Morningstar 4.7.4 Instrukcja Instalacji

© 2014 EcoInnovation Ltd (NZ) Page 1 PowerSpout Basic System Design and Installation Manual PLT, TRG and LH turbines Industrial PLT Off grid

© 2014 EcoInnovation Ltd (NZ) Page 10 1.2. Installation checklist The installation shall be carried out by installers with recognized and approve

© 2014 EcoInnovation Ltd (NZ) Page 100 Low Head (LH and LH Pro) turbine assembly The LH and LH Pro are fully assembled apart from the PMA stator a

© 2014 EcoInnovation Ltd (NZ) Page 101 The generator temperature should always be checked as part of the turbine commissioning by the installer, pa

© 2014 EcoInnovation Ltd (NZ) Page 102 Purging the pipe  Allow pipe to run and purge of any air bubbles (this can take a few hours). Keep checkin

© 2014 EcoInnovation Ltd (NZ) Page 103 Documenting the system Once you are happy that you have successfully commissioned the turbine you should rec

© 2014 EcoInnovation Ltd (NZ) Page 104 can decide what compromise to make with the packing and what penalty you will pay for not changing it.

© 2014 EcoInnovation Ltd (NZ) Page 105 FM60 tends to track down from the Voc and MC250 (in hydro mode) tends to track up from the battery voltage.

© 2014 EcoInnovation Ltd (NZ) Page 106 The above illustration shows where the top and bottom jet exhaust water should be hitting the clear screen f

© 2014 EcoInnovation Ltd (NZ) Page 107 This is best illustrated in the Smart Drive test graph (Figure 1). A 10% reduction in the rotor magnetism to

© 2014 EcoInnovation Ltd (NZ) Page 108 8.4.8. Thermal Checks A PowerSpout has an enclosed generator. The inside stator core temperature of the gen

© 2014 EcoInnovation Ltd (NZ) Page 109 8.5. Installation details We recommend you take note of and let us know the final system details (as below

© 2014 EcoInnovation Ltd (NZ) Page 11  check for excessive noise.  complete turbine testing and commissioning.  ensure that all protective

© 2014 EcoInnovation Ltd (NZ) Page 110 Labelling requirements Local codes and standards list many labels and notices that must be installed on thes

© 2014 EcoInnovation Ltd (NZ) Page 111 9. Operating your system efficiently The PowerSpout is a durable machine but it runs 24/7 so regular checks

© 2014 EcoInnovation Ltd (NZ) Page 112 Volt, Amp and Ohm at play MPPT controller or grid tied inverter will display the generation Watts and often

© 2014 EcoInnovation Ltd (NZ) Page 113 PLT  Front SKF 6205-2Z OD52mm ID25mm  Rear SKF 6005-2Z OD47mm ID25mm TRG & LH  Front and Rear SKF

© 2014 EcoInnovation Ltd (NZ) Page 114 9.4. Changing the bearings You will need to check the bearings every year and replace if required (note our

© 2014 EcoInnovation Ltd (NZ) Page 115  Loctite 680 the front bearing shaft position as shown.  Smear the loctite evenly over the surfaces (1-2

© 2014 EcoInnovation Ltd (NZ) Page 116 If you are concerned your system is not operating correctly then measure the PowerSpout output voltage and c

© 2014 EcoInnovation Ltd (NZ) Page 117 10.3. Noise Noise is not normally an issue. Our turbines are normally quieter than others as they turn slowe

© 2014 EcoInnovation Ltd (NZ) Page 118 11. Examples of good hydro system installations Taking care in planning and installation, completing all co

© 2014 EcoInnovation Ltd (NZ) Page 119 6.4kW from 4 x PLT200’s (running at 171 VDC) feeding into 2 x 4kW EnaSolar inverters Features of th

© 2014 EcoInnovation Ltd (NZ) Page 12  The client has read manuals, viewed online videos and read installation examples before starting on this p

© 2014 EcoInnovation Ltd (NZ) Page 120 11.2. Poor quality hydro systems With a little more effort the installs below could have been made tidy, saf

© 2014 EcoInnovation Ltd (NZ) Page 121 11.3. Hydro installations with room for improvement This example has a few issues which could have been avo

© 2014 EcoInnovation Ltd (NZ) Page 122 11.4. Poor quality turbine install, maintenance and servicing With a little more care and more careful atten

© 2014 EcoInnovation Ltd (NZ) Page 123 12. Units and conversions  An ampere (amp, A) is the unit of measurement of electric current produced in

© 2014 EcoInnovation Ltd (NZ) Page 124 13. Warranty and disclaimer The following applies to complete PowerSpout turbines only and hence excludes k

© 2014 EcoInnovation Ltd (NZ) Page 125  Our maximum liability is limited to the full amount paid for the turbine. If you are an overseas customer

April 2014 draft. version 17. Annex I: Jet sizing tables Jet sizing tables have been removed from this update of the installation manual. The ad

PowerSpout Installation Manual © 2014 EcoInnovation Ltd (NZ) Page 127 Table 3. China PVC pipe sizes OD of pipe 0.63 Mpa 0.63 Mpa ID 0.8 Mpa 0.8 Mpa

PowerSpout Installation Manual © 2014 EcoInnovation Ltd (NZ) Page 128 19. Annex III Noise measurements Noise test at PowerSpout on PLT turbine Te

PowerSpout Installation Manual © 2014 EcoInnovation Ltd (NZ) Page 129 1m away from running turbine: 83.3 dBA 2m away from running turbine: 81.

© 2014 EcoInnovation Ltd (NZ) Page 13 1.6. Fairing safety warnings The fairing on your PowerSpout turbine forms part of an electrical enclosure an

© 2014 EcoInnovation Ltd (NZ) Page 14 1.8. Connecting to the Grid (power network) PowerSpout PLT/TRG/LH grid-tied options (no batteries required)

© 2014 EcoInnovation Ltd (NZ) Page 15 2. Step by step design overview This section briefly outlines the main choices you will need to make in the

© 2014 EcoInnovation Ltd (NZ) Page 16 PowerSpout turbines have been tested for compatibility with a number of MPPT inverter/controllers and results

© 2014 EcoInnovation Ltd (NZ) Page 17 2.9. Optional extras you may wish to order Check the pricelist for additional items that you may wish to hav

© 2014 EcoInnovation Ltd (NZ) Page 18 2.9.4. Adjustable jet options Adjustable spear jets are available (to order) for the PowerSpout PLT. Howeve

© 2014 EcoInnovation Ltd (NZ) Page 19 3. Renewable energy from a PowerSpout turbine Congratulations on your choice of a PowerSpout turbine. This i

© 2014 EcoInnovation Ltd (NZ) Page 2 CONTENTS 1. Scope of Application, and Safety ...

© 2014 EcoInnovation Ltd (NZ) Page 20 In the case of the LH turbines, the propeller turbine is normally near to the surface in an elevated flume.

© 2014 EcoInnovation Ltd (NZ) Page 21 3.1.3. Worked example If for example the head is 20 metres and the flow is 10 litres per second then the pow

© 2014 EcoInnovation Ltd (NZ) Page 22 3.4. How can we be sure of getting the right voltage out of the turbine? Your turbine will have been designe

© 2014 EcoInnovation Ltd (NZ) Page 23 3.5. Understanding open circuit voltage (Voc) When there is no current, because the turbine spinning is disc

© 2014 EcoInnovation Ltd (NZ) Page 24 4. Designing your site layout and choosing your turbine model 4.1. Measuring Head You will need to measure

© 2014 EcoInnovation Ltd (NZ) Page 25 4.2. Measuring Flow IMPORTANT: "Gallons," "gals," and "gpm" refer to the US Im

© 2014 EcoInnovation Ltd (NZ) Page 26 Version Head (m) Flow (l/s) photo PowerSpout PLT (Pelton) 3 – 130 m 0.1 – 10 l/s PowerSpout TRG (Turgo) 2 –

© 2014 EcoInnovation Ltd (NZ) Page 27 4.4. Siting your PowerSpout turbine Some tips for locating a good site for your turbine include: 4.4.1.

© 2014 EcoInnovation Ltd (NZ) Page 28 4.4.3. Keep your PLT/TRG turbine as low as possible Maximise the head, but do ensure that it is above maximu

© 2014 EcoInnovation Ltd (NZ) Page 29 Dual install, one unit runs on 30m (98 ft) head the other 10m (33 ft) head 4.6. PowerSpout site data re

© 2014 EcoInnovation Ltd (NZ) Page 3 4.6. PowerSpout site data requirements ...

© 2014 EcoInnovation Ltd (NZ) Page 30 Hydro site data required for PowerSpout product manufacture Question Units PowerSpout turbine type PLT, TRG,

© 2014 EcoInnovation Ltd (NZ) Page 31 4.7.1. Pipe sizes Pipe sizes commonly used with our hydro products include:  PVC for larger sizes based o

© 2014 EcoInnovation Ltd (NZ) Page 32 Table 1. Pipes common in NZ (Rural Direct)– indicative prices 2014 Pipe OD Pipe ID Material Pressure rating

© 2014 EcoInnovation Ltd (NZ) Page 33 If the penstock simply discharges "full bore" (for example, to flush out sediment) then the flow wi

© 2014 EcoInnovation Ltd (NZ) Page 34 4.7.8. Pipe thrust blocks On larger hydro schemes using rigid pipes, thrust pads and anchor blocks may be re

© 2014 EcoInnovation Ltd (NZ) Page 35 Angled guides and screen - the best! Perforated box in concrete Commercial intake on road culvert Perfor

© 2014 EcoInnovation Ltd (NZ) Page 36 Some ideas for intakes made from scrap stainless steel components 4.8.1. Water usage with minimum im

© 2014 EcoInnovation Ltd (NZ) Page 37 4.9. Turbine "manifold" connecting options PLT and TRG The manifold is the system of pipes that co

© 2014 EcoInnovation Ltd (NZ) Page 38 4.9.4. The connections made to the penstock You will need up to 2 penstock connections for every PLT turbine

© 2014 EcoInnovation Ltd (NZ) Page 39 4.9.6. Pipe fittings - Y’s PVC “Y” fittings suit higher flow TRG sites that commonly use 160 or 200mm OD PVC

© 2014 EcoInnovation Ltd (NZ) Page 4 5.7.6. Factoring in the cable voltage drop ...

© 2014 EcoInnovation Ltd (NZ) Page 40 4.9.7. PVC 4 jet manifold – for PVC pipes and the TRG turbine A PVC manifold option is available to special

© 2014 EcoInnovation Ltd (NZ) Page 41 4.9.10. Mock up your manifold off-site first You will save a lot of time if you mock up your manifold and ex

© 2014 EcoInnovation Ltd (NZ) Page 42 The pressure tapping kit (optional extra) allows you to insert a quick release pressure fitting at points of

© 2014 EcoInnovation Ltd (NZ) Page 43 5. Electrical System Components From the coils in the alternator to the heaters that control the battery cha

© 2014 EcoInnovation Ltd (NZ) Page 44 In order to comply with standards for conducted and radiated emission noise, the 3-Phase rectifier in your Po

© 2014 EcoInnovation Ltd (NZ) Page 45 5.3.3. Klampit "crowbar" protection circuits (optional) A Klampit is a proprietary safety device t

© 2014 EcoInnovation Ltd (NZ) Page 46 5.3.5. PowerSpout TRG versions Common versions of PowerSpout TRG with no overvolts crowbar Off-grid* On-gri

© 2014 EcoInnovation Ltd (NZ) Page 47 hence the cost of the cable). Changing the "design load voltage" will also have a dramatic effect,

© 2014 EcoInnovation Ltd (NZ) Page 48 5.5.2. MPPT (Maximum Power Point Tracking) controllers MPPT (Maximum Power Point Tracking) controllers work

© 2014 EcoInnovation Ltd (NZ) Page 49 Once the controller recognizes that your battery charge rate has reached the highest safe level it diverts an

© 2014 EcoInnovation Ltd (NZ) Page 5 6.9. Installation example ...

© 2014 EcoInnovation Ltd (NZ) Page 50 USA NEC Requirements To comply with NEC 690.72 (B), the following requirements will apply when using a divers

© 2014 EcoInnovation Ltd (NZ) Page 51 Tracking is the process by which the MPPT device changes the voltage to find the maximum power. Modern inver

© 2014 EcoInnovation Ltd (NZ) Page 52 Victron Energy Blue solar MPPT 150/70 Micro Care 20-60amp MPPT with intergrated DC breakers Xantrex XW MP

© 2014 EcoInnovation Ltd (NZ) Page 53 600 V DC input units XW MPPT 80- 600 Solar (24 & 48 V DC output) TriStar MPPT 600 Volt Solar Tri

© 2014 EcoInnovation Ltd (NZ) Page 54 over-voltage protection built in) may be used with MPPT controllers but you must be careful if you do this. T

© 2014 EcoInnovation Ltd (NZ) Page 55 5.7.7. Summary: Matching your turbine to an MPPT controller and your battery The various voltage criteria ar

© 2014 EcoInnovation Ltd (NZ) Page 56 The PLT/TRG 100C turbine allows us to operate at a cable voltage of 100V with reduced costs and reduced los

© 2014 EcoInnovation Ltd (NZ) Page 57 If you intend to run a PLT turbine on a MPPT controller/inverter you must:  Tell us prior to ordering  Ha

© 2014 EcoInnovation Ltd (NZ) Page 58 Some MPPT controllers contain programmable "auxiliary" relays that can be used to control larger DC

© 2014 EcoInnovation Ltd (NZ) Page 59  Fit a PWM controller (with lower settings) to the battery as well 5.8.1. Diversion via the inverter outp

© 2014 EcoInnovation Ltd (NZ) Page 6 10. Troubleshooting ...

© 2014 EcoInnovation Ltd (NZ) Page 60 Installers must put a large sign by the hot water tank that says “Do not drain this tank without first turnin

© 2014 EcoInnovation Ltd (NZ) Page 61 This should be adequate for one PowerSpout turbine. For 12V systems, use two in parallel. For 48V systems,

© 2014 EcoInnovation Ltd (NZ) Page 62 Why use "PV trigger"? PV trigger prevents nuisance tripping of the crowbar protection in the follo

© 2014 EcoInnovation Ltd (NZ) Page 63 Operating PowerVoltage Watts40 16750 26060 37570 51080 66790 844100 1042110 1260120 1500Operating PowerVoltag

© 2014 EcoInnovation Ltd (NZ) Page 64 5.12. Preventing excessively hot water with PWM & MPPT regulation Overheating your water tank can be a pr

© 2014 EcoInnovation Ltd (NZ) Page 65 Inverter There are two types of inverters: battery-based ones for stand-alone off-grid systems, and grid-tie

© 2014 EcoInnovation Ltd (NZ) Page 66 The old GE400 has been displaced by a PLT350 option using the Aurora Power wind interface to regulate Voc.

© 2014 EcoInnovation Ltd (NZ) Page 67 5.14.1. MPPV and Voc considerations Operation with MPPT controllers and with grid-tied inverters are very si

© 2014 EcoInnovation Ltd (NZ) Page 68 6. System Wiring This section covers the items you will need to safely wire the components of your system t

© 2014 EcoInnovation Ltd (NZ) Page 69 Common sizes are:  10 Amp  16 Amp  20 Amp  25 Amp  32 Amp  40 Amp  50 Amp  63 Amp Common br

© 2014 EcoInnovation Ltd (NZ) Page 7 Disclaimer UNLESS SPECIFICALLY AGREED TO IN WRITING, ECOINNOVATION LIMITED: (a) MAKES NO WARRANTY AS TO THE

© 2014 EcoInnovation Ltd (NZ) Page 70 that creates a voltage between items will create a large current in the earth bonding that will blow a fuse a

© 2014 EcoInnovation Ltd (NZ) Page 71 On a 12/24 VDC battery systems, earthing of the bulkhead may not be required.  Where the hydro turbine is c

© 2014 EcoInnovation Ltd (NZ) Page 72 at some distance from a building. Ground-fault protection is not just for residential roofs. The 2008 NEC, re

© 2014 EcoInnovation Ltd (NZ) Page 73 6.4.4. Cable connection errors New Zealand electrical regulations allow you to work on systems up to 50 V AC

© 2014 EcoInnovation Ltd (NZ) Page 74 NEVER work on your renewable energy system with the hydro in operation. EcoInnovation will not be liable

© 2014 EcoInnovation Ltd (NZ) Page 75 6.5.1. PWM battery regulation Turbine types that can be used:  PLT 14/28/56/56C  TRG 28/56/56C Two PWM

© 2014 EcoInnovation Ltd (NZ) Page 76 6.6. Diagrams of wiring with MPPT controllers The drawings below illustrate the minimum installation require

© 2014 EcoInnovation Ltd (NZ) Page 77 6.6.1. 150-250 V DC MPPT Turbine types that can be used:  PLT 40/80  TRG 40/80  LH & LH Pro 150/2

© 2014 EcoInnovation Ltd (NZ) Page 78 6.6.3. 150-250 V MPPT with aux SSR relay diversion on battery side Turbine types that can be used:  PLT 40

© 2014 EcoInnovation Ltd (NZ) Page 79 6.6.5. 150 V MPPT – Midnite Classic KID The KID is able to divert surplus power (in excess of that needed t

© 2014 EcoInnovation Ltd (NZ) Page 8 PowerSpout Contact details Web: www.powerspout.com If you cannot find the answers to your questions ab

© 2014 EcoInnovation Ltd (NZ) Page 80 6.7. Diagrams of wiring for grid connection The drawings below illustrate the minimum installation requireme

© 2014 EcoInnovation Ltd (NZ) Page 81 6.8. Key to wiring diagrams. These wiring diagrams are an easy to follow representations of typical systems.

© 2014 EcoInnovation Ltd (NZ) Page 82 necessary to remove power to the controller when changing settings etc, so a point of local isolation is valu

© 2014 EcoInnovation Ltd (NZ) Page 83 The 3-pole HRC fuse holders can serve a multi-purpose of providing current protection for each battery string

© 2014 EcoInnovation Ltd (NZ) Page 84 6.9. Installation example A potential customer wants to purchase a PLT80 PowerSpout hydro turbine that will

© 2014 EcoInnovation Ltd (NZ) Page 85 7. Getting the best from your batteries 7.1. Lead acid battery type, size and life 7.1.1. Flooded or wet

© 2014 EcoInnovation Ltd (NZ) Page 86 7.1.4. What is electricity and what is a battery? Electricity is the flow of electrons along a wire. Metal i

© 2014 EcoInnovation Ltd (NZ) Page 87 draw more than 2.42 kW for a sustained period you should install a larger battery bank and inverter. 7.1.6.

© 2014 EcoInnovation Ltd (NZ) Page 88  Consider fitting battery recombination vents to significantly reduce the need to top up with water. Water

© 2014 EcoInnovation Ltd (NZ) Page 89 Do not install any fuses in a small battery enclosure as this is a potential source of ignition. Take care

© 2014 EcoInnovation Ltd (NZ) Page 9 IP24 ingress IK10 impact Model type: PLT, TRG, LH, LH Pro Rated Power:

© 2014 EcoInnovation Ltd (NZ) Page 90 7.2.4. Battery installation example 2 This example provides excellent mechanical protection for batteries an

© 2014 EcoInnovation Ltd (NZ) Page 91 7.3. Safety clothing Minimum safety clothing includes:  Plastic apron over overalls  Rubber gloves  E

© 2014 EcoInnovation Ltd (NZ) Page 92 8. Turbine Installation and Commissioning Before commencing the installation process you should have select

© 2014 EcoInnovation Ltd (NZ) Page 93 illustrated in the plan view below. Fixings are provided with the PowerSpout for connection to a timber frame

© 2014 EcoInnovation Ltd (NZ) Page 94 8.2.2. Mounting TRG A framed timber base made from 100 x 50 timbers and covered in 12-17mm thick plywood sh

© 2014 EcoInnovation Ltd (NZ) Page 95 Manifold pipe Supports Pipes full of water are heavy and will sag over time. It is very important to provide

© 2014 EcoInnovation Ltd (NZ) Page 96 8.3.2. Cutting the jets to correct size The plastic tapering jets can be cut on site with a sharp knife. Th

© 2014 EcoInnovation Ltd (NZ) Page 97 8.3.3. Pelton (PLT) turbine assembly Turbine arrives fully assembled, other than the jet holders. This expl

© 2014 EcoInnovation Ltd (NZ) Page 98 Pelton fixing washers front and rear views  Insert M12 bolt, spring washer and washers as shown.  In

© 2014 EcoInnovation Ltd (NZ) Page 99 Pelton Runner Alignment You can view the Pelton runner by looking through the jet as shown. The water jet nee