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' Aqua 4 Gen Owners Manual'




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AQUA4GEN OWNERS MANUAL CE
LVM AQ412 12 Volt LVM AQ424 24 Volt
CHECK LIST
1 Generator
1 Drive Coupling
1 Dee Shackle 8mm
1 Turbine Shaft Assembly
4 Turbine Blades 2 off 115mm 2 off 90mm
1 M6 x 20 Stainless Steel Cap Head
4 M6 x 20 Stainless Steel Button Head Screws
1 M6 Stainless Steel Spring Washer
2 M6 Stainless Steel Washers
2 M6 Stainless Steel Washers 18mm Dia Aqua4gen performance with 115mm
1 Tow Rope 15 Metres long turbine blades fitted
2 CableRope Clamps
1 Mounting Rope 3 Metres long 12
Amps output 12v
1 Allen Key 5 mm AF
1 Allen Key 4 mm AF
1 80mm length of Seizing wire 8
Guarantee 0 1 2 3 4 5 6 7 8 9 10
Thank you for purchasing this product It has been manufactured to
exacting standards and LVM Products guarantees that should any Boat speed in materials or workmanship
occur within ONE YEAR of the
date of purchase we will repair or replace the defective part free of
charge Aqua4gen performance with 90mm
Damage caused by misuse failure to follow instructions negligence turbine blades fitted
and modification or transit damage will not be Products will not be liable for any loss of revenue or any 12
Amps output loss or damage to property or persons from any cause
your purchase invoice as it will be needed in the event of a 8
warranty claim 6
What is Not Covered 2
Damage due to improper installation
0 1 2 3 4 5 6 7 8 9 10
Damage due to improper wiring
Boat speed knots
Note Amps output of a 24v
model will be half shown above
Please read the manual thoroughly If you have any contact us at Aquagen is designed to mount onto the pushpit using the 3M x12mm
Dia braid on braid rope supplied It is VERY IMPORTANT to use the rope
mounting method as shown in photos 1 3 this keeps the unit balanced
and allows the Aquagen to swivel and pivot correctly to track the to use this exact method of mounting will cause vibration and
excessive wear on the bronze bushes in the drive coupling Ensure the
knots shown in photo 2 are made on the front face of the unit and the rope
goes back through the lower mounting holes of the unit then tied off to the
bottom rail as shown in photos 2 3 If only one rail is available fit a deck
mounted eyebolt to retain the lower section of the mounting ASSEMBLY
Fit the plastic propeller blades onto the turbine
hub using the M6 X 20 Button Head Screws M6
Stainless steel washers using the Allen key
supplied Note the large diameter washers are
used on the thinnest section of the blade Photo 4
Photo 5 ATTACHING THE DRIVE COUPLING TO THE AQUAGEN MAIN SHAFT
Align the M6 clearance hole in the drive coupling with the M6 tapped hole in the main shaft Fit the M6 spring washer under
the head of the M6 x 20 Allen bolt Insert the bolt through the M6 clearance hole in the drive coupling and fully tighten it into
the main shaft using the Allen key 6 ATTACHING THE TOW ROPE TO THE TURBINE AND DRIVE COUPLING
The Aquagen is supplied with 2 off cablerope clamps these should be used as shown in Photos 5 6
ELECTRICAL DATA
Aqua4gen output cable colour Code The Brown output wire is POSITIVE The Blue output wire is NEGATIVE
Wire Rating The output wires of the Aqua4gen will require extending Electrical systems lose energy from the resistance of
the wire size used The larger the wire size the smaller the loss however larger cross sectional area wire can be costly and
in some cases more difficult to source The following table shows recommended wire sizes they are based on a 3 and
5 energy loss at an average boat speed of 7 knots It is recommended a minimum wire size of 25 sq mm be used
Single Wire Length
0 5 Metres 6 10 Metres 11 20 Drop 3 5 3 5 3
5
12 volt Aqua4gen 60 mm2 40 mm2 10 mm2 60 mm2 25 mm2 16 mm2
24 volt Aqua4gen 25 mm2 25 mm2 40 mm2 25 mm2 60 mm2 40 mm2
Useful wire cross sectional area mm2 conversion to AWG
25 mm2 14AWG 40 mm2 12 AWG 60 mm2 10 AWG
100 mm2 8 AWG 160 mm2 6 AWG 250mm2 4AWG
If the Aqua4gen is connected directly to the battery terminals
we recommend a 15 Amp fuse for 12V Models and a 75 Amp
fuse for 24v Models is fitted in the brown positive wire from
the generator to the battery so that if a dead short occurred it
would prevent serious damage to the wiring and the BROWN OUTPUT WIRE output is connected to the
POSITIVE terminal of the battery The BLUE OUTPUT
WIRE to the NEGATIVE terminal of the the Aquagen output cable carefully through a deck
gland attach the push on connectors and covers supplied
to the end of the output cable and the end of your Observing polarity plug them together The output wires
are then connected to the battery See Diagram 5 opposite
The BROWN WIRE is connected to the POSITIVE terminal
and the BLUE WIRE to the NEGATIVE IMPORTANT BE CAREFUL AS INCORRECT CONNECTION WILL DAMAGE THE RECTIFIER WARRANTY
WILL BE THE AQUAGEN MUST NEVER RUN OPEN CIRCUIT AS HIGH VOLTAGES CAN BE PRODUCED AND CAPACITORS MAX VOLTAGE MAY BE output wires of the Aqua4gen
can be connected directly to the terminals of the battery that requires charging as shown
in diagram 5 however if the terminal voltage of the battery is not continually monitored for over voltage 142v for and 284v for 24v batteries the
battery can be seriously damaged Fitting an LVM voltage regulator will protect
the battery from becoming over charged You may well have chosen a voltage regulator when purchasing the Aqua4gen
but we would recommend you look at page 9 SELECTING THE CORRECT LVM VOLTAGE REGULATOR to make sure
you have purchased the correct unit
You may also consider installing an ammeter voltmeter or an amphour meter all are available from I LVM Products part
number as follows LVM67 0 20A Ammeter LVM69 015v dc Voltmeter LVM200 Digital Amp Hour Meter
VERY IMPORTANT
If you do not intend to use a LVM voltage regulator with the Aquagen it is extremely important that a similar type of
regulator is used ie It must be a shunt diverting type regulator that always keeps the Aquagen on load
YOU MUST NEVER USE A REGULATOR THAT SIMPLY TURNS OFF AND ON THE OUTPUT OF THE AQUAGEN
WHEN THE BATTERY IS FULLY CHARGED THIS CAN LEAVE THE AQUAGEN IN AN OPEN CIRCUIT WILL ALLOW THE TURBINE TO ROTATE AT VERY HIGH SPEED AND DAMAGE THE
towrope with the turbine attached should be stored in a neat coil close to the Aquagen
Once under way in deep water the turbinetow rope can be payed out It is safer to do this at around 12 Knots as the
rope will start to turn as soon as it enters the water The turbine is designed to surface at the following 115mm turbine blade 9 Knots Small 90mm
turbine blade 11 the turbinetow rope can be achieved in two ways
1 Slow yachtboat to 12 Knots then pull in towrope
2 Make a tack to turn the yachtboat at 90 Deg to slow it down and bring along side the turbinetow rope
When pulling in the towrope it is very important that it is untwisted and coiled neatly ready to use again
Note If for any reason the turbine surfaces before 9 knots when using the 115mm blades or 11 knots using the 90mm
this may be caused by your particular hull shape of the yacht creating an underwater wash effect add one or two
25mm propeller shaft anodes to the turbine shaft close to the turbine hub or increase the length of the Check drive shackle bronze bushes for wear
Apply a little marine grease
to the bronze bushes from time to time Typical life of the bronze bushes
3000 7000 nautical miles
2 Check the tow rope for wear at intervals particularly the area around the
Dee Shackle and Eye bolt on the turbine shaft By cutting 1 to 2 inches off
the rope a new section can be created
3 Check tightness of the Dee Shackle pin
TROUBLE SHOOTING
The AQUA4GEN generator unit is design to give many years of reliable service as it contains really only one moving part
and one electronic component they are the permanent magnet rotor and a 3 phase only parts that can wear are the main bearing ball TEST
A simple test to prove there is an output voltage from the Aqua4gen can be carried out whilst the Aqua4gen is in its
working position Disconnect the Aqua4gen output cable from the battery or the TB regulator if fitted With the turn the main shaft it should turn
freely Note There will always be a slight resistance felt this is the of the generator then touch the two output leads together shorting them the
main shaft should now be difficult to turn If this does not happen check that your extension wire connection from the actual Aqua4gen output
cables are not corroded or have become disconnected If there is a fuse fitted in the output cable check it has not blown
The following tools and equipment will be needed to carry out tests and repairs to the Aqua4gen
A multimeter which can read 0 100 volts DC measure resistance have a diode test and a continuity buzzer test
Pozi drive iron and of hardwood and a brass rod 12mm diameter X 250mm long or similar
For pivot bearing replacement a bench vice will be OUTPUT VOLTAGE
If you have a lathe or some other means of turning the main shaft at a known RPM a 12v model produces 006v per rev
and a 24v model 012v per rev
If no voltage is present check that your extension wire connection from the actual generators output cables are not
corroded or have become disconnected If there is a fuse fitted in the output cable check it has not blown Check again at the generators actual output
cable If there is still no voltage output go to the instructions and tests listed
under heading NO OUTPUT
1 Check turbine blades are not damaged
2 Check towrope is not kinked and twisted
3 Check main shaft of Aquagen turns freely Note There will always be a slight resistance felt this is the cogging effect of
the generator
4 If the output from the Aquagen has been connected to the battery the wrong way round reverse connection the be damaged but still may give a reduced
output Replace a multimeter check continuity of output extension cable and Check fuse
3 Remove the generator from mounting Remove the rear cover 6 off screws and hinge back cover A component called
a rectifier that converts the 3 Phase AC output voltage of the stator into DC volts is mounted on the inside of the cover
Note later models have also suppression capacitors soldered to the the 3 push fit connectors output wires from stator which are attached to the
centre terminals of the rectifier No
need to remember which order or terminal they come from as they can fit on any of the 3 centre a multimeter set on resistance measurement ohms check
the resistance in turn of the of 3 output wires in pairs
from the stator They should read 16 ohms 12v model 65 ohms 24v AC OUTPUT VOLTAGE OF STATOR
Set the multimeter to read AC volts attach test leads to the 3 off stator output wires in pairs then turn the main shaft of
the generator by hand any direction small voltage should be indicated on the the stator and suppression capacitors do not look burnt or overheated
Check tightness of stator retaining screws
If at any time the generators output leads have ever been connected to battery terminals the wrong way round or the
generator has been struck by lightening then the rectifier may be have been damaged
RECTIFIER taken of a Good a multimeter to diode test then check
1 Disconnect all connectors from the rectifier
2 Attach the red test lead from multimeter to the plus terminal of the rectifier attach the black test lead to the negative
terminal RESULT No Reading
3 Reverse the test leads ie attach the red test lead to the negative terminal of the rectifier then the black test lead to the
plus terminal RESULT 08 09 volts
4 Connect the test leads to the 3 centre terminals of the rectifier in pairs RESULT No taken of a Faulty Disconnect all connectors from the Attach
the red test lead from multimeter to the plus terminal of the rectifier attach the black test lead to the negative
terminal RESULT 0 Volts
3 Reverse the test leads ie attach the red test lead to the negative terminal of the rectifier then the black test lead to the
plus terminal RESULT 0 the test leads to the 3 centre terminals of the rectifier in turn in pairs RESULT 0 Volts
If in doubt about the condition of the rectifier replace with a new one Refit the 3 off 3 phase stator output leads to the
centre terminals of the multimeter to read DC volts Attach the red test lead of the multimeter onto the plus terminal of the rectifier then
the black test lead onto the negative terminal Turn the main shaft of the generator by hand any direction this a voltage on the multimeter Refit Red
and Black DC output leads from the rectifier Refit rear cover using a new
gasket make sure all wires are clear of the rotor
SOUND ONCE PER the generator is in its working position check that the M6 allen screw which retains the drive coupling assembly to
the main shaft is fully rear cover and check the condition of the rotor it may be rubbing on the stator
Inner main bearing could be worn check for axial and radial movement Check the tightness of the 4off M5 stator this can cause a noise if slightly
MECHANICAL CONTINUOUS NOISE
Remove the towrope and check axial and radial play in the main front bearing Remove rear cover and check inner main
bearing in the same manner If large amount of play is found replace main instructions listed REPLACING MAIN ELECTRICAL VIBRATION NOISE
It is normal for the Aqua4gen to produce a very slight magnetic cogging vibration when rotating and an electrical charging This noise will be greatly
amplified if the Aqua4gen is mounted on a very hollow section of a FOR REMOVING AND REPLACING MAIN required 2 off Main bearings
LVM Part No Bearing 783
1 off Main shaft water seal LVM Part No Seal 650
1 off Rear cover gasket LVM Part No Gasket 548
2 off Circlips 15mm LVM Part No Circlip 862
6 off Rear cover retaining screws LVM Part No Screw 664
1 off Small amount of Loctite 638 in tube
Tools required Hammer Circlip pliers Pozi drive screwdriver Piece of hardwood and a brass rod 12mm diameter X
250mm long or similar
1 Disconnect output leads and remove Aqua4gen from mounting
2 Remove the main shaft water seal pierce seal front face with screw driver and lever out
3 Remove the front 15mm circlip on the main shaft
4 Remove 6 off selftapping screws retaining the rear cover
5 Place a piece of hard wood on a concrete floor Holding the Aqua4gen with the rear cover held back and main shaft
downwards lift and force downwards the generators main shaft onto the piece of hard wood This should displace
the main shaft inwards Alternatively the main shaft can be pressed out or hammered out but take care not to bruise
the end of main shaft
6 The main shaft rotor assembly should now have moved inwards into the main housing
7 Using a piece of brass rod or similar so as not to damage the end of the main shaft tap the shaft through both the
bearings and remove rotor assembly from the rear of the main housing
8 Having removed the rotor from casting Check the main shaft for wear particularly the areas the main bearings are
positioned If the shaft wear is found to be excessive a new shaft will have to be fitted Contact LVM Products
9 Remove the large internal circlip which is located in front of the main outer bearing then using a brass rod and a
hammer knock out the main bearings from the casting
10 Refit new main bearings using a little Loctite Bearing Fit smeared on the OD of the bearings
11 Refit large internal circlip in front of main outer bearing this circlip is acts as a spacer for the water seal
12 Clean the main shaft then clean the rotor magnet with sellotape sticky side to remove small pieces of steel pickup
13 Smear a little Loctite Bearing Fit onto the main shaft close to the rotor and in the bore of the outer main bearing
14 Insert the main shaftrotor assembly into the generator main bearings WARNING The rotor magnets are very powerful
and will quickly draw the assembly into the stator When the main shaftrotor assembly is fully inserted check it rotates
without rubbing
15 Smear a little Loctite Bearing Fit on the outer main bearing inner race to shaft ie between the OD of the shaft and
the ID of the inner race Push the main shaft in and out a little to spread the Loctite between the outer main bearings
bore and the main shaft
16 Fit new 15mm circlip on main shaft
17 Fit new main shaft water seal grease well on assembly
18 Refit rear cover using a new gasket make sure all internal wiring is clear of the rotor
SELECTING THE CORRECT LVM VOLTAGE REGULATOR
The output of the Aquagen can be simply connected directly to the terminals of the battery that requires charging however
if the terminal voltage of the battery is not continually monitored for over voltage 142v for 12v batteries and 284v for the battery can be seriously
damaged Fitting an LVM voltage regulator will protect the battery from becoming
over COMPENSATION This additional feature is available on all LVM regulators If the battery is located in a
building where the ambient temperature is always around 20 degC then standard regulators can be used However if you
intend to locate a battery where temperatures may go down to freezing and perhaps rise to tropical temperatures then you
should install a regulator that is fitted with a temperature compensation circuit This automatically allows the battery to be
charged at a higher voltage as the temperature drops and a lower voltage if the temperature increases Simply add T
after the LVM Product No ie 4TB12 T
The regulator suitable for the Aqua4gen
Twin battery regulator LVM product No 4TB12 4TB24 These units are connected between the output of the Aquagen
or Solargen module and the battery terminals They control the actual output voltage of Aquagen or Solargen by to a high wattage wire wound dump
resistor when their output voltage reaches 142v 12v systems or 284 They have two schottky blocking diodes built into the regulator which enables them
to monitor and control the
charge to two batteries totally independent of each other therefore making it ideal for separate charging of engine starting
and domestic batteries The battery with the lowest terminal voltage will be charged first then gradually when both fully charged the Aquagen or
Solargen modules output is automatically diverted to the dump resistor this does two
things it stops the batteries over charging and keeps the Aqua4gen always on load
Note This regulator draws NO standby current from the available from LVM Products are Diode Units LVM product No 4DU 6DU
The 4DU when combined with a 2TB or 4TB regulator enables one additional battery to be charged
The 6DU when combined with a 4TB regulator enables two additional batteries to be charged
The Aqua4gen and a Solargen modules output may often be combined the table below shows the recommended regulator
for various systems Note Two batteries wired in parallel are classed as one independent battery Having selected regulator model from the table simply
add the voltage required ie 4TB12 for a 12v system or 4TB24 for a 24v
system Basic wiring diagram are shown on page 10 If you cannot find your particular system or application within the table
or require full wiring diagrams please check our web site or call our sales office who will email fax or post
you REGULATOR TABLE
Number of independent batteries to be charged
SYSTEM 1 2 3 4
1 x Aqua4gen 4TB 4TB 4TB 4DU 4TB 6DU
1 x Aqua4gen 5w Solargen panel 4TB 4TB 4TB 4DU 4TB 6DU
1 x Aqua4gen 10w Solargen panel 4TB 4TB 4TB 4DU 4TB 6DU
1 x Aqua4gen 17w Solargen panel 4TB 4TB 4TB 4DU 4TB 6DU
1 x Aqua4gen 25w Solargen panel 4TB 4TB 4TB 4DU 4TB 6DU
1 x Aqua4gen 25w10w Solargen panel 4TB 4TB 4TB 4DU 4TB 6DU
1 x Aqua4gen 25w25w Solargen panel 4TB 4TB 4TB 4DU 4TB 6DU
1 x Aqua4gen up to 100w Solargen panels 4TB 4TB 4TB 4DU 4TB 6DU

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