Manual 1 - Service and Assembly

      The Stream Engine Personal Hydropower Owner’s Manual

Table of Contents

Introduction

Site Evaluation

Head Measurement

Flow Measurement

Intake, Pipeline & Tailrace

Batteries, Inverters & Controllers

Wiring & Load Center

Output Adjustment

Service and Assembly

Wiring Diagrams

The New Universal Nozzle

New Current Measurement Technique

SERVICE & ASSEMBLY

In order to remove the generator you must first remove the turbine wheel. The machine's wheel is unscrewed from the shaft by holding the rotor using the 1/4" diameter rod inserted into one of the holes in the edge of the rotor. The turbine wheel is assembled with a washer and then a spacer on top. The shaft is made with standard right hand threads for the turbine wheel so it will unscrew in a counter-clockwise direction when looking at the shaft (with the machine upside down). Then you can remove the four bolts (with 5/32" allen hex heads).

You should replace bearings as soon as you notice any looseness. If they are too loose, severe damage to both the rotor and the stator can result. This machine uses three 6203 ball bearings with non-contact seals. These are press fit into the alternator housing and must be installed and removed using a press of adequate capacity and a proper sized mandrel.

Click on image for larger view

COPPER WIRE RESISTENCE

Wire Gauge	Diameter Inches	Ohms per 1000'	Ohms per Mile
0000	0.460	0.05	0.26
000	0.410	0.06	0.33
00	0.364	0.08	0.42
0	0.324	0.10	0.52
2	0.258	0.16	0.84
4	0.204	0.25	1.34
6	0.162	0.40	2.13
8	0.128	0.64	3.38
10	0.102	1.02	5.38
12	0.081	1.62	8.56
14	0.064	2.58	13.6
16	0.051	4.10	21.6
18	0.040	6.52	34.4

PIPE FRICTION LOSS

Polyethylene SDR - Pressure Rated Pipe
Pressure Loss from Friction in Feet of Head per 100 Feet of Pipe

Flow US GPM
	0.5	0.75	1	1.25	1.5	2	2.5	3
1	1.13	0.28	0.09	0.02
2	4.05	1.04	0.32	0.09	0.04
3	8.60	2.19	0.67	0.19	0.09	0.02
4	14.6	3.73	1.15	0.30	0.14	0.05
5	22.1	5.61	1.75	0.46	0.21	0.07
6	31.0	7.89	2.44	0.65	0.30	0.09	0.05
7	41.2	10.5	3.24	0.85	0.42	0.12	0.06
8	53.1	13.4	4.14	1.08	0.51	0.16	0.07
9		16.7	5.15	1.36	0.65	0.18	0.08
10		20.3	6.28	1.66	0.78	0.23	0.09	0.02
12		28.5	8.79	2.32	1.11	0.32	0.14	0.05
14		37.9	11.7	3.10	1.45	0.44	0.18	0.07
16			15.0	3.93	1.87	0.55	0.23	0.08
18			18.6	4.90	2.32	0.69	0.30	0.09
20			22.6	5.96	2.81	0.83	0.35	0.12
22			27.0	7.11	3.36	1.00	0.42	0.37
24			31.7	8.35	3.96	1.17	0.49	0.16
26			36.8	9.68	4.58	1.36	0.58	0.21
28				11.1	5.25	1.56	0.67	0.23
30				12.6	5.96	1.77	0.74	0.25
35				16.8	7.94	2.35	1.00	0.35
40				21.5	10.2	3.02	1.27	0.44
45				26.8	12.7	3.75	1.59	0.55
50				32.5	15.4	4.55	1.91	0.67
55					18.3	5.43	1.96	0.81
60					21.5	6.40	2.70	0.94
65					23.8	7.41	3.13	1.08
70					28.7	8.49	3.59	1.24
75					32.6	9.67	4.07	1.40
80						10.9	4.58	1.59
85						12.2	5.13	1.77
90						13.5	5.71	1.98
95						15.0	6.31	2.19
100						16.5	6.92	2.42
150						34.5	14.7	5.11
200							25.0	8.70
300								18.4

PIPE FRICTION LOSS - PVC Class 160 PSI Plastic Pipe

Pressure Loss from Friction in Feet of Head per 100 Feet of Pipe

Flow US GPM	Pipe Diameter, Inches
	1	1.25	1.5	2	2.5	3	4	5	6	8	10
1	0.05	0.02
2	0.14	0.05	0.02
3	0.32	0.09	0.04
4	0.53	0.16	0.09	0.02
5	0.80	0.25	0.12	0.04
6	1.13	0.35	0.18	0.07	0.02
7	1.52	0.46	0.23	0.08	0.02
8	1.93	0.58	0.30	0.10	0.04
9	2.42	0.71	0.37	0.12	0.05
10	2.92	0.87	0.46	0.16	0.07	0.02
11	3.50	1.04	0.53	0.18	0.07	0.02
12	4.09	1.22	0.64	0.20	0.09	0.02
14	5.45	1.63	0.85	0.28	0.12	0.04
16	7.00	2.09	1.08	0.37	0.14	0.04
18	8.69	2.60	1.33	0.46	0.18	0.07
20	10.6	3.15	1.63	0.55	0.21	0.09	0.02
22	12.6	3.77	1.96	0.67	0.25	0.09	0.02
24	14.8	4.42	2.32	0.78	0.30	0.12	0.04
26	17.2	5.13	2.65	0.90	0.35	0.14	0.05
28	19.7	5.89	3.04	1.04	0.41	0.16	0.05
30	22.4	6.70	3.45	1.17	0.43	0.18	0.05
35		8.90	4.64	1.56	0.62	0.23	0.07
40		11.4	5.89	1.98	0.78	0.30	0.09	0.02
45		14.2	7.34	2.48	0.97	0.37	0.12	0.04
50		17.2	8.92	3.01	1.20	0.46	0.14	0.04
55		20.5	10.6	3.59	1.43	0.55	0.16	0.05
60		24.1	12.5	4.21	1.66	0.64	0.18	0.07	0.02
70			16.6	5.61	2.21	0.85	0.25	0.09	0.03
80			21.3	7.18	2.83	1.08	0.32	0.12	0.04
90				8.92	3.52	1.36	0.39	0.14	0.07
100				10.9	4.28	1.66	0.48	0.18	0.07	0.02
150				23.2	9.06	3.50	1.04	0.37	0.16	0.05
200					15.5	5.96	1.75	0.62	0.28	0.07	0.02
250					23.4	9.05	2.65	0.94	0.42	0.12	0.05
300						12.6	3.73	1.34	0.58	0.16	0.05
350						16.8	4.95	1.78	0.76	0.21	0.07
400						21.5	6.33	2.25	0.97	0.28	0.10
450							7.87	2.81	1.20	0.32	0.12
500							9.55	3.41	1.45	0.42	0.14
550							11.4	4.07	1.75	0.48	0.16
600							13.4	4.78	2.05	0.58	0.18
650							15.5	5.54	2.37	0.67	0.23
700							17.8	6.37	2.71	0.76	0.25
750							20.3	7.22	3.10	0.86	0.30
800								8.14	3.50	0.97	0.32
850								9.11	3.89	1.08	0.37
900								10.1	4.32	1.20	0.42
950								10.8	4.79	1.34	0.46
1000								12.3	5.27	1.45	0.51

POWER OUTPUT IN WATTS (CONTINUOUS)

Net Head, Feet	Flow Rate in U.S. Gallons per Minute
	5	10	15	20	30	40	50	75	100	150	200	300
5				5	8	10	15	20	30	40
10			7	12	18	23	30	45	60	80	100
15	5	10	15	20	30	40	50	75	100	125	150	200
20	8	16	25	32	50	65	85	125	170	210	275	350
30	12	30	45	60	90	120	150	225	300	400	500	700
40	16	40	60	80	120	160	200	300	400	500	600
50	20	50	75	100	150	200	250	375	500	600
75	30	75	110	150	225	300	375	560	700
100	40	100	150	200	300	400	500	650
150	60	150	225	300	400	550	650
200	80	200	300	400	550	700
300	120	240	360	480	720
400	160	320	480	640