PowerSpout Basic System Design and Installation Manual PLT, TRG and LH turbines Industrial PLT Off grid domestic PLT Grid connected domestic PLT Domestic TRG Domestic LH Please read this manual carefully before beginning installation.
CONTENTS 1. Scope of Application, and Safety ................................................................................ 9 1.1. 1.2. 1.3. 1.4. 1.5. 1.6. 1.7. 1.8. 2. Turbine serial numbers .................................................................................................. 9 Installation checklist .................................................................................................... 10 CE and FCC Declaration ................................................................
4.6. PowerSpout site data requirements............................................................................. 29 4.7. The Penstock............................................................................................................... 30 4.7.1. Pipe sizes ....................................................................................................................... 31 4.7.2. Pipe material ...................................................................................................
5.7.6. Factoring in the cable voltage drop .............................................................................. 54 5.7.7. Summary: Matching your turbine to an MPPT controller and your battery ................ 55 5.7.8. Illustrative example....................................................................................................... 55 5.7.9. Legal limits to voltage (extra low voltage) .................................................................... 56 5.7.10. Future trends ...........
6.9. 7. Installation example .................................................................................................... 84 Getting the best from your batteries ........................................................................ 85 7.1. Lead acid battery type, size and life ............................................................................. 85 7.1.1. Flooded or wet cells (can be topped up with distilled water) ...................................... 85 7.1.2. Sealed batteries .....
10. Troubleshooting ................................................................................................. 115 10.1. 10.2. 10.3. 11. Making the most of your pressure gauge ................................................................ 116 Turbine case flooding............................................................................................. 116 Noise .....................................................................................................................
Disclaimer UNLESS SPECIFICALLY AGREED TO IN WRITING, ECOINNOVATION LIMITED: (a) MAKES NO WARRANTY AS TO THE ACCURACY, SUFFICIENCY OR SUITABILITY OF ANY TECHNICAL OR OTHER INFORMATION PROVIDED IN ITS MANUAL OR OTHER DOCUMENTATION. (b) ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSS OR DAMAGE, WHETHER DIRECT, INDIRECT, CONSEQUENTIAL OR INCIDENTAL, WHICH MIGHT ARISE OUT OF THE USE OF SUCH INFORMATION. THE USE OF ANY SUCH INFORMATION WILL BE ENTIRELY AT THE USER’S RISK. Revisions history 1.1.
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 www.powerspout.com, please visit www.powerspout.com/faq and submit a question. We will answer this as quickly as possible, and you will be notified by email when this occurs. PowerSpout is a product proudly designed and manufactured by: EcoInnovation Ltd 671 Kent Road New Plymouth R.D.
1. Scope of Application, and Safety This document is part of the product. This section addresses safety concerns as required by international standards. If you are not technically competent, experienced and qualified you should not install this equipment alone and should engage the services of a suitably trained professional. Electrical equipment can be installed or operated in such a manner that hazardous conditions can occur; compliance with this manual does not by itself assure a 100% safe installation.
1.2. Installation checklist The installation shall be carried out by installers with recognized and approved qualifications, and experience relating to general electrical installations and micro-generators. To meet good working practices and safety requirements for this installation, the installer must: IN GENERAL check for any transit damage to the product prior to installing it, if damaged it must not be installed. connect equipment in compliance with the relevant national standards.
check for excessive noise. complete turbine testing and commissioning. ensure that all protective fairing/enclosures are in position after commissioning and prior to client hand over. comply with signage requirements as listed in relevant national standards complete all documentation as required in this manual and local wiring rules. make relevant notes in the manuals that will be of assistance to future service personal.
The client has read manuals, viewed online videos and read installation examples before starting on this project. We advise engaging an experienced/qualified installer who has good electrical, mechanical and plumbing skills. Flooding risks: On the upstream side the limit is normally the intake screen (trashrack and the rack cleaning machine - if installed). On the downstream side the limit is normally the flooding height that can engulf equipment.
1.6. Fairing safety warnings The fairing on your PowerSpout turbine forms part of an electrical enclosure and carries the following warning signs. There are both rotational and electrical hazards present. Turbines must be turned off at the valve and the electrical breaker turned off prior to removing this cover.
1.8. Connecting to the Grid (power network) PowerSpout PLT/TRG/LH grid-tied options (no batteries required) are available for clients that are already connected to the grid and have a good water resource close by. In NZ, Australia and the UK the EnaSolar inverter can be used if the MPP tracking rate is slowed.www.enasolar.net Also Aurora wind turbine inverters from Power-One can be used in most global markets www.power-one.
2. Step by step design overview This section briefly outlines the main choices you will need to make in the design of your system and ordering the delivery. 2.1. Survey your site Section 4 describes how to measure the head and flow of your hydro power site. You will also arrive at a length for the "penstock" or pipeline between the intake and the turbine site, and the length of the cable to your point of use. Take this information to the online Advanced Calculator or to a dealer.
PowerSpout turbines have been tested for compatibility with a number of MPPT inverter/controllers and results are available on the website. This list is anticipated to grow as testing continues so please check the website www.powerspout.com/compatibility for updates. More information on MPPT regulators is included in the 2014 Technical manual. 2.5. Cable voltage You need a cable to carry the DC power from your turbine to your point of use.
2.9. Optional extras you may wish to order Check the pricelist for additional items that you may wish to have shipped with your turbine at no extra shipping cost in many cases. The list includes some useful tools, for example, the DC current clamp meter, which is indispensable for trouble-shooting battery systems of all kinds. 2.9.1. Bearings You will need to check the bearings every year and replace if required.
2.9.4. Adjustable jet options Adjustable spear jets are available (to order) for the PowerSpout PLT. However, adjustable jets may cause more problems than they solve and demand for them is generally low. Adjustable spear valves as shown can be supplied for a surcharge and operate in the range 3-14mm (circular jet equivalent). They allow you to quickly adjust the flow rate to suit the stream flow.
3. Renewable energy from a PowerSpout turbine Congratulations on your choice of a PowerSpout turbine. This ingenious little device will give you years of trouble free generation, avoiding the need for expensive generators or power bills. Not only does the PowerSpout give you renewable energy, it is also made of predominately recycled materials, making it one of the most eco-friendly micro-hydro generators available on the global market.
In the case of the LH turbines, the propeller turbine is normally near to the surface in an elevated flume. You can measure the head from the intake surface level down to the water surface in the tailrace below. 3.1.2.
3.1.3. Worked example If for example the head is 20 metres and the flow is 10 litres per second then the power generated is about 1000 watts or 1 kW continuously (20 x 10 x 5 = 1000). The turbine will therefore produce 24 kWh of energy per day and over 700 kWh units of energy per month. This exceeds typical household energy consumption in most countries. If the power output is only 500 watts then you would get half as many units per month, which would still suffice in many cases.
3.4. How can we be sure of getting the right voltage out of the turbine? Your turbine will have been designed to produce maximum power at the chosen operating voltage. Turbine voltage depends on speed. The design process involves predicting the best rotational speed for the turbine, which depends in turn on the pressure of the water, which depends on the head you measured.
3.5. Understanding open circuit voltage (Voc) When there is no current, because the turbine spinning is disconnected, we can measure the "open circuit voltage" (Voc). The Voc depends directly on the turbine speed in rpm. Double the speed and you double the Voc. Different turbines will have different Voc/rpm ratio, depending on the site and the required voltage. But any turbine will have a much higher voltage when it is running faster off load than it will when working optimally.
4. Designing your site layout and choosing your turbine model 4.1. Measuring Head You will need to measure the vertical drop in feet or meters (referred to as head or fall). A map with contours can be useful for initial feasibility study followed by a site survey using the methods below. It's a good idea to use more than one approach, so you can check accuracy. Altimeter - obtain an altimeter accurate to 10 feet (3m), this is good for measuring falls greater that 70 feet (20m).
4.2. Measuring Flow IMPORTANT: "Gallons," "gals," and "gpm" refer to the US Imperial Gallon (3.8 litres), as opposed to the UK Imperial Gallon. Try and find a place in the stream where it drops quickly over a rock, place your bucket below and measure the time to fill it. At lower flow rates, less than 150 gpm (10 l/s) you need to be accurate in measuring the flow. If you have a 2 gallon paint pail and the river can fill it in 2 seconds you have 1 gps = 60 gpm, which equates to 227 l/min, 3.8 l/s.
Version Head (m) Flow (l/s) PowerSpout PLT (Pelton) 3 – 130 m 0.1 – 10 l/s PowerSpout TRG (Turgo) 2 – 30 m PowerSpout LH (Low Head) 1–5 metres (below turbine in draft tube) photo 8 – 16 l/s 25 – 56 l/s When you have found out the head and flow rate at your site, the chart on the next page will quickly tell you the maximum power you can generate (refer to black angled lines indicate 100W to 12kW).
4.4. Siting your PowerSpout turbine Some tips for locating a good site for your turbine include: 4.4.1. Choose a place that is accessible. If necessary make steps and put in rope handrails to ensure that your turbine can be accessed safely. 4.4.2. Choose a site that has the most fall You should position the PowerSpout to obtain the greatest fall (head of pressure) possible with the shortest length of pipe. If it makes the cable unacceptably long then look at using MPPT to raise the cable voltage.
4.4.3. Keep your PLT/TRG turbine as low as possible Maximise the head, but do ensure that it is above maximum river flood level. Your PLT/TRG turbine should also be positioned at least 50-100 mm above ground height to allow exhaust water to escape. Choose a site where the exhaust water can be returned back to the river cleanly. 4.4.4. Place it as close to your battery bank or point of grid connection as possible, The cost of the cable is important, although cost depends on the chosen voltage.
Dual install, one unit runs on 30m (98 ft) head the other 10m (33 ft) head 4.6. PowerSpout site data requirements In order to assess your hydro site potential you can either Visit our web site www.powerspout.com and complete the advanced calculator, or Complete the table below and email it to questions@powerspout.com we will reply promptly with the best hydro option available for your site. Your turbine will be designed for the site data you supply above.
Hydro site data required for PowerSpout product manufacture Question PLT, TRG, PowerSpout turbine type LH or LH Pro Have you read the PowerSpout product manuals? Yes/No You must do so before placing an order Head at site (vertical drop/fall of pipe) Pipe or flume length required to get fall Supply pipe inside diameter if installed Do you want us to advise your pipe size? Yes / No Flow available at intake What is the cable length from turbine to the power shed? If cable is installed, what size is it? Do you
4.7.1. Pipe sizes Pipe sizes commonly used with our hydro products include: PVC for larger sizes based on OD (110-300 mm normally) MDPE or HDPE based on OD (50-110 mm normally) LDPE based on ID in NZ/AUS (40-50 mm normally) 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.
Table 1. Pipes common in NZ (Rural Direct)– indicative prices 2014 Pipe OD Pipe ID mm 57 mm Material Pressure Pressure Pressure Pressure Approx Approx rating rating rating rating cost/m cost/ft PSI M MDPE 102 70 63 53 HDPE 131 90 63 50 HDPE 174 120 75 65 HDPE 116 80 90 79 HDPE 116 80 110 94 HDPE 116 80 Bold indicates the change from ID to OD sizing 4.7.4. 50 kPa 700 900 1200 800 800 800 Bar 7 9 12 8 8 8 NZ$ 4.00 5.00 7.00 6.80 8.60 11.50 US$ 1.05 1.30 1.80 1.75 2.25 3.
If the penstock simply discharges "full bore" (for example, to flush out sediment) then the flow will be large, and there will be no pressure left. Pressure is all used up in pipe friction. Normally the turbine uses jets to restrict the flow and convert the pressure into velocity to drive the runner. The flow in the penstock will be controlled by the size(s) of jet(s) that you use in your turbine(s).
4.7.8. Pipe thrust blocks On larger hydro schemes using rigid pipes, thrust pads and anchor blocks may be required to prevent movement of the pipe work. On these larger hydro schemes professional engineering advice must be engaged to calculate the supports needed. 4.8. Intake design and placement The intake for a PLT or TRG turbine should be positioned at the base of a small set of rapids typically no more than 300-500mm high (to allow room for a sloping intake screen as shown below).
Angled guides and screen - the best! Perforated box in concrete Commercial intake on road culvert Perforated box Stainless woven tube from scrap yard Intake made from stainless steel scrap Intake screens such as these can be purchased. However, they are easy enough to make to suit your site. You can use a stainless steel mesh and a plywood box, make sure you support the screen from behind with stainless steel rods/frame otherwise during floods the mesh will be pushed in.
Some ideas for intakes made from scrap stainless steel components 4.8.1. Water usage with minimum impact on the environment Micro-hydro systems may potentially affect: Plants and fish in the water. Plants and animals beside the water. Stream banks and surrounding land. You must check with your local authorities to see if you need to obtain consent either to build any structures or to take/return water from a waterway.
4.9. Turbine "manifold" connecting options PLT and TRG The manifold is the system of pipes that connects your penstock to your turbine jets. The penstock is what we call the main pipeline from the intake. 1-5+ hydro turbines are commonly connected to a single penstock. It is helpful if at the end of the penstock there is a large valve so the pipe can be flushed to purge sand/silt. Turbine manifold pipes are often branched off the main run before this flush valve.
4.9.4. The connections made to the penstock You will need up to 2 penstock connections for every PLT turbine, and up to 4 for every TRG turbine. Connection to the penstock can be made in the following ways: Bolt over saddles and flexible hoses Pipe fittings - T’s and Y’s Our PVC 4 jet manifold – for PVC pipes and the TRG turbine Our PVC 2 jet manifold – for PVC pipes and the PLT turbine 4.9.5.
4.9.6. Pipe fittings - Y’s PVC “Y” fittings suit higher flow TRG sites that commonly use 160 or 200mm OD PVC pipes. PowerSpout can supply this optional PVC manifold kit as shown below. The end user has to glue it together. It suits sites in the head range 5-20m and flows up to 4 l/s per jet with 50mm ID pipework. For sites in the 2-5m range, 3” camlocks and flexible pipe connections should be considered.
4.9.7. PVC 4 jet manifold – for PVC pipes and the TRG turbine A PVC manifold option is available to special order, as shown. These are tricky to put together and final gluing must be done by the end client. They do give a very clean and professional look and some clients will prefer this option. 4.9.8. PVC manifolds for our PLT turbines PowerSpout can supply PVC manifolds for our PLT turbines with either 2” BSP/NPT threads or 2.5” BSP threads.
4.9.10. Mock up your manifold off-site first You will save a lot of time if you mock up your manifold and exhaust water collection off site where it is easier to work. This picture shows 2 x PLT100C turbines trial fitted off site prior to carrying all the parts 800m into dense forest. Note the mac unions so that the turbines can be easily removed. 4.9.11. Other manifold options There are many possible manifold solutions; there are some pictures below to give you ideas for your situation. 4.9.12.
The pressure tapping kit (optional extra) allows you to insert a quick release pressure fitting at points of interest. You will need to drill and tap the pipes ¼ BSP to use these fittings. When a reading is not being taken they can be plugged with a length of solid tube supplied. If turbine performance is less than estimated in the Advanced Calculation tool, check that you have not installed an undersized manifold by measuring the pressure loss across the manifold.
5. Electrical System Components From the coils in the alternator to the heaters that control the battery charge, every part of the electrical system needs to be compatible with the others so that the whole thing works properly. Your PowerSpout dealer can design your system for you but it is helpful to understand these relationships and to be familiar with the options and the safety issues of your system. 5.1.
In order to comply with standards for conducted and radiated emission noise, the 3-Phase rectifier in your PowerSpout may include a noise filtering module for conducted emissions. This EMC filter in only included if your turbine was ordered for a grid-connect application. Rectifiers get hot due to losses and lower voltage systems have greater losses. In a 12 V system you lose approximately 10% of the energy you generate in the rectifier, whereas this figure is only 3% for a 48 V system. 5.2.
5.3.3. Klampit "crowbar" protection circuits (optional) A Klampit is a proprietary safety device that short circuits the PowerSpout at a pre-set voltage. Shorting the turbine does not harm it, but removes the dangerous voltage until the Klampit is manually reset (usually by stopping the turbine). This type of device is called a crowbar circuit and is given the abbreviation “C” in the turbine product name. You may or may not need to use one.
5.3.5. PowerSpout TRG versions Common versions of PowerSpout TRG with no overvolts crowbar TRG model Max cable length m MPPV 28 150 28 Max open circuit V 75 Off-grid* 40 250 40 120 ELV NZ/AUS 56 500 56 80 1000 80 On-grid 170 200 1000 1000 170 200 150 220 <450 <550 Controller/inverter PWM MPPT PWM MPPT Grid-tie Grid-tie * PWM signifies direct connection to battery with diversion load control.
hence the cost of the cable). Changing the "design load voltage" will also have a dramatic effect, which may lead you to choose an MPPT controller for sites with long cables. Try to keep losses as low as possible, particularly if you have limited hydro generation and need all the power you can get. A loss of 5% in cables is normal.
5.5.2. MPPT (Maximum Power Point Tracking) controllers MPPT (Maximum Power Point Tracking) controllers work with higher voltage turbines, and convert this voltage down to charge the battery. The MPPT function is especially useful for optimising the turbine speed automatically. They control battery charge by restricting the current that reaches the battery but often allow you to harvest surplus energy via an auxiliary relay. Pros: MPPT adjusts voltage automatically for maximum Watts output.
Once the controller recognizes that your battery charge rate has reached the highest safe level it diverts any additional incoming power to a diversion load. Such controllers normally allow you to set the voltage threshold at which power diversion starts according to the type of battery in use. This threshold will also be automatically adjusted for the stages of battery charging (absorb, equalise, float) and the battery temperature.
USA NEC Requirements To comply with NEC 690.72 (B), the following requirements will apply when using a diversion charge controller on an unregulated charging source: Second Independent Means If the diversion load controller is the only means of regulating the battery charging, then a second independent means to prevent overcharging the battery must be added to the system. The second means can be another diversion controller, or a different means of regulating the charging.
Tracking is the process by which the MPPT device changes the voltage to find the maximum power. Modern inverters/controllers tend to have very fast MPPT tracking. Since a hydro turbine has rotational inertia, a fast tracking increment (many track every 0.2 seconds) may not correctly locate the maximum power point. This is because the rotor takes time to change speed and stores kinetic energy, which can fool the logic of the MPPT trackers in some cases.
Victron Energy Blue solar MPPT 150/70 Micro Care 20-60amp MPPT with intergrated DC breakers Xantrex XW MPPT 60-150 200-300 V DC input units Midnite Classic 200/250 (Manufacturer approved for hydro use) Steca Tarom MPPT 6000 (Manufacturer approved for hydro use) Apollo T80HV Power Master PM-SCC-80AMW AERL Coolmax SRHVW (Manufacturer approved for hydro use) © 2014 EcoInnovation Ltd (NZ) Page 52
600 V DC input units TriStar MPPT 600 Volt Solar XW MPPT 80- 600 Solar TriStar MPPT 600 Volt with DC disconnect (24 & 48 V DC output) Solar In selecting an MPPT controller you need to carefully consider the following points: Maximum DC voltage rating Current rating (Amps) Cost of MPPT controller Cost savings in the size of power cable needed to connect your PowerSpout at this voltage Programmable "auxiliary" relay(s) to divert surplus power to a hot water tank MPPT tracking stability when used
over-voltage protection built in) may be used with MPPT controllers but you must be careful if you do this. This is because the risk of over-voltage and hence controller damage is greatly increased. The turbine operating voltage on load (known as maximum power point voltage MPPV) needs to be above battery charging voltage. In fact even higher voltages are useful in reducing the cost of the cable.
5.7.7.
The PLT/TRG 100C turbine allows us to operate at a cable voltage of 100V with reduced costs and reduced losses. It also allows us to use a 48V battery, popular with modern systems. The downside is that the Klampit may operate too frequently if the controller allows the voltage to rise above 120V. This would then have to be manually reset by stopping the turbine.
If you intend to run a PLT turbine on a MPPT controller/inverter you must: Tell us prior to ordering Have an accurate measure of the head of your system Check runaway Voc (with various numbers of jets) prior to hook up Cable run up to 1000m can be affordable at higher operating voltages. 5.7.10.
Some MPPT controllers contain programmable "auxiliary" relays that can be used to control larger DC/DC solid state relays (SSRs) to send surplus DC generation to hot water elements. A new MPPT controller made by Midnite Classic and called the "KID" can divert directly to a resistive element and no external SSR is needed. This is the only product we are aware of that can do this. The "KID" can also divert on the input or output sides of the regulator as shown.
5.8.1. Fit a PWM controller (with lower settings) to the battery as well Diversion via the inverter output The schematics show diversion of surplus energy on the DC side of the system. It is also possible to divert surplus energy to heat on the 230/240/110 V AC output side of the inverter. A water pump or water heater can be turned on to soak up this surplus.
Installers must put a large sign by the hot water tank that says “Do not drain this tank without first turning off the hot water element in the power shed at the location indicated”. In the power shed put a label that says “Before draining the hot water system turn off this breaker”. If you have a PWM controller you will also need a note to “turn off the hydro turbine before draining this tank”. 5.9.1.
This should be adequate for one PowerSpout turbine. For 12V systems, use two in parallel. For 48V systems, use two in series. If this particular size of resistor is not to be found, or costs too much then a search through stock lists may well throw up a bargain in a different size. 5.10.2. Common air elements 120/240 V Common sources of air elements are: Elements for electric towel rails 100/150/200/300/400/500/600/750 Watt Hob elements in electric stoves typically 1500W 5.10.3.
Why use "PV trigger"? PV trigger prevents nuisance tripping of the crowbar protection in the following scenario. A PLT/TRG 100C turbine (with an internal crowbar) is needed (for Outback FM60/80 controllers) because otherwise the turbine voltage might exceed 150V and damage the controller. The crowbar short circuits the turbine for safety if the voltage exceeds 120V (see 5.3.3).
120V -1500W water elements This is best illustrated by way of an example. Let us assume you have a PLT40 turbine that is rated for 750W at 40 V. We want to use a 120V 1500W water element as they are common in the USA. The table shows the Wattage of the element in 10 volt increments from 40-120 V. As a PLT turbine will develop maximum power at about 40 VDC MPPV we can set the PV trigger to operate at say 50 V.
5.12. Preventing excessively hot water with PWM & MPPT regulation Overheating your water tank can be a problem on larger hydro installs or when the home owners are away on holiday. Low pressure vented copper water tanks that are fitted with tempering valves can generally be allowed to boil. Other systems may have an upper temperature limit, as may the connected pipe work.
Inverter There are two types of inverters: battery-based ones for stand-alone off-grid systems, and grid-tie ones that do not use batteries. Both convert DC to AC power. Battery based inverters convert the energy generated by your PowerSpout or stored by the battery bank to a voltage and frequency suitable for typical household appliances – usually 230/240 V in Europe/Australasia and 110/120 V in North America.
The old GE400 has been displaced by a PLT350 option using the Aurora Power wind interface to regulate Voc. Please note that the popular SMA Windy Boy inverter range has been recently withdrawn from the market. This leaves the Aurora wind inverter range that is globally available and approved for wind and hydro input. For the UK, NZ and AUS markets there is also the EnaSolar inverter range. Aurora PVI-4000 wind interface for 230 VAC markets. Aurora PVI-7200 wind interface for 120 VAC markets.
5.14.1. MPPV and Voc considerations Operation with MPPT controllers and with grid-tied inverters are very similar situations for PowerSpout turbines. It's important to make sure that the turbine best operating voltage ("maximum power point voltage" or MPPV) is within the range that the MPPT device can work over. It's also important that the Voc of the turbine is not so high as to damage the MPPT device. Any inverter selected must have an MPPT operating range lower than 170/200 V DC.
6. System Wiring This section covers the items you will need to safely wire the components of your system together. There are wiring diagrams to cover all typical system configurations. For electrical safety you need to protect against fire and shock hazards. 6.1. Fuses and Circuit Breakers Batteries are very unlikely to give you an electric shock because their voltage is low, but a battery is a source of energy that can deliver thousands of amps of current into a short circuit that will turn wire red hot.
Common sizes are: 10 Amp 16 Amp 20 Amp 25 Amp 32 Amp 40 Amp 50 Amp 63 Amp Common brands that are widely used include: Noark, Schneider and ABB. 6.2. DC Earthing/grounding explained Earthing (aka grounding) is done to protect against electric shock hazard. It also helps to protect against equipment damage from lightning-induced voltage surges in the system. There is much confusion about what earthing means. The words can mean any of 3 things: 1.
that creates a voltage between items will create a large current in the earth bonding that will blow a fuse and disable the system. Also connect this protective wiring to an earth electrode so you are protected from electric shocks when you are also touching earth or earthed objects. This is very basic electrical safety. It is also the front line of protecting sensitive equipment against lightning induced surges of voltage.
On a 12/24 VDC battery systems, earthing of the bulkhead may not be required. Where the hydro turbine is close to the power shed, a green earth wire from the turbine bulkhead must be connected to the main earthing rod via the equipment earthing. Where the hydro turbine is distant to the power shed, the turbine bulkhead should be connected to a local earthing rod. You may be able to rely on this rod for earthing or you may also need an earth wire in your supply cable.
at some distance from a building. Ground-fault protection is not just for residential roofs. The 2008 NEC, requires ground-fault protection for all “grounded DC photovoltaic arrays.” The NEC lists two exceptions to general GFPD requirements. The first exception is for ground or pole-mounted systems that are isolated from any buildings and limited to one or two parallel source circuits. This exception might apply to a remote water pumping system.
6.4.4. Cable connection errors 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. Your local installer or PowerSpout dealer can assist you with local wiring rules. You may also need to hold insurance and comply with various safety regulations. In the USA the National Fire Protection Agency (NFPA) provides wiring rules that are generally adopted by each state.
NEVER work on your renewable energy system with the hydro in operation. EcoInnovation 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. 6.5. Diagram of direct-to-battery wiring using diversion controllers In order to reduce the size of this manual wiring diagrams have been removed as they will not be relevant for many readers.
6.5.1. PWM battery regulation Turbine types that can be used: PLT 14/28/56/56C TRG 28/56/56C Two PWM regulators - Complies with NEC 690.
6.6. Diagrams of wiring with MPPT controllers The drawings below illustrate the minimum installation requirements for PowerSpout turbines connected to MPPT controllers. These drawings show both ungrounded and a negative ground battery installation. Each component and its selection criteria are discussed in section 6.8. The diagrams that follow are indicative only, always check with your local installer that they meet the rules in your country.
6.6.1. 150-250 V DC MPPT Turbine types that can be used: PLT 40/80 TRG 40/80 LH & LH Pro 150/250 MPPT regulators no diversion load Simple diagram 6.6.2.
6.6.3. 150-250 V MPPT with aux SSR relay diversion on battery side Turbine types that can be used: PLT 40/80/100C/170C/200C TRG 40/80/100C/170C/200C LH & LH Pro 150/250 MPPT regulators with SSR relay diversion load Simple diagram 6.6.4.
6.6.5. 150 V MPPT – Midnite Classic KID The KID is able to divert surplus power (in excess of that needed to charge the connected batteries) to a diversion load, typically a water heater. It can divert either at the battery voltage (Load side) or at the input voltage (Clipper side) and no change of wiring is needed, all you do is move the green 30 amp automotive fuse and change the diversion element. No external SSR is needed to do this.
6.7. Diagrams of wiring for grid connection The drawings below illustrate the minimum installation requirements for the PowerSpout turbines connected to a grid tied inverter. Each component and its selection criteria are discussed in section 6.8. The diagrams that follow are indicative only, always check with your local installer that they meet the rules in your country. 6.7.1.
6.8. Key to wiring diagrams. These wiring diagrams are an easy to follow representations of typical systems. All installations must give regard to: Local and national regulations Advice in this document Advice in manuals for supporting products shown Where such advice conflicts or is unclear, you should seek advice from an experienced renewable energy installer who is familiar with these products and regulations that apply in your country. DB - Double Pole DC breakers (HRC fuses can also be used).
necessary to remove power to the controller when changing settings etc, so a point of local isolation is valuable. Installers must put a large sign by the hot water tank that says “Do not drain this tank without first turning off the hot water element in the power shed at the location indicated”. In the power shed put a label that says “before draining the hot water system turn off this breaker”. If you have PWM controller you will also need a note to “turn off the hydro turbine before draining this tank”.
The 3-pole HRC fuse holders can serve a multi-purpose of providing current protection for each battery string (maybe required by regulation in some jurisdictions), act as a combiner for multiple strings and act a busbar termination point for other connections needed in the system. The picture on the right shows a HRC 3-pole fuse holder with a top combiner link and busbar for 3 battery strings.
6.9. Installation example A potential customer wants to purchase a PLT80 PowerSpout hydro turbine that will generate up to 1000 W on their site data. The rated voltage is 80 VDC and the unloaded voltage (Voc) is 240 VDC. They intend to use a Midnight Classic 250 controller and the aux relay will be used to turn on a 327 W water heater (1500W at 120 V element is used) with surplus energy not needed to charge the batteries.
7. Getting the best from your batteries 7.1. Lead acid battery type, size and life 7.1.1. Flooded or wet cells (can be topped up with distilled water) These are the most common lead-acid battery type in use today. They are available in a wide range of sizes and are often the most cost effective solution. 7.1.2. Light duty batteries are for cars (thin plates with lots of surface area).
7.1.4. What is electricity and what is a battery? Electricity is the flow of electrons along a wire. Metal is a good conductor of electricity as the electrons in each atom of metal are free to move from one atom to another. Consider how difficult it is to store the energy of a car that is moving. Understanding the fact that electricity is the flow of electrons helps us to understand that electricity is also difficult to store as it is energy in motion.
draw more than 2.42 kW for a sustained period you should install a larger battery bank and inverter. 7.1.6. Battery life expectancy 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. Keeping them in a good state of charge (near full charge) will prolong their life.
Consider fitting battery recombination vents to significantly reduce the need to top up with water. Watering intervals can be as long as 12 months with such vents fitted. Batteries are not for anyone to touch. Sufficient security is required to prevent a child or unknowing adult from tampering with them. Not everybody understands batteries. There are recommended safety signs that must be displayed above your battery bank warning people of the possible hazards.
Do not install any fuses in a small battery enclosure as this is a potential source of ignition. Take care that the wrench/spanner handle does not bridge between terminals when connecting batteries as this can cause arcs, burns and explosions. Insulate all tools with insulating tape prior to any work on your battery bank.
7.2.4. Battery installation example 2 This example provides excellent mechanical protection for batteries and ensures safe seismic restraint. Ventilation slots at ground level on the front and at the top of the lid behind the hinge provide through flow ventilation so any hydrogen gas produced can rise easily up and away from the batteries. Ideally the lid should be slanted to prevent incidental use of the lid as a shelf. (Objects will slide off).
7.3.
8. Turbine Installation and Commissioning Before commencing the installation process you should have selected the appropriate components and consulted your local regulations concerning use of water and undertaking electrical work. This manual includes information and links to relevant tools to facilitate this process. It should take no more than one day for two people to install a PowerSpout PLT/TRG turbine, depending on site terrain. Pipe and cable laying can take much longer in difficult terrain. 8.1.
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 PLT unit is 400 mm high. Plan view of a PowerSpout turbine A TYPICAL PLT TURBINE BASE: A framed timber base made from 100x50 timbers and covered in 1217mm thick plywood sheet on top with a hole 160 x 390 mm cut for the exhaust water.
8.2.2. Mounting TRG A framed timber base made from 100 x 50 timbers and covered in 12-17mm thick plywood sheet on-top with a hole 320 x 320mm cut for the exhaust water is a typical TRG turbine base. A PowerSpout TRG unit is 430 mm high. A timber or concrete turbine base is less likely to produce resonant noise issues than say a steel or aluminium base. 8.2.3.
Manifold pipe Supports Pipes full of water are heavy and will sag over time. It is very important to provide support to all manifold pipes close to where they connect to the turbine. Pipes are normally supported as follows: A steel fence post, also called a T-post, a Y-post or a star post. These steel posts are hammered into the ground either side of the pipe. There are holes in the posts and timbers can be used to sandwich the pipes in place. Screws are used to hold the timbers to the posts.
8.3.2. 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 your jet to the correct size cleanly so that the water jet can break smoothly without spray. We recommend using a sharp knife and paring away at the jet, cutting from the inside edge out. With practice a very accurate and sharp edged jet can be prepared in the field.
8.3.3. Pelton (PLT) turbine assembly Turbine arrives fully assembled, other than the jet holders. This exploded diagram will assist you once it comes time to service the turbine. It would be prudent for the installer to remove the PMA and check that all connections are tight and familiarise themselves with the product so the can quickly service it in the future.
Pelton fixing washers front and rear views Insert M12 bolt, spring washer and washers as shown. Install alignment washers as shown. Note you may need to alter the position of the washers until the centre of the jet aligns with the splitter of the Pelton spoons. Attach the Pelton runner to the shaft as shown below. Top hat drain hole points down Attach Pelton runner to the shaft and tighten to 50 Nm (35 lb/ft).
Pelton Runner Alignment You can view the Pelton runner by looking through the jet as shown. The water jet needs to hit the middle of the Pelton spoon splitter. If the jet is misaligned then pack the runner across using the washers supplied. You can see in the picture that the Pelton runner needs packing to move the rotor to the left. 8.3.4. Turgo (TRG) turbine assembly Turgo turbines are fully assembled apart from the 4 jets. These are assembled as shown. Grease all the threads and tighten until snug.
Low Head (LH and LH Pro) turbine assembly The LH and LH Pro are fully assembled apart from the PMA stator and rotor. To attach the stator and rotor follow this procedure: 8.3.5.
The generator temperature should always be checked as part of the turbine commissioning by the installer, particularly if installed in very hot climates. In some environments moist condensing air will result in heavy condensation on the bulkhead. This will run down the bulkhead and out of the drain hole. You must ensure that a 15-20mm unrestricted hole is drilled at the lowest point to ensure that condensation can drain away freely. 8.4. Commissioning procedures 8.4.1.
Purging the pipe Allow pipe to run and purge of any air bubbles (this can take a few hours). Keep checking the pressure gauge until it reaches a steady reading. It may help to close the turbine valves and allow air to escape upwards to the intake for a few hours while you check the pipe for high spots and adjust its gradient to remove airlocks. While it is purging, walk the pipe and lift sections (it will feel light) to locate any air locks and fit riser vents as required.
Documenting the system Once you are happy that you have successfully commissioned the turbine you should record the following details (see Section 8.5): Jets sizes installed Flow rate through turbine (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.
can decide what compromise to make with the packing and what penalty you will pay for not changing it. Optimisation is a trial and error process whereby you run the turbine, check the output current, stop the turbine, adjust the knob on the magnet rotor, run and test again. Once you have found the best position for the rotor you can pack behind it with washers to lock it gently in that position. (Note: 1mm thick stainless steel washers are supplied for packing). Do not over-tighten the plastic nut.
FM60 tends to track down from the Voc and MC250 (in hydro mode) tends to track up from the battery voltage. Once it gets to about 80 VDC input it will also have 1.6kW on the display. For more detailed information on the set up of FM60/FM80 , MC150/200/250, MC KID and other makes of MPPT controllers refer to the new 2014 Technical Manual. 8.4.5.
The above illustration shows where the top and bottom jet exhaust water should be hitting the clear screen for optimal performance. The spray pattern may also give clues to any misalignment of the jet axis relative to the turbine buckets. If the exhaust water does not hit the clear front at 90 degrees to the jet, then there are a few possible issues that should be checked. Note the output power and compare this to what you were advised prior to purchase.
This is best illustrated in the Smart Drive test graph (Figure 1). A 10% reduction in the rotor magnetism to the stator reduces the power line’s height by 10% and the amps / volts lines by 5% approximately. Figure 1. Simplified Smart Drive test graph This example assumes that calculations for your site data predicted that you could get 530 W at 1000 rpm (brown line) and 70% generator efficiency (red line) on a fully charged 48 V DC bank at 56 V DC.
8.4.8. Thermal Checks A PowerSpout has an enclosed generator. The inside stator core temperature of the generator will depend on: Output power of the turbine Revolutions (speed) of turbine – higher rpm has more cooling Ambient air temperature Water temperature Voltage of operation (lower voltages have more rectification losses) The generator core is cooled by air flow across the stator.
8.5. Installation details We recommend you take note of and let us know the final system details (as below) for future reference and to help with ordering replacements or upgrading the system. This information and a picture of the final installation is required for all warrantees greater than 12 months.
Labelling requirements Local codes and standards list many labels and notices that must be installed on these systems. Consult these documents and your local installer to make sure you comply. Generally labels cover the following: Breakers should be clearly labelled and state what it is they do. DC wire should be clearly labelled to avoid confusion with AC wires. Emergency shutdown procedure should be clearly stated, markers on your property may be required to direct emergency services.
9. Operating your system efficiently The PowerSpout is a durable machine but it runs 24/7 so regular checks and maintenance are advised. A PowerSpout may do more revolutions in one year than a car engine during the life of the car. A car engine has a filtered and pumped oil lubrication system, whereas a small hydro turbine does not. You must pay special attention to the bearings. A bearing maintenance schedule is outlined below and you are required to follow it if your 3-year warranty is to be honoured.
MPPT controller 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: Blocked intake screen or 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.
PLT Front SKF 6205-2Z OD52mm ID25mm Rear SKF 6005-2Z OD47mm ID25mm TRG & LH Front and Rear SKF 6005-2Z OD47mm ID25mm 9.3.1. Manually applied lubrication Sealed bearings do need to be re-greased at times as hydro turbines run 24/7 and see very high cycle rates. The PowerSpout is provided with a re-greasing nipple so this can be easily done with the turbine in operation.
9.4. Changing the bearings You will need to check the bearings every year and replace if required (note our warranty terms require annual replacement if automatic grease cans are not installed). Bearings are inexpensive and easy to replace. We recommend you hold a spare set of bearings on the shelf. 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 unless an automatic grease can is fitted.
Loctite 680 the front bearing shaft position as shown. Smear the loctite evenly over the surfaces (1-2 drops per surface is sufficient). Insert shaft the correct way around (spline protruding through rear bearing). You may need to use a small workshop press to press the shaft home. Clean up any excess loctite with a clean rag. Apply 1 drop of loctite to the shaft thread. Attach shaft retaining nut and snug up but do not over tighten. Shaft should spin freely without any tightness.
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. Multiply the voltage (V) reading by the current (A) to determine the Watts your PowerSpout is producing. If the 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 optimisation.
10.3. Noise Noise is not normally an issue. Our turbines are normally quieter than others as they turn slower and are fully enclosed.
11. Examples of good hydro system installations Taking care in planning and installation, completing all commissioning tests, and observing and documenting correct operation are all the responsibility of the installer. Pictures of various installs follow, in the hope that these assist you in doing a quality job. 11.1.
6.
11.2. Poor quality hydro systems With a little more effort the installs below could have been made tidy, safe and compliant with wiring codes and recommended install procedures. Your system should be an asset not a liability.
11.3. Hydro installations with room for improvement This example has a few issues which could have been avoided: The turbine is difficult to access for servicing With the door closed, the humidity in this plastic enclosure can get very high. If you do this ensure good ventilation to outside air. Plastic PVC pipe work could be tidier with fewer bends This example shows the turbine and inverter enclosed in same structure.
11.4. Poor quality turbine install, maintenance and servicing With a little more care and more careful attention to the detail in this manual your turbine will last much longer between service intervals. The pictures opposite show water stains caused by not installing the O-ring seals on the case/valve and then leaving the joints to leak. Such leaks can result in water spray/mist that is then drawn into the casing via the cooling system.
12. 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. 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.
13. Warranty and disclaimer The following applies to complete PowerSpout turbines only and hence excludes kit sets and parts. Trade customers on selling this product must facilitate warranty claims with the final client. EcoInnovation will only deal with the Trade customer in such cases. Our warranty is valid provided the turbine has been correctly installed (within 12 months of sale), commissioned and maintained over the duration of its use.
Our maximum liability is limited to the full amount paid for the turbine. If you are an overseas customer that has purchased this equipment by mail order over the internet then this is the maximum extent of our liability. EcoInnovation reserves the right to improve the product and alter the above conditions without notice. EcoInnovation takes safety very seriously and we endeavour to reduce all risks to the extent possible and warn you of hazards.
17. Annex I: Jet sizing tables Jet sizing tables have been removed from this update of the installation manual. The advanced calculation tool can perform jet size calculations in metric and imperial for 1-4 jets, it is faster and more accurate than using a table. http://www.powerspout.com/calculators/ 18. Annex II: Common PVC pipe sizes The tables below are to assist in the understanding of the PVC pipe sizes available in your country.
PowerSpout Installation Manual Table 3. China PVC pipe sizes OD of pipe 0.63 Mpa Wall mm 0.63 Mpa ID pipe mm 0.8 Mpa Wall mm 0.8 Mpa ID pipe mm 1.0 Mpa Wall mm 1.0 Mpa ID pipe mm 1.25 Mpa Wall mm 1.25 Mpa ID pipe mm 1.6 Mpa Wall mm 1.6 Mpa ID pipe mm 50 63 75 90 110 160 200 250 315 355 2.0 2.0 2.3 2.8 2.7 4.0 4.9 6.2 7.7 8.7 46.0 59.0 70.4 84.4 104.6 152.0 190.2 237.6 299.6 337.6 2.2 2.5 2.9 3.5 3.4 4.9 6.2 7.7 9.7 10.9 45.6 58.0 69.2 83.0 103.2 150.2 187.6 234.6 295.6 333.2 2.4 3.0 3.6 4.
PowerSpout 19. Installation Manual Annex III Noise measurements Noise test at PowerSpout on PLT turbine Test parameters: Watts: 1000 Flow: 3,05 l/s Pressure: 95,5 psi Head: 600 kPa In front of running turbine: 93.8 dBA © 2014 EcoInnovation Ltd (NZ) On top of running turbine: 81.
PowerSpout Installation Manual 1m away from running turbine: 83.3 dBA 2m away from running turbine: 81.9 dBA 6m away from running turbine: 73.9 dBA 12m away from running turbine: 56.
