HG600/HG800. Hydro-Power Unit. Installation and Operation Guide

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1 HG600/HG800 Hydro-Power Unit Installation and Operation Guide

2 Copyright 04 HydroSpin, All rights reserved. The data contained in this document is proprietary to HydroSpin. It is disclosed to the receiving party only for the sole purpose stated herein, and shall not be disclosed by the receiving party to any third party, and shall not be duplicated, used or disclosed in whole or in part for any purpose other than the purpose specifically stated. This publication, or any parts thereof, may not be reproduced in any form without the express written permission of HydroSpin. NOTE: All specifications in this manual are subject to change without notice. DISCLAIMER This document and other information from HydroSpin and/or its authorized distributors provide product information and installation instructions for users having the relevant technical expertise. Due to the variety of operating conditions for this product, the user is solely responsible for its correct installation and for assuring that all performance, safety and warning requirements of the application are understood and adhered to. Published by HydroSpin December 04 Contents Safety 5 Introduction 7 Overview 7 Purpose of this Document 7 Applicable Documents 7 Major Components 8 Principle of Operation 8 Generator Unit 9 The HydroCharger Unit 0 Installation and Operation Product Unpacking and Inspection Site Preparation Insertion Unit Orientation Installing the Insertion Unit Generator Unit Orientation 4 Installing the Generator Unit 4 Installing the HydroCharger 5 Connecting the Cables 5 Operation 5 System Specifications 7 General Specifications 7 Electrical ICD 8

3 Safety Safety HG600/HG800 has been designed to meet all known safety requirements. Under normal operation, HG600/HG800 presents no hazards to its operator or other personnel. Please read all safety information before installing or operating the unit. HIGH VOLTAGE WARNING: HG600/HG800 generates high voltage that may cause injury and property damage if relevant precautions are not applied. Use caution when operating the HG600/HG800 Hydro-Power Unit. HIGH PRESSURE: Before starting any assembly or disassembly operation, the water line must be depressurized. Removing HG600/HG800 under line pressure could result in serious personal injury. Before reopening the water, verify that installation is complete, and all bolts are fastened. CAUTION The installation of the HydroSpin HG600/HG800 must comply with all applicable federal, state, and local rules, regulations, and codes. 4 5

4 Introduction Overview Introduction Overview The HG600/HG800 concept is based on a surprisingly simple idea: use the water running in the city pipelines to generate the electric energy needed to power the water monitoring devices that harvest data throughout the water network. Hydrospin s new groundbreaking approach to water management offers the ability to access your entire water network s data. This innovative, unprecedented access revolutionizes the way smart water networks are managed, delivering a comprehensive response to the need for energy efficient, water supply measurement and monitoring. Purpose of this Document This document assists the user during installation and operation of the HG600/HG800 unit. Applicable Documents For additional information regarding HG600/HG800, refer to: Mechanical ICD drawing Electrical ICD drawings HydroSpin Website 6 7

5 Introduction Generator Unit Major Components Pipe saddle (4) welded to the pipeline (5) for attachment of the HG600/HG800 unit. Insertion unit () attached to the pipe saddle, to enable inserting and extracting the generator unit (). Generator unit () inserted into a water pipe and generates AC voltage delivered to the HydroCharger. HydroCharger () receives AC voltage from the generator and converts it to DC power. 4 5 Generator Unit The HG600/HG800 generator unit consists of the following parts: Insertion unit () houses the generator unit. Inserted through an opening of the water pipe and attached to the pre-fitted pipe saddle flange. Turbine (4) submerged into the water flow which spins the turbine blades and rotates the generator rotor. Generator socket () connects the generator to the HydroCharger with a cable. Service valves () two hydraulic valves used to extract the generator unit during service tasks. Principle of Operation HG600/HG800, inserted into a water pipeline, converts kinetic energy from the water flow into an electrical charge that powers devices in a smart water network. Water flow activates a turbine connected that produces DC voltage, and charges an internal battery. Even at low water flow rate, optimal energy harvesting is possible as the HydroCharger maximizes the power produced by the generator, in dynamic flow and voltage, to charge its internal battery. AC Power NOTES: The generator unit must be inserted in correct orientation inside the pipeline in relation to the water flow (see Insertion Unit Orientation on page ). The flared opening in the lower section and the two service valves must face the water source. Open the service valves only during the extraction process of the generator unit. Water flow DC Power 8 9

6 The HydroCharger Unit The HydroCharger consists of: Interconnection Panel The HydroCharger front panel includes: Generator input (4) cable connected to the generator unit. Power () DC power output to peripheral devices. Predefined output voltage: 8,, or 4 VDC. COM () communication to a host computer (supporting MODBUS protocol). I/O () input and output for peripheral devices. Control Indication Three indication lights on the top of the unit: RPM () green LED that flashes every 00 revolutions of the generator turbine. ALARM () red LED that flashes if there is a problem in the system. COM () blue LED flashes when communication with host is active. Mounting Plate Attached to the bottom of the HydroCharger unit. The HydroCharger is mounted on this plate which includes: Wall mount holes () enables attaching the plate to a wall. Snaps () connect the plate to the HydroCharger unit. Pipeline connections () connect the plate to pipe clamps. 4 Installation Installation and Operation Product Unpacking and Inspection and Operation Product Unpacking and Inspection HG600/HG800 is packed inside two carton boxes. After opening the package, the product and accessories should be visually inspected for any physical damage that may have occurred during shipment. Box # Content Generator unit Insertion unit HydroCharger, mounting plate and connection cable HydroCharger banderole Sealing gasket and O-ring Service valve Set of eight 8 mm bolts, washers (for connecting the generator unit). Box # Content Flange Pipe saddle Set of eight 0 mm bolts, washers, and nuts (for the insertion unit). NOTE: If product damage is detected, the company must be notified within 48 hours of delivery and a claim must be filed with the carrier. A claim for equipment damage in transit is the sole responsibility of the purchaser. 0

7 Installation and Operation Insertion Unit Orientation Site Preparation Before beginning an installation, check the following: Positioning of HG600/HG800 is accessible for installation and maintenance. Corrosion or damage in the pipeline where the unit is installed is inspected and repaired according to local standards and codes. Water shut-off valve is closed and the pipe is drained.. Place the pipe saddle on the pipe and mark the area for welding with chalk.. Cut the metal with a disc cutter (it is recommended not to use a flame cutter due to the concrete that lines the inner pipe).. Cut and smooth the concrete and straighten it from inside so that the insertion unit can be inserted easily. 4. Place the pipe saddle on the pipeline and put the insertion unit inside, to verify that the unit fits in easily. 5. Weld the branch connection at four points. 6. Using a spirit level, verify that the saddle is straight. 7. Weld the pipe saddle to the pipeline and verify that it is water-tight. Insertion Unit Orientation Before installation, verify correct orientation of the insertion unit with relation to the pipeline water flow: The port () and the turbine water inlet () must face toward the water source direction. Installing the Insertion Unit. Place the sealing gasket (6) on the saddle flange (4).. Carefully lower the insertion unit () into the pipe in the correct orientation.. Fasten the two flanges with eight 0 mm bolts (), washers and nuts (5). Tighten the bolts using the star pattern method. 4. Place Teflon tape on the service valve () thread and connect it to the insertion unit flange (7)

8 Generator Unit Orientation Verify correct orientation of the generator unit with relation to the pipeline water flow: The service valve (), an arrow indication (), and the turbine water inlet () must face toward the water source direction. Installing the HydroCharger. Choose a location for the HydroCharger. Installation and Operation Installing the HydroCharger. Attach the mounting plate onto the pipe or a wall (see Mounting Plate on page 0).. Place the HydroCharger unit on the mounting plate. Connecting the Cables. Connect the main cable connector () to the generator unit socket. See Electrical ICD on page 8 for details about the cables.. Connect the external devices power cord to the power socket () located on the HydroCharger panel. Installing the Generator Unit. Place the O-ring () in the dedicated step located on the generator unit cover (6).. Lower the generator unit (6) into the insertion unit (4) in the correct orientation. A shaped pin (5) located on the bottom of the turbine must be inserted in the correct orientation into the groove in the insertion unit, after making sure that it is completely clean.. Verify that the generator unit is in the correct position. The generator unit flange (6) must be attached to the insertion unit flange (4). 4. Fasten the generator unit flange (6) to the insertion unit (4) with eight 8 mm bolts () and washers () Operation. Make sure the generator unit is properly installed.. Make sure all cables are connected securely and in the correct sockets.. Open water flow in pipeline, smoothly and gradually. 4. A gentle whirring sound is normal; investigate any other sounds. 5. On the HydroCharger panel, verify the status of the following LEDs: RPM light () is flashing steadily. ALARM light () is OFF. 4 5

9 4 System Specifications System Specifications General Specifications General Specifications Generator Unit: HG600 fits pipe 6 (50 mm) HG800 fits pipe 8 (00 mm) Water resistant casing IP68 rating Pressure grading PN0 Three-phase AC generator Optimal charging capabilities, at meter per second HydroCharger: Dimensions 5 X 0 cm Communication Modbus protocol Input voltage AC voltage alternating between V to 40V from the generator Output voltage 8,, or 4 VDC (predefined) Battery type 5. AH battery Battery life time 5 years 6 7

10 Electrical ICD Main Cable (J) I/O Cable System Specifications Electrical ICD Pin no. Color Description Red Input P Black Input M White Input P 4 Green Input M 5 Yellow Output 6 Gray (Violet) GND 7 Orange Output 8 Blue GND 9 Brown Output 0 Violet GND & (Short) - Pin no. Color Description Red RS-TXD Black RS-RXD White RS-DTR 4 Green Reset 5 Yellow GND 6 Gray (Violet) GND Communication Cable (J4) Power Cable (J6) Pin no. Color Description Red RS-TXD Black RS-RXD White RS-DTR 4 Green Reset 5 Yellow GND 6 Gray (Violet) GND Pin no. Color Description Red Battery Black GND 8 9

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