AQUA6GEN OWNERS MANUAL CE
Contents
1. DIAGRAM SHOWING THE 4TB REGULATOR CONTROLLING AN AQUA6GEN AND A SOLAR MODULE REGULATOR MODEL MAX SOLAR PANEL WATTAGE 4TB 50 WATTS SOLAR MODULE SEE TABLE ABOVE FOR MAX WATTAGE ECECECECEECECEEGC TO LLLLELLLLLLLLLLLL AQUA6GEN PreeCe reer cere LLL LL EE EE CEL ILE EPP Er Pr rE i ec Wa CELCLECCLCELELECLCE n RED J BLACK BLACK RED BLOCKING DIODE H WITH A CURRENT RATING A al TO MATCH SOLAR PANELS MAX OUTPUT Note position of band ma TERMINAL BLOCK DUMP RESISTOR RED 00 BLACK TB UNIT GREY CABLE GREY CABLE a FUSE SEE TABLE WITHIN INSTUCTION LEAFLET FOR RATING d RED CABLE BLACK CABLE FUSE _ RED CABLE j HEAVY DUTY LINK CABLE I I No 1 BATTERY No 2 BATTERY 102. Loctite between the outer main bearings bore and the main shaft 16 Fit new 15mm circlip on main shaft 17 Fit new main shaft water seal grease well on assembly 18 Refit rear cover using a new gasket make sure all internal wiring is clear of the rotor OCO ENH qnH eulquny 00S MANOS poe uong A949S 0ZX9NW 16 M3HSVM JOYUSDM QW LEL M3HSVMI oig wwg JOUSDM SIN S23S90V Fld COL 318VO lqeo Indino SIT SLYVd N499YNO _ 060 3GV18 pojg eulqun ZLO AdOUN Se4JoW 61 edoy moj uebgonby L00 LIVHS JOYS ulqinl 68S YASILOIN 19144094 espud q OVS YIHSVM JeUSPM APIS N ae CN N k x j _ 68 Lod sea sexon 100 dWvID dujb o edoy N M L00 N3SVnO0V Bulsog uN a a YZO MOLVIS AVZ 49191S eee asun A ZIL YOLVISH AZL 4041S j 84 9NIYVIg NV Ew 1 WonddzosgysNn fa lt p UlADS Uuojd ulio 6S LAN PN EW SSS SMES i ee Loo ONNdNoo budnog aaug L00 HSnd LYG M3HSVA 4 HdsDA 24914 SW EOS A389S M S K N L00 GNVIO purjo qoo X x N N ANNA dLE YIACO 19409 spey a ZZ YOLIOVdVO Ajollopdpo Uolsseuddng _ Gry YIHSVM JeysoM Bulo SW LG8 A33O0S Melos Bululpjey 491D1S S X SW SSSSRSS
3. AQUA6GEN OWNERS MANUAL CE DEE SHACKLE LVM AQ612 12 Volt LVM AQ624 24 Volt CHECK LIST Generator Drive Coupling Dee Shackle 8mm Turbine Shaft Assembly Turbine Blades 90mm DRIVE COUPLING M6 x 20 Stainless Steel Cap Head M6 x 20 Stainless Steel Button Head Screws M6 Stainless Steel Spring Washer 1 OUTPUT CABLE P Pp a a oa M6 Stainless Steel Washers M6 Stainless Steel Washers 18mm Dia Aqua6gen performance with 90mm Tow Rope 19 Metres long turbine blades fitted Cable Rope Clamps Mounting Rope 3 Metres long Allen Key 5 mm A F Allen Key 4 mm A F 80mm length of Seizing wire N oa ak ak 32 Ph PP a Amps output 12v 3 0 2 4 6 8 10 12 14 Boat speed knots Note Amps output of a 24v model will be half shown above Guarantee Thank you for purchasing this product It has been manufactured to exacting standards and LVM Products guarantees that should any defect in materials or workmanship occur within ONE YEAR of the date of purchase we will repair or replace the defective part free of charge Damage caused by misuse failure to follow instructions negligence and modification or transit damage will not be warranted LVM Products will not be liable for any loss of revenue or any consequential loss or damage to property or persons from any cause whatsoever Retain your purchase inv
4. ORSS gt f 49 Z usng zuo4jg WHE gol N wo oe v99 MANOS m s dD 49S 6 X VON 87S LINSVO J9xSOQ 19409 4091 ZLO AdON F S j9W odoy BullunoWw u 6pnby XY 00S ASSY LIVHS Ajquuessy 1040Y X HOUS UIDW N O placed ose aiSia Jeysom Buds gW SLE MAINOS M 9J9S ddd WWOZXOW 0S9 TYIS IbeS ubus Z98 d 193l9 doo wwe 100 d 9W3I9 dll9440 wwoy L00 TSNOVHS B 4ODYS q SELECTING THE CORRECT LVM VOLTAGE REGULATOR The output of the Aquagen can be simply connected directly to the terminals of the battery that requires charging however if the terminal voltage of the battery is not continually monitored for over voltage 14 2v for 12v batteries and 28 4v for 24v batteries the battery can be seriously damaged Fitting an LVM voltage regulator will protect the battery from becoming over charged TEMPERATURE COMPENSATION This additional feature is available on all LVM regulators If the battery is located in a building where the ambient temperature is always around 20 deg C then standard regulators can be used However if you intend to locate a battery where temperatures may go down to freezing and perhaps rise to tropical temperatures then you should install a regulator that is fitted with a temperature compensation circuit This automatica
5. connectors from the rectifier 2 Attach the red test lead from multimeter to the plus terminal of the rectifier attach the black test lead to the negative terminal RESULT No Reading 3 Reverse the test leads i e attach the red test lead to the negative terminal of the rectifier then the black test lead to the plus terminal RESULT 0 8 0 9 volts 4 Connect the test leads to the 3 centre terminals of the rectifier Readings taken of a Faulty Rectifier 1 Disconnect all connectors from the rectifier in pairs RESULT No Reading 2 Attach the red test lead from multimeter to the plus terminal of the rectifier attach the black test lead to the negative terminal RESULT 0 Volts 3 Reverse the test leads ie attach the red test lead to the negative terminal of the rectifier then the black test lead to the plus terminal RESULT 0 Volts 4 Connect the test leads to the 3 centre terminals of the rectifier in turn in pairs RESULT 0 Volts If in doubt about the condition of the rectifier replace with a new one Refit the 3 off 3 phase stator output leads to the centre terminals of rectifier Set the multimeter to read DC volts Attach the red test lead of the multimeter onto the plus terminal of the rectifier then the black test lead onto the negative terminal Turn the main shaft of the generator by hand any direction this should indicate a voltage on the multimeter Refit Red and Black DC output leads f
6. do this at around 1 2 Knots as the rope will start to turn as soon as it enters the water The turbine is designed to surface at the following speeds Small 90mm turbine blade 14 knots Retrieving the turbine tow rope can be achieved in two ways 1 Slow yacht boat to 1 2 Knots then pull in towrope 2 Make a tack to turn the yacht boat at 90 Deg to slow it down and bring along side the turbine tow rope When pulling in the towrope it is very important that it is untwisted and coiled neatly ready to use again Note If for any reason the turbine surfaces before 14 knots when using the using the 90mm blades this may be caused by your particular hull shape of the yacht creating an underwater wash effect add one or two 25mm propeller shaft anodes should be fitted to the turbine shaft close to the turbine hub increase the length of the tow rope VERY IMPORTANT If you do not intend to use the LVM voltage regulator with the Aquagen it is extremely important that a similar type of regulator is used ie It must be a shunt diverting type regulator that always keeps the Aquagen on load YOU MUST NEVER USE A REGULATOR THAT SIMPLY TURNS OFF AND ON THE OUTPUT OF THE AQUAGEN WHEN THE BATTERY IS FULLY CHARGED THIS CAN LEAVE THE AQUAGEN IN AN OPEN CIRCUIT CONDITION WHICH WILL ALLOW THE TURBINE TO ROTATE AT VERY HIGH SPEED AND DAMAGE THE UNIT MAINTENANCE 1 Check drive shackle bronze bushes for wear Apply a little marine grease to the bronze bushes
7. from time to time Typical life of the bronze bushes 3 000 7 000 nautical miles e 2 Check the tow rope for wear at intervals particularly the area around the 9 Dee Shackle and Eye bolt on the turbine shaft By cutting 1 to 2 inches off the rope a new section can be created i 3 Check tightness of the Dee Shackle pin Drive coupling assembly TROUBLE SHOOTING The AQUA6GEN generator unit is design to give many years of reliable service as it contains really only one moving part and one electronic component they are the permanent magnet rotor and a 3 phase rectifier The only parts that can wear are the main bearing ball races SIMPLE TEST A simple test to prove there is an output voltage from the Aqua6gen can be carried out whilst the Aqua6gen is in it s working position Disconnect the Aqua6gen output cable from the battery or the TB regulator if fitted With the towrope disconnected turn the main shaft it should turn freely Note There will always be a slight resistance felt this is the cogging effect of the generator then touch the two output leads together shorting them the main shaft should now be noticeably more difficult to turn If this does not happen check that your extension wire connection from the actual Aqua6gen output cables are not corroded or have become disconnected If there is a fuse fitted in the output cable check it has not blown The following tools and equipment will be needed to carry out
8. ging vibration when rotating and an electrical vibration whilst charging This noise will be greatly amplified if the Aqua4gen is mounted on a very hollow section of a yacht boat INSTRUCTIONS FOR REMOVING AND REPLACING MAIN BEARINGS Parts required 2 off Main bearings LVM Part No Bearing 783 1 off Main shaft water seal LVM Part No Seal 650 1 off Rear cover gasket LVM Part No Gasket 548 2 off Circlips 15mm LVM Part No Circlip 862 6 off Rear cover retaining screws LVM Part No Screw 664 1 off Small amount of Loctite 638 in tube Tools required Hammer Circlip pliers Pozi drive screwdriver Piece of hardwood and a brass rod 12mm diameter X 250mm long or similar 1 Disconnect output leads and remove Aqua4gen from mounting 2 Remove the main shaft water seal pierce seal front face with screw driver and lever out 3 Remove the front 15mm circlip on the main shaft 4 Remove 6 off self tapping screws retaining the rear cover 5 Place a piece of hard wood on a concrete floor Holding the Aqua4gen with the rear cover held back and main shaft downwards lift and force downwards the generators main shaft onto the piece of hard wood This should displace the main shaft inwards Alternatively the main shaft can be pressed out or hammered out but take care not to bruise the end of main shaft 6 The main shaft rotor assembly should now have moved inwards into the main housing 7 Using a piece of brass rod or similar s
9. he battery regulator See Diagram 5 opposite The BROWN WIRE is connected to the POSITIVE terminal and the BLUE WIRE to the NEGATIVE terminal VERY IMPORTANT BE CAREFUL AS INCORRECT CONNECTION WILL DAMAGE THE RECTIFIER WARRANTY WILL BE DISCLAIMED WARNING THE AQUAGEN MUST NEVER RUN OPEN CIRCUIT AS HIGH VOLTAGES CAN BE PRODUCED AND THE SUPPRESSION CAPACITORS MAX VOLTAGE MAY BE EXCEEDED VOLTAGE REGULATION The output wires of the Aqua6en can be connected directly to the terminals of the battery that requires charging as shown in Fig 5 however if the terminal voltage of the battery is not continually monitored for over voltage 14 2v for 12v batteries and 28 4v for 24v batteries the battery can be seriously damaged Fitting an LVM voltage regulator will protect the battery from becoming over charged You may well have chosen a voltage regulator when purchasing the Aero4gen but we would recommend you look at page 9 SELECTING THE CORRECT LVM VOLTAGE REGULATOR to make sure you have purchased the correct unit You may also consider installing an ammeter voltmeter or an amphour meter all are available from LVM Products part number as follows LVM67 0 20A Ammeter LVM69 0 15v dc Voltmeter LVM200 Digital Amp Hour Meter OPERATING INSTRUCTIONS The towrope with the turbine attached should be stored in a neat coil close to the Aquagen Once under way in deep water the turbine tow rope can be payed out It is safer to
10. ies to be charged The Aqua6gen and a Solargen modules output may often be combined the table below shows the recommended regulator for various systems Note Two batteries wired in parallel are classed as one independent battery Having selected the recommended regulator model from the table simply add the voltage required ie 4TB12 for a 12v system or 4TB24 for a 24v system Basic wiring diagram are shown on page 10 If you cannot find your particular system or application within the table or require full wiring diagrams please check our web site www lvm ltd com or call our sales office who will e mail fax or post you copies VOLTAGE REGULATOR TABLE Number of independent batteries to be charged SYSTEM 1 2 3 4 1 x Aqua6gen 4TB 4TB 4TB 4DU 4TB 6DU 1x Aqua6gen 5w Solargen panel 4TB 4TB 4TB 4DU 4TB 6DU 1x Aqua6gen 10w Solargen panel 4TB 4TB 4TB 4DU 4TB 6DU 1 x Aqua6gen 17w Solargen panel 4TB 4TB 4TB 4DU 4TB 6DU 1 x Aqua6gen 25w Solargen panel 4TB 4TB 4TB 4DU 4TB 6DU 1 x Aqua6gen 25w 10w Solargen panel 4TB 4TB 4TB 4DU 4TB 6DU 1 x Aqua6gen 25w 25w Solargen panel 4TB 4TB 4TB 4DU 4TB 6DU TO AQUASGEN DUMP RESISTOR LTRS GREY CABLE GREY CABLE i _ RED CABLE 5 BLACK CABLE FUSE g HEAVY DUTY LINK CABLE No 1 BATTERY No 2 BATTERY TWIN BATTERY VOLTAGE REGULATOR WIRING DIAGRAM CIRCUIT
11. lly allows the battery to be charged at a higher voltage as the temperature drops and a lower voltage if the temperature increases Simply add T after the LVM Product No ie 4TB12 T The regulator suitable for the Aqua4gen Twin battery regulator LVM product No 4TB12 4TB24 These units are connected between the output of the Aquagen or Solargen module and the battery terminals They control the actual output voltage of Aquagen or Solargen by diverting power to a high wattage wire wound dump resistor when their output voltage reaches 14 2v 12v systems or 28 4 24v systems They have two schottky blocking diodes built into the regulator which enables them to monitor and control the charge to two batteries totally independent of each other therefore making it ideal for separate charging of engine starting and domestic batteries The battery with the lowest terminal voltage will be charged first then gradually when both batteries become fully charged the Aquagen or Solargen modules output is automatically diverted to the dump resistor this does two things it stops the batteries over charging and keeps the Aqua4gen always on load Note This regulator draws NO standby current from the battery Also available from LVM Products are Diode Units LVM product No 4DU 6DU The 4DU when combined with a 2TB or 4TB regulator enables one additional battery to be charged The 6DU when combined with a 4TB regulator enables two additional batter
12. o as not to damage the end of the main shaft tap the shaft through both the bearings and remove rotor assembly from the rear of the main housing 8 Having removed the rotor from casting Check the main shaft for wear particularly the areas the main bearings are positioned If the shaft wear is found to be excessive a new shaft will have to be fitted Contact LVM Products 9 Remove the large internal circlip which is located in front of the main outer bearing then using a brass rod anda hammer knock out the main bearings from the casting 10 Refit new main bearings using a little Loctite Bearing Fit smeared on the O D of the bearings 11 Refit large internal circlip in front of main outer bearing this circlip is acts as a spacer for the water seal 12 Clean the main shaft then clean the rotor magnet with sellotape sticky side to remove small pieces of steel pickup 13 Smear a little Loctite Bearing Fit onto the main shaft close to the rotor and in the bore of the outer main bearing 14 Insert the main shaft rotor assembly into the generator main bearings WARNING The rotor magnets are very powerful and will quickly draw the assembly into the stator When the main shaft rotor assembly is fully inserted check it rotates without rubbing 15 Smear a little Loctite Bearing Fit on the outer main bearing inner race to shaft i e between the O D of the shaft and the I D of the inner race Push the main shaft in and out a little to spread the
13. o retain the lower section of the mounting rope 2 Front view of Aquagen correctly mounted 3 Rear view of Aquagen correctly mounted TURBINE ASSEMBLY Fit the plastic propeller blades onto the turbine hub using the M6 X 20 Button Head Screws M6 Stainless steel washers using the Allen key supplied Note the large diameter washers are used on the thinnest section of the blade Photo 4 2 4 Turbine Assembly Fully tighten Dee Shackle pin and mouse with seizing wire supplied 5 Attaching the tow rope to the drive coupling 6 Attaching the tow rope to the turbine Photo 5 ATTACHING THE DRIVE COUPLING TO THE AQUAGEN MAIN SHAFT Align the M6 clearance hole in the drive coupling with the M6 tapped hole in the main shaft Fit the M6 spring washer under the head of the M6 x 20 Allen bolt Insert the bolt through the M6 clearance hole in the drive coupling and fully tighten it into the main shaft using the Allen key supplied Photo 6 ATTACHING THE TOW ROPE TO THE TURBINE AND DRIVE COUPLING The Aquagen is supplied with 2 off cable rope clamps these should be used as shown in Photos 5 amp 6 ELECTRICAL DATA Aqua6gen output cable colour Code The Brown output wire is POSITIVE The Blue output wire is NEGATIVE Wire Rating The output wires of the Aero6gen will require extending Electrical systems lose energy from the resistance of the wire size used The larger the wire size the smaller the loss however larger cross sectional a
14. oice as it will be needed in the event of a warranty claim What is Not Covered e Damage due to improper installation e Damage due to improper wiring Please read the manual thoroughly If you have any questions please contact us at Jabsco amp Rule Bingley Road Hoddesdon Hertfordshire EN11 OBU UK Tel 44 0 1992 450 145 Fax 44 0 1992 467 132 Jabsco UK Sales Icknield way Letchworth Garden City Hertfordshire SG6 1EZ UK Tel 44 0 1462 480 380 Fax 44 0 1462 482 422 Jabsco GmbH OststraBe 28 22844 Norderstedt GERMANY Tel 49 0 40 53 53 73 0 Fax 49 0 40 5353 73 11 Jabsco Marine Halia S r l Via Tommaseo 6 20059 Vimercate Milano ITALY Tel 39 039 6852323 Fax 39 039 666307 Discover Jabsco at www LVM Ltd com MOUNTING The Aquagen is designed to mount onto the pushpit using the 3M x12mm Dia braid on braid rope supplied It is VERY IMPORTANT to use the rope mounting method as shown in photos 1 3 this keeps the unit balanced and allows the Aquagen to swivel and pivot correctly to track the turbine Failure to use this exact method of mounting will cause vibration and excessive wear on the bronze bushes in the drive coupling Ensure the knots shown in photo 2 are made on the front face of the unit and the rope goes back through the lower mounting holes of the unit then tied off to the bottom rail as shown in photos 2 3 If only one rail is available fit a deck mounted eyebolt t
15. rea wires can be costly and in some cases more difficult to source The following table shows recommended wire sizes they are based ona 3 and 5 energy loss at an average boat speed of 10 knots It is recommended a minimum wire size of 2 5 sq mm be used Single Wire Length 0 5 Metres 6 10 Metres 11 20 Metres Voltage Drop 3 5 3 5 3 5 12 volt Aqua6gen 6 0 mm 4 0 mm 16 mm 10 0 mm 25 mm 16 mm 24 volt Aqua6gen 2 5 mm 2 5 mm 4 0 mm 2 5 mm 6 0 mm 4 0 mm A useful wire cross sectional area mm conversion to AWG 2 5mm 14AWG 4 0mm 12 AWG 6 0 mm 10 AWG 10 0 mm 8 AWG 16 0 mm 6 AWG 25 0mm 4AWG If the Aqua6gen is connected directly to the battery terminals we recommend a 20 Amp fuse for 12V Models and a 10 Amp fuse for 24v Models is fitted in the brown positive wire from the generator to the battery so that if a dead short occurred it would prevent serious damage to the wiring and the generator The BROWN OUTPUT WIRE output is connected to the f POSITIVE terminal of the battery FUSE The BLUE OUTPUT WIRE to the NEGATIVE terminal of the a y BLUE WIRE battery BROWN WIR wl Thread the Aquagen output cable carefully through a deck gland attach the push on connectors and covers supplied to the end of the output cable and the end of your extension cable Observing polarity plug them together The output wires are then connected to t
16. rom the rectifier Refit rear cover using a new gasket make sure all wires are clear of the rotor ELECTRICAL COMPONENT DIAGRAM OF AQUA6GEN 3 PHASE STATOR WINDING STAR CONNECTED 3 PHASE RECTIFIER S20VT80 Cable Gland GLAND 001 Output Cable CABLE 700 LE NAME AQ6TEST ELECTRICAL SCHEMATIC DIAGRAM OF AQUA6GEN 3 PHASE STATOR WINDING STAR CONNECTED RESISTANCE OF EACH PHASE 2v MODEL 0 9 OHMS 24v MODEL 1 7 OHMS 1uF tuf 250v 250v 3 PHASE vv Vv RECTIFIER Cable Gland GLAND 001 t Output Cable CABLE 700 BROWN WIRE N BLUE WIRE KNOCKING SCRAPING SOUND ONCE PER REVOLUTION Whilst the generator is in it s working position check that the M6 allen screw which retains the drive coupling assembly to the main shaft is fully tightened Remove rear cover and check the condition of the rotor it may be rubbing on the stator Inner main bearing could be worn check for axial and radial movement Check the tightness of the 4off M5 stator retaining screws this can cause a noise if slightly loose GENERAL MECHANICAL CONTINUOUS NOISE Remove the towrope and check axial and radial play in the main front bearing Remove rear cover and check inner main bearing in the same manner If large amount of play is found replace main bearings Follow instructions listed REPLACING MAIN BEARINGS GENERAL ELECTRICAL VIBRATION NOISE It is normal for the Aqua4gen to produce a very slight magnetic cog
17. tests and repairs to the Aqua6gen A multimeter which can read 0 100 volts DC measure resistance have a diode test and a continuity buzzer test Pozi drive screwdriver Circlip pliers Soldering iron and solder Hammer Piece of hardwood and a brass rod 12mm diameter X 250mm long or similar For pivot bearing replacement a bench vice will be required MEASURING OUTPUT VOLTAGE If you have a lathe or some other means of turning the main shaft at a known RPM a 12v model produces 0 036v per rev and a 24v model 0 072v per rev If no voltage is present check that your extension wire connection from the actual generators output cables are not corroded or have become disconnected If there is a fuse fitted in the output cable check it has not blown Check output voltage again at the generators actual output cable If there is still no voltage output go to the instructions and tests listed under heading NO OUTPUT REDUCED OUTPUT 1 Check turbine blades are not damaged 2 Check towrope is not kinked and twisted 3 Check main shaft of Aquagen turns freely Note There will always be a slight resistance felt this is the cogging effect of the generator 4 If the output from the Aquagen has been connected to the battery the wrong way round reverse connection the rectifier will be damaged but still may give a reduced output Replace rectifier NO OUTPUT 1 Using a multimeter check continuity of output extension cable and connec
18. tors 2 Check fuse 3 Remove the generator from mounting Remove the rear cover 6 off screws and hinge back cover A component called a rectifier that converts the 3 Phase A C output voltage of the stator into D C volts is mounted on the inside of the cover Note later models have also suppression capacitors soldered to the rectifier Disconnect the 3 push fit connectors output wires from stator which are attached to the centre terminals of the rectifier No need to remember which order or terminal they come from as they can fit on any of the 3 centre terminals Using a multimeter set on resistance measurement ohms check the resistance in turn of the of 3 output wires in pairs from the stator They should read 0 9 ohms 12v model 3 5 ohms 24v model CHECKING A C OUTPUT VOLTAGE OF STATOR Set the multimeter to read A C volts attach test leads to the 3 off stator output wires in pairs then turn the main shaft of the generator by hand any direction small voltage should be indicated on the multimeter Check the stator and suppression capacitors do not look burnt or overheated Check tightness of stator retaining screws If at any time the generators output leads have ever been connected to battery terminals the wrong way round or the generator has been struck by lightening then the rectifier may be have been damaged RECTIFIER TEST Readings taken of a Good Rectifier Set a multimeter to diode test then check 1 Disconnect all
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