Summary of Contents for EcoInnovation PowerSpout TRG 28
- Page 1 PowerSpout Turbine Installation Manual PowerSpout TRG © 2018 EcoInnovation Ltd (NZ) Page 1...
- Page 2 Web: www.ecoinnovation.co.nz If you need to contact EcoInnovation by phone then email first via our web site and check the local time in NZ if calling from overseas. Business hours are 9:00am to 5:00pm (NZ time) weekdays only. EcoInnovation is closed for up to 3 weeks over the Christmas break.
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Page 3: Table Of Contents
Operation of control valves ................37 2.4.4. Optimisation of jet size ................. 38 2.4.5. Thermal Checks ................... 40 2.4.6. Maintenance....................40 2.4.7. Spare parts ....................41 2.4.8. Troubleshooting ................... 42 Last revised July 2018 © 2018 EcoInnovation Ltd (NZ) Page 3... - Page 4 2.4.10. Turbine case flooding .................. 43 Reference section ....................... 44 3.1. Units and conversions .................... 44 3.2. Common versions of PowerSpout TRG ..............44 3.3. TRG Specifications ....................45 Last revised July 2018 © 2018 EcoInnovation Ltd (NZ) Page 4...
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Page 5: Introduction
When operating and maintaining your TRG turbine Your log book Bearing care guide Our worldwide network of dealers can also help you with system design and choosing the best equipment for your situation. Last revised July 2018 © 2018 EcoInnovation Ltd (NZ) Page 5... -
Page 6: Product Scope And Specification
PowerSpout dealers may request to see the Compliance Folder if required by authorities. 1.2.3. Standards and certification All PowerSpout turbines have been evaluated against major international standards. Refer to compliance declaration documentation and EMC test reports. Last revised July 2018 © 2018 EcoInnovation Ltd (NZ) Page 6... -
Page 7: Turbine Serial Numbers
Risk of electric shock that could result in personal injury or loss of life Caution Cautions identify condition or practices that could result in damage to equipment or personal injury, other than by electric shock. Last revised July 2018 © 2018 EcoInnovation Ltd (NZ) Page 7... -
Page 8: Electrical Hazards
Batteries give off hydrogen and oxygen gas during charging in the correct proportions for an explosion. Ventilation of the enclosure is required. Terminals should be checked annually for tightness and clean if any corrosion is observed. Last revised July 2018 © 2018 EcoInnovation Ltd (NZ) Page 8... -
Page 9: Mechanical Hazards
Penstocks (pipelines) are often routed through steep locations with various hazards including danger of falling from heights, or rocks etc falling from above. Take care to prepare suitable access to the site and install safety ropes, steps, etc. Last revised July 2018 © 2018 EcoInnovation Ltd (NZ) Page 9... - Page 10 Electrical hazard Rotating machinery hazard Made in New Zealand identification Recycling identification Last revised July 2018 © 2018 EcoInnovation Ltd (NZ) Page 10...
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Page 11: Your Trg Turbine
Note that it is normal to feel some resistance when spinning the magnetic rotor by hand. You will hear a slight humming sound. The rotor will slow to a halt after 2-3 seconds. Last revised July 2018 © 2018 EcoInnovation Ltd (NZ) Page 11... -
Page 12: Turbine Protective Casing
Can be mounted directly on TRG jet-holders, but when used with camlocks and hoses we recommend fitting the valves at the supply pipe end of the hoses instead. Grease the threads well. Last revised July 2018 © 2018 EcoInnovation Ltd (NZ) Page 12... -
Page 13: Pressure Gauge
If turbine output is low then the pressure gauge helps you find the cause. Low pressure could mean blocked filter, lack of water flow, or trapped air in the pipe. Higher than usual running pressure could mean an obstructed jet. Last revised July 2018 © 2018 EcoInnovation Ltd (NZ) Page 13... -
Page 14: Camlock Fittings
2.1.5. Jet sleeve and cap Supplied with turbine. Grease threads liberally. Tighten the camlock onto jet sleeve outer end with a wrench. Last revised July 2018 © 2018 EcoInnovation Ltd (NZ) Page 14... -
Page 15: Jet Inserts
Take care, as it is easy to slip, which could result in a significant flesh wound. If you have Kevlar gloves, wear them. Last revised July 2018 © 2018 EcoInnovation Ltd (NZ) Page 15... - Page 16 Armed with a heat gun this can be fixed if the above has occurred and the force to correct on the jet support feels too high. Last revised July 2018 © 2018 EcoInnovation Ltd (NZ) Page 16...
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Page 17: Turbine Runner/Rotor Mounting
Tighten the nut to 50 Nm torque or "very tight". The runner may be damaged if it slips. (50Nm/37ftlb is the same as 25kg weight at the end of a 20cm long spanner or wrench.) Last revised July 2018 © 2018 EcoInnovation Ltd (NZ) Page 17... -
Page 18: Shaft And Bearing Block Installation
Fit the locking plate to prevent rotation and loosening. Locking plate Manual grease nipple Last revised July 2018 © 2018 EcoInnovation Ltd (NZ) Page 18... -
Page 19: Changing The Bearings
Finally tighten the locknut on the dry end, using the same technique as used to remove it. Do not over-tighten. You want the bearings to spin freely Last revised July 2018 © 2018 EcoInnovation Ltd (NZ) Page 19... -
Page 20: Greasing The Bearings
Every 12 months for generation up to 300 W. Every 6 months for generation up to 600 W. Every 3 months for generation up to 1600 W. Last revised July 2018 © 2018 EcoInnovation Ltd (NZ) Page 20... - Page 21 check the movement of the plunger, top them up on a regular basis, and to revert to manual greasing in colder weather. Last revised July 2018 © 2018 EcoInnovation Ltd (NZ) Page 21...
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Page 22: The Stator
Snuggly tighten the four machine screws that hold it down, using an 11mm socket spanner (7/16" wrench). Last revised July 2018 © 2018 EcoInnovation Ltd (NZ) Page 22... - Page 23 Smart Drives in hydro turbines for over 15 years and have not seen a failed one yet. It is normal to see about 4 cracks as per the picture. Generally units are sent out without cracks, but these will form in due course. Last revised July 2018 © 2018 EcoInnovation Ltd (NZ) Page 23...
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Page 24: Rectifier
Output current (Voltage is highest when there is no output) Rotational speed in RPM (related to water pressure and output current) Magnetic field strength (from the magnet rotor). Last revised July 2018 © 2018 EcoInnovation Ltd (NZ) Page 24... - Page 25 42 fingers on stator Type 2 (default) Type 2+ 36 fingers on stator Type 3 Type 4 (default) For more information about Smart Drive stators and rotors see the SD applications manual Last revised July 2018 © 2018 EcoInnovation Ltd (NZ) Page 25...
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Page 26: Turbine Installation
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. Last revised July 2018 © 2018 EcoInnovation Ltd (NZ) Page 26... - Page 27 It is important that the installer makes the site safe and that no rotational or electrical hazards exist. Last revised July 2018 © 2018 EcoInnovation Ltd (NZ) Page 27...
- Page 28 Often the air takes a day or so to escape, and the pressure (and Voc) after this is completed may be higher. Last revised July 2018 © 2018 EcoInnovation Ltd (NZ) Page 28...
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Page 29: Commissioning Procedures
So if your turbine is designed to work at 80V for example, the open circuit voltage may exceed 200V. This may be hazardous to personnel and equipment. Last revised July 2018 © 2018 EcoInnovation Ltd (NZ) Page 29... -
Page 30: Commissioning The Turbine
The jet position can be moved slightly within the casing. Once optimized, secure and support the pipe. Last revised July 2018 © 2018 EcoInnovation Ltd (NZ) Page 30... -
Page 31: Commissioning (Models Trg40, 80 Or 200) Connected To Mppt Or Gti
“MC4” type waterproof connectors may be used provided they are never opened under load. All wiring must be enclosed for safety so that it is inaccessible to touch. An EMC filter must be fitted in all grid-connected installations. Last revised July 2018 © 2018 EcoInnovation Ltd (NZ) Page 31... - Page 32 Confirm that measured Voc is at least 10V below 90% of the safe limit for your MPPT controller or GT inverter. (This allows a margin for ripple in the voltage.) Last revised July 2018 © 2018 EcoInnovation Ltd (NZ) Page 32...
- Page 33 Adjust MPPT set point (turbine voltage) from highest to lowest voltage and note power output at each setting. Then select best power result. Last revised July 2018 © 2018 EcoInnovation Ltd (NZ) Page 33...
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Page 34: All Turbine Models - Final Commissioning Checks
When turbine testing and commissioning is completed and documented, ensure that the protective fairing is are in position prior to client hand over. Comply with signage requirements as listed in relevant national standards. Last revised July 2018 © 2018 EcoInnovation Ltd (NZ) Page 34... -
Page 35: Labeling Requirements
1. Turn off the turbine circuit breaker. 2. Turn off all the battery circuit breakers. 3. Pull out the main battery fuse-holder to isolate the battery. To start up, follow the above procedure in reverse. Last revised July 2018 © 2018 EcoInnovation Ltd (NZ) Page 35... -
Page 36: Installation Details
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. Last revised July 2018 © 2018 EcoInnovation Ltd (NZ) Page 36... -
Page 37: Turbine Operation
Power output will be less than full power but at least with a full pipe the best use is being made of the available water. Last revised July 2018 © 2018 EcoInnovation Ltd (NZ) Page 37... -
Page 38: Optimisation Of Jet Size
This is best illustrated in the Smart Drive test graph (Error! Reference source not found.). 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. Last revised July 2018 © 2018 EcoInnovation Ltd (NZ) Page 38... - Page 39 As low flow often coincides with very sunny weather, solar PV can normally make up any shortfall in hydropower during dry periods. Last revised July 2018 © 2018 EcoInnovation Ltd (NZ) Page 39...
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Page 40: Thermal Checks
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. Last revised July 2018 © 2018 EcoInnovation Ltd (NZ) Page 40... -
Page 41: Spare Parts
A spare shaft and bearing block as shown below is good insurance because these are the parts that suffer the most wear and highest failure rate. Last revised July 2018 © 2018 EcoInnovation Ltd (NZ) Page 41... -
Page 42: Troubleshooting
PowerSpout TRG installation 2018 2.4.8. Troubleshooting For assistance with your system please contact your equipment installer or provider. Last revised July 2018 © 2018 EcoInnovation Ltd (NZ) Page 42... -
Page 43: Making The Most Of Your Pressure Gauge
Remove the magnetic rotor and clean off any magnetic grit carried by the water. Regrease the bearings and run the turbine so that internal generator heat will dry it out. Damage caused by water submersion is not covered under warranty. Last revised July 2018 © 2018 EcoInnovation Ltd (NZ) Page 43... -
Page 44: Reference Section
Grid-tie Grid-tie *All off grid MPPT turbines can charge 12, 24 or 48 V battery bank except TRG40 that can only be used in 12 and 24 V systems. Last revised July 2018 © 2018 EcoInnovation Ltd (NZ) Page 44... -
Page 45: Trg Specifications
100 amp air cooled rectifier Dimensions 430 x 410 x 350 mm (16.9 x 16.1 x 13.8 inches) Net Weight 15kg, with pipe fittings 28kg. Up to 30kg packed Weight weight Last revised July 2018 © 2018 EcoInnovation Ltd (NZ) Page 45...
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