Marlec Rutland FM1803-2 Furlmatic, Installation & Owner'S Manual

Page 1: ...Document No SM 146 Issue G 01 11 20 Rutland FM1803 2 Furlmatic Windcharger Turbine MPC2 Controller Installation Owner s Manual ...

Page 2: ...nstallation Operation Document No SM 146 Issue G 01 11 20 Marlec Engineering Co Ltd 1 GENERAL SCHEMATIC Note The schematic also shows an optional solar panel charging system connected in parallel to the same battery bank ...

Page 3: ...HE TURBINE 10 Blade Hub Assembly 10 Tail Assembly 12 Tower Preparation 13 Control Unit Installation 14 BATTERIES 15 CABLE SPECIFICATION 16 FUSES 16 ELECTRICAL CONNECTION 17 CONTROL UNIT WIRING 18 FITTING THE GENERATOR TO THE TOWER 20 Final Mechanical check 20 UP AND RUNNING 21 LCD Display Features Explained 21 OPERATION EXPLAINED 22 Backlight 22 Low High Wind Modes 22 Manual Shutdown 22 Batteries ...

Page 4: ...th the risks associated with electrical and mechanical installation and if in doubt seek professional advice The key safety risk factors to be assessed are The rotating turbine Risk of injury to persons Install the turbine at a location and height where persons cannot interfere with the path of the blades No attempt to access the turbine should be made until it has been restrained from turning if ...

Page 5: ...eck that the voltage indicated on the connection label and the side of the housing corresponds with your battery voltage Temperature Sensor packed with control unit 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 36mm s...

Page 6: ...d 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 locating the turbine...

Page 7: ...its 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 The post adaptor is designed to be fixed to the mounting pole and the cable exits to the inside of the mounting pole Tail Assembly The inclined tail fin is hinged to the r...

Page 8: ...rge mode Note 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 Marlec for advice on factory setting or the interface cable and PC app Remote NTC Temperature Sensor Temperature compensation ensures that the battery voltage sw...

Page 9: ... 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 A RJ11 Serial Data output is provided for connection of other devices e g Computer which can read serial data This requires a special interface cable and PC app Some operating parameters can be changed using bespoke PC app contac...

Page 10: ... 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 install...

Page 11: ...ND INSTALLATION OF THE TURBINE Blade Hub Assembly Fig 3 Blade Hub Assembly Correct position of front hub plate to locate nose cone fixing holes Nose cone fixing boss 3 fixings Flat Side of Blade faces the wind Front Hub Plate Rear Hub Plate Windshaft note socket at end to place 8mm Allen key to hold during assembly ...

Page 12: ...ust comes up against the front plate 5 Pull the rotor assembly forward slightly rotate as necessary to align the hexagonal hole in the front plate over the M24 nut 6 Rotate the whole rotor assembly clockwise to thread the nut onto the windshaft The windshaft can be held using an 8mm Allen key in the socket in the end of the windshaft Alternatively hold the rotor assembly still rotate the windshaft...

Page 13: ...the short tab against a flat on each screw head Bend the long tab so that it follows the circumference of the pole tap lightly with a mallet to maintain the curve this prevent screws from working loose in service Tighten to a torque of 20Nm Note When fitted the tail fin will be inclined 15 to the vertical This must be maintained to ensure effective operation of the furling mechanism in high winds ...

Page 14: ...h four positions diametrically opposite at 45 to the pipe seam if necessary 20mm from the top of the tube 2 Drill four holes 12 5mm in diameter on centre punch positions remove burrs 3 Ensure that the top section of the mounting pole is no more than 90mm outside diameter This is essential to ensure that blade running clearance is achieved This top section may then be securely attached to a wider s...

Page 15: ... the batteries 2m length of the main battery leads is recommended as a maximum The unit should be protected from battery fumes from vented batteries The control unit is fan cooled and ventilation of a minimum of 10cm is required above and below the unit These vents must not be covered or obstructed The unit is not weatherproof and therefore must be suitably protected indoors If selected position a...

Page 16: ...rms of charge discharge cycles must be used Suitable battery chemistries include lead acid sealed non sealed Absorbed Glass Mat or Gel Other types can be used but may require different regulating voltage settings These can be factory set when ordering or using a Marlec interface cable and PC app Minimum battery capacities recommended 400Ah 12v 200Ah 24v 100Ah 48V Only batteries of similar type cap...

Page 17: ...anded cable Minimum 10mm and 1 5m length Remote Temperature Sensor 1 5m cable supplied with controller Remote Voltage Sensing Wires A pair of conductors 0 5 to 0 75mm from the battery terminals to the controller Optional to fit where 1 5m battery cables are used Caution System performance and safety are compromised if smaller cable sizes are installed and there is risk of electrical damage in high...

Page 18: ...s from the control unit front panel see Fig 6 As the panel lifts away unplug the LCD connection ribbon cable from the PCB in the main housing 4 Using the cables selected pass each through the grommeted holes in the base of the control unit The grommets can be replaced by M20 glands if preferred Ensure the battery cables are not yet connected to the battery i e DO NOT MAKE LIVE CONNECTIONS 5 Make t...

Page 19: ...polarity or colour sequence required Battery Connections CAUTION Do not reverse or allow contact to cross over Remote Sensor optional connect required length to battery and Remote Shutdown optional volt free contact connect RJ11 Serial Data port optional See page 8 for pin outs Remote Temperature Sensor supplied Installation recommended Voltage Identification label according to unit supplied Earth...

Page 20: ...Rutland FM1803 2 Installation Operation Document No SM 146 Issue G 01 11 20 Marlec Engineering Co Ltd 19 Fig 11 Control Unit Connections ...

Page 21: ...is is shown in Fig 12 3 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 4 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 5 Secure the wind...

Page 22: ...rve correct polarity when connecting the batteries otherwise serious damage will result 4 At power up the LCD backlight will switch on and a brief introduction screen displays system voltage detected serial number firmware revision The controller starts in manual shutdown mode with the turbine stalled then defaults to the screen below battery voltage will be as the system connected The backlight r...

Page 23: ...w wind mode the bottom line will display with a left moving arrow to show it is about to change to low wind mode when it changes Low Wind will display this on the screen Manual Shutdown At any time while the turbine is running if Run Stall button is pressed for 3 seconds the controller will enter MANUAL SHUTDOWN mode and stall the turbine the display backlight will light and remain lit This mode o...

Page 24: ... temperature the cooling fan will automatically switch on when the sensors detect a high temperature within the controller components If an over temperature occurs the turbine will stall the source of the over temperature will display on the screen when the over temperature subsides the control unit will resume normal operation re start the turbine The backlight will switch on remain on for the du...

Page 25: ...ANCE The curve shown below is for ideal non turbulent wind conditions this may not be achieved in some installations Note Charge current Amps of the 48V is calculated by 24V charge current x 0 5 Tower Top Weight 35 32Kg Shipping Dimensions 1 pallet 1200x675x520mm 74Kg Controller Dimensions 310x290x147mm 12Kg Outline Dimensions mm ...

Page 26: ...e 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 be lowered to the ground or secured to prevent the generator from t...

Page 27: ... Note that once fully charged the system remains stalled until the battery voltage level reaches a lower limit for auto re starting Re start can be manually invoked by 1 short press of the run stall button when the backlight is on i e 2 short presses when the backlight is off Is a battery connected to the control unit Check that a battery voltage displays on the LCD Is the battery in good conditio...

Page 28: ...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 29: ...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 30: ...mited Rutland House Trevithick Road Corby Northamptonshire NN17 5XY England or to an authorised Marlec agent The Warranty is made void in the event of improper installation owner neglect misuse damage caused by flying debris or natural disasters including lightning strikes and hurricane force winds This Warranty is made void where a non Terrain or furling model is installed on land This Warranty d...