EcoInnovation PowerSpout TRG 170 Installation Manual Download Page 23 | Manualshive

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PowerSpout

TRG installation 2018

Last revised July 2018

© 2018 EcoInnovation Ltd (NZ)

Page 23

Stress Relief Cracks in Stator

You may notice if you service a PowerSpout that the stator may have developed some
cracks.

These cracks are normal. You normally observe 1-4. They are caused as stresses in the
steel/plastic-molded assembly relax during operation.

These cracks do not result in failure and are only cosmetic - so no need to panic. We have
been installing 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.

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Summary of Contents for PowerSpout TRG 170

Page 1: ...2018 EcoInnovation Ltd NZ Page 1 PowerSpout Turbine Installation Manual PowerSpout TRG...

Page 2: ...eeks over the Christmas break 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 INFO...

Page 3: ...fittings 14 2 1 5 Jet sleeve and cap 14 2 1 6 Jet inserts 15 2 1 7 Turbine runner rotor mounting 17 2 1 8 Shaft and bearing block installation 18 2 1 9 Changing the bearings 19 2 1 10 Greasing the bea...

Page 4: ...d July 2018 2018 EcoInnovation Ltd NZ Page 4 2 4 9 Making the most of your pressure gauge 43 2 4 10 Turbine case flooding 43 3 Reference section 44 3 1 Units and conversions 44 3 2 Common versions of...

Page 5: ...ef summary of documents that will answer your questions 1 1 1 When planning your system Site assessment guide Intake guide and Coanda intake guide Pipe selection guide Manifold guide Hydro design and...

Page 6: ...where the customer understands that no net energy will be generated The installer must Check for any transit damage to the product prior to installing it If damaged it must not be installed If the tur...

Page 7: ...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...

Page 8: ...on the identification plate Loose connections can cause electric arcs to occur that could ignite flammable materials Tighten all electrical connections inside the turbine very securely during installa...

Page 9: ...hen working with batteries Burns acid splashes and even electric shocks can occur If you do not have sufficient skill and or experience to install and care for this equipment you should engage a renew...

Page 10: ...ater supply valve s Check for excessive noise Complete turbine testing and commissioning and ensure that all protective fairing enclosures are in position after commissioning and prior to client hand...

Page 11: ...he turbine and what is supplied with it If you disassemble your turbine take careful note of the positions of parts including any washers Take photographs to remind you of the details Your turbine wil...

Page 12: ...arate document Warranty and terms in the index 2 1 1 Turbine protective casing The PowerSpout TRG is encased in a very durable LDPE casing and fairing ensuring all internal parts are protected from ra...

Page 13: ...you should vent it by pushing the rubber bung aside with a thumbnail This allows air to enter or leave the casing Or snip off the nipple on the top of the plug if plug is uppermost Measure the static...

Page 14: ...our turbine from the pipework for servicing Our camlock fittings are rated for up to 6 bar 87 PSI or 60m head and include 1 male and 1 female thread Be aware that at flows exceeding 3 litres second pe...

Page 15: ...for your site as you have reported it Four spare jet inserts are also supplied with your turbine The hole inside is tapered Enlarge the jet by shortening the plastic insert on site with a sharp knife...

Page 16: ...ess During manufacture a jig is used to obtain good jet alignment The jig is a 1mm wire that is held centrally in the jet holder but can be moved in and out Alignment is done by heat setting the case...

Page 17: ...is factory set using the correct number of shim washers If you remove the runner then take care to keep these washers and refit them exactly as supplied The turgo runner itself is clamped to the shaft...

Page 18: ...black plastic cap nut This cap has hexagonal part 91mm across the flats Be sure to tighten it very securely so the turbine does not come loose You can make a box spanner wrench using a PVC 90 63 OD p...

Page 19: ...air of grips Use the jaws of the vice not tightened as a support for the block Then strike the end of the shaft to drive it out of the block Take care not to damage the shaft Knock the shaft out of th...

Page 20: ...ied lubrication Sealed bearings do need to be re greased at times because hydro turbines run 24 7 and see very high cycle rates The PowerSpout is provided with a re greasing nipple Zerk fitting so thi...

Page 21: ...brass fitting Remove the automatic grease can from the holder clip if fitted and activate It is activated by turning the grey cap until you hear the canister pop There are detailed instructions on th...

Page 22: ...then you may need a different stator Assembly Before mounting the stator to the TRG turbine you must connect the three wires to the rectifier that is mounted on the baseplate beneath it Also connect t...

Page 23: ...You normally observe 1 4 They are caused as stresses in the steel plastic molded assembly relax during operation These cracks do not result in failure and are only cosmetic so no need to panic We hav...

Page 24: ...st be ordered if your turbine is to be used for a grid connect application Rectifiers get hot due to power losses and lower voltage systems have greater losses In a 12 V system you lose approximately...

Page 25: ...the rotor always with extractor knob fitted Grease the mating splines Place the rotor on the dry end of the shaft over the stator Take care as it will be pulled on forcefully Rotate it gently whilst h...

Page 26: ...safely connect the turbine to anything Take care to check the open circuit voltage see next section on commissioning The electrical equipment to connect the turbine to your battery or utility grid is...

Page 27: ...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 co...

Page 28: ...s still need to be fitted to these turbines In some cases you can also flush trapped air pockets out of the pipe in this way Often there is not enough flow available or the pipe gradient is uneven so...

Page 29: ...mmeter between the chassis ground connection and positive output A short circuit in the wiring will cause an internal current that brakes the turbine makes it harder to turn and so these tests will re...

Page 30: ...s Verify that the water pressure is as stated on the plate If the water pressure is much lower then you should find and fix the cause because otherwise you will need a different stator supplied Connec...

Page 31: ...oltage You may need more washers at lower flows or lower battery voltage Optimisation can be repeated when flow conditions change markedly differing jet sizes used so you can decide what compromise to...

Page 32: ...ge Take great care that no person is exposed to lethal voltages Perhaps you can insert the probes of a multimeter into your turbine circuit breaker in place of the transmission cable You may now open...

Page 33: ...it emerging from the bearing dust seal See section 2 1 10 for details Check all connections are tight the baseplate is earthed wiring is well clear of rotor and then fit magnetic rotor with the extra...

Page 34: ...see the pdf guides in the document index Here are links to some of these guides Outback FM60 FM80 Midnite Classic150 200 250 Midnite KID Morningstar Tracer Studer Schneider and Fangpusun 2 3 6 All tu...

Page 35: ...tem manual should be supplied Durable label kits for on grid and off grid solar PV systems are available for purchase that comply with relevant standards from your local renewable energy installer Hyd...

Page 36: ...eter m or inch Pipe length m or ft Jet size mm or inch Static pressure on gauge turbine off kPa or PSI Dynamic pressure on gauge turbine running kPa or PSI System nominal voltage V Cable length m or f...

Page 37: ...pressure reading normally means that there is air in the pipe due to insufficient flow or a blockage at the intake filter If pressure is high but output is low then there may be a blockage in a jet du...

Page 38: ...et size further will actually reduce the power output but consume even more water When using the online calculator you will find that you cannot increase flow beyond this point where the pipe is 66 ef...

Page 39: ...of the turbine will be slow due to an oversized generator combined with poor turgo runner efficiency because it is not running at the optimum speed Packing the magnetic rotor out a small amount will...

Page 40: ...utions 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 t...

Page 41: ...ut 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 2 4 7 Spare parts If you live in a remote p...

Page 42: ...PowerSpout TRG installation 2018 Last revised July 2018 2018 EcoInnovation Ltd NZ Page 42 2 4 8 Troubleshooting For assistance with your system please contact your equipment installer or provider...

Page 43: ...than predicted then you need to be prepared for higher power than expected or you need to reduce the size of your jets The turbine will be running a bit faster so there will be more voltage and you ma...

Page 44: ...from an electric circuit steadily for 1 hour Volts x Amps Watts To convert To Multiply by Centimeters Inches 0 3937 Sq millimeters Sq inches 0 0015 Meters Feet 3 2808 Miles per hour Feet per second 1...

Page 45: ...stainless steel Recycled content up to 68 Turgo rotor material GF30 Nylon 90mm PCD Runner Turgo wheel Impulse turbine Jets 1 4 jets with range 2 25mm jet diameter each Turgo wheel Number of spoons on...

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