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Capstone

Capstone 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

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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: service@capstoneturbine.com Capstone Technical Support (Japan) Telephone: (818) 407-3700 Facsimile: (818) 734-1080 E-mail: servicejapan@capstoneturbine.com If you are an Authorized Service Provider (ASP), the Capstone Members Only Website (http://www.capstoneturbine.com/login.asp) may provide solutions to some of 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.

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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
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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 (CONTD)


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

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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 (CONTD)


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

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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

About this Document


This document provides user instructions to operate and maintain the Capstone Turbine Corporation MicroTurbine. This document is intended for user personnel who may not have specific training on the MicroTurbine. Capstone Authorized Service Providers (ASPs) have received rigorous training and have been certified to perform commissioning, troubleshooting, and repair of the MicroTurbine. 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.

Safety Information
This section presents safety information for the user of Capstone Turbine Corporation MicroTurbines. The user must read and understand this manual before operation of the equipment. Failure to obey all safety precautions and general instructions may cause personal injury and/or damage to the equipment. It is the Users responsibility to read and obey all safety procedures and to become familiar with these procedures and how to safely operate this equipment.

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

Symbols
There are three very important symbols used in this document: Warnings, Cautions, and Notes. Warnings and Cautions alert you to situations and procedures that can be dangerous to people and/or cause equipment damage. Notes provide additional information relating to a specific operation or task. WARNING A Warning means that personal injury or death is possible.

CAUTION

A Caution means that damage to the equipment is possible.

NOTE

A Note is used to clarify instructions or highlight information that might be overlooked.

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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

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

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

Only Capstone Authorized Service Providers are permitted access to the inside of the component enclosures. Read and understand the User's Manual before operating the equipment. Read and obey all warnings and cautions. Make sure all fuel connections are tight, free from leaks, and protected from damage. Make sure all electrical connections are tight, clean, dry, and protected from weather and damage. Use hearing protection when you work on or near a MicroTurbine in operation. The MicroTurbine is heavy. Be careful when you move or lift the MicroTurbine. Keep the equipment clean. Keep all flammable materials away from the MicroTurbine and its components. Do not operate or work on the equipment if mentally or physically impaired, or after consumption of alcohol or drugs. Make sure all fasteners are installed and properly tightened. Keep an ABC rated fire extinguisher near the MicroTurbine. Obey all applicable local, state, and national codes and regulations.

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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

Electrical Precautions
The output voltage and residual capacitor voltage of this equipment is dangerous. High voltage can kill or injure. Use caution when you work on electrical equipment. The MicroTurbine system can include multiple sources of power. Turn off the system and lockout the power supply prior to all work on the equipment. NOTE

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

Only Capstone Authorized Service Providers are permitted access to the inside of the component enclosures. Command the MicroTurbine system to OFF. Open the battery isolation switch and unplug the battery cable. Wait five (5) minutes for any capacitive stored voltage to dissipate. Always disconnect all power sources. Use a voltmeter to make sure that all circuits are de-energized. The MicroTurbine system contains and produces high voltage. High voltage can injure or kill. Obey all safety procedures when you work around electrical equipment. Make sure the system is off and the dedicated disconnect switch is in the open position and is locked. This will help prevent injury and damage to the equipment.

WARNING

WARNING

Fuel Precautions
The Capstone MicroTurbine operates on approved liquid or gaseous fuels. Keep flames, sparks, pilot lights, equipment that produces electrical arcs, switches or tools, and all other sources of ignition away from areas where fuel and fumes are present. If there is a fire, use a multi-purpose dry chemical or CO2 fire extinguisher. Fuel lines must be secure and free of leaks. Fuel lines must also be separated or shielded from electrical wiring. If you smell fuel fumes, immediately stop operation of the equipment, close the fuel isolation valve, and locate and repair the source of the leak or call a qualified professional. WARNING MicroTurbine fuel is flammable and explosive. An explosion can cause death or injury to personnel and/or damage to equipment. No open flame or smoking is allowed near the MicroTurbine. Liquid and gaseous fuels can be corrosive. Concentrations of Hydrogen Sulfide (H2S) can be found in Sour Natural Gas and Sour High Btu Gas. Injury to personnel and/or damage to equipment can occur. Minimize exposure to liquid or gaseous fuels and provide satisfactory fresh airflow when you are around equipment.

WARNING

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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

Exhaust Precautions
The Capstone MicroTurbine is designed to produce very safe emissions. The exhaust is clean and oxygen rich (approximately 18% O2), with very low levels of air pollutants. Like all fossil fuel combustion technology, the MicroTurbine can produce dangerous emissions (like nitrogen dioxide and carbon monoxide) from the fuel combustion process. Although the MicroTurbine has ultra low nitrogen dioxide (NO2), and carbon monoxide (CO) emission levels, make sure precautions are taken to prevent personnel from being exposed to nitrogen dioxide and carbon monoxide while the system is operating. Nitrogen dioxide and carbon monoxide are poisonous at high concentrations. WARNING The MicroTurbine exhaust contains nitrogen dioxide and carbon monoxide, which are poisonous at high concentrations. Make sure there is satisfactory fresh airflow when you work around the equipment. The exhaust airflow and pipes are hot enough to cause personal injury or fire. The exhaust airflow can reach temperatures as high as 371 C (700 F). Keep people, equipment, and other items away from the exhaust airflow and pipes. Always vent exhaust away from personnel. Hot surfaces and hot exhaust can be dangerous. Personal injury and/or damage to equipment are possible. Be careful when you work on equipment.

WARNING

WARNING

Acoustic Emissions Precautions


The Capstone MicroTurbine is designed to produce safe acoustic emissions when properly installed in an acoustically treated enclosure. However, when working at a radius of 10 meters (or 33 feet) from an enclosed Capstone MicroTurbine, sound level exposure will average approximately 70 dBA. Capstone recommends that hearing protection be worn when working on or in the immediate vicinity of operating MicroTurbines for extended periods. Other acoustic emissions regulations may apply to your specific installation location. Always check to be certain that your installation complies with all codes required by the local jurisdiction.

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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

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

MicroTurbine Introduction
The Capstone MicroTurbine is an adaptable, low-emission, and low maintenance power generation system that can be used for generating DC voltage in applications such as Hybrid Electric Vehicles (HEV). The MicroTurbine(s) can generate power in series with an on-board battery pack or other DC power supply. The system consists of a turbine engine, solid-state power electronics, and a fuel system. The turbine engine includes a compressor, a recuperator (exhaust gas heat exchanger), a combustor, a turbine, and a generator. The MicroTurbine turbine engine is air-cooled and does not require any lubricants. The compressor impeller, turbine rotor, and generator rotor are mounted on a single shaft, which comprises the only moving part in the engine, and is supported on air-lubricated compliant foil bearings. Power electronics are solid-state, double conversion type, producing direct current (DC) output power from the high-frequency alternating current engine output. The fuel system monitors, regulates, and delivers the fuel to the engine from a fuel source and supports gaseous as well as liquid fuels, depending on system configuration. The MicroTurbine can efficiently use a wide range of approved hydrocarbon-based gaseous and liquid fuels, depending on system configuration. The MicroTurbine produces dry, oxygen-rich exhaust with ultra-low emissions. Utilizing both the generated electric power and the exhaust heat can provide even greater energy cost savings.

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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

Key Mechanical Components


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

Figure 2. Typical Capstone MicroTurbine Engine

Main Features
The various features of the Capstone MicroTurbine are listed below:

State-of-the-art Digital Power Controller with built-in protective relay functions provides direct current (DC) output. Patented air bearings eliminate the need for oil or other lubricants. Air-cooled design of the entire system (turbine and controller) eliminates the need for liquid coolants or lubricants. Center shaft is the only moving part. No gears, belts, or turbine-driven accessories are used. Advanced combustion control eliminates the need for ceramics or other costly materials or any catalytic combustion, and provides ultra-low emissions. Digital control technology facilitates advanced control, monitoring, and diagnostic capabilities, both on-board and remotely (via an RS-232 link). Near zero emissions. Compact size and weight. Minimum maintenance.

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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

MicroTurbine Basic Operation


Ambient air is drawn into turbine engine through an air filter (customer supplied). This air is used to cool the generator, provides air to the air bearings, and used for the combustion process. 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. This process increases the overall efficiency. The heated compressed air is mixed with fuel and burned in the combustion chamber. Patented techniques in the combustion process result in an extremely low emission exhaust stream. The combusted hot gases expand through the turbine, providing rotational power to drive compressor impeller and generator. See Figure 3 for a system air flow diagram.
Generator Cooling Fins Exhaust Outlet Recuperator Combustion Chamber

Electrical Output

Communications and Control

User Interface

Air Bearings Generator Compressor Turbine

Figure 3. Air Flow in MicroTurbine

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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

The output of the generator is variable voltage, variable frequency AC power. Power electronics convert this to programmable DC power for HEV applications. Electrical power output is Direct Current (DC), into the vehicle's main electrical bus. The purpose of the Capstone MicroTurbine HEV system is to generate DC power in series with the HEV battery. The unit accepts commands from a Vehicle Management System (via a RS-232 connection) and outputs the commanded power. Starting and control power are sourced directly from the high voltage DC bus of the vehicle. For vehicles with nominal battery voltage less than 200 volts DC (Model C30), 300 volts DC (Model C60), an external 12-volt (Model C30) or 25-volt (Model C60) battery supply is required to start the system. Figure 4 shows the basic series hybrid configuration.

Figure 4. Basic Series Hybrid Configuration

MicroTurbine System Components


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

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

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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

Fuel System
The MicroTurbine includes an integral fuel delivery and control system. The standard C30 and C60 systems are designed for pressurized hydrocarbon-based gaseous fuels. Other C30 models are available for gaseous fuels with lower heat content and liquid fuels. Contact Capstone for data on approved fuels and performance specifications.

Controllers
The Model C30 HEV system has a single digital power electronics controller called the Digital Power Controller (DPC). The Model C60 HEV System consists of two digital power electronics controllers, Engine Control Module (ECM) and Battery Control Module (BCM). The digital power electronics control the MicroTurbine system operation and all subsystem operations. The digital power electronics changes the variable frequency AC power from the generator to DC voltage, and then to constant DC output to synchronize to the battery pack. During start up, the digital power electronics operate as a variable frequency drive, and motors the generator until the MicroTurbine has reached ignition and power is available from the MicroTurbine. 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.

Figure 5. System Schematic

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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

System Performance Information


NOTE Refer to HEV MicroTurbine Product Specification 460009 for performance derating metric data.

The control modules source power from the vehicle's main DC bus. This DC power is then converted into high frequency AC current, which is used to motor the MicroTurbine engine prior to combustion. Once self-sustaining combustion is achieved, the system enters a warm-up period. As the warm-up is completed, the MicroTurbine system will source power to the vehicle's main DC bus.

Performance Ratings at Full Load Power


NOTE Refer to the Model C30 (410004) and Model C60 (410005) Performance Technical Reference for updated performance ratings.

The following reference performance ratings are listed at full load power and ISO conditions. ISO conditions are defined as: 15 C (59 F), 60% relative humidity, at sea level altitude.
Performance Rating Net Output Power Output Voltage Range Output Current Thermal Efficiency Emissions (NOx) Model C60 60.0 (+0/-2) kW maximum 200 to 700 volts DC 300 Amps (max.continuous) 28.0 ( 2) % <9 ppm V @ 15% O2 Model C30 (NG or Liquid) HPNG: 30.0 (+0/-1) kW maximum Liquid: 29 1 KW minimum 150 to 700 volts DC 128 Amps (max. continuous) HPNG: 25.0 ( 2) Liquid: 26.0 ( 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.

When operating at any other condition other than ISO conditions, the MicroTurbine performance may be reduced due to any combination of the following. Temperature (defined as the actual temperature of the air measured at the compressor inlet). Altitude (ambient pressure) Inlet pressure loss Exhaust back pressure

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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

Electrical Ratings
NOTE Refer to Model C30 (410030) and Model C60 (410031) HEV Electrical Technical Reference manuals for more detail and updated information.

The following table presents the Electrical Ratings for reference only:
Description Battery Voltage Oper. 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, maximum 300 Amps DC, max. steady state 6.8 kW peak, 0.014 kW-Hr, 42 sec 2.0 kW peak, 0.3 kW-Hr, 90 sec 0.8 kW Model C30 150 to 700 VDC 2 Wire + Ground 0 to 30 kW HPNG 1 kW/second, maximum 3 kW/second, maximum w/software version 2.05 or higher 125 Amps DC, max. steady state 3.5 kW peak, 0.014 kW-Hr, 30 Seconds 2.8 kW peak, 0.147 kW-Hr, 5 minutes, typical 0.5 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.

The MicroTurbine system will normally operate within a varied range of parameters, including the following environmental conditions:
Parameter Operating Altitude Relative Humidity Engine/Electronics Air Temperature Ambient Operating Temperature Storage/Shipping Temperature Limitation -1000 to +11,000 feet above sea level 0 to 100%, 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)

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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

System Components
Engine Details
The engine assembly is delivered complete as shown in Figure 6. The engine includes the compressor, recuperator, combustor, turbine, and generator. The assembly is mounted on a frame along with the fuel system that is described in the next section. Four mounting holes are provided on the underside of the frame for mounting to vehicle.

Model C60

Model C30

Figure 6. Engine Details

Model Engine Specifications (Full Power and ISO Conditions)


Typical engine installation specifications are presented in the following table for reference only. Refer to HEV MicroTurbine Product Specification 460009 for performance details, updated information and related drawings (see Appendix B).
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
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Model C60 884 mm (34.8 inch) 666 mm (26.2 inch) 759 mm (29.9 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 (811,000 Btu/hr) Approximately 2000 watts 571,000 kJ/hr <10 microns particulate filter

Model C30 836 mm (32.9 inch) 572 mm (22.5 inch) 729 mm (28.7 inch) 91 kg (200 pounds) 283 liters/sec (600 cfm) -20 to 50 C (-4 to 122 F) 275 C (530 F) 457,000 kJ/Hr (433,000 Btu/hr) Approximately 1500 watts 327,000 kJ/hr <25 microns particulate filter
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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

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). Minimum service clearance access must be provided as detailed on the relevant detail drawing, for removal of maintenance items such as injectors, igniter, and thermocouple. Engine installation requires an independent air plenum, normally to be drawn from the same source as the power electronics. The engine air inlet temperature must be within two degrees of the electronics control module(s) cooling air inlet temperature. For Model C60 only, the generator cooling air must be ducted away from engine air inlet via 2.5-inch diameter hose. Refer to Engine Detail drawing for location of the vent near the center of generator. The engine must be cooled such that the component temperatures do not exceed specified values, as noted on relevant detail drawings and below. The fuel manifold surface temperature must not exceed a value of 70 C (158 F). The personality module (PM) and ambient climate module (ACM) surface temperature must not exceed a value of 65 C (149 F). The dump valve surface temperature must not exceed a value of 70 C (158 F). The generator housing ambient temperature must not exceed 93C (200 F). The engine dump valve exhausts air at 227 C (441F) in bursts during MicroTurbine deceleration in a fault condition.

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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

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. For gaseous fuels, the fuel system incorporates a Smart Proportional Valve (SPV25), fuel manifold, pressure transducer, fuel shutoff valve, fuel lines, and fuel injectors. For liquid fuels, the fuel system incorporates a fuel pump, fuel manifold, fuel filter, fuel lines, injectors, air-assist manifold, valves, regulator and air lines. See Figure 7 for fuel system packages.

Model C60

Model C30

Figure 7. Fuel System Package

Fuel System Specifications


Typical fuel system specifications are presented in the following table for reference only. See Appendix B for related drawings.
Fuel System Specification Mean Length Mean Width Mean Height Approximate Weight Model C60 514.1 mm (20.24 in.) 359.7 mm (14.16 in.) 125.6 mm (4.94 in.) 11.35 kg (25 lbs) Model C30 482.6 mm (19.00 in) 463.5 mm (18.25 in) 152.0 mm (6.00 in) 9.07 mm (20.00 in)

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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

Fuel System Installation Requirements


The following are fuel system installation requirements:

The fuel shutoff valve must be mounted with the solenoid in the vertical position, as presented on the relevant detail drawing (provided as a separate document). Minimum service clearance access must also be provided as outlined on the relevant detail drawing. Any optional mounting orientation may require re-orientation of the fuel shutoff valve. This may also require a new fuel shutoff valve, mounting bracket, plus other hardware as necessary. All components must be cooled such that the component temperatures do not exceed specified values as noted on relevant detail drawings and below. The fuel manifold surface temperature must not exceed a value of 70C (158 F). The gas inlet port for a Model C60 is per SAE J1926-12. For liquid fuel systems, an external air supply is required for starting, low power and cooldown. Refer to Air Assist Requirements for Liquid Fuel Systems in the Integration Section.

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. See Appendix B for related drawings.

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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

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.

The Engine Control Module (ECM) is air-cooled and is the primary controller of the generator power and interface to the vehicles control unit. It takes the variable high frequency AC power out of the generator, converts it to high voltage DC power, and sends it to the Battery Control Module (BCM). During engine start-up, the generator uses power from the BCM via vehicle battery to start the MicroTurbine. After warm-up, power is reversed and delivered to the BCM for conversion to the vehicle main DC bus voltage load. Power is reversed again to motor the generator during cooldown, prior to shutdown, to cool components. The ECM Assembly is shown in Figure 8 below.

Figure 8. ECM Assembly

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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

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.

Typical ECM details are presented in the following table. See Appendix B for related drawings.
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). Minimum service clearance access must also be provided as outlined on the relevant detail drawing. ECM installation requires an independent air plenum, normally to be drawn from the same source as the engine such as outside ambient air. Cooling air needs to be clean and dry. Allowable inlet air temperature: -20 C to 50 C (-4 F to 122 F). The ECM air inlet temperature must be within two degrees of the engine air inlet temperature. The ECM must be cooled such that the component temperatures do not exceed specified values. Maximum static pressure drop from the air inlet to air outlet should be 0.2 inches in water.

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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

Battery Control Module Details (Model C60)


The Battery Control Module (BCM) (see Figure 9) is an air cooled, 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.e., the battery voltage). 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.

Figure 9. BCM Assembly

BCM Specifications
Typical BCM installation details are presented in the following table. 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) 406.4 mm (16 inches) 242 mm (9.5 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). Minimum service clearance access must also be provided as outlined on the relevant detail drawing. BCM installation requires an independent air plenum, normally to be drawn from the same source as the engine such as outside ambient air. Allowable inlet air temperature: -20 C to 50 C (-4 F to 122 F). BCM air inlet temperature must be within two degrees of the engine air inlet temperature. The BCM must be cooled such that component temperatures do not exceed specified values. Cooling air needs to be clean and dry. Maximum static pressure drop from air inlet to air outlet should be 0.2 inches in water.
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480009-001 Rev B (October 2004)

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

DPC Controller (Model C30)

Figure 10. 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 DPC (see Figure 10) is air-cooled and is the primary controller of the generator power and interface to the vehicles control unit. It takes the variable high frequency AC power out of the generator, converts it to high voltage DC power, and then back to AC power where the phases combine to form single-phase DC power to the vehicle's battery. During engine start-up, the generator uses power via vehicle battery to start the MicroTurbine. After warm-up, power is reversed and delivered to the vehicles main DC bus voltage load. Power is reversed again to motor the generator during cooldown, prior to shutdown, to cool components.

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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

DPC Specifications (Model C30)


NOTE An external 12 VDC (-.5/+2.5V) power supply is required. See Appendix B for related
Parameter Data 825 mm (32.50 inches) 311 mm (12.25 inches) 464 mm (18.25 inches) 68.5 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. drawings.


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). Minimum service clearance access must also be provided as outlined on the relevant detail drawing. DPC installation requires an independent air plenum (do not connect to engine inlet plenum), normally to be drawn from the same source as the engine such as outside ambient air. Cooling air needs to be clean and dry. Allowable inlet air temperature: -20 C to 50 C (-4 F to 122 F). DPC air inlet temperature must be within two degrees of the engine air inlet temperature. The DPC must be cooled such that the component temperatures do not exceed specified values. Maximum static pressure drop from the air inlet to air outlet should be 0.2 inches in water.

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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

User Connection Board (UCB) (Model C30)


The User Connection Board (see Figure 11) is used for interfacing with auxiliary components. There are terminals for connecting an emergency stop contactor, which should be normally closed during operation. Also, there is a terminal for a 12 VDC auxiliary power supply required for start up. The UCB is delivered inside an enclosure for protection. It can be removed and relocated into a suitable enclosure inside the vehicle. See Appendix B for related drawings.

+12V

Gnd

E-Stop

Figure 11. HEV User Connection Board

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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

Liquid Fuel Controller (LFC) (Model C30)


For liquid fuel systems, a Liquid Fuel Controller (see Figure 12) is required to control or monitor the liquid fuel devices such as the fuel pump speed, fuel manifold, drain valve, 3-way valve, start air-assist valve, and the air-assist pressure switch. The LFC 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). Easy access to the LFC is required for troubleshooting and replacement, if necessary. See Appendix B for related drawings.

Figure 12. HEV Liquid Fuel Controller

Cables
Each system is delivered with the required cables to interconnect all system components included in the MicroTurbine system. Refer to Appendix B for a list of cables and schematics that indicate the cable number (W1XX) required for each type of system. Most cables have a defined length and some have the option to purchase different lengths. If a particular length is required, please contact Capstone for availability and costs. During the design and integration process, the integrator needs to be aware of cable routing and its effect on the system. The MicroTurbine system has both power cables and communication cables. 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.

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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

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. Items to be supplied and incorporated by the OEM/Integrator are listed, but not necessarily limited to the following items:

Enclosures for all System Components Inlet Air filtration and Ducting to Engine Cooling Air Filtration and Ducting to Controllers Exhaust Ducting Engine Heat Rejection Fuel Delivery System to Engine Fuel System Engine and Controller Mounting Air Assist for Liquid Fuels (C30 Only) Electrical System Grounding Cables, Isolation Switch, and Circuit Breakers from MicroTurbine 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, debris, and projectiles. 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. Several of the components and connections in the system are not rated for water spray or mud. Therefore, the OEM/integrator is responsible for protecting and shielding the components and systems. The electronic controllers can be located together within an existing enclosure with other components on the vehicle. If the engine is mounted near the ground or behind the rear wheels on a vehicle, 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.

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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

Inlet Air Filtration and Ducting to Engine


NOTE Refer to HEV Product Specification (460009) for inlet pressure derating specifications.

The OEM/Integrator is responsible for providing air filtration, routing, and ducting for the air intake to the MicroTurbine engine inlet. Air Inlet Requirements:

Air Flow: 900 Standard Cubic Feet per Minute (scfm) for Model C60. Air Flow: 600 Standard Cubic Feet per Minute (scfm) for Model C30. Air Filtration: <10 micron particle size at an efficiency of 99% Intake Ducting Size: > 283.5 square centimeters (44.2 square inches) Maximum Pressure Drop: 2 inches of water column at conditions other than ISO

The turbine engine uses ambient air for combustion and cooling the generator during operation. This air needs to be drawn from the cleanest and coolest location that is possible on the vehicle. Locating the air inlet near the ground or directly behind the wheels of the vehicle is not recommended. The highest location above ground is preferred. Easy access to the air filter is also preferred for removal and regular maintenance. Care must be taken to design an inlet to avoid blockage by airborne plastic film or similar materials, and to avoid icing and water ingestion. The entire ducting must also preclude the use of screws or other potentially loose fasteners that could be ingested by engine and cause failure. The minimum filter size and maximum length of ducting needs to be determined based on several factors. Pressure drop from ambient conditions to the engine inlet is critical to engine performance. A maximum restriction of airflow with a dirty air filter should be calculated and should not exceed the required limit. Capstone recommends that a dirty air filter be calculated as though one-half of its surface area is blocked. Sizing the filter also should take into account operational conditions and maintenance intervals. A small filter will become dirtier faster and therefore cause high-pressure drop and require cleaning or replacing in very short intervals, where as a larger filter will help prolong the maintenance schedule. Capstone recommends using the largest filter possible for maximum engine performance. The design of the filter attachment should also address sealing around the filter. Unfiltered air is not permitted to the turbine. Inlet air temperature also needs to be considered. The actual air inlet temperature into the engine is measured inside the generator housing before entering the compressor. The inlet ducting should be designed to reduce the rise from ambient to actual engine inlet temperature and the maximum temperature rise should not exceed 3 C. The air inlet ducting should also take into account acoustical considerations. Refer to the Acoustical Considerations section for more data. Capstone recommends that an air inlet plenum be designed to house the filter and accommodate acoustical treatment, if necessary. Interfacing to the turbine can be as simple as a rubber boot to seal out unfiltered air. Figure 13 presents a typical Model C60 installation using a flat silicone rubber boot stretched over the turbine opening. The seal may be used for Model C30 and C60 applications and allows for some engine misalignment, while accommodating some engine movement due to vehicle shock loads and vibration.
480009-001 Rev B (October 2004) Page 29 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

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

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

Cooling Air Filtration and Ducting to Controllers


The OEM/Integrator is responsible for providing air filtration, routing, and ducting for the cooling air for the electronic controllers. Cooling Air Requirements for each controller:

Air Flow: 250 Standard Cubic Feet per Minute (scfm) for Model C60 BCM Air Flow: 250 Standard Cubic Feet per Minute (scfm) for Model C60 ECM. Air Flow: 460 Standard Cubic Feet per Minute (scfm) for Model C30 DPC. Air Filtration: Coarse air filter to reduce dust, moisture and foreign object debris. Maximum Pressure Drop from Ambient: 0.5 inch of water column. Inlet air temperature needs to be within 2 C of engine air inlet temperature.

Each controller contains power electronics, which produce up to 2300 watts and 800 watts of heat at full power for the ECM and BCM respectively, and up to 2000 watts for the DPC. Cooling airflow is required to dissipate this heat and prevent overheating of controllers. The controllers include their own internal air management with fans and vents, but do not include external ducting or connections. Installation of the controllers must consider airflow paths both into the controller fans and away from the controller vents. The design must also prevent recirculation of cooling air from exit to inlet and from controller to controller. A coarse air filter can be used to filter large particles and provide protection from water and debris. Use caution not to insert a filter that will cause a pressure drop that exceeds requirements. Pressure drop from ambient conditions to the controller inlet is critical to controller performance and overall system performance. A maximum restriction of airflow with a dirty air filter should be calculated and should not exceed the required limit. Capstone recommends that a dirty air filter be calculated as though one-half of its surface area is blocked. As part of a regular maintenance schedule, the filter should be cleaned, and the controllers should be opened and compressed air should be used to blow any accumulation off the control boards and other components.
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, 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

Engine Exhaust Ducting


The OEM/Integrator is responsible for providing routing and ducting for engine exhaust. Engine Exhaust Requirements:

Maximum Steady State Exhaust Temperature: 305 C (580 F) for Model C60. Maximum Steady State Exhaust Temperature: 275 C (530 F) for Model C30. Nominal Total Exhaust Energy: 571,000 kJ/hr (541,000 Btu/hr) or Model C60. Nominal Total Exhaust Energy: 322,000 kJ/hr (310,000 Btu/hr) or Model C30. Maximum Exhaust Back Pressure: 203 mm (8 inch) of water column.

The MicroTurbine exhaust has a formed sheet metal flange that can be used with a band type clamp for easy assembly. An exhaust duct needs to be supplied by the integrator to exhaust hot and potentially dangerous gases away from personnel. This duct should be located away from all flammable materials. Care must be taken to design an exhaust duct that minimizes backpressure and does not exceed the maximum backpressure requirement, while allowing removal for service. Backpressure in the exhaust system will cause a reduction in engine efficiency. NOTE Refer to HEV Product Specification (460009) for exhaust backpressure derating specifications.

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

Generator Exhaust Air (Model C60 Only)


On the Model C60 engine, some of the engine inlet air that is used to cool the generator is exhausted out a 2.5-inch diameter port (see Figure 14) in the center of the generator, which is the center of the engine inlet. This generator exhaust air can be approximately 50 to 70 degrees hotter than the inlet air. 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. Therefore, the OEM/Integrator is responsible for ducting exhaust air away from engine inlet by using a flexible duct similar to system shown below.

Figure 14. C60 Generator Cooling Air Outlet


480009-001 Rev B (October 2004) Page 31 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

Engine Heat Rejection


The MicroTurbine combusts fuel to make power and therefore produces heat in the process. The recuperator is designed to capture this heat and preheat the compressed air before entering the combustor. Insulation is used to help keep this heat within the recuperator. The surface temperature of this insulation can range from 163 to 288C (325 to 550 F) depending on location. Maximum heat rejection is up to approximately 2000 watts. 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. In addition, this heat should not be allowed to heat the generator housing or fuel components beyond their maximum specification during operation. Fans or vents can be used to draw the heat out of an enclosure. 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. It is recommended to install a heat shield between the generator housing and the recuperator if the engine will be installed in an enclosure. The heat shield can be sheet metal with insulation attached. This shield will keep the engine divided into a hot compartment side and a cool compartment side. The recuperator side of the engine should be kept hot and the generator side should be kept as cool as possible. This helps keep the generator housing form heating up, thus heating the engine inlet air, and causing a derating due to elevated inlet temperatures. Figure 15 shows the typical layout inside an enclosure with a heat shield installed to split the compartment into hot and cold sections.

Figure 15. Typical Layout of Engine with Heat Shield

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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

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.

The OEM/Integrator is responsible for providing a fuel delivery system from the fuel tank to the engine fuel system. The MicroTurbine fuel system is basically a metering device and a distribution system for the injectors. It is the OEM/integrators responsibility to provide the fuel at the required pressure and temperature. For gaseous fuels, the delivery system should consist of, but is not limited to, a fuel filter, coalescing filter (6 micron @95% of particles), regulator, and a shut off valve. The shut off valve should be as close to the MicroTurbine as possible. For liquid fuels, the delivery system should consist of, but be limited to, a boost pump, fuel filter (10 microns@45 of particles), and a shutoff value. For gaseous fuels, it is critical that only vapor be delivered to the MicroTurbine fuel system. The presence of liquid fuel particles in a gaseous fuel will damage the MicroTurbine. A gasification system with a heater will be required for operation with compressed liquid fuels. Particular care must be taken to ensure that fuel in lines after shutdown is conditioned before next start up. Trapped fuel can change phases overnight and cause liquids to form in lines.

Air Assist Requirements for Liquid Fuel Systems


NOTE Refer to the HEV Liquid Fuel Technical Reference (410029) for detailed and updated information.

For liquid fuel systems, an external air supply is required for system start-up, low power (idle) and shutdown. This air supply assists the fuel system to atomize the fuel in the combustion chamber. The required air can be supplied from a separate system or from an onboard air system. And in either case, a 10-micron (or less) filter and a coalescing filter/separator should be installed before the turbine system. The air needs to be clean, dry and free of any oils. The following are liquid fuel system air-assist requirements (for reference only): Start/Cooling mode 80 slpm @ 427.8 kPa (62 psig) for approx. 1.5 minutes Idle Mode ( 6 kW) 60 slpm @ 427.8 kPa (62 psig) for duration of idle

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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

Mechanical Interface Parameters


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

Acceleration
Maximum allowable operating acceleration is 6G in the vertical and 5G in the lateral and longitudinal axis. Maximum allowable non-operating acceleration is 18G. It is recommended that component mountings in vehicular applications be designed to withstand crash loads of 30G for 100 milliseconds.

Orientation
The MicroTurbine generator should be mounted with its axis normally level with respect to gravity but otherwise may be oriented for convenience. The MicroTurbine controller must be mounted within 60 degrees of vertical. The MicroTurbine gaseous fuel valve must be mounted within 90 degrees of vertical. Other system components may be oriented as desired.

Vibration
The MicroTurbine produces nearly zero measurable vibration, but may be susceptible to outside vibration. The OEM/Integrator must mount the components in the frequency window between 4 and 10 Hz.

Component Locations
Component locations must meet component requirements as noted in component sections and be accessible for diagnosis and repairs. The OEM/Integrator must also assure that the cable connections are accessible and the minimum bend radii for all cables and hoses are observed. NOTE Reference cable drawings for maximum lengths.

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.

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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

Acoustical Parameters
The system OEM/Integrator is responsible for meeting their specific acoustics requirements for the installation or application. The Capstone noise attenuation design goal that has been established and met is 65 dBA at 10 meters. Noise attenuation efforts are close-coupled to pressure drop, maintenance, inlet heating, and environmental requirements. To achieve lower overall noise requires an understanding of the individual noise sources and then targeting specific reductions for each area. Engineering reference material specific to noise reduction may be found in as noted: L. L. Beranek and Istvan L. Ver, Noise and Vibration Control Engineering Principles and Applications, John Wiley and Sons Inc., New York, NY 1992. David A. Bies and Colin H. Hansen, Engineering Noise Control Theory and Practice, Second Edition, Chapman and Hall, New York, NY 1996. (Also published in Japan).

Noise levels or sound power is the strength of the noise source (normally measured in decibels or dBA). Notice that sound power does not depend on distance or direction. Typically, 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, the exhaust ducting, and the overall packaging environment. The acoustic characteristics include attenuation, directivity, and location. Each package or installation will have its own unique acoustic characteristics, and each potential acoustic pathway should be designed to ensure that target noise levels are met. The four major noise types associated with the MicroTurbine are detailed in the following paragraphs.

Turbulence Noise
Turbulence noise is widespread, and originates mainly in the air intake area, the combustor chamber, and in the exhaust duct. This type of noise is broadband and occurs typically at frequencies of between 1000 and 5000 Hz.

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. This noise is tonal in nature with the strongest occurring at blade passing frequencies. The blade passing frequencies occur at 14,400 Hz for the compressor and at 20,800 Hz for the turbine.

Electro-Mechanical Noise
Electro-mechanical noise is caused by the magnetic fields within the generator, and is then passed through the stator and the stator housing. This noise is also tonal in nature with the strongest occurring at 1 and 2 times shaft speeds. That places the tonal frequencies at 1600 Hz and 3200 Hz with a shaft speed of 96,000 rpm.

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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

Combustion Noise
Combustion noise is both broadband and low on the frequency scale. This noise peaks at approximately 400 to 800 Hz and manifests itself primarily in the exhaust stream. For purposes of this Application Guide, noise terminology for the MicroTurbine is defined as noted in the paragraphs that follow.

Sound Pressure
Sound Pressure measures acoustic pressure fluctuations at a particular point in space. These measurements are dependent on both the source and the associated surroundings.

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.

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 Spectrums
NOTE Refer to the Model C30 Acoustic Emissions Technical Reference (410025) for additional technical information and updated data.

Sound spectrum has to do with the description of a sound waves resolution into components. Each component has a different frequency and (usually) different amplitude and phase. The main acoustic pathways from within the MicroTurbine include the following three items: Inlet Noise Exhaust Noise Case Radiated Noise

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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

Noise Attenuation Methods


As pointed out earlier in this document, the Capstone noise attenuation goal (which has been continuously met) has been 65 dBA at 10 meters. Additional noise reduction opportunities exist for the OEM/Integrator, and may add value to a particular application. Noise attenuation efforts are close-coupled to pressure drop, maintenance, inlet heating, and environmental requirements. Efforts have been made to achieve lower overall noise, 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. 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.

Extruded Metal
Typical extruded metal and/or felt-type metal enclosure materials can be effective. However, they may not be very cost effective.

Bulk Attenuator
The bulk attenuator method of noise reduction is recommended by Capstone. This method may be employed for both the MicroTurbine inlet air stream and the exhaust pathway. Bulk attenuation materials consist of perforated metal sheeting with greater than 30% open area, screen-type materials, and/or fiberglass or foam sheeting items. These materials should be temperature appropriate and resistant to damage that may be caused by various weather conditions. WARNING It should be pointed out that fiberglass materials may pose a significant problem if the fibers were to be ingested by the MicroTurbine.

Capstone currently uses a foam-type material for noise attenuation instead of fiberglass. If the foam-type material under consideration attenuates noise at 2 kHz, then it should also be adequate for the higher band of frequencies. Sources of composite foam currently in use at Capstone include the following: The Soundcoat Company, Inc., 16901 Armstrong Avenue, Irvine, CA 92606. Phone: (949) 955-9202; Fax: (949 )222-0834; E-mail: http://www.soundcoat.com E.A.R. Speciality Composites, 7911 Vionsville Road, Indianapolis, IN 46268. Phone: (877) 327-4332; Fax: (317) 692-3111; E-mail: http://www.soundcoat.com

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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

Electrical System Grounding


The OEM/Integrator is responsible for providing all grounding cables from each component to a common ground. In order for the system components to operate and communicate properly, they need to be grounded properly. 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. Each component has a grounding stud or eyelet for attaching a cable. Use of #10 wire gage or larger is required. Refer to Figure 16 for details.

Turbine Engine
IDEAL HEV GROUNDING DIAGRAM

Generator

DPC

To Battery Bus

SPV
Use #10 AWG wire or larger, for grounding +

HUCB
-

BMS

12 VDC Aux Power

Single Point Chassis Ground

Figure 16. Grounding Layout (Model C30 shown)

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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

Cables from MicroTurbine to Battery Pack


The OEM/Integrator is responsible for providing all cables, circuit breakers, switches, insulation, conduit, 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. The battery pack needs to be connected to the MicroTurbine while MicroTurbine is in standby, starting, running, and during cooldown modes. All hardware associated with connecting the controller module to the battery pack is the responsibility of the OEM/Integrator. Capstone requires a double pole isolation switch between the MicroTurbine control module and the battery pack. This isolation switch must be mounted as close as practical to the MicroTurbine controller for service to the controller, if required.

External Power Supply


The OEM/Integrator is responsible for providing an external power supply to the MicroTurbine. The Model C30 MicroTurbine requires a power supply of 12 VDC (-.5/+2.5V) and 8 Amps to power the system at start up. 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. 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. 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.

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. HEV applications using a Capstone MicroTurbine require a battery management system be developed for the specific application. This system is required to manage the battery state of charge and determine when the MicroTurbine is required for charging the batteries, as well as how much MicroTurbine power is required during charging periods. 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. A 9-pin serial null modem cable is used for this particular connection. RS-232 communication protocol is described in Capstone Engineering Specification ES0276 Software Requirements, Communications Specification (HEV) (provided as separate document). This document describes the basic communication scheme required of the battery management system, initialization of the system, and the connections required for typical system operation.
480009-001 Rev B (October 2004) Page 39 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

Safety-related Design Considerations


Capstone suggests that the following safety items be considered during any design efforts. Proper safety considerations will lead to an efficient and safe design application.

High Temperatures
The surface temperature of the MicroTurbine can reach 288 C (550 F). Care must be taken to prevent people or inappropriate materials from coming into contact with the MicroTurbine. Do not remove or cover high temperature warning labels on the MicroTurbine components. The exhaust stream and piping can reach 315 C (600 F) under extreme conditions. Route, guard, and label exhaust piping to prevent people from coming into contact with the piping or exhaust stream. Keep flammable materials clear of the exhaust pipe and exhaust stream. The MicroTurbine radiates 1400 watts at full load. Electrical cables and harnesses must not be attached to hot surfaces or to fuel lines. Additionally, electrical cables and harnesses must not contact sharp surfaces or protruding objects.

High Voltages
The MicroTurbine installation designer must consider that the system produces and stores electricity at levels that can burn, injure, or kill. Connection wiring and isolation switches must be properly sized and installed per manufacturer recommendations. The MicroTurbine system components must be mounted and connected as recommended herein. Warning labels on the MicroTurbine system components must remain visible to technicians after installation. Capstone strongly recommends the provision of lockout devices to prevent energization of circuits during maintenance procedures.

Flammable Fuels
Fuel storage and delivery systems should be designed in consideration of the highly flammable nature of the fuel. The MicroTurbine fuel handling components must be installed as specified in this Application Guide. The turbine air inlet must be free of fuel-carrying components, and all fuel lines must be physically kept from contacting the MicroTurbine or other hot surfaces. In addition, fuel lines must not contact any sharp edges or protruding objects, and electrical cables and harnesses must not be attached to fuel lines. 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.

480009-001 Rev B (October 2004)

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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

Emergency Stop (E-Stop)


The MicroTurbine system includes emergency stop functionality, but does not include an emergency stop switch. Design parameters must include emergency stop devices that are easily visible and accessible to the general public. These devices must be remotely mounted by the vehicle operator to ensure access in the event of an emergency. The MicroTurbine system incorporates an E-stop circuit on the User Control Board. It is a normally-closed circuit and can be connected to an external switch or button that will close the circuit. Activation of the E-Stop immediately shuts off fuel and electrical output. This will cause the compressor bypass valve to open, vent the compressed air out of the MicroTurbine, and the turbine will coast to a stop. After an emergency stop, 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. Emergency stops increase stress on the system components and will result in reduced service life of the MicroTurbine. CAUTION Repeated use of the optional Emergency Stop switch will result in damage to the MicroTurbine. Use only in emergency situations.

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. In addition, finger guards must be designed to cover all exposed fans. The air intake filter pathways must prevent incidental human contact with hot surfaces or electrically live components by distance or labyrinth or both.

Fuel Leak Detectors


The designer of the MicroTurbine installation should consider fuel leak detection systems. These systems are recommended by, but not required or supplied by Capstone.

Fire Suppression Detectors


The designer of the MicroTurbine installation should consider fire suppression systems. These systems are recommended by, but not required or supplied by Capstone.

Warning Labels
High Voltage labels must be applied to the Digital Power Controller, and High Temperature labels must be applied to the MicroTurbine. Additionally, labels must comply with the intent to prevent injury. Standard UL signage must be employed.

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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

Communication Requirements
NOTE Refer to the Communications Technical Reference Manual (410042) for detailed explanations and additional information for both C30 and C60 systems.

The HEV version of the MicroTurbine system requires the user to give commands to the system for starting, power levels and stopping. The communication to the system is done through an RS-232 serial port using RS-232 protocol. Each system has two serial ports. The first is reserved for the user (vehicle operation and the second is used for monitoring and/or maintenance. For basic operation, the user needs to connect a computer or PLC using a null modem adapter or a modem to one of the ports. The user serial port requires a password for control operations. Without a password, information and data is available for monitoring only. For the simplest operation, two commands are used. 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. The command STRCMD = 1 is used to start the MicroTurbine, STRCMD = 0 shuts down the MicroTurbine, and PWRDMD = <watts> is used to set the desired output power level. Additionally, each RS-232 command may be issued without an argument to query the current value being used by the MicroTurbine. For example, STRCMD issued without the equal sign and value will return a 0 or 1 indicating that the MicroTurbine is currently running, or in a shutdown state. This is useful for monitoring the overall system operation. When the battery management system is monitoring the battery state of charge, and it determines that it is getting low enough that it wants the MicroTurbine to start charging, a start command (STRCMD =1) should be issued. A few minutes should be allowed for the MicroTurbine to warm-up, and get to the point where it is capable of outputting power when this is issued (for example, do not start the MicroTurbine with the state of charge too low as it will take the MicroTurbine a few minutes before charging begins). A desired power demand may immediately be issued, and when the warm-up cycle is completed, the MicroTurbine will immediately ramp up to the desired output power level. A power demand (PWRDMD) between 0 and 60000 watts may be commanded. Most likely, once the battery management system sends a start command, 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. It is much more efficient to leave the MicroTurbine on, and the power output limited then to turn the MicroTurbine off and then start it again. The MicroTurbine remains in a Standby state after power up, until a STRCMD = 1 command is received. 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.
480009-001 Rev B (October 2004) Page 42 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

The MicroTurbine is then started and fuel added to the system. The Run state is the warm-up period. The warm-up period is a total of one minute, and includes the time to reach the idle temperature set point. When the load state is reached, the MicroTurbine begins outputting the demanded power level. When the battery management system provides a stop command (STRCMD = 0), the MicroTurbine will transition through cooldown and then shutdown, and then back to Standby. CAUTION When the bus is normally shut off at the end of the day, the battery supply must not be disconnected until the MicroTurbine has gone through this cooldown/shutdown cycle and is back in Stand By.

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. A STRCMD without any values attached may be issued to determine if the engine is running. A response of STRCMD,0 = 1 reports that the system is still operating. If it is 0, then the MicroTurbine has shut down for some reason. A start command may be issued at any time, and the MicroTurbine will attempt a re-start if it is in an appropriate state (and there are no faults) to do so. The PWRDMD command may be issued at any time. The MicroTurbine only reacts to the commanded value when in the Load state. The STRCMD = 0 may be given at any time and the MicroTurbine will safely stop outputting power and move into cooldown. The power demand may be changed as often as required, but the MicroTurbine will rate itself to control the changes to reach the most recent demanded value. Giving a power demand from 0 to 60 kW (full on load), will take approximately two minutes, so the battery management system should use some scheme that keeps MicroTurbine response in mind. That is to say, command a start before the minimum state of charge 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. The MicroTurbine is tested for full on and off loads, so any value changes in the power demand are allowed and a stop command can be given at any load. The SYSSTA command provides textual output of the current operational state of the MicroTurbine. This may be used to monitor when the MicroTurbine reaches the Load state or has entered a Fault / Shutdown state. The same data may be received in a hexadecimal format using the SYSCON command. There are two parts to the SYSCON command results: (1) the system state and (2) the mode. Only the state portion is relevant, as vehicle systems only operate in one mode. SYSCON returns a four-digit ASCII representation of a hex value with the last three representing the state.

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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

The following may be used: system_state = SYSCON & 0x0FFF Where system_state is of type SYS_STATE: typedef enum { SYS_POWER_UP = 0, SYS_STAND_BY = 1, SYS_PREP_START = 2, SYS_LIFTOFF = 3, SYS_OPEN_LIGHT = 4, SYS_CLSD_ACCEL = 5, SYS_RUN SYS_LOAD = 6, = 7,

SYS_RECHARGE = 8, SYS_COOLDOWN = 9, SYS_WARMDOWN = 10, SYS_RESTART SYS_FAULT SYS_DISABLE = 11, = 13, = 14, SYS_SHUTDOWN = 12,

SYS_BAD_CONFIG = 15, SYS_SW_DNLOAD = 16, SYS_IDLE_RCHRG = 17 } SYS_STATE; The SYS_RECHARGE and SYS_IDLE_RCHRG states are used only by Stand Alone AC output units. HEV systems will never be operating in these states. Important for HEV systems is that the battery management system must keep sending RS-232 commands, queries or commanded values, at least once every 10 seconds. If the MicroTurbine does not receive any communication for 10 seconds, lost communication is assumed and the system will shutdown with a communications timeout fault. This prevents over charging a battery when communication that would have lowered the power demand or shut the MicroTurbine down has been lost. The battery management system may be implemented to send any RS-232 command, query or setting, to achieve this communication rate. One option is to continually send the STRCMD = 1 followed by PWRDMD = 60000 to continue operating at full power. A start from the display panel disables this fault so that system operation may be verified before completion of the battery management system operation.

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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

System Configuration
Upon delivery of a Capstone MicroTurbine, several parameters will need to be configured as part of the system commissioning. This is required due to the unique battery packs and fuels used in various applications. Each of these commands is issued one time to configure the system and may be accomplished through a personal computer RS-232 connection, or via the display panel.

Baud Rate
Based on the battery management system, the baud rate used for RS-232 communications may need to be adjusted. The default setting is 57600 bps. To change the setting to match the baud rate of the sending port of the battery management system, the UBAUDR command will be used. To change the setting to 9600 bps, the command UBAUDR=9600 will be sent. No response will be received if this is successful as communication is now at a different rate. The connection must be re-connected using the new baud rate. The baud rate may also be set through the display panel Baud Rate submenu under System Settings.

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.

The MicroTurbine has protective relays that are used to protect the system and the battery pack from overvoltages or undervoltages. These protective relay settings must be adjusted to match the specific battery voltages being used and system requirements. If any of these relays are tripped, the system will perform a warmdown sequence. Therefore it is recommended that the battery monitoring device monitor and control the voltage levels by controlling the power output of the turbine. The relay set points should be slightly higher (overvoltage) or lower (undervoltage) than the setpoints in the battery control unit to prevent turbine shutdowns. All settings may be configured using the display panel under the HEV Connection menu RS-232 commands, or CRMS.

Fuel Indices
Fuel indices are used to determine fuel flow required for operation of various fuels. Both fuel index 1 and fuel index 2 should be adjusted as necessary for the specific fuel being used. Natural gas is the system default, and requires no change.

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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

System Design Guidelines and Processes


This section describes the OEM Design Qualification Process, the successful completion of which will result in activation of Capstones factory warranty for the OEM Partners product model. Once the model warranty activation has been achieved, 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. Production Build Sheets are discussed in this document; refer to Capstones HEV Commissioning Checklist Instructions (440075) for more information about the Commissioning Checklist (460030). The Design Qualification Process involves four steps: (1) Application, (2) Product Design, (3) Prototype Inspection, and (4) Design Approval. In addition to these four steps, Production Manufacturing and System Installation are also critical elements to achieving reliable MicroTurbine system operation. The flowchart detailed below illustrates this process.
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.

Step 1 Application
The OEM Partner submits a Product Specification describing the proposed design application. 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. The original Product Specification in addition to any written comments from Capstone will signify a completion of Step 1 Application.
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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

Step 2 Product Design


The OEM Partner submits Product Documentation for Capstones review and comment. In general, the Product Documentation should include the following:

Engineering Drawings Control System Specifications Various schematics illustrating the interfaces to the Capstone MicroTurbine system, and other systems as necessary.

Additionally, 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, including component mounting, access, and the necessary plumbing Controller mounting and access, 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. Description of fasteners, connections, and fittings used. Ventilation and proximity to flammable or heat-sensitive materials must be adequate. Plumbing and wire routing in the MicroTurbine area must be adequate. Careful allowance must be made for maintenance access; especially to allow component troubleshooting and replacement according to the time values allowed by the Capstone standard Flat Rate Schedule for valid warranty claims.

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).
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480009-001 Rev B (October 2004)

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

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). Description of the cooling air inlet and outlet.

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)

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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

Fuel System
Fuel system details are presented as follows:

Fuel components must be mounted and installed as specified in the relevant Outline & Interface drawing. For propane systems, a complete description of gasification process (including drawings of system and components) is required. 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, including possible recommendations or requirements from Capstone to make design modifications. The OEM Partners implementation of the Capstone requirements into the design will indicate completion of Step 2 Product Design.

Step 3 Prototype Inspection


When the OEM Partner has a prototype ready for final approval, Capstone will physically inspect the prototype and the accompanying test reports (including temperature measurements, pressure drop measurements, etc.) to confirm compliance with the Capstone specifications and details. Based upon the inspection of prototype and test results, Capstone will issue technical instructions to the OEM Partner indicating possible design modifications. Implementation of the modifications indicates completion of Step 3 Prototype Inspection.

Step 4 Design/Installation Approval


Capstone will issue a letter signifying approval of the OEM Partners product model after the successful completion of Steps 1 3.

480009-001 Rev B (October 2004)

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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

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. The Commissioning Checklist Instructions can be found in document 440075. An ASP is required to complete and sign every checklist. 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.

480009-001 Rev B (October 2004)

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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

The complete OEM Design Qualification Process is detailed in Figure 17.

Figure 17. OEM Design Qualification Process

480009-001 Rev B (October 2004)

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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

Capstone Remote Monitoring Software


The Capstone Remote Monitoring Software (CRMS) is a software tool that provides dispatch, control, monitoring, trending, E-mail alarming, data logging, and automation for Capstone MicroTurbines. For additional information with regards to operating CRMS, please refer to CRMS Users Manual (400001) for basic user information, and CRMS Technical Reference Manuals (410013 and 410014) for integration-level maintenance and monitoring.

Maintenance Items
NOTE Refer to MicroTurbine Standard Maintenance Schedule Work Instructions (440000) for recommended service intervals.

For maintenance items such as the injectors, ignitors, pump, and the SPV, the integrator needs to allow for clearance for removal and installation of each item. In particular, the injectors require 8.5 inches (Model C30), and 9.0 inches (Model C60) clearances to remove from the engine. Figure 18 shows examples of Model C60 and C30 injector removal.

Model C60

Model C30

Figure 18. Injector Removal

480009-001 Rev B (October 2004)

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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

ASP Training
Capstone offers training courses for personnel to become Authorized Service Providers (ASP) and Certified Technician training for the MicroTurbine system. The courses are intended to train individuals on the overview for both the C30 and C60 systems, including control systems, fuel systems, available accessories and maintenance. ASP training will also provide additional information and training on troubleshooting, component functionality, programming and commissioning of a system. Please contact Capstone for additional information on class schedules and costs.

Warranty Information
Warranty details are provided in the Standard Warranty, the 1-Year Extended Warranty, and the 2-Year Extended Warranty.

Related Documents
A listing of related documents is provided in the following table. Document No. 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 - User Level CRMS Technical Reference Manual - 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
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Title

480009-001 Rev B (October 2004)

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

NOTES

480009-001 Rev B (October 2004)

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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

Appendix A Available Accessories for HEV Systems


This appendix contains a list of available accessories for HEV systems. 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, Seal Nuts Filter Support Filter Filter Plate Wing Nut Washer Description

C30 Plenum, 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. 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

Appendix B - Drawings and Diagrams


Appendix B contains a list of reference drawings related to HEV system operation. Click on the Members Only section of the Capstone website (http://www.capstoneturbine.com/login.asp) and select the Sales/Marketing tab (HEV drawings) to access the complete set of HEV drawings. Model C30
Drawing 510366 (O & I, HEV, 20 Engine, Liquid Fuel) Drawing 510627 (O & I, HEV, 20 Engine, Compressed Natural Gas) Drawing 514418 (Schematic, HEV, Liquid Fuel, Top-Level) Drawing 514691 (Schematic, HEV, HP, Top Level) Drawing 508691 (DPC, HEV Engine Control, 20 degree) Drawing 508694 (HEV, UCB) Drawing 509060 (Controller Assembly, Liquid Fuel) Drawing 508881 (CABA, W101, HEV, V1, Engine Peripheral & PM) Drawing 508882 (CABA, W102, HEV, V1, Intra & UCB Option) Drawing 514367 (CABA, W105, HEV, V1, LFC Manifold) Drawing 509149 (CABA, W106, HEV, V1, LFC Fuel Pump Power) Drawing 508709 (CABA, W107, HEV, V1, PMG Power) Drawing 509140 (CABA, W114, HEV, V1, SPV Fuel Manifold) Drawing 509143 (CABA, W115, HEV, V1, SPV Fuel Pressure) Drawing 513667 (CABA, W122, HEV, LFC P-Sense/Drain Switch) Drawing 514080 (Filter and Boost Pump Assembly)

Model C60
Drawing 512965 (O & I, Engine, Top-Level, Natural Gas, OEM) Drawing 512842 (O & I, Fuel, Top-Level, Natural Gas, OEM) Drawing 512451 (O & I, Engine Controller, Top-Level, AC, OEM) Drawing 512452 (O & I, Battery Controller, Top-Level, OEM) Drawing 512866 (Schematic, HEV, Top-Level) Drawing 511958 (Schematic, HEV, BCM) Drawing 510073 (CABA, W101, Engine Peripheral and PM) Drawing 512986 (CABA, W102, Intra Harness Connection) Drawing 513027 (CABA, W103, Inter Sys Connect) Drawing 510077 (CABA, W105, Ext Jam PMG Power to ECM) Drawing 511371 (CABA, W106, T1 Thermistor to ACM ) Drawing 513028 (CABA, W107, Aux Power/E-Stop) Drawing 511909 (CABA, W114, Bus ECM/BCM, C60 LIP) Drawing 512462 (CABA, W118, Fan Ext with Shield, C60 LIP)
480009-001 Rev B (October 2004) Page B-1

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.

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