Sunset Marlec HRSi User guide

HRSi Charge Regulator Installation and Operation

RUTLAND HRSi

CHARGE REGULATOR

INSTALLATION AND OPERATION

Doc No : SM-346 Issue B 24.04.08 Marlec Engineering Co Ltd

HRSi Charge Regulator Installation and Operation

Introduction

Congratulations and thank you for purchasing Marlec’s HRSi Charge Regulator.

This is the latest technology for voltage regulation of small Rutland wind turbines and solar panels.

Summary of Features & Uses

• Protects batteries from overcharging.

• Protects electronic equipment from high battery voltage damage.

• Automatic 12 Volt or 24 Volt setting.

• Temperature compensation for optimum charge regime.

• Multi stage charging for optimum charge regime.

• Built in charge / stop switch for installation & maintenance.

• For use with Rutland 503, 504, 913, 914 and FM-910-3 Windchargers.

• Additional input for up to 160Watts of solar panels.

• May be connected in parallel with other charge sources (not through the HRSi)

• For use with a single battery bank.

HRSi Layout & Main Features

Charge status LED - illuminates ONLY
when charging or regulating are taking
place.

Symbols
explaining
functions.

Battery status LED - illuminates at all times
battery connection is maintained.

Wall mounting
fixing hole.

Ventilation
slots that must
never be
obstructed.

Charge / Stop Switch shown in stop
position as used for installation /

Wiring block for inputs from Windcharger

and solar panels and output to battery bank.

maintenance.

Doc No : SM-346 Issue B 24.04.08 Marlec Engineering Co Ltd

HRSi Charge Regulator Installation and Operation

Ten Step Quick Start Guide

The sequence of connection is critical to the voltage set up of the HRSi. Follow these
instructions carefully to ensure no connections are live. See Fig 2 for guidance.

1. Select a covered dry wall location in a ventilated area close to the batteries.

2. Select cables and connectors that will continuously carry a minimum of 10 Amps. No less than

4.0 mm² gauge cable should be used to provide the link from the HRSi to the battery.

3.

Cut the minimum cable necessary to link the HRSi to the battery, thus avoiding voltage drop and
ensuring accurate voltage sensing. The maximum recommended length is 1.5m.

4. Caution. Before any connections to the HRSi are made, cover any solar panels and restrain the
Windcharger from turning. Ensure that any other charge sources to the battery are stopped.

5. Set the HRSi Charge / Stop switch to the Stop position.

6. Connect the 2 Windcharger cables to the Windcharger positions ( WG + & WG - ) and the solar
panel cables to the solar panel positions ( PV + & PV - ) ensuring correct polarity is observed.
Note : Solar panels must be fitted with appropriate blocking diodes , parallel panels having one
each. Keep the solar panels covered and Windcharger tied.

7. Connect the battery link cables to the HRSi battery positions, (BAT+ & BAT- ).

8. Connect the other ends of the battery link cables to the battery terminals, ( + & - ) ensuring

correct polarity. This senses the battery voltage and establishes 12V or 24V operation.

9. Uncover any solar panels and untether the Rutland Windcharger.

10. Move the Charge / Stop switch to the Charge position and the system is operational.

Operating Principles

The HRSi Regulator protects batteries from overcharge. It uses pulse width modulation and
multi-stage charge technology to maximise the power delivered to and retained in the battery. In the
bulk/absorption phase all the available wind and solar power is used to charge the battery as quickly
as possible. The float phase ensures charge is maintained whilst minimising gassing thus prolonging
battery life. Any discharging of the battery recommences this cycle.

The temperature compensation feature automatically adjusts the voltage regulation settings according
to deviations of ambient temperature from 25°C. The pre-programmed settings are suitable for lead
acid, AGM (absorbed glass matt) and most Gel type batteries. Other settings are available, contact
Marlec to discuss your requirements. Default settings are:

Nominal Battery Voltage at 25°C 12V 24V

Maximum Float Voltage at 25°C 13.8V 27.6V

Maximum Bulk Voltage at 25°C 14.4V 28.8V

Doc No : SM-346 Issue B 24.04.08 Marlec Engineering Co Ltd

HRSi Charge Regulator Installation and Operation

Understanding The LED

Operating Symbols

LED
Colour

Green

Amber

Red

No LED
lit

Flashing
Red

Symbol

All available wind and solar

The HRSi is starting to

The HRSi is fully regulating

Charge Status LED

What is happening ?

power is charging the
battery.

regulate. Current is flowing
to the battery at a reduced
rate. The Windcharger may
slow down.

and no charge current is
flowing to the battery. The
Windcharger will run at a
slow “idle” speed.

Windcharger not rotating
fast enough to produce a
current or insufficient
sunlight to generate power.

Symbol

Battery voltage is above 13 V

Battery voltage is between 12 V

Battery voltage is below 12 V

Battery Status LED

What is happening ?

( 26 V ).

and 13 V ( 24 V and 26 V ).

( 24 V).

HRSi to battery connection not
established or broken.

Battery voltage is below 11V at
25°C. Switch load off to avoid
deep discharge to the battery.

Doc No : SM-346 Issue B 24.04.08 Marlec Engineering Co Ltd

HRSi Charge Regulator Installation and Operation

Easy Steps To Avoiding Damage To

The HRSi Charge Regulator

1. During installation or maintenance set the Stop position. See Fig 1 :-

2. Do not use the Stop switch to brake a speeding Windcharger.

3. During installation the first “live” connection must be to the battery.
This configures the 12V or 24V operation.

4. Never disconnect the HRSi from the battery unless the Stop switch is
activated and ensure reconnection is made before returning to the Run
position. Any on-board battery management systems must not break this
connection.

5. Never connect an open circuit running Windcharger to the HRSi as this

will cause permanent damage.

6. Never make the connection of a solar panel in direct sunlight to the HRSi .

7. Do not exceed the recommended 160W of solar panels.

8. Always fit an appropriate blocking diode to each solar panel input.

9. Never connect the HRSi to the battery or any charge sources in reverse polarity.

10. Avoid exceeding the recommended wiring distance between HRSi and battery. Longer distances
require heavier gauge cable or charging efficacy will be affected.

11. Never obstruct the ventilation slots of the HRSi.

12. Note that in high levels of auxiliary charge, eg from an engine, the HRSi may enter regulating
mode and thus the windcharger will run at a slow speed.

Please take note of these steps to avoid the loss of warranty cover.

Fig 1 Charge / Stop

Switch

STOP

CHARGE

Doc No : SM-346 Issue B 24.04.08 Marlec Engineering Co Ltd

HRSi Charge Regulator Installation and Operation

WG -Windcharger

Cut Away of HRSi Wiring Block

WG+ WG– PV+ PV- BAT+ BAT-

HRSi Charge Regulator

PV— Solar Module

(Max 160 W)

BLOCKING DIODE

MUST BE FITTED*

Wiring block

* Parallel panels each
require a blocking diode .

Battery

Fig 2 Basic Wiring Scheme

Doc No : SM-346 Issue B 24.04.08 Marlec Engineering Co Ltd

HRSi Charge Regulator Installation and Operation

Doc No : SM-346 Issue B 24.04.08 Marlec Engineering Co Ltd

HRSi Charge Regulator Installation and Operation

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: [phone]

Fax: [phone]

Email: [e-mail]

www.marlec.co.uk

Doc No : SM-346 Issue B 24.04.08 Marlec Engineering Co Ltd