CapstoneCapstone Turbine Corporation • 21211 Nordhoff Street • Chatsworth • CA 91311 • USA Telephone: (818) 734-5300 • Facsimile: (818) 734-5320 • Website: www.microturbine.com Application Guide Model C30 and C60 HEV Application Information This document presents application information for the Capstone Model C30 and C60 Hybrid Electric Vehicle (HEV) MicroTurbine systems. Figure 1. Model C60 HEV MicroTurbine 480009-001 Rev B (October 2004) Page 1 of 54 This 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. Capstone Turbine Corporation • 21211 Nordhoff Street • Chatsworth • CA 91311 • USA Application Guide: C30 and C60 Hybrid Electric Vehicle (HEV) Application Information for Capstone How to Contact Capstone For additional information or if specific questions arise, contact the HEV Application Manager at: Capstone Turbine Corporation 21211 Nordhoff Street Chatsworth, California 91311, USA Telephone: (818) 734-5300 Facsimile: (818) 734-5320 Website: http://www.microturbine.com/ Capstone Technical Support Toll Free Telephone: (877) 282-8966 Telephone: (818) 407-3600 Facsimile: (818) 734-1080 E-Mail:
[email protected] Capstone Technical Support (Japan) Telephone: (818) 407-3700 Facsimile: (818) 734-1080 E-mail:
[email protected] If you are an Authorized Service Provider (ASP), the Capstone Member’s Only Website (http://www.capstoneturbine.com/login.asp) may provide solutions to some of your questions. This 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. 480009-001 Rev B (October 2004) Page 2 of 54 This 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. Capstone Turbine Corporation • 21211 Nordhoff Street • Chatsworth • CA 91311 • USA Application Guide: C30 and C60 Hybrid Electric Vehicle (HEV) Application Information for Capstone TABLE OF CONTENTS How to Contact Capstone ............................................................................................................. 2 About this Document..................................................................................................................... 6 Safety Information.......................................................................................................................... 6 Introduction..................................................................................................................................... 6 Symbols........................................................................................................................................... 6 General Precautions ...................................................................................................................... 7 Electrical Precautions ................................................................................................................... 8 Fuel Precautions ........................................................................................................................... 8 Exhaust Precautions..................................................................................................................... 9 Acoustic Emissions Precautions .................................................................................................. 9 Document Overview..................................................................................................................... 10 MicroTurbine Introduction .......................................................................................................... 10 Key Mechanical Components..................................................................................................... 11 Main Features ............................................................................................................................. 11 MicroTurbine Basic Operation ................................................................................................... 12 MicroTurbine System Components........................................................................................... 13 MicroTurbine Engine................................................................................................................... 13 Air Bearings................................................................................................................................. 13 Fuel System ................................................................................................................................ 14 Controllers ................................................................................................................................... 14 System Performance Information.............................................................................................. 15 Performance Ratings at Full Load Power .................................................................................. 15 Performance Derating Factors ................................................................................................... 15 Electrical Ratings ........................................................................................................................ 16 Environmental Limitations........................................................................................................... 16 System Components ................................................................................................................... 17 Engine Details ............................................................................................................................. 17 Model Engine Specifications (Full Power and ISO Conditions) ................................................ 17 Engine Installation Requirements............................................................................................... 18 Fuel System Details .................................................................................................................... 19 Fuel System Specifications......................................................................................................... 19 Fuel System Installation Requirements...................................................................................... 20 Engine Fuel Requirements ......................................................................................................... 20 Engine Control Module Details (Model C60) ............................................................................. 21 ECM Specifications..................................................................................................................... 22 Battery Control Module Details (Model C60) ............................................................................. 23 BCM Specifications..................................................................................................................... 23 DPC Controller (Model C30)....................................................................................................... 24 DPC Controller Details (Model C30)...................................................................................................24 DPC Specifications (Model C30).........................................................................................................25 User Connection Board (UCB) (Model C30) ............................................................................. 26 Liquid Fuel Controller (LFC) (Model C30).................................................................................. 27 Cables ............................................................................................................................................ 27 480009-001 Rev B (October 2004) Page 3 of 54 This 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. Capstone Turbine Corporation • 21211 Nordhoff Street • Chatsworth • CA 91311 • USA Application Guide: C30 and C60 Hybrid Electric Vehicle (HEV) Application Information for Capstone TABLE OF CONTENTS (CONT’D) Integrating the MicroTurbine into the Vehicle System ........................................................... 28 Enclosures................................................................................................................................... 28 Inlet Air Filtration and Ducting to Engine .................................................................................... 29 Cooling Air Filtration and Ducting to Controllers ........................................................................ 30 Engine Exhaust Ducting ............................................................................................................. 31 Generator Exhaust Air (Model C60 Only) .................................................................................. 31 Engine Heat Rejection ................................................................................................................ 32 Fuel Delivery System to Engine Fuel System............................................................................ 33 Air Assist Requirements for Liquid Fuel Systems...................................................................... 33 Mechanical Interface Parameters............................................................................................... 34 Acceleration...........................................................................................................................................34 Orientation .............................................................................................................................................34 Vibration.................................................................................................................................................34 Component Locations..........................................................................................................................34 Acoustical Parameters................................................................................................................ 35 Turbulence Noise..................................................................................................................................35 Blade Interaction Noise ........................................................................................................................35 Electro-Mechanical Noise ....................................................................................................................35 Combustion Noise ................................................................................................................................36 Sound Pressure....................................................................................................................................36 Sound Power ........................................................................................................................................36 A-Weighted Sound Level.....................................................................................................................36 Sound Spectrums ....................................................................................................................... 36 Noise Attenuation Methods ........................................................................................................ 37 Tuned Cavity.........................................................................................................................................37 Extruded Metal......................................................................................................................................37 Bulk Attenuator......................................................................................................................................37 Electrical System Grounding...................................................................................................... 38 Cables from MicroTurbine to Battery Pack ................................................................................ 39 External Power Supply ............................................................................................................... 39 Vehicle Battery Management System........................................................................................ 39 Safety-related Design Considerations ...................................................................................... 40 High Temperatures ..................................................................................................................... 40 High Voltages.............................................................................................................................. 40 Flammable Fuels ........................................................................................................................ 40 Emergency Stop (E-Stop)........................................................................................................... 41 Equipment Access ...................................................................................................................... 41 Fuel Leak Detectors.................................................................................................................... 41 Fire Suppression Detectors ........................................................................................................ 41 Warning Labels ........................................................................................................................... 41 Communication Requirements .................................................................................................. 42 System Configuration.................................................................................................................. 45 Baud Rate ................................................................................................................................... 45 Protective Relays ........................................................................................................................ 45 Fuel Indices ................................................................................................................................. 45 480009-001 Rev B (October 2004) Page 4 of 54 This 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. Capstone Turbine Corporation • 21211 Nordhoff Street • Chatsworth • CA 91311 • USA Application Guide: C30 and C60 Hybrid Electric Vehicle (HEV) Application Information for Capstone TABLE OF CONTENTS (CONT’D) System Design Guidelines and Processes .............................................................................. 46 Step 1 – Application .................................................................................................................... 46 Step 2 – Product Design............................................................................................................. 47 MicroTurbine Module Mounting...........................................................................................................47 MicroTurbine Inlet .................................................................................................................................47 MicroTurbine Exhaust ..........................................................................................................................48 Electrical Ventilation..............................................................................................................................48 Electrical Connections..........................................................................................................................48 Fuel System ..........................................................................................................................................49 Control System .....................................................................................................................................49 Step 3 – Prototype Inspection .................................................................................................... 49 Step 4 – Design/Installation Approval ........................................................................................ 49 Production System Installation ................................................................................................... 50 Capstone Remote Monitoring Software.................................................................................... 52 Maintenance Items ....................................................................................................................... 52 ASP Training ................................................................................................................................. 53 Warranty Information................................................................................................................... 53 Related Documents...................................................................................................................... 53 NOTES ........................................................................................................................................ 54 Appendix A – Available Accessories for HEV Systems ....................................................... A-1 Appendix B - Drawings and Diagrams ................................................................................... B-1 480009-001 Rev B (October 2004) Page 5 of 54 This 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. Users who have not received certification of satisfactory completion of this training should not attempt any procedures other than those specifically described in this document. Introduction The Capstone MicroTurbine is an advanced power generation system with user and material safety foremost in mind. or used for any purposes other than the specific purpose for which this document was delivered. . 480009-001 Rev A (June 2004) Page 6 of 54 This information is proprietary to Capstone Turbine Corporation. Failure to obey all safety precautions and general instructions may cause personal injury and/or damage to the equipment. and repair of the MicroTurbine. Notes provide additional information relating to a specific operation or task. Cautions. and/or the contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction. electrical systems. Neither this document nor the information contained herein shall be copied.Capstone Turbine Corporation • 21211 Nordhoff Street • Chatsworth • CA 91311 • USA Application Guide: C30 and C60 Hybrid Electric Vehicle (HEV) Application Information for Capstone About this Document This document provides user instructions to operate and maintain the Capstone Turbine Corporation MicroTurbine. the product specifications. Capstone Authorized Service Providers (ASPs) have received rigorous training and have been certified to perform commissioning. The user must read and understand this manual before operation of the equipment. and engine control software. Capstone reserves the right to change or modify without notice. WARNING A Warning means that personal injury or death is possible. troubleshooting. NOTE A Note is used to clarify instructions or highlight information that might be overlooked. Fail-safe operation includes mechanical systems. Safety Information This section presents safety information for the user of Capstone Turbine Corporation MicroTurbines. and Notes. This document is intended for user personnel who may not have specific training on the MicroTurbine. CAUTION A Caution means that damage to the equipment is possible. Warnings and Cautions alert you to situations and procedures that can be dangerous to people and/or cause equipment damage. Symbols There are three very important symbols used in this document: Warnings. It is the User’s responsibility to read and obey all safety procedures and to become familiar with these procedures and how to safely operate this equipment. the design. disclosed to others. Only Capstone Authorized Service Providers are permitted access to the inside of the component enclosures. Be careful when you move or lift the MicroTurbine.Capstone Turbine Corporation • 21211 Nordhoff Street • Chatsworth • CA 91311 • USA Application Guide: C30 and C60 Hybrid Electric Vehicle (HEV) Application Information for Capstone General Precautions The following general precautions must be observed and followed at all times. and national codes and regulations. and/or the contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction. ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ 480009-001 Rev B (October 2004) Page 7 of 54 This information is proprietary to Capstone Turbine Corporation. Make sure all fasteners are installed and properly tightened. but it is important to be aware of them. Obey all applicable local. Do not operate or work on the equipment if mentally or physically impaired. free from leaks. Use hearing protection when you work on or near a MicroTurbine in operation. disclosed to others. Keep all flammable materials away from the MicroTurbine and its components. Keep an ABC rated fire extinguisher near the MicroTurbine. clean. or after consumption of alcohol or drugs. dry. Failure to do so may result in personal injury and/or equipment damage. Capstone reserves the right to change or modify without notice. Neither this document nor the information contained herein shall be copied. state. the design. NOTE ♦ Some of the following precautions do not directly apply to users. and protected from damage. Make sure all electrical connections are tight. or used for any purposes other than the specific purpose for which this document was delivered. the product specifications. The MicroTurbine is heavy. Make sure all fuel connections are tight. . Keep the equipment clean. Read and obey all warnings and cautions. Read and understand the User's Manual before operating the equipment. and protected from weather and damage. The MicroTurbine system can include multiple sources of power. pilot lights. and all other sources of ignition away from areas where fuel and fumes are present. If you smell fuel fumes. WARNING MicroTurbine fuel is flammable and explosive. High voltage can kill or injure. Command the MicroTurbine system to OFF. Fuel lines must also be separated or shielded from electrical wiring. . Injury to personnel and/or damage to equipment can occur.Capstone Turbine Corporation • 21211 Nordhoff Street • Chatsworth • CA 91311 • USA Application Guide: C30 and C60 Hybrid Electric Vehicle (HEV) Application Information for Capstone Electrical Precautions The output voltage and residual capacitor voltage of this equipment is dangerous. Concentrations of Hydrogen Sulfide (H2S) can be found in Sour Natural Gas and Sour High Btu Gas. Capstone reserves the right to change or modify without notice. Only Capstone Authorized Service Providers are permitted access to the inside of the component enclosures. Obey all safety procedures when you work around electrical equipment. The MicroTurbine system contains and produces high voltage. Wait five (5) minutes for any capacitive stored voltage to dissipate. and locate and repair the source of the leak or call a qualified professional. Use caution when you work on electrical equipment. Turn off the system and lockout the power supply prior to all work on the equipment. immediately stop operation of the equipment. but it is important to be aware of them. sparks. disclosed to others. use a multi-purpose dry chemical or CO2 fire extinguisher. This will help prevent injury and damage to the equipment. equipment that produces electrical arcs. close the fuel isolation valve. switches or tools. the design. Open the battery isolation switch and unplug the battery cable. Always disconnect all power sources. Keep flames. No open flame or smoking is allowed near the MicroTurbine. Use a voltmeter to make sure that all circuits are de-energized. Neither this document nor the information contained herein shall be copied. Fuel lines must be secure and free of leaks. ♦ ♦ ♦ ♦ ♦ WARNING WARNING Fuel Precautions The Capstone MicroTurbine operates on approved liquid or gaseous fuels. NOTE ♦ Some of the following precautions do not directly apply to users. An explosion can cause death or injury to personnel and/or damage to equipment. WARNING 480009-001 Rev B (October 2004) Page 8 of 54 This information is proprietary to Capstone Turbine Corporation. If there is a fire. Liquid and gaseous fuels can be corrosive. Minimize exposure to liquid or gaseous fuels and provide satisfactory fresh airflow when you are around equipment. High voltage can injure or kill. Make sure the system is off and the dedicated disconnect switch is in the open position and is locked. and/or the contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction. the product specifications. or used for any purposes other than the specific purpose for which this document was delivered. WARNING The MicroTurbine exhaust contains nitrogen dioxide and carbon monoxide. Like all fossil fuel combustion technology. when working at a radius of 10 meters (or 33 feet) from an enclosed Capstone MicroTurbine. equipment. Capstone recommends that hearing protection be worn when working on or in the immediate vicinity of operating MicroTurbines for extended periods. with very low levels of air pollutants. The exhaust is clean and oxygen rich (approximately 18% O2). Always vent exhaust away from personnel. Keep people. Make sure there is satisfactory fresh airflow when you work around the equipment. However. Neither this document nor the information contained herein shall be copied. Always check to be certain that your installation complies with all codes required by the local jurisdiction. make sure precautions are taken to prevent personnel from being exposed to nitrogen dioxide and carbon monoxide while the system is operating. Capstone reserves the right to change or modify without notice. which are poisonous at high concentrations. the MicroTurbine can produce dangerous emissions (like nitrogen dioxide and carbon monoxide) from the fuel combustion process. the product specifications. The exhaust airflow can reach temperatures as high as 371 °C (700 °F). the design. Nitrogen dioxide and carbon monoxide are poisonous at high concentrations. disclosed to others. Personal injury and/or damage to equipment are possible. sound level exposure will average approximately 70 dBA. or used for any purposes other than the specific purpose for which this document was delivered. Hot surfaces and hot exhaust can be dangerous. WARNING WARNING Acoustic Emissions Precautions The Capstone MicroTurbine is designed to produce safe acoustic emissions when properly installed in an acoustically treated enclosure. and/or the contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction. and carbon monoxide (CO) emission levels. and other items away from the exhaust airflow and pipes. Be careful when you work on equipment. 480009-001 Rev B (October 2004) Page 9 of 54 This information is proprietary to Capstone Turbine Corporation.Capstone Turbine Corporation • 21211 Nordhoff Street • Chatsworth • CA 91311 • USA Application Guide: C30 and C60 Hybrid Electric Vehicle (HEV) Application Information for Capstone Exhaust Precautions The Capstone MicroTurbine is designed to produce very safe emissions. Other acoustic emissions regulations may apply to your specific installation location. . Although the MicroTurbine has ultra low nitrogen dioxide (NO2). The exhaust airflow and pipes are hot enough to cause personal injury or fire. depending on system configuration. which comprises the only moving part in the engine. The MicroTurbine(s) can generate power in series with an on-board battery pack or other DC power supply. operate. The compressor impeller. depending on system configuration. and delivers the fuel to the engine from a fuel source and supports gaseous as well as liquid fuels. and low maintenance power generation system that can be used for generating DC voltage in applications such as Hybrid Electric Vehicles (HEV). a combustor. and a generator. 480009-001 Rev B (October 2004) Page 10 of 54 This information is proprietary to Capstone Turbine Corporation. Power electronics are solid-state. low-emission. Neither this document nor the information contained herein shall be copied. and maintain the Capstone MicroTurbine in a Customer defined application. regulates.Capstone Turbine Corporation • 21211 Nordhoff Street • Chatsworth • CA 91311 • USA Application Guide: C30 and C60 Hybrid Electric Vehicle (HEV) Application Information for Capstone Document Overview Capstone offers a 30 kilowatt system (Model C30) and a 60 kilowatt (Model C60) for direct current voltage output for hybrid vehicle applications. The MicroTurbine turbine engine is air-cooled and does not require any lubricants. The MicroTurbine produces dry. a turbine. oxygen-rich exhaust with ultra-low emissions. and/or the contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction. The turbine engine includes a compressor. solid-state power electronics. the product specifications. Capstone reserves the right to change or modify without notice. Utilizing both the generated electric power and the exhaust heat can provide even greater energy cost savings. The system consists of a turbine engine. and is supported on air-lubricated compliant foil bearings. disclosed to others. The fuel system monitors. a recuperator (exhaust gas heat exchanger). This document provides the data necessary for the user to integrate. producing direct current (DC) output power from the high-frequency alternating current engine output. . the design. turbine rotor. The MicroTurbine can efficiently use a wide range of approved hydrocarbon-based gaseous and liquid fuels. double conversion type. and a fuel system. or used for any purposes other than the specific purpose for which this document was delivered. and generator rotor are mounted on a single shaft. MicroTurbine Introduction The Capstone MicroTurbine is an adaptable. Center shaft is the only moving part. Near zero emissions. monitoring. and provides ultra-low emissions. and/or the contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction. . or turbine-driven accessories are used. Compact size and weight. belts. Air-cooled design of the entire system (turbine and controller) eliminates the need for liquid coolants or lubricants. both on-board and remotely (via an RS-232 link). Neither this document nor the information contained herein shall be copied. Minimum maintenance. 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 functions provides direct current (DC) output. Patented air bearings eliminate the need for oil or other lubricants. and diagnostic capabilities. disclosed to others.Capstone Turbine Corporation • 21211 Nordhoff Street • Chatsworth • CA 91311 • USA Application Guide: C30 and C60 Hybrid Electric Vehicle (HEV) Application Information for Capstone Key Mechanical Components The key mechanical components that comprise the Capstone MicroTurbine are shown below in Figure 2. 480009-001 Rev B (October 2004) Page 11 of 54 This information is proprietary to Capstone Turbine Corporation. the design. Capstone reserves the right to change or modify without notice. the product specifications. Advanced combustion control eliminates the need for ceramics or other costly materials or any catalytic combustion. Digital control technology facilitates advanced control. No gears. or used for any purposes other than the specific purpose for which this document was delivered. providing rotational power to drive compressor impeller and generator. Neither this document nor the information contained herein shall be copied.Capstone Turbine Corporation • 21211 Nordhoff Street • Chatsworth • CA 91311 • USA Application Guide: C30 and C60 Hybrid Electric Vehicle (HEV) Application Information for Capstone MicroTurbine Basic Operation Ambient air is drawn into turbine engine through an air filter (customer supplied). and used for the combustion process. Generator Cooling Fins Exhaust Outlet Recuperator Combustion Chamber Electrical Output Communications and Control User Interface Air Bearings Generator Compressor Turbine Figure 3. Capstone reserves the right to change or modify without notice. disclosed to others. provides air to the air bearings. the product specifications. . The air is compressed by the compressor impeller and passes through the recuperator where its temperature is elevated by the exhaust gases expelled from the turbine. Air Flow in MicroTurbine 480009-001 Rev B (October 2004) Page 12 of 54 This information is proprietary to Capstone Turbine Corporation. The heated compressed air is mixed with fuel and burned in the combustion chamber. See Figure 3 for a system air flow diagram. This process increases the overall efficiency. The combusted hot gases expand through the turbine. the design. This air is used to cool the generator. or used for any purposes other than the specific purpose for which this document was delivered. Patented techniques in the combustion process result in an extremely low emission exhaust stream. and/or the contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction. and/or the contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction. Air Bearings The MicroTurbine utilizes gas foil bearings (air bearings) for high-reliability. into the vehicle's main electrical bus. Starting and control power are sourced directly from the high voltage DC bus of the vehicle. a gas film separates the shaft from the bearings and protects it from wear. Neither this document nor the information contained herein shall be copied. turbine. Figure 4 shows the basic series hybrid configuration. For vehicles with nominal battery voltage less than 200 volts DC (Model C30). the design. . Capstone reserves the right to change or modify without notice. the product specifications. This allows fewer parts and the absence of any liquid lubrication to support the rotating group. 480009-001 Rev B (October 2004) Page 13 of 54 This information is proprietary to Capstone Turbine Corporation. Basic Series Hybrid Configuration MicroTurbine System Components MicroTurbine Engine The MicroTurbine engine is a combustion turbine that includes a compressor. variable frequency AC. an external 12-volt (Model C30) or 25-volt (Model C60) battery supply is required to start the system. generator. When the MicroTurbine is in operation. The permanent magnet generator is cooled by the airflow into the MicroTurbine. or used for any purposes other than the specific purpose for which this document was delivered. 300 volts DC (Model C60). disclosed to others. The unit accepts commands from a Vehicle Management System (via a RS-232 connection) and outputs the commanded power. low maintenance. Power electronics convert this to programmable DC power for HEV applications. combustor. The generator is used as a motor during start-up and cooldown cycles.Capstone Turbine Corporation • 21211 Nordhoff Street • Chatsworth • CA 91311 • USA Application Guide: C30 and C60 Hybrid Electric Vehicle (HEV) Application Information for Capstone The output of the generator is variable voltage. The output of the generator is variable voltage. variable frequency AC power. Electrical power output is Direct Current (DC). and a recuperator. and safe operation. Figure 4. The purpose of the Capstone MicroTurbine HEV system is to generate DC power in series with the HEV battery. The rotating components are mounted on a single shaft supported by patented air bearings and spin at up to 96.000 RPM. The digital power electronics control the MicroTurbine system operation and all subsystem operations. The digital power electronics changes the variable frequency AC power from the generator to DC voltage. disclosed to others. Contact Capstone for data on approved fuels and performance specifications. Neither this document nor the information contained herein shall be copied. Engine Control Module (ECM) and Battery Control Module (BCM). the design. the digital power electronics operate as a variable frequency drive. Controllers The Model C30 HEV system has a single digital power electronics controller called the Digital Power Controller (DPC). The Model C60 HEV System consists of two digital power electronics controllers. Other C30 models are available for gaseous fuels with lower heat content and liquid fuels. Figure 5.Capstone Turbine Corporation • 21211 Nordhoff Street • Chatsworth • CA 91311 • USA Application Guide: C30 and C60 Hybrid Electric Vehicle (HEV) Application Information for Capstone Fuel System The MicroTurbine includes an integral fuel delivery and control system. The digital power electronics again operate as a drive during cooldown to remove heat stored in the recuperator and within the MicroTurbine engine in order to protect the system components. Figure 5 shows a typical system schematic. 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 reserves the right to change or modify without notice. and then to constant DC output to synchronize to the battery pack. System Schematic 480009-001 Rev B (October 2004) Page 14 of 54 This information is proprietary to Capstone Turbine Corporation. The standard C30 and C60 systems are designed for pressurized hydrocarbon-based gaseous fuels. or used for any purposes other than the specific purpose for which this document was delivered. During start up. . and motors the generator until the MicroTurbine has reached ignition and power is available from the MicroTurbine. the product specifications. 0 (± 2) Liquid: 26. The control modules source power from the vehicle's main DC bus.0 (± 2) % <9 ppm V @ 15% O2 Model C30 (NG or Liquid) HPNG: 30. Neither this document nor the information contained herein shall be copied. the design.continuous) 28. the product specifications. the MicroTurbine performance may be reduced due to any combination of the following. .0 (± 2) % HPNG <9 ppm V @ 15% O2 Performance Derating Factors NOTE Refer to the Model C30 (410004) and Model C60 (410005) Performance Technical Reference for additional updated performance derating data. the system enters a warm-up period. Once self-sustaining combustion is achieved. Performance Ratings at Full Load Power NOTE Refer to the Model C30 (410004) and Model C60 (410005) Performance Technical Reference for updated performance ratings. or used for any purposes other than the specific purpose for which this document was delivered.Capstone Turbine Corporation • 21211 Nordhoff Street • Chatsworth • CA 91311 • USA Application Guide: C30 and C60 Hybrid Electric Vehicle (HEV) Application Information for Capstone System Performance Information NOTE Refer to HEV MicroTurbine Product Specification 460009 for performance derating metric data. Altitude (ambient pressure) Inlet pressure loss Exhaust back pressure 480009-001 Rev B (October 2004) Page 15 of 54 This information is proprietary to Capstone Turbine Corporation. at sea level altitude. disclosed to others.0 (+0/-1) kW maximum Liquid: 29 ± 1 KW minimum 150 to 700 volts DC 128 Amps (max. This DC power is then converted into high frequency AC current. 60% relative humidity. • • • • Temperature (defined as the actual temperature of the air measured at the compressor inlet). which is used to motor the MicroTurbine engine prior to combustion. and/or the contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction. continuous) HPNG: 25. When operating at any other condition other than ISO conditions. ISO conditions are defined as: 15 °C (59 °F). Capstone reserves the right to change or modify without notice. As the warm-up is completed. Performance Rating Net Output Power Output Voltage Range Output Current Thermal Efficiency Emissions (NOx) Model C60 60. the MicroTurbine system will source power to the vehicle's main DC bus.0 (+0/-2) kW maximum 200 to 700 volts DC 300 Amps (max. The following reference performance ratings are listed at full load power and ISO conditions. disclosed to others.8 kW peak.0 kW peak.014 kW-Hr. or used for any purposes other than the specific purpose for which this document was delivered.000 feet above sea level 0 to 100%. maximum ± 3 kW/second. 42 sec 2. max. 30 Seconds 2. The MicroTurbine system will normally operate within a varied range of parameters. Range Output Voltage Connection Output Power Output Power Ramp Rate Model C60 200 to 700 VDC 2 Wire + Ground 0 to 60 kW HPNG ± 2 kW/second.05 or higher 125 Amps DC.014 kW-Hr.5 kW Output Current Power Required @ Start Command (per MT) @Cooldown Power (per MT) Standby Power Environmental Limitations NOTE Refer to the HEV Product Specification (460009) and the Model C30 (410004) and Model C60 (410005) Performance Technical Reference for additional updated information. 0. steady state 6.147 kW-Hr.3 kW-Hr.8 kW Model C30 150 to 700 VDC 2 Wire + Ground 0 to 30 kW HPNG ± 1 kW/second. Capstone reserves the right to change or modify without notice. typical 0.Capstone Turbine Corporation • 21211 Nordhoff Street • Chatsworth • CA 91311 • USA Application Guide: C30 and C60 Hybrid Electric Vehicle (HEV) Application Information for Capstone Electrical Ratings NOTE Refer to Model C30 (410030) and Model C60 (410031) HEV Electrical Technical Reference manuals for more detail and updated information. and/or the contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction. maximum 300 Amps DC. . max.8 kW peak. The following table presents the Electrical Ratings for reference only: Description Battery Voltage Oper. steady state 3. Neither this document nor the information contained herein shall be copied. Condensing -20 °C to +50 °C (-40 °F to +122° F) -20 °C to +50 °C (-4 °F to +122° F) -40 °C to +65 °C (-40 °F to +149° F) 480009-001 Rev B (October 2004) Page 16 of 54 This information is proprietary to Capstone Turbine Corporation. 90 sec 0. 5 minutes. including the following environmental conditions: Parameter Operating Altitude Relative Humidity Engine/Electronics Air Temperature Ambient Operating Temperature Storage/Shipping Temperature Limitation -1000 to +11. 0. 0. 0. the product specifications. maximum w/software version 2. the design.5 kW peak. Engine Specification Mean Length Mean Width Mean Height Approximate Weight Air Inlet Volume Air Inlet Temp Exhaust Gas Temp Average Fuel Consumption (Flow) Engine Heat Rejection Engine Exhaust Output Minimum Inlet Air Filtration 480009-001 Rev B (October 2004) Model C60 884 mm (34.5 inch) 729 mm (28.000 Btu/hr) Approximately 1500 watts 327. Four mounting holes are provided on the underside of the frame for mounting to vehicle. Capstone reserves the right to change or modify without notice. disclosed to others. Refer to HEV MicroTurbine Product Specification 460009 for performance details.9 inch) 572 mm (22.8 inch) 666 mm (26. or used for any purposes other than the specific purpose for which this document was delivered. recuperator. and generator. updated information and related drawings (see Appendix B). Engine Details Model Engine Specifications (Full Power and ISO Conditions) Typical engine installation specifications are presented in the following table for reference only.000 kJ/Hr (811. combustor. The engine includes the compressor. Model C60 Model C30 Figure 6. The assembly is mounted on a frame along with the fuel system that is described in the next section.000 kJ/hr <10 microns particulate filter Model C30 836 mm (32.7 inch) 91 kg (200 pounds) 283 liters/sec (600 cfm) -20 to 50° C (-4 to 122 °F) 275 °C (530 °F) 457.9 inch) 135 kg (300 pounds) 425 liters/sec (900 cfm) -20 to 50° C (-4 to 122 °F) 305 °C (580 °F) 855. .000 kJ/Hr (433. Neither this document nor the information contained herein shall be copied. the design. and/or the contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction. the product specifications.000 Btu/hr) Approximately 2000 watts 571.Capstone Turbine Corporation • 21211 Nordhoff Street • Chatsworth • CA 91311 • USA Application Guide: C30 and C60 Hybrid Electric Vehicle (HEV) Application Information for Capstone System Components Engine Details The engine assembly is delivered complete as shown in Figure 6. turbine.2 inch) 759 mm (29.000 kJ/hr <25 microns particulate filter Page 17 of 54 This information is proprietary to Capstone Turbine Corporation. or used for any purposes other than the specific purpose for which this document was delivered. the generator cooling air must be ducted away from engine air inlet via 2.5-inch diameter hose. igniter.Capstone Turbine Corporation • 21211 Nordhoff Street • Chatsworth • CA 91311 • USA Application Guide: C30 and C60 Hybrid Electric Vehicle (HEV) Application Information for Capstone Engine Installation Requirements The following are engine installation requirements: ♦ The engine must be mounted and oriented as outlined on the relevant detail drawing (provided as a separate document). and thermocouple. normally to be drawn from the same source as the power electronics. The generator housing ambient temperature must not exceed 93°C (200 °F). ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ 480009-001 Rev B (October 2004) Page 18 of 54 This information is proprietary to Capstone Turbine Corporation. 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. for removal of maintenance items such as injectors. Engine installation requires an independent air plenum. The engine dump valve exhausts air at 227 °C (441°F) in bursts during MicroTurbine deceleration in a fault condition. Minimum service clearance access must be provided as detailed on the relevant detail drawing. Neither this document nor the information contained herein shall be copied. Capstone reserves the right to change or modify without notice. as noted on relevant detail drawings and below. The personality module (PM) and ambient climate module (ACM) surface temperature must not exceed a value of 65 °C (149 °F). disclosed to others. The engine must be cooled such that the component temperatures do not exceed specified values. The dump valve surface temperature must not exceed a value of 70° C (158 °F). Refer to Engine Detail drawing for location of the vent near the center of generator. the design. . For Model C60 only. The engine air inlet temperature must be within two degrees of the electronics control module(s) cooling air inlet temperature. The fuel manifold surface temperature must not exceed a value of 70° C (158 °F). the fuel system incorporates a Smart Proportional Valve (SPV25). the product specifications.) 359. disclosed to others. injectors. fuel lines. For gaseous fuels.00 in) 480009-001 Rev B (October 2004) Page 19 of 54 This information is proprietary to Capstone Turbine Corporation. the design.Capstone Turbine Corporation • 21211 Nordhoff Street • Chatsworth • CA 91311 • USA Application Guide: C30 and C60 Hybrid Electric Vehicle (HEV) Application Information for Capstone Fuel System Details The fuel system is delivered complete and is part of the engine assembly as described and shown in the Engine detail section.16 in. and fuel injectors. See Figure 7 for fuel system packages.24 in. Capstone reserves the right to change or modify without notice. pressure transducer.0 mm (6. the fuel system incorporates a fuel pump. and/or the contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction. fuel manifold. See Appendix B for related drawings.6 mm (19.35 kg (25 lbs) Model C30 482. fuel manifold. Fuel System Specification Mean Length Mean Width Mean Height Approximate Weight Model C60 514. fuel shutoff valve. regulator and air lines.) 125.25 in) 152. air-assist manifold.07 mm (20. fuel filter. or used for any purposes other than the specific purpose for which this document was delivered.00 in) 9. Fuel System Package Fuel System Specifications Typical fuel system specifications are presented in the following table for reference only. fuel lines. For liquid fuels.) 11. valves.00 in) 463.1 mm (20. Neither this document nor the information contained herein shall be copied.6 mm (4. .94 in.5 mm (18. Model C60 Model C30 Figure 7.7 mm (14. The fuel manifold surface temperature must not exceed a value of 70°C (158 °F). The gas inlet port for a Model C60 is per SAE J1926-12. This may also require a new fuel shutoff valve. low power and cooldown. Any optional mounting orientation may require re-orientation of the fuel shutoff valve. Capstone reserves the right to change or modify without notice. ♦ ♦ ♦ ♦ Engine Fuel Requirements Refer to the Capstone MicroTurbine Fuel Requirements Technical Reference (410002) for detail information regarding HEV fuel specifications and available fuels for each model. Minimum service clearance access must also be provided as outlined on the relevant detail drawing. 480009-001 Rev B (October 2004) Page 20 of 54 This information is proprietary to Capstone Turbine Corporation. For liquid fuel systems. All components must be cooled such that the component temperatures do not exceed specified values as noted on relevant detail drawings and below. as presented on the relevant detail drawing (provided as a separate document). plus other hardware as necessary. Neither this document nor the information contained herein shall be copied. disclosed to others. the design. or used for any purposes other than the specific purpose for which this document was delivered. 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. mounting bracket. Refer to “Air Assist Requirements for Liquid Fuel Systems” in the Integration Section. .Capstone Turbine Corporation • 21211 Nordhoff Street • Chatsworth • CA 91311 • USA Application Guide: C30 and C60 Hybrid Electric Vehicle (HEV) Application Information for Capstone 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. See Appendix B for related drawings. an external air supply is required for starting. to cool components. During engine start-up. converts it to high voltage DC power. The Engine Control Module (ECM) is air-cooled and is the primary controller of the generator power and interface to the vehicle’s control unit. The ECM Assembly is shown in Figure 8 below. and sends it to the Battery Control Module (BCM). disclosed to others. It takes the variable high frequency AC power out of the generator. Neither this document nor the information contained herein shall be copied. Power is reversed again to motor the generator during cooldown. prior to shutdown. the design. power is reversed and delivered to the BCM for conversion to the vehicle main DC bus voltage load.Capstone Turbine Corporation • 21211 Nordhoff Street • Chatsworth • CA 91311 • USA Application Guide: C30 and C60 Hybrid Electric Vehicle (HEV) Application Information for Capstone Engine Control Module Details (Model C60) NOTE Refer to the Electrical Ratings chart in the HEV Electrical Technical Reference (410031) for actual starting and cooldown power requirements. After warm-up. and/or the contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction. . the generator uses power from the BCM via vehicle battery to start the MicroTurbine. Figure 8. ECM Assembly 480009-001 Rev B (October 2004) Page 21 of 54 This information is proprietary to Capstone Turbine Corporation. 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 product specifications. Neither this document nor the information contained herein shall be copied. disclosed to others.2 inches in water. normally to be drawn from the same source as the engine such as outside ambient air. Minimum service clearance access must also be provided as outlined on the relevant detail drawing. Maximum static pressure drop from the air inlet to air outlet should be 0. Capstone reserves the right to change or modify without notice.Capstone Turbine Corporation • 21211 Nordhoff Street • Chatsworth • CA 91311 • USA Application Guide: C30 and C60 Hybrid Electric Vehicle (HEV) Application Information for Capstone ECM Specifications NOTE An external 25 VDC (±1V) power supply is required for ECM on systems where battery voltage may be less than 300 VDC. the product specifications. . Typical ECM details are presented in the following table. ♦ ♦ ♦ ♦ ♦ ♦ ♦ 480009-001 Rev B (October 2004) Page 22 of 54 This information is proprietary to Capstone Turbine Corporation. See Appendix B for related drawings. Cooling air needs to be clean and dry. the design. ECM Details Mean Length Mean Width Mean Height Approximate Weight Air Inlet Volume Air Inlet Temp ECM Heat Rejection Parameter Data 1245 mm (49 inches) 381 mm (15 inches) 242 mm (9.5 inches) 69 kg (152 pounds) 118 liters/sec (250 cfm) -20 to 50 °C (-4 to 122 °F) Approximately 2300 watts ECM installation requirements are as follows: ♦ The ECM must be mounted and oriented as presented on the relevant detail drawing (provided as a separate document). The ECM air inlet temperature must be within two degrees of the engine air inlet temperature. ECM installation requires an independent air plenum. or used for any purposes other than the specific purpose for which this document was delivered. The ECM must be cooled such that the component temperatures do not exceed specified values. and/or the contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction. Allowable inlet air temperature: -20 °C to 50 °C (-4 °F to 122 °F). . .5 inches) 68 kg (150 pounds) 118 liters/sec (250 cfm) -20 to 50 °C (-4 to 122 °F) Approximately 2300 watts BCM installation requirements are as follows: ♦ ♦ ♦ ♦ ♦ ♦ ♦ The BCM must be mounted and oriented as presented on the relevant detail drawing (provided as a separate document). Changes in DC bus voltage are automatically tracked and current is adjusted based on power command. The BCM is a current provider based on the battery voltage and power demand by the user. the product specifications. See Appendix B for related drawings. BCM Details Mean Length Mean Width Mean Height Approximate Weight Air Inlet Volume Air Inlet Temp BCM Heat Rejection Parameter Data 1066 mm (42 inches) 406. BCM air inlet temperature must be within two degrees of the engine air inlet temperature. Maximum static pressure drop from air inlet to air outlet should be 0. The BCM must be cooled such that component temperatures do not exceed specified values. Capstone reserves the right to change or modify without notice. Allowable inlet air temperature: -20 °C to 50 °C (-4 °F to 122 °F). the battery voltage). bi-directional DC-toDC converter that converts the high voltage DC output of the ECM to the voltage of the vehicle main DC bus (i.2 inches in water. Page 23 of 54 480009-001 Rev B (October 2004) This information is proprietary to Capstone Turbine Corporation. disclosed to others. normally to be drawn from the same source as the engine such as outside ambient air.4 mm (16 inches) 242 mm (9. Neither this document nor the information contained herein shall be copied.e.Capstone Turbine Corporation • 21211 Nordhoff Street • Chatsworth • CA 91311 • USA Application Guide: C30 and C60 Hybrid Electric Vehicle (HEV) Application Information for Capstone Battery Control Module Details (Model C60) The Battery Control Module (BCM) (see Figure 9) is an air cooled. and/or the contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction. the design. BCM installation requires an independent air plenum. BCM Assembly BCM Specifications Typical BCM installation details are presented in the following table. Cooling air needs to be clean and dry. Figure 9. or used for any purposes other than the specific purpose for which this document was delivered. Minimum service clearance access must also be provided as outlined on the relevant detail drawing. Neither this document nor the information contained herein shall be copied. the product specifications. and then back to AC power where the phases combine to form single-phase DC power to the vehicle's battery. It takes the variable high frequency AC power out of the generator. power is reversed and delivered to the vehicle’s main DC bus voltage load. disclosed to others. During engine start-up.Capstone Turbine Corporation • 21211 Nordhoff Street • Chatsworth • CA 91311 • USA Application Guide: C30 and C60 Hybrid Electric Vehicle (HEV) Application Information for Capstone DPC Controller (Model C30) Figure 10. to cool components. prior to shutdown. Power is reversed again to motor the generator during cooldown. converts it to high voltage DC power. or used for any purposes other than the specific purpose for which this document was delivered. After warm-up. and/or the contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction. the design. Model C30 HEV Digital Power Controller (DPC) DPC Controller Details (Model C30) NOTE Refer to the Electrical Ratings chart in the HEV Electrical Technical Reference (410030) for actual starting and cooldown power requirements. the generator uses power via vehicle battery to start the MicroTurbine. 480009-001 Rev B (October 2004) Page 24 of 54 This information is proprietary to Capstone Turbine Corporation. The DPC (see Figure 10) is air-cooled and is the primary controller of the generator power and interface to the vehicle’s control unit. Capstone reserves the right to change or modify without notice. . Cooling air needs to be clean and dry. The DPC must be cooled such that the component temperatures do not exceed specified values. the design. or used for any purposes other than the specific purpose for which this document was delivered.2 inches in water. 480009-001 Rev B (October 2004) Page 25 of 54 This information is proprietary to Capstone Turbine Corporation. Capstone reserves the right to change or modify without notice. See Appendix B for related Parameter Data 825 mm (32. Allowable inlet air temperature: -20 °C to 50 °C (-4 °F to 122 °F). the product specifications. normally to be drawn from the same source as the engine such as outside ambient air. Maximum static pressure drop from the air inlet to air outlet should be 0. . DPC Details Mean Length Mean Width Mean Height Approximate Weight Air Inlet Volume Air Inlet Temp Heat Rejection DPC installation requirements are as follows: • • • • • • • • The DPC must be mounted and oriented as presented on the relevant detail drawing (provided as a separate document).25 inches) 464 mm (18.25 inches) 68. DPC air inlet temperature must be within two degrees of the engine air inlet temperature. Minimum service clearance access must also be provided as outlined on the relevant detail drawing.5 kg (151 pounds) 217 liters/sec (460 cfm) -20 to 50 °C (-4 to 122 °F) Approximately 2150 watts DPC details are presented in the following table.5V) power supply is required. drawings. disclosed to others.50 inches) 311 mm (12.Capstone Turbine Corporation • 21211 Nordhoff Street • Chatsworth • CA 91311 • USA Application Guide: C30 and C60 Hybrid Electric Vehicle (HEV) Application Information for Capstone DPC Specifications (Model C30) NOTE An external 12 VDC (-. DPC installation requires an independent air plenum (do not connect to engine inlet plenum).5/+2. and/or the contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction. Neither this document nor the information contained herein shall be copied. disclosed to others. the product specifications. Also. or used for any purposes other than the specific purpose for which this document was delivered. The UCB is delivered inside an enclosure for protection. and/or the contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction. the design. There are terminals for connecting an emergency stop contactor. . HEV User Connection Board 480009-001 Rev B (October 2004) Page 26 of 54 This information is proprietary to Capstone Turbine Corporation. It can be removed and relocated into a suitable enclosure inside the vehicle. See Appendix B for related drawings. which should be normally closed during operation. Capstone reserves the right to change or modify without notice. Neither this document nor the information contained herein shall be copied.Capstone Turbine Corporation • 21211 Nordhoff Street • Chatsworth • CA 91311 • USA Application Guide: C30 and C60 Hybrid Electric Vehicle (HEV) Application Information for Capstone User Connection Board (UCB) (Model C30) The User Connection Board (see Figure 11) is used for interfacing with auxiliary components. +12V Gnd E-Stop Figure 11. there is a terminal for a 12 VDC auxiliary power supply required for start up. and the air-assist pressure switch. 480009-001 Rev B (October 2004) Page 27 of 54 This information is proprietary to Capstone Turbine Corporation. the product specifications. The MicroTurbine system has both power cables and communication cables. Refer to Appendix B for a list of cables and schematics that indicate the cable number (W1XX) required for each type of system. HEV Liquid Fuel Controller Cables Each system is delivered with the required cables to interconnect all system components included in the MicroTurbine system. If a particular length is required. a Liquid Fuel Controller (see Figure 12) is required to control or monitor the liquid fuel devices such as the fuel pump speed. 3-way valve. Capstone reserves the right to change or modify without notice. During the design and integration process. Every effort should be made to keep these two types of cables separated at least two feet apart and/or shielded in conduit to reduce high frequency noise interference. Figure 12. See Appendix B for related drawings. the integrator needs to be aware of cable routing and its effect on the system. disclosed to others. or used for any purposes other than the specific purpose for which this document was delivered. the design. drain valve. start air-assist valve.Capstone Turbine Corporation • 21211 Nordhoff Street • Chatsworth • CA 91311 • USA Application Guide: C30 and C60 Hybrid Electric Vehicle (HEV) Application Information for Capstone Liquid Fuel Controller (LFC) (Model C30) For liquid fuel systems. The LFC is delivered inside an enclosure and the integrator is responsible for mounting it in a cool location inside the vehicle (refer to LFC drawing for mounting hole locations). please contact Capstone for availability and costs. . Neither this document nor the information contained herein shall be copied. if necessary. and/or the contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction. Most cables have a defined length and some have the option to purchase different lengths. fuel manifold. Easy access to the LFC is required for troubleshooting and replacement. Capstone Turbine Corporation • 21211 Nordhoff Street • Chatsworth • CA 91311 • USA Application Guide: C30 and C60 Hybrid Electric Vehicle (HEV) Application Information for Capstone Integrating the MicroTurbine into the Vehicle System The vehicle system OEM/Integrator will design and integrate the Capstone MicroTurbine components into the target application in compliance with the Capstone MicroTurbine system interface requirements. . A separate enclosure is recommended for the engine to shield other components from heat and noise and provide protection for the engine from environmental elements. If the engine is mounted near the ground or behind the rear wheels on a vehicle. the product specifications. or used for any purposes other than the specific purpose for which this document was delivered. Isolation Switch. the design. and Circuit Breakers from MicroTurbine to Battery Pack External VDC Power Supply Vehicle Battery Management System Overall Safety Considerations ♦ ♦ ♦ Enclosures The OEM/Integrator is required to install each of the MicroTurbine components in a location and environment that is free from water. and projectiles. skid plates 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. Items to be supplied and incorporated by the OEM/Integrator are listed. Capstone reserves the right to change or modify without notice. Neither this document nor the information contained herein shall be copied. debris. disclosed to others. 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. the OEM/integrator is responsible for protecting and shielding the components and systems. Several of the components and connections in the system are not rated for water spray or mud. Therefore. and/or the contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction. 480009-001 Rev B (October 2004) Page 28 of 54 This information is proprietary to Capstone Turbine Corporation. The electronic controllers can be located together within an existing enclosure with other components on the vehicle. Figure 13 presents a typical Model C60 installation using a flat silicone rubber boot stretched over the turbine opening. The highest location above ground is preferred. the design. Neither this document nor the information contained herein shall be copied. or used for any purposes other than the specific purpose for which this document was delivered.Capstone Turbine Corporation • 21211 Nordhoff Street • Chatsworth • CA 91311 • USA Application Guide: C30 and C60 Hybrid Electric Vehicle (HEV) Application Information for Capstone Inlet Air Filtration and Ducting to Engine NOTE Refer to HEV Product Specification (460009) for inlet pressure derating specifications. and to avoid icing and water ingestion. Care must be taken to design an inlet to avoid blockage by airborne plastic film or similar materials. Locating the air inlet near the ground or directly behind the wheels of the vehicle is not recommended. the product specifications. Refer to the “Acoustical Considerations” section for more data. Interfacing to the turbine can be as simple as a rubber boot to seal out unfiltered air.5 square centimeters (44. Unfiltered air is not permitted to the turbine. A maximum restriction of airflow with a dirty air filter should be calculated and should not exceed the required limit. Easy access to the air filter is also preferred for removal and regular maintenance. disclosed to others. A small filter will become dirtier faster and therefore cause high-pressure drop and require cleaning or replacing in very short intervals. The minimum filter size and maximum length of ducting needs to be determined based on several factors. Inlet air temperature also needs to be considered. Air Inlet Requirements: ♦ ♦ ♦ ♦ ♦ Air Flow: 900 Standard Cubic Feet per Minute (scfm) for Model C60. Air Filtration: <10 micron particle size at an efficiency of 99% Intake Ducting Size: > 283. Capstone reserves the right to change or modify without notice. The entire ducting must also preclude the use of screws or other potentially loose fasteners that could be ingested by engine and cause failure. routing. The seal may be used for Model C30 and C60 applications and allows for some engine misalignment. 480009-001 Rev B (October 2004) Page 29 of 54 This information is proprietary to Capstone Turbine Corporation.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 during operation. Capstone recommends using the largest filter possible for maximum engine performance. 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 recommends that a dirty air filter be calculated as though one-half of its surface area is blocked. The inlet ducting should be designed to reduce the rise from ambient to actual engine inlet temperature and the maximum temperature rise should not exceed 3 ºC. if necessary. The OEM/Integrator is responsible for providing air filtration. The actual air inlet temperature into the engine is measured inside the generator housing before entering the compressor. Pressure drop from ambient conditions to the engine inlet is critical to engine performance. where as a larger filter will help prolong the maintenance schedule. The air inlet ducting should also take into account acoustical considerations. The design of the filter attachment should also address sealing around the filter. Sizing the filter also should take into account operational conditions and maintenance intervals. and ducting for the air intake to the MicroTurbine engine inlet. while accommodating some engine movement due to vehicle shock loads and vibration. Capstone recommends that an air inlet plenum be designed to house the filter and accommodate acoustical treatment. Air Flow: 600 Standard Cubic Feet per Minute (scfm) for Model C30. . This air needs to be drawn from the cleanest and coolest location that is possible on the vehicle. disclosed to others. and ducting for the cooling air for the electronic controllers. Air Flow: 460 Standard Cubic Feet per Minute (scfm) for Model C30 DPC. Generator-to-Plenum Seal (Model C60 shown) Cooling Air Filtration and Ducting to Controllers The OEM/Integrator is responsible for providing air filtration. Inlet air temperature needs to be within 2 °C of engine air inlet temperature. A coarse air filter can be used to filter large particles and provide protection from water and debris. but do not include external ducting or connections. The design must also prevent recirculation of cooling air from exit to inlet and from controller to controller. As part of a regular maintenance schedule. 480009-001 Rev B (October 2004) Page 30 of 54 This information is proprietary to Capstone Turbine Corporation. Neither this document nor the information contained herein shall be copied. the filter should be cleaned. the product specifications.5 inch of water column. Pressure drop from ambient conditions to the controller inlet is critical to controller performance and overall system performance. and/or the contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction. . Figure 13. The controllers include their own internal air management with fans and vents. the design. routing. Each controller contains power electronics. Installation of the controllers must consider airflow paths both into the controller fans and away from the controller vents. Capstone recommends that a dirty air filter be calculated as though one-half of its surface area is blocked. or used for any purposes other than the specific purpose for which this document was delivered. Use caution not to insert a filter that will cause a pressure drop that exceeds requirements. Capstone reserves the right to change or modify without notice. and up to 2000 watts for the DPC. 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.Capstone Turbine Corporation • 21211 Nordhoff Street • Chatsworth • CA 91311 • USA Application Guide: C30 and C60 Hybrid Electric Vehicle (HEV) Application Information for Capstone Recommended generator-to-plenum sealing is shown in Figure 13 below. Maximum Pressure Drop from Ambient: 0. Air Filtration: Coarse air filter to reduce dust. Cooling airflow is required to dissipate this heat and prevent overheating of controllers. and the controllers should be opened and compressed air should be used to blow any accumulation off the control boards and other components. A maximum restriction of airflow with a dirty air filter should be calculated and should not exceed the required limit. which produce up to 2300 watts and 800 watts of heat at full power for the ECM and BCM respectively. moisture and foreign object debris. Figure 14. the design. Care must be taken to design an exhaust duct that minimizes backpressure and does not exceed the maximum backpressure requirement. A simple flapper cap is recommended or the exhaust tip can be angled downward for water protection.5-inch diameter port (see Figure 14) in the center of the generator. Therefore.000 Btu/hr) or Model C60. . some of the engine inlet air that is used to cool the generator is exhausted out a 2. Engine Exhaust Requirements: ♦ ♦ ♦ ♦ ♦ Maximum Steady State Exhaust Temperature: 305 °C (580 °F) for Model C60. which is the center of the engine inlet.Capstone Turbine Corporation • 21211 Nordhoff Street • Chatsworth • CA 91311 • USA Application Guide: C30 and C60 Hybrid Electric Vehicle (HEV) Application Information for Capstone Engine Exhaust Ducting The OEM/Integrator is responsible for providing routing and ducting for engine exhaust.000 Btu/hr) or Model C30. disclosed to others. An exhaust duct needs to be supplied by the integrator to exhaust hot and potentially dangerous gases away from personnel.000 kJ/hr (310. NOTE Refer to HEV Product Specification (460009) for exhaust backpressure derating specifications. the product specifications. Maximum Steady State Exhaust Temperature: 275 °C (530 °F) for Model C30. or used for any purposes other than the specific purpose for which this document was delivered. Testing has shown that there can as much as 4 kW derating if this generator exhaust air is not ducted away from engine air inlet. C60 Generator Cooling Air Outlet 480009-001 Rev B (October 2004) Page 31 of 54 This information is proprietary to Capstone Turbine Corporation. Maximum Exhaust Back Pressure: 203 mm (8 inch) of water column. This generator exhaust air can be approximately 50 to 70 degrees hotter than the inlet air. Any exhaust system that is vented to ambient needs to be protected from rain and potential water spray from washing the vehicle. Neither this document nor the information contained herein shall be copied. This duct should be located away from all flammable materials. Nominal Total Exhaust Energy: 322. and/or the contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction. the OEM/Integrator is responsible for ducting exhaust air away from engine inlet by using a flexible duct similar to system shown below. Backpressure in the exhaust system will cause a reduction in engine efficiency. Capstone reserves the right to change or modify without notice. The MicroTurbine exhaust has a formed sheet metal flange that can be used with a band type clamp for easy assembly. Generator Exhaust Air (Model C60 Only) On the Model C60 engine. while allowing removal for service.000 kJ/hr (541. Nominal Total Exhaust Energy: 571. this heat should not be allowed to heat the generator housing or fuel components beyond their maximum specification during operation. Insulation is used to help keep this heat within the recuperator. or used for any purposes other than the specific purpose for which this document was delivered. Neither this document nor the information contained herein shall be copied. Typical Layout of Engine with Heat Shield 480009-001 Rev B (October 2004) Page 32 of 54 This information is proprietary to Capstone Turbine Corporation. Figure 15. . The surface temperature of this insulation can range from 163 to 288°C (325 to 550 F) depending on location. and/or the contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction. thus heating the engine inlet air. The recuperator is designed to capture this heat and preheat the compressed air before entering the combustor. the design. The recuperator side of the engine should be kept hot and the generator side should be kept as cool as possible. This shield will keep the engine divided into a hot compartment side and a cool compartment side. It is not recommended to blow cool air onto the hot components since this may cause reduced efficiency or could direct hot air onto other components. disclosed to others. The OEM/Integrator is not required to remove this heat for system operation but it is recommended that care be taken to not allow this heat to come in contact with combustible materials. and causing a derating due to elevated inlet temperatures. This helps keep the generator housing form heating up. Maximum heat rejection is up to approximately 2000 watts. the product specifications. Figure 15 shows the typical layout inside an enclosure with a heat shield installed to split the compartment into hot and cold sections. The heat shield can be sheet metal with insulation attached. Capstone reserves the right to change or modify without notice. Fans or vents can be used to draw the heat out of an enclosure. In addition.Capstone Turbine Corporation • 21211 Nordhoff Street • Chatsworth • CA 91311 • USA Application Guide: C30 and C60 Hybrid Electric Vehicle (HEV) Application Information for Capstone Engine Heat Rejection The MicroTurbine combusts fuel to make power and therefore produces heat in the process. 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 MicroTurbine fuel system is basically a metering device and a distribution system for the injectors. For gaseous fuels. For liquid fuel systems. The following are liquid fuel system air-assist requirements (for reference only): • • Start/Cooling mode – 80 slpm @ 427. Particular care must be taken to ensure that fuel in lines after shutdown is conditioned before next start up.5 minutes Idle Mode (≤ 6 kW) – 60 slpm @ 427. and a shut off valve. Neither this document nor the information contained herein shall be copied. And in either case. . fuel filter (10 microns@45 of particles). low power (idle) and shutdown. the product specifications.Capstone Turbine Corporation • 21211 Nordhoff Street • Chatsworth • CA 91311 • USA Application Guide: C30 and C60 Hybrid Electric Vehicle (HEV) Application Information for Capstone Fuel Delivery System to Engine Fuel System NOTE Refer to the Fuel Requirements Technical Reference (410002) for detailed fuel requirements and additional information for both C30 and C60 systems. Air Assist Requirements for Liquid Fuel Systems NOTE Refer to the HEV Liquid Fuel Technical Reference (410029) for detailed and updated information. The air needs to be clean.8 kPa (62 psig) for duration of idle 480009-001 Rev B (October 2004) Page 33 of 54 This information is proprietary to Capstone Turbine Corporation.8 kPa (62 psig) for approx. disclosed to others. and/or the contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction. a boost pump. and a shutoff value. coalescing filter (6 micron @95% of particles). but be limited to. the delivery system should consist of. it is critical that only vapor be delivered to the MicroTurbine fuel system. It is the OEM/integrator’s responsibility to provide the fuel at the required pressure and temperature. For gaseous fuels. The OEM/Integrator is responsible for providing a fuel delivery system from the fuel tank to the engine fuel system. The shut off valve should be as close to the MicroTurbine as possible. the delivery system should consist of. regulator. Capstone reserves the right to change or modify without notice. The required air can be supplied from a separate system or from an onboard air system. or used for any purposes other than the specific purpose for which this document was delivered. Trapped fuel can change phases overnight and cause liquids to form in lines. This air supply assists the fuel system to atomize the fuel in the combustion chamber. For liquid fuels. 1. dry and free of any oils. the design. an external air supply is required for system start-up. The presence of liquid fuel particles in a gaseous fuel will damage the MicroTurbine. a fuel filter. A gasification system with a heater will be required for operation with compressed liquid fuels. a 10-micron (or less) filter and a coalescing filter/separator should be installed before the turbine system. but is not limited to. 480009-001 Rev B (October 2004) Page 34 of 54 This information is proprietary to Capstone Turbine Corporation. Capstone reserves the right to change or modify without notice. It is recommended that component mountings in vehicular applications be designed to withstand crash loads of 30G for 100 milliseconds.Capstone Turbine Corporation • 21211 Nordhoff Street • Chatsworth • CA 91311 • USA Application Guide: C30 and C60 Hybrid Electric Vehicle (HEV) Application Information for Capstone Mechanical Interface Parameters The MicroTurbine will require typical mounting requirements as noted in the paragraphs that follow. Vibration The MicroTurbine produces nearly zero measurable vibration. The system is provided with interconnect cables which lengths define the maximum distances between the various system components. Component connection orientations and locations may slightly affect these maximum distances. The OEM/Integrator must mount the components in the frequency window between 4 and 10 Hz. and/or the contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction. Neither this document nor the information contained herein shall be copied. or used for any purposes other than the specific purpose for which this document was delivered. disclosed to others. The MicroTurbine controller must be mounted within 60 degrees of vertical. Acceleration Maximum allowable operating acceleration is 6G in the vertical and 5G in the lateral and longitudinal axis. Other system components may be oriented as desired. Maximum allowable non-operating acceleration is 18G. Component Locations Component locations must meet component requirements as noted in component sections and be accessible for diagnosis and repairs. . the design. The OEM/Integrator must also assure that the cable connections are accessible and the minimum bend radii for all cables and hoses are observed. but may be susceptible to outside vibration. The MicroTurbine gaseous fuel valve must be mounted within 90 degrees of vertical. the product specifications. NOTE Reference cable drawings for maximum lengths. Orientation The MicroTurbine generator should be mounted with its axis normally level with respect to gravity but otherwise may be oriented for convenience. . Neither this document nor the information contained herein shall be copied. the combustor chamber. Notice that sound power does not depend on distance or direction. the design. and originates mainly in the air intake area. L. Noise and Vibration Control Engineering Principles and Applications. Electro-Mechanical Noise Electro-mechanical noise is caused by the magnetic fields within the generator. Engineering reference material specific to noise reduction may be found in as noted: • L.800 Hz for the turbine. Bies and Colin H. This noise is tonal in nature with the strongest occurring at blade passing frequencies. 480009-001 Rev B (October 2004) Page 35 of 54 This information is proprietary to Capstone Turbine Corporation. Ver. This type of noise is broadband and occurs typically at frequencies of between 1000 and 5000 Hz. (Also published in Japan). and location.Capstone Turbine Corporation • 21211 Nordhoff Street • Chatsworth • CA 91311 • USA Application Guide: C30 and C60 Hybrid Electric Vehicle (HEV) Application Information for Capstone Acoustical Parameters The system OEM/Integrator is responsible for meeting their specific acoustics requirements for the installation or application. This noise is also tonal in nature with the strongest occurring at 1 and 2 times shaft speeds. or used for any purposes other than the specific purpose for which this document was delivered.. Engineering Noise Control Theory and Practice. New York. the sound pressure levels distributed around the package depend on the strength of the noise sources as well as the acoustic characteristics of the inlet ducting. Chapman and Hall. directivity. Hansen. To achieve lower overall noise requires an understanding of the individual noise sources and then targeting specific reductions for each area. and is then passed through the stator and the stator housing. NY 1996. • Noise levels or sound power is the strength of the noise source (normally measured in decibels or dBA). inlet heating.000 rpm. Second Edition. Beranek and Istvan L. New York. David A. John Wiley and Sons Inc. and each potential acoustic pathway should be designed to ensure that target noise levels are met. maintenance. the exhaust ducting. disclosed to others. and the overall packaging environment. The blade passing frequencies occur at 14. and in the exhaust duct. and/or the contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction. Noise attenuation efforts are close-coupled to pressure drop.400 Hz for the compressor and at 20. The Capstone noise attenuation design goal that has been established and met is 65 dBA at 10 meters. Turbulence Noise Turbulence noise is widespread. Each package or installation will have its own unique acoustic characteristics. NY 1992. Capstone reserves the right to change or modify without notice. The four major noise types associated with the MicroTurbine are detailed in the following paragraphs. The acoustic characteristics include attenuation. the product specifications. Typically. Blade Interaction Noise Blade interaction noise is caused by an interaction of the high speed turbine blades and the compressor blades with specificity at local flow disturbances. That places the tonal frequencies at 1600 Hz and 3200 Hz with a shaft speed of 96. and environmental requirements. and/or the contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction. the product specifications. . A-Weighted Sound Level A-Weighted is a method for presenting noise data that penalizes frequencies to which humans have more sensitivity and thus minimizes those frequencies to which humans are less sensitive. Sound spectrum has to do with the description of a sound wave’s resolution into components. For purposes of this Application Guide. Sound Spectrums NOTE Refer to the Model C30 Acoustic Emissions Technical Reference (410025) for additional technical information and updated data. Sound Pressure Sound Pressure measures acoustic pressure fluctuations at a particular point in space. disclosed to others.Capstone Turbine Corporation • 21211 Nordhoff Street • Chatsworth • CA 91311 • USA Application Guide: C30 and C60 Hybrid Electric Vehicle (HEV) Application Information for Capstone Combustion Noise Combustion noise is both broadband and low on the frequency scale. Capstone reserves the right to change or modify without notice. Neither this document nor the information contained herein shall be copied. Each component has a different frequency and (usually) different amplitude and phase. These measurements are dependent on both the source and the associated surroundings. noise terminology for the MicroTurbine is defined as noted in the paragraphs that follow. The main acoustic pathways from within the MicroTurbine include the following three items: • • • Inlet Noise Exhaust Noise Case Radiated Noise 480009-001 Rev B (October 2004) Page 36 of 54 This information is proprietary to Capstone Turbine Corporation. the design. Sound Power Sound Power is calculated using sound pressure measurements integrated over a specific area. This functionality serves to isolate noise characteristics of the source alone. or used for any purposes other than the specific purpose for which this document was delivered. This noise peaks at approximately 400 to 800 Hz and manifests itself primarily in the exhaust stream. soundcoat. Inc. and may add value to a particular application. This is based upon the fact that a tuned cavity must be placed at different locations and must function at different frequencies and times during MicroTurbine operation. If the foam-type material under consideration attenuates noise at 2 kHz. CA 92606.Capstone Turbine Corporation • 21211 Nordhoff Street • Chatsworth • CA 91311 • USA Application Guide: C30 and C60 Hybrid Electric Vehicle (HEV) Application Information for Capstone Noise Attenuation Methods As pointed out earlier in this document. However. Noise attenuation efforts are close-coupled to pressure drop. the design.R. Fax: (949 )222-0834. These materials should be temperature appropriate and resistant to damage that may be caused by various weather conditions. . including the following methodologies: • • • Tuned Cavity Extruded Metal Bulk Attenuator Tuned Cavity The tuned cavity approach to noise reduction is relatively ineffective for the MicroTurbine..A. the Capstone noise attenuation goal (which has been continuously met) has been 65 dBA at 10 meters. then it should also be adequate for the higher band of frequencies. WARNING It should be pointed out that fiberglass materials may pose a significant problem if the fibers were to be ingested by the MicroTurbine. inlet heating. 7911 Vionsville Road. Capstone reserves the right to change or modify without notice. Efforts have been made to achieve lower overall noise. Speciality Composites.com 480009-001 Rev B (October 2004) Page 37 of 54 This information is proprietary to Capstone Turbine Corporation. E-mail: http://www. This method may be employed for both the MicroTurbine inlet air stream and the exhaust pathway. Indianapolis. the product specifications. Irvine. Capstone currently uses a foam-type material for noise attenuation instead of fiberglass. Phone: (949) 955-9202. and/or the contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction. IN 46268. Sources of composite foam currently in use at Capstone include the following: • • The Soundcoat Company. Additional noise reduction opportunities exist for the OEM/Integrator.soundcoat. 16901 Armstrong Avenue. Extruded Metal Typical extruded metal and/or felt-type metal enclosure materials can be effective. or used for any purposes other than the specific purpose for which this document was delivered. disclosed to others. Bulk Attenuator The bulk attenuator method of noise reduction is recommended by Capstone. Fax: (317) 692-3111. Bulk attenuation materials consist of perforated metal sheeting with greater than 30% open area. screen-type materials. they may not be very cost effective. maintenance.com E. Neither this document nor the information contained herein shall be copied. and/or fiberglass or foam sheeting items. E-mail: http://www. Phone: (877) 327-4332. and environmental requirements. the design. the product specifications. Refer to Figure 16 for details. Grounding Layout (Model C30 shown) 480009-001 Rev B (October 2004) Page 38 of 54 This information is proprietary to Capstone Turbine Corporation. disclosed to others. or used for any purposes other than the specific purpose for which this document was delivered. The preferred method of grounding is to attach a grounding cable to each component and route to a common point that is grounded to a chassis or other grounding point for the vehicle. Capstone reserves the right to change or modify without notice. . Turbine Engine IDEAL HEV GROUNDING DIAGRAM Generator DPC To Battery Bus SPV Use #10 AWG wire or larger.Capstone Turbine Corporation • 21211 Nordhoff Street • Chatsworth • CA 91311 • USA Application Guide: C30 and C60 Hybrid Electric Vehicle (HEV) Application Information for Capstone Electrical System Grounding The OEM/Integrator is responsible for providing all grounding cables from each component to a common ground. Neither this document nor the information contained herein shall be copied. In order for the system components to operate and communicate properly. Use of #10 wire gage or larger is required. Each component has a grounding stud or eyelet for attaching a cable. and/or the contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction. they need to be grounded properly. for grounding + HUCB - BMS 12 VDC Aux Power Single Point Chassis Ground Figure 16. This external power supply needs to be connected to the ECM as described in the User Connection section and shown on the System Schematic drawing. All hardware associated with connecting the controller module to the battery pack is the responsibility of the OEM/Integrator.5/+2. Capstone reserves the right to change or modify without notice. External Power Supply The OEM/Integrator is responsible for providing an external power supply to the MicroTurbine. or used for any purposes other than the specific purpose for which this document was delivered. as well as how much MicroTurbine power is required during charging periods.5V) and 8 Amps to power the system at start up. conduit. Neither this document nor the information contained herein shall be copied. Vehicle Battery Management System The OEM/Integrator is responsible for providing a battery management system to monitor the battery pack and give power commands to the MicroTurbine.Capstone Turbine Corporation • 21211 Nordhoff Street • Chatsworth • CA 91311 • USA Application Guide: C30 and C60 Hybrid Electric Vehicle (HEV) Application Information for Capstone Cables from MicroTurbine to Battery Pack The OEM/Integrator is responsible for providing all cables. RS-232 communication protocol is described in Capstone Engineering Specification ES0276 “Software Requirements. if required. The battery pack needs to be connected to the MicroTurbine while MicroTurbine is in standby. and during cooldown modes. Communications Specification (HEV)” (provided as separate document). This isolation switch must be mounted as close as practical to the MicroTurbine controller for service to the controller. A 9-pin serial null modem cable is used for this particular connection. the product specifications. This system is required to manage the battery state of charge and determine when the MicroTurbine is required for charging the batteries. This document describes the basic communication scheme required of the battery management system. and/or the contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction. The Model C60 MicroTurbine system requires a power supply of 25 VDC (± 1V) and 5 Amps to power the system in the event the battery pack is below 300 Volts at start up. and the connections required for typical system operation. the design. running. starting. This external power supply needs to be connected to the UCB as described in the User Connection section and shown on the System Schematic drawing. insulation. The Model C30 MicroTurbine requires a power supply of 12 VDC (-. HEV applications using a Capstone MicroTurbine require a battery management system be developed for the specific application. 480009-001 Rev B (October 2004) Page 39 of 54 This information is proprietary to Capstone Turbine Corporation. disclosed to others. switches. The battery management system is connected to the MicroTurbine through an RS-232 connection to the User Interface Port on the Digital Power Controller (DPC) for the Model C30 and Engine Control Module (ECM) for the Model C60. initialization of the system. circuit breakers. and mounting from the MicroTurbine system to the vehicle battery pack. . The MicroTurbine produces DC voltage for charging the battery pack on a vehicle and uses the battery pack for starting the MicroTurbine. Capstone requires a double pole isolation switch between the MicroTurbine control module and the battery pack. and all fuel lines must be physically kept from contacting the MicroTurbine or other hot surfaces.Capstone Turbine Corporation • 21211 Nordhoff Street • Chatsworth • CA 91311 • USA Application Guide: C30 and C60 Hybrid Electric Vehicle (HEV) Application Information for Capstone Safety-related Design Considerations Capstone suggests that the following safety items be considered during any design efforts. Warning labels on the MicroTurbine system components must remain visible to technicians after installation. and/or the contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction. the product specifications. or used for any purposes other than the specific purpose for which this document was delivered. In addition. High Voltages The MicroTurbine installation designer must consider that the system produces and stores electricity at levels that can burn. electrical cables and harnesses must not contact sharp surfaces or protruding objects. The MicroTurbine system components must be mounted and connected as recommended herein. Capstone reserves the right to change or modify without notice. Proper safety considerations will lead to an efficient and safe design application. 480009-001 Rev B (October 2004) Page 40 of 54 This information is proprietary to Capstone Turbine Corporation. Care must be taken to prevent people or inappropriate materials from coming into contact with the MicroTurbine. The OEM/Integrator should seek assistance from a third party if the engineering efforts connected with fuel storage and fuel filling is beyond his/her scope of expertise. and label exhaust piping to prevent people from coming into contact with the piping or exhaust stream. disclosed to others. Neither this document nor the information contained herein shall be copied. Electrical cables and harnesses must not be attached to hot surfaces or to fuel lines. The MicroTurbine fuel handling components must be installed as specified in this Application Guide. The exhaust stream and piping can reach 315 °C (600 °F) under extreme conditions. and electrical cables and harnesses must not be attached to fuel lines. High Temperatures The surface temperature of the MicroTurbine can reach 288 °C (550 °F). The turbine air inlet must be free of fuel-carrying components. Additionally. guard. Do not remove or cover high temperature warning labels on the MicroTurbine components. Flammable Fuels Fuel storage and delivery systems should be designed in consideration of the highly flammable nature of the fuel. injure. fuel lines must not contact any sharp edges or protruding objects. or kill. . Keep flammable materials clear of the exhaust pipe and exhaust stream. Capstone strongly recommends the provision of lockout devices to prevent energization of circuits during maintenance procedures. The MicroTurbine radiates 1400 watts at full load. Route. the design. Connection wiring and isolation switches must be properly sized and installed per manufacturer recommendations. and High Temperature labels must be applied to the MicroTurbine. Fire Suppression Detectors The designer of the MicroTurbine installation should consider fire suppression systems. The air intake filter pathways must prevent incidental human contact with hot surfaces or electrically live components by distance or labyrinth or both. Design parameters must include emergency stop devices that are easily visible and accessible to the general public. the power to the MicroTurbine must be turned off for 30 seconds before a restart can be attempted. Emergency stops should NEVER be used for routine shutdowns. vent the compressed air out of the MicroTurbine. the product specifications. Emergency stops increase stress on the system components and will result in reduced service life of the MicroTurbine. and the turbine will coast to a stop. but not required or supplied by Capstone. . CAUTION Repeated use of the optional Emergency Stop switch will result in damage to the MicroTurbine. finger guards must be designed to cover all exposed fans. Additionally. Fuel Leak Detectors The designer of the MicroTurbine installation should consider fuel leak detection systems. After an emergency stop. Use only in emergency situations. In addition. 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 Application Guide: C30 and C60 Hybrid Electric Vehicle (HEV) Application Information for Capstone Emergency Stop (E-Stop) The MicroTurbine system includes emergency stop functionality. It is a normally-closed circuit and can be connected to an external switch or button that will close the circuit. labels must comply with the intent to prevent injury. Activation of the E-Stop immediately shuts off fuel and electrical output. but not required or supplied by Capstone. or used for any purposes other than the specific purpose for which this document was delivered. These devices must be remotely mounted by the vehicle operator to ensure access in the event of an emergency. These systems are recommended by. Equipment Access Internal access to the system should be by key or by special tool to preclude accidental contact with hot surfaces or electrically live components. These systems are recommended by. Standard UL signage must be employed. disclosed to others. The MicroTurbine system incorporates an E-stop circuit on the User Control Board. Warning Labels High Voltage labels must be applied to the Digital Power Controller. This will cause the compressor bypass valve to open. but does not include an emergency stop switch. Neither this document nor the information contained herein shall be copied. Capstone reserves the right to change or modify without notice. 480009-001 Rev B (October 2004) Page 41 of 54 This information is proprietary to Capstone Turbine Corporation. the design. the user needs to connect a computer or PLC using a null modem adapter or a modem to one of the ports.Capstone Turbine Corporation • 21211 Nordhoff Street • Chatsworth • CA 91311 • USA Application Guide: C30 and C60 Hybrid Electric Vehicle (HEV) Application Information for Capstone Communication Requirements NOTE Refer to the Communications Technical Reference Manual (410042) for detailed explanations and additional information for both C30 and C60 systems. and get to the point where it is capable of outputting power when this is issued (for example. This is useful for monitoring the overall system operation. When the battery management system is monitoring the battery state of charge. The command STRCMD = 1 is used to start the MicroTurbine. A power demand (PWRDMD) between 0 and 60000 watts may be commanded. each RS-232 command may be issued without an argument to query the current value being used by the MicroTurbine. Capstone reserves the right to change or modify without notice. The HEV version of the MicroTurbine system requires the user to give commands to the system for starting. Additionally. 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. It is much more efficient to leave the MicroTurbine on. Without a password. and the power output limited then to turn the MicroTurbine off and then start it again. and PWRDMD = <watts> is used to set the desired output power level. The user serial port requires a password for control operations. the MicroTurbine will be kept on with varying power levels until the bus is shut off at which time a STRCMD = 0 will be issued to shutdown the MicroTurbine. power levels and stopping. STRCMD issued without the equal sign and value will return a 0 or 1 indicating that the MicroTurbine is currently running. 480009-001 Rev B (October 2004) Page 42 of 54 This information is proprietary to Capstone Turbine Corporation. the design. or used for any purposes other than the specific purpose for which this document was delivered. A few minutes should be allowed for the MicroTurbine to warm-up. Each system has two serial ports. It will then transition to a PREP_START state where it determines if the contactor can be closed and the proper power board voltage is achieved for operation. STRCMD = 0 shuts down the MicroTurbine. and it determines that it is getting low enough that it wants the MicroTurbine to start charging. do not start the MicroTurbine with the state of charge too low as it will take the MicroTurbine a few minutes before charging begins). The MicroTurbine remains in a Standby state after power up. For the simplest operation. two commands are used. or in a shutdown state. Most likely. The communication to the system is done through an RS-232 serial port using RS-232 protocol. Neither this document nor the information contained herein shall be copied. and when the warm-up cycle is completed. For basic operation. The RS-232 command STRCMD is used to start and stop the MicroTurbine and PWRDMD is used to tell the MicroTurbine how much power output is desired. . disclosed to others. The first is reserved for the user (vehicle operation and the second is used for monitoring and/or maintenance. For example. a start command (STRCMD =1) should be issued. A desired power demand may immediately be issued. information and data is available for monitoring only. the MicroTurbine will immediately ramp up to the desired output power level. until a STRCMD = 1 command is received. once the battery management system sends a start command. and then back to Standby. the product specifications. The same data may be received in a hexadecimal format using the SYSCON command. The MicroTurbine only reacts to the commanded value when in the Load state. This may be used to monitor when the MicroTurbine reaches the Load state or has entered a Fault / Shutdown state. Capstone reserves the right to change or modify without notice. There are two parts to the SYSCON command results: (1) the system state and (2) the mode. and the MicroTurbine will attempt a re-start if it is in an appropriate state (and there are no faults) to do so. will take approximately two minutes. so the battery management system should use some scheme that keeps MicroTurbine response in mind. If it is 0. If the MicroTurbine becomes disconnected from the batteries. the system will not be able to sustain operation and will go through a warmdown state (high temp cooldown for the MicroTurbine components that may cause engine damage) and then to the fault state. The PWRDMD command may be issued at any time. When the battery management system provides a stop command (STRCMD = 0). or used for any purposes other than the specific purpose for which this document was delivered. so any value changes in the power demand are allowed and a stop command can be given at any load. SYSCON returns a four-digit ASCII representation of a hex value with the last three representing the state. the MicroTurbine begins outputting the demanded power level. then the MicroTurbine has shut down for some reason. the MicroTurbine will transition through cooldown and then shutdown. CAUTION When the bus is normally shut off at the end of the day. The warm-up period is a total of one minute. Giving a power demand from 0 to 60 kW (full on load).Capstone Turbine Corporation • 21211 Nordhoff Street • Chatsworth • CA 91311 • USA Application Guide: C30 and C60 Hybrid Electric Vehicle (HEV) Application Information for Capstone The MicroTurbine is then started and fuel added to the system. The Run state is the warm-up period. A response of STRCMD. The SYSSTA command provides textual output of the current operational state of the MicroTurbine. The MicroTurbine is tested for full on and off loads.0 = 1 reports that the system is still operating. The STRCMD = 0 may be given at any time and the MicroTurbine will safely stop outputting power and move into cooldown. . A STRCMD without any values attached may be issued to determine if the engine is running. as vehicle systems only operate in one mode. That is to say. the design. A start command may be issued at any time. and includes the time to reach the idle temperature set point. the battery supply must not be disconnected until the MicroTurbine has gone through this cooldown/shutdown cycle and is back in Stand By. and/or the contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction. 480009-001 Rev B (October 2004) Page 43 of 54 This information is proprietary to Capstone Turbine Corporation. Neither this document nor the information contained herein shall be copied. disclosed to others. command a start before the minimum state of charge is reached. but the MicroTurbine will rate itself to control the changes to reach the most recent demanded value. When the load state is reached. The INVPWR RS-232 command may be used to view the MicroTurbine output power once reaching the Load state before changing the PWRDMD setting. Only the state portion is relevant. The power demand may be changed as often as required. to achieve this communication rate. the design. = 13. lost communication is assumed and the system will shutdown with a communications timeout fault. = 14. queries or commanded values. and/or the contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction. disclosed to others. The battery management system may be implemented to send any RS-232 command. Neither this document nor the information contained herein shall be copied. HEV systems will never be operating in these states. A start from the display panel disables this fault so that system operation may be verified before completion of the battery management system operation. SYS_BAD_CONFIG = 15. SYS_RUN SYS_LOAD = 6. SYS_IDLE_RCHRG = 17 } SYS_STATE. = 7.Capstone Turbine Corporation • 21211 Nordhoff Street • Chatsworth • CA 91311 • USA Application Guide: C30 and C60 Hybrid Electric Vehicle (HEV) Application Information for Capstone The following may be used: system_state = SYSCON & 0x0FFF Where system_state is of type SYS_STATE: typedef enum { SYS_POWER_UP = 0. query or setting. This prevents over charging a battery when communication that would have lowered the power demand or shut the MicroTurbine down has been lost. SYS_COOLDOWN = 9. If the MicroTurbine does not receive any communication for 10 seconds. 480009-001 Rev B (October 2004) Page 44 of 54 This information is proprietary to Capstone Turbine Corporation. SYS_SW_DNLOAD = 16. . SYS_OPEN_LIGHT = 4. the product specifications. One option is to continually send the STRCMD = 1 followed by PWRDMD = 60000 to continue operating at full power. SYS_LIFTOFF = 3. SYS_SHUTDOWN = 12. SYS_WARMDOWN = 10. SYS_RECHARGE = 8. or used for any purposes other than the specific purpose for which this document was delivered. Important for HEV systems is that the battery management system must keep sending RS-232 commands. The SYS_RECHARGE and SYS_IDLE_RCHRG states are used only by Stand Alone AC output units. SYS_RESTART SYS_FAULT SYS_DISABLE = 11. SYS_PREP_START = 2. SYS_STAND_BY = 1. SYS_CLSD_ACCEL = 5. at least once every 10 seconds. Capstone reserves the right to change or modify without notice. or used for any purposes other than the specific purpose for which this document was delivered. The MicroTurbine has protective relays that are used to protect the system and the battery pack from overvoltages or undervoltages. the baud rate used for RS-232 communications may need to be adjusted. the product specifications. Capstone reserves the right to change or modify without notice. Each of these commands is issued one time to configure the system and may be accomplished through a personal computer RS-232 connection. The baud rate may also be set through the display panel Baud Rate submenu under System Settings. To change the setting to 9600 bps.Capstone Turbine Corporation • 21211 Nordhoff Street • Chatsworth • CA 91311 • USA Application Guide: C30 and C60 Hybrid Electric Vehicle (HEV) Application Information for Capstone System Configuration Upon delivery of a Capstone MicroTurbine. Baud Rate Based on the battery management system. These protective relay settings must be adjusted to match the specific battery voltages being used and system requirements. or via the display panel. or CRMS. The connection must be re-connected using the new baud rate. 480009-001 Rev B (October 2004) Page 45 of 54 This information is proprietary to Capstone Turbine Corporation. several parameters will need to be configured as part of the system commissioning. disclosed to others. Natural gas is the system default. To change the setting to match the baud rate of the sending port of the battery management system. If any of these relays are tripped. the command UBAUDR=9600 will be sent. This is required due to the unique battery packs and fuels used in various applications. and/or the contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction. the UBAUDR command will be used. . the design. the system will perform a warmdown sequence. Neither this document nor the information contained herein shall be copied. No response will be received if this is successful as communication is now at a different rate. Therefore it is recommended that the battery monitoring device monitor and control the voltage levels by controlling the power output of the turbine. Both fuel index 1 and fuel index 2 should be adjusted as necessary for the specific fuel being used. The relay set points should be slightly higher (overvoltage) or lower (undervoltage) than the setpoints in the battery control unit to prevent turbine shutdowns. and requires no change. The default setting is 57600 bps. Protective Relays NOTE Refer to Model C30 and C60 HEV Electrical Technical Reference Manuals (410030 and 410031) for detailed explanations and additional information for both C30 and C60 systems. All settings may be configured using the display panel under the HEV Connection menu RS-232 commands. Fuel Indices Fuel indices are used to determine fuel flow required for operation of various fuels. the product specifications. (3) Prototype Inspection. the design. 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 Qualification Process involves four steps: (1) Application. and (4) Design Approval. In addition to these four steps. The original Product Specification in addition to any written comments from Capstone will signify a completion of Step 1 – Application. Once the model warranty activation has been achieved. disclosed to others. Prototype Inspection Design/ Installation Approval Production System Installation Application Product Design The various Design Qualification steps are detailed in the paragraphs presented on the following pages. Neither this document nor the information contained herein shall be copied.Capstone Turbine Corporation • 21211 Nordhoff Street • Chatsworth • CA 91311 • USA Application Guide: C30 and C60 Hybrid Electric Vehicle (HEV) Application Information for Capstone System Design Guidelines and Processes This section describes the OEM Design Qualification Process. Step 1 – Application The OEM Partner submits a Product Specification describing the proposed design application. and/or the contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction. Production Manufacturing and System Installation are also critical elements to achieving reliable MicroTurbine system operation. the successful completion of which will result in activation of Capstone’s factory warranty for the OEM Partner’s product model. the OEM Partner will submit Production Build Sheets as appropriate and end user Commissioning Checklists to activate the Capstone factory warranty for individual MicroTurbine systems. . The Product Specification must include the following items: ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ Overall description of the OEM product MicroTurbine power versus demand profile (including derating) MicroTurbine air intake system description MicroTurbine exhaust system description Digital controller air intake and exhaust system description MicroTurbine load control algorithm description MicroTurbine power interface description Regulatory requirements Safety features and options description Monitoring and/or diagnostics system description Any other pertinent information Capstone will review and comment on the Product Specification and then return the Product Specification to the OEM Partner with constructive feedback. (2) Product Design. Production Build Sheets are discussed in this document. 480009-001 Rev B (October 2004) Page 46 of 54 This information is proprietary to Capstone Turbine Corporation. refer to Capstone’s HEV Commissioning Checklist Instructions (440075) for more information about the Commissioning Checklist (460030). The flowchart detailed below illustrates this process. Plumbing and wire routing in the MicroTurbine area must be adequate. plus the cooling air system and filter drawings All interconnection wiring diagrams ♦ ♦ MicroTurbine Module Mounting Module mounting details are presented as follows: ♦ The MicroTurbine must be mounted as specified in the relevant Outline & Interface (O&I) drawing.Capstone Turbine Corporation • 21211 Nordhoff Street • Chatsworth • CA 91311 • USA Application Guide: C30 and C60 Hybrid Electric Vehicle (HEV) Application Information for Capstone Step 2 – Product Design The OEM Partner submits Product Documentation for Capstone’s review and comment. including component mounting. Ventilation and proximity to flammable or heat-sensitive materials must be adequate. and other systems as necessary. or used for any purposes other than the specific purpose for which this document was delivered. In general. Neither this document nor the information contained herein shall be copied. connections. Capstone reserves the right to change or modify without notice. the Product Documentation should include the following: ♦ ♦ ♦ Engineering Drawings Control System Specifications Various schematics illustrating the interfaces to the Capstone MicroTurbine system. ♦ ♦ ♦ ♦ MicroTurbine Inlet Inlet details are presented as follows: ♦ MicroTurbine air inlet must be installed per the specification provided in the O&I drawing Intake filter brand and model Intake filter micron rating must meet Capstone specifications Inlet filter pressure drop at full load with a new air filter Inlet pressure drop at full load with the filter one-half blocked Description of the MicroTurbine intake inlet and ducting Description of sound attenuation (if applicable). and the necessary plumbing Controller mounting and access. Page 47 of 54 ♦ ♦ ♦ ♦ ♦ ♦ 480009-001 Rev B (October 2004) This information is proprietary to Capstone Turbine Corporation. and fittings used. disclosed to others. access. Additionally. Careful allowance must be made for maintenance access. the following items should be used as a guideline during the design and manufacturing process and should assist in developing the Product Documentation: ♦ ♦ MicroTurbine air intake/filter and exhaust system drawings Fuel system drawings. and/or the contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction. the design. the product specifications. Description of fasteners. especially to allow component troubleshooting and replacement according to the time values allowed by the Capstone standard “Flat Rate Schedule” for valid warranty claims. . the design. ♦ ♦ ♦ Electrical Connections Electrical connection details are presented as follows: ♦ ♦ Description of cable assembly routing for all subsystem components Subsystem electrical components must be mounted and installed per relevant Outline & Interface drawings Isolation switch brand and model Isolation switch electrical rating Description of isolation switch control and operation Description of external emergency stop switch (if applicable) Description of emergency stop control and operation The OEM package must be properly grounded in accordance with all of the various Capstone specifications and details ♦ ♦ ♦ ♦ ♦ ♦ 480009-001 Rev B (October 2004) Page 48 of 54 This information is proprietary to Capstone Turbine Corporation.Capstone Turbine Corporation • 21211 Nordhoff Street • Chatsworth • CA 91311 • USA Application Guide: C30 and C60 Hybrid Electric Vehicle (HEV) Application Information for Capstone MicroTurbine Exhaust Exhaust details are presented as follows: ♦ ♦ ♦ Description of the exhaust connection to the MicroTurbine Back pressure at full load Back pressure must meet Capstone specifications as illustrated in the relevant MicroTurbine Outline & Interface drawing Description of the ducting and proximity to flammable or heat sensitive materials Description of the exhaust outlet orientation ♦ ♦ Electrical Ventilation Electrical ventilation details are presented as follows: ♦ Air intake must meet Capstone specifications for all electronics as specified in the relevant Outline & Interface drawings Intake filter brand and model for the Electronic Controller(s). Pressure drop across the Controller(s). or used for any purposes other than the specific purpose for which this document was delivered. disclosed to others. the product specifications. Description of the cooling air inlet and outlet. Capstone reserves the right to change or modify without notice. and/or the contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction. . Neither this document nor the information contained herein shall be copied. Capstone reserves the right to change or modify without notice. etc. the product specifications. The OEM Partner’s implementation of the Capstone requirements into the design will indicate completion of Step 2 – Product Design. pressure drop measurements. . Capstone will issue technical instructions to the OEM Partner indicating possible design modifications. Step 3 – Prototype Inspection When the OEM Partner has a prototype ready for final approval. the design. disclosed to others. or used for any purposes other than the specific purpose for which this document was delivered.) to confirm compliance with the Capstone specifications and details. Neither this document nor the information contained herein shall be copied. Step 4 – Design/Installation Approval Capstone will issue a letter signifying approval of the OEM Partner’s product model after the successful completion of Steps 1 – 3. including possible recommendations or requirements from Capstone to make design modifications.Capstone Turbine Corporation • 21211 Nordhoff Street • Chatsworth • CA 91311 • USA Application Guide: C30 and C60 Hybrid Electric Vehicle (HEV) Application Information for Capstone Fuel System Fuel system details are presented as follows: ♦ Fuel components must be mounted and installed as specified in the relevant Outline & Interface drawing. and/or the contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction. 480009-001 Rev B (October 2004) Page 49 of 54 This information is proprietary to Capstone Turbine Corporation. Based upon the inspection of prototype and test results. Shutoff valve and pressure regulator installed Pressure regulator brand and model Pressure regulator pressure rating Inlet strainer/filter assembly must be accessible Fuel components must be accessible ♦ ♦ ♦ ♦ ♦ ♦ Control System Control system details are presented as follows: ♦ ♦ ♦ Communications and control description via RS-232 Description of output relay connections in the User Connection Bay (UCB) Description of other interfaces to the MicroTurbine Capstone will review the Product Documentation and will offer constructive feedback. For propane systems. Implementation of the modifications indicates completion of Step 3 – Prototype Inspection. a complete description of gasification process (including drawings of system and components) is required. Capstone will physically inspect the prototype and the accompanying test reports (including temperature measurements. Neither this document nor the information contained herein shall be copied. disclosed to others. Capstone reserves the right to change or modify without notice. the design. the product specifications.Capstone Turbine Corporation • 21211 Nordhoff Street • Chatsworth • CA 91311 • USA Application Guide: C30 and C60 Hybrid Electric Vehicle (HEV) Application Information for Capstone Production System Installation The OEM partner is responsible for completing and submitting an HEV Commissioning Checklist (460030) for EVERY system that is installed in order to receive warranty and technical assistance from Capstone Turbine Corporation. An ASP is required to complete and sign every checklist. The Commissioning Checklist Instructions can be found in document 440075. The HEV Commissioning Checklist includes the following information: • • • • • • • Manufacturer Information Vehicle Owner Information MicroTurbine component part numbers and serial number Summary of checklist Operational verification and data System configuration and relay settings Any other pertinent functionality items The OEM partner will keep the master copy of the OEM Commissioning Checklist and will send a copy to Capstone for each system manufactured via FAX or e-mail. and/or the contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction. or used for any purposes other than the specific purpose for which this document was delivered. 480009-001 Rev B (October 2004) Page 50 of 54 This information is proprietary to Capstone Turbine Corporation. . Capstone reserves the right to change or modify without notice. disclosed to others. OEM Design Qualification Process 480009-001 Rev B (October 2004) Page 51 of 54 This information is proprietary to Capstone Turbine Corporation.Capstone Turbine Corporation • 21211 Nordhoff Street • Chatsworth • CA 91311 • USA Application Guide: C30 and C60 Hybrid Electric Vehicle (HEV) Application Information for Capstone The complete OEM Design Qualification Process is detailed in Figure 17. . or used for any purposes other than the specific purpose for which this document was delivered. the design. and/or the contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction. Neither this document nor the information contained herein shall be copied. Figure 17. the product specifications. 0 inches (Model C60) clearances to remove from the engine. the injectors require 8. data logging. For maintenance items such as the injectors. and automation for Capstone MicroTurbines.Capstone Turbine Corporation • 21211 Nordhoff Street • Chatsworth • CA 91311 • USA Application Guide: C30 and C60 Hybrid Electric Vehicle (HEV) Application Information for Capstone Capstone Remote Monitoring Software The Capstone Remote Monitoring Software (CRMS) is a software tool that provides dispatch. please refer to CRMS User’s Manual (400001) for basic user information. For additional information with regards to operating CRMS.5 inches (Model C30). pump. Neither this document nor the information contained herein shall be copied. Injector Removal 480009-001 Rev B (October 2004) Page 52 of 54 This information is proprietary to Capstone Turbine Corporation. the design. Maintenance Items NOTE Refer to MicroTurbine Standard Maintenance Schedule Work Instructions (440000) for recommended service intervals. Figure 18 shows examples of Model C60 and C30 injector removal. Model C60 Model C30 Figure 18. monitoring. disclosed to others. and 9. and CRMS Technical Reference Manuals (410013 and 410014) for integration-level maintenance and monitoring. control. trending. and the SPV. or used for any purposes other than the specific purpose for which this document was delivered. In particular. the product specifications. E-mail alarming. Capstone reserves the right to change or modify without notice. . and/or the contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction. the integrator needs to allow for clearance for removal and installation of each item. ignitors. or used for any purposes other than the specific purpose for which this document was delivered. The courses are intended to train individuals on the overview for both the C30 and C60 systems. available accessories and maintenance.Maintenance Level Model C30 Acoustic Emissions Technical Reference HEV Liquid Fuel Technical Reference Model C30 HEV Electrical Requirements Technical Reference Model C60 HEV Electrical Requirements Technical Reference MicroTurbine Communications Technical Reference Model C30 Service Manual Model C60 Service Manual MicroTurbine Standard Maintenance Schedule Work Instructions Engine Air Filter Cleaning Work Instructions HEV Commissioning Checklist Work Instructions HEV Product Specification HEV Commissioning Checklist Page 53 of 54 Title 480009-001 Rev B (October 2004) This information is proprietary to Capstone Turbine Corporation. disclosed to others. including control systems. component functionality. Please contact Capstone for additional information on class schedules and costs. Warranty Information Warranty details are provided in the Standard Warranty. Neither this document nor the information contained herein shall be copied.User Level CRMS Technical Reference Manual . the product specifications. Document No. and the 2-Year Extended Warranty. 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 Application Guide: C30 and C60 Hybrid Electric Vehicle (HEV) Application Information for Capstone ASP Training Capstone offers training courses for personnel to become Authorized Service Providers (ASP) and Certified Technician training for the MicroTurbine system. Capstone reserves the right to change or modify without notice. the 1-Year Extended Warranty. 400001 410002 410004 410005 410013 410014 410025 410029 410030 410031 410042 430004 430017 440000 440053 440075 460009 460030 MicroTurbine Users Manual MicroTurbine Fuel Requirements Technical Reference Model C30 Performance Technical Reference Model C60 Performance Technical Reference CRMS Technical Reference Manual . fuel systems. . programming and commissioning of a system. ASP training will also provide additional information and training on troubleshooting. the design. Related Documents A listing of related documents is provided in the following table. disclosed to others. . Neither this document nor the information contained herein shall be copied.Capstone Turbine Corporation • 21211 Nordhoff Street • Chatsworth • CA 91311 • USA Application Guide: C30 and C60 Hybrid Electric Vehicle (HEV) Application Information for Capstone NOTES 480009-001 Rev B (October 2004) Page 54 of 54 This information is proprietary to Capstone Turbine Corporation. Capstone reserves the right to change or modify without notice. and/or the contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction. or used for any purposes other than the specific purpose for which this document was delivered. the product specifications. the design. Capstone Turbine Corporation • 21211 Nordhoff Street • Chatsworth • CA 91311 • USA Application Guide: C30 and C60 Hybrid Electric Vehicle (HEV) Application Information for Capstone Appendix A Available Accessories for HEV Systems This appendix contains a list of available accessories for HEV systems. Seal Nuts Filter Support Filter Filter Plate Wing Nut Washer Description C30 Plenum. . Capstone reserves the right to change or modify without notice. disclosed to others. the design. Neither this document nor the information contained herein shall be copied. and/or the contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction. DPC Air Intake C60 Air Filter C60 Air Filter Housing 480009-001 Rev B (October 2004) Page A-1 This information is proprietary to Capstone Turbine Corporation. or used for any purposes other than the specific purpose for which this document was delivered. the product specifications. Part Number 514428 510278 511332 Drain Tank Display C30 Air Filter Kit Includes the following (part of kit only): 507878 507555 507885 507566 507567 509453 509454 509455 513510 510896 512072 Seal Flange. HEV. T1 Thermistor to ACM ) Drawing 513028 (CABA. V1.Capstone Turbine Corporation • 21211 Nordhoff Street • Chatsworth • CA 91311 • USA Application Guide: C30 and C60 Hybrid Electric Vehicle (HEV) Application Information for Capstone Appendix B . Compressed Natural Gas) Drawing 514418 (Schematic. V1. Top-Level. W114. W102. W102. Engine Peripheral and PM) Drawing 512986 (CABA. Fan Ext with Shield. W105. disclosed to others. Engine. V1. Inter Sys Connect) Drawing 510077 (CABA.Drawings and Diagrams Appendix B contains a list of reference drawings related to HEV system operation. HEV. Engine Peripheral & PM) Drawing 508882 (CABA. Top-Level) Drawing 511958 (Schematic. LFC Manifold) Drawing 509149 (CABA. Bus ± ECM/BCM. Natural Gas. BCM) Drawing 510073 (CABA. HP. AC. OEM) Drawing 512451 (O & I. HEV. UCB) Drawing 509060 (Controller Assembly. Intra & UCB Option) Drawing 514367 (CABA. V1. HEV. W122. Liquid Fuel. W115. Liquid Fuel) Drawing 510627 (O & I. W106. C60 LIP) 480009-001 Rev B (October 2004) Page B-1 This information is proprietary to Capstone Turbine Corporation. W114. LFC P-Sense/Drain Switch) Drawing 514080 (Filter and Boost Pump Assembly) Model C60 Drawing 512965 (O & I. 20º Engine. OEM) Drawing 512842 (O & I.asp) and select the Sales/Marketing tab (“HEV drawings”) to access the complete set of HEV drawings. 20 degree) Drawing 508694 (HEV. HEV. and/or the contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction. SPV Fuel Pressure) Drawing 513667 (CABA. Top Level) Drawing 508691 (DPC. HEV. Intra Harness Connection) Drawing 513027 (CABA. W107. W101. V1. Top-Level. . Fuel. Battery Controller. Click on the Member’s Only section of the Capstone website (http://www. C60 LIP) Drawing 512462 (CABA. HEV. HEV. V1. Natural Gas. W101. Top-Level. 20º Engine. W118. the design. or used for any purposes other than the specific purpose for which this document was delivered. HEV. Aux Power/E-Stop) Drawing 511909 (CABA. Top-Level. Ext Jam PMG Power to ECM) Drawing 511371 (CABA. W105. SPV Fuel Manifold) Drawing 509143 (CABA. HEV. HEV. LFC Fuel Pump Power) Drawing 508709 (CABA. W107. Capstone reserves the right to change or modify without notice. Liquid Fuel) Drawing 508881 (CABA. the product specifications. HEV. Engine Controller. HEV.capstoneturbine. OEM) Drawing 512452 (O & I.com/login. HEV Engine Control. OEM) Drawing 512866 (Schematic. Neither this document nor the information contained herein shall be copied. Model C30 Drawing 510366 (O & I. PMG Power) Drawing 509140 (CABA. Top-Level) Drawing 514691 (Schematic. W103. W106. V1. HEV.