Rutland Furlmatic FM1803 Owner'S Manual Download

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Rutland FM1803-2

Installation & Operation

Document No: SM-146 Issue D 14.03.08

Marlec Engineering Co Ltd

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

Summary of Contents for Furlmatic FM1803

Page 1: ...Document No SM 146 Issue D 14 03 08 Rutland FM1803 2 Furlmatic Windcharger Owners Manual ...

Page 2: ...Rutland FM1803 2 Installation Operation Document No SM 146 Issue D 14 03 08 Marlec Engineering Co Ltd 1 ...

Page 3: ...ION 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...

Page 4: ...ge 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 fi...

Page 5: ...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 ...

Page 6: ...e 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 t...

Page 7: ...ssembly 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 d...

Page 8: ...t 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...

Page 9: ...ode 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 ...

Page 10: ...ing 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 co...

Page 11: ...ent 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 ...

Page 12: ...Rutland FM1803 2 Installation Operation Document No SM 146 Issue D 14 03 08 Marlec Engineering Co Ltd 11 Fig 2 Typical Tower R4400 1300 2600 2600 ...

Page 13: ...lade 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 screw Spinner fixing boss ...

Page 14: ...ve 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...

Page 15: ...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 ...

Page 16: ...al 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...

Page 17: ...it 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...

Page 18: ...ealer 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 combinatio...

Page 19: ...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 10mm 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 insta...

Page 20: ...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 g...

Page 21: ...method of achieving this is shown in Fig 11 Carefully locate the wind generator post adaptor into the top of the tower ensuring the flat on the post adaptor aligns with the pipe seam if necessary Push the adaptor into the tower while the cable is gently pulled from the tower base to ensure it is not trapped continue until the post adaptor is fully inserted into the tower and the fixing holes align...

Page 22: ...ition Take care to avoid all moving parts when raising and lowering the wind generator When raised secure the structure firmly in an upright position The performance of your Windcharger can be impaired if the pole is not vertical Connect the battery cables to the battery terminals using suitable permanent connections It is vital to observe correct polarity when connecting the batteries otherwise s...

Page 23: ...urbulent wind conditions this may not be achieved in some installations Tower Top Weight 35 32Kg Shipping Dimensions 1 pallet 1200x675x520mm 74Kg Controller Weight 9 94Kg CHARGE CURRENT v WINDSPEED 0 10 20 30 40 50 60 70 0 5 10 15 20 25 30 35 40 WINDSPEED M S CHARGE CURRENT INTO 12V BATTERY AMPS 0 5 10 15 20 25 30 35 CHARGE CURRENT INTO 24V BATTERY AMPS Outline Dimensions mm ...

Page 24: ...ed to determine future scheduled maintenance A maintenance schedule sheet is provided for convenience It is recommended that the maintenance schedule is completed kept safe available if contacting the manufacturer for advice or technical information From the findings of the 3 6 12 months inspections the user should determine a suitable service interval Before inspection the turbine should either b...

Page 25: ...s lit it indicates that the battery is fully charged the wind generator will be in stall mode Is a battery connected to the control unit Check the control unit LEDs if no LED is lit this indicates no battery connection to the control unit wind generator will be in stall mode Is the battery in good condition Check the voltage and electrolyte level of each battery Check electrical continuity through...

Page 26: ...ge Remarks Control Unit Serial Number Battery Capacity Battery Type Tower Height Date of Installation Service Interval 3 months 6 months 12 months Check Date Remarks Date Remarks Date Remarks Blade Bolts All other nuts bolts Turbine for smooth free rotation Yaw axis for smooth free rotation Tail hinge for smooth free rotation General Condition Tower assembly condition Guy wire tension if applicabl...

Page 27: ...m Voltage Remarks Control Unit Serial Number Battery Capacity Battery Type Tower Height Date of Installation Service Interval Check Date Remarks Date Remarks Date Remarks Blade Bolts All other nuts bolts Turbine for smooth free rotation Yaw axis for smooth free rotation Tail hinge for smooth free rotation General Condition Tower assembly condition Guy wire tension if applicable ...

Page 28: ...ve parts must be returned by prepaid post to 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 or natural disasters and does not extend to support posts inverters or batteries No responsibility is assumed for incidental or consequential d...

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