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PowerSpout Installation Manual Domestic install

1. 3 8 Assembling Smart Drive Generator First connect the AC wires as shown below wire order is not important January 2010 2010 Ecolnnovation Ltd NZ Page 11 PovverSpout Installation Manual Shots shovving vviring and location of generator stator Place the generator stator and vvasher into position attach vvith 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 clockvvise until the rotor is pulled fully home do not over tighten finger tight only Attaching the Smart Drive rotor 3 9 Electrical checks vvith covers off These instructions are for PovverSpout BE only Similar tests for other versions of PovverSpout are included in the Technical Manual and should only be conducted by suitably qualified electricians These tests ensure you have completed the output connections and have no unwanted earth connections Operation of the protection electronics is also confirmed 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 soeed 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
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3. 12 1 Link to online updates Please refer to our online FAQ for the most recent updates January 2010 2010 Ecolnnovation Ltd NZ Page 41 PovverSpout 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 nits 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 12 24 48 Volts MPPT controller you intend to use O tie inverter you intend to use 13 2 Installation details What is the cable length from turbine to batteries 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 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 m or inch m or ft mm or inch kPa or PSI kPa or PSI System nominal voltage ANNA m or ft mm 7conductor 100 80 60 60dc S
4. PovverSpout Installation Manual 12 Troubleshooting The fault finding procedure here is concerned vvith only the PovverSpout 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 If Watts are less than 20 then do the ab
5. delta star Performance data Vs or gal min January 2010 2010 Ecolnnovation Ltd NZ Page 42 PovverSpout Installation Manual 13 3 Feedback We welcome your feedback on how we can improve our products including this manual 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 January 2010 2010 Ecolnnovation Ltd NZ Page 43 PovverSpout Installation Manual 14 Units and conversions 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 An ohm 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 A Watt is the electrical unit of power that is the rate of energy transfer equivalent to 1 ampere flowing under
6. rs Joy ee si v lo z r z l lo a v v zzi sor se z es ee ee zi er s z r z l Jo 2 eri 102 es o eo ler oe se l l zi 6 9 r z l Jo to ver zi es sz es ler ee ez or fu Je 9 ir z li Jo irs yei vor os o ss le re liz yi v le ie z l Jo 2 en es ze es lor oe te ti or 2 e z l Jo es en s laz c os ec ez oz ci or 2 s e z l jo os zo os vz 109 ev ve ze le zi s 2 ie z l jo s rior fes oz zs sr re se je s e l y ic z l jo w vo fe os es ev ze ve l r lo s l y e li jo 0 e ez l lov lec loc ez si lo z s y z l ll jo z roe z ss lsr se uz oz ls z s e iz v l jo v os Jos o ze re C s l r e iz l lo Jo os es lev se iz l r Tu z s y le iz y lo Jo rr z fes lev se fiz lsr u z s y e iz y lo Jo w oe 192 o l r z e l r le iz z r lo Jo s PIC OL LL 8 6 9L 6 21 OL Z 8 9L S YI shd s y uj ul 1939UeI ZIS jor DOJA f jof ouo um aynuIW d suolleb ul MO 9 3 8 jenueyy UOHE E SU nodS od Installation Manual PovverSpout Table 7 Flow in liters per second I s with two jets Jet Size Diameter in mm Jet Velocity m s 4 4 14 02 03 03 04 0 5 08 10 13 171 211 30 41 54 68 75 101 17
7. 3 2 1 Cutting the jets to correct size ss 9 3 3 Installing jet assemblies 4h 8382882 888 8338 9 3 4 Installing the Pelton rotor 4 9 3 5 Pelton Rotor Alignment 2 ss 10 3 6 Assemble lubrication system asa c CER e nec ee ee 10 3 7 Assembling rectifier wire and plug lead 11 3 8 Assembling Smart Drive Generator VU 11 3 9 Electrical checks with covers off 12 3 10 Installing rear B 47 8 13 3 11 Installing front glazing 8888 43284388333333 13 4 Where and how to site the turbine 2888888888 88 8833333333 14 4 1 Regulations and good practice guidance 14 4 2 Siting your PowerSpout turbine ss 14 4 2 1 Cable sizing rule of thumb method for long Cables 15 4 2 2 Connecting two small streams into one PovverSpout 15 20 A ne EE a Teraa Taduse haces 16 A U ii ii ee 17 5 Ensuring good water supply 18 0k L 7 r ee 16 SF e 18 52 MIDES abri 19 0202 00 ii 20 5 5 LAYING and Securing pipes sees ee ee ee eee 20 5 6 Intake design and placement 20 5 7 Water diversion and return 21 5 8 Connecting the pieces 22 5 8 1 Connecting your pipe to the PovverSpout 22
8. 5 8 2 Advice for USA and all countries that use NPT threads 22 AA s d b s d does at acier cree ions 22 6 Getting the best from your batteries 23 6 1 Battery type size and life 23 6 1 1 What is electricity and batteries 23 Dz Os 24 6 2 1 Battery installation example 1 25 2010 Ecolnnovation Ltd NZ PovverSpout Installation Manual 6 2 2 Battery installation example 2 25 7 Cable connections PovverSpout BE Vs 26 7 1 PovverSpout BE wiring Battery Enabled 26 li FUSO d n 27 Falla o b ee 27 daa as 28 si o m es 28 50 50 A ee 28 7 1 6 Earthing requirements 28 5 FONTOS A 29 Ye PES COMMISSIONING acrea o De m no 30 9 1 Packing out the sise 31 9 2 Thermal Checks ce ss s s 33 10 Operating your system efficiently siens 35 10 1 Spare Oli m ib D b 10 2 Lubricating the bearings 0 7 36 10 3 Changing the bearings Rs 36 AO s b v Si lab 39 11 1 Front glazing and rear cap safety vvarnings 39 11 2 Pressurised water pipes assassins 39 11 3 Grid power network connections VU 40 12 oo T nb 41 12 1 Link to online updates 4750 Ses 41 13 Site
9. 60 degrees Celsius after 2 3 hours of operation Ecolnnovation will have fitted air vents for turbines above 400W 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 be 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 January 2010 2010 Ecolnnovation Ltd NZ Page 34 PovverSpout Installation Manual 10 Operating your system efficientiy The PovverSpout is a durable machine but it runs 24 7 so regular checks and maintenance are advised A PovverSpout may do more revolutions in one year than a car engine during the life of the car so 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 to be honored Should you have a bearing failure during the 3 year vvarranty period vve vvill ask to see your log book as proof you have follovved the maintenance schedule To maintain your hydro scheme in a good condition for years to come vve recommend you keep a log book and regularly every week initially and once you become familiar with your system every 2 vveeks do the follovving 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
10. Average daily draw from the battery bank allowing for 10 battery loss and 10 inverter loss 500W x 0 8 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 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 20 more than you use to allow for system losses Two parallel battery strings are better than one if you do get a loose 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 e Batteries operate best when kept
11. 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 January 2010 2010 Ecolnnovation Ltd NZ Page 35 PovverSpout Installation Manual block Table 3 since spare parts from NZ can take up to 10 vvorking days to arrive to global destinations Table 3 Recommended minimum spare parts set Sub 2 PS020 PS022 Nos Shaft and bearing assembiy 660600 1 Bearing block D76x118mm 8882 1 Front bearing 6205 OD52 ID25mm 0806060 8023 1 Rear bearing 6005 OD47 ID25mm PS024 1 Sha D25x276mmlong 60 8025 1 Shaft retaining nut 32AFx mm thick 00600 10 2 Lubricating the bearings You should lubricate your PovverSpout bearings at the time you first use it and then e Every 12 months for generation up to 300 VV e Every 6 months for generation up to 600 VV e Every 3 months for generation up to 1200 VV Any good quality automotive type grease can be used For high povver units and in high ambient air temperatures a grease suitable for operation at 60 degrees Celsius should be used With the turbine running connect your grease gun onto the grease nipple provided Pump into the bearing block about 25 mL of grease This is normally about 15 25 pumps of
12. The water jet should hit the splitter the straight knife edge of the Pelton spoons January 2010 2010 Ecolnnovation Ltd NZ Page 9 PovverSpout Installation Manual RD 7 4 E N gt 0 Q 2 h d E y y E L lt T d A TEL af z h r T Pelton fixing washers front and rear views e T e Insert bolt PS040 spring washer PS1043 and washer PS042 as shown e Install alignment washers 5041 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 L A AR Top hat drain hole points dovvn La 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 bearing block are pointing downwards 3 5 Pelton Rotor Alignment You can view the Pelton rotor by looking through the jet as shown below 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 below 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 5091 PS094 as shown below and tighten January 2010 2010 Ecolnnovation Ltd NZ Pa
13. a pressure of 1 volt at unit power factor 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 January 2010 2010 Ecolnnovation Ltd NZ Page 44 PovverSpout 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 effectiveness of our range of water turbines Hence we offer you e Full refund if 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 PowerSpout must be given the opportunity to rectify the problem Clients need to pay for return freight cos
14. acid level in your batteries and top up with distilled water as required BE ME HE e Check PowerSpout air vent 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 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 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 plug in large resistive heaters as these can knock years off your battery life and overload your inverter system
15. 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 further the pressure in the pipe resulting in less power generation Another common myth is that pipe bends cause 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 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 p
16. 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 January 2010 2010 Ecolnnovation Ltd NZ Page 12 PovverSpout Installation Manual 3 10 Installing rear cover Once all internal components have been installed the rear cap can be attached To prevent rain vvater leaking into the casing a sticky backed sealing strip PS003 is attached to the main casing PS001 The lid is then held in place with six fixings PS0004 Do not over tighten fixings or you vvill strip the thread in the plastic housing Vievv shovving rear cover installed For the BE and HE version the lid vvill need to be removed vvhile 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 co
17. 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 this equipment you should engage a renewable energy professional to do it for you 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 terminals 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 the 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 January 2010 2010 Ecolnnovation Ltd NZ Page 25 PovverSpout Installation Manual 7 Cable connections PovverSpout BE This section included wiring diagrams for PowerSpout BE only for other versions please refer to the Po
18. 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 January 2010 2010 Ecolnnovation Ltd NZ Page 16 PovverSpout Installation Manual applications such as city vvater intake reservoir facilities for control valves and instrumentation povver and povver 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 preventing 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 5005 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 provi
19. 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 January 2010 2010 Ecolnnovation Ltd NZ Page 24 PovverSpout Installation Manual 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 soanner 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 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
20. data for hydro specification and improvements 42 13 1 PowerSpout site data e ee 42 13 2 Installation 461 5 47 42 AN o 0 5 r 43 14 Units and conversions 2888 888888 4883883383 8 33 e iii 3333333333 44 15 Warranty and disclaimer 2 iii 45 16 Annex I Jet sizing tables as X en 47 17 Annex Il Common PVC pipe SIZES sn 51 Figures Figure 1 Water supply system 2 Figure 2 PowerSpout BE system setup 888882 8338833 9 3 Figure 3 PowerSpout ME system setup 4 Figure 4 PowerSpout GE system setup 4 Figure 5 PowerSpout HE system 4 Tables Table 1 Different versions of PowerSpout Table 2 Pipes common in NZ indicative prices 2009 19 Table 3 Recommended minimum spare paris set 36 Table 4 Hydro site data required for product manufacture 42 Table 5 Flow in liters per second l s with one jet 47 Table 6 Flow in gallons per minute gal min with one fet 48 Table 7 Flow in liters per second l s with two jets 49 Table 8 Flow in gallons per minute gal min with two j
21. 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 WA controller for dumping in the dump resistor Fuse 5 should not break 8 unless fuse 4 has already broken or been disconnected To achieve this fuse 5 should be chosen to be tvvice the breaking rating of fuse 4 9 Linked circuit breakers see picture are available vvith tvvo poles linked together where if one breaker breaks then the others will also e 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 c your system uses Ac 8 7 1 5 Fuse6 Fuse 6 carries all load current from the batteries to the AC inverter t 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 BE output will continue to be connected to both the batteries and the diversion load controller and maintain DC voltage regulation 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
22. 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 a check 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 are 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 n Turn knob to optimize pack vvith plastics washers and tighten to ensure rotor stays in position set note a Y thickness stainless steel washer is also supplied 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 w
23. ks MA d f d N X LA dJ gn PEN 3 A E C V s E xs G r 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
24. of fuses be placed in the system for protection Fuse ratings will be dependent on the overall power rating and type of components in your system Main battery fuse holder 2 12 Meter box We strongly recommend our standard cabinet and meters with pre wired regulator and diversion load to go with your hydro turbine 1 M AS UNA b 4 Standard cabinet regulator and diversion load air resistive coil A January 2010 2010 Ecolnnovation Ltd NZ Page 7 PovverSpout Installation Manual 2 Assembling your PovverSpout 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 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 PS026 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 this should be pointing downwards Shaft PS024 Drain hole points down o Assembling shaft and seal slingers Front Pelton vvheel side Back smart drive side P
25. the four fixings 5026 January 2010 2010 Ecolnnovation Ltd NZ Page 36 PovverSpout Installation Manual Detach bearing lubrication tube PS093 Remove four slinger fixings PS034 You can 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 mallet hit the end the Smart Drive attaches to 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 The rear bearing PS023 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 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 January 2010 2010 Ecolnnovation Ltd NZ Page 37 PovverSpout Installation Manual e Clean up any excess loctite vvith a clean rag e Attach shaft retaining nut and snug up but do not over tighten Shaft should spin freely without any tightness e Spin the shaft in your fi
26. valves turned off e Dynamic pressure of pipe turbine running e Generator equilibrium temperature see Section 9 2 e Picture of installation e 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 e Allow pipe to run and purge of air bubbles on long small pipes this can take a few hours e Check for current flow to the load e Check regulators are working e 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 e Check for pipe and turbine fitting leaks and remedy as required e Walk the pipe and lift sections to locate any air locks and fit riser vents as required January 2010 2010 Ecolnnovation Ltd NZ Page 30 PovverSpout Installation Manual m r ma ae A ae 1 b e 2258 t m We a x C 5 AB 2 Guat gt AR d 5 kanye ak 0 Standard cabinet regulator and diversion 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 shovvs 3 amps diverted to the resistive load The picture shows the air diversion element with a slight glow indicating that it
27. Cells are the most common lead acid battery type in use today They are available in a vvide 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 Power stored in a battery Watt hours amp hours x volts For example e A 6 volts 225 amp hour battery can store 6 x 225 1350 Watt hours this will have a mass of about 30 kg 66 Ibs 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 lbs 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
28. In many cases you can install the equipment yourself and then have the electrician complete the final hookup and turn on If this is the case talk to your electrician first before you start on this as he or she 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 usage 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 PovverSpout 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 gro
29. PowerSpout WATER GOES IN OWER COMES OUT PowerSpout Installation Manual Industrial install Please read this manual carefully before beginning installation innovation January 2010 PovverSpout Installation Manual Notice of Copyright PovverSpout Installation Manual Copyright 2010 All rights reserved Notice of Trademark PovverSpout 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 2010 Ecolnnovation Ltd NZ PovverSpout Installation Manual 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 our website at powerspout com please visit 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
30. Spout HE is also a possible option Cv Xora AA 7 7 A Ey dip 4 i eet a E 112 y R o zi ey RET gt ve a im Ty a i l gt QI r A s z gt at c e es ars 1 if Ta 1 db 7 3 yg ma dores a a gt A se L a Typical good commercial install natural rock foundation power for reservoir Auckland city storage Typical good domestic install on 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 cable voltage is 100 then power loss is 7 3 e Ifthe cable voltage is 50 then power loss is 15 If you use this rule of thumb method for cable sizing and then round up to the next cable size available then losses are typically in the 5 10 band There are many tools on the web that will determine the 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 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 a
31. a domestic type grease gun Subsequent re greasing should be about 10 mL of Remember to grease your new grease about 7 10 pumps PowerSpout 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 your log book 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 bearings is supplied with each new turbine 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 1000 W you should seek our advice Generally units running above our approved ratings only carry a limited 1 year duration warranty To replace bearings Remove front glazing PS008 and casing end cap 5002 Remove Pelton rotor PS050 by removing bolt 5040 e Remove Smart Drive rotor PS061 by turning extractor knob PS063 e Remove Smart Drive stator PS060 by removing
32. ad 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 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 115 V and 380 V for ME and GE respectively This ensures the nominal voltage of 120 V and 400 V is never exceeded January 2010 2010 Ecolnnovation Ltd NZ Page 6 PovverSpout Installation Manual 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 it can be used with most types of MPPT regulators that have a maximum input voltage exceeding 120 V DC in addition to a suitable power rating for your hydro application Outback FlexMax FM60 MPPT Regulator 2 11 Fuses In order to prevent system damage through shorts and malfunctions and for general ease of maintenance it is recommended that a number
33. and checking all joiners are tight will eliminate such risks Ensure you install pipe with the correct pressure rating January 2010 2010 Ecolnnovation Ltd NZ Page 39 PovverSpout Installation Manual 11 3 Grid povver netvvork connections PovverSpout GE is a grid tied option no batteries required available for clients that are already connected to the grid and have a good vvater resource close by Figure 4 see page 4 shovvs the system configuration for a grid tied PovverSpout using a SunnyBoy inverter from SMA The PovverSpout 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 voltages 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 January 2010 2010 Ecolnnovation Ltd NZ Page 40
34. at uses transformers and also in cases where a 3 core wire has been purchased 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 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 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 Australasia and 110 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 sens
35. ations on each of the negative connections to the common negative battery terminal Please refer to your local wiring regulations for what is required in your location Negative ground battery H T C40 Diversion load controller Common negative Common negative 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 7 1 1 Fuse 1 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 control 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 f
36. ault 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 January 2010 2010 Ecolnnovation Ltd NZ Page 27 PovverSpout Installation Manual 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 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
37. d by water jets impacting on the turbine rotor spinning the rotor and hence the turbine which generates electricity Micro hydro generators produce 3 Phase AC current There are four versions of PowerSpout available to suit different situations These are briefly described in Table 1 and further detail 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 1 There are also Education and Demonstration versions available Please contact us for more information January 2010 2010 Ecolnnovation Ltd NZ Page 2 PovverSpout Installation Manual e f you are living off grid and cable cost for 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 ME version at up to 120 V DC with a Maximum Power Point Tracking MPPT function regulator to alter the voltage and harvest optimum power 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
38. ded 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 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 fingers 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 January 2010 2010 Ecolnnovation Ltd NZ Page 17 PovverSpout 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 pu
39. 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 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 ME is less than 115 V DC GE less than 380 V DC If more than this 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 are supplied with 6 wires for Star or Delta connection Changing the connection type may solve this problem see Technical Manual e 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 have a problem you cannot resolve email us via our web site at www powerspout com with all your data and we will tr
40. either to build any structures or to take return water from a waterway The impact of your system on stream January 2010 2010 Ecolnnovation Ltd NZ Page 21 PovverSpout Installation Manual ecology will usually be considered 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 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 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 available for purchase that fit onto LDPE and MDPE pipe wi
41. er 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 January 2010 2010 Ecolnnovation Ltd NZ Page 45 PovverSpout Installation Manual danuary 2010 2010 Ecolnnovation Ltd NZ Page 46 y b d ZN 011 uonEAouulo94 OLOZ 0LOG Menuer oor et ro se 199 ey ee ze re or er 180 zo so vo eo w fest jou vor zs eo l v ze oz vz or zi s0 zo 90 vo eo ev es en zor foe r sv ve sz oz sv ri go 90 190 yo eo zr ZY poll 166 182 09 yr joe 94 joz St bb 80 190 90 Y 60 lh feet eo s 162 os vo ez ez si yi or zo 90 so yo eo se vel oor os tz vs or ez zz er vr or zo 190 yo eo zo e evi ee 62 leo ev se 192 oz or zi 160 90 so yo eo zo ee clr ve oz 09 197 ve ez er st ri eo 90 so yo eo zo te z
42. ets 50 Table 9 NZ PVC Pipe 512659 51 Table 10 China PVC pipe 512659 52 Table 11 USA PVG DING SIZES aka ab aya manada 53 2010 Ecolnnovation Ltd NZ PovverSpout Installation Manual 1 ntroduction Congratulations on your choice of PovverSpout This ingenious little device vvill give you years of trouble free generation avolding the need for expensive generators or povver 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 PovverSpout is installed correctly and runs efficiently PowerSpout turbines have been shown to achieve up to 60 efficiency and with multiple units some sites generate up to 10 kilowatts kW You can estimate your generation capacity with our online 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 l
43. ffer when significantly discharged The thin plates are quickly damaged and may even disintegrate January 2010 2010 Ecolnnovation Ltd NZ Page 23 PovverSpout Installation Manual 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 sustained 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 2 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 The charge rate is 500 48 10 A maximum allowable 10 x 2 x 200 40 A
44. ficant difference as the speed is increased to coincide with optimum Pelton rotor running speed rpm 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 January 2010 2010 Ecolnnovation Ltd NZ Page 33 PovverSpout Installation Manual The generator core is cooled by air flovv across the stator The vvarmed air then transfers this heat through the aluminum bulk head into the exhaust vvater of the hydro turbine The air temperature inside the housing is typically 30 degrees Celsius This dry vvarm environment ensures a near constant temperature of the Smart Drive bearings thus reducing moisture ingress 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 and 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
45. ge 10 PovverSpout Installation Manual 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 your rules in your own country In many counties earth connections are optional but 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 e Connect rectifier as shown There is no incorrect wiring sequence into the rectifier from the generator for the 3 Phase AC input The 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 The thermal 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
46. icture 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 boulders with brackets and cement l ih a LEITET N road culvert FA T Angled screen Flat screen in January 2010 2010 Ecolnnovation Ltd NZ Page 20 PovverSpout Installation Manual intake Angled guides and screen Perforated box in concrete 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 Ge L C PSS FE PRE NE PUISQUE ee A LASS Some ideas for intakes made from scrap stainless steel components 5 7 VVater 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
47. inks 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 the installation process It starts with an overview of a 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 January 2010 2010 Ecolnnovation Ltd NZ Page 1 PovverSpout 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 second 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 How Much Power calculator Water intake Pipe length Head Up vertical amp height Yon 7 gt Me PovverSpout Figure 1 Water supply system 2 1 Generator PowerSpout A micro hydro generator like the PovverSpout converts the potential energy of a vvatercourse to electricity This is achieve
48. ith no packing required January 2010 2010 Ecolnnovation Ltd NZ Page 31 PovverSpout 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 voltage 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 TS ae Too fast L Bottom Jet Fast Good Slow aes i EPA Sa The above illustration shows where the top and bottom jet exhaust water should be hitting the clear screen for optimal performance January 2010 2010 Ecolnnovation Ltd NZ Page 32 PovverSpout Installation Manual If the exhaust water
49. itive 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 line may fail to start even on large pure sign wave 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 January 2010 2010 Ecolnnovation Ltd NZ Page 5 PovverSpout Installation Manual 2 5 Regulator charge controller 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 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 Charge control is provided using any good quality charge controller such as a Xantrex C40 or Morningstar TS45 A E Photovoltaic PV regulator is NOT suitable for mic
50. ll the power you can get A loss of 5 10 in cables is normal Cables with losses greater than 20 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 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 January 2010 2010 Ecolnnovation Ltd NZ Page 15 PovverSpout Installation Manual L C eS A por Dual install one unit runs on 30m 98 ft head the other 10m 33 ft head 4 3 Mounting The main case dimensions 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 470 22 145 Plan view of a PowerSpout turbine 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
51. lly 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 right 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 January 2010 2010 Ecolnnovation Ltd NZ Page 19 PovverSpout Installation Manual 5 4 Pipe myth VVe 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 it 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
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53. ngers 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 January 2010 2010 Ecolnnovation Ltd NZ Page 38 PovverSpout Installation Manual 11 Safety VVe have tried to ensure you can install and operate your PovverSpout vvith 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 H V y TA N i A N HE HR NA ff ya A A FA i AMA 0 Fi i X N De LT R 1 y A Ea UN r A fA A a 1 i N r x L N N fof LA E I AA E d ieee 4 N N d L f h Fr b A FT R N ra F V 4 d d MA d N d Fi 4 F h 4 yi i L het EF
54. not exceed 120 V DC Most clients will use the GE version that is designed for grid tied situations for inverters that commonly operate at up to 400 V DC e f you are living off grid and cable cost for your hydro is too high even with the ME version then you should use 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 Lt 1 Different 65 of ares Features 0000 diversion load controller for system regulation controller such as the Outback FM60 generated povver into the national grid PovverSpout HE High voltage Enabled Connected directly to a battery bank via three FRE step dovvn transformers with a diversion load controller for system regulation 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 PovverSpout BE Battery bank Diversion load Diversion load controller ny Generated power To inverter e Dumped excess power providing User load power for loads Figure 2 PowerSpout BE system setup January 2010 2010 Ecolnnovation Ltd NZ Page 3 PovverSpout Installation Manual PovverSpout ME MPPT charge Battery bank controller Dump load inside water
55. o 108 22 129 ev Z ee 83 rt Vl 180 190 vo vo 60 zo oe ror sz s vs be joe ie zt er ov eo so vo eo 0 zo ez s6 vz 69 joe ee sz oz or er or zo so vo 160 zo zo x fos oo vs zy ze veo 21 ev 11 s0 90 wo eo eo zo vo x zz es ev 18 ez ve st zi 1 60 zo so yo eo zo zo vo 0 29 ov ty jee sz fer ci or eo loo so eo eo 120 zo vo a vs ee ve zz oz st for eo 10 so yo eo zo zo ro vo w 96 42 iyc l vb bb zo 190 90 vo 60 zo vo to ro jro o 6 SL 9L FL 21 6 2 9 y e S W AM OT A ww ul 1 azie jor r jaf auo YM S PUODAS Jad SJd9 I ul MOJ GS QEL suo e e3sul o1pAy 191 om pue auo Jo SHUN 6 pue yjoq Ul papinoJd ae S lQE U 9181 MO J 3 q8e 1ene pue pesy je ays JO z s jel ajewixoJdde sy pyommb noA lqeu s lqe Sulollol ay s lqe BUIZIS jor x uuy Ol jenueyy UOHE E SU nodsismod ZN 011 uonEAouulo94 OLOZ 01 02 Menuer ser var oer ou 2 20 l r re e z zi ls 19 e li Jo st reer esr ver oor ve ro i ee iz or zi s s c li Jo cr er est oz zor ie zo sp ee oz si u le e c li Jo si sil zvi ver es ez es vr oe let si u le e c li lo ea Der li ou ve e is fer ee e v lo z s c l Jo ai d k ver vir 106 iz
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57. on amps Annual output can be calculated as follows kVVh 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 ADC clamp meter be careful not to buy the cheaper AC clamp meter e PS110 amp box that 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 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 January 2010 2010 Ecolnnovation Ltd NZ Page 29 PovverSpout 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 e Jets sizes installed e Flow rate through turbine e Output Watts amps x volts e Static pressure of pipe turbine
58. osition seal PS032 Position the two slingers PS031 one close to the bulk head one close to shaft end Position slinger housing top hat PS030 vvith the drain hole dovvn Position slinger galvanized steel washer PS033 Insert the four fixings PS034 Tighten fixings to 10 Nm 7 lb ft 3 2 Jet size The jet sizing tables see Annex Jet sizing tables enable you to quickly determine the approximate jet size required for your site i e at the head and available flow rate 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 may vary slightly from the above and some fine 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 Two equal sized jets must be used for turbines with an output greater than 500 Watts January 2010 2010 Ecolnnovation Ltd NZ Page 8 PovverSpout Installation Manual 3 2 1 Cutting the jets to correct size The plastic tapering jets can be cut on site with 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 you
59. osts 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 common in NZ indicative prices 2009 Pipe Pressure Pressure Pressure Pressure Approx Approx ID Material rating rating rating rating cost m cost m PSI m kPa Bar NZ US LDPE 65 45 450 4 5 LDPE 87 60 600 6 LDPE 51 35 350 3 5 LDPE 102 70 700 7 LDPE 8 60 600 6 MDPE 131 90 900 9 MDPE 174 120 1200 12 MDPE 116 80 800 MDPE 116 80 800 Bold indicates the change from D to OD sizing 8 8 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 norma
60. outlet Generated povver To inverter providing gt Dumped excess power for loads User load power Figure 3 PowerSpout ME system setup PowerSpout GE Grid tie inverter National Grid 4 ST L Y R load inside vvater outlet gt Generated power gt Dumped excess power Figure 4 PowerSpout GE system setup 38 step down Diversionload Diversion transformer and Battery bank controller load rectifier i B 2 PowerSpout HE gt Generated power me Dumped excess power Toinverter User load power providing for loads Figure 5 PovverSpout HE system setup danuary 2010 2010 Ecolnnovation Ltd NZ Page 4 PovverSpout Installation Manual 2 1 2 AC or DC power Contrary to the common myth it is more efficient to send DC along a cable than AC for the same cable size The only exception in 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 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 current produced by the micro hydro to DC current for supply to the battery bank Generally DC is conveyed from the turbine to your battery bank The main exception is the HE version th
61. ove plus the following for your version of PovverSpout o PovverSpout BE f output voltage is OV 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 OA o PowerSpout ME and GE f 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 s Stop the PowerSpout ME GE and restart Voltage should then be 115V 380V for GE Clamp circuit will operate to 0 8V if PowerSpout ME GE has no water flow 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
62. 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 first 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 2010 Ecolnnovation Ltd NZ PovverSpout Installation Manual Table of Contents EOLUCLO ii n 1 2 Components of your hydro system VU 2 2 1 Generator 2 2 1 1 Setup for different systems 3 212 957 DOWEN ainsi aa a a en 5 A A 5 25 AO Elite 5 e VOOR A en 5 2 5 Regulator charge controller Vs 6 2 0 Backup Regulator adada ns creme encens n aaz 6 2 Diversion Load Hot Water Element ss 6 2 8 Diversion Load Air Resistive Coll 8 888 88 9338838 6 2 9 Diversion within turbine ME GE versions 6 2 10 MPPT regulators TN 7 De MA 7 2100710 a de ee id 7 3 Assembling your PovverSpout l tes 8 3 1 Installing bearing block shaft and Slinger 4 8 0 00 b nr 8
63. r 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 If you have plenty of water and want to generate the 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 ensures the valve and jet sleeve seals onto the casing and does not leak The 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
64. 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 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 January 2010 2010 Ecolnnovation Ltd NZ Page 26 PovverSpout Installation Manual If the ground connection is not to be installed then additional fuses are normally required by local wiring regul
65. rge 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 indicates 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 D 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 D 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 i
66. ro 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 Xantrex C40 Regulator damage It is highly recommended that two regulators be used to reduce the likelihood of damaging your system When using a MPPT tracking charge controller 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 2 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 230 240 110 V AC mains voltage load 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 Lo
67. rrect 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 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 January 2010 2010 Ecolnnovation Ltd NZ Page 13 PovverSpout Installation Manual 4 VVhere and hovv to site the turbine 4 1 Regulations and good practice guidance In most 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 Both PowerSpout BE and PowerSpout ME 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
68. s 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 of 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 available Easy to lay and able to bend around obstacles Able to be purchased in long lengths The PowerSpout has a maximum running head rating of 100 m and allowing for up to 30 pipe friction loses then sites up to 130 m can be used A higher water head can be used successfully but with reduced lifespan and warranty January 2010 2010 Ecolnnovation Ltd NZ Page 18 PovverSpout Installation Manual LPDE and MDPE pipes can vvork 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 c
69. t 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 f there 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 The cost 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 If you can find a similar quality retail product advertised by a manufacturer or authorized dealer 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 ov
70. th the following OD 63 mm 2 5 75 mm 3 90 mm 3 57 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 9 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 bolted flange connections if required Do not connect the 2 jets to the main supply pipe line using undersize pipes or this can cause significant losses WS Turbine supply pipes too small January 2010 2010 Ecolnnovation Ltd NZ Page 22 PovverSpout Installation Manual 6 Getting the best from your batteries 6 1 Battery type size and life Flooded or Wet
71. und 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 up to 75 by doubling the generation and cable transfer voltage With this approach we generate and 9 Ecolnnovation holds considerable stocks of cable at very good prices for our NZ customers January 2010 2010 Ecolnnovation Ltd NZ Page 14 PovverSpout Installation Manual transmit at about 100 V DC to a MPPT regulator close to your battery bank this equlpment 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 vvith the PovverSpout For example solar PV systems can struggle in vvinter 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 Power
72. werSpout Technical Manual Earthing of your renewable energy generation system is 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 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 005SB 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 serious connection errors such as 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
73. 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 loose health when not charged The car battery is a lead acid battery A car battery is designed for starting a car s engine 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 very short the total amount of energy is not that great automotive batteries su
74. 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 January 2010 2010 Ecolnnovation Ltd NZ Page 28 PovverSpout Installation Manual 8 Povver 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 12 A separate meter is only needed 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 Reducing river 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 generati
75. y 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 your 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 at 2 3 of static pressure you will notice that more Smart Drive rotor packing does not make a significant difference when close to the maximum power point This is because you are on the top of the performance curve so slight changes in rpm of the rotor will not make a dramatic difference in output power You will also notice that when you are operating at a state close to the static pressure of the pipeline that packing of the Smart Drive rotor will make a very signi

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