480009 HEV Application Guide[1]

7/31/2019 480009 HEV Application Guide[1]

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480009-001 Rev B (October 2004) Page 1 of 54This information is proprietary to Capstone Turbine Corporation. Neither this document nor the information contained herein shall be copied, disclosed to others, orused for any purposes other than the specific purpose for which this document was delivered. Capstone reserves the right to change or modify without notice, thedesign, the product specifications, and/or the contents of this document without incurring any obligation either with respect to equipment previously sold or in the

process of construction.

Capstone Turbine Corporation 21211 Nordhoff Street Chatsworth CA 91311 USA

Telephone: (818) 734-5300 Facsimile: (818) 734-5320 Website: www.microturbine.com

Capstone

Appl ic at ion Guide

Model C30 and C60 HEV Applicat ion Informat ion

This document presents application information for the Capstone Model C30 and C60Hybrid Electric Vehicle (HEV) MicroTurbine systems.

Figure 1. Model C60 HEV MicroTurbine


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Capstone Turbine Corporation 21211 Nordhoff Street Chatsworth CA 91311 USAApplication Guide: C30 and C60 Hybrid Electric Vehicle (HEV) Application Information for Capstone



How to Contac t Capstone

For additional information or if specific questions arise, contact the HEV ApplicationManager at:

Capstone Turbine Corporation21211 Nordhoff Street Chatsworth, California 91311, USATelephone: (818) 734-5300Facsimile: (818) 734-5320Website: http://www.microturbine.com/

Capstone Technical SupportToll Free Telephone: (877) 282-8966Telephone: (818) 407-3600Facsimile: (818) 734-1080E-Mail: [email protected]

Capstone Technical Support (Japan)Telephone: (818) 407-3700Facsimile: (818) 734-1080E-mail: [email protected]

If you are an Authorized Service Provider (ASP), the Capstone Members Only Website(http://www.capstoneturbine.com/login.asp ) may provide solutions to some of yourquestions.

This information is proprietary to Capstone Turbine Corporation. Neither this documentnor the information contained herein shall be copied, disclosed to others, or used forany purposes other than the specific purpose for which this document was delivered.Capstone reserves the right to change or modify without notice, the design, the productspecifications, and/or the contents of this document without incurring any obligation

either with respect to equipment previously sold or in the process of construction.


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TABLE OF CONTENTS

How to Contact Capstone............................................................................................................. 2About this Document..................................................................................................................... 6Safety Information.......................................................................................................................... 6Introduction..................................................................................................................................... 6Symbols........................................................................................................................................... 6General Precautions ...................................................................................................................... 7

Electrical Precautions ................................................................................................................... 8Fuel Precautions ...........................................................................................................................8Exhaust Precautions..................................................................................................................... 9

Acoustic Emissions Precautions ..................................................................................................9Document Overview.....................................................................................................................10MicroTurbine Introduction .......................................................................................................... 10

Key Mechanical Components.....................................................................................................11Main Features .............................................................................................................................11

MicroTurbine Basic Operation ...................................................................................................12MicroTurbine System Components........................................................................................... 13

MicroTurbine Engine................................................................................................................... 13Air Bearings.................................................................................................................................13Fuel System ................................................................................................................................14Controllers...................................................................................................................................14

System Performance Information.............................................................................................. 15Performance Ratings at Full Load Power ..................................................................................15Performance Derating Factors ...................................................................................................15

Electrical Ratings ........................................................................................................................16Environmental Limitations...........................................................................................................16

System Components ................................................................................................................... 17Engine Details .............................................................................................................................17Model Engine Specifications (Full Power and ISO Conditions) ................................................17Engine Installation Requirements...............................................................................................18Fuel System Details ....................................................................................................................19Fuel System Specifications.........................................................................................................19Fuel System Installation Requirements......................................................................................20Engine Fuel Requirements......................................................................................................... 20Engine Control Module Details (Model C60) .............................................................................21ECM Specifications..................................................................................................................... 22Battery Control Module Details (Model C60) .............................................................................23BCM Specifications..................................................................................................................... 23DPC Controller (Model C30)....................................................................................................... 24

DPC Controller Details (Model C30)...................................................................................................24DPC Specifications (Model C30).........................................................................................................25

User Connection Board (UCB) (Model C30) .............................................................................26Liquid Fuel Controller (LFC) (Model C30)..................................................................................27

Cables ............................................................................................................................................ 27


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TABLE OF CONTENTS (CONTD)



Integrating the MicroTurbine into the Vehicle System ........................................................... 28Enclosures...................................................................................................................................28Inlet Air Filtration and Ducting to Engine....................................................................................29Cooling Air Filtration and Ducting to Controllers ........................................................................30Engine Exhaust Ducting ............................................................................................................. 31Generator Exhaust Air (Model C60 Only) ..................................................................................31Engine Heat Rejection ................................................................................................................ 32Fuel Delivery System to Engine Fuel System............................................................................33

Air Assist Requirements for Liquid Fuel Systems......................................................................33Mechanical Interface Parameters............................................................................................... 34

Acceleration...........................................................................................................................................34Orientation.............................................................................................................................................34Vibration.................................................................................................................................................34Component Locations..........................................................................................................................34

Acoustical Parameters................................................................................................................35Turbulence Noise..................................................................................................................................35Blade Interaction Noise........................................................................................................................35Electro-Mechanical Noise....................................................................................................................35Combustion Noise................................................................................................................................36Sound Pressure....................................................................................................................................36Sound Power ........................................................................................................................................36

A-Weighted Sound Level.....................................................................................................................36Sound Spectrums .......................................................................................................................36Noise Attenuation Methods ........................................................................................................37

Tuned Cavity.........................................................................................................................................37Extruded Metal......................................................................................................................................37Bulk Attenuator......................................................................................................................................37

Electrical System Grounding......................................................................................................38Cables from MicroTurbine to Battery Pack................................................................................39External Power Supply ...............................................................................................................39Vehicle Battery Management System........................................................................................39

Safety-related Design Considerations ...................................................................................... 40High Temperatures .....................................................................................................................40High Voltages.............................................................................................................................. 40Flammable Fuels ........................................................................................................................40Emergency Stop (E-Stop)...........................................................................................................41Equipment Access ......................................................................................................................41Fuel Leak Detectors....................................................................................................................41Fire Suppression Detectors ........................................................................................................41Warning Labels ...........................................................................................................................41

Communication Requirements .................................................................................................. 42System Configuration..................................................................................................................45

Baud Rate ...................................................................................................................................45Protective Relays ........................................................................................................................45Fuel Indices.................................................................................................................................45


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TABLE OF CONTENTS (CONTD)



System Design Guidelines and Processes .............................................................................. 46Step 1 Application....................................................................................................................46Step 2 Product Design............................................................................................................. 47

MicroTurbine Module Mounting...........................................................................................................47MicroTurbine Inlet .................................................................................................................................47MicroTurbine Exhaust..........................................................................................................................48Electrical Ventilation..............................................................................................................................48Electrical Connections..........................................................................................................................48Fuel System..........................................................................................................................................49Control System .....................................................................................................................................49

Step 3 Prototype Inspection ....................................................................................................49Step 4 Design/Installation Approval ........................................................................................ 49Production System Installation...................................................................................................50

Capstone Remote Monitoring Software.................................................................................... 52Maintenance Items....................................................................................................................... 52

ASP Training .................................................................................................................................53Warranty Information...................................................................................................................53Related Documents......................................................................................................................53NOTES........................................................................................................................................ 54Appendix A Available Accessories for HEV Systems ....................................................... A-1Appendix B - Drawings and Diagrams................................................................................... B-1


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480009-001 Rev A (June 2004) Page 6 of 54This information is proprietary to Capstone Turbine Corporation. Neither this document nor the information contained herein shall be copied, disclosed to others,or used for any purposes other than the specific purpose for which this document was delivered. Capstone reserves the right to change or modify without notice,the design, the product specifications, and/or the contents of this document without incurring any obligation either with respect to equipment previously sold or in

the process of construction.

About this Docum ent

This document provides user instructions to operate and maintain the CapstoneTurbine Corporation MicroTurbine.

This document is intended for user personnel who may not have specific training on theMicroTurbine. Capstone Authorized Service Providers (ASPs) have received rigoroustraining and have been certified to perform commissioning, troubleshooting, and repairof the MicroTurbine.

Users who have not received certification of satisfactory completion of thistraining should not attempt any procedures other than those specificallydescribed in this document.

Safet y Information

This section presents safety information for the user of Capstone Turbine CorporationMicroTurbines. The user must read and understand this manual before operation of theequipment. Failure to obey all safety precautions and general instructions may cause

personal injury and/or damage to the equipment.

It is the Users responsibility to read and obey all safety procedures and tobecome familiar with these procedures and how to safely operate this equipment.

Introduct ion

The Capstone MicroTurbine is an advanced power generation system with user andmaterial safety foremost in mind. Fail-safe operation includes mechanical systems,electrical systems, and engine control software.

Symbols

There are three very important symbols used in this document: Warnings, Cautions,and Notes. Warnings and Cautions alert you to situations and procedures that can bedangerous to people and/or cause equipment damage. Notes provide additionalinformation relating to a specific operation or task.

WARNING A Warning means that personal injury or death is possible.

CAUTION A Caution means that damage to the equipment is possible.

NOTEA Note is used to clarify instructions or highlight information that mightbe overlooked.


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480009-001 Rev B (October 2004) Page 7 of 54This information is proprietary to Capstone Turbine Corporation. Neither this document nor the information contained herein shall be copied, disclosed to others,or used for any purposes other than the specific purpose for which this document was delivered. Capstone reserves the right to change or modify without notice,the design, the product specifications, and/or the contents of this document without incurring any obligation either with respect to equipment previously sold or in


General Precautions

The following general precautions must be observed and followed at all times. Failureto do so may result in personal injury and/or equipment damage.

NOTE Some of the following precautions do not directly apply to users, but itis important to be aware of them.

Only Capstone Authorized Service Providers are permitted access to the insideof the component enclosures.

Read and understand the User's Manual before operating the equipment.

Read and obey all warnings and cautions.

Make sure all fuel connections are tight, free from leaks, and protected fromdamage.

Make sure all electrical connections are tight, clean, dry, and protected fromweather and damage.

Use hearing protection when you work on or near a MicroTurbine in operation.

The MicroTurbine is heavy. Be careful when you move or lift the MicroTurbine.

Keep the equipment clean.

Keep all flammable materials away from the MicroTurbine and its components.

Do not operate or work on the equipment if mentally or physically impaired, orafter consumption of alcohol or drugs.

Make sure all fasteners are installed and properly tightened.

Keep an ABC rated fire extinguisher near the MicroTurbine.

Obey all applicable local, state, and national codes and regulations.


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Elect rical Precaut ions

The output voltage and residual capacitor voltage of this equipment is dangerous. Highvoltage can kill or injure. Use caution when you work on electrical equipment. TheMicroTurbine system can include multiple sources of power. Turn off the system andlockout the power supply prior to all work on the equipment.

NOTESome of the following precautions do not directly apply to users, but itis important to be aware of them.

Only Capstone Authorized Service Providers are permitted access to the insideof the component enclosures.

Command the MicroTurbine system to OFF.

Open the battery isolation switch and unplug the battery cable.

Wait five (5) minutes for any capacitive stored voltage to dissipate.

Always disconnect all power sources.

Use a voltmeter to make sure that all circuits are de-energized.

WARNINGThe MicroTurbine system contains and produces high voltage. Highvoltage can injure or kill. Obey all safety procedures when you workaround electrical equipment.

WARNINGMake sure the system is off and the dedicated disconnect switch is inthe open position and is locked. This will help prevent injury anddamage to the equipment.

Fuel Precautions

The Capstone MicroTurbine operates on approved liquid or gaseous fuels. Keepflames, sparks, pilot lights, equipment that produces electrical arcs, switches or tools,and all other sources of ignition away from areas where fuel and fumes are present. Ifthere is a fire, use a multi-purpose dry chemical or CO2 fire extinguisher.

Fuel lines must be secure and free of leaks. Fuel lines must also be separated orshielded from electrical wiring. If you smell fuel fumes, immediately stop operation ofthe equipment, close the fuel isolation valve, and locate and repair the source of theleak or call a qualified professional.

WARNINGMicroTurbine fuel is flammable and explosive. An explosion cancause death or injury to personnel and/or damage to equipment. Noopen flame or smoking is allowed near the MicroTurbine.

WARNING

Liquid and gaseous fuels can be corrosive. Concentrations ofHydrogen Sulfide (H2S) can be found in Sour Natural Gas and SourHigh Btu Gas. Injury to personnel and/or damage to equipment canoccur. Minimize exposure to liquid or gaseous fuels and providesatisfactory fresh airflow when you are around equipment.


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Exhaust Precaut ions

The Capstone MicroTurbine is designed to produce very safe emissions. The exhaustis clean and oxygen rich (approximately 18% O2), with very low levels of air pollutants.Like all fossil fuel combustion technology, the MicroTurbine can produce dangerous

emissions (like nitrogen dioxide and carbon monoxide) from the fuel combustionprocess.

Although the MicroTurbine has ultra low nitrogen dioxide (NO2), and carbon monoxide(CO) emission levels, make sure precautions are taken to prevent personnel from beingexposed to nitrogen dioxide and carbon monoxide while the system is operating.Nitrogen dioxide and carbon monoxide are poisonous at high concentrations.

WARNINGThe MicroTurbine exhaust contains nitrogen dioxide and carbonmonoxide, which are poisonous at high concentrations. Make sure thereis satisfactory fresh airflow when you work around the equipment.

WARNING

The exhaust airflow and pipes are hot enough to cause personal injury or

fire. The exhaust airflow can reach temperatures as high as 371 C (700F). Keep people, equipment, and other items away from the exhaustairflow and pipes. Always vent exhaust away from personnel.

WARNINGHot surfaces and hot exhaust can be dangerous. Personal injury and/ordamage to equipment are possible. Be careful when you work onequipment.

Acoust ic Emissions Precaut ions

The Capstone MicroTurbine is designed to produce safe acoustic emissions when

properly installed in an acoustically treated enclosure. However, when working at aradius of 10 meters (or 33 feet) from an enclosed Capstone MicroTurbine, sound levelexposure will average approximately 70 dBA.

Capstone recommends that hearing protection be worn when working on or in theimmediate vicinity of operating MicroTurbines for extended periods.

Other acoustic emissions regulations may apply to your specific installation location.Always check to be certain that your installation complies with all codes required by thelocal jurisdiction.


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Docum ent Overview

Capstone offers a 30 kilowatt system (Model C30) and a 60 kilowatt (Model C60) fordirect current voltage output for hybrid vehicle applications.

This document provides the data necessary for the user to integrate, operate, andmaintain the Capstone MicroTurbine in a Customer defined application.

MicroTurbine Introduct ion

The Capstone MicroTurbine is an adaptable, low-emission, and low maintenance powergeneration system that can be used for generating DC voltage in applications such asHybrid Electric Vehicles (HEV). The MicroTurbine(s) can generate power in series with anon-board battery pack or other DC power supply. The system consists of a turbineengine, solid-state power electronics, and a fuel system.

The turbine engine includes a compressor, a recuperator (exhaust gas heatexchanger), a combustor, a turbine, and a generator. The MicroTurbine turbine engine

is air-cooled and does not require any lubricants. The compressor impeller, turbinerotor, and generator rotor are mounted on a single shaft, which comprises the onlymoving part in the engine, and is supported on air-lubricated compliant foil bearings.

Power electronics are solid-state, double conversion type, producing direct current (DC)output power from the high-frequency alternating current engine output.

The fuel system monitors, regulates, and delivers the fuel to the engine from a fuelsource and supports gaseous as well as liquid fuels, depending on systemconfiguration.

The MicroTurbine can efficiently use a wide range of approved hydrocarbon-basedgaseous and liquid fuels, depending on system configuration.

The MicroTurbine produces dry, oxygen-rich exhaust with ultra-low emissions. Utilizingboth the generated electric power and the exhaust heat can provide even greaterenergy cost savings.


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Key Mechanical Components

The key mechanical components that comprise the Capstone MicroTurbine are shownbelow in Figure 2.

Figure 2. Typical Capstone MicroTurbine Engine

Main Features

The various features of the Capstone MicroTurbine are listed below:

State-of-the-art Digital Power Controller with built-in protective relay functionsprovides direct current (DC) output.

Patented air bearings eliminate the need for oil or other lubricants.

Air-cooled design of the entire system (turbine and controller) eliminates theneed for liquid coolants or lubricants.

Center shaft is the only moving part. No gears, belts, or turbine-drivenaccessories are used.

Advanced combustion control eliminates the need for ceramics or other costlymaterials or any catalytic combustion, and provides ultra-low emissions.

Digital control technology facilitates advanced control, monitoring, anddiagnostic capabilities, both on-board and remotely (via an RS-232 link).

Near zero emissions.

Compact size and weight.

Minimum maintenance.


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MicroTurbine Basic Operation

Ambient air is drawn into turbine engine through an air filter (customer supplied). Thisair is used to cool the generator, provides air to the air bearings, and used for thecombustion process.

The air is compressed by the compressor impeller and passes through the recuperatorwhere its temperature is elevated by the exhaust gases expelled from the turbine. Thisprocess increases the overall efficiency.

The heated compressed air is mixed with fuel and burned in the combustion chamber.Patented techniques in the combustion process result in an extremely low emissionexhaust stream. The combusted hot gases expand through the turbine, providingrotational power to drive compressor impeller and generator.

See Figure 3 for a system air flow diagram.

User Interface

ElectricalOutput

Communications and Control

Figure 3. Air Flow in MicroTurbine


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The output of the generator is variable voltage, variable frequency AC power. Powerelectronics convert this to programmable DC power for HEV applications. Electricalpower output is Direct Current (DC), into the vehicle's main electrical bus.

The purpose of the Capstone MicroTurbine HEV system is to generate DC power inseries with the HEV battery. The unit accepts commands from a Vehicle Management

System (via a RS-232 connection) and outputs the commanded power.Starting and control power are sourced directly from the high voltage DC bus of thevehicle. For vehicles with nominal battery voltage less than 200 volts DC (Model C30),300 volts DC (Model C60), an external 12-volt (Model C30) or 25-volt (Model C60)battery supply is required to start the system.

Figure 4 shows the basic series hybrid configuration.

Figure 4. Basic Series Hybrid Configuration

MicroTurbine System Components

MicroTurbine Engine

The MicroTurbine engine is a combustion turbine that includes a compressor,combustor, turbine, generator, and a recuperator. The rotating components aremounted on a single shaft supported by patented air bearings and spin at up to 96,000RPM. The permanent magnet generator is cooled by the airflow into the MicroTurbine.The output of the generator is variable voltage, variable frequency AC. The generator isused as a motor during start-up and cooldown cycles.

Air Bearings

The MicroTurbine utilizes gas foil bearings (air bearings) for high-reliability, lowmaintenance, and safe operation. This allows fewer parts and the absence of any liquidlubrication to support the rotating group. When the MicroTurbine is in operation, a gasfilm separates the shaft from the bearings and protects it from wear.


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Fuel System

The MicroTurbine includes an integral fuel delivery and control system. The standardC30 and C60 systems are designed for pressurized hydrocarbon-based gaseous fuels.Other C30 models are available for gaseous fuels with lower heat content and liquid

fuels. Contact Capstone for data on approved fuels and performance specifications.

Controllers

The Model C30 HEV system has a single digital power electronics controller called theDigital Power Controller (DPC).

The Model C60 HEV System consists of two digital power electronics controllers,Engine Control Module (ECM) and Battery Control Module (BCM).

The digital power electronics control the MicroTurbine system operation and allsubsystem operations. The digital power electronics changes the variable frequency ACpower from the generator to DC voltage, and then to constant DC output to synchronize

to the battery pack.During start up, the digital power electronics operate as a variable frequency drive, andmotors the generator until the MicroTurbine has reached ignition and power is availablefrom the MicroTurbine. The digital power electronics again operate as a drive duringcooldown to remove heat stored in the recuperator and within the MicroTurbine enginein order to protect the system components.

Figure 5 shows a typical system schematic.

Figure 5. System Schematic


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System Performanc e Inform ation

NOTERefer to HEV MicroTurbine Product Specification 460009 for performancederating metric data.

The control modules source power from the vehicle's main DC bus. This DC power is

then converted into high frequency AC current, which is used to motor the MicroTurbineengine prior to combustion. Once self-sustaining combustion is achieved, the systementers a warm-up period. As the warm-up is completed, the MicroTurbine system willsource power to the vehicle's main DC bus.

Perform ance Ratings at Full Load Pow er

NOTERefer to the Model C30 (410004) and Model C60 (410005) PerformanceTechnical Reference for updated performance ratings.

The following reference performance ratings are listed at full load power and ISOconditions. ISO conditions are defined as: 15 C (59 F), 60% relative humidity, at sea

level altitude.

Performance Rating Model C60 Model C30 (NG or Liquid)

Net Output Power 60.0 (+0/-2) kW maximum HPNG: 30.0 (+0/-1) kW maximumLiquid: 29 1 KW minimum

Output Voltage Range 200 to 700 volts DC 150 to 700 volts DC

Output Current 300 Amps (max.continuous) 128 Amps (max. continuous)

Thermal Efficiency 28.0 ( 2) % HPNG: 25.0 ( 2)Liquid: 26.0 ( 2) % HPNG

Emissions (NOx)


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Elect rical Ratings

NOTERefer to Model C30 (410030) and Model C60 (410031) HEV ElectricalTechnical Reference manuals for more detail and updated information.

The following table presents the Electrical Ratings for reference only:

Description Model C60 Model C30

Battery Voltage Oper. Range 200 to 700 VDC 150 to 700 VDC

Output Voltage Connection 2 Wire + Ground 2 Wire + Ground

Output Power 0 to 60 kW HPNG 0 to 30 kW HPNG

Output Power Ramp Rate 2 kW/second, maximum

1 kW/second, maximum 3 kW/second, maximumw/software version 2.05 orhigher

Output Current300 Amps DC, max. steady

state

125 Amps DC, max. steady

state

Power Required@ Start Command (per MT)

6.8 kW peak, 0.014 kW-Hr, 42sec

3.5 kW peak,0.014 kW-Hr, 30 Seconds

@Cooldown Power (per MT) 2.0 kW peak, 0.3 kW-Hr, 90 sec2.8 kW peak, 0.147 kW-Hr,5 minutes, typical

Standby Power 0.8 kW 0.5 kW

Environmental Limit ations

NOTE

Refer to the HEV Product Specification (460009) and the Model C30

(410004) and Model C60 (410005) Performance Technical Reference foradditional updated information.

The MicroTurbine system will normally operate within a varied range of parameters,including the following environmental conditions:

Parameter Limitation

Operating Altitude -1000 to +11,000 feet above sea level

Relative Humidity 0 to 100%, Condensing

Engine/Electronics Air Temperature -20 C to +50 C (-40 F to +122 F)

Ambient Operating Temperature -20 C to +50 C (-4 F to +122 F)

Storage/Shipping Temperature -40 C to +65 C (-40 F to +149 F)


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System Components

Engine Detail s

The engine assembly is delivered complete as shown in Figure 6. The engine includesthe compressor, recuperator, combustor, turbine, and generator. The assembly is

mounted on a frame along with the fuel system that is described in the next section.Four mounting holes are provided on the underside of the frame for mounting tovehicle.

Figure 6. Engine Details

Model Engine Spec ific ations (Full Pow er and ISO Conditions)

Typical engine installation specifications are presented in the following table for

reference only. Refer to HEV MicroTurbine Product Specification 460009 forperformance details, updated information and related drawings (see Appendix B).

Engine Specification Model C60 Model C30

Mean Length 884 mm (34.8 inch) 836 mm (32.9 inch)

Mean Width 666 mm (26.2 inch) 572 mm (22.5 inch)

Mean Height 759 mm (29.9 inch) 729 mm (28.7 inch)

Approximate Weight 135 kg (300 pounds) 91 kg (200 pounds)

Air Inlet Volume 425 liters/sec (900 cfm) 283 liters/sec (600 cfm)

Air Inlet Temp -20 to 50 C (-4 to 122 F) -20 to 50 C (-4 to 122 F)

Exhaust Gas Temp 305 C (580 F) 275 C (530 F)

Average Fuel Consumption(Flow)

855,000 kJ/Hr (811,000Btu/hr)

457,000 kJ/Hr (433,000Btu/hr)

Engine Heat Rejection Approximately 2000 watts Approximately 1500 watts

Engine Exhaust Output 571,000 kJ/hr 327,000 kJ/hr

Minimum Inlet Air Filtration


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Engine Installation Requirement s

The following are engine installation requirements:

The engine must be mounted and oriented as outlined on the relevant detaildrawing (provided as a separate document).

Minimum service clearance access must be provided as detailed on the relevantdetail drawing, for removal of maintenance items such as injectors, igniter, andthermocouple.

Engine installation requires an independent air plenum, normally to be drawnfrom the same source as the power electronics.

The engine air inlet temperature must be within two degrees of the electronicscontrol module(s) cooling air inlet temperature.

For Model C60 only, the generator cooling air must be ducted away from engineair inlet via 2.5-inch diameter hose. Refer to Engine Detail drawing for locationof the vent near the center of generator.

The engine must be cooled such that the component temperatures do notexceed specified values, as noted on relevant detail drawings and below.

The fuel manifold surface temperature must not exceed a value of 70 C (158 F).

The personality module (PM) and ambient climate module (ACM) surfacetemperature must not exceed a value of 65 C (149 F).

The dump valve surface temperature must not exceed a value of 70 C (158 F).

The generator housing ambient temperature must not exceed 93C (200 F).

The engine dump valve exhausts air at 227 C (441F) in bursts duringMicroTurbine deceleration in a fault condition.


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Fuel System Details

The fuel system is delivered complete and is part of the engine assembly as describedand shown in the Engine detail section. For gaseous fuels, the fuel systemincorporates a Smart Proportional Valve (SPV25), fuel manifold, pressure transducer,fuel shutoff valve, fuel lines, and fuel injectors. For liquid fuels, the fuel system

incorporates a fuel pump, fuel manifold, fuel filter, fuel lines, injectors, air-assistmanifold, valves, regulator and air lines. See Figure 7 for fuel system packages.

Figure 7. Fuel System Package

Fuel System Specific ations

Typical fuel system specifications are presented in the following table for referenceonly. See Appendix B for related drawings.

Fuel System Specification Model C60 Model C30

Mean Length 514.1 mm (20.24 in.) 482.6 mm (19.00 in)

Mean Width 359.7 mm (14.16 in.) 463.5 mm (18.25 in)

Mean Height 125.6 mm (4.94 in.) 152.0 mm (6.00 in)

Approximate Weight 11.35 kg (25 lbs) 9.07 mm (20.00 in)

Model C60 Model C30


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Fuel System Installation Requirements

The following are fuel system installation requirements:

The fuel shutoff valve must be mounted with the solenoid in the vertical position,as presented on the relevant detail drawing (provided as a separate document).

Minimum service clearance access must also be provided as outlined on therelevant detail drawing.

Any optional mounting orientation may require re-orientation of the fuel shutoffvalve. This may also require a new fuel shutoff valve, mounting bracket, plusother hardware as necessary.

All components must be cooled such that the component temperatures do notexceed specified values as noted on relevant detail drawings and below.

The fuel manifold surface temperature must not exceed a value of 70C (158 F).

The gas inlet port for a Model C60 is per SAE J1926-12.

For liquid fuel systems, an external air supply is required for starting, low powerand cooldown. Refer to Air Assist Requirements for Liquid Fuel Systems in theIntegration Section.

Engine Fuel Requirem ents

Refer to the Capstone MicroTurbine Fuel Requirements Technical Reference (410002)for detail information regarding HEV fuel specifications and available fuels for eachmodel. See Appendix B for related drawings.


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Engine Cont rol Module Details (Model C60)

NOTERefer to the Electrical Ratings chart in the HEV Electrical TechnicalReference (410031) for actual starting and cooldown powerrequirements.

The Engine Control Module (ECM) is air-cooled and is the primary controller of thegenerator power and interface to the vehicles control unit. It takes the variable highfrequency AC power out of the generator, converts it to high voltage DC power, andsends it to the Battery Control Module (BCM).

During engine start-up, the generator uses power from the BCM via vehicle battery tostart the MicroTurbine. After warm-up, power is reversed and delivered to the BCM forconversion to the vehicle main DC bus voltage load. Power is reversed again to motorthe generator during cooldown, prior to shutdown, to cool components.

The ECM Assembly is shown in Figure 8 below.

Figure 8. ECM Assembly


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ECM Spec ifications

NOTEAn external 25 VDC (1V) power supply is required for ECM on systemswhere battery voltage may be less than 300 VDC.

Typical ECM details are presented in the following table. See Appendix B for relateddrawings.

ECM Details Parameter Data

Mean Length 1245 mm (49 inches)

Mean Width 381 mm (15 inches)

Mean Height 242 mm (9.5 inches)

Approximate Weight 69 kg (152 pounds)

Air Inlet Volume 118 liters/sec (250 cfm)

Air Inlet Temp -20 to 50 C (-4 to 122 F)

ECM Heat Rejection Approximately 2300 watts

ECM installation requirements are as follows:

The ECM must be mounted and oriented as presented on the relevant detaildrawing (provided as a separate document).


ECM installation requires an independent air plenum, normally to be drawn fromthe same source as the engine such as outside ambient air.

Cooling air needs to be clean and dry. Allowable inlet air temperature: -20 C to 50 C (-4 F to 122 F).

The ECM air inlet temperature must be within two degrees of the engine air inlettemperature.

The ECM must be cooled such that the component temperatures do not exceedspecified values.

Maximum static pressure drop from the air inlet to air outlet should be 0.2inches in water.


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Batt ery Cont rol Module Details (Model C60)

The Battery Control Module (BCM) (see Figure 9) is an air cooled, bi-directional DC-to-DC converter that converts the high voltage DC output of the ECM to the voltage of thevehicle main DC bus (i.e., the battery voltage). Changes in DC bus voltage areautomatically tracked and current is adjusted based on power command. The BCM is acurrent provider based on the battery voltage and power demand by the user.

Figure 9. BCM Assembly

BCM Specific ations

Typical BCM installation details are presented in the following table. See Appendix Bfor related drawings.

BCM Details Parameter Data

Mean Length 1066 mm (42 inches)

Mean Width 406.4 mm (16 inches)


Approximate Weight 68 kg (150 pounds)



BCM Heat Rejection Approximately 2300 watts

BCM installation requirements are as follows:

The BCM must be mounted and oriented as presented on the relevant detaildrawing (provided as a separate document).


BCM installation requires an independent air plenum, normally to be drawn from

the same source as the engine such as outside ambient air. Allowable inlet air temperature: -20 C to 50 C (-4 F to 122 F).

BCM air inlet temperature must be within two degrees of the engine air inlettemperature.

The BCM must be cooled such that component temperatures do not exceedspecified values. Cooling air needs to be clean and dry.

Maximum static pressure drop from air inlet to air outlet should be 0.2 inches inwater.


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DPC Cont rol ler (Model C30)

Figure 10. Model C30 HEV Digital Power Controller (DPC)

DPC Controller Details (Model C30)

NOTERefer to the Electrical Ratings chart in the HEV Electrical TechnicalReference (410030) for actual starting and cooldown powerrequirements.

The DPC (see Figure 10) is air-cooled and is the primary controller of the generatorpower and interface to the vehicles control unit. It takes the variable high frequency AC

power out of the generator, converts it to high voltage DC power, and then back to ACpower where the phases combine to form single-phase DC power to the vehicle'sbattery.

During engine start-up, the generator uses power via vehicle battery to start theMicroTurbine. After warm-up, power is reversed and delivered to the vehicles main DCbus voltage load. Power is reversed again to motor the generator during cooldown, priorto shutdown, to cool components.


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DPC Spec ific ati ons (Model C30)

NOTE An external 12 VDC (-.5/+2.5V) power supply is required.

DPC details are presented in the following table. See Appendix B for related

drawings.

DPC Details Parameter Data

Mean Length 825 mm (32.50 inches)

Mean Width 311 mm (12.25 inches)


Approximate Weight 68.5 kg (151 pounds)



Heat Rejection Approximately 2150 watts

DPC installation requirements are as follows:

The DPC must be mounted and oriented as presented on the relevant detaildrawing (provided as a separate document).


DPC installation requires an independent air plenum (do not connect to engineinlet plenum), normally to be drawn from the same source as the engine such asoutside ambient air.

Cooling air needs to be clean and dry.

Allowable inlet air temperature: -20 C to 50 C (-4 F to 122 F). DPC air inlet temperature must be within two degrees of the engine air inlet

temperature.

The DPC must be cooled such that the component temperatures do not exceedspecified values.

Maximum static pressure drop from the air inlet to air outlet should be 0.2 inchesin water.


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User Connect ion Boar d (UCB) (Model C30)

The User Connection Board (see Figure 11) is used for interfacing with auxiliarycomponents. There are terminals for connecting an emergency stop contactor, whichshould be normally closed during operation. Also, there is a terminal for a 12 VDCauxiliary power supply required for start up. The UCB is delivered inside an enclosure

for protection. It can be removed and relocated into a suitable enclosure inside thevehicle. See Appendix B for related drawings.

Figure 11. HEV User Connection Board

E-Sto+12V Gnd


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Liquid Fuel Cont rol ler (LFC) (Model C30)

For liquid fuel systems, a Liquid Fuel Controller (see Figure 12) is required to control ormonitor the liquid fuel devices such as the fuel pump speed, fuel manifold, drain valve,3-way valve, start air-assist valve, and the air-assist pressure switch. The LFC isdelivered inside an enclosure and the integrator is responsible for mounting it in a coollocation inside the vehicle (refer to LFC drawing for mounting hole locations). Easyaccess to the LFC is required for troubleshooting and replacement, if necessary. See

Appendix B for related drawings.

Figure 12. HEV Liquid Fuel Controller

Cables

Each system is delivered with the required cables to interconnect all system

components included in the MicroTurbine system. Refer to Appendix B for a list ofcables and schematics that indicate the cable number (W1XX) required for each type ofsystem. Most cables have a defined length and some have the option to purchasedifferent lengths. If a particular length is required, please contact Capstone foravailability and costs.

During the design and integration process, the integrator needs to be aware of cablerouting and its effect on the system. The MicroTurbine system has both power cablesand communication cables. Every effort should be made to keep these two types ofcables separated at least two feet apart and/or shielded in conduit to reduce highfrequency noise interference.


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Integ rating t he MicroTurbine into t he Vehicle System

The vehicle system OEM/Integrator will design and integrate the Capstone MicroTurbinecomponents into the target application in compliance with the Capstone MicroTurbinesystem interface requirements. Items to be supplied and incorporated by the

OEM/Integrator are listed, but not necessarily limited to the following items:

Enclosures for all System Components

Inlet Air filtration and Ducting to Engine

Cooling Air Filtration and Ducting to Controllers

Exhaust Ducting

Engine Heat Rejection

Fuel Delivery System to Engine Fuel System

Engine and Controller Mounting

Air Assist for Liquid Fuels (C30 Only) Electrical System Grounding

Cables, Isolation Switch, and Circuit Breakers from MicroTurbine toBattery Pack

External VDC Power Supply

Vehicle Battery Management System

Overall Safety Considerations

EnclosuresThe OEM/Integrator is required to install each of the MicroTurbine components in alocation and environment that is free from water, debris, and projectiles. A separateenclosure is recommended for the engine to shield other components from heat andnoise and provide protection for the engine from environmental elements.

Several of the components and connections in the system are not rated for water sprayor mud. Therefore, the OEM/integrator is responsible for protecting and shielding thecomponents and systems. The electronic controllers can be located together within anexisting enclosure with other components on the vehicle.

If the engine is mounted near the ground or behind the rear wheels on a vehicle, skidplates and shields should be used to eliminate the possibility of the engine and fuel

system being damaged by obstacles and flying debris such as rocks and foreign objects.


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Inlet Air Filtration and Duct ing to Engine

NOTERefer to HEV Product Specification (460009) for inlet pressure deratingspecifications.

The OEM/Integrator is responsible for providing air filtration, routing, and ducting for

the air intake to the MicroTurbine engine inlet.Air Inlet Requirements:

Air Flow: 900 Standard Cubic Feet per Minute (scfm) for Model C60.

Air Flow: 600 Standard Cubic Feet per Minute (scfm) for Model C30.

Air Filtration: 283.5 square centimeters (44.2 square inches)

Maximum Pressure Drop: 2 inches of water column at conditions other than ISO

The turbine engine uses ambient air for combustion and cooling the generator duringoperation. This air needs to be drawn from the cleanest and coolest location that ispossible on the vehicle. Locating the air inlet near the ground or directly behind thewheels of the vehicle is not recommended. The highest location above ground ispreferred. Easy access to the air filter is also preferred for removal and regularmaintenance. Care must be taken to design an inlet to avoid blockage by airborneplastic film or similar materials, and to avoid icing and water ingestion. The entire ductingmust also preclude the use of screws or other potentially loose fasteners that could beingested by engine and cause failure.

The minimum filter size and maximum length of ducting needs to be determined basedon several factors. Pressure drop from ambient conditions to the engine inlet is critical toengine performance. A maximum restriction of airflow with a dirty air filter should becalculated and should not exceed the required limit. Capstone recommends that a dirtyair filter be calculated as though one-half of its surface area is blocked.

Sizing the filter also should take into account operational conditions and maintenanceintervals. A small filter will become dirtier faster and therefore cause high-pressure dropand require cleaning or replacing in very short intervals, where as a larger filter will helpprolong the maintenance schedule. Capstone recommends using the largest filterpossible for maximum engine performance. The design of the filter attachment shouldalso address sealing around the filter. Unfiltered air is not permitted to the turbine.

Inlet air temperature also needs to be considered. The actual air inlet temperature intothe engine is measured inside the generator housing before entering the compressor.The inlet ducting should be designed to reduce the rise from ambient to actual engineinlet temperature and the maximum temperature rise should not exceed 3 C. The airinlet ducting should also take into account acoustical considerations. Refer to the

Acoustical Considerations section for more data.Capstone recommends that an air inlet plenum be designed to house the filter andaccommodate acoustical treatment, if necessary. Interfacing to the turbine can be assimple as a rubber boot to seal out unfiltered air. Figure 13 presents a typical ModelC60 installation using a flat silicone rubber boot stretched over the turbine opening. Theseal may be used for Model C30 and C60 applications and allows for some enginemisalignment, while accommodating some engine movement due to vehicle shock loadsand vibration.


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Recommended generator-to-plenum sealing is shown in Figure 13 below.

Figure 13. Generator-to-Plenum Seal (Model C60 shown)

Cooling Air Filtrat ion and Duct ing to ControllersThe OEM/Integrator is responsible for providing air filtration, routing, and ducting for thecooling air for the electronic controllers.

Cooling Air Requirements for each controller:

Air Flow: 250 Standard Cubic Feet per Minute (scfm) for Model C60 BCM

Air Flow: 250 Standard Cubic Feet per Minute (scfm) for Model C60 ECM.

Air Flow: 460 Standard Cubic Feet per Minute (scfm) for Model C30 DPC.

Air Filtration: Coarse air filter to reduce dust, moisture and foreign object debris.

Maximum Pressure Drop from Ambient: 0.5 inch of water column.

Inlet air temperature needs to be within 2 C of engine air inlet temperature.

Each controller contains power electronics, which produce up to 2300 watts and 800watts of heat at full power for the ECM and BCM respectively, and up to 2000 watts forthe DPC. Cooling airflow is required to dissipate this heat and prevent overheating ofcontrollers. The controllers include their own internal air management with fans andvents, but do not include external ducting or connections. Installation of the controllersmust consider airflow paths both into the controller fans and away from the controllervents. The design must also prevent recirculation of cooling air from exit to inlet and fromcontroller to controller.

A coarse air filter can be used to filter large particles and provide protection from water

and debris. Use caution not to insert a filter that will cause a pressure drop that exceedsrequirements. Pressure drop from ambient conditions to the controller inlet is critical tocontroller performance and overall system performance. A maximum restriction of airflowwith a dirty air filter should be calculated and should not exceed the required limit.Capstone recommends that a dirty air filter be calculated as though one-half of itssurface area is blocked. As part of a regular maintenance schedule, the filter should becleaned, and the controllers should be opened and compressed air should be used toblow any accumulation off the control boards and other components.


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Engine Exhaust Duct ing

The OEM/Integrator is responsible for providing routing and ducting for engine exhaust.

Engine Exhaust Requirements:

Maximum Steady State Exhaust Temperature: 305 C (580 F) for Model C60.

Maximum Steady State Exhaust Temperature: 275 C (530 F) for Model C30.

Nominal Total Exhaust Energy: 571,000 kJ/hr (541,000 Btu/hr) or Model C60.

Nominal Total Exhaust Energy: 322,000 kJ/hr (310,000 Btu/hr) or Model C30.

Maximum Exhaust Back Pressure: 203 mm (8 inch) of water column.

The MicroTurbine exhaust has a formed sheet metal flange that can be used with aband type clamp for easy assembly. An exhaust duct needs to be supplied by theintegrator to exhaust hot and potentially dangerous gases away from personnel. Thisduct should be located away from all flammable materials.

Care must be taken to design an exhaust duct that minimizes backpressure and does

not exceed the maximum backpressure requirement, while allowing removal for service.Backpressure in the exhaust system will cause a reduction in engine efficiency.

NOTERefer to HEV Product Specification (460009) for exhaust backpressurederating specifications.

Any exhaust system that is vented to ambient needs to be protected from rain andpotential water spray from washing the vehicle. A simple flapper cap is recommendedor the exhaust tip can be angled downward for water protection.

Generator Exhaust Air (Model C60 Only)

On the Model C60 engine, some of the engine inlet air that is used to cool the

generator is exhausted out a 2.5-inch diameter port (see Figure 14) in the center ofthe generator, which is the center of the engine inlet. This generator exhaust air canbe approximately 50 to 70 degrees hotter than the inlet air. Testing has shown thatthere can as much as 4 kW derating if this generator exhaust air is not ducted awayfrom engine air inlet. Therefore, the OEM/Integrator is responsible for ducting exhaustair away from engine inlet by using a flexible duct similar to system shown below.

Figure 14. C60 Generator Cooling Air Outlet


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Engine Heat Rejec t ion

The MicroTurbine combusts fuel to make power and therefore produces heat in theprocess. The recuperator is designed to capture this heat and preheat the compressedair before entering the combustor. Insulation is used to help keep this heat within the

recuperator. The surface temperature of this insulation can range from 163 to 288C(325 to 550 F) depending on location. Maximum heat rejection is up to approximately2000 watts.

The OEM/Integrator is not required to remove this heat for system operation but it isrecommended that care be taken to not allow this heat to come in contact withcombustible materials. In addition, this heat should not be allowed to heat the generatorhousing or fuel components beyond their maximum specification during operation. Fansor vents can be used to draw the heat out of an enclosure. It is not recommended toblow cool air onto the hot components since this may cause reduced efficiency or coulddirect hot air onto other components.

It is recommended to install a heat shield between the generator housing and the

recuperator if the engine will be installed in an enclosure. The heat shield can be sheetmetal with insulation attached. This shield will keep the engine divided into a hotcompartment side and a cool compartment side. The recuperator side of the engineshould be kept hot and the generator side should be kept as cool as possible. This helpskeep the generator housing form heating up, thus heating the engine inlet air, andcausing a derating due to elevated inlet temperatures. Figure 15 shows the typicallayout inside an enclosure with a heat shield installed to split the compartment into hotand cold sections.

Figure 15. Typical Layout of Engine with Heat Shield


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Fuel Delivery System to Engine Fuel System

NOTERefer to the Fuel Requirements Technical Reference (410002) for detailedfuel requirements and additional information for both C30 and C60 systems.

The OEM/Integrator is responsible for providing a fuel delivery system from the fuel tankto the engine fuel system.

The MicroTurbine fuel system is basically a metering device and a distribution system forthe injectors. It is the OEM/integrators responsibility to provide the fuel at the requiredpressure and temperature. For gaseous fuels, the delivery system should consist of, butis not limited to, a fuel filter, coalescing filter (6 micron @95% of particles), regulator, anda shut off valve. The shut off valve should be as close to the MicroTurbine as possible.For liquid fuels, the delivery system should consist of, but be limited to, a boost pump,fuel filter (10 microns@45 of particles), and a shutoff value.

For gaseous fuels, it is critical that only vapor be delivered to the MicroTurbine fuelsystem. The presence of liquid fuel particles in a gaseous fuel will damage theMicroTurbine. A gasification system with a heater will be required for operation withcompressed liquid fuels. Particular care must be taken to ensure that fuel in lines aftershutdown is conditioned before next start up. Trapped fuel can change phasesovernight and cause liquids to form in lines.

Air Assist Requirement s for Liquid Fuel Systems

NOTERefer to the HEV Liquid Fuel Technical Reference (410029) for detailedand updated information.

For liquid fuel systems, an external air supply is required for system start-up, low power(idle) and shutdown. This air supply assists the fuel system to atomize the fuel in thecombustion chamber. The required air can be supplied from a separate system or froman onboard air system. And in either case, a 10-micron (or less) filter and a coalescingfilter/separator should be installed before the turbine system. The air needs to be clean,dry and free of any oils.

The following are liquid fuel system air-assist requirements (for reference only):

Start/Cooling mode 80 slpm @ 427.8 kPa (62 psig) for approx. 1.5 minutes

Idle Mode ( 6 kW) 60 slpm @ 427.8 kPa (62 psig) for duration of idle


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Mechanical Interface Paramet ers

The MicroTurbine will require typical mounting requirements as noted in the paragraphsthat follow.

Accelerat ion

Maximum allowable operating accel

480009 HEV Application Guide[1]

Documents

Transcript of 480009 HEV Application Guide[1]