' Aqua 4 Gen Owners Manual'

AQUA4GEN OWNERS MANUAL CELVM AQ412 12 Volt LVM AQ424 24 VoltCHECK LIST1 Generator1 Drive Coupling1 Dee Shackle 8mm1 Turbine Shaft Assembly4 Turbine Blades 2 off 115mm 2 off 90mm1 M6 x 20 Stainless Steel Cap Head4 M6 x 20 Stainless Steel Button Head Screws1 M6 Stainless Steel Spring Washer2 M6 Stainless Steel Washers2 M6 Stainless Steel Washers 18mm Dia Aqua4gen performance with 115mm1 Tow Rope 15 Metres long turbine blades fitted2 CableRope Clamps1 Mounting Rope 3 Metres long 12 Amps output 12v1 Allen Key 5 mm AF 101 Allen Key 4 mm AF1 80mm length of Seizing wire 8 6 4 2 0Guarantee 0 1 2 3 4 5 6 7 8 9 10Thank you for purchasing this product It has been manufactured toexacting standards and LVM Products guarantees that should any Boat speed knotsdefect in materials or workmanship occur within ONE YEAR of thedate of purchase we will repair or replace the defective part free ofcharge Aqua4gen performance with 90mmDamage caused by misuse failure to follow instructions negligence turbine blades fittedand modification or transit damage will not be warrantedLVM 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 8warranty claim 6 4What is Not Covered 2 0 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 abovePlease read the manual thoroughly If you have any contact us at MOUNTINGThe Aquagen is designed to mount onto the pushpit using the 3M x12mmDia braid on braid rope supplied It is VERY IMPORTANT to use the ropemounting method as shown in photos 1 3 this keeps the unit balancedand allows the Aquagen to swivel and pivot correctly to track the turbineFailure to use this exact method of mounting will cause vibration andexcessive wear on the bronze bushes in the drive coupling Ensure theknots shown in photo 2 are made on the front face of the unit and the ropegoes back through the lower mounting holes of the unit then tied off to thebottom rail as shown in photos 2 3 If only one rail is available fit a deckmounted eyebolt to retain the lower section of the mounting ropeTURBINE ASSEMBLYFit the plastic propeller blades onto the turbinehub using the M6 X 20 Button Head Screws M6Stainless steel washers using the Allen keysupplied Note the large diameter washers areused on the thinnest section of the blade Photo 4 2Photo 5 ATTACHING THE DRIVE COUPLING TO THE AQUAGEN MAIN SHAFTAlign the M6 clearance hole in the drive coupling with the M6 tapped hole in the main shaft Fit the M6 spring washer underthe head of the M6 x 20 Allen bolt Insert the bolt through the M6 clearance hole in the drive coupling and fully tighten it intothe main shaft using the Allen key suppliedPhoto 6 ATTACHING THE TOW ROPE TO THE TURBINE AND DRIVE COUPLINGThe Aquagen is supplied with 2 off cablerope clamps these should be used as shown in Photos 5 6ELECTRICAL DATAAqua4gen 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 ofthe wire size used The larger the wire size the smaller the loss however larger cross sectional area wire can be costly andin some cases more difficult to source The following table shows recommended wire sizes they are based on a 3 and5 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 MetresVoltage Drop 3 5 3 5 3 512 volt Aqua4gen 60 mm2 40 mm2 10 mm2 60 mm2 25 mm2 16 mm224 volt Aqua4gen 25 mm2 25 mm2 40 mm2 25 mm2 60 mm2 40 mm2Useful wire cross sectional area mm2 conversion to AWG25 mm2 14AWG 40 mm2 12 AWG 60 mm2 10 AWG100 mm2 8 AWG 160 mm2 6 AWG 250mm2 4AWGIf the Aqua4gen is connected directly to the battery terminalswe recommend a 15 Amp fuse for 12V Models and a 75 Ampfuse for 24v Models is fitted in the brown positive wire fromthe generator to the battery so that if a dead short occurred itwould prevent serious damage to the wiring and the generatorThe BROWN OUTPUT WIRE output is connected to thePOSITIVE terminal of the battery The BLUE OUTPUTWIRE to the NEGATIVE terminal of the batteryThread the Aquagen output cable carefully through a deckgland attach the push on connectors and covers suppliedto the end of the output cable and the end of your extensioncable Observing polarity plug them together The output wiresare then connected to the battery See Diagram 5 oppositeThe BROWN WIRE is connected to the POSITIVE terminal 3and the BLUE WIRE to the NEGATIVE terminalVERY IMPORTANT BE CAREFUL AS INCORRECT CONNECTION WILL DAMAGE THE RECTIFIER WARRANTYWILL BE THE AQUAGEN MUST NEVER RUN OPEN CIRCUIT AS HIGH VOLTAGES CAN BE PRODUCED AND THESUPPRESSION CAPACITORS MAX VOLTAGE MAY BE REGULATIONThe output wires of the Aqua4gen can be connected directly to the terminals of the battery that requires charging as shownin diagram 5 however if the terminal voltage of the battery is not continually monitored for over voltage 142v for 12vbatteries and 284v for 24v batteries the battery can be seriously damaged Fitting an LVM voltage regulator will protectthe battery from becoming over charged You may well have chosen a voltage regulator when purchasing the Aqua4genbut we would recommend you look at page 9 SELECTING THE CORRECT LVM VOLTAGE REGULATOR to make sureyou have purchased the correct unit You may also consider installing an ammeter voltmeter or an amphour meter all are available from I LVM Products partnumber as follows LVM67 0 20A Ammeter LVM69 015v dc Voltmeter LVM200 Digital Amp Hour MeterVERY IMPORTANTIf you do not intend to use a LVM voltage regulator with the Aquagen it is extremely important that a similar type ofregulator is used ie It must be a shunt diverting type regulator that always keeps the Aquagen on loadYOU MUST NEVER USE A REGULATOR THAT SIMPLY TURNS OFF AND ON THE OUTPUT OF THE AQUAGENWHEN THE BATTERY IS FULLY CHARGED THIS CAN LEAVE THE AQUAGEN IN AN OPEN CIRCUIT CONDITIONWHICH WILL ALLOW THE TURBINE TO ROTATE AT VERY HIGH SPEED AND DAMAGE THE UNITOPERATING towrope with the turbine attached should be stored in a neat coil close to the AquagenOnce under way in deep water the turbinetow rope can be payed out It is safer to do this at around 12 Knots as therope will start to turn as soon as it enters the water The turbine is designed to surface at the following speedsStandard 115mm turbine blade 9 Knots Small 90mm turbine blade 11 the turbinetow rope can be achieved in two ways1 Slow yachtboat to 12 Knots then pull in towrope2 Make a tack to turn the yachtboat at 90 Deg to slow it down and bring along side the turbinetow ropeWhen pulling in the towrope it is very important that it is untwisted and coiled neatly ready to use againNote If for any reason the turbine surfaces before 9 knots when using the 115mm blades or 11 knots using the 90mmthis may be caused by your particular hull shape of the yacht creating an underwater wash effect add one or two25mm 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 greaseto the bronze bushes from time to time Typical life of the bronze bushes3000 7000 nautical miles2 Check the tow rope for wear at intervals particularly the area around theDee Shackle and Eye bolt on the turbine shaft By cutting 1 to 2 inches offthe rope a new section can be created3 Check tightness of the Dee Shackle pin 4TROUBLE SHOOTINGThe AQUA4GEN generator unit is design to give many years of reliable service as it contains really only one moving partand one electronic component they are the permanent magnet rotor and a 3 phase rectifierThe only parts that can wear are the main bearing ball racesSIMPLE TESTA simple test to prove there is an output voltage from the Aqua4gen can be carried out whilst the Aqua4gen is in itsworking 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 coggingeffect of the generator then touch the two output leads together shorting them the main shaft should now be noticeablymore difficult to turn If this does not happen check that your extension wire connection from the actual Aqua4gen outputcables are not corroded or have become disconnected If there is a fuse fitted in the output cable check it has not blownThe following tools and equipment will be needed to carry out tests and repairs to the Aqua4genA multimeter which can read 0 100 volts DC measure resistance have a diode test and a continuity buzzer testPozi drive iron and of hardwood and a brass rod 12mm diameter X 250mm long or similarFor pivot bearing replacement a bench vice will be OUTPUT VOLTAGEIf you have a lathe or some other means of turning the main shaft at a known RPM a 12v model produces 006v per revand a 24v model 012v per revIf no voltage is present check that your extension wire connection from the actual generators output cables are notcorroded or have become disconnected If there is a fuse fitted in the output cable check it has not blown Check outputvoltage again at the generators actual output cable If there is still no voltage output go to the instructions and tests listedunder heading NO OUTPUTREDUCED OUTPUT1 Check turbine blades are not damaged2 Check towrope is not kinked and twisted3 Check main shaft of Aquagen turns freely Note There will always be a slight resistance felt this is the cogging effect ofthe generator4 If the output from the Aquagen has been connected to the battery the wrong way round reverse connection the rectifierwill be damaged but still may give a reduced output Replace rectifierNO OUTPUT1Using a multimeter check continuity of output extension cable and connectors2 Check fuse3 Remove the generator from mounting Remove the rear cover 6 off screws and hinge back cover A component calleda rectifier that converts the 3 Phase AC output voltage of the stator into DC volts is mounted on the inside of the coverNote 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 Noneed to remember which order or terminal they come from as they can fit on any of the 3 centre terminalsUsing a multimeter set on resistance measurement ohms check the resistance in turn of the of 3 output wires in pairsfrom the stator They should read 16 ohms 12v model 65 ohms 24v modelCHECKING AC OUTPUT VOLTAGE OF STATORSet the multimeter to read AC volts attach test leads to the 3 off stator output wires in pairs then turn the main shaft ofthe 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 screwsIf at any time the generators output leads have ever been connected to battery terminals the wrong way round or thegenerator has been struck by lightening then the rectifier may be have been damaged 5RECTIFIER TESTReadings taken of a Good RectifierSet a multimeter to diode test then check 1 Disconnect all connectors from the rectifier2 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 Reading3 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 volts4 Connect the test leads to the 3 centre terminals of the rectifier in pairs RESULT No taken of a Faulty Rectifier1 Disconnect all connectors from the rectifier2 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 Volts3 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 Volts4Connect the test leads to the 3 centre terminals of the rectifier in turn in pairs RESULT 0 VoltsIf in doubt about the condition of the rectifier replace with a new one Refit the 3 off 3 phase stator output leads to thecentre terminals of rectifierSet the multimeter to read DC volts Attach the red test lead of the multimeter onto the plus terminal of the rectifier thenthe black test lead onto the negative terminal Turn the main shaft of the generator by hand any direction this shouldindicate a voltage on the multimeter Refit Red and Black DC output leads from the rectifier Refit rear cover using a newgasket 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 tothe main shaft is fully rear cover and check the condition of the rotor it may be rubbing on the statorInner 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 looseGENERAL MECHANICAL CONTINUOUS NOISERemove the towrope and check axial and radial play in the main front bearing Remove rear cover and check inner mainbearing in the same manner If large amount of play is found replace main bearingsFollow instructions listed REPLACING MAIN ELECTRICAL VIBRATION NOISEIt 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 BEARINGSParts 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 tubeTools required Hammer Circlip pliers Pozi drive screwdriver Piece of hardwood and a brass rod 12mm diameter X250mm 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 out3 Remove the front 15mm circlip on the main shaft4 Remove 6 off selftapping screws retaining the rear cover5 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 shaft6 The main shaft rotor assembly should now have moved inwards into the main housing7 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 housing8 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 pickup13 Smear a little Loctite Bearing Fit onto the main shaft close to the rotor and in the bore of the outer main bearing14 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 rubbing15 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 shaft16 Fit new 15mm circlip on main shaft17 Fit new main shaft water seal grease well on assembly18 Refit rear cover using a new gasket make sure all internal wiring is clear of the rotor 78 SELECTING THE CORRECT LVM VOLTAGE REGULATORThe output of the Aquagen can be simply connected directly to the terminals of the battery that requires charging howeverif the terminal voltage of the battery is not continually monitored for over voltage 142v for 12v batteries and 284v for 24vbatteries the battery can be seriously damaged Fitting an LVM voltage regulator will protect the battery from becomingover COMPENSATION This additional feature is available on all LVM regulators If the battery is located in abuilding where the ambient temperature is always around 20 degC then standard regulators can be used However if youintend to locate a battery where temperatures may go down to freezing and perhaps rise to tropical temperatures then youshould install a regulator that is fitted with a temperature compensation circuit This automatically allows the battery to becharged at a higher voltage as the temperature drops and a lower voltage if the temperature increases Simply add Tafter the LVM Product No ie 4TB12 TThe regulator suitable for the Aqua4gen Twin battery regulator LVM product No 4TB12 4TB24 These units are connected between the output of the Aquagenor Solargen module and the battery terminals They control the actual output voltage of Aquagen or Solargen by divertingpower to a high wattage wire wound dump resistor when their output voltage reaches 142v 12v systems or 284 24vsystems They have two schottky blocking diodes built into the regulator which enables them to monitor and control thecharge to two batteries totally independent of each other therefore making it ideal for separate charging of engine startingand 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 twothings it stops the batteries over charging and keeps the Aqua4gen always on load Note This regulator draws NO standby current from the batteryAlso available from LVM Products are Diode Units LVM product No 4DU 6DUThe 4DU when combined with a 2TB or 4TB regulator enables one additional battery to be chargedThe 6DU when combined with a 4TB regulator enables two additional batteries to be chargedThe Aqua4gen and a Solargen modules output may often be combined the table below shows the recommended regulatorfor various systems Note Two batteries wired in parallel are classed as one independent battery Having selected therecommended regulator model from the table simply add the voltage required ie 4TB12 for a 12v system or 4TB24 for a 24vsystem Basic wiring diagram are shown on page 10 If you cannot find your particular system or application within the tableor require full wiring diagrams please check our web site wwwlvmltdcom or call our sales office who will email fax or postyou copiesVOLTAGE REGULATOR TABLE Number of independent batteries to be charged SYSTEM 1 2 3 41 x Aqua4gen 4TB 4TB 4TB 4DU 4TB 6DU1 x Aqua4gen 5w Solargen panel 4TB 4TB 4TB 4DU 4TB 6DU1 x Aqua4gen 10w Solargen panel 4TB 4TB 4TB 4DU 4TB 6DU1 x Aqua4gen 17w Solargen panel 4TB 4TB 4TB 4DU 4TB 6DU1 x Aqua4gen 25w Solargen panel 4TB 4TB 4TB 4DU 4TB 6DU1 x Aqua4gen 25w10w Solargen panel 4TB 4TB 4TB 4DU 4TB 6DU1 x Aqua4gen 25w25w Solargen panel 4TB 4TB 4TB 4DU 4TB 6DU1 x Aqua4gen up to 100w Solargen panels 4TB 4TB 4TB 4DU 4TB 6DU 910