Use and Care Instructions for your new T2 Turgo Micro-hydroelectric Generator Models: MHG-T2 Asian Phoenix Resources Ltd.
READ THIS FIRST This manual contains important information concerning your new PowerPal T2 Turgo micro-hydroelectric generator. It covers Model MHG-T2. You should read this manual carefully before installing PowerPal or allow a trained technician from your local PowerPal Service Center to install it for you. Your PowerPal generator is designed to be simple to operate and easy to maintain. If used in accordance with these instructions your PowerPal will give you many years of service.
POWERPAL COMPONENTS Inside your PowerPal box you will find: • • • • • • • • 1 x generator-turbine assembly 1 x penstock adaptor flange, internal diameter 110mm 1 x rubber gasket 4 x M10 foundation nuts and bolts 1 x control panel including electronic load controller 1 x ballast load 1 x Guarantee Card 1 x this instruction manual. Please advise immediately if any parts are missing. Complete your Guarantee Card and have it signed by your PowerPal dealer.
A. B Forebay, or water tank Atmospheric vent Penstock, or intake pipe Spear valve Turbine B. C. A D. E.
SELECTING A SITE PowerPal is designed for use in a wide range of locations. There are two critical factors that influence power output – head and flow. Head is the vertical distance between the turbine and the water source (forebay), measured in meters. Flow is the amount of water that passes through the turbine at any instant, measured in litres per second (l/sec). See Page 17 for detailed head, flow rate and output data for the three T2 models.
Measuring Flow The best way to measure the water flow is to take a piece of pipe the same diameter as the penstock, insert it in the stream or dam where the flow is expected to come from, and measure the flow from there. In the diagram below, a short length of pipe (less than 1 meter) is buried into the side of a small ‘dam’ using mud or improvised sandbags. The top end of the pipe is completely submerged and part of the normal stream flow is diverted through the pipe.
A B The penstock is shown by the black line A-B. In the first diagram (A) the penstock follows the stream. This may lead to unnecessary length and cost. In diagram B, the most direct route is selected to reduce length and cost. Diagram C shows the best alternative where a side channel or ‘power conduit’ is cut into the side of the hill. This carries the water to a point as close to above the turbine as possible and best reduces the length of penstock required.
SYSTEM INSTALLATION Mechanical Aspects After locating a suitable site and completing the civil works, your PowerPal is ready for installation. To do this: 1. Bolt the turbine to a turbine stand or base which allows at least 300mm clearance between the turbine and the ground. This clearance is required to prevent splashback that will disrupt turbine performance. The turbine stand should be made from concrete with the four M12 foundation bolts embedded.
hydro turbine Main network or house distribution board Electronic Load Controller - ELC A 220VAC house supply Ballast load B C To connect the electrical components, please follow these steps: The electrics should be installed by persons competent in mains voltage wiring. This system operates on a switched neutral basis. Neutral and phase connections to the load elements should be treated as live at all times! 1.
4. Connect the user load cables L1 and L2 between the control box and the house. 5. Connect the ballast load (C) to the control box and user load cable. The ballast load is rated 10-15% (maximum) higher than the rated power output of the generator e.g. 2.2kW for model MHG-T2. As such, it will become hot, up to 100°C. To prevent injury and the risk of fire, the ballast load must be installed in a safe place and preferably in an additional enclosure. 6.
5. Operate like this for 15 minutes while observing any unusual noise, excessive temperature or other problems and if OK then switch on the power to the user. Up till now the ballast load has been receiving all the power and should be hot, but once switching on the user load the power to the ballast load will fall. 6. The voltage should remain stable as loads are switched on or off. If the voltage falls below 220V then check the water flow conditions.
Changing the Bearings and Seal Apart from greasing the bearing, there are only two tasks that must be completed at regular intervals. These are the changing of the lower generator bearing & turbine bearing and the lower bearing seal every two years. See the section on Technical Specifications at the end of this manual for part numbers. These are commonly available in most countries but if in doubt contact your dealer. To replace the bearings and seal, follow these steps: 1.
A C E B D F TROUBLESHOOTING If any problems are encountered, check this section before contacting your Service Center. 1. Head and flow conditions appear to be OK, but PowerPal will not work. It is likely that the system has been installed incorrectly. Check this by following the steps once more.
2. PowerPal has provided electricity for a while and suddenly the electricity stops. If this instruction manual is not followed and power consumption is too high, or if there is a short circuit in an appliance the circuit breaker in the electronic load controller will trip. This will stop the electric current. If this occurs, check for possible causes and rectify. Reset the switch on the circuit breaker to the ‘on’ position. 3. Voltage is 220V under zero-load conditions but falls when a load is applied.
a) Start the generator and adjust the spear valve to obtain 220-240 volts, 0 amps at the panel. [Do not turn the circuit breaker on]. b) Adjust the potentiometer on the circuit board very slowly to the left. When you detect a small decrease in voltage, stop. Turn on the circuit breaker and increase water to increase power to the unit. Increase power until a load of 2kW is indicated (P =VI). c) If adjusting the potentiometer does not correct the problem, then contact PowerPal.
APPENDIX A – FOREBAY DESIGN The instructions given on page 7 of this manual to design the forebay are adequate for most cases. The most important aspects of forebay design are: 1) To allow a continual flow of water to the penstock so that the turbine keeps functioning. 2) To have sufficient safeguards to prevent sand, vegetation and other debris from entering the penstock which could cause blockages and disrupt the turbine.
POWERPAL T2 TURGO MODELS T-2 Model (1.5kW) (single nozzle) H (head, in metres) 14 15 16 17 18 19 Q (flowrate, in l/sec) 18.5 17.3 16.2 15.2 14.4 13.6 18.5 17.3 16.3 15.4 14.6 18.5 17.4 16.5 15.6 18.5 17.5 16.6 18.5 17.5 18.5 T-2 Model (2.0kW Med H) (single nozzle) H (head, in metres) 16 17 18 19 Q (flowrate in l/sec) 23 21.6 20.4 19.4 23.0 21.7 20.6 23.0 21.8 23.0 Output (watts) 20 12.9 13.9 14.8 15.7 16.6 17.6 18 1250 1361 1452 1543 1633 1724 1750 Output (watts) 20 18.4 19.6 20.7 21.8 23.
