Asian Phoenix Resources PowerPal MHG-200LH Guía de referencia rápida

Use and Care

Instructions

for your new

Low Head

Micro-hydroelectric Generator

Models: MHG-200LH

MHG-500LH

MHG-1000LH

Asian Phoenix Resources Ltd., Canada

READ THIS FIRST

This manual contains important information concerning your new PowerPal low head

micro-hydroelectric generator. It covers Models MHG-200LH, MHG-500LH and

MHG-1000LH. You should read this manual before installing PowerPal or allow a

trained technician from your local PowerPal Service Center to install it for you.

Your PowerPal generator is designed to be simple to operate and easy to maintain. If

used in accordance with these instructions your PowerPal will give you many years of

service. PowerPal is also designed with safety in mind, but any electric device can be

dangerous if not used correctly. At several points in this manual, instructions

requiring special attention that must be followed are shown as:

SAFETY FIRST

•Never allow electrical contacts to become wet. Beware of electrocution.

•Never attempt to cut electrical wires or open appliances for repair if the generator

is working. Unplug the main cable first.

•Inform children of the dangers of electrocution. Never allow them to play with

electrical connections.

•Keep fingers away from the moving propeller. If partly blocked with debris,

remove the generator from the canal before cleaning.

•If you have any questions about safety, please ask your PowerPal Service Center.

OPERATING CAUTIONS

•Under conditions of higher water flow rates than given for each model in this

manual, PowerPal is able to generate higher power outputs than rated. This is a

bonus, but only up to a limit. If maximum power consumption listed in this

manual is exceeded then the copper coils in PowerPal may be irrepairably

damaged and require total rewiring. See the section on ‘Technical Specifications’.

•Do not forget to grease the bearings at the recommended times. Failure to do this

will result in excessive wear on the bearings and shorten their life. Always ensure

that the Electronic Load Controller is set at approximately 220V. Otherwise, the

life of lights and appliances may be reduced.

Warning symbol -beware of hazards or unsafe practices that may cause

injury or death.

Caution symbol –beware of hazards or unsafe practices that may damage the

product.

While electricity improves your life, it can also be dangerous if simple

precautions are not followed:

Your PowerPal generator is designed for simple operation and low

maintenance. However, the following operating cautions must be followed to

ensure a long life for PowerPal:

PowerPal™Low Head 2

•Low frequencies will result if the generator rotor is rotating slower than usual.

Low frequencies may prevent proper functioning of appliances such as televisions

and will harm electric motors. PowerPal is designed to stop working if the rotor

speed becomes too low, as the drag on the rotor becomes too great to sustain its

rotation. This in-built mechanism is there to avoid problems associated with low

frequencies. High frequencies will occur if the rotor is rotating faster than usual.

This is due to either a high water flow rate or the use of a small load. It can be

corrected by adjusting the flow gate, or by turning on another appliance to

increase the load. High frequencies do not normally damage electric motors or

affect television picture quality. Light bulbs are not affected by frequency but are

affected by voltage.

POWERPAL COMPONENTS

Inside your PowerPal box you will find:

•1 x generator-turbine assembly

•1 x electronic load controller

•1 x spare lower bearing, ELC fuses

•1 x Guarantee Card

•1 x this instruction manual.

Please advise immediately if any parts are missing. Complete your Guarantee Card

and have it signed by your PowerPal dealer.

The PowerPal system consists of two major components –a hydroelectric generator

and an electronic load controller. Other components are necessary and these can be

manufactured locally. The water intake canal can be made from tin plate, wood,

fiberglass or concrete. The water outlet pipe is usually made from tinplate. Your

PowerPal dealer can advise you about this.

Therefore, other parts which are not included in the box but which are required to

make PowerPal work are:

•1 x water intake canal

•1 x water outlet pipe

•electrical wire from generator to house. See the section on ‘Technical

Specifications’ for the correct size wire.

•household wiring.

These are available from your dealer or local electrical store.

SYSTEM DIAGRAM

The following diagram shows how the non-electrical components fit together. Further

reading of this manual will provide the necessary explanations. The components are:

PowerPal™Low Head 3

1000

250/350/450

200/300/400

1500

130/199/270

Head = 1500

200/300/450

325/470/705

R218/290/430

R200/268/402

R182/247/370

R164/225/337

R146/203/304

R128/182/273

D130/199/270

220/330/450

Canal -Plan View

Water Level

1700/1800/1950

SCALE 1:10

(1mm = 1cm)

-Scaled for MHG-200LH -

All units in mm

xxx/xxx/xxx

First number is for MHG-200LH,

Second number is for MHG-500LH,

Third number is for MHG-1000LH.

PowerPal™Low Head 4

A. Alternator / generator

B. Turbine

C. Water intake canal

D. Water outlet pipe

E. Waterfall, dam wall, or cutting

F. Stream bed.

The various measurements show how to properly construct and set up your system.

The lower diagram (Canal –Plan View) shows the precise internal measurements in

order to construct the water intake canal.

SELECTING A SITE

PowerPal is designed for use in a wide range of locations. The most critical factor is

sufficient water flow. Water flow is the amount of water that passes through the

turbine at any instant, measured in liters per second (l/sec). The second important

factor is head (see below). The following table shows the minimum flow rate and

head to achieve the quoted power output for each model:

MHG-200LH MHG-500LH MHG-1000LH

Flow (l/sec): 35 70 130

Head (m): 1.5 1.5 1.5

Measuring Flow

Flow can be calculated approximately by knowing the water speed. This speed,

multiplied by the cross-sectional area of the intake canal will give you an idea of the

flow rate. Minimum water flow speeds for each model are:

MHG-200LH: 0.54 m/sec.

MHG-500LH: 0.50 m/sec.

MHG-1000LH: 0.41 m/sec.

As a rule, say half a meter per second, or 5 meters in 10 seconds. Drop a leaf

upstream and read the time it takes to travel the measured distance. Note that this

method is only a guide and you will need a sufficient volume of water flowing at this

rate to make the larger models work.

Measuring Head

The head is the height from the water surface flowing into the turbine down to the

water surface in the stream below. It is shown in the System Diagram.

This head should be 1.5 meters for all PowerPal models. If it is smaller then the power

output will be reduced. If it is larger then your power output will be increased. While

increased power output appears desirable, if the head is too large then the rotor will

turn too fast and reduce the life of the bearings. Try to keep the head in the range of

1.4 meters to 1.6 meters.

Do not attempt to exceed the recommended head height.

PowerPal™Low Head 5

To achieve the recommended flow and head it may be necessary to modify your

stream. The next section tells how.

SITE PREPARATION

There are three basic situations that are suitable for installing PowerPal. They are:

1. Waterfall

This is the simplest method. If your house is near a stream with a small waterfall

around 1.5 meters high then you can use this as a platform. Minor modifications to

channel the flow may be required.

2. Dam

If the stream is flat you may need to build a dam. It can be constructed from clay and

river boulders, clay and bamboo (or other wood) or even concrete. The dam wall

should be 1.75 meters high to allow for the head. If there is a waterfall less than 1.5

meters high it may be easy to use this as your dam site to keep the dam small. If, after

constructing the dam the water flow rate is too high then a separate diversion channel

will need to be cut into the dam wall to reduce the flow to the turbine.

Although this is the simplest method it is

also the most affected by changes in

stream flow. Rainstorms or dry periods

may make site modifications necessary.

Dams have both advantages and dis-

advantages. If used in a village setting

they can provide additional uses as a

fish pond and washing area. The dam

wall may support a row of PowerPal

generators so that several families can

have access to electricity. If the village

works together to build the dam the

time and construction costs are lower.

Dams are less likely to be effected by

flooding if diversion channels are

adequate, so PowerPal can be used

effectively during the rainy season.

PowerPal™Low Head 6

The flow rate is also much more stable than a waterfall set up. Disadvantages are the

flooding of an area to make the lake, a land area that might be used otherwise. The

more incised the stream, the smaller the lake.

3. Side Channel

This is an alternative to a dam and has the advantage of being simpler to construct

while providing a good degree of stream flow control. It is suitable for incised streams

with soil banks. Dig a trench along the bank parallel to the stream, starting at the

upstream end where water can enter. The trench should follow the contour, i.e. be

almost horizontal. Make the trench long enough so that when you have finished it is

around 1.5 meters above the water surface in the stream below. Excavate this area so

that the water can enter the trench, flow along it and exit back into the stream below.

Some modifications may be required to achieve the required flow rate. Try inclining

the trench floor in a downstream direction, or lining the trench with smooth material

such as a plastic tarpaulin to reduce friction.

SYSTEM INSTALLATION

After locating a suitable site and completing the earthworks (if any), your PowerPal is

ready for installation. To do this:

1. Connect the water intake canal (A) to the water outlet pipe (B). Insert the rubber

seal (C) at the connection point. Bolt the canal and pipe together. Note that the

connections should be airtight or performance will be significantly reduced.

Simpler than a dam, it is most suitable

for small villages or isolated houses. It

also avoids the worst of flooding as

most of the stream flow will follow the

main stream channel.

A B

PowerPal™Low Head 7

Canal and pipe connection should be airtight.

2. Place the canal-pipe assembly in the stream and support the pipe end so that the

pipe is not touching the stream bed. The lower end of the pipe must be at least 20

cm above the stream bed as well as at least 20 cm below the water surface (see the

System Diagram). The water level in the canal should be at least 20cm and the

recommended flow rate should be available. The base of the canal must be level,

or horizontal. When installed correctly, a vortex should be observed over the hole

that enters the pipe.

3. If provided, insert the debris screen into the upstream end of the canal, but not the

flow gate.

4. Place the turbine end of PowerPal into the hole in the canal (shown below). This

should be a good fit so that PowerPal is vertical and does not move from side to

side. You will notice from the sound and gentle vibrations that PowerPal begins

working immediately. If you do not notice this then there is a problem with your

site. Check again that you have followed the initial procedures correctly. The

lower bearing is lubricated by water so water must be allowed to enter the lower

hole drilled in the shaft tube.

5. If the rate of water flow entering the canal is too high you will need to insert the

flow gate to the required position to reduce this rate. One way to determine if the

flow rate is too high is if the water level in the canal is too high. The water level

should not be so high that it overflows the canal sides. Another indicator is the

presence of ‘standing waves’, or stationary waves on the water surface in the

canal. The water surface should be reasonably smooth, without stationary waves.

If, after inserting the flow gate there is a high level of water turbulence you will

have to reduce this. The easiest way is to modify the stream flow upstream of the

canal. Use boulders or sticks to achieve the desired flow.

6. Plug in the electronic load controller (ELC) into the socket on PowerPal.

Keep fingers away from the moving propeller.

Do not allow electrical

contacts to become wet.

Use dry hands. Beware

of electrocution.

About the electronic load controller

The water turbine captures the water’s energy and converts it into electricity. The

generator’s output voltage is dependent on the load consumption. When there is no power

being consumed, the output voltage can reach 280V –300V. This output voltage will

decrease with any increase in power consumption. The electronic load controller is used to

eliminate this excess output voltage (>220V) so that it is safe to usehousehold appliances.

PowerPal™Low Head 8

7. Make sure that both the white dial and the red switch on the ELC are in the ‘off’

position. Adjust the output voltage by turning the white dial until the voltmeter

shows a reading of 220V (photo A). Then turn the red switch to the ‘on’ position

(photo B).Commence testing by plugging in a light bulb or small appliance into

one of the sockets on the load controller (photo C). The appliance should now be

working properly and the test is complete. Unplug the appliance.

8. Run the required length of two-strand, jacketed electrical cable from PowerPal to

your house etc. Use 3.75 Ampere wire (0.75 sq. mm / Amp) for both MHG-200

and MHG-500 models. This is thicker than is required but thinner wires are more

fragile. For the MHG-1000 model use 5 Ampere wire (1.0 sq. mm / Amp). Insert

the two-pin plug end into the socket on the generator part of PowerPal. Hang the

electronic load controller in a dry place inside the house and connect to the socket

end of the cable. Repeat the setup procedure for the ELCas above. You can now

plug lights and appliances directly into the load controller ready for use, with or

without additional house wiring. The voltage shown on the load controller should

still be 220V. The voltage needs only to be checked and adjusted if the water flow

rate changes. Heavy rain may increase the flow rate, or a prolonged dry period

may gradually reduce it. Check the voltmeter from time to time and adjust if

necessary.

CARE AND MAINTENANCE

General care for your PowerPal will enhance its life. Following the instructions in this

manual is important.

If flooding causes the inside of the generator assembly to become wet, remove the cap

and leave PowerPal in the sun to dry. No permanent damage will result, but check the

upper bearing to see if it has collected water. If so, turn PowerPal upside down to

drain and dry the internal shaft assembly. Do not try to dry it near a fire as the rotor is

bonded with epoxy that could be damaged by excessive heat. Before using again,

make sure that the power socket is also dry. Condensation inside the generator is

normal in tropical areas and will not effect the performance of PowerPal.

There is only one task that must be completed at regular intervals. This is greasing of

the upper bearing bearing assembly.

Avoid plugging appliances directly into PowerPal without using the load

controller. Incorrect voltage may result, which can damage your appliance.

BCA

PowerPal™Low Head 9

Greasing the Bearings

PowerPal has three bearings, two at the top of the shaft below the generator and one at

the bottom of the shaft above the turbine. The upper bearing assembly consists of two

steel ball bearing units placed 5cm apart. Both have been greased in the factory ready

for use and require re-greasing every 3 months of continuous use. Two cubic

centimeters of grease is enough for each bearing. The lower bearing is made of

polyamide composite material and is lubricated by water. No greasing is required.

To grease the upper bearing assembly, disconnect and remove the generator from the

canal. Stand it on the ground, vertically. Then follow these steps:

1. Remove cap.

2. Place steel bar through propeller to stop it rotating.

3. Unbolt nut on top-center of the rotor. Unbolt clockwise.

4. Screw in 2 x M8 bolts into holes in top of rotor, then pull the rotor out (photo A).

This may require additional effort to overcome the magnet’s effects.

5. Remove metal ring (tube) from the axle.

6. The topmost bearing is visible, ready for greasing. Run a small amount of grease

around the top of the bearing (photo B). When working again, heat will allow the

grease to run down into both steel bearing assemblies. If a grease gun is

unavailable then a screwdriver or a clean stick coated with grease will do.

Failure to grease the bearings on

time will shorten their life and

require their replacement. The

increased friction will also reduce

power output. Always dry

PowerPal before greasing.

Alternator /

Generator

Upper bearing

Lower bearing

Turbine

PowerPal™Low Head 10

Este manual sirve para los siguientes modelos

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