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PowerSpout Installation Manual Domestic installs Industrial install

1. ISOLATE AND TURN OFF WATER SUPPLY BEFORE REMOVING THIS COVER WWW POWERSPOUT COM Electrical hazard Rotating machinery hazard Made in New Zealand identification Recycling identification Once the turbine has been commissioned the front glazing needs to be fastened in place with the fixings in addition to the quick release toggle latches The toggle latches are intended for commissioning and jet optimization Once this is complete permanent fixings need to be used This precaution ensures that children cannot remove the front cover and be exposed to a rotational hazard The Pelton spoons are sharp and could cause serious hand injury The turbine installer should ensure that the turbine is mounted such that children cannot reach up under the turbine and be able to touch the spinning Pelton rotor 11 2 Pressurised water pipes Legislation covering pressurized pipes applies in most countries for pipe pressures over 10 Bar The PowerSpout runs at less than 10 Bar in all approved applications Check with your local authority if you have any legal requirement that may concern this installation in your country Generally there is little risk at less than 10 Bar pressure The biggest risk is insecurely fastened pipe joiners that blow off with the free end of the pipe hitting people Securing the pipe at regular intervals particularly near the joins and checking all joiners are tight will eliminate such risks Ensure yo
2. e The Pelton rotor is not hitting the jets it has been packed out correctly and packer washer have not been missed out e The magnetic rotor turns freely you have not picked up magnetic debris on the magnets when putting in together e The bearings have been greased correctly as per the manual e he bearings are in good condition likely the cause if noise has increased gradually over time e he unit is running at the correct speed see manual for correct speed images This is caused by clients installing jets that are too large for the generator power rating resulting in excessive RPM e heunit is performing as estimated please supply data as per the manual e henoise is not related to how the turbine has been mounted A heavy timber or concrete base will be quieter than steel aluminum framed base e The line is free from air compressed air expansions at the jet are very noisy We have not taken noise level readings as all hydro sites are different and it does not seem to be an issue That said some clients have installed turbines too close to their homes Generally the higher the head the more noise from the unit Our test site at 160m head and 1 6 KW you can talk normally together standing by the turbine but you are very aware it is there You can just hear it at 30 40m away It sounds like a washing machine in spin On low head sites less than 10m 30ft the river is likely to make more noise than the turbine A turbine can b
3. iii 60 2011 Ecolnnovation Ltd NZ PowerSpout Installation Manual Figures Figure 1 Water supply SyStem i 2 Figure 2 PowerSpout BE system setup sees eee eeeeeeese esse eeseeeseeseeeeaeeeaeeseeeaeeeaeeeaes 4 Figure 3 PowerSpout ME system Setup ie 4 Figure 4 PowerSpout GE system setup nnne nnne nnn nnn nnns 4 Figure 5 PowerSpout HE system setup cese anue ENEE 5 Figure 6 Simplified Smart Drive test graph nee 42 Tables Table 1 Different versions of PowerSpout nennen nens 3 Table 2 Pipes common in NZ indicative prices 2009 23 Table 3 Recommended minimum spare parts Set i 46 Table 4 Hydro site data required for product manufacture nne 52 Table 5 Flow in liters per second l s with one jet i 56 Table 6 Flow in gallons per minute gal min with one jet ecceeeeeeeseeeeeeeeeeeeeeeeeees 57 Table 7 Flow in liters per second l s with two jets te nnnnnnnnnennennnnnne 58 Table 8 Flow in gallons per minute gal min with two jetS t anennnnnnnnnnnnnennennn 59 Table 9 NZ PVG PIDO SZOS acerca east eis er 60 Table 10 China PVC pipe SIZESs enne nnn 61 Table 11 USA PVC pipe SIzes eR rese 62 2011 Ecolnnovation Ltd
4. 12 1 Link to online updates Please refer to our online FAQ for the most recent updates www powerspout com faq February 2011 2011 Ecolnnovation Ltd NZ Page 51 PowerSpout Installation Manual 13 Site data for hydro specification and improvements 13 1 PowerSpout site data In order to assess your hydro site potential you can either e Visit our web site www powerspout com and complete the advanced calculator or e Complete the table below and email it to questions powerspout com we will reply promptly with the best hydro option available for your site Table 4 Hydro site data required for product manufacture For ME version state the make and model of MPPT controller you intend to use For GE version state the make and model of grid tie inverter you intend to use Unis Head at site vertical drop fall of pipe Pipe length required to get fall Pipe inside diameter if installed Do you want us to advise your pipe size Flow available at intake What is the cable length from turbine to batteries If cable is installed what size is it Do you want us to advise cable size For BE and ME version state your battery voltage Your turbine will be designed for the site data you supply above If you operate it on a different site the output power will differ and not necessarily match the prediction of the advanced calculator A new generator core may be required to obtain the best results in such cases If you intend to run your
5. 70 86 104 124 14 21 31 42 5 70 86 104 124 16 25 36 18 28 40 54 71 90 111 134 160 19 30 44 59 78 98 121 147 175 21 33 47 22 35 50 69 24 37 54 25 39 56 26 41 59 27 43 62 30 46 67 32 50 71 34 53 76 35 55 80 37 58 84 39 61 87 40 63 91 42 66 94 43 68 98 Ft s iN CO CO NI NI O5 O1 O1 NO DIN W O ININIO 0o AVI iN 101 107 112 118 123 128 133 138 C2 pa merui ss mis N CO 1G 1G O O O IN O NM EN EN IND 9 st o C2 G a acid ck O O NIN 4 01 01 G Co PO 0 S em hs hmi i mh omi cis mt mes mee ms PR NI OQ DI 01 4 Col M 0 N O1 O1 N SI TDS JSS Soy Ne po a a ee ee BH B W M O O O N 01 01 8 IIIN O A GO CO 1G G M MIN NM IN IMIR A WIM O1 WO IN D H W O O O N O O11 Pj February 2011 2011 Ecolnnovation Ltd NZ Page 59 PowerSpout Installation Manual 17 Annex Il Common PVC pipe sizes The tables below are to assist in the understanding of the PVC pipe sizes available in your country Countries that have sizes very similar to other countries are shown colored the same so they are easy to spot Table 9 NZ PVC Pipe sizes 80 200 ES 277 3 300 375 NB refers to nominal bore which is the approximate inside diameter of the pipe series February 20
6. NZ PowerSpout Installation Manual 1 Introduction Congratulations on your choice of PowerSpout This ingenious little device will give you years of trouble free generation avoiding the need for expensive generators or power bills Not only does the PowerSpout give you renewable energy it is also made of predominately recycled materials making it one of the most eco friendly generators available on the global market This manual will help guide you through the process of installation so that your PowerSpout is installed correctly and runs efficiently PowerSpout turbines have been shown to achieve up to 60 efficiency and with multiple units up to 16 kilowatts kW Single turbines can generate up to 1 6 kW You can estimate your generation capacity with our online Advanced Calculator www powerspout com Be assured that our calculations take into account pipe and cable losses so we will not fall into the common trap of overstating output Before commencing the installation process you should have selected the appropriate components and consulted your local regulations concerning use of water and undertaking electrical work This manual includes information and links to relevant tools to facilitate this process It should take no more than one day for two people to install a PowerSpout depending on site terrain The manual is intended to guide you through PowerSpout assembly and the installation process It starts with an overview of a
7. Pelton wheel side Back smart drive side Position seal PS032 Position the two slingers PS031 one close to the bulk head one close to shaft end Position slinger housing top hat PS030 with the drain hole down Position slinger galvanized steel washer PS033 Insert the four fixings PS034 Tighten fixings to 5 Nm 4 Ib ft Revision of PowerSpout water sealing Testing the PowerSpout seals with a water blaster showed it is possible for water to track along the 4 x BSW fixings This water can then enter the bearing block and drops out of the drain hole To prevent this water ingress we have made a number of small changes e Addition of hard nylon washers under the head of the 4 BSW fixings to seal them from water ingress e Addition of a deflector on the Top Hat drain hole to prevent exhaust spray water from entering February 201 1 2011 Ecolnnovation Ltd NZ Page 10 PowerSpout Installation Manual Drain deflector Ta i e a B v e e 4 A DI V ET 9 New sealing parts 3 2 Jet size The jet sizing tables see Annex l Jet sizing tables enable you to quickly determine the approximate jet size required for your site i e at the head and available flowrate These four tables are provided in both metric and imperial units for one and two jet hydro installations They are based on theoretical calculations Flow rates in the field will vary slightly from these tables and some fi
8. We also suggest you are wary of complacency Since these systems work and give free power people tend to keep adding more and more loads until they reach the limit of the system Hence we recommend you e Fit aremote power meter to your inverter that will alert you if you exceed your peak load and advise you how many kWhrs you are using each day e Tell your guests about living off the grid and that they cannot Citi plug in large resistive heaters as these can knock years off your battery life and overload your inverter system Power meter 10 1 Spare parts If you live in a remote part of the world you should consider having a full spare parts kit on the shelf These are not expensive and will mean that whatever the problem you can get your system going again quickly At the very least you should hold a spare shaft and bearing February 201 1 2011 Ecolnnovation Ltd NZ Page 45 PowerSpout Installation Manual block Table 3 since spare parts from NZ can take up to 10 working days to arrive to global destinations Table 3 Recommended minimum spare parts set Shaft and bearing assembly Bearing block D76x113mm Front bearing 6205 0D52 ID25mm Rear bearing 6005 0D47 ID25mm Shaft D25x276mm long Shaft retaining nut 32AFx5mm thick 10 2 Lubricating the bearings Factory fitted bearings in your PowerSpout hydro turbine are top quality SKF explorer series sealed bearings which can last many times longer than low cost bearings
9. When you order your PowerSpout BE you will be advised of the maximum current your PowerSpout BE can deliver at your site Please ensure that you use a fuse that Is just large enough to carry this current Fuse 4 is connected to the battery side of all other fuses This is essential to ensure that the failure of any one fuse will not result in damage to any other equipment A battery must be connected when using a PowerSpout BE to prevent over voltage from damaging the inverter 7 1 4 Fuse 5 Fuse 5 carries all excess energy within the system to the division load P4 i controller for dumping in the dump resistor Fuse 5 should not break 9 0 unless fuse 4 has already broken or been disconnected To achieve this fuse 5 should be chosen to be twice the breaking rating of fuse y 4 Linked circuit breakers see picture are available with two poles linked together where if one breaker breaks then the others will also break This can be used to replace fuse 4 and 5 in a single unit Be sure to use breakers rated for the DC current at the battery voltage your system uses February 201 1 2011 Ecolnnovation Ltd NZ Page 35 PowerSpout Installation Manual 7 1 5 Fuse 6 Fuse 6 carries all load current from the batteries to the AC inverter It is important that fuse 6 will always blow before fuse 1 If there is a major fault in the inverter only fuse 6 should break and so leave the rest of the fuses in place This way the PowerSpout
10. 0 Power meles ili oi Ms 37 9 Turbine Gre tieni eal aio clean i 38 9 1 Packingouttherotor iii fi 39 9 2 Thermal Checks sidus cin Gh pat deity Eras ku dina Eb E Re RU Fed barn a ini 43 9 9 Turbine case TOOGIING s srecetina Pew dpt gave add oa eausa cn a Men e re 44 10 Operating your system efficiently nmn 45 Un ESSI e EE Um UU MM Tm cm 45 10 2 Lubricating the DeafllitjS essai mhsend duras iwteddcinu esu asia iac KG NN MEO E BUE tad reat 46 10 3 Changing the bearings eeseee re Eee 47 iE o Hi DEA 49 11 1 Front glazing and rear cap safety warnings cccccccceccecc eee eceeceeseeeeeeeeeeseeaeeaeees 49 11 2 Pressurised Water DIDGS zse retra Eee E oe ttr rens 49 11 3 Grid power network CONNECHtIONS nennen nene 50 12 TROUDICSNOOUNG escono hio eee es Mtt rel ee te irr ee Ores ta eir Ruin 51 12 1 Link to online updates eese nnn nenne nnns 51 13 Site data for hydro specification and improvements 52 13 1 PowerSpout site data fg 52 13 2 Installation details MR 52 Noale m 53 p ME elele WE MD iena 53 14 Units and conversione MZ ii 54 15 Warranty and disclaimer nennen nennen nne nnne nnn nane 55 16 Annex I Jet sizing table 56 17 Annex II Common PVC pipe sizes
11. Ao WOON e LLTT H HPM 19 44 Poor T T UU m 20 SE S d Ne oiu dile els IE E EAA AE Eaa 22 NAA CARE TTI 22 NARDO CNL Ch NNMERO ER 22 orn C RARE 23 o CPPS idiota deri ni lia iii 24 Bios Laying and SSCUMING NSCS uan 24 5 60 Intake design ANG placement siii 24 5 7 Water diversion and return i 26 59 Gonnecind NS pece S eee ne epee eee ee eee ee eee 27 5 8 1 Connecting your pipe to the PowerSpout 27 5 8 2 Advice for USA and all countries that use NPT threads 27 5 8 3 TWO CECO ANNEO ria ia 27 6 Getting the best from your batteries eee 29 6 1 Battery type size and life e 29 6 1 1 What is electricity and batterieS 29 2011 Ecolnnovation Ltd NZ PowerSpout Installation Manual PE eigo 30 6 2 1 Battery installation example 1 ne 31 6 2 2 Battery installation example 2 nenne 31 6 2 3 Battery installation example 3 nne 32 7 Cable connections PowerSpout BE ii 33 7 1 PowerSpout BE wiring Battery Enabled 34 Fetele FUSC J M 35 Tee FPE qo E S 35 e PUO A ET 35 xc a A E ra 39 ER FUSCO Lane 36 7 1 6 Earthing requiremeEntSs iii 36
12. BE output will continue to be connected to both the batteries and the diversion load controller and maintain DC voltage regulation Warning many breakers are not DC rated and must not be used Breakers rated for DC will say on the body of the breaker DC breakers cost more than common AC breakers DC type breakers are often polarized this means that they have to be installed the correct way round The side of the breaker with the sign means this side is connected in the system on the side that is more positive in a fault condition the battery side will always be more positive 7 1 6 Earthing requirements This configuration only fuses one side of all DC connections In most countries an earth connection is required for the common side Please refer to your local country wiring rules to determine the correct size of this conductor Only one earth connection should be provided to the common wire connection Adding a second or more earth connection s to the common side may result in additional electrical noise which could interfere with radio reception February 2011 2011 Ecolnnovation Ltd NZ Page 36 PowerSpout Installation Manual 8 Power meters It is Important that you have a means of permanently displaying the power generated by your hydro turbine We strongly recommend our standard cabinet and meters with pre wired regulator and diversion load to go with your hydro turbine Section 2 14 A separate meter is only need
13. DC battery systems will be suitable since they are below 37 8 volts A turbine that was designed and set up for an operating voltage below 37 8 volts will not have a voltage high enough when free spinning to damage the MPPT regulator For installations done by those who are not registered electricians the maximum DC voltage you are allowed to work at replaces the maximum input voltage 140 V DC in the calculation above 120 V DC is the upper limit in Australasia and some other parts of the world and 50 70 V DC is also common globally If the ELV limit in your country is less than 90 V DC then you can only use our BE turbine on 12 VDC battery bank via an MPPT regulator to comply with both the Law over voltage limit of your FM60 80 12 V DC systems are not common these days with the majority of systems being 24 or 48 V DC The example above illustrates that if you use a BE turbine and an MPPT regulator on a 24 V DC battery your cable voltage will be about 38 V DC The losses at 38 V DC compared to 100 V DC that our ME 120 turbine typically runs at results in a cable that is 1 7 of the area and about 1 7 of the cost So if you intend to run a BE turbine on a MPPT regulator you must e Tellus prior to ordering e Haveashortcable run e Havea120r24V DC battery bank e Havean accurate measure of the head of your system If a BE turbine causes overvoltage damage to a MPPT regulator Ecolnnovation will not be liable You should buy an ME turbine tha
14. Do not make the mistake of evaluating batteries only by amp hours as this is not an indication of total energy storage Battery weight is often a good measure by which to compare batteries This quality can be used to help spot the over enthusiastic sales person 6 1 1 What is electricity and batteries Electricity is the flow of electrons along a wire Metal is a good conductor of electricity as the electrons in each atom of metal are free to move from one atom to another Consider how difficult it is to store the energy of a car that is moving Understanding the fact that electricity is the flow of electrons helps us to understand that electricity is also difficult to store as it is energy in motion Batteries do not store electricity as such but use the flow of electrons to alter the number of electrons in the chemicals inside the battery Then when the battery is discharged the chemicals return to their original state However the chemical process means that batteries degrade with use and time Renewable energy systems normally use batteries based on lead acid chemistry as they are still the most cost effective and readily available type Lead acid batteries are made from plates of lead in a solution of sulfuric acid While the discharging and recharging of lead acid batteries is a reversible process all lead acid batteries lose health when not charged The car battery is a lead acid battery A car battery is designed for starting a car s e
15. a solid flat supporting surface Good access for installation and replacement to avoid lifting injuries is required e Batteries give off hydrogen and oxygen gas during charging in the correct proportions for an explosion Ventilation is required e Batteries are not maintenance free All batteries need to be measured individually for voltage and flooded batteries also need to be checked with a hydrometer e Batteries are not for anyone to touch Sufficient security is required to prevent a child or unknowing adult from tampering with them e Not everybody understands batteries There are recommended safety signs that must be displayed above your battery bank warning people of the possible hazards You should always take care when working with batteries Burns acid splashes and electric shocks can occur If you do not have sufficient skill and or experience to install and care for this equipment you should engage a renewable energy professional to do it for you Myth The old myth about not storing batteries on concrete floors is just that a myth This story has been around for 100 years and originated back when battery cases were made up of wood and asphalt The acid would leak from them and form a slow discharging circuit through the now acid soaked and conductive floor 6 2 1 Battery installation example 1 Here each battery is in a separate battery case Each case provides ventilation and prevents accidental contact with the termin
16. by 10 and the amps volts lines by 5 approximately Model 80 07S 03P S operating into a 57V load Smart Drive Prediction tool Version 4 1200 1100 Amps Nm x10 ed LL LL LL LDL 0 LE 0 0 80 0 200 400 60 0 1000 1200 1400 1600 1800 2000 Watts rpm Electrical watts P Mech Pwr P Torque Output Amps Figure 6 Simplified Smart Drive test graph Overall efficiency This example assumes that calculations for your site data predicted that you could get 530 W at 1000 RPM brown line and 70 generator efficiency red line on a fully charged 48 V DC bank at 56 V DC At maximum power increasing or decreasing the RPM of the Smart Drive by packing will make little difference to the output power it can produce as the gradient of the brown line is shallow In summer when a smaller jet is used and generation potential falls to only 200 W the turbine operates at close to the static pressure of the pipe line and the power curve has a steep gradient The speed of the turbine will be slow due to an oversized generator combined with poor Pelton rotor efficiency because it is not running at the optimum speed Packing the rotor out a small amount will have a dramatic effect Rotor packing flattens and moves to the right the brown power line and the red efficiency line this allows the Pelton rotor to pick up speed and become more efficient at extracting power from the water j
17. for pipe and turbine fitting leaks and remedy as required Walk the pipe and lift sections to locate any air locks and fit riser vents as required Check that the drain hole in the rear turbine case is at the lowest point If condensing water from the bulk head pools onto the floor of the turbine case drill a small hole at this low point to allow this water to drain out Check there is no water leaking from the drain hole in the rear bearing block If you see a leak make sure you have installed the slinger top cap seal and tightened correctly February 2011 2011 Ecolnnovation Ltd NZ Page 38 PowerSpout Installation Manual Standard meter cabinet and resistive load The meters above confirm that both units are operating hydro 1 at 20 amps and hydro 2 at 11 amps respectively The air diversion meter shows 3 amps diverted to the resistive load The picture shows the air diversion element with a slight glow indicating that it is working Make sure the pipe is secured firmly just prior to the turbine A large pipe full of water can be heavy and may need support You can support the pipe by installing a wooden post either side of the pipe with a horizontal member above and below the pipe to secure it As acheck it is recommended that the exhaust water from the turbine is collected to determine the flow rate of water through the jet measure this by noting the time to fill a container of known volume Cutting and aligning the jets ar
18. have a 3 core cable installed then combining 2 of the cables into one and sending DC down these 2 cables is more efficient that sending AC If you do not already have such a cable then you should use DC for transmission unless you intend to install the PowerSpout HE 2 2 Rectifier A rectifier converts the 3 Phase AC produced by the micro hydro to DC for supply to the battery bank to minimise losses Generally DC is conveyed from the turbine to your battery bank The main exception is the HE version that uses transformers 3 phase rectifier Rectifiers get hot due to losses and lower voltage systems have greater losses On new systems the preferred option is 48 V DC though 24 V DC is also common provided cable costs are not too high 12 V DC cannot be used for sites where more than 50m of cable is needed 2 3 Battery Bank In off grid systems a battery bank is required to store power The voltage of the battery bank dictates the voltage of the system 12 V 24 V or 48 V DC with 48 V being the most common The quantity of batteries in the bank is dependent on the power requirements and the intermittency of power generation at your site It is typical to have a number of batteries arranged in parallel and series to provide the desired voltage Lead acid batteries are most commonly used although most other types are also suitable 4 how Battery bank February 201 1 2011 Ecolnnovation Ltd NZ Page 5 PowerSpout Instal
19. in the same application e Front SKF 6205 2Z OD52mm ID25mm e Hear SKF 6005 2Z OD47mm ID25mm Sealed bearings do need to be re greased at times as hydro turbines run 24 7 and see very high cycle rates The PowerSpout is provided with a re greasing nipple so this can be easily done with the turbine in operation You should lubricate your PowerSpout bearings at the time you first use it and then e Every 12 months for generation up to 300 W e Every 6 months for generation up to 600 W e Every 3 months for generation up to 1200 W A good quality grease must be used We recommend SKF LESA 2 grease for all PowerSpout applications or close equivalent http www mapro skf com pub pds LESA2 datasheet e pdf With the turbine running connect your grease gun onto the grease nipple provided Pump into the bearing block about 20 mL of grease This is normally about Remember to grease your new 20 pumps of a domestic type grease gun Subsequent PowerSpout re greasing should be about 5 mL of grease about 5 pumps Do not over grease the bearings as the excess grease forced out can block the drain hole in the bearing block and top hat housing If you turn your turbine off during the dry season or for any period greater than 2 weeks you should lubricate as above prior to turning off Remember your PowerSpout 3 year warranty is conditional on bearing replacement every 12 months and the above lubrication regime that you should document in yo
20. micro hydro system and then proceeds through each stage of the installation Advice is also provided on basic maintenance to ensure safe and reliable supply of power for years to come Videos to introduce PowerSpout and demonstrate PowerSpout assembly and bearing replacement are available via www powerspout com A video on the history of the Smart Drive generator over the last 20 years may interest many Customers The PowerSpout is larger than a standard airfreight carton In order to get economic global freight that can be included in the price and to allow for global drop shipping for no extra charge the unit has to be broken down into 3 4 sub assemblies which only take 5 10 minutes to put back together again Each turbine has been fully assembled and tested prior to being broken down for freight Putting the turbine together also helps dealers customers fully understand the product for future servicing needs February 2011 2011 Ecolnnovation Ltd NZ Page 1 PowerSpout Installation Manual 2 Components of your hydro system A typical hydro system includes a good water supply a generator and some type of electricity storage The generation capacity of your site is determined by the water supply primarily by the vertical distance the water falls head and how much water flows in a given time flow rate A rough estimate of generation potential can be calculated as follows Generation Watts head metres x flow litres per se
21. our website at WWW powerspout com please visit www powerspout com faq and submit a question We will answer this as quickly as possible and you will be notified by email when this occurs PowerSpout is a product proudly designed and manufactured by Ecolnnovation Ltd 671 Kent Road New Plymouth R D 1 New Zealand 4371 Web www ecoinnovation co nz If you need to contact Ecolnnovation by phone then email first via our web site and check the local time in NZ if calling from overseas Business hours are 9 00am to 5 00pm weekdays only Ecolnnovation is closed for up to 3 weeks over the Christmas break from 24 December 2011 Ecolnnovation Ltd NZ PowerSpout Installation Manual Table of Contents EM eife eie lia 1 2 Components of your hydro systemM eene nennen nennen nnn nns 2 2 1 Generator PowerSpoUt i 2 2 1 1 Setup for different systems ie 3 2 1 2 AC OF DC PONG ioni aaa ie 5 22 ede HT A 5 2 9 BAN BAR 5 24 MVOLOP utei gue icit E esed MM E EU I 6 2 5 Regulator charge controller eese 6 2 0 BAGHIPRIASGUAIO riavere pian 6 2 7 Diversion Load Hot Water Element nennen nnne 7 2 8 Diversion Load Air Resistive Coil nennen 7 2 9 Diversion within turbine ME GE versions i 7 Zope TR UU UU MT gm TS 7 2 11 MPPT re
22. terminal Please refer to your local wiring regulations for what is required in your location Negative ground battery IIl cao Diversion load controller Common negative 2 w D D c c o E E o O Battery positive Load positive Batt to mains inverter R1 Dump load PowerSpout BE Output output Chassis Please note that both fuse 4 and fuse 2 connect directly to the battery The hydro turbine must connect directly to a battery string If fuse 4 was accidently connected at the junction of fuses 1 5 amp 6 then removing fuse 1 will result in over voltage to the inverter Be careful to avoid this potential problem Remember also that the cables used in each part of the circuit need to be large enough to carry any currents that do not blow the corresponding fuses The fuse has to be between the rating of the cable and the rating of the load duty cable highest fuse middle load smallest February 2011 2011 Ecolnnovation Ltd NZ Page 34 PowerSpout Installation Manual 7 1 1 Fusel Fuse 1 is required by most electrical jurisdictions around the world to protect against damage in the event of a short circuit within the wiring of the main switchboard Should fuse 1 blow the charge controller will not provide over charge protection for the batteries If left with fuse 1 removed then the batteries and inverter may be damaged This system relies on the diversion load controller for charge contro
23. 00 respectively This ensures the maximum voltage of 120 V and 400 V is never exceeded See Technical Manual for more information on this voltage clamp V Clamp function 2 10 MPPT regulators Maximum Power Point Tracking MPPT regulators have become common in recent years mainly for the large solar PV market These regulators can also be used on hydro and wind applications as long as additional voltage protection is provided The PowerSpout ME includes this additional voltage protection so that it can be used with most types of MPPT regulators Different versions of the ME turbine are available from 100 to 250 V DC to match the maximum input Outback FlexMax FM60 voltages of your MPPT regulator and local wiring rules MPPT regulator 2 11 MPPT regulators BE and ME turbine options The PowerSpout BE turbine has been designed to run directly connected to the battery bank at 12 24 48 V DC Our ME turbines have been designed to run just below 100 120 140 or 250 V DC via an MPPT regulator to your battery bank at 12 24 48 V DC The main advantage of the ME turbines is that you can save significant costs on cabling at the higher voltage Although an MPPT regulator will get more power from the turbine by not clamping the generation voltage such regulators have internal losses of about 5 so there only a small net gain A correctly optimized BE turbine will generate just as much but an ME will automatically optimize for you and is a more fle
24. 1000 Connected to a battery bank through a MPPT Enabled controller such as the Outback FM60 Designed for inverters and MPPT regulators operating at less than 120 V DC 120 ELV ME 140 MPPT 50 1500 Connected to a battery bank through a MPPT Enabled controller such as the Outback FM60 Designed for inverters and MPPT regulators operating at less than 140 V DC ME 250 MPPT 50 2000 Connected to a battery bank through a MPPT Enabled controller such as the Midnite Classic 250 Designed for inverters and MPPT regulators operating at less than 250 V DC GE 400 Grid Enabled 0 2000 Connected to a grid tied inverter to feed hydro generated power into the national grid or for use in mini grids via Sunny Island type inverters Designed for inverters operating at less than 400 V DC High voltage 500 2000 Connected directly to a battery bank via three step for system regulation 120 ELV extra low voltage laws in some countries allow home owners to install equipment up to 120 DC without regulatory control applying to them Each of the key components is briefly described below For further information please refer to the PowerSpout Technical Manual 2 1 1 Setup for different systems Different systems use different configurations of components as shown in the diagrams below Instructions for electrical connections are included in Section 7 February 2011 2011 Ecolnnovation Ltd NZ Page 3 PowerSpout Installatio
25. 11 2011 Ecolnnovation Ltd NZ Page 60 PowerSpout Installation Manual Table 10 China PVC pipe sizes 87 426 47 836 90 28 844 66 96 NENNEN ni 98 3804 3826 o J Jj February 201 1 2011 Ecolnnovation Ltd NZ Page 61 PowerSpout Installation Manual Table 11 USA PVC pipe sizes 73 0 88 9 101 6 114 3 8 6 108 141 3 219 1 201 7 192 2 273 1 10 8 10 0 323 9 11 9 11 3 332 1 315 2 13 1 12 4 406 4 379 5 361 0 14 9 1 6 2 0 4 0 9 0 0 0 9 2 3 3 4 5 6 Ti 7 6 138 Pie 457 2 426 9 406 8 16 8 508 0 476 1 452 5 18 7 609 6 572 6 544 0 22 5 Provided in metric and imperial February 2011 2011 Ecolnnovation Ltd NZ Page 62
26. 59 75 93 112 134 6 9 12 16 25 36 49 63 80 99 120 143 ERE NN UM E r NW ON 1 Ecolnnovation Ltd NZ Page 57 PowerSpout Table 7 Flow in liters per second l s with two jets mE February 2011 Jet Velocity m s 10 14 17 20 22 24 26 28 30 31 33 34 36 37 38 40 41 42 43 44 SS TS Eee Ee e eee e DIL BR B LA Oo w w SS VE ISIS IS IF eec esee o 0 NINNI Jet Size Diameter in mm 3 3 5 4 5 0 1 02 0 2 0 3 0 4 A nia 2 SS E E d EE jolo lo NI NIN O1 01 Oo Po Po is exBeeemeeE olo Sla lale w Io IO o O O NIN On S CO Po oO ojo10 20 oNImNILAoOo Io N Daw A 0 0 P O O o N IO o o Oj RIO 7 0 6 0 7 1 0 1 3 1 4 1 6 1 8 1 9 2 0 2 2 2 3 2 4 2 9 2 6 2 2 8 2 9 3 0 3 1 3 2 3 2 8 9 10 12 14 0 7 09 11 16 22 0 9 1 3 1 6 3 7 1 9 2 1 2 3 2 5 27 34 42 60 82 28 3 0 31 40 49 74 96 3 3 3 4 3 5 10 8 3 7 3 8 3 9 4 0 12 3 41 52 42 54 66 95 130 2011 Ecolnnovation Ltd NZ Installation Manual 16 18 19 22 29 37 10 7 13 5 14 2 17 9 16 9 21 4 Page 58 PowerSpout Installation Manual Table 8 Flow in gallons per minute gal min with two jets Jet Velocity Jet Size Diameter in Inches 3 16 7 32 14 5 16 3 8 7 16 12 9 6 5 8 11 16 3 4 8 12 18 50 60 71 14 21 31 42 55
27. Power pout WATER GOES IN lel ha NU I PowerSpout Installation Manual AUS CO d P Domestic installs Please read this manual carefully before beginning installation Notice of Copyright PowerSpout Installation Manual Copyright 2011 All rights reserved amp nnovation ee February 2011 Version 1 2 PowerSpout Installation Manual Notice of Trademark PowerSpout is a USA registered Trademark Notice of Company Registration Ecolnnovation is a NZ Registered Limited Company Disclaimer UNLESS SPECIFICALLY AGREED TO IN WRITING ECOINNOVATION LIMITED a MAKES NO WARRANTY AS TO THE ACCURACY SUFFICIENCY OR SUITABILITY OF ANY TECHNICAL OR OTHER INFORMATION PROVIDED IN ITS MANUAL OR OTHER DOCUMENTATION b ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSS OR DAMAGE WHETHER DIRECT INDIRECT CONSEQUENTIAL OR INCIDENTAL WHICH MIGHT ARISE OUT OF THE USE OF SUCH INFORMATION THE USE OF ANY SUCH INFORMATION WILL BE ENTIRELY AT THE USER S RISK Revisions history 1 1 Minor text and picture revisions Jan 2011 1 2 Updated PowerSpout versions available and further minor revisions Feb 201 1 2011 Ecolnnovation Ltd NZ PowerSpout Installation Manual PowerSpout WATER GOES IN POWER COMES OUT PowerSpout Contact details Web WWW powerspout com If you cannot find the answers to your questions about our product renewable energy systems or your site s potential in this document or on
28. Q E PowerSpout 16 10 147 1 3 152 43 08 04 05 07 08 12 16 21 26 32 46 63 82 104 116 TT lt O co L wel ee 11 9 16 0 3 8 GO 42 03 04 05 06 08 11 15 20 25 31 45 61 8 0 102 3 m E LO CO O r N Jet Size Diameter in mm 1 3 125 1 6 EINE 38 03 04 05 O6 07 10 14 18 23 29 41 56 73 93 103 13 9 40 03 04 05 06 07 11 14 19 24 30 43 58 76 96 107 143 41 osl o4 os5 06 08 11 15 20 25 30 44 44 os 04 os 07 os8 12 16 21 27 38 48 Velocity Dd o na Page 56 2011 Ecolnnovation Ltd NZ February 2011 PowerSpout Table 6 Flow in gallons per minute gal min with one jet Jet 1 32 1 16 3 32 BE MEM cw EE February 2011 A Installation Manual Velocity Jet Size Diameter in Inches 18 5 32 3 16 7 32 1 4 516 3 8 7 16 1 2 9 16 5 8 11 16 3 4 i 2 2 3 4 6 9 12 16 20 25 30 36 2 3 4 5 7 11 15 2 27 35 43 52 62 2 3 4 T 210 27 35 43 5200 62 2 3 4 el 5 m 18 24 32 40 50 60 n 2 3 5 7 9 14 20 27 35 45 55 67 80 2 4 5 7 10 15 22 30 39 49 61 73 87 201 3 4 e6 9 11 18 25 34 45 57 70 85 101 5 7 9 12 19 27 36 48 60 74 90 107 5 7 10 13 21 30 40 53 67 82 99 118 5 8 t 14 21 31 42 55 70 86 104 124 el 8 n 15 23 33 45
29. V and current is OA then check water flow is the turbine spinning and is the turbine electrically connected f output voltage is OV and current is at or above the design current then check electrical connections for a short circuit and correct fault f output voltage is much higher than the battery voltage then check and correct electrical connections to batteries check for blown fuse current will be near 0A pew topo ME and GE If output voltage is OV and current is OA then check water flow and that the turbine is spinning and electrically connected f output voltage is about 0 8V and there are other PowerSpouts BE version or other types of generators connected to the PowerSpout ME GE output then disconnect the other PowerSpouts Stop the PowerSpout ME GE and restart Voltage should then be 115V 380V for GE The emergency clamp circuit will operate to short the generator to about 0 8V if PowerSpout ME GE has no water flow and is being supplied power by other attached turbines f output voltage is about 0 8V for a single PowerSpout ME GE then check and correct electrical connections to internal dump load inside PowerSpout The internal dump load resistance is 10 Ohm for ME 40 Ohm for GE If internal dump load is correct contact Ecolnnovation for additional help f output voltage is 115V 380V for GE and the current is OA then check and correct electrical connections to MPPT controller Grid tied inverter for GE
30. ably qualified electricians February 201 1 2011 Ecolnnovation Ltd NZ Page 14 PowerSpout Installation Manual These tests ensure you have completed the output connections and have no unwanted connections through wiring faults to the PowerSpout chassis 1 Connect a DC volt meter to the DC output from the generator 2 Use an electric drill with a 19 mm 3 4 socket to spin the rotor by slowly driving the rotor fixing bolt PS040 3 Watch the voltmeter and increase the drill speed until the voltmeter reads close to your system battery voltage 4 The turbine should spin freely with little noise If you are using the PowerSpout BE without a ground connection 5 Connect an ammeter use a 10 A DC range between the chassis ground connection and negative output and spin the turbine to near the same speed as in step 3 above The turbine should spin freely with little noise and the ammeter must read zero Repeat steps 5 and 6 above but with the ammeter between the chassis ground connection and positive output 3 10 Installing rear cover Once all internal components have been installed the rear cap can be attached To prevent rain water leaking into the casing a sticky backed sealing strip PS008 is attached to the main casing PS001 The lid is then held in place with six fixings PS004 Do not over tighten fixings or you will strip the thread in the plastic housing It you do strip the plastic holes you can rotate the lid and make ne
31. al unit of power that is the rate of energy transfer equivalent to 1 ampere flowing under a pressure of 1 volt at unit power factor e A Watthour is an electric energy unit of measure equal to 1 Watt of power supplied to or taken from an electric circuit steadily for 1 hour Volts x Amps Watts To convert centimeters sq millimeters meters miles per hour liters liters per second kilowatts degrees Celsius To convert inches Feet feet per second gallons gallons per minute horsepower electrical degrees Fahrenheit February 2011 2011 Ecolnnovation Ltd NZ Page 54 PowerSpout Installation Manual 15 Warranty and disclaimer The following applies to complete water turbines only and hence excludes kit sets and parts Trade customers on selling this product must facilitate warrantee claims with the final client Ecolnnovation will only deal with the Trade customer in such cases Our warranty is valid provided the turbine has been correctly installed commissioned and maintained over the duration of its use The end user must return installation details to Ecolnnovation and keep a log book to record maintenance activity Ecolnnovation may request to see the log book and pictures of the installation and failed component prior to processing any warrantee claim Please also refer to warranty upgrades and support options as detailed on our web site Ecolnnovation is confident in the performance reliability and cost
32. als Note the very clear safety warnings making it obvious what is inside the boxes Access for servicing is straight forward 6 2 2 Battery installation example 2 This example provides excellent mechanical protection for batteries and ensures safe seismic restraint Ventilation slots at ground level on the front and at the top of the lid behind the hinge provide through flow ventilation so any hydrogen gas produced can rise easily up and away from the batteries Ideally the lid should be slanted to prevent incidental use of the lid as a shelf Objects will slide off The use of a child proof catch and signage on the outside top of the lid is also required February 201 1 2011 Ecolnnovation Ltd NZ Page 31 PowerSpout Installation Manual 6 2 3 Battery installation example 3 This locked battery room example provides good mechanical protection for the batteries and safe seismic restraint Ventilation vents at ground level and at the top of the battery room ensure good air flow ventilation so any hydrogen gas produced can rise easily up and away from the batteries The Installation includes Seismic restraint Distilled top up water storage DC disconnect below battery terminals Fire extinguisher Eye wash Battery care box with gloves apron hydrometer and log book Smoke alarm Hazard warning signs Minimum safety clothing includes Plastic apron Rubber gloves Eye protection Boots Eye wa
33. cond x 5 Generation Watts head feet x flow gallons per minute 10 Please refer to www PowerSpout com for more information and to use the Advanced Calculator tool There is also an Advanced Calculator manual available for download giving instructions and worked examples Water intake Pipe length Head Yo vertical Q height Yop PowerSpout Figure 1 Water supply system 2 1 Generator PowerSpout A micro hydro generator like the PowerSpout converts the potential energy of a watercourse to electricity This is achieved by water jets impacting on the turbine rotor spinning the rotor and hence the generator which generates electricity Micro hydro generators produce 3 Phase AC power There are different versions of the PowerSpout available to suit different situations These are briefly described in Table 1 and further information is provided in the PowerSpout Technical Manual Seek advice if you are unsure on the best PowerSpout option to meet your needs Cable choice is a key factor in selecting your PowerSpout version since this can have a significant impact on the installed system cost Some versions enable you to reduce cable costs by increasing the system voltage There are also Education and Demonstration versions available Please contact us for more information February 201 1 2011 Ecolnnovation Ltd NZ Page 2 PowerSpout Installation Manual e f you are living off grid and cable cost f
34. e closer to a dwelling in such cases Vegetation around the turbine will dramatically reduce the distance that noise carries 13 4 Feedback We welcome your constructive feedback on how we can improve our products including this manual Testimonials for our hydro products can be view at www powerspout com testimonials As Ecolnnovation endeavors to reduce their footprint in many different ways e g to save on paper and airfreight this manual is only supplied electronically to customers We encourage users to minimize printing where appropriate and to provide feedback via our website or via email see Contact details inside front cover February 2011 2011 Ecolnnovation Ltd NZ Page 53 PowerSpout Installation Manual 14 Units and conversions e An ampere amp A is the unit of measurement of electric current produced in a circuit by 1 volt acting through a resistance of 1 ohm e A Btu or British Thermal Unit is a standard unit for measuring the quantity of heat energy equal to the quantity of heat required to raise the temperature of 1 pound 16 ounces of water by 1 degree Fahrenheit e A current is a flow of electrons in an electrical conductor The strength or rate of movement of the electricity is measured in amperes e Anohm is the unit of measurement of electrical resistance It is the resistance of a circuit in which a potential difference of 1 volt produces a current of 1 ampere e A Watt is the electric
35. e fundamental to turbine optimization Please refer to sections 3 2 and 3 5 above for more details 9 1 Packing out the rotor Once plumbed in the jets should be turned on and the output of the turbine optimized Optimization of BE and HE PowerSpout options is done by noting the output current on the meter and then gradually packing out the magnetic rotor until the point of maximum power is achieved This is very important and will make a significant difference to power generation Once this point has been found the rotor should be packed with the packing washers provided and the rotor tightened finger tight only ra D Turn knob to optimize pack with plastics washers and tighten to ensure rotor stays in position set note 1mm thick stainless steel washer are supplied for packing If you are using our ME or GE option then the MPPT in this equipment will automatically adjust the speed of the turbine and optimize it for you with no packing required February 2011 2011 Ecolnnovation Ltd NZ Page 39 PowerSpout Installation Manual If the MPPT controller is unable to automatically find the correct operating point then manually set the MPPT controller load voltage Adjust MPPT set point load voltage from highest to lowest voltage and note power output at each setting Then select best power result If best power is achieved at the maximum or minimum limits of either the MPPT controller PowerSpout ME GE or your battery bank v
36. e is installed tighten the shaft retaining nut to 50 Nm 35 Ib ft This tube helps to prevent bearing spin that can damage the shaft and is normally only installed on high power units e Spin the shaft in your fingers there should be no tight spots if there are it is likely you have not pushed the bearing fully home Remove the shaft and press the bearing home Note for low output turbines running at less than 200W you can remove the inner bearing dust seals as this will reduce bearing losses Never remove the outer dust seals Make sure that the drain holes in the top hat and bearing block are free of grease and obstructions so any water can drain out freely February 201 1 2011 Ecolnnovation Ltd NZ Page 48 PowerSpout Installation Manual 11 Safety We have tried to ensure you can install and operate your PowerSpout with little or no damage to you others or your environment You can also contribute to this by ensuring you are aware of the potential hazards that exist when dealing with moving parts electricity access to your hydro site high pressure water and taking steps to help others recognize and avoid such hazards 11 1 Front glazing and rear cap safety warnings The rear cap of this turbine forms part of an electrical enclosure and carries the following warning sign There are both rotational and electrical hazards present Turbines must be turned off and unplugged or breaker turned off prior to removing this cover
37. e site e n many situations it is possible to divert the water pipe close to the home to provide a pressurised water supply as well as electrical generation In combined power and water schemes electric power is often employed to UV treat the water In some cases the PowerSpout is only used for UV treatment at remote water storage tanks for small communities this is often more cost effective that installing grid power to the site e Place it as close to your battery bank or point of grid connection as possible e Hydro turbines do make some noise so keep them at least 30 m from your home e Keep your turbine as low as possible while ensuring that is it above maximum river flood level e Your turbine should be positioned at least 50 100 mm above ground height to allow exhaust water to escape e Choose a site where the exhaust water can be returned back to the river cleanly The distance between your turbine and batteries has a significant bearing upon the cable size required To keep cable size and hence cost down we usually recommend 48 V DC systems be installed In such cases we generate a voltage at the turbine about 5 higher that your battery voltage due to voltage sag in the cable Turbine sites up to 500 m away are often economically viable using 2 core aluminium cable The PowerSpout ME offers an opportunity to reduce the cost of the cable by generating at higher voltage For example the PowerSpout ME 120 which generates and tra
38. ealer at a more competitive price we will beat it by 20 We will require an original copy of the advertisement This offer excludes trade specials and second hand units e Our maximum liability is limited to the full amount paid for the turbine If you are an overseas customer that has purchased this equipment by mail order over the internet then this is the maximum extent of our liability e Ecolnnovation reserves the right to improve the product and alter the above conditions without notice Ecolnnovation takes safety very seriously and we endeavor to reduce all risks to the extent possible and warn you of hazards We encourage you to have the PowerSpout installed by a professional renewable energy installer if you do not have the skill qualifications and experience to install this equipment safely Customers that ignore such risks and advice do so at their own risk The warranty is only valid for 12 months if no documentation see Section 13 2 is returned within 11 months of sale February 201 1 2011 Ecolnnovation Ltd NZ Page 55 Installation Manual Annex I Jet sizing tables The following tables enable you to quickly determine the approximate jet size required for your site at your head and available flow rate The tables are provided in both metric and imperial units for one and two jet hydro installations _ i c O Ka m 3 oO c o Q o o ES Q 9 LS o has S gt LL LO E
39. ed if you purchased a BE version The ME and GE versions of the PowerSpout do not need a power display meter as the MPPT regulator or grid tied inverter will display the generation Watts and often log this information for you A meter enables you to see any change in the output power which could indicate a problem that needs your attention such as e Blocked intake screen or e Reducingriver flow requiring smaller jets to be fitted You may notice a gradual decline in output power that may be due to sediment and organic growths in the pipeline This may need to be cleaned out using a pipe pig or by flushing the pipe with high velocity water As the voltage of most systems is relatively constant the output Watts is determined by multiplying the system voltage and the generation amps Annual output can be calculated as follows kWh year generation Watts x 24 x 365 For example a 500 W 0 5 kW hydro will generate 4380 kWh year To read amps in the cable you can either buy e A DC clamp meter be careful not to buy the cheaper AC clamp meter e PS110 ampboxthat can be used at either end of the cable and provide a permanent display of generation amps in your power shed One of the meters above is required so that the BE turbine can be optimised for your site We strongly recommend that any household living off the grid buys a good quality DC clamp meter as this will be very useful in a Renewable Energy RE system and learn how to use
40. effectiveness of our range of water turbines Hence we offer you e Full refundif you are not satisfied after the turbine has been running at your site for a 30 day period this must occur within 3 months of dispatch and Ecolnnovation must be given the opportunity to rectify the problem Clients need to pay for return freight cost and the turbine must be returned in as new condition for a full refund e Performance guaranteed if our installation advice is followed for turbines that have output power greater than 200 W Below 200 W a margin of 20 applies e 3 year warranty from the time of purchase invoice date subject to maintenance specified in the PowerSpout Installation Manual including re lubrication and replacement of bearings e Extended warranty available up to 10 years premium per additional year e Ifthere is a problem email us a picture of the failed part and we will fix it by dispatching a replacement part to you promptly The labor cost to fit this part to your turbine is not covered under this warranty The 3 year warranty is limited to the supply of replacement parts within 3 years of initial purchase e hecost of any single replacement part excluding the casing outside the 3 year warranty period for the original purchaser of our turbine will not be more than 100 US plus freight 5 year limit from purchase date of turbine e If you can find a similar quality retail product advertised by a manufacturer or authorized d
41. em Main battery fuse holder 2 14 Meter box We strongly recommend our standard cabinet and meters with pre wired regulator and diversion load to go with your hydro turbine Standard cabinet and diversion load air resistive coil February 2011 2011 Ecolnnovation Ltd NZ Page 9 PowerSpout Installation Manual 3 Assembling your PowerSpout As soon as you receive your PowerSpout please unpack and unwrap the parts and check them against the online parts list Please inform us immediately if you find any parts that appear to have been damaged in transit or are missing Videos of turbine assembly are available from www powerspout com Products manuals are updated on a regular basis and should be used in preference to video material for ensuring compliance with the latest updates 3 1 Installing bearing block shaft and slinger Take the turbine casing PS001 which already has the bulk head PS005 attached Remove the eight stainless steel fixings P8026 and PS034 from the bearing block and all other items until you have only the bearing block and installed shaft remaining From the back of the turbine casing with the circular opening where the end cap PS002 attaches insert and align the bearing block as shown Note that the bearing block has a small drain hole in it protected by a deflection shield this should be pointing downwards Shaft PS024 Drain hole points down Assembling shaft and seal slingers Front
42. et increasing the RPM even more Your PowerSpout will have been shipped with a Smart Drive generator optimized for maximum efficiency at your maximum power level expected This has the result of reducing the requirement to pack the rotor However if you are using your PowerSpout BE on a wide range of flow rates some rotor packing will be needed To improve efficiency at low flow rates you should purchase a reduced core stator February 2011 2011 Ecolnnovation Ltd NZ Page 42 PowerSpout Installation Manual 9 2 Thermal Checks A PowerSpout has an enclosed generator The inside stator core temperature of the generator will depend on e Output power of the turbine Revolutions speed of turbine higher rom has more cooling Ambient air temperature Water temperature Voltage of operation less heat at higher voltages due to lower currents The generator core is cooled by air flow across the stator The warmed air then transfers this heat through the aluminum bulk head into the exhaust water of the hydro turbine The air temperature inside the housing is typically 30 degrees Celsius This warm environment ensures a near constant temperature of the Smart Drive bearings thus reducing moisture ingress due to condensation that is common in the damp environments in which hydro turbines are often installed After the turbine has been running for 2 3 hours turn off the water supply remove the rear cover remove the Smart Drive magnetic rotor a
43. f the pipe 5 2 Pipe criteria A pipe should be e Equal to or larger than recommended from the calculations that specified the output power Watts of your turbine Cost effective tough and durable for 20 50 years Able to handle the static pressure of the head of water Easy to lay and bend around obstacles Able to be purchased in long lengths The PowerSpout has a maximum running head rating of 100 m 120 m in special cases and allowing for up to 30 pipe friction loss sites up to 130 m static head can be used A higher water head can be used successfully but with reduced lifespan and warranty February 2011 2011 Ecolnnovation Ltd NZ Page 22 PowerSpout Installation Manual LPDE and MDPE pipes can work in this range The range and the fact that they are durable low cost and commonly available in a wide range of sizes pressure ratings and lengths makes these pipes the obvious choice for the PowerSpout Remember that you can change the pipe grade to minimise costs For example if you have a 100 m head you can use a length of low grade 35 m 50 psi 3 5 bar pipe a length of 6 bar then 9 bar and finally 12 bar Laying 12 bar pipe all the way would almost double the cost of the pipeline If you do this the pipe ID will change so the calculated output may not be correct To avoid disappointment use the smallest pipe ID in the online calculator and your turbine should generate a little more than predicted Table 2 Pipes co
44. further the pressure in the pipe resulting in less power generation Another common myth is that pipe bends are the cause of a lot of losses In reality relative to the long hydro pipe a few bends will make no noticeable difference 5 5 Laying and securing pipes When laying the pipe try to do the following e Install a good strong intake structure Secure the pipe against flash floods during the install process Obtain a good fall in the first 5 10 m of pipe Lay the pipe on a gradual always descending line where possible Keep the number of high points to a minimum and vent these to avoid air locks Avoid siphon systems if possible Securely fasten the pipe line to rocks trees or ground anchors to prevent it moving down the incline 5 6 Intake design and placement The intake for a Pelton turbine should be positioned at the base of a small set of rapids to allow room for a sloping intake screen Water flows over the top of the screen falling into the chamber below that feeds the supply line Leaves and twigs are washed away preventing the intake from blocking Intakes often need to be made to suit each site The examples below illustrate different ways to do the same job The picture of the angled guides and screen is the recommended way to make a good strong maintenance free intake screen You must ensure you securely attach the intake screen to the riverbed by driving galvanized stakes into the ground or attaching to large bou
45. g serious damage to the fingers of inquisitive children 4 4 Protection The PowerSpout is encased in a very durable LDPE housing ensuring all internal parts are protected from rain moisture ingress rodents children and UV The internal aluminum bulkhead PS005 has been designed to help control the temperature in the enclosed generation compartment of the PowerSpout The Smart Drive generator has a peak efficiency of up to 80 and will get warm Heat is dissipated from the generator core by a fan which blows the warm air over the water cooled aluminum bulk head ensuring that temperatures within the PowerSpout remain at acceptable levels Extra cooling is provided by three louver vents inserted in the PowerSpout casing These are generally only required for turbines generating more than 400 Watts or more than 10 amps Below this output these vents are not normally installed 2 x side air vents and 1 x rear lid air vent February 2011 2011 Ecolnnovation Ltd NZ Page 20 PowerSpout Installation Manual This warm enclosure ensures the generator and electrical junction box do not become corroded from damp ingress In higher power situations gt 400 Watts the generator temperature needs to be checked as part of the turbine commissioning by the installer The LDPE enclosure also helps reduce noise and dampens any slight vibrations The main benefit however is that there are no exposed rotating hazards that might catch the finger
46. gulators BE and ME turbine options esee 7 2 12 MPPT regulators Future trends menn 9 CRKNIUITI ee 9 2 CR MEE DO MEET C 9 3 Assembling your PowerSpoUt RR ees eecceecceeseeeseeees 10 3 1 Installing bearing block shaft and slinger 10 orci EY a Eno 11 3 2 1 Cutting the jets to correct size enne 11 3 3 Installing jet assemblies K 8 amp enm Hn 12 3 4 Installing the Pelton rotor 5 eene mmm 12 3 5 Pelton Rotor Alignment 1 esses nenne nenne nne nennen 13 3 6 Assemble lubrication SyStem ie 13 3 7 Assembling rectifier wire and plug lead eeee eee eee eeeeeseeeeeeeeeeeeeeeeas 13 3 8 Assembling Smart Drive Generator nennen 14 3 9 Electrical checks with covers ON mf ener nena 14 3 10 Installing rear cover We iii 15 3 11 Installing front glazing emm N 15 4 Where and how to site the turbine mm 17 4 1 Regulations and good practice guidance e 17 4 2 Siting your PowerSpout turbiNe nennen 17 4 2 1 Cable sizing rule of thumb method for long cables 18 4 2 2 Connecting two small streams into one PowerSpout 18
47. he DC output for correct polarity must be connected brown or red positive and black or blue negative The rectifier has and markings and you must connect them the correct way round Reverse polarity may damage the rectifier e Thethermal paste PS085 supplied ensures that a good thermal connection is made between the rectifier and the bulk head that acts as a water cooled heat sink e Where an earth connection is not required connect as shown above e For positive earth connection link from the brown red positive wire to the green earth wire connection e For negative earth connection link from the blue black negative wire to the green earth wire connection 3 8 Assembling Smart Drive Generator First connect the AC wires as shown below wire order is not important Shots showing wiring and location of generator stator Place the generator stator and washer into position attach with four fixings and tighten to 10 Nm 7 lb ft Insert extractor knob then place the rotor over the shaft Wiggle the rotor until the knob engages on the thread Turn the knob clockwise until the rotor is pulled fully home magnets are fully over the steel laminations do not over tighten finger tight only Attaching the Smart Drive rotor 3 9 Electrical checks with covers off These instructions are for PowerSpout BE only Similar tests for other versions of PowerSpout are included in the Technical Manual and should only be conducted by suit
48. humb method for cable sizing and then round up to the next cable size available then losses are typically in the 5 1096 band There are many tools on the web that will determine the 96 power lost in the cable for you The Advanced Calculator on the www powerspout com web site will work out the cable size for you for a given loss or the loss for a given cable size This tool clearly demonstrates the effect that increasing the cable loss has on the cable size and hence the cost of the cable Try to keep losses as low as possible particularly if you have limited hydro generation and need all the power you can get A loss of 5 in cables is normal Cables with losses greater than 10 should only be used in cases where the cable cost is very significant in the total equipment cost and or where you can generate plenty of power more than needed 4 2 2 Connecting two small streams into one PowerSpout We are often asked if two small streams can be piped into a common two jet turbine This is not recommended unless the head and pipe friction losses for each pipe are very similar February 201 1 2011 Ecolnnovation Ltd NZ Page 18 PowerSpout Installation Manual Generally we would advise two turbines one for each site The electrical output of both would then be joined together into a common supply cable ER SS Dual install one unit runs on 30m 98 ft head the other 10m 33 ft head 4 3 Mounting The main case dimension
49. icates the wall thickness American pipes were categorized by inside diameter ID in the past but this was abandoned to improve compatibility with pipe fittings and joiners that usually fit the OD of the pipe Inside diameter is critical for calculation of pipe friction loss since a variation of as little as 1 mm can have a very significant effect on the output power of the turbine Take care with which diameter you are referring to since if calculations are done based on pipe ID and the pipe is then purchased based on OD your turbine will generate less power than predicted due to increased pipe friction Pipes below 40 mm ID cannot normally be used as friction losses are too high Pipe sizes commonly used with our hydro products include e PVC for larger sizes based on OD 110 300 mm normally e LDPE based on ID in NZ AUS 40 50 mm normally e MDPE or HDPE based on OD 50 110 mm normally LDPE and MDPE pipes Pipes have different pressure ratings so a given pipe size is often available in a number of pressure ratings These different ratings are achieved by either altering the material grade or increasing the pipe wall thickness The OD is kept constant so standard pipe joiners still fit In NZ for example polyethylene PE pipes can be purchased from 35 m 50 psi head rating to 160 m 230 psi head rating Some mainly LDPE sizes are based on ID but most are based on OD sizing so be careful and double check with your supplier the OD and ID o
50. ight for the application they are commonly used PVC left in direct sunlight will weaken and become brittle with age We see larger PVC pipes 150 mm and larger used for lower head applications below 20 m and often with less than 200 m of pipe needed In this case culvert grade farm pipes glued together are the lowest cost PVC pipe you can obtain There are also larger sized HDPE culvert pipes up to 450 mm but these often require expensive joiners as they cannot be glued together though plastic welding is possible February 2011 2011 Ecolnnovation Ltd NZ Page 23 PowerSpout Installation Manual 5 4 Pipe myth We often get told that the pipe has to reduce in size in order to keep up the pressure This is a huge misconception and arises from confusion with irrigation schemes If you decrease the pipe size you decrease the pressure you do not increase tt The pipe for an irrigation scheme supplying many farms will reduce in size as the last farm has to convey a smaller amount of water The start of the pipe has to be larger because it has to convey the water needed for all the farms on the line The pipe myth arises because pictures of irrigation schemes have often been used to depict hydro schemes People also confuse pressure with velocity if you increase the velocity by reducing pipe size the pressure will decrease Reducing pipe size increases water velocity increased water velocity further increases pipe friction and reduces even
51. ilable for purchase that fit onto LDPE and MDPE pipe with the following OD 63 mm 2 5 75 mm 3 90 mm 3 5 These joiners have 2 British Standard Pipe threads BSP threads on the end to connect into the valves on the turbine These larger fittings are supplied for an extra charge 5 8 2 Advice for USA and all countries that use NPT threads Fittings obtained in the USA will have 2 National Pipe Tapered threads NPT threads A PowerSpout sent to these destinations will have a ball valve with a 2 BSP thread on one side and 2 NPT thread on the other side These clients connect to our turbine and the pipeline by buying a suitable fitting locally 5 8 3 Two jet connection Connection of 2 jets to a common pipe line is normally done by one of the following means e Placing a T in your LDPE or MDPE pipe line and plumbing the pipe to both jets The losses due to one T will make no difference to turbine performance e Using our two jet PVC manifold that connects the two jets together all you need to do is connect to the 75 mm OD 3 PVC pipe We have many options for our manifold including LDPE pipe connectors mac unions and bolted flange connections if required February 2011 2011 Ecolnnovation Ltd NZ Page 27 PowerSpout Installation Manual PowerSpout with factory fitted manifold Common PE pipe fitting options Do not connect the 2 jets to the main supply pipe line using undersize pipes or this can cause
52. ine is only used for winter generation then the turbine should be removed to a dry indoor storage area with the back rear cover left off while in storage 9 3 Turbine case flooding On low head hydro sites turbines are more exposed to flooding risk BE and ME turbines up to 140 vdc can handle submersion on rare occasions ME 250 GE 400 and HE turbines cannot and will be damaged Immediately following a submersion of the turbine you must e Remove the magnetic rotor and clean off any magnetic grit carried by the water e Regrease the bearings and run the turbine so that internal generator heat will dry it out e Clean out any excess grease from the front of the bearing block and top hat drain hole as this can block with grease preventing water from draining away Corrosion damage caused by water submersion is not covered under warrantee LS a Flooded turbine February 2011 2011 Ecolnnovation Ltd NZ Page 44 PowerSpout Installation Manual 10 Operating your system efficiently The PowerSpout is a durable machine but it runs 24 7 so regular checks and maintenance are advised A PowerSpout may do more revolutions in one year than a car engine during the life of the car A car engine has a filtered and pumped oil lubrication system whereas a small hydro turbine does not You must pay special attention to the bearings A bearing maintenance schedule is outlined below and you are required to follow it if your 3 year warranty is
53. ined draw to 10 of battery capacity e Limit the maximum charge rate to 10 of battery capacity For example for a hydro turbine generating 500 W 0 5 kW into a 48 V DC battery bank that consists of two banks at 200 Ah each use e DOD each day 10 x x 200 x 48 1920 Whrs e Maximum sustained draw of 10 x 200 x 2 x 48 500 2420 W for a time not exceeding 1 hour e he charge rate is 500 48 10 A maximum allowable 10 x 2 x 200 40 A This 40 amp limit is a concern only when backup charging from a gen set Average daily draw from the battery bank allowing for 10 battery loss and 10 inverter loss 500W x 0 9 x 0 9 is 400 W 9 6 kWh day 0 4 kW x 24 hrs day total consumption This is normally fine for an energy efficient home using a 3 kW inverter If you wish to draw more than 2 42 kW for a sustained period you should install a larger battery bank and inverter In practice battery life is generally around 3 12 years with 7 8 year life typical Batteries are occasionally flattened accidentally and this can have a significant impact on their total life Although there are many instruments to help determine battery state of charge the most reliable method is a hydrometer A hydrometer can only be used with wet cell batteries Check your battery state of charge weekly and keep a log book Either increase generation or decrease consumption if your state of charge is falling You need to generate at least 2096 more than you use to a
54. is concerned with only the PowerSpout operation For assistance with your system please contact your equipment installer or provider The following is designed to locate the majority of possible faults If you do not understand the electrical measurements below then please consult your installer or electrical worker for assistance If you are concerned your system is not operating correctly then measure the PowerSpout output voltage and current at the PowerSpout and compare with the data supplied with your PowerSpout Also multiply the voltage V reading by the current A to determine the Watts your PowerSpout is producing e Ifthe Watts from your PowerSpout is within 10 of the design Watts provided for your site then the PowerSpout is working correctly but may be in need of further optimization e Ifthe Watts are between 20 and 80 of the design Watts o Confirm you have sufficient water If a first assessment of your PowerSpout installation then also check the accuracy of your water resource information supplied when you ordered your PowerSpout o Check your penstock for leaks blockages airlocks clogged intake jet sizes etc o Check your PowerSpout turbine for correct jet alignment bearing health correct rotor mounting and that no moving parts are rubbing and all wires are connected internally e If Watts are less than 20 then do the above plus the following for your version of PowerSpout o PowerSpout BE f output voltage is O
55. it We also advise you to learn the difference between volts amps Watts and Watt hours as it is very difficult for installers advisors to assist over the phone or by email if you confuse these terms The Technical Manual has further information and there are numerous websites on this topic February 2011 2011 Ecolnnovation Ltd NZ Page 37 PowerSpout Installation Manual 9 Turbine Commissioning It is Important to formally commission the turbine and associated system to ensure it is working correctly prior to leaving the site for the day Once you are happy that you have successfully commissioned the turbine you should record see Section 13 2 Jets sizes installed Flow rate through turbine Output Watts amps x volts Static pressure of pipe turbine valves turned off Dynamic pressure of pipe turbine running Generator equilibrium temperature see Section 9 2 Picture of installation Date for next service check see Section 10 2 Once the turbine has been mounted on a suitable base the pipe attached and secured and the power cable connected to the inverter MPPT regulator or battery bank you may turn on the turbine Allow pipe to run and purge of air bubbles on long small pipes this can take a few hours Check for current flow to the load Check regulators are working Check that the intake still has surplus overflow water If not fit smaller jets so you are not drawing air into the pipe at the intake Check
56. l so it is very important that this fuse never actually blows in normal operation Fuse 1 must be large enough so that the inverter can never draw enough current to break under maximum load conditions Fuse 1 must also be small enough that the batteries have sufficient energy to break it in a fault situation It is normal for fuse 1 to be twice the rating of fuse 6 Or for fuse 1 to be a motor rated fuse while fuse 6 is not motor rated for the same current rating 7 1 2 Fuse2 amp 3 Each parallel string of batteries must have its own individual fuse This is to limit the damage caused by internal failures such as an internal short circuits within a cell in a battery string These fuses are also an advantage when working on batteries so that an individual string can be isolated for testing without shutting down the entire system Like fuse 1 these fuses should never blow in the event of an external fault Fuses F2 and F3 can be omitted when 1 battery string is used 7 1 3 Fuse 4 The cable from the PowerSpout BE to your battery room can be very long and needs to be protected from excess current The excess current comes from the battery end of the cable not the PowerSpout The maximum operating current for the PowerSpout is typically 30 higher than normal operating current and is not able to blow a fuse Fuse 4 is therefore located at the battery room to protect the cable from battery supplied current in the event of a cable short circuit
57. lation Manual Batteries can also be used in on grid systems to provide power when the grid is down If there is a grid power cut your GE PowerSpout will disconnect itself from the grid so your home will also lose power The extra cost to install a backup battery bank is difficult to justify unless you have frequent grid outages 2 4 Inverter Inverters convert the energy stored by the battery bank to a voltage and frequency suitable for typical household appliances usually 230 240 V in Europe Australasia and 110 120 V in North America Square wave inverters tend to be cheaper but pure sine wave inverters produce a higher quality waveform that is necessary for more sensitive electronics commonly found in the modern home Induction motors as found in most refrigerators workshop machine tools and air compressors tend to overheat when used on square wave or modified sine wave inverters Large induction motors starting direct on Outback inverter and line may fail to start even on large pure sign wave regulator system inverters Inverters are available in a variety of power ratings depending on the intended loads and with a variety of surge ratings A high surge rating allows loads with a high start up power surge to run without overloading tripping the inverter or failing to start at all Some inverters can also serve as charge controllers to regulate input from backup petrol diesel LPG generators 2 5 Regulator charge contr
58. lders with brackets and cement February 2011 2011 Ecolnnovation Ltd NZ Page 24 PowerSpout Installation Manual en In road culvert RY ICL SLE maree Y Commercial intake on road culvert Perforated box February 2011 2011 Ecolnnovation Ltd NZ Page 25 PowerSpout Installation Manual INS 4 j ne V i P 4 D 2 r Paty oM es otainless woven tube from scrap yard Intake made from stainless steel scrap Intake screens such as these can be purchased However they are easy enough to make to suit your site You can use a stainless steel mesh and a plywood box make sure you support the screen from behind with stainless steel rods frame otherwise during floods the mesh will be pushed in A fine smooth stainless steel gauze with a hole size no more than 1mm should then be placed over the stronger frame This smooth gauze will allow debris to slide off easily and prevent small aquatic life forms from entering the pipe line Some ideas for intakes made from scrap stainless steel components 5 7 Water diversion and return Micro hydro systems may potentially affect e Plants and fish in the water e Plants and animals beside the water e Stream banks and surrounding land You must check with your local authorities to see if you need to obtain consent either to build any structures or to take return water from a waterway The impact of your system on stream ecology will usually be conside
59. llow for system losses Two parallel battery strings are better than one if you do get aloose connection or forget to turn off the hydro turbine when working on your system you may not face any ill effects Generally it is regarded as good practice not to have more than three parallel banks Connecting batteries in series increases the voltage but not the amp hour capacity Connecting batteries in parallel increases the amp hour capacity but not the voltage 6 2 Housing Batteries need to be understood for what they are Here are some key points February 201 1 2011 Ecolnnovation Ltd NZ Page 30 PowerSpout Installation Manual e Batteries operate best when kept cool around 10 C to 20 C but never freeze them Fully charged batteries are hard to freeze but flat batteries are more easily frozen e Batteries are full of sulfuric acid lead and small amounts of other chemicals which must not leak into the environment e Chemicals must not fall on or into batteries as this may cause a chemical reaction Rain water should be avoided as it may wash other material into the cells e Batteries store energy in chemical form and can release this as electricity very quickly if there is a short circuit A short circuit can convert a steel ruler or spanner to molten metal spray and cause significant personal injury Protection from falling objects is required Protection from electrical faults is also required e Batteries are heavy and need
60. mmon in NZ indicative prices 2009 Pressure Pressure Pressure Approx cost m Pipe Pipe Pressure OD ID Material rating mm mm PSI NZ US 44 38 LDPE 45 1 8 44 38 LDPE 60 600 6 30 21 57 50 LDPE 35 2 4 57 50 LDPE 70 38 27 63 55 LDPE 60 60 6 X 36 25 63 55 MDPE 90 900 9 49 34 63 50 MDPE 120 5 2 80 800 8 4X 74 52 90 79 MDPE 80 1800 8 85 60 Bold indicates the change from ID to OD sizing Approx cost m 5 3 PVC pipes PVC pipes are widely used in applications ranging from low cost road culverts to mains pressure water distribution networks in cities PVC pipe sizes vary around the world see Annex Il Common PVC pipe sizes and frequently the available pipe sizes differ between countries Most countries seem to either use the American or British pipe size dimensions or develop their own standards for pipe sizes PVC pipes are often more cost effective than PE pipes in sizes above 90 mm As the pipes glue together the cost to join them is low so short lengths can be used normally 4 6 m They can be bent in situ by applying heat to the tension side of the bend We therefore see them mainly used at lower head sites where more water flow is available and often on sites running multiple turbines from a common pipe line PVC is not as durable as PE and can be shattered by falling rocks and trees Where these risks can be managed and the price is r
61. most amount of power that your pipeline can deliver before pipe friction chokes the output power you should set the jet size so that the pressure on the gauge drops to 2 3 of the static pressure 3 3 Installing jet assemblies Install the jet assembly as shown The PVC jet sleeve PS070 is mounted inside the turbine with the PVC ball valve on the outside Note that there is also a Jet O ring PS076 that fits on the jet sleeve thread after being inserted into the casing This O ring ensures the valve and jet sleeve seals onto the casing and does not leak The O ring is on the outside of the casing 3 4 Installing the Pelton rotor Jet assembly in position Ensure that when you mount the Pelton rotor you fit it the correct way round The water jet should hit the splitter the straight knife edge of the Pelton spoons T 4 DI me a M ng Y E e i 7 x LI B t r Pelton fixing washers front and rear views e Insert bolt PS040 spring washer PS1043 and washer PS042 as shown e Install alignment washers PS041 as shown Note you will need to alter the number of washers until the centre of the jet aligns with the splitter of the Pelton spoons e Attach the Pelton rotor to the shaft as shown below Top hat drain hole points down Attach Pelton rotor to the shaft and tighten to 50 Nm 35 Ib ft Ensure that the drain holes in both the slinger housing top hat and the bea
62. n Manual PowerSpout BE Battery bank Diversion load controller e ce cid Generated power To inverter gt Dumped excess power providing User load power for loads Figure 2 PowerSpout BE system setup PowerSpout ME MPPT charge controller T bun load inside water outlet Generated power gt pumped excess power _ User load power Figure 3 PowerSpout ME system setup PowerSpout GE Grid tie inverter P n LL a load inside water outlet Generated power gt pumped excess power Figure 4 PowerSpout GE system setup February 2011 2011 Ecolnnovation Ltd NZ Diversion load Battery bank To inverter providing for loads National Grid i L M rn strie i j as m ne Page 4 PowerSpout Installation Manual 38 step down Diversion load Diversion transformer and Battery bank controller load rectifier EN PowerSpout HE g P pf Een uL Generated power e Dumped excess power Toinverter User load power providing for loads Figure 5 PowerSpout HE system setup 2 1 2 AC or DC power Contrary to the common myth it is more efficient to send DC along acable than AC for the same cable size The only exception is where you already own a cable with 3 conductors suitable for 3 phase AC If we rectified the 3 phase AC and sent it as DC down 2 of the cables then the losses would be more the cable area used is less in this case If you do
63. nd hold your hand on the copper coils if it is too hot to comfortably hold your hand there more cooling is needed 2 x side air vents and 1 x rear lid air vent More cooling may be required in warmer climates and where the output of the turbine exceeds 400 Watts or 10 amps The ideal stator core temperature should be in the range 40 60 degrees Celsius after 2 3 hours of operation Ecolnnovation will have fitted 3 air vents for turbines above 500W and 1 vent below 500W if your turbine is running too hot hot climate and 12 V operation then more cooling may be required Contact Ecolnnovation and we will send out vents that you can easily install with a hole saw and drill The person responsible for installing and commissioning the turbine needs to do a thermal check as outlined above The temperature inside the bottom of a PowerSpout GE operating at 1 6kW on a 130m running head test site reached 36 C Due to a farm animal breaking the water pipe the unit was left not operating The following data was inadvertently collected e Case temperatures rose up to 39 C caused by sunlight heating Ambient air temperatures were around 25 C e Relative humidity was around 40 during operation and increased to 95 when not operating February 2011 2011 Ecolnnovation Ltd NZ Page 43 PowerSpout Installation Manual This observation is interesting and shows that a turbine should not be turned off for extended periods of time If your turb
64. ne tuning of the jets may be required If your water source dries up in summer you may need to reduce jet size This ensures water cover over the intake so you do not draw air into the pipe at the intake In situations where you always have plenty of water at your site and then once jets have been sized for your pipe line no further adjustment is needed 3 2 1 Cutting the jets to correct size The plastic tapering jets can be cut on sitewith a sharp knife The jets are inexpensive so a trial and error approach can quickly determine the correct jet size It is important to cut your jet to the correct size cleanly so that the water jet can break smoothly without spray We recommend using a sharp knife and paring away at the jet cutting from the inside edge out With practice a very accurate and sharp edged jet can be prepared in the field The taper gauge and knife supplied in the optional tool kit help to make this task easy Holding the plastic jet PS072 within a spare holder sleeve PS070 and end cap PS071 will ensure the jet is held firmly while you cut it to size Take care as it is easy to slip which could result in a significant flesh wound Cutting the jet to size and checking it with the taper gauge Two equal sized jets must be used for turbines with an output greater than 500 Watts February 2011 2011 Ecolnnovation Ltd NZ Page 11 PowerSpout Installation Manual If you have plenty of water and want to generate the
65. ngine and so has thin plates to provide as much surface area as possible which allows the chemical reaction to occur in a short time This type of battery can provide large currents to meet the high power demands of starting an engine As the duration of engine starting is For further information on energy and units see Section 14 or refer to the PowerSpout Technical Manual February 201 1 2011 Ecolnnovation Ltd NZ Page 29 PowerSpout Installation Manual very short the total amount of energy is not that great automotive batteries suffer when significantly discharged The thin plates are quickly damaged and may even disintegrate The plates also have a high resistance so loose energy making a car type battery less efficient as an energy storage device They can be employed in some hydro situations where there is plenty of power to meet the base load of the home the battery merely providing short duration peak load storage A deep cycle battery designed for standby energy systems has heavy plates that are much more robust against deep discharges However a deep cycle battery has limited surface area and cannot convert stored energy as quickly Thus deep cycle batteries must not be subjected to heavy currents or there will be damage to the battery For battery bank sizing we generally refer to the 10 10 10 rule of thumb For a 10 year life e Cycle batteries no more than 10 depth of discharge DOD each day e Limit the maximum susta
66. now remove the shaft and bearing assembly Sub 02 from unit Remove shaft retaining nut PS025 Hold shaft in vice to do this Hit the end of the shaft with a raw hide mallet hit the end the Smart Drive attaches to You may need to use a small workshop press to push the shaft out Remove shaft Use a punch to knock out the old bearings from the bearing block and recycle Thoroughly clean the bearing block PS020 Using a large socket as a drift on the outer ring of the bearing tap the new front bearing PS022 fully home as shown e herear bearing PS028 can be tapped home on the outer ring of the bearing with a hammer as shown e Clean the inside bearings and shaft with a solvent e Apply Loctite 680 bearing mount or similar anaerobic adhesive using the rear bearing inside diameter as shown February 2011 2011 Ecolnnovation Ltd NZ Page 47 PowerSpout Installation Manual e Loctite 680 the front bearing shaft position as shown e Smear the loctite evenly over the surfaces 1 2 drops per surface is sufficient e Insert shaft the correct way around spline protruding through smaller rear bearing You may need to use a small workshop press to press the shaft home e Clean up any excess loctite with a clean rag e Attach shaft retaining nut and snug up but do not over tighten Shaft should spin freely without any tightness On high power turbines a bearing to bearing inner sleeve tube is installed Where this tub
67. nsmits at about 100 V DC to a MPPT regulator close to your battery bank can reduce the cost of the Ecolnnovation holds considerable stocks of cable at very good prices for our NZ customers February 2011 2011 Ecolnnovation Ltd NZ Page 17 PowerSpout Installation Manual cable by up to 75 by doubling the generation and cable transfer voltage The regulator changes the voltage to suit your 12 24 48 V DC battery bank The benefit of this approach is that existing 12 24 V DC systems can be cost effectively integrated with the PowerSpout For example solar PV systems can struggle in winter time when you have viable stream flows Adding a PowerSpout to your system can often eliminate the need for fossil fuel generation as solar and hydro resources tend to complement each other For very long cable runs up to 2 km the PowerSpout HE and GE are also possible options w w Typical good domestic install on Typical good commercial install natural rock foundation power for reservoir Auckland city storage 4 2 1 Cable sizing rule of thumb method for long cables Multiplying the current by the cable length in meters and dividing this answer by 100 determines approximate cable size for long runs at 50 100 V DC For example 5 amps over 500 m cable length needs a cable size of 5 x 500 100 25 mm e Ifthe cable voltage is 100 then power loss is 7 3 e fthe cable voltage is 50 then power loss is 15 If you use this rule of t
68. oller Regulators also known as diversion load controllers or charge controllers are an essential component of your renewable energy system Regulators are responsible for ensuring correct charge rate and protection of your battery bank from overcharging Once the regulator recognizes A that your battery bank is fully charged it diverts additional incoming power to a diversion load Regulators often allow you to set the voltage threshold at which power diversion starts Xantrex C40 regulator Charge control is provided using any good quality charge controller such as a Xantrex C40 or Morningstar TS45 A Photovoltaic PV regulator is NOT suitable for micro hydro and wind applications The positioning and type of regulator used in a renewable energy system is critical to protecting not only the generator but also the rest of the system from damage It is highly recommended that two regulators be used to reduce the likelihood of damaging your system should a single regulator fail When using a MPPT tracking charge controller and ME PowerSpout an additional backup controller is not normally required 2 6 Backup Regulator A secondary or backup regulator is recommended in all renewable energy systems Since regulators are relatively inexpensive components redundancy will protect the higher value components in your system in the event of failure of the primary regulator February 2011 2011 Ecolnnovation Ltd NZ Page 6 PowerSpout In
69. oltage ME version then please contact Ecolnnovation for further assistance Once optimization is complete the turbine exhaust water should be hitting the clear glazing at 90 degrees to the jet If the exhaust water bounces back towards the jet then the turbine is running too slow and you should pack it more If the exhaust water travels through and hits the opposite side of the casing then the turbine is running too fast and you should reduce the packing Top and bottom jet exhaust water is bouncing back towards the jet turbine is running slow a little more packing is needed Too fast Too slow Slow t Bottom Jet Fast Good stow MI RR iii The above illustration shows where the top and bottom jet exhaust water should be hitting the clear screen for optimal performance February 2011 2011 Ecolnnovation Ltd NZ Page 40 PowerSpout Installation Manual If the exhaust water does not hit the clear front at 90 degrees to the jet then there are a few possible issues that should be checked e Note the output power and compare this to what you were advised prior to purchase If this is similar then it is likely all is well and no further adjustment is needed e Check that the Pelton rotor knife edge aligns with the centre of the jets and adjust by altering the packers behind the rotor e Apply downwards upwards and sideways pressure to the jet to alter the angle slightly and see what effect this has
70. on output The jet position can be moved slightly within the casing Once optimized secure and support the pipe The jet retaining cap should only be hand tight and ensure the thread is well greased so it will come apart in the future e Check that the running voltage for your turbine is less than the maximum ME GE voltage you purchased If more than advised below then the turbine might be activating the internal voltage clamp load that will divert some of the power generated to internal water heating The ME and GE Smart Drive stators may be supplied with 6 wires for Star or Delta connection Changing the connection type may solve this problem see Technical Manual ME 100 turbine runs at 95 V DC or less ME 120 turbine runs at 115 V DC or less ME 140 turbine runs at 135 V DC or less ME 250 turbine runs at 240 V DC or less GE 400 turbine runs at 385 V DC or less Try increasing the swept range of the MPPT controller or grid tied inverter so that they sweep over a wider range of the open circuit voltage of the generator If you cannot resolve a problem email all your data and pictures of the install to us via our web site at www powerspout com with and we will try to help you find a solution Note the number of washers required for a particular jet size and when running on one or two jets Change the packers with the corresponding jet sizes as your river flow changes with the seasons Hang the jets and packing washers on nails in yo
71. or your hydro is affordable e g the cable costs less than the hydro turbine cost then you should use the BE version at 12 24 or 48 V DC direct to your battery bank e f you are living off grid and cable cost for your hydro is a major part of your overall cost then you should use the appropriate ME version at up to 250 V DC with a Maximum Power Point Tracking MPPT function regulator to alter the voltage and harvest optimum power while charging your battery at 12 24 or 48 V DC e f you are living on the grid network you may use the ME version where the maximum input voltage of the inverter does not exceed 100 120 140 or 250 V DC depending on ME version Most clients will use the GE 400 version that is designed for grid tied situations via inverters that commonly operate at up to 400 V DC e For customers in New Zealand only there is the HE version for up to 500 V AC 3 Phase output Only consider the HE version if your supply cable can be installed safely The HE turbine is rarely used as the ME or GE turbine can usually be employed and will be more efficient because transformers are not required Table 1 Different versions of PowerSpout Version Description Cable Features length m approx Enabled load controller for system regulation ME 100 abled 50 750 Designed for inverters and MPPT regulators abled operating at less than 100 V DC 120 ELV or for the Latronic grid tied inverters made in Australia ME 120 MPPT 50
72. ous errors All the following errors we have observed over the last 15 years e Connecting a hydro turbine to a solar regulator not designed for a hydro turbine e Connecting the hydro turbine polarity in reverse this normally destroys the rectifier e Connecting the hydro turbine to the inverter lead and then removing the battery and regulator fuses This results in a high voltage input to the inverter which damages it e Using a poor quality second hand battery bank with dirty corroded terminals which results in the battery not being connected in the system This is fatal to inverters as the battery is the primary voltage regulation and must remain connected to the turbine at all times when the turbine is running e Forgetting to tighten the battery terminal bolts resulting in the battery bank being disconnected from the systems result as above e Not checking that the regulator is working correctly prior to leaving the site e Installing a regulator that is too small or one that does not work and not knowing how to determine if the regulator is working e Installing a regulator close to its maximum amp rating in a tin shed that works most of the time but in summer trips out resulting in the batteries being overcharged damage The backup regulator if fitted also trips It is not the regulator s that have failed but the summer environment in the tin shed that is too hot You have to de rate regulators in summer when above 20 degree
73. red during this process Ecolnnovation have some consent application examples for NZ that we can email you that might help in your application Most micro hydro systems divert a fraction of the main water flow through an intake screen to the generator A good intake will lead to negligible erosion and the screen will minimize February 201 1 2011 Ecolnnovation Ltd NZ Page 26 PowerSpout Installation Manual the chance of fish leaves etc entering the supply pipe Taking less than 50 of the minimum seasonal flow rate in your water source means there is no impediment to fish moving up or down stream and hence gives aquatic life a better chance to survive You should take care to ensure that the exhaust water from the turbine can return to the river without scouring the bank of your waterway Line the bank with concrete timber or plastic sheet as required Some systems utilise the exhaust water for irrigation allowing the water to percolate through the soil before returning to the waterway E i V p M x 4 ms MM amp Good example showing e Concreted river bank e Timber boards to prevent river bed erosion 5 8 Connecting the pieces 5 8 1 Connecting your pipe to the PowerSpout Two standard nylon pipe fittings are supplied that will allow connection to 50 mm or 2 ID LDPE pipe where this pipe size has been selected For larger pipe sizes we have pipe joiners ava
74. ring block are pointing downwards February 2011 2011 Ecolnnovation Ltd NZ Page 12 PowerSpout Installation Manual 3 5 Pelton Rotor Alignment You can view the Pelton rotor by looking through the jet as shown The water jet needs to hit the middle of the Pelton spoon splitter If the jet is misaligned then pack the rotor across using the washers supplied You can see in the picture that the Pelton rotor needs packing to move the rotor to the left Pack Pelton rotor to align in middle of jet 3 6 Assemble lubrication system Attach the lubrication components PS091 PS094 as shown below and tighten Grease lubrication system 3 7 Assembling rectifier wire and plug lead Pass the pre wired PS083 plug and flex PS082 through the gland PS084 mounted in the case wall and tighten the gland to restrain the cable Note that many countries do not require extra low voltage equipment to be earthed You will need to check with the rules in your own country In many counties earth connections are optional the USA is the main exception that does require an earth connection 3 phase AC Order not important Positive Red or Brown Negative Black Earth Green or Blue Rectifier wiring BE version February 2011 2011 Ecolnnovation Ltd NZ Page 13 PowerSpout Installation Manual e Connect rectifier as shown There is no incorrect wiring sequence into the rectifier from the generator for the 3 Phase AC input e
75. s clothes or hair of inquisitive children ensuring a very safe product Access to the rotating parts is only achieved with the use of a tool to remove the covers All tools to do this are supplied in the optional tool kit We have noticed in our monitoring log data that humidity within the casing is higher when no vent is provided Hence at least one vent is installed on all turbines and 3 vents are installed on all high power versions February 2011 2011 Ecolnnovation Ltd NZ Page 21 PowerSpout Installation Manual 5 Ensuring good water supply The online advanced calculator at www powerspout com will have advised the appropriate size of pipe based on the site data you entered You should position the PowerSpout to obtain the greatest fall possible in the shortest possible distance Try to lay the pipe to avoid high spots in the line that might trap air bubbles If this is unavoidable you will need to place a bleed valve at the high point in the pipeline to purge air Air locks in the line will significantly affect the power output of the turbine The longer the line is the more of a problem this tends to be Pipelines over 1 km long can be problematic if there are many high spots in the line 5 1 Pipe sizes Many different standards exist for pipe sizes which vary depending on industry and geographical area The pipe size designation normally includes two numbers one that indicates the outside diameter OD and the other that ind
76. s mm and the four holes in the PowerSpout casing for turbine mounting are illustrated in the plan view below Fixings are provided with the PowerSpout for connection to a timber framed base These dimensions are sufficient to plan for the mounting of the turbine prior to its arrival on site A PowerSpout unit is 400 mm high Plan view of a PowerSpout turbine A timber or concrete turbine base is less likely to produce resonant noise issues than say a steel or aluminum base February 201 1 2011 Ecolnnovation Ltd NZ Page 19 PowerSpout Installation Manual At sites where no water leakage can be allowed slip hazards for staff etc you can attach sealing strips of adhesive neoprene to the base of the turbine before bolting it down to ensure the turbine is completely sealed around the base In situations where there is a high risk of dropping tools into the floor sump you should cover the floor opening with stainless steel mesh so that any dropped tools or parts will not disappear under the floor This tends to apply to industrial sites including common applications such as city water intake reservoir facilities for control valves and instrumentation power and power for large hydro schemes at the intake This precaution is not required at domestic sites where the turbines are typically mounted outside A mesh or exhaust pipe over the exhaust water opening will prevent access into the rotating Pelton rotor from underneath thus preventin
77. s Celsius Such a failure is the result of an incorrect installation environment e Installing equipment in a damp humid environment resulting is corrosion problems e Insect infestation in equipment resulting in corrosion damage from insect excrement February 201 1 2011 Ecolnnovation Ltd NZ Page 33 PowerSpout Installation Manual e Bird and rat nests inside and behind cooling fans or inside electrical enclosures resulting in failure and fire hazard In most cases this would have been avoided if good installation practice had been followed e Connecting the plug supplied with the PowerSpout turbine in reverse polarity This will result in the turbine wire fuse blowing and may damage the rectifier in the turbine NEVER work on your renewable energy system with the hydro in operation Ecolnnovation will not be liable if you connect this equipment incorrectly and in doing so damage other equipment in your system If you are not skilled then have a suitably qualified professional install the equipment for you 7 1 PowerSpout BE wiring Battery Enabled The drawing below shows the minimum installation requirements for the PowerSpout BE This drawing shows a negative ground installation Each component and its selection criteria are discussed below If the ground connection is not to be installed then additional fuses are normally required by local wiring regulations on each of the negative connections to the common negative battery
78. sh February 2011 2011 Ecolnnovation Ltd NZ Page 32 PowerSpout Installation Manual 7 Cable connections PowerSpout BE This section includes wiring diagrams for PowerSpout BE only for other versions please refer to the PowerSpout Technical Manual Earthing of your renewable energy generation system may be required for personal safety and protection of the system from electrical faults Not all 12 24 48 V DC systems are earthed and the rules vary from country to country Systems operating over 140V should almost always have an earth connection New Zealand electrical regulations allow you to work on systems up to 50 V AC and 120 V DC without qualifications Outside NZ you need to check your rules to see what you can legally do yourself In the USA the National Fire Protection Agency NFPA provides wiring rules that are generally adopted by each state You can access these wiring rules free on line at http www nfpa org freecodes free access document asp id 7005SB Please also check with your local state authority if you are in the USA as each state may vary from the NFPA wiring rules The 2005 release of the NFPA National Electric Code NEC indicates a ground connection is required for all DC power systems in the USA This is not the case for many other countries so check if a ground connection is needed Many home owners attempting to install a renewable energy system themselves for the first time can make some fairly seri
79. significant losses Ta i J P ij A PR Tl Turbine supply pipes too small Correct size February 201 1 2011 Ecolnnovation Ltd NZ Page 28 PowerSpout Installation Manual 6 Getting the best from your batteries 6 1 Battery type size and life Flooded or Wet Cells are the most common lead acid battery type in use today They are available in a wide range of sizes and are often the most cost effective solution Light duty batteries are for cars thin plates with lots of surface area Heavy duty batteries are for trucks boats and deep cycle for renewable energy applications Gel cells are sealed and cannot be re filled with electrolyte Controlling the rate of charge is important or the battery will be ruined Absorbed Glass Mat AGM batteries instead of using a gel use a fiberglass like separator to hold the electrolyte in place Since they are also sealed controlling the rate of charge is important or the battery will be ruined Many people are often confused by terms such as voltage V amp hours Ahrs Watts W and Watt hours Whrs Your batteries store energy power is the rate of delivery of energy Energy stored in a battery Watt hours amp hours x volts For example e A6volt 225 amp hour battery can store 6 x 225 1350 Watt hours this will have a mass of about 30 kg 66 lbs e A 12 volt 200 amp hour battery can store 12 x 200 2400 Watt hours this will have a mass of about 55 kg 120 Ibs
80. site the turbine 4 1 Regulations and good practice guidance In many jurisdictions around the world electrical work on equipment with operating voltages over 50 V AC and 120 V DC must be carried out by a registered electrical worker The voltage limits are defined as the maximum voltage across any two points in the system A system operating with balanced DC which is 60 and 60 V DC relative to ground has a maximum potential of 120 V and is at the limit of unregistered electrical work PowerSpout BE PowerSpout ME 100 and ME 120 meet these requirements for unregistered electrical workers in New Zealand NZ and Australia AUS For PowerSpout HE and GE options please ensure that an electrician who is also a registered electrical worker completes your installation In many cases you can install the equipment yourself and then have the electrician complete the final hookup and turn on but you should talk to your electrician before you start The electrician will be responsible for your workmanship and may be reluctant to certify your workmanship which may not be accessible after the work has started 4 2 Siting your PowerSpout turbine Some tips for locating a good site for your turbine include e Choose a place that is accessible If necessary make steps and put in rope handrails to ensure that your turbine can be accessed safely e Choose a site that has the most fall even if it lengthens the cable needed to send the power to the usag
81. stallation Manual 2 7 Diversion Load Hot Water Element A diversion load is required to dissipate excess power Typically with micro hydro units diversion occurs regularly due to the constant power generation and hence it is advantageous to divert to a hot water heater element special element required to make use of this excess power Some regulators also contain programmable relays that allow ot water diversion element 230 240 110 V AC loads to be turned on when there is surplus power For example when there is surplus a water pump or water heater can be turned on to soak up this excess power Generally diversion loads need to be very robust and where there is any chance of failure a secondary diversion load to an air resistive element should be installed 2 8 Diversion Load Air Resistive Coil The secondary or backup regulator should dissipate power through diversion to an air resistive coil that expends excess power through generation of heat This is also recommended for wind and PV systems where the random nature of excess energy diversion will not contribute significantly to the water heating requirements of the household Air diversion element 2 9 Diversion within turbine ME GE versions In the PowerSpout ME and GE power is dumped into a water cooled load inside the turbine if the output voltage exceeds a preset limit The preset voltage limits are set just below the maximum e g 115 V and 385 V for ME 120 and GE 4
82. t will prevent this and allow you to use a 48 V DC battery bank If an ME turbine can be shown to have damaged an MPPT regulator then Ecolnnovation will pay for it to be repaired February 2011 2011 Ecolnnovation Ltd NZ Page 8 PowerSpout Installation Manual 2 12 MPPT regulators Future trends As the cost of MPPT regulators fall we will see a move towards MPPT regulation for the following reasons e ME turbines are fail safe unlike a BE turbines with diversion regulation that in the event of a failure may damage your system It is for this reason we recommend a backup regulator and diversion load on BE systems e Clients have less time inclination to manually optimise the turbine automatic optimisation is great e Professional installers prefer a plug in and go solution that the ME and MPPT regulators offer Midnight solar 250 VDC MPPT regulator We are also starting to see MPPT regulators that can operate at up to 250 VDC This means that BE turbines can be used on 12 24 48 V DC sites without any internal regulation 68 V DC line voltage and at up to 250 V DC with internal voltage regulation 2 13 Fuses In order to prevent system damage through shorts and 144 malfunctions and for general ease of maintenance it is recommended that a number of fuses be placed in the system for protection Fuse ratings will be dependent on m 4 i the overall power rating and type of components in your syst
83. to be honored Should you have a bearing failure during the 3 year warranty period we will ask to see your log book as proof you have followed the maintenance schedule To maintain your hydro scheme in a good condition for years to come we recommend you keep alog book and regularly every week initially and once you become familiar with your system every 2 weeks do the following e Check the specific gravity of your batteries with a hydrometer and reduce your power usage if battery charge is falling BE ME HE e Check the acid level in your batteries and top up with distilled water as required BE ME HE e Check PowerSpout air vents are clean e Check hydro output is normal and has not changed since last checked e Check your diversion load is working BE ME HE e Check you have surplus water at the intake If not reduce your jet sizes e Check there are no obstructions twigs that have got in your pipe and are partially blocking the jets e Walk the pipe line each year and check for any damage to the pipe e One a year check termination points on your battery regulator inverter fuses and diversion load Clean and tighten as required If you observe any heat damage or corrosion at terminations attend to these and repair Remember to turn off all generation your inverter and remove battery fuses before cleaning tightening any termination points You should pay special attention to your diversion load and battery terminals
84. turbine over a wide range of flow rates you need to state this at the time of ordering A different generator core can be supplied for an additional charge 13 2 Installation details We recommend you take note of and let us know the final system details as below for future reference and to help with ordering replacements or upgrading the system Installation details Date installed Location of installation Pipe inside diameter Pipe length Jet size otatic pressure on gauge turbine off Dynamic pressure on gauge turbine running System nominal voltage Cable length m or ft Cable wire size mm Generator name e g 100 14S 1P delta 100 80 60 60dc S Performance data Flow rate of water through turbine Voltage on DC rectifier pins at hydro Voltage at battery terminals oP il o x x 3 Q9 U U 3 j Si ge olo asg mc ad 3 ES vigile P lt lt 5 Q lt 95 5 Current generated February 201 1 2011 Ecolnnovation Ltd NZ Page 52 PowerSpout Installation Manual We would also like you to let us know your performance data so that we can determine conversion efficiency at your site This helps us refine our calculations for future clients As every site is different efficiency will vary from site to site 13 3 Noise Noise is not normally an issue Our turbine in normally quieter than others as it turns slower and is fully enclosed Hence if noise is an issue at your site you should check the following
85. u install pipe with the correct pressure rating February 201 1 2011 Ecolnnovation Ltd NZ Page 49 PowerSpout Installation Manual 11 3 Grid power network connections PowerSpout GE is a grid tied option no batteries required available for clients that are already connected to the grid and have a good water resource close by Figure 4 shows the system configuration for a grid tied PowerSpout using a SunnyBoy inverter from SMA The PowerSpout Technical Manual contains further details including a wiring diagram and guidance on multiple PowerSpout turbines The PowerSpout GE provides a DC output which is electronically limited to never exceed 400 V DC Internally the output voltage is limited to approximately 385 V DC With this feature the PowerSpout GE may be connected directly to grid tied inverters and produce AC power to your local electricity distribution network from clean renewable hydro power WARNING Operating voltage within a PowerSpout GE is normally around 350 V DC At this voltage electrocution is likely 350 V DC is much more dangerous than the 230 V AC found in many European countries and must only be installed or serviced by persons trained in electrical work Please ensure you use a registered electrical worker who is familiar with this type of equipment and voltages February 2011 2011 Ecolnnovation Ltd NZ Page 50 PowerSpout Installation Manual 12 Troubleshooting The fault finding procedure here
86. ur log book February 2011 2011 Ecolnnovation Ltd NZ Page 46 PowerSpout Installation Manual 10 3 Changing the bearings You will need to check the bearings every year and replace if required note our warranty terms require annual replacement Bearings are inexpensive and easy to replace We recommend you hold a spare bearing block and shaft on the shelf to make this procedure very easy and quick to do A spare set of lower quality bearings is supplied with each new turbine these are only to tide you over until you can buy the correct SKF explorer bearing specified for this equipment Some of our Pelton turbines have been running on original bearings at customer sites for over three years though we do not recommend that you do this For turbines running at high pressures above 100 m head and high output power above 1200 W you should seek our advice Generally units running above our approved ratings only carry a limited 1 year duration warranty The PowerSpout ME and GE is available in a high power special version that is capable 1 6kW at 1600 rpm on a 120m running head To replace bearings Remove front glazing P8008 and casing end cap PS002 Remove Pelton rotor P8050 by removing bolt P8040 Remove Smart Drive rotor PS061 by turning extractor knob PS063 Remove Smart Drive stator P8060 by removing the four fixings PS026 Detach bearing lubrication tube PS093 Remove four slinger fixings P9034 You can
87. ur power shed for wet normal and dry period flows You may be able to further increase the power output from your turbine using larger jet sizes This has the effect of increasing the flow rate There comes a point when the increase in flow rate causes a dramatic drop off in pressure due to increased pipe friction losses This occurs when the pressure in the pipe Just prior to the jet drops to 2 3 of the static pressure pressure when valve closed When this point is reached increasing the jet size further will reduce the power output but consume more water The jet sizes required will have been calculated based on the head pipe size and flow indicated Some fine tuning on site will be required When operating your Smart Drive generator near the maximum power level for the rpm it is operating at you will notice that a little more or less Smart Drive rotor packing does not make a significant difference A 1096 reduction in rotor magnetism results in approximately a 10 drop in Smart Drive generator input torque which results in an approximately 5 rise in Pelton wheel rpm which results in a 5 increase in Smart Drive torque The two 5 rises will be almost as much as the 10 reduction in rotor magnetization February 201 1 2011 Ecolnnovation Ltd NZ Page 41 PowerSpout Installation Manual This is best illustrated in the Smart Drive test graph Figure 6 A 10 reduction in the rotor magnetism to the stator reduces the power line s height
88. w ones CERES View showing rear cover installed For the BE and HE version the lid will need to be removed while turbine performance is being optimized Remember to replace the lid once optimization is complete The Smart Drive rotor is a rotating hazard that will cause injury if touched during motion The rear cap of this turbine forms part of an electrical enclosure and carries warning signs indicating there are both rotational and electrical hazards present The turbine must be turned off and unplugged or breaker turned off prior to removing this cover 3 11 Installing front glazing The front glazing enables the owner to see that the turbine is running at the correct speed and that the water jet is clean and hitting the Pelton rotor at the correct position It also protects anyone from accidently touching the rotating Pelton rotor and from getting very wet February 201 1 2011 Ecolnnovation Ltd NZ Page 15 PowerSpout Installation Manual View showing front glazing installed Six toggle latches allow you to quickly attach and remove the front glazing for jet size optimization Once optimization is complete six self tapping fixings also need to be attached to prevent accidents Turbines that are installed in locked buildings do not need these fixings though it is best to use the fixings so that water does not leak February 2011 2011 Ecolnnovation Ltd NZ Page 16 PowerSpout Installation Manual 4 Where and how to
89. xible platform for variable flow sites February 2011 2011 Ecolnnovation Ltd NZ Page 7 PowerSpout Installation Manual We have noticed a trend by other hydro manufactures to approve MPPT regulators without any voltage limiting control in the turbine We can advise that our BE turbine may be used with MPPT regulators if you have a 12 or 24 V DC battery bank This is because the risk of overvoltage and hence regulator damage is increased at 48 V DC e MPPT Regulators have a maximum input voltage above which they will be damaged You can estimate the maximum battery voltage you can have without voltage protection if you assume that most MPPT regulators stop working 10 volts below their stated maximum input voltage e The static head of the site determines the maximum revolutions RPM of the unloaded turbine This occurs when the rotor is running at the same speed as the water jet e Measurement errors of the head may result in a 10 overestimate 90 correct of the jet velocity The running voltage of the hydro turbine will be 60 of the open circuit voltage at the correct running RPM e A free spinning unloaded hydro turbine spins at 2 times its normal speed For example MPPT regulators like the Outback FM60 80 will be damaged if voltages exceeds 150 V DC but will stop working at 140 V DC Therefore the maximum battery voltage you can have without any over voltage protection is 140 x 0 9 x 0 6 2 37 8 V DC Therefore 24 and 12 V

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