913 with HRS913 Regulator Wiring Diagram
                 Rutland 913

                    Red                                       Brown

                   Black                                       Black          Red

                                                       Charge Fuse


Rutland 913 with HRDX Controller


                                    Solar Panel
                                    100 Watts

                    Rutland 913



                                       Battery                Battery

 Document SM-130 Issue G 26.10.06                 12                            Marlec Engineering Co Ltd
Rutland 913 Windcharger                                                                          Owner's Manual


· Before raising and securing the wind generator, check that:
1. All final mechanical checks have been made.
2. The cable is not trapped.
3. All electrical connections are secure and safe.

· The wind generator can now be raised into position.
  Take care to avoid all moving parts when raising and lowering the wind

· When raised, secure the structure firmly in an upright position. The
  performance of your Windcharger can be impaired if the pole is not vertical.

The curve shown below is for ideal, non-turbulent wind conditions; this may not be achieved in some installations.

        Charge into 12v Battery (Amperes)                          Charge into 24v Battery (Amperes)

           20                                                                                          10

           18                                                                                          9

           16                 WINDSPEED CONVERSION                                                     8

           14                       MPH = Knots x 1.15                                                 7
                                   M/S = Knots x .515
           12                                                                                          6

           10                                                                                          5

            8                                                                                          4

            6                                                                                          3

            4                                                                                          2

            2                                                                                          1

            0                                                                                          0

                0        5         10        15         20        25         30        35         40

                                               Windspeed (Knots)

Document SM-130 Issue G 26.10.06                        13                            Marlec Engineering Co Ltd
Rutland 913 Windcharger                                                  Owner's Manual


The Rutland 913 requires no scheduled maintenance but an annual inspection
should be carried out to monitor the general condition of the system to ensure the
electrical and mechanical integrity and safety of the system.

WARNING! Before inspection, the turbine should either be lowered to the ground
or tied to prevent the generator from turning. To stop the generator from turning
proceed as follows:
1. Either rotate the switch to stall mode on the HRDX Controller if used OR turn
   the wind generator out of the wind (180°) using the tail, a hole is provided in the
   tail fin to assist in this. The generator will gradually slow down.
2. Tie a blade to the mounting pole to prevent it from rotating.

Whilst the generator is stationary, the following routine checks should be

1. Check the blades for damage, eg chips or nicks. Replace any damaged blades.
   The turbine should not be operated with damaged blades as this may cause
   imbalance resulting in premature wear and possible failure. Check the blade
   screws for tightness.
2. Check all other nuts, bolts and screws for tightness.
3. Check the yaw axis for free rotation.
4. Check tower assembly for condition.
5. Check the tension of the guy wires if applicable. The tension of guy wires
should be checked frequently during the first year.
6. The unit can be wiped with a mild detergent and rinsed with water to remove
dirt and debris.

Note: The Windcharger is designed for continuous running to achieve maximum
resistance to water ingress, should the unit be restrained for any extended period it
is recommended that it be covered.

Document SM-130 Issue G 26.10.06          14                    Marlec Engineering Co Ltd
Rutland 913 Windcharger                                                Owner's Manual


In the unlikely event that your Rutland 913 should develop a defect, the turbine
should first be tied to prevent the blades from turning to perform the static tests
below. (Follow the procedure described in the Inspection and Maintenance section)
It will be necessary to let it run for the tests to check for power production.

1. Read the Electrical Connection and Up and Running sections and be satisfied
   that your system complies.

2. Is there sufficient wind? The Rutland 913 needs 5 knots wind speed to start
   charging. The wind speed across the turbine blades may be greatly reduced in a
   marina or built-up area compared with the reading on a masthead anemometer or
   weather reports.

3. Static Tests:
· Is the battery in good condition? Check the voltage and electrolyte level of
   each battery.
· Check electrical continuity throughout the system, especially corrosion and
   poor connections in cable joins and connector blocks.

4. Running Tests:
· Check for power output from the windcharger, following this procedure:
A. Set a digital multimeter to DC Amps, scale of between 5 and 10 if possible.
   Connect the meter positive (+) probe to the wind generator output positive cable
   and the meter negative (-) to the regulator input positive. Provided there is
   sufficient wind there should be a current reading. This establishes that power is
   being delivered.
B. Using the same multimeter setting as above measure between the regulator to
   battery + and the battery +. Provided there is sufficient wind there should be a
   current reading. This establishes if power is passing through the regulator.
C. If both above are unsuccessful set the multimeter to DC Volts. Disconnect the
   wind generator from the regulator and connect the meter + to the wind
   generator + and the meter ­ to the wind generator -. Provided there is sufficient
   wind there should be a variable voltage reading according to the speed of the
   wind seen at the wind turbine. This will establish if the wind generator is able
   to deliver power or not.
D. If tests A and C are successful but test B fails to produce results connect the
   wind generator directly to the battery. Set the digital multimeter to DC Amps
   and measure power between the wind generator + and the battery +. If a
   reading is measured, providing there is sufficient wind, then the regulator is
E. If the wind turbine fails to deliver any current or open circuit V reading
   undertake the further tests below.

Document SM-130 Issue G 26.10.06         15                   Marlec Engineering Co Ltd
Rutland 913 Windcharger                                                  Owner's Manual

5. Mechanical inspection. It may be necessary to remove the windcharger from
   its pole for the following tests.

· Check the brushes and slipring for wear or damage. To inspect the brushes,
  remove the nacelle by removing the three fixing screws and slide the nacelle
  backwards towards the tail fin. The brushes and slipring can be inspected by
  removing the four self-tapping screws holding the brush holder assembly in
  place. Remove any black deposits from slipring with emery paper. Heavy
  deposits and reduced power indicate a possible reverse connection to the battery
  (see Page 10).

· Check hub for free rotation with generator disconnected from battery.
  If the hub does not rotate freely, check for a possible short circuit in the wiring.
  If no wiring fault is found refer to your dealer or manufacturer.

    If the above checks have identified a need for spare parts or failed to identify
    the problem you should contact Marlec who can advise you of your nearest
    distributor in their world wide network. In the first instance we recommend
    that you contact the company from whom the product was originally

If in doubt, refer to your dealer or manufacturer.

Document SM-130 Issue G 26.10.06          16                    Marlec Engineering Co Ltd
Rutland 913 Windcharger                                                   Owner's Manual

For your future reference we recommend you note the following:

Serial Number:

Date of Purchase:

Date of Installation:

Type of Regulator:

Document SM-130 Issue G 26.10.06          17                     Marlec Engineering Co Ltd
                            LI M I T E D W A R R A N T Y

The Marlec Engineering Company Limited Warranty provides free replacement cover for
all defects in parts and workmanship for 12 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 are so found by Marlec upon
inspection. A valid proof of purchase will be required if making a warranty claim.

Defective parts must be returned by prepaid post to the manufacturer Marlec Engineering
Company Limited, Rutland House, Trevithick Road, Corby, Northamptonshire, NN17
5XY, England, or to an authorised Marlec agent.

This Warranty is void in the event of improper installation, owner neglect, misuse, damage
caused by flying debris or natural disasters including lightning and hurricane force winds.
This warranty does not extend to support 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. No responsibility is assumed for damage caused by user
modification to the product or the use of any unauthorised components.

No responsibility is assumed for use of a non "furling" versions of the Rutland
Windcharger where Marlec or one of its authorised agents finds that a generator
incorporating a furling device should have been used.

                                Manufactured in the UK by
                                Marlec Engineering Co Ltd
                                      Rutland House,
                                      Trevithick Rd,
                                    Corby, Northants,
                                      NN17 5XY UK
                     Tel: +44 (0)1536 201588 Fax: +44 (0)1536 400211

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