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' Rutland Fm 910 3 Manual Issue D'


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  Rutland Furlmatic 910-3 Windcharger
            Owners Manual

Document No: SM124 Issue D 30.01.07
Marlec Eng Co Ltd                                                     Installation Instructions


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


                     Final Mechanical Check............................... 13

BASIC WIRING DIAGRAMS.............................................. 14

UP & RUNNING..........................................................          15

SPECIFICATION & PERFORMANCE.................................... 15

INSPECTION & MAINTENANCE...................................                     16

TROUBLESHOOTING.....................................................            17

Document No: SM124 Issue D 30.01.07          1
Marlec Eng Co Ltd                                                     Installation Instructions


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.


· 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.

Document No: SM124 Issue D 30.01.07          2
Marlec Eng Co Ltd                                                     Installation Instructions

· 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

Document No: SM124 Issue D 30.01.07          3
Marlec Eng Co Ltd                                                     Installation Instructions


·   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.



·   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

Document No: SM124 Issue D 30.01.07          4
Marlec Eng Co Ltd                                                          Installation Instructions

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

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.

                                                      AREA OF TURBULENCE



               2H                                      20H

Document No: SM124 Issue D 30.01.07          5
Marlec Eng Co Ltd                                                     Installation Instructions



         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

Document No: SM124 Issue D 30.01.07            6
Marlec Eng Co Ltd                                                     Installation Instructions


         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
         · 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.

                                  Fig.2                                               Fig.3

                                                                     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.
Document No: SM124 Issue D 30.01.07            7
Marlec Eng Co Ltd                                                     Installation Instructions


         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).



Document No: SM124 Issue D 30.01.07            8
Marlec Eng Co Ltd                                                     Installation Instructions

         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

         Fig. 5

            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)

Document No: SM124 Issue D 30.01.07            9
Marlec Eng Co Ltd                                                     Installation Instructions

         Tower Preparation (Fig. 6)

         Having selected a suitable pole from the guidelines on page 7:

         1. The post adaptor fitted to the FM910-3 is designed to fit inside a
           standard 41mm (1") internal diameter tube. The adaptor 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 the 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 Land Tower Kit, items 2 and 3 can be ignored as
the unit is pre-drilled.


Document No: SM124 Issue D 30.01.07            10
Marlec Eng Co Ltd                                                          Installation Instructions

         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

         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.

         We strongly recommend that one of the voltage regulators available from
         Marlec is fitted to prevent batteries becoming overcharged in strong winds
         and is essential with gel/sealed batteries.

         Batteries may be linked as follows:

         · In parallel to increase amp hours (Fig.6).

         · In series to increase voltage (Fig.7).

                                             Red is + Positive
                                             Black is - Negative

                                     Fig.6                                                    Fig.7
                    Total = 12v                                       Total = 24v
                            120Ah                                             60Ah
                            1440Wh                                            1440Wh


                                                                    12v                 12v
                         12v                                       60Ah                60Ah


Document No: SM124 Issue D 30.01.07            11
Marlec Eng Co Ltd                                                      Installation Instructions

         The cable used for connection of the Windcharger to the batteries should be
         in accordance with table 1. The use of a smaller cable than recommended
         will reduce the performance of the charging system.

         Cable and connectors are available from your dealer or the manufacturer.

            Cable Run    Cable Size       Cable Size
               (m)         (mm˛)            (mm˛)
                          12 Volt          24 Volt
              0-20          2.5              1.5
              21-30          4               2.5
              31-45          6                4
              46-80          10               6


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

         2. Select one of the 2 basic systems on page 14 and follow the manual
            provided with the charge regulator selected.

         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. 8
                                                                  20A Fuse
                                                                  and Fuse holder

         4. Connect the Wincharger flying lead to the cable protruding from the top
            of the tower using the connector block supplied, taking care to observe
Document No: SM124 Issue D 30.01.07            12
Marlec Eng Co Ltd                                                     Installation Instructions

            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 the
            environment. Alternatively join the cables using a latching type plug and

         6. Locate the Windcharger into the tower whilst gently easing the cable
            from the tower base to ensure the cable is not trapped. Secure the
            Windcharger to the tower using the button cap screws and shake-proof
            washers provided. Tighten using the 6mm Allen key supplied.


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

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

Document No: SM124 Issue D 30.01.07            13
Marlec Eng Co Ltd                                                      Installation Instructions

         Regulator and Fuse
         Wiring Diagram

              FM910-3 WIND

                     RED                                       BROWN

                    BLACK                                      BLACK

                                                       CHARGE FUSE


         Charge Controller
         Wiring Diagram

            FM910-3 WIND



                                             BATTERY              BATTERY

Document No: SM124 Issue D 30.01.07            14
Marlec Eng Co Ltd                                                                                        Installation Instructions


   · 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.


                                                  14                                                                         7

                                                                                                                                 CHARGE CURRENT INTO 24v BATTERY (AMPS)
                                                  12                                                                         6

                                                  10                                                                         5

                                                  8                                                                          4

                                                  6                                                                          3

                                                  4                            WINDSPEED CONVERSION                          2

                                                                                    MPH = M/S x 2.23
                                                  2                                 Knots = M/S x 1.94                       1

                                                  0                                                                          0
                                                       0   5   10   15        20         25     30           35         40
                                                                         WINDSPEED M/S

Document No: SM124 Issue D 30.01.07            15
Marlec Eng Co Ltd                                                     Installation Instructions


   The Rutland Furlmatic 910-3 requires no scheduled maintenance but an annual
   inspection should be carried out to monitor the general condition of the system.

· 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 follow
  one of the procedures below:

1) Lower the windcharger on its tower to the ground, coming to rest on a structure
   that will prevent the windcharger from striking the ground. Take care that all
   persons are clear of the area. The turbine will eventually slow down. Tie a blade
   to the mounting pole to prevent it from rotating.

2) If the tail boom is safely accessible, using the tail boom, rotate the generator out
   of the wind; the turbine will eventually slow down. 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 blade screws for tightness.
2) Check all other nuts, bolts and screws for tightness.
3) Check the yaw axis for free rotation.
4) Check the tail fin moves freely.
5) Check tower assembly for condition.
6) Check the tension of the guy wires if applicable. The tension of guy wires
   should be checked frequently during the first year.
7) The unit can be wiped with a mild detergent and rinsed with water to remove
   dirt and debris.

Document No: SM124 Issue D 30.01.07            16
Marlec Eng Co Ltd                                                     Installation Instructions


In the unlikely event that your Rutland Furlmatic 910-3 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 (page 12) and Up & Running (page 15)
   sections and be satisfied that your system complies.

2. Is there sufficient wind? The Rutland 910-3 needs approximately 5 knots wind
   speed to start charging. The wind speed across the turbine blades may be greatly
   reduced in built-up area compared with weather reports for example.

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 gen +
   and the meter ­ to the wind gen -. 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 gen directly to the battery. Set the digital multimeter to DC Amps and
   measure power between the wind gen + and the battery +. If a reading is
   measured, providing there is sufficient wind, then the regulator is faulty.
E. If the wind turbine fails to deliver any current or open circuit V reading
   undertake the further tests below.
5. Mechanical inspection. It may be necessary to remove the Windcharger from
Document No: SM124 Issue D 30.01.07            17
Marlec Eng Co Ltd                                                     Installation Instructions

   its pole for the following tests.

· Check the brushes and slipring for wear or damage. To inspect the brushes,
  remove the cover from the main housing by removing the four fixing screws.
  The brushes and slipring can be then 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 11).
· 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 No: SM124 Issue D 30.01.07            18
Marlec Eng Co Ltd                                                     Installation Instructions


Document No: SM124 Issue D 30.01.07            19
Marlec Eng Co Ltd                                                     Installation Instructions


Document No: SM124 Issue D 30.01.07            20
Marlec Eng Co Ltd                                                     Installation Instructions

                             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 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

Document No: SM124 Issue D 30.01.07            21

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