Capstone Document Library/Application Guides
Contents
1. cccccccecceeeeessssneeeeeeeeesssssneaseeeeeeeesssssnaees 12 Figure 3 Installing Mounting Frame to MICroTUIbDING ccccccssseeeeeseseneeeeeesssneeeeeeesseseeeeeeeeees 13 PIGUFEA Liting the Air PACK iichiceisssnacte tecatstussbsubsiecatin a E a 14 Figure 5 ARM Rain OOO sisstierieinssirrettivn n a T O 14 Figure 6 Installing Air Pack on Mounting Frame scccccceeesssssneeeeeeeesssssenaeeeeeeeesssesenaeeeeees 15 Figure 7 View of HRM Showing Rain Hood and Drain Pipe cccsscceeessssseeeeeessssseeeeeeess 16 Foures IMStalling AI OUTET IAIN sxt 6ehereciet cho taco a de ete cede eat 17 Figure 9 Connecting Conduit with 3 Wires to UCB without Precharge cccccssseeeessneees 19 Figure 10 Wiring Between DC Air Pack and UCB without Precharge cceeeeeeeeeeeeees 20 Figure 11 Connecting Conduit with 3 Wires to UCB with Precharge cccceseeeeeeee 21 Figure 12 Installing Conduit with 4 Signal Wires to Bottom of UCB ccceecseeeeessssteeeeeees 22 Figure 13 Connectors J12 and J15 on UCB BOald cccccccesssseeeessseeeessseeeeessseeeeeesseeeeesssaes 23 480038 Rev A March 2008 Page 4 of 32 Capstone reserves the right to change or modify without notice the design specifications and or contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction Capstone Turbine Corporation2. 480038 Rev A March 2008 Page 22 of 32 Capstone reserves the right to change or modify without notice the design specifications and or contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction Capstone Turbine Corporation e 21211 Nordhoff Street e Chatsworth e CA 91311 e USA Capstone Air Pack Installation Procedure A CUL E Tsg o W 1 Wa wos bh Tham a ior M tl ia IEn mya erm WE Terminal J15 Terminal Block pobre ra as a Ten ATN Lt bem ian La F E P F b F N i 1 d E ns I a r Seam AS TE Ke ore hese anita Pe smmm a tE U Ty HE 1 a Lb yates eee fey Woe ICG ony Nee Ls i N gt p ai E i He hs z 7 k i at n 2 _ E yp j i n a E ea mie T J a m oy bi 7 hy pimi 3 va ri L i 2 ki b oA mags be 9 ii a re yj ose a nthe akaso START P E e aala E F eee Sali oie ah eh E J15 Pin 2 maai a vn y 7 ip Ji z f 4 3 i p i i prin eo frais cee 7 hae ie Ppi orgre L 7 pone J15 Pin 1 UCB Board Figure 13 Connectors J12 and J15 on UCB Board Table 2 UCB Board Wiring Connections Air Pack l Control Wire Color UCB Terminal 480038 Rev A March 2008 Page 23 of 32 Capstone reserves the right to change or modify without notice the design specifications and or contents of this document without in
3. 17 of 32 Capstone reserves the right to change or modify without notice the design specifications and or contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction Capstone Turbine Corporation e 21211 Nordhoff Street e Chatsworth e CA 91311 e USA Capstone Air Pack Installation Procedure Software Setup The following steps require a qualified Capstone ASP to perform CAUTION Program the MicroTurbine software before making any electrical connections to the Air Pack to prevent damage to the MicroTurbine Program the MicroTurbine software as follows 1 Ensure that there are no electrical connections between the MicroTurbine and the Air Pack 2 Power up the MicroTurbine only energize electrically but do not start the turbine a Ifthe MT with the mounted Air Pack is in Grid Connect mode ensure the utility facility AC breaker is on If the MT is in Stand Alone mode open the front door and turn on the battery breaker Close the front door and press the BATT START button on the display panel to wake up the system b Connect a laptop PC with CRMS software to the UCB Maintenance port J3 or User port J5 After successful login to the MT using CRMS select the MicroTurbine window then select the Relays window 3 Program the output relays as follows The Capstone software must be set up to treat the Air Pack as an External Auxiliary Load
4. able to supply the necessary 10 cfm cubic feet per minute air input at 65 psig to the turbine Refer to Work Instruction 440172 for procedures to install the External Air Assist Kit INSTALLATION OVERVIEW The installation of the Air Pack involves mechanical mounting an electrical harness connection including DC power interface and an air line outlet connection from the Air Pack to the MicroTurbine The Air Packs are provided as kits Each kit includes the required mounting hardware and an air outlet kit for installation and connection to the MicroTurbine MT Consult factory or your authorized Capstone distributor if needed to confirm which type of MTs are installed at a specific site NOTE The Air Pack Assembly weighs approximately 420 pounds Ensure 31 inches of rear service clearance to allow full swing access of NOTE the 27 inch Air Pack door Refer to O amp l Drawing 524089 100 for clearance information and dimensional requirements 480038 Rev A March 2008 Page 8 of 32 Capstone reserves the right to change or modify without notice the design specifications and or contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction Capstone Turbine Corporation e 21211 Nordhoff Street e Chatsworth e CA 91311 e USA Capstone Air Pack Installation Procedure Tools Required Use the Capstone s Recommended Tools
5. ao a Description Perform Software setup before any Air Pack electrical connections are made followed by power down of MT Using a voltmeter verify that no voltage exists in the High Voltage DC bay Make Electrical Connections per Step 1 of section for DC Air Pack Connect communication wiring per Step 1 d of the Electrical Connections section Replace UCB covers per Step 1 of Closeout amp Operational Check section 18 Visually check overall installation ee 480038 Rev A March 2008 Page 26 of 32 Capstone reserves the right to change or modify without notice the design specifications and or contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction Capstone Turbine Corporation e 21211 Nordhoff Street e Chatsworth e CA 91311 e USA Capstone Air Pack Installation Procedure APPENDIX A AIR PACK COMMISSIONING PROCEDURE AND CHECKLIST PURPOSE This Commissioning Procedure and Checklist presents information sufficient to allow an Authorized Service Provider ASP to properly verify that the Air Pack has been installed and configured correctly Before taking responsibility of the system and submitting the Commissioning Checklist to Capstone the ASP must perform and satisfy the procedures in this document COMMISSIONING PROCEDURE Perform the commissioning procedure as described in the following paragraphs Site Evaluation 1 C
6. e 21211 Nordhoff Street e Chatsworth e CA 91311 e USA Capstone Air Pack Installation Procedure USING THIS DOCUMENT This document provides specific instructions on how to properly install and interface the Capstone Air Pack with a C65 MicroTurbine This document should be used after the a access areas are reserved and documented b kit inspection inventory is complete c safety measures are in place and d necessary drawings are at hand as required Read this document completely before starting work An Installation Completion Checklist Table 3 with a column for signoff initials is provided within this document to record setup and verification of actual installation steps A signed copy of the checklist must be provided to Capstone Customer Service upon completion of installation Refer to the back of this document for Capstone contact information SYMBOLS There are three very important symbols used in this document Warnings Cautions and Notes Warnings and Cautions alert you to situations and procedures that can be dangerous to people and or cause equipment damage Notes provide additional information relating to a specific operation or task These symbols are as follows WARNING A Warning means that personal injury or death is possible CAUTION A Caution means that damage to the equipment is possible NOTE A Note is used to clarify instructions or highlight information that might be overlo
7. or in the process of construction Capstone Turbine Corporation e 21211 Nordhoff Street e Chatsworth e CA 91311 e USA Capstone Air Pack Installation Procedure INTRODUCTION The Air Pack is installed on the C65 Liquid Fuel LF model MicroTurbine MT It is mounted to the back of the C65 enclosure though it is not a part of the MicroTurbine itself The Air Pack provides air to the turbine during start and low power operations Figure 1 shows a MicroTurbine installation with the Air Pack MicroTurbine Air Pack Figure 1 MicroTurbine with Air Pack 480038 Rev A March 2008 Page 7 of 32 Capstone reserves the right to change or modify without notice the design specifications and or contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction Capstone Turbine Corporation e 21211 Nordhoff Street e Chatsworth e CA 91311 e USA Capstone Air Pack Installation Procedure Configuration Options The Air Pack is available only in a DC version that uses power from the MicroTurbine to operate The customer can choose to connect the MicroTurbine to facility air rather than install the Air Pack This requires the External Air Assist Kit to provide the interface between the MicroTurbine and the facility air supply It also requires that the facility air is
8. 400003 or equivalent to perform procedures listed in this document Additional tools materials required are as follows e Strap cutters e 2 Open End Wrench e 1 1 16 Open End Wrench e 1 1 4 Open End Wrench e 12 Adjustable Wrench e 15 Adjustable Wrench e 15 Crescent Wrench e Socket Drive e 7 16 Wrench e 7 16 Socket e 1 mm Wrench e 1 7mm Socket e 13mm Socket e 8mm Socket e Spanner bar for lifting Air Pack with eyebolts e Chain or cable rated for 1000 lbs minimum for lifting Air Pack e Pipe Wrench e Torque Wrench e Wire Stripper e Flat head Screwdriver e Gas pipe Teflon thread tape e Soldering iron solder and tinning flux e Soap solution brush for leak detection 480038 Rev A March 2008 Page 9 of 32 Capstone reserves the right to change or modify without notice the design specifications and or contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction Capstone Turbine Corporation e 21211 Nordhoff Street e Chatsworth e CA 91311 e USA Capstone Air Pack Installation Procedure Torque Requirements Torque requirements for fasteners used in this document are as follows e M8 Fasteners Up to 18 lb foot 24 4 Nm 5 e M10 Fasteners Up to 32 lb foot 43 4 Nm 5 Air Pack Installation Components Components used for installing the Air Pack are listed in Table 1 Table 1 Air Pack Installation Compone
9. Any of the output relays may be configured to perform this function however the specified wiring connections demonstrate the use of Relay 1 Using CRMS proceed as follows a On the UCB Relays menu Relay 1 submenu set EXT LOAD to ACTIVE CLOSED b On the System Settings menu Fault Input 1 submenu set Fault Input 1 to ENABLE and ACTIVE CLOSED On Fault Input 1 submenu set SSL to 3 and time to 12 seconds This fault input will be used to transmit fault indication from the Air Pack to the MicroTurbine 4 Power down the MicroTurbine as follows a Reverse Step 2a above i e open the utility breaker for Grid Connect mode or open the MicroTurbine battery breaker for Stand Alone mode b Lock out the utility breaker or the battery breaker as applicable c Wait five minutes for any capacitive voltage to dissipate 480038 Rev A March 2008 Page 18 of 32 Capstone reserves the right to change or modify without notice the design specifications and or contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction Capstone Turbine Corporation e 21211 Nordhoff Street e Chatsworth e CA 91311 e USA Capstone Air Pack Installation Procedure Electrical Connections 1 Make the Air Pack DC connections as directed in the following steps Verify that no voltage exists in the High Voltage DC bay before any installation work begins a Connect
10. Se Fitting ii epee 7 i My Figure 4 HRM Rain Hood The Air Pack Assembly weighs approximately 420 pounds Use WARNING appropriate lifting equipment At least one person is recommended to help keep the Air Pack steady during lifting and positioning operation 6 Using appropriate lifting equipment lift the Air Pack using the four eyebolts see Figure 5 until it completely clears the wooden pallet Use spanner bars to maintain load vertically on eyebolts Do not exceed a 22 angle from vertical on the lifting chain or cable If installing the Air Pack on an ICHP system make sure the lifting equipment clears the top of the Heat Recovery Module HRM Air Pack Figure 5 Lifting the Air Pack 480038 Rev A March 2008 Page 14 of 32 Capstone reserves the right to change or modify without notice the design specifications and or contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction Capstone Turbine Corporation e 21211 Nordhoff Street e Chatsworth e CA 91311 e USA Capstone Air Pack Installation Procedure 7 Lift the Air Pack and carefully align it above the mounting frame paying special attention to the outlet valve and inlet filter under the Air Pack and the hanging conduits Route the two conduits through the corner of the mounting frame near the inlet filter as you lower the Air Pack See Figure 6 Install the Air Pack i
11. W Capstone INN CAPSTONE TURBINE CORPORATION K A CAPSTONE AIR PACK INSTALLATION PROCEDURE 480038 Rev A March 2008 Page 1 of 32 Capstone reserves the right to change or modify without notice the design specifications and or contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction Capstone Turbine Corporation e 21211 Nordhoff Street e Chatsworth e CA 91311 e USA Capstone Air Pack Installation Procedure Copyright 2007 Capstone Turbine Corporation All Rights Reserved Publisher Capstone Turbine Corporation 21211 Nordhoff Street Chatsworth e CA 91311 e USA Telephone 818 734 5300 Facsimile 818 734 5320 Website www microturbine com 480038 Rev A March 2008 Page 2 of 32 Capstone reserves the right to change or modify without notice the design specifications and or contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction Capstone Turbine Corporation e 21211 Nordhoff Street e Chatsworth e CA 91311 e USA Capstone Air Pack Installation Procedure TABLE OF CONTENTS USING THAIS DOCUMENT ceinion bende eens ts iuieeehbhesneebene aes 5 oN Bs MEGS oer ee ene ene me ee ed eee ee 5 SAFE TY al pl 7718 eee ee nee ne ee Oe Pm nn ee ean 6 INTRODUCTION a tecisce ares etic 0 laachanie bab a reco naa tlele bel teins aaa A Commgurat
12. curring any obligation either with respect to equipment previously sold or in the process of construction Capstone Turbine Corporation e 21211 Nordhoff Street e Chatsworth e CA 91311 e USA Capstone Air Pack Installation Procedure Closeout 1 Replace the UCB covers 2 Visually check overall installation 3 Lock the control console door using the locking key located near the upper left corner inside the console Store the key in a safe place CAUTION The commissioning procedures must only be done by a Capstone Authorized Service Provider ASP 4 Perform the Commissioning Procedure and Checklist contained in Appendix A 480038 Rev A March 2008 Page 24 of 32 Capstone reserves the right to change or modify without notice the design specifications and or contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction Capstone Turbine Corporation e 21211 Nordhoff Street e Chatsworth e CA 91311 e USA Capstone Air Pack Installation Procedure Installation Completion Checklist Table 3 is a checklist to be filled as the installation progresses noting item complete signoffs and remarks of problems mitigations This document should be provided to the customer and Capstone along with a signed Commissioning Checklist See Appendix A Table 3 Installation Completion Checklist 2 Carefully remove shrink wrapping shipping straps and verify all parts ar
13. e present per Step 2 of Mechanical Installation section Locate mark and drill frame per Step 3 if required then install mounting frame heat deflector assembly to MicroTurbine per Step 4 of Mechanical Installation section 3 4 Lift Air Pack so it completely clears the pallet per Step 6 of Mechanical Installation section 5 ICHP Systems Only Remove the rain hood on the HRM per Step 5 of Mechanical Installation section If necessary install the handles on the outlet isolation valve per Step 8 of Mechanical Installation ICHP Systems Only Re install the rain hood on the HRM per Step 8 of Mechanical Installation section Install the air outlet kit per Step 10 of Mechanical Installation section 10 Clear the area per Step 11 of Mechanical Installation section 11 Re install MicroTurbine side panels per Step 12 of Mechanical Installation section 12 Remove UCB panel covers per Step 13 of Mechanical Installation section 480038 Rev A March 2008 Page 25 of 32 Capstone reserves the right to change or modify without notice the design specifications and or contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction Install Air Pack on the mounting frame per Step 7 of Mechanical Installation section Capstone Turbine Corporation e 21211 Nordhoff Street e Chatsworth e CA 91311 e USA Capstone Air Pack Installation Procedure
14. equipment previously sold or in the process of construction Capstone Turbine Corporation e 21211 Nordhoff Street e Chatsworth e CA 91311 e USA Capstone Air Pack Installation Procedure 4 If not already done remove the side panels from the MicroTurbine Install the mounting frame to the back of the MicroTurbine with the six M8 fasteners flat washers lock washers and stiffeners using a 13mm wrench and socket The stiffeners are installed inside the rear vertical MicroTurbine supports see Figure 3 Remove the packing material from the mounting frame Heat Deflector Mounting Frame M8 Fasteners Stiffener Behind Panel Inside Enclosure M8 Fastener Figure 3 Installing Mounting Frame to MicroTurbine 480038 Rev A March 2008 Page 13 of 32 Capstone reserves the right to change or modify without notice the design specifications and or contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction Capstone Turbine Corporation e 21211 Nordhoff Street e Chatsworth e CA 91311 e USA Capstone Air Pack Installation Procedure 5 For ICHP Systems Only Loosen the mounting screws for the rain hood at the back of the Heat Recovery Module HRM and lift the rain hood off of the HRM Also remove the pipe Tee fitting together with the vent screen and set aside see Figure 4 aa geared Rain Hood Vent Screen Do y Pipe Tee es
15. ground stud in HVDC bay wall using an 8mm socket wrench 480038 Rev A March 2008 Page 20 of 32 Capstone reserves the right to change or modify without notice the design specifications and or contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction Capstone Turbine Corporation e 21211 Nordhoff Street e Chatsworth e CA 91311 e USA Capstone Air Pack Installation Procedure High Voltage DC Power Bay Precharge Assembly Red Wire Left ee i i Figure 11 Connecting Conduit with 3 Wires to UCB with Precharge d Install the flexible conduit with four control signal wires to the bottom of the MT Communications bay on the UCB see Figure 12 The four wires are labeled with the connection locations Connect according to Table 2 Refer to Figure 10 and Figure 13 for UCB terminal locations 480038 Rev A March 2008 Page 21 of 32 Capstone reserves the right to change or modify without notice the design specifications and or contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction Capstone Turbine Corporation e 21211 Nordhoff Street e Chatsworth e CA 91311 e USA Capstone Air Pack Installation Procedure UCB Communications Bay Cable with ____ _ _ gt 5 4 wires Figure 12 Installing Conduit with 4 Signal Wires to Bottom of UCB
16. he process of construction Capstone Turbine Corporation e 21211 Nordhoff Street e Chatsworth e CA 91311 e USA Capstone Air Pack Installation Procedure COMMISSIONING CHECKLIST Cont d Page 2 of 2 Inspections Mechanical 1 Does the installation meet service access specifications 2 Has the entire air system from the Air Pack through to the Yes _ MicroTurbine inlet s been tested and fixed for leaks under Air Pack operating conditions 3 Is this an Indoor or Outdoor Installation and is it in a salt air Indoor environment Outdoor Salt air 4 Does the installation meet service specifications including the Yes No 31 inch clearance zone 5 Does the enclosure and conduit installation meet all Yes No mechanical and code requirements 6 Is installation properly corrosion proofed especiallly if in salt No air environment Electrical Communications 1 Are control wires run in a separate conduit from the power Yes INo_ cables 2 Are the proper color wires including chassis ground Yes connected to corresponding DC ground terminals of the MicroTurbine Follow all safety precautions 3 Are the metallic conduits for power wiring grounded at the penetration points for both the MicroTurbine and the Air Pack 4 Are the metallic conduits for the control wiring grounded at the penetration points for both the MicroTurbine and the Air Pack 5 Are the DC power cables inside liquid tight UL condu
17. it 480038 Rev A March 2008 Page A 4 Capstone reserves the right to change or modify without notice the design specifications and or contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction Capstone Turbine Corporation e 21211 Nordhoff Street e Chatsworth e CA 91311 e USA Capstone Air Pack Installation Procedure Responsibility It is the responsibility of Capstone to make these procedures available to the Authorized Service Providers so they can successfully complete this task It is the responsibility of the Authorized Service Providers to read this document understand its contents and effectively complete the procedures It is the responsibility of the Authorized Service Providers to submit the signed original of the Commissioning Checklist to Capstone within 30 days of commissioning for activation of warranty terms REFERENCE DOCUMENTS Table 4 lists applicable Capstone reference documents Table 4 Reference Documents Document Title 400001 C30 C60 MicroTurbine User s Manual 400017 C65 MicroTurbine User s Manual 522944 100 O amp l Drawing Liquid Fuel Stand Alone C65 400020 MicroTurbine User s Manual Addendum A 480038 Rev A March 2008 Page A 5 Capstone reserves the right to change or modify without notice the design specifications and or contents of this document without incurring any obligation either with respec
18. n Figure 7 O Rain Hood Drain Pipe Vent Screen Pipe Tee Fitting re Install at the end of the extended drain pipe g Air Pack M O O Figure 7 View of HRM Showing Rain Hood and Drain Pipe 480038 Rev A March 2008 Page 16 of 32 Capstone reserves the right to change or modify without notice the design specifications and or contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction Capstone Turbine Corporation e 21211 Nordhoff Street e Chatsworth e CA 91311 e USA Capstone Air Pack Installation Procedure 10 Install the air outlet kit and air filter as shown in Figure 8 Refer to O amp Drawing 522944 100 for installation details Use gas rated yellow tape or equivalent on all threaded joints NOTE The gas rated yellow thread tape or equivalent must be used on all threaded joints It should be wrapped 2 to 4 times around the threads in the direction of the threads The first outermost thread must be left bare Outlet Isolation Valve MT Air Pack Inlet 3 8 Inch NPT Connector ie ee 11 Close outlet isolation valve 12 Re install MicroTurbine s side panels 13 Remove UCB panel covers 480038 Rev A March 2008 9 oe Air Pack Air Filter Air Outlet Kit Figure 8 Installing Air Outlet Kit Page
19. n place with the M10 fasteners flat washers and lock washers using a 1 mm socket and wrench Mounting Frame Air Filter F PA i s View A i Route Conduits Here Figure 6 Installing Air Pack on Mounting Frame 480038 Rev A March 2008 Page 15 of 32 Capstone reserves the right to change or modify without notice the design specifications and or contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction Capstone Turbine Corporation e 21211 Nordhoff Street e Chatsworth e CA 91311 e USA Capstone Air Pack Installation Procedure 8 If not already installed install the handle on the outlet isolation valve using the nut and star washer on the valve body 9 For ICHP Systems Only a Re install the rain hood at the back of the Heat Recovery Module HRM see Figure 7 Tighten the rain hood mounting screws b Use NPT sealant on the following NPT connections Decide which side left or right of Air Pack is convenient for extending the drain pipe and install a 90 34 NPT fitting not supplied by Capstone to the drain pipe Install an extra piece of 34 NPT pipe threaded at both ends not supplied by Capstone to the 90 fitting Install the pipe Tee fitting to the end of the extended pipe with vent screen facing upwards not shown o
20. nts Part Number 523765 100 Air Pack Assembly DC w Outlet Kit Includes air outlet kit and air filter 480038 Rev A March 2008 Page 10 of 32 Capstone reserves the right to change or modify without notice the design specifications and or contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction Capstone Turbine Corporation e 21211 Nordhoff Street e Chatsworth e CA 91311 e USA Capstone Air Pack Installation Procedure INSTALLATION Mechanical Installation 1 Carefully remove the shrink wrap packing material and shipping straps without damaging side panels and vent covers 2 Identify the Air Pack Kit parts as follows The following components are included as part of the complete Air Pack Kit Confirm that all components are present before proceeding NOTE The stiffeners and fasteners may be found inside the Air Pack control panel turn the red handle switch to the Off position to open the panel door Air Pack Control Panel a Air Pack b Mounting Frame c Stiffeners with Heat Deflector d M10 Fasteners Qty 4 e M8 Fasteners Qty 6 d and e Fasteners f Air Outlet Kit f Air Filter 480038 Rev A March 2008 Page 11 of 32 Capstone reserves the right to change or modify without notice the design specifications and or contents of this document without incurring any obligation either with
21. oked 480038 Rev A March 2008 Page 5 of 32 Capstone reserves the right to change or modify without notice the design specifications and or contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction Capstone Turbine Corporation e 21211 Nordhoff Street e Chatsworth e CA 91311 e USA Capstone Air Pack Installation Procedure SAFETY PRECAUTIONS Do not operate the MicroTurbine the Air Pack or related equipment if a fuel leak is detected WARNING Read and understand the Safety Information section of the Capstone MicroTurbine User s Manual 400001 for C60 or 400017 for C65 and the User s Manual Addendum A 400020 before working on Capstone MicroTurbines the Air Pack and related equipment Failure to obey all safety precautions and general instructions may cause personal injury and or damage to the equipment Any work on fuel or electrical interfaces or internal Air Pack equipment is restricted only to a certified Capstone Authorized Service Provider ASP User personnel must not open or work on any Capstone equipment unless they have successfully completed the Capstone ASP training course 480038 Rev A March 2008 Page 6 of 32 Capstone reserves the right to change or modify without notice the design specifications and or contents of this document without incurring any obligation either with respect to equipment previously sold
22. omplete a thorough inspection of the Air Pack and all interfaces electrical mechanical and air 2 Make any adjustments or additions required to the existing installation before commissioning the system Mechanical Procedures 1 Air Pack door clearance Ensure 31 Inches of clearance to allow full Swing access of the 27 inch Air Pack door 2 Side Clearances Ensure that there is a minimum of 30 inches of clearance on the right and left sides of the Air Pack 3 Verify air tight integrity from the Air Pack through to the MicroTurbine inlet Electrical Procedures 1 Verify the chassis of the Air Pack enclosure is connected to a proper ground in the UCB as described in the Electrical Connections section 2 Ensure the power and control terminals are properly connected per interface definition in the Electrical Connections section 3 Ensure the control wires run in a separate conduit from the power cables 480038 Rev A March 2008 Page A 1 Capstone reserves the right to change or modify without notice the design specifications and or contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction Capstone Turbine Corporation e 21211 Nordhoff Street e Chatsworth e CA 91311 e USA Capstone Air Pack Installation Procedure Operational Procedures WARNING Do not ever start the MicroTurbine with the fuel supply OFF 1 Configure the Air Pack and MT fo
23. on OPUONS arig a a caede earcacna egies 8 INS TALLA TION OVERVIEW oreari aa a aa a ai 8 TOOS REJUNG Aesan E ene uote 9 Torgue ACQUIGMEGINS seriya a Maadeade baled 10 Air Pack Installation COmponentS sere T E 10 INS TALLA FION oisein a a E 11 Mechanical IMSTANATON sasic a E bumaennrretadeauilaws 11 SORAW OCTU ian EE TE 18 Heciical CONMECIONS sarritan a E a Phat A ks 19 Closeout and Operational CHECK isiru a 24 Installation Gompletion GHEGKIS t seire aire decease dened oss TEE EE EEEE ERETGE 25 AIR PACK COMMISSIONING PROCEDURE AND CHECKLIST ccccecsscesssseeeesseeeens A 1 PURPOSE reer a a E A 1 COMMISSIONING PROGE DURE oaresececieeecnebccescassostededteuetece vues utessecvassuncsssaceennc duvsteesee asel es A 1 icin 2 Be 10 eememateeee heroic eea ee E RAT ea nen nee ee een Cok eee er el ee eee eae eee A 1 Mechanical Procedures rocaid e thiersachlad te Ene A 1 Electnical Procedure Sassan eno aa O a dat A 1 Operational Procedi G Saraca a a a taeda leas A 2 ASP RESPONSIDIIIGS stiisdeo nianie e a d AEE E A 2 COMMISSIONING GHEGKKIEIS Treza AE A 3 CUStOMEr INONMA UO is E ere eed A 3 IA SEANATIOMIMOMMANON esse e RO A 3 MSPECTONS sisena T a E a mai A 4 Mechanical ssaa a be auntiiautateneneanudtos A 4 Eletica GC OMIMUMICAUONS sa ing his cccectecnasie cnc Saceieutesnacaleunctcxtedchad iaa a eia A 4 RoSPONSIDIII szasa a a A 5 REFERENCE DOCUMENTS orrs a wate etna aa A 5 CAPSTONE CONTACT INFORMATION oe tsscisccccececessnatteccinatescheessae
24. pstone C60 C65 MicroTurbine a eacanema Ereren S en ere 3 phase High Voltage JUCB Run Fault e AC DC f oo000 blold Chassis J12 J15 l oo0 0 0 Ground l u 14 Gauge FLT l2 3 4 Xx I 600 V Black i PGND eB i i Sake TE Ground ACI A l i Stud Chassis l Power E 14 Gauge i po l 600 V yal Red 600 Shield _ vee Green ss Rea PES re a ages ee caer D Eee eave ee ee eee ee ee oe i eee Mee eee te A EEE 1 2 inch Conduit UL a 2 A Gnd w 4 conductor 20 Gauge 1 2 inch Conduit UL A Shielded cable A E aa N E 2 I A 5 FLT AC1 B 1 i j AC1 A Figure 10 Wiring Between DC Air Pack and UCB without Precharge Ensure that the red wire is connected to the left terminal and CAUTION in Figure 11 black wire is connected to the right terminal and no bare wire is exposed after connecting the red and black wires as shown c For UCBs with a Precharge Assembly in HVDC Bay Cut away the Anderson connectors from the red and black DC power wires from the Air Pack Strip each wire end by 1 2 inch twist the wire strands and tin the stripped area Referring to Figure 11 insert the red wire fully into the left terminal and make sure that no bare wire is exposed cut away as necessary and tighten in place Repeat for black wire but insert it into the right terminal Connect the green wire to the
25. r power up 2 Make sure that the manual fuel shut off valve s on the MicroTurbine are open 3 Open the outlet isolation valve at the Air Pack 4 Verify that the initial manual priming of the MicroTurbine has been done as described in the MicroTurbine User s Manual Addendum A 400020 5 Initiate a START Verify the MicroTurbine starts and loads normally 6 Check air fittings for leaks with leak detecting fluid i e soapy water If an air leak is detected from the Air Pack or air plumbing shut down MicroTurbine and all power and tighten mitigate all leaks Resume procedure 7 After a 5 minute run initiate a STOP command Verify the MicroTurbine shuts down normally 8 Initiate a START and run at full power for 15 minutes Verify Air Pack and MicroTurbine s operate together normally ASP Responsibilities 1 Present the end user owner operator with the Micro Turbine User s Manual Addendum A 400020 shipped with the system 2 Discuss general safety precautions regarding electrical fuel exhaust and acoustics including any site specific details electrical and fuel breaker and shutoff locations 3 Explain the expected performance for the Air Pack as contained in the Micro Turbine User s Manual Addendum A 400020 4 Explain Air Pack Preventive Maintenance as contained in the MicroTurbine User s Manual Addendum A 400020 5 Provide Capstone contact information 480038 Rev A March 2008 Page A 2 Capstone
26. reserves the right to change or modify without notice the design specifications and or contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction Capstone Turbine Corporation e 21211 Nordhoff Street e Chatsworth e CA 91311 e USA Capstone Air Pack Installation Procedure COMMISSIONING CHECKLIST Page 1 of 2 NOTE The Commissioning Checklist must be completed AFTER performing all of the steps on the Commissioning Procedure above Upon completion of commissioning of the Air Pack system provide a NOTE signed copy of the Commissioning Checklist to end user and provide the signed original to Capstone A separate Commissioning Checklist form must be completed for each Air NOTE Pack commissioned __ 65X XXX XXXX Catalog No C65 ___ 523765 1XX Air Pack MT Serial No one with Air Pack Air Pack Serial No Commissioning Date Customer Information Unit Owner ContactName ssi Name Contact E Mail oe Phone Installation Information ASP Company ASP Technician ASP Cell Phone ASP E Mail Miscellaneous Information dates etc Customer Signature ASP Signature 480038 Rev A March 2008 Page A 3 Capstone reserves the right to change or modify without notice the design specifications and or contents of this document without incurring any obligation either with respect to equipment previously sold or in t
27. respect to equipment previously sold or in the process of construction Capstone Turbine Corporation e 21211 Nordhoff Street e Chatsworth e CA 91311 e USA Capstone Air Pack Installation Procedure When drilling holes in the MT rear panel use care to not damage the CAUTION cable assemblies that are behind the panel 3 If holes are not already provided in the MT rear panel drill the holes as follows a Locate and mark the 32 3 8 vertical distance on the left and right sides on the back of the MT see Figure 2 Use other dimensions as reference MICROTURBINE REAR VIEW THREE HOLES UCB EACH SIDE 1 25 IN 2 75 IN z 32 3 8 IN Figure 2 Mounting Frame Hole Locations on Back of MicroTurbine b Using the Mounting Frame as a template see Figure 3 align the two upper mounting holes with the 32 3 8 line Make sure the mounting frame is at equal distances from right and left edges of MT and mark the locations of the six holes c Remove the side panels from the Micro Turbine d Carefully drill six holes in the rear panel using size 11 32 drill bit Place a block of wood or other material between the panel and the cable assemblies to prevent drilling into the cable assemblies 480038 Rev A March 2008 Page 12 of 32 Capstone reserves the right to change or modify without notice the design specifications and or contents of this document without incurring any obligation either with respect to
28. t to equipment previously sold or in the process of construction Capstone Turbine Corporation e 21211 Nordhoff Street e Chatsworth e CA 91311 e USA Capstone Air Pack Installation Procedure CAPSTONE CONTACT INFORMATION lf questions arise regarding Air Pack installation please contact Capstone Turbine Corporation for assistance and information Capstone Applications Toll Free Telephone 866 4 CAPSTONE or 866 422 7786 Fax 818 734 5385 E mail applications capstoneturbine com Capstone Service Capstone Technical Support Toll Free Telephone 877 282 8966 Service Telephone 818 407 3600 e Fax 818 734 1080 E mail service capstoneturbine com Capstone Technical Support J apan Service Telephone 818 407 3700 e Fax 818 734 1080 E mail servicejanan capstoneturbine com 480038 Rev A March 2008 Page A 6 Capstone reserves the right to change or modify without notice the design specifications and or contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction
29. tcevaeeedhiaeliveecsaiecescacsleuceee A 6 Capstone AD PlICAUONS ssns teda e a a E A 6 Capstone SEMIC E sri tioec Bea se acta bedi aac teresa hea tadecdhaesee berated eeeG A 6 Capsione Technical SUBDOM seccsstccrssen dec chegeuteestradtes lic teatha aiaa linede n een anaiai A 6 Capstone Technical Support JAPAN cc ccecesseccessseeeeesseeeeeessseeeeessseeeeeesseeeeesseeeeeeessaes A 6 480038 Rev A March 2008 Page 3 of 32 Capstone reserves the right to change or modify without notice the design specifications and or contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction Capstone Turbine Corporation e 21211 Nordhoff Street e Chatsworth e CA 91311 e USA Capstone Air Pack Installation Procedure LIST OF TABLES Table 1 Air Pack Installation COMPONENMS cccccessseecececsssseeeeeeesssseeeeeeesssaeeeeeeessseeeeeeessseaes 10 Table 2 UGB Board Wing GONMECIONS sisacrsssnscseees veh E ea ravenetlseetoens 23 Table 3 Installation Completion Che cklist cccccccessccececeesseeeceeessseeeeeeessseeeeeseessseeeeeeeeesenees 25 Table 4 Reference DOCUIMOMIS aiessreccesicieesectaus eet nn sheeestleesedaus luebeltievedecabbexeetaeane 5 LIST OF FIGURES Figure 1 Micro Turbine with Air Pack ccccccsssssscceceeeessssseeeeeeeeessssseeseeeceeesssseeeseeeeesessssssnseeess 7 Figure 2 Drilling Holes on Back of Micro Turbine
30. the 1 liquid tight flexible conduit with three wires from the Air Pack to the bottom of the High Voltage DC HVDC power bay on the UCB b For UCBs without Precharge Assembly in HVDC Bay Connect the red and black power wires to the mating Anderson connectors black to black and red to red Connect the green wire to the ground stud in HVDC bay wall using an 8mm socket wrench Refer to Figure 9 and Figure 10 as required 4 b a a Fe Ted as ihn ee a EE High Voltage aisi DC Power Bay Anderson Connectors i pane eee d Fa r a a T i rel k F m T Er 4c T ae Se T1 r at i i es PT a f a ge sile EF baie HE i i m rh ey 2 1 aial F at ik P T p q arl mny f a I an 7 Pew r 1 a ff HEE 5 wt ee f i p f f val gt C m aa onnection L i T ae 1 e a Eg p si a y r pmf PET Figure 9 Connecting Conduit with 3 Wires to UCB without Precharge 480038 Rev A March 2008 Page 19 of 32 Capstone reserves the right to change or modify without notice the design specifications and or contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction Capstone Turbine Corporation e 21211 Nordhoff Street e Chatsworth e CA 91311 e USA Capstone Air Pack Installation Procedure Capstone Air Pack Ca
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