Asian Phoenix Resources PowerPal MHG-200LH Quick reference guide

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:
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•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:
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1000
250/350/450
200/300/400
1500
130/199/270
Head = 1500
200/300/450
200/300/450
200/300/450
325/470/705
R218/290/430
R200/268/402
R182/247/370
R164/225/337
R146/203/304
R128/182/273
R128/182/273
D130/199/270
45
220/330/450
.
A
B
C
D
E
F
Canal -Plan View
Water Level
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.
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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.
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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.
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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
A
C
A
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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.
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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
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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
AB
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When you reassemble PowerPal make sure that all parts are correctly in place and that
all bolts are tightened.
TROUBLESHOOTING
If any problems are encountered, check this section before contacting your Service
Center.
1. Head and flow conditions appear to be OK, but PowerPal will not work.
It is likely that the system has been installed incorrectly. Check this. If still not
working, remove the cap from the generator and use your fingers to quickly turn the
nut on top of the rotor. If the rotor begins to spin freely then PowerPal is working.
2. PowerPal has provided electricity for a while and suddenly the electricity stops.
If this instruction manual is not followed and power consumption is too high, or if
there is a short circuit in an appliance the fusein the electronic load controller will
break. This will stop the electric current. It is important to replace this fuse with
another of the same size (see Technical Specifications below). If the fuse breaks and
an oversize fuse is inserted then the copperwiring in the stator may be damaged in the
future. If that happens the stator will need rewiring by an experienced motor rewirer.
3. Testing in the stream showed that PowerPal was capable of producing the rated
output power (200W, 500W or 1000W, depending on model). However, after
running the electrical cable to the house this output power was found to be less.
Due to resistance from the cable, long cable runs will result in a small loss of output
power. Power loss over a 100m cable run is approximately 10W. If the loss is greater
than this it means that the wrong diameter cable was used.
4. Power output has been falling recently.
Falling output suggests that the turbine is rotating more slowly than usual. Check that
the canal and propeller are free of leaves and other debris.
5. Frequency varies too much to safely use an appliance that is rated for use at a
specific frequency.
If an exact frequency is required for frequency-sensitive appliances it will be
necessary to attach a battery system.
6. An appliance is supposed to be grounded (earthed).
PowerPal is not grounded by its position in the stream. If grounding is required for
certain appliances it will be necessary to ground them separately. The usual method is
to run a wire from the earth pin to a metal stake in the ground outside.
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TECHNICAL SPECIFICATIONS
MHG-200LH MHG-500LH MHG-1000LH
1Ratedpower output 200W 500W 1000W
2Maximum allowable load 250W 650W 1200W
3Intended voltage 220V~ 220V~ 220V~
4Frequency at rated power output 50-60Hz 50-60 Hz 50-60 Hz
5Frequency at runaway speed 75 Hz 75 Hz 60Hz
6Rotor runaway speed 1500rpm 1500rpm 1200rpm
7Weight 16kg 32kg 75kg
8Height 68cm 78cm 92cm
9Diameter 20cm 30cm 42.5cm
10 Generator Single phase permanent magnet alternator
11 Rotor characteristics NdFeB 3-pair pole permanent magnet
12 Stator wire size 0.5mm 0.7mm 1.0mm
13 Load controller fuse 1.0A 2.5A 5.0A
14 UpperBearings size 6203 6204 6206
15 Recommendedcable 0.50 sq.mm/A 0.75 sq.mm/A 1.50 sq.mm/A
16 Operatingtemperature 5 to 50°C 5 to 50°C 5to 50°C
17 Operatinghumidity 0to 90% 0to 90% 0 to90%
Notes:
1,2. Rated power output is the manufacturer’s specified output for the given head
and flow conditions. A higher output is possible if the head is greater or the flow is
faster than recommended. If the maximum allowable load is exceeded then permanent
damage to the stator may occur.
3. Is approximately 220V when the ELC is used.
5,6. Runaway speed is the speed of the rotor if no load is applied. This speed is
reduced under load.
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