Energy Systems & Design Easy Tune Stream Engine Manuale utente

The Stream Engine®

Easy Tune® Generator

Owner’s Manual

Please Read Carefully

Made in North America

PO Box 4557

Sussex NB

Canada E4E 5L7

Phone +1 (506) 433-3151

Fax +1 (506) 433-6151

Email: [email protected]

Website: www.microhydropower.com

The Stream Engine and Easy Tune are a Trademark of Energy Systems & Design Ltd.

V1.0 7-2011

Congratulations on your purchase of a new Easy Tune Stream Engine! With a proper installation and a

little routine maintenance, your Stream Engine will provide you with years of trouble-free operation.

This manual will help you to install your machine as well as assist you in trouble-shooting and problem

solving. Of course, you may contact Energy Systems & Design Ltd. if you run into trouble.

May your RE adventures prove successful!

Table of Contents

Introduction..............................................................................................3

Site Evaluation.........................................................................................3

Head Measurement ..................................................................................3

Flow Measurement...................................................................................4

Stream Engine Output in Watts Table .....................................................5

Intake, Pipeline & Tailrace......................................................................6-7

Batteries, Inverters & Controllers............................................................7-8

Wiring and Load Center...........................................................................8-9

Design Example.......................................................................................9-10

Output Adjustment...................................................................................11

High Voltage ...........................................................................................12

Determining Nozzle Size.........................................................................12

Nozzle flow chart......................................................................................13

Disassembly and Bearing Replacement ..................................................13-15

Copper Wire Resistance Chart ................................................................15

Pipe Friction Head Loss Charts..............................................................16-17

Wiring......................................................................................................18-19

Installation Examples……………………………………………………20-21

INTRODUCTION

The Stream Engine uses a tunable permanent magnet type alternator called the Easy Tune ®. This

design eliminates the need for brushes and the maintenance that accompany them while increasing

efficiency. The Easy Tune’s output can be optimized by simply moving the upper part of the generator.

This manual describes The Easy Tune Stream Engine, which is manufactured by Energy Systems and

Design Ltd. The installer must have some knowledge of plumbing and electrical systems, as should the

end user of the system. These machines are small, but can generate very high voltages. Even 12-volt

machines can produce high voltages under certain conditions. Practice all due safety. Electricity cannot

be seen and can be lethal.

It is important to consult with local officials before conducting any watercourse alteration. ES&D

advises following all local laws and ordinances regarding watercourses.

Electricity is produced from the potential energy in water moving from a high point to a lower one. This

distance is called "head" and is measured in units of distance (feet, meters) or in units of pressure

(pounds per square inch, kilo-Pascals). "Flow" is measured in units of volume (gallons per minute -

gpm, or liters per second - l/s), and is the second portion of the power equation. The power available is

related to the head and the flow.

The Stream Engine is designed to operate over a wide range of heads and flows. This is achieved with

the use of a Turgo runner, or wheel. Nozzle diameters of 1/8 to 1 inch (3-25mm) are available, and up to

four nozzles can be used on one machine, to utilize heads as low as four feet and as high as hundreds.

SITE EVALUATION

Certain information must be determined concerning your site, in order to use its potential for maximum

output. Head and flow must first be determined. Other factors are: pipeline length, transmission distance,

and the system voltage. These factors determine how much power can be expected.

Power is generated at a constant rate by the Stream Engine and stored in batteries as direct current (DC).

Power is supplied, as needed, by the batteries, which store energy during periods of low consumption for

use in periods where consumption exceeds the generation rate. Appliances can be used that operate

directly from batteries, or 120 volt alternating current (AC) power can be supplied through an inverter,

converting DC to AC power.

Sites may vary, so carefully consider flow and head when choosing yours. Remember, maximum head

can be achieved by placing the Stream Engine at as low an elevation as possible, but going too low may

cause the machine to become submerged (or washed away!).

HEAD MEASUREMENT

Head may be measured using various techniques. A garden hose or length of pipe can be submerged

with one end upstream and the other end downstream. Anchor the upstream end with rocks or have an

assistant hold it; water should flow out the low end, especially if the pipeline is pre-filled. Once water is

flowing, raise the downstream end until it stops. Do this slowly since the water tends to oscillate. When

the flow has stabilized, measure the distance down to the level of water in the stream with a tape

measure. This will give a very accurate measurement of that stream section. Mark the spot and then

repeat the procedure until the entire distance is covered.

Another technique is to use a surveyor's transit. This method can also be approximated using a

carpenter's level along with a measuring stick or a "story pole." This technique is also done in a series of

steps to arrive at the overall head. A variation on this method is the use of altimeters. GPS equipment

could also be used to measure elevation.

FLOW MEASUREMENT

The easiest method to measure small flows is to channel the water into a pipe using a temporary dam

and to fill a container of known volume. Measuring the time to fill the container enables you to calculate

the flow rate.

WEIR MEASUREMENT TABLE

Table shows water flow in gallons/minute (gpm) that will flow over a weir one inch wide and from

1/8 to 10-7/8 inches deep.

Inches 1/8 1/4 3/8 1/2 5/8 3/4 7/8

00.0 0.1 0.4 0.7 1.0 1.4 1.9 2.4

13.0 3.5 4.1 4.8 5.5 6.1 6.9 7.6

28.5 9.2 10.1 10.9 11.8 12.7 13.6 14.6

315.5 16.5 17.5 18.6 19.5 20.6 21.7 22.8

423.9 25.1 26.2 27.4 28.5 29.7 31.0 32.2

533.4 34.7 36.0 37.3 38.5 39.9 41.2 42.6

643.9 45.3 46.8 48.2 49.5 51.0 52.4 53.9

755.4 56.8 58.3 59.9 61.4 63.0 64.6 66.0

867.7 69.3 70.8 72.5 74.1 75.8 77.4 79.1

980.8 82.4 84.2 85.9 87.6 89.3 91.0 92.8

10 94.5 96.3 98.1 99.9 101.7 103.6 105.4 107.3

Example of how to use weir table:

Suppose depth of water above stake is 9 3/8 inches. Find 9 in the left-hand column and 3/8 in the

top column. The value where they intersect is 85.9 gpm. That's only for a 1-inch weir, however. You

multiply this value by the width of your weir in inches to obtain water flow.

The weir method is more versatile and may prove useful for higher flows. This technique uses a

rectangular opening cut in a board or piece of sheet metal set into the brook like a dam. The water is

channeled into the weir and the depth is measured from the top of a stake that is level with the edge of

the weir and several feet upstream. Looking at the chart that follows will enable you to convert the width

and depth of flowing water into gallons per minute.

Measuring the flow at different times of the year helps you estimate maximum and minimum usable

flows. If the water source is seasonally limited, you may have to depend on some other source of power

during dry times (solar, wind). Keep in mind that a reasonable amount of water must be left in the

stream (Don't take it all, that water supports life forms).

When head and flow are determined, the expected power output can be determined from the following

chart. Keep in mind that chart values represent generated output and that actual power delivered to the

batteries will be reduced by transmission lines, power converters, and other equipment required by the

system. All systems should be carefully planned to maximize power output.

Stream Engine Output in Watts (Continuous)

Flow Rate

Liters/sec (Gallons/min)

Net Head

Meters Feet 0.67

(10) 1.33

(20) 2.50

(40) 5.00

(75) 6.67

(100) 7.50

(112) 9.50

(150)

3 10 - 20 40 75 100 130 150

6 20 15 40 80 150 200 250 350

15 49 45 100 200 375 500 650 800

30 98 80 200 400 750 1000 * *

60 197 150 400 800 1500 * * *

90 295 200 550 1200 * * * *

120 394 300 700 1500 * * * *

150 492 400 850 1900 * * * *

* In these higher output situations, it may be worthwhile to utilize more than one Stream Engine.

INTAKE, PIPELINE, AND TAILRACE

Most hydro systems require a pipeline. Even systems operating directly from a dam require at least a

short plumbing run. It is important to use the correct type and size of pipe to minimize restrictions in the

flow to the nozzle(s). When possible, pipelines should be buried; this stabilizes the line and prevents

animals from chewing it.

At the inlet of the pipe, a filter should be installed. A screened box can be used with the pipe entering

one side, or add a section of pipe drilled full of holes wrapped with screen or small holes and used

without screen. Make sure that the filter openings are smaller than the smallest nozzle used.

Note that particles over about ¼” or 6mm in size may lodge in the runner.

The intake must be above the streambed so as not to suck in silt and should be deep enough so as not to

suck in air. The intake structure should be placed to one side of the main flow of the stream so that the

force of the flowing water and its debris bypasses it. Routinely clean the intake of any leaves or other

debris.

If the whole pipeline doesn't run continuously downhill, at least the first section should, so the water can

begin flowing. A bypass valve may be necessary. This should be installed at a low point in the pipe.

For pipelines running over dams, or in conditions that create a siphon, the downstream side may be

filled by hand. Once filled, the stop valve at the turbine can be opened to start the flow. If full pressure is

not developed, or air builds up in the line, a hand-powered vacuum pump can be used to remove air

trapped at the high point.

At the turbine end of the pipeline a bypass valve may be necessary to allow water to run through the

pipe without affecting the turbine, purging the line of air or increasing flow to prevent freezing.

A stop valve should be installed upstream of the nozzle. A pressure gauge should be installed upstream

of the stop valve so both the static head (no water flowing) and the dynamic head (water flowing) can be

read.

The stop valve on a pipeline should always be closed slowly to prevent water hammer (the column of

water in the pipe coming to an abrupt stop). This can easily destroy your pipeline and for this reason,

you may wish to install a pressure relief valve just upstream of the stop valve. This can also occur if

debris clogs the nozzle. In a single nozzle machine a nozzle that becomes clogged suddenly may create a

water hammer.

Nozzles can be installed or changed by removing the nozzle. The nozzle is removed by unscrewing its

four nuts using a 7/16” (11 mm) wrench. The use of flexible pipe makes it easier to remove the

plumbing from the nozzles.

OUTSIDE DIMENSION

9 1/2” Square Base Opening

24cm

12” 30.5cm

11”

28cm

BOLT HOLES

–

¼” dia 6m

11” 28c

The turbine housing can be mounted on two boards to suspend it above the stream. It is recommended to

have the Stream Engine in a small enclosure or under some cover to keep it dry and provide a place for

auxiliary equipment. Mounting the machine in concrete is also possible (you may wish to try a

temporary wood mounting first). The opening under the housing to catch the water should be at least the

size of the turbine housing opening, and preferably a little larger. Make certain the tailrace (exit channel)

provides enough flow for the exiting water. The diameter of the bolt holes is ¼” (6mm).

In cold climates, it may be necessary to build a "trap" into the exit. This prevents outside air from

entering the housing and causing freeze-ups.

BATTERIES, INVERTERS & CONTROLLERS

System Voltage

A small system with a short transmission distance can be designed to operate at 12 volts. Larger systems

can also be 12 volts, but if higher power is desired or the transmission distance is long, then a system of

24 volts or higher may be preferable. This is especially true if all loads are inverter-powered. In a 12-

volt system operating at a low power level, it may be advantageous to operate all loads directly from

batteries. Many 12-volt appliances and small inverters are available. In 24-volt systems, it may also be

preferable to operate the loads directly (although not as many appliances are available).

In higher power systems, it is usually better to use an inverter to convert battery voltage to regular 120

volt AC power at 60Hz (cycles per second), or 240 volt 50Hz in some countries. This has been made

feasible with the advent of reliable high power inverters. Thousands of home power systems are in

operation with only AC loads.

Sizing Battery Bank

A typical hydro system should have about one or two days of battery storage capacity. This will

generally keep lead-acid cells operating in the middle of their charge range where they are the most

efficient and long-lived.

Batteries should be located outside of any living space, or adequate ventilation should be provided, as a

rising charge level tends to produce both hydrogen gas and corrosive fumes. Also, distilled water should

be added as needed to maintain the electrolyte level.

Charge Control

Unlike solar systems, a hydro system must always be connected to a load even when the batteries are

fully charged. If the output power does not have a load, system voltage can rise to very high levels. This

situation provides an opportunity to do something with the excess power like water or space heating.

As the batteries become fully charged, their voltage rises. At some point, the charging process should

stop and the excess power be diverted to the dump load. Most charge controllers permit different charge

levels such as bulk, absorption, and float. Literature supplied with the controller should be consulted to

determine the set points of the charge controller. Be sure to set the controller for hydro diversion.

Watt-Hour meters are available that monitor the battery state of charge.

An ammeter that monitors turbine output should always be installed in a high traffic or living space so

difficulties with the machine can be easily detected. If a drop in output is noticed, the machine should be

inspected. This could be caused by air in the pipeline, or a blocked or partially blocked nozzle. More

importantly, a drop in output could be the beginning of bearing failure. Bearing failure will cause serious

damage to the machine. Early detection of problems with the bearings is vital.

WIRING AND LOAD CENTER

Every system requires wiring to connect the various components. Load centers are available as a

complete package that easily facilitates the connection of loads and power source(s). All circuits in the

system should use wire of adequate size and have fuses or breakers of sufficient capacity to carry the

expected load current. The Stream Engine must be fused since it can suffer from a short or similar fault

just like anything else in the system.

DESIGN EXAMPLE

This example shows how to proceed with a complete installation. The parameters of the example site

are:

-120 feet of head over a distance of 1000 feet

-a flow of 30 gpm (most of the time)

-100 feet of distance from the house to the hydro machine

-24 volt system

The first thing we do is determine the pipeline size. Although maximum power is produced from a given

size pipe when the flow loss is 1/3 of the static head, more power can be obtained from the same flow

with a larger pipe, which has lower losses. Therefore, pipe size must be optimized based on economics.

The pipe flow charts show us that two-inch diameter polyethylene pipe has a head loss of 1.77 feet of

head per 100 feet of pipe at a flow rate of 30 gpm. This is 17.7 feet of loss for 1000 feet of pipe.

Using two-inch PVC gives us a loss of 1.17 feet of head per 100 feet of pipe or 11.7 feet for 1000 feet.

Polyethylene comes in continuous coils because it is flexible (and more freeze resistant). PVC comes in

shorter lengths and has to be glued together or purchased with gaskets (for larger sizes). Let's say we

select polyethylene.

The maximum output occurs with a flow of about 45 gpm since that gives us a head loss of 3.75 feet per

100 feet of pipe, or 37.5 feet of loss for our 1000 feet of pipe. This is 37.5' loss/120' head = 31% loss.

A flow of 30 gpm gives a net head of 102.3 feet (120' - 17.7'). The losses caused by the various pipe

fittings and intake screen will further decrease the dynamic head, so 100 feet is a good working figure

for the net head. Looking at the nozzle flow chart, we see that a 3/8” nozzle will produce a flow of 27.6

gpm at a head of 100’. This is very close to the design point and the net head will be a bit higher since

the flow is less. Looking at the output chart we see that the machine could generate about 300 watts.

That is, at a 30 meter head or about 100 feet and halfway between 20 and 40 gpm. A simple rule of

thumb to use is to multiply the head in feet (meters) by the flow in gpm (liters per second) and divide by

ten (multiply by five for metric or SI units) which will roughly give the output in watts.

Since we require 24 volts and the transmission distance is fairly short, we can generate and transmit 24

volts using the Stream Engine. This Stream Engine could also be used for higher voltages like 48 and

120 or 240. With higher voltages, the power could be transmitted longer distances.

We need to go 100' with 300 watts at our site. This will be about 10 amps at 30 volts at the generator.

Note that there will be some voltage drop in the line and 24-volt batteries require somewhat higher

voltages than nominal to become charged. So the 10 amps must pass through 200' of wire for the round

trip. Resistance losses should be kept as low as economics permit, just like the pipeline losses.

Let's say we can accept around a 10% loss. This is 30 watts out of the original 300. The formula for

resistive loss is I2R = watts. I = Intensity (current in amps) and R = Resistance (in ohms).

(10 amps)² x R (ohms) = 30 watts

100 amps x R (ohms) = 30 watts

R = 30 watts/100 amps

R = 0.3 ohms

This is the wire resistance that will produce a 10% loss. The wire loss chart shows loss per 1000', so:

1000'/200' x 0.3 ohms = 1.5 ohms per 1000'.

The chart shows 12 ga. Wire has a resistance of 1.62 ohms per 1000', so:

200'/1000' x 1.62 ohms = 0.32ohms. This is close to the desired level.

10 amps x 10 amps x 0.32 ohms = 32 watts of loss.

Increasing the wire size further would reduce the losses. Voltage drop in the wire is equal to:

IR = 10 amps x 0.32 ohms = 3.2 volts

So if the battery voltage is 26.8 the generator will be operating at 30.0 volts. Keep in mind that it is

always the batteries that determine the system voltage. That is, all voltages in the system rise and fall

according to the battery's state of charge.

At the site, we would be generating 10 amps continuously. If we use lead acid batteries and wish to have

two days of storage capacity, then:

10 amps x 24 hrs x 2 days = 480 amp. hours (Ah) Capacity

We would probably use an inverter and load controller with the system. The diagram for such a system

would look like this:

Diagram of a typical battery-based system:

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