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WhatisaSmartDrive?

Fisher&PaykelSmartDriveWashingMachines

Disclaimer
Systemsrunningon60voltsandlowercannot,undernormalcircumstances, causedeathinhumansbyelectrocution.Whenfreelyspinning,SmartDrive unitscanproduceover1500volts,andhavethepotentialtodeliveralethal currentthroughthehumanb Extremecaremustbetakentoensurethatnocontactismadewiththese highvoltages. EcoInnovationacceptsnoresponsibilityforanydamage,injuryordeath resultingfromworkingonSmartDrivewashingmachinemotors.Itisyour responsibilitytoensureyoursafetyandthesafetyofothersthatmaycome intocontactwiththegenerationunit.

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Introduction: ..............................................................................................................3 AdvantageofaSmartdrive: ............................................................................................3 SmartDrivePartsyouneedtofind ..................................................................................3 RenewableEnergySystems.............................................................................................4 HowtofindyourownSmartDriveunitforfree ..............................................................5 Howtogetthepartsyouneed..........................................................................................5 EcoInnovationremovingbearingassemblies ...................................................................7 Machiningthebearingassemblyplastichousing.............................................................8 Conditionofunits............................................................................................................8 Bearingreplacement........................................................................................................9 Spinningofshaftinbearings ...........................................................................................9 DealerEnquirers............................................................................................................10 TestingofSmartDrivesatEcoInnovation .....................................................................10 MaximumPowerPointTrackers(MPPT)......................................................................10 TransformerApplications..............................................................................................11 Howtodecidewhichmodelyoutomakeorpurchase....................................................11 SmartDrivegeneratordata............................................................................................12 StarandDeltaConnections............................................................................................13 SmartDriveStarPoint...................................................................................................14 FirstGenerationstators(100SStarunits).......................................................................14 SecondGenerationstators(80SStarunits) ....................................................................15 ThirdGenerationstators(60SStarunits) .......................................................................15 TypeOneandtypeTworotors ......................................................................................16 3PhaseRectification .....................................................................................................16 SmartDriveReconnections ...........................................................................................17 24voltStar&Delta.......................................................................................................17 80SPStator 24volt.....................................................................................................18 Conclusion.................................................................................................................18

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Introduction:
ThisintroductionisintendedtogiveanoverviewoftheuseofSmartDrivemotorsas generatorsinrenewableenergysystems.Incontainsanoverviewofresultsfor18 SmartDrivegeneratoroptionsat12/24/48volts.Fordetailedinformationonhowto reconnectaSmartDriveyouwillneedtopurchasetheEcoInnovationSmartDrive manual.

AdvantageofaSmartdrive:
Lowspeedgeneratorduetolargediameter Brushlessdesign Lowcostandwidelyavailable Generatorwindingscannotbeburntout Veryefficient Easilyconvertedfordifferentvoltages Largestainlesssteelshaftforeasymounting Goodcorrosionresistance

SmartDrivePartsyouneedtofind
Themotorcomprisesthefollowingcomponents: 25mStainlessSteelshaft Aluminumbearingholder Stator(3typesavailable) MagneticRotor(2typesavailable) 4fixingscrews 2statorwashers 1largeflatwasher

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RenewableEnergySystems

TheabovediagramshowsthemaincomponentsinaRenewableEnergysystem. SmartDrivewindturbine SmartDriveturgoturbine PhotoVoltaicpanels(PV) Solarhotwaterheating Batterybank Inverterconvertsbatterydcpowerto230voltacfornormalhouseuse Regulatorcontrolsbatterycharginganddivertspowernotrequiredtohot water

HydroisthemostcosteffectiveasinglePeltonorturgoturbinecangenerateallthe powerthatanenergyefficienthouseneeds.Anoffgridhousewithouthydrowill normallyneedbothawindandsolarPVsystem. IfyouwantRenewableEnergytosucceed,establishyourhousetobeenergy efficient: Goodenergyefficientrefrigeration Compactflorescentlights LCDflatscreenTVandcomputer(preferred) Goodinsulationanddoubleglazingwithpassivesolarheating Goodenergyefficienthabits LPGcooking Sparinguseofelectricappliancesthatproduceheat Solarhotwaterheatingwithwoodfire(orLPGgas)backup

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HowtofindyourownSmartDriveunitforfree

IfyouliveineitherNewZealandorAustraliayoushouldbeabletolocatesuitable partsatthelocaltip,transferstation,orrecyclingcenter.Anotheroptionistoplace anadvertinthewantedcolumnofyourlocalpaperBrokenF&PSmartDrive washingmachinesforparts. Unfortunately,inNewZealandtheHealthandSafetylawsoftenpreventprivate individualsfromenteringlocaltipsastheownersareliableshouldyouhavean accidentwhilelookingforparts.Ifthisisthecaseaskthepeoplethatworkatthe yardtoputasideafewSmartDrivewashingmachinesforyouandthatyouwill eitherpayforthemordropthemoffafewdozenbeersfortheirtrouble.Ifyouare aftersignificantnumbersthenapproachtheownersformallywithaproposaland makeitclearthatyourorganizationtakesfullresponsibilityforthesafetyofyour workerswhileonsite.Youllneedhardhatsandfluorescentjacketsandtheworkers sentwillneedtobetrainedetc,butitcanbedoneanditisworthyourwhileifyou wishtolocatesignificantnumbersoftheseunits.Imawareofanothercompanythat isalreadyactivelydoingjustthisinNewZealand.Ibelievetheypay$10perunitto thetipowners.

Howtogetthepartsyouneed
ThereisverylittletoaSmartDrivewashingmachine,theycanbedismantledina matterofminutes.Removetheplastictopunhookthe4bowlhangersfrominside andliftouttheentirebowlasshown.

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Removethecapfromthetopoftheagitator,reachinsideandundotheplasticnut thatholdstheagitatorontotheshaft.Removetheagitatorthenundothescrewson theretainingring.

Youcannowremovethestainlesssteelbowlfromwithintheplasticouterbowl. Turntheunitoverandworkfromthebottom,removethemagneticplasticrotor.It shouldlooklikethepicturebelow.

Undothefourfixingscrewsthatholdthecopperwirewoundstatorontothebearing assemblyyoucannowcutoutthebearingassemblyfromtheplasticbowlwitha sabersaw.Ifyoudonthaveasabersawyoucouldhireone.Theotherwaywould betouseajigsawtocutthebottomofftheplasticbowlandthenuseabandsawto cutthebearingassemblyfromthispiece.Resistthetemptationtouseachainsaw itisnotagoodidea. Thecutbearingassemblyshouldlooklikethis:

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Thepicturesshowtheroughcutbearingassemblyviewedfrombothends,andthen thesameviewaftertheunithasbeenmachinedonalathe.Notethatthesealhas beenremovedandtheplasticmachineddowntoexposethealuminumfixing channels.Thisallowstheunittobefixedtoamountingsurface.

EcoInnovationremovingbearingassemblies

RecyclingatEcoInnovation

Roughcutbearingassembliesbythe100s cleanedupandreadytomake intoproducts.

Bearingassemblies directfromF&P

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EcoInnovationshaftsandbearingassembliesjustafewandthemany thousandinstock

Machiningthebearingassemblyplastichousing
Tomachineonalathe,puttheshaftintothe3jawlathechuck,slideonthebearing assemblywiththefourfixingscrewshalfin,sothatthescrewsrestinbetweenthe jawsofthechuck.Whenthelatheisstartedthebearingassemblywillrotatewith theshaftandcanbemachineddown.Takeonlysmallcutsotherwiseyouwillshear offthefixingscrewsfromthebearinghousing.Forproductionwork,makea dedicatedjigtoholdtheroughcutbearingholderssecurelysothatlargecutscanbe made.

Conditionofunits
TheSmartDriveunitsyoumanagetolocatemaynotbeinexcellentcondition.Itis fairlycommonontheseunitsforradialcracks(likespokesonawheel)tohave formedintheplastichousingofthecopperwoundstator.Todatetheydonotseem tobeaproblem,inawashingmachineapplicationthemotorstatorissubjectedto repeatedhightorquereversals(notthecaseinrenewableenergyapplications).The cracksaremadebythehightorquereversalsandtemperaturechangesinthemotor. Thecracksformbutgenerallydonotgetanyworse.Wehaveneverhadaunitfail yetduetoacrackedstator.Wesellcrackedunitsinourinvertorskitsataverygood price,ifyouwanttogetyourhandsonathecompletehistoryoftheSmartDrivein onehitthentheinventorskitisthewaytogo.AllotherunitssoldbyEcoInnovation areinexcellentconditionwithupto1hairlinecrackornocrackspresentintherotor. Youpayalittlemoreforthem.

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Typicalcrackonaninventorskitstator

Bearingreplacement
Thebearingsareeasyandcheaptoreplace.Toreplacebearingsknocktheoldones outfromtheinside(usealengthofsteelrodoroldbolt)andpressthenewonesinto place,useamallettotapthemfullyhome.Suggestyouthoroughlycleanthenew bearingsandhousingsurfaceandapplyasmallamountofLoctiteontothesurfaces priortoassembly.

Spinningofshaftinbearings
Afteranumberofearlyfailures,EcoInnovationbecameawarethatinorderto preventthebearingspinningontheshaftisitabsolutelynecessarytoloctitethe shaftontothebearings.Remembertothoroughlycleanthesurfacetobegluedfirst. Thispreventsthebearingfromspinningwhichwouldotherwisedamagetheshaft leadingtomisalignmentofthestatorandrotor. Anothergoodtipistolightlyknurlthebearingsurfaceonalathe.Thisroughensthe surfaceandprovidesgoodadhesionfortheloctite.Knurlingalsoincreasesthe outsidediametersothefitchangesfromaclearancefittoaninterferencefitandthe shaftwillneedtobetappedintothebearingwithamallet.Thisisadvisableon highlyloadedshaftswherethereissignificantsideloadingfromachainorVbelt.

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Ifyoudoforgettodothisandtheshaftspinsinthebearing,ifthedamageisonly minortotheshaftyoucandotpunchtoraisethebearingsurface,thenloctiteand tapthebearingonwithamallet,thisusuallyfixestheproblem.Itpaystoloctiteit first.EcoInnovationcansupplyreplacementshaftsverycosteffectivelyifrequired.

DealerEnquirers
EcoInnovationhasinstockhundredsofSmartDrivesandareopentodiscussionon volumeordersofSmartDrivestoindividualsorcompanieswishingtomaketheir ownRenewableEnergyproductswiththem.WeusuallysendasampleSmartDrive airfreightatcosttoaninterestedcompany,quantityorderswouldthenbea minimumof50unitssentbyseafreight.Allunitsarecheckedandcleanedpriorto dispatchandaresoldinasnewcondition.Asignificantdiscountisofferedonsuch orders.

TestingofSmartDrivesatEcoInnovation
EcoInnovationtestedSmartDrivesonamodifiedlathethatwasfittedwithavariable speeddrive.Thepowerofthedrivingmotorlimitedthetestresultsto600700Watts ofoutput.However,theperformancetrendhasbeenestablishedbythesetestsand itispossibletoextrapolatethistrendtoestimatetheperformanceathighrpms.The SmartDriverotorisnotbalanceandrunsverysmoothlyinthe11200rpmrange. Vibrationscanbedetectedabove1200rpmandthemagneticrotorshouldbe balanceabovethisspeed.Inthe12001800rpmrangeguardagainstrotorfailure andcovertheSmartDriveincaseoffailure.Thistendstoapplytoenginedriven SmartDrivesandhighspeedwaterturbineapplications.Inthewindturbine applicationsensureyourmaximumrpmiskeptunder1800rpmandthatthestatoris balanced. Testswereconductedonasimulated12/24/48voltbatterysystemwithXantrexC40 chargecontrollermaintainingsystemvoltageat13.8/27.6/55.2voltsrespectively. ThetestresultsaccuratelyrepresenttheperformanceofaSmartDriveconnected directlytoabatterybankatconstantvoltage.Thetestsincludedrectificationlosses andtheefficiencygraphsshouldbeusedtoindicatethemostsuitableunitfora particularapplication. EcoInnovationiscurrentlyhavingmoretestsdoneusingonly36fingersoftheSmart Driveandincludingthelatesttypefour(cogfree36finger)design.The36finger optionresultsinmanydifferentreconnectionoptionsnotavailableifall42fingers areused.Thesetestswillgenerateover1000datasetsandtheinformationwillbe availableforsaleonCDonly.

MaximumPowerPointTrackers(MPPT)
ThetechnologybehindMPPTislikelytorevolutionizetheuseofgeneratorsinwind andhydroapplicationsinthefuture.TodateMPPTsaretooexpensivefortheDIY enthusiast.Theseunitsallowthegeneratortorunatitsoptimumpowerpointwhile deliveringthevoltagerequiredtoyourbatterybank.Ineffecttheyhavetheabilityto matchthegeneratortotheapplicationforyou.Insteadystatehydroapplications thisisnotrequiredbutinwindturbineapplicationscouldresultinsignificant increasedoutputoftheturbine.EcoInnovationiskeepingacloseeyeonsuch developmentsasintimeitwillhopefullybecomemorecosteffective.

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TheotheradvantageofMPPTisthatyoucangenerateamuchhighervoltagethan yourequireatthebatteryendtosaveoncablinglosses.Thereareanumberof hydroschemesremotefromthebatterybanksthatdojustthis.AMPPTatover $1000isstillmuchmoreexpensivethatusing3xtoroidaltransformerstodothe samejob.Transformersrequiremuchmoreskillinsettingupbutcostlessthan$300 andtheyarelesssensitivetobeingaccidentallydamagedbyahighvoltagespike.A MPPTwouldbemoreefficientatabout95%comparedto80%for3transformers.

TransformerApplications
SmartDrivesarehighfrequency3phasegenerators,thefrequencyoftheunit= rpm/2.15.SmartDrivesrunningat500rpmwillhaveafrequencyof232Hz.Units runningatmaximumpowerof1.4kWcanputoutover700Hz,whichistoohighfor normalofftheshelftransformers. EcoInnovationhasdevelopedatransformerapplicationusing3toroidaltransformers, theseoperatewellathighfrequenciesandarecheaptopurchase.Itispossibleusing 3x300VAtransformerstomakeatransformerpackcapableofdelivering1.4kWof powerat24and48volts.Thetransformerswillneedgoodaircirculationandasmall fantoassistcoolingifpushedabovethe900VArating. Insettinguptransformersyouwillbedealingwithvoltagesinthe300500volt rangesoyouneedtobecareful,wedonotrecommendthattheDIYenthusiastwork withthesehighervoltagesunlesssufficientlyskilledandqualifiedtodoso. ThetransformerprimariescanbeconnectedinStarorDelta,ascanthesecondaries. Thetransformerwillalmostcertainlyhavemultipleprimaryandsecondarytaps.The SmartDrivecanalsobeconfiguredinStarorDeltaandusedwiththe100S,80Sor 60Sstatorsinthisapplication.Thetypicalconfigurationofthissetupisindicated below: 3xJaycartransformers110/230to12/24 230voltprimaryconnectedintostarofdelta Secondaryconnectedintostarordelta SSmartDriveineitherstarordelta

Notethe24volttappingisusedfor48voltsystems(asthetransformersare runningabove230volttheyweredesignedfor)andthe12volttappingfor24volt applications.

Howtodecidewhichmodelyoutomakeorpurchase
RefertotheattachedSmartDriveTestResultSummaryGraphsthesearethefirst6 graphs.Thetestrigwasnotabletotesttheunitsbeyond600700Wattsofoutput power.Bystudyingalltestresultsitispossibletoobservethetrendandtherefore makefairlyaccurateestimatesoftheperformanceofSmartDriveabovethe600700 wattrangetested. FurthertestsconductedbyEcoInnovationindicatethatthemaximumpoweroutput ofaSmartDriveisintheregionof1.4kWat16001800rpm.Thiswasachievedan 80SPunitconnectedtoa48voltbatterybank. Notation

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160=1.6mmwirediameter(30turns/finger),youcanrewiretheunitsby handifyouwish 100=1.0mmwirediameter,asusedonfirstgenerationSmartDrives 80=0.8mmwirediameter,asusedonsecondgenerationSmartDrives 60=0.6mmwirediameter,asusedonthirdgenerationSmartDrives S =seriesconnection,asstandard SP =halfserieshalfparallelconnection P =parallelconnection

SmartDrivegeneratordata
Model Wire Diameter mm Wire Configuration Number Of Turnsper Phase 616 88 44 1610 230 115 2380 340 170 Effective WireArea mm^2 Approx Current Rating Delta/Star Amps 12/8 84/56 168/112 4.5/3 32/21 64/42 2/1.5 14/10 28/20

100S 100SP 100P 80S 80SP 80P 60S 60SP 60P

1.0 1.0 1.0 0.8 0.8 0.8 0.6 0.6 0.6

Series Series/Parallel Parallel Series Series/Parallel Parallel Series Series/Parallel Parallel

0.79 5.50 11.00 0.50 3.52 7.04 0.28 2.00 4.00

ChangingfromanStoaSPincreasesthewireareaby7timesandreducesthe numberofturnsby7times.Theoperationalperformancewillthereforebeatseven timesthespeedandgoodfor7timesthecurrent.Likewise,changingfromanStoa Pincreasesthewireareaby14timesandreducesthenumberofturnsby14times. Theoperationalperformancewillthereforebeat14timesthespeedandgoodfor14 timesthecurrent. TheSmartDriverotorprovidesexcellentcoolingitisveryunlikelyoverheatingwill beaproblem.Themaxcurrentsindicatedintheabovetableshouldnotbetakenas thecontinuousoperationalcurrentratingbuttheabsolutemaximumthattheunit candeliver.Continuousoperationshouldbeatlessthantheabovevalues.Someof thevaluesintheabovetable,100SPforexample,willrequirerpmsmuchhigher thanthemaximumrecommendedrunningspeedof1800rpm. Itispossibletoreconnecttheunitsintomoreconfigurations.Thenineoptions presentedherehavebeenadoptedasthereconnectionsutilizeall42fingersofthe unit.Otheroptionssuchasathirdinseriesandtwothirdsparallelwoulduse36 fingersandwouldyieldaperformancebetweentheSPandPconfiguration.The SmartDriveunitscanthereforebetailoredtoyouexactrequirements. Theunityoumanagetoobtainwillhaveacertainwiresize.Ifyoulocateaunitwith 0.8mmwiresizethenthisunitisreferredtoasan80Smodel.Fromthismodelyou canmakeeitheran80SPor80P.Youwillneedtodecidewhichmodelyouwishto makethiswilldependontheoperationalspeedandpoweryourequireforyour

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application.Youshouldperusetheperformancegraphsinordertodeterminethis. Refertothesummarygraphsforallmodelsgroupedbyvoltage12/24/48. Decidewhichvoltagesystemyouintendtouse.Avoid12voltsifpossibleassuch systemshavehighinherentlosses.Mostcountriestelephoneexchangesarerunon 48voltsystems.Thesetelephonecompaniesareagoodsourceofequipmentsuch assecondhandbatteries,charger/rectifiersets(forgeneratorchargingyourbattery bank),cabling,inverters,cabinets,meters,andonoccasionsPVpanels.Ifyou choosea48voltsystemthenthereisagoodchanceyoucanscroungeretired equipmentfromthem.ForthesereasonsEcoInnovationinstallspredominantly48 voltsystems.Also48voltsystemshavehighergeneratorefficienciesandfewer lossesincablingandrectification. 12and24voltsystemsareverycommonandthecheapertypesquarewave invertersfromTaiwanarereadilyavailableatthesevoltages. Onceyouhavedecidedthesystemvoltage,youneedtoselectaperformancecurve thatmeetstherequirementsofyourapplication. Theperformanceoftheunitscanbetunedbypackingthemagneticrotorupfrom thefullyhomepositionthisreducesthemagneticfieldstrengthandincreasesthe operatingspeedontheunits. ThefollowingexamplesshouldassistyouinselectingthecorrectSmartDrivefor yourapplication.

StarandDeltaConnections
Smartdrivemotorsarewoundwiththreephases,youwillnotice6connectionsona SmartDrivestatorthesearethetwoendsofeachphase. Manyreaderswillbeunawareofthetwotypesofconnectionthat3phasemotors andgeneratorscanbeconfiguredinto:thesesarecommonlyreferredtoasStaror Delta.Howtheunitisconnectedhasasignificantbearingontheoperating performanceoftheunits,thereforeeachunitcanbeconfiguredtohavetwo operatingpoints.Theseconfigurationsareillustratedbelow.Thecopperwindings thatmakeupeachphase(14fingersonaSmartDrivestator)areillustratedbelow intheStarandDeltaconfiguration.AllSmartDrivesasconnectedinFisher&Paykel washingmachinesareconnectedinStar.Thispointiseasytoidentifyasa3 prongedbrassclipformsthestarpointasshownbelow.

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SmartDriveStarPoint

StarConnection

DeltaConnection

FirstGenerationstators(100SStarunits)
Theseunitscanberecognizedquicklybythewirediameterusedtowindthestator. Itisapproximately1.00mmdiameterandSerieswoundinStarhencethename 100SStar.

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Resistanceofeachphase=1.0ohms

SecondGenerationstators(80SStarunits)
Theseunitscanberecognizedquicklybythewirediameterusedtowindthestator andtheirverytidyappearance.Itisapproximately0.80mmdiameterandSeries woundinStarhencethename80SStar.

Resistanceofeachphase=5.8ohms

ThirdGenerationstators(60SStarunits)
Theseunitscanberecognizedquicklybythewirediameterusedtowindthestator. Itisapproximately0.60mmdiameterandSerieswoundinStarhencethename 60SStar.

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Resistanceofeachphase=15.2ohms

TypeOneandtypeTworotors
Theearlytypeonerotorsareverydistinctivewith56separatemagnets.These rotorsarecommonlyfoundonwashingmachinesthathave100Sstatorsinside.The typetworotorsappeartohave14largemagnets,thishoweverisanillusion,as withineachmagnetthereareinfact4separatemagnets.

Type1rotor(olddesign)

Type2rotor(latestdesign)

3PhaseRectification
ASmartDriveisa3phasealternator.Ithastobeforittobeforbrushlessdesign. ForDCoutputyouneedtousea3phaserectifier.Youcaneitherbuyoneormake oneyourself.Singlephaserectifierblocksareverycommon.Fromthreeofthese blocksyoucanmakea3phaserectifierwhichislessexpensivethanbuyinga dedicated3phaseunit.Caralternatorsalsohaveinsidethem3phaserectifiersand shopsthatsupplycaralternatorscansupplyyou.

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Automotivetype singlephaserectifiers

Electricalcomponenttype

DIYfrom3

Ontheautomotivetypeunitshowntheheatsinksarethepositiveandnegative terminals,thethreeACterminalsareclearlyshown. Electricalcomponent3phaserectifierscanbeexpensiveinthelargesizesthese have5terminalsasshown. DIYrectifiersyoucanmakeyourselfwith3singlephaserectifiersatshown.Solder allthepositivesandallthenegativestogetherandeachphaseontothetwoACpins oneachsinglerectifierblock.

SmartDriveReconnections
AftermanyyearsofexperimentingwithSmartDrivemotorsforuseasgenerators EcoInnovationhasdevelopedamethodofreconnectionthatisrelativelystraight forward,andprovidessecureconnectionswiththeoptiontofinallyconnectthestator intoeitherStarorDelta.Youwillneedtopurchaseourreconnectionmanualto obtainhowtodothisandafullsetoftestgraphs.Aselectionofafewofthese graphsfollow.

SmartDriveTestResultSummaryGraphs

24voltStar&Delta

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24VStar
700 600 OutputPower 500 400 300 200 100 0 0 200 400 RPM 600 800 1000 160S 100SP 100S 80S 80SP 80P 60S 60SP 60P

TestResultDetailedGraphs
DiamondmarkersPower(Watts),SquaremarkersEfficiency(%)

80SPStator24volt
80SP24VStar
700 600 OutputPower 500 400 300 200 100 0 0 200 400 RPM 600 800 1000

Conclusion
TheretaskingofSmartDrivesasgeneratorscanbean environmentallyfriendlyprocess,recyclingacomponentthatwould otherwiseendupinlandfill,creatingclean,renewableenergy efficiently,anddecreasingtheusersdependenceonfossilfuels.Allof ushereatEcoInnovationwishyougoodluckwithyourproject.

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