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WARNING: If the information in this manual
is not followed exactly, a fire or explosion
may result causing property damage, personal
injury or loss of life.
-
Do not store or use gasoline or other flammable
vapors and liquids in the vicinity of this or any
other appliance.
-
WHAT TO DO IF YOU SMELL GAS:
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use
any phone in your building.
• Immediately call your gas supplier from a
neighbour's phone. Follow the gas supplier's
instructions.
• If you cannot reach your gas supplier, call the
fire department.
WARNING: Improper installation,
adjustment, alteration, service or
maintenance can cause injury
or property damage. Read the
installation, operating and maintenance
instructions thoroughly before installing
or servicing this equipment.
WARNING: For Outdoor Use Only
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Table of Contents
Related Manuals for Global S-8500
Summary of Contents for Global S-8500
- Page 1 WARNING: If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life. Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.
- Page 2 AVERTISSEMENT: si l’information de ce manuel n’est pas suivie exactement, un incen- die ou une explosion peut résulter entraînant des dégâts matériaux, des blessures ou la perte de vie. Ne pas entreposer ou utiliser de l’essence, d’autres liquides ou vapeurs inflammables à proximité...
- Page 3 S-8500 THERMOELECTRIC GENERATOR Operating Manual CSA T.I.L R-10 Thermoelectric Generators #16, 7875 - 57th Street SE Calgary, Alberta Canada T2C 5K7 Main: +1 403 236 5556 Fax: +1 403 236 5575 www.globalte.com 64131 Rev 2...
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Page 5: Table Of Contents
TABLE OF CONTENTS 1 WARNINGS & CAUTIONS ..........1 1.1 WARNINGS &... -
Page 7: Warnings & Cautions
The Thermoelectric Generator should be inspected before use and at least annually by a qualified service person. More frequent cleaning may be required as necessary. It is imperative that control compartment, burners and circulating air passageways of the appliance be kept clean. Global Power Technologies S-8500... -
Page 8: General Information
The model S-8500 TEG has been independently tested by Intertek and certified to CSA T.I.L.-R10 Thermoelectric Generators and is authorised to carry the ETL mark. -
Page 9: Site Preparation
See Appendix E Service and Installation Tools. 2.1 SITE PREPARATION The site should be prepared in advance of the arrival of the TEG. The Model S-8500 is designed for General Area use and Outdoor Applications. No shelter is required for operation of this TEG. -
Page 10: Assembly
1/4 NPT nipple (A7 and A8 in Appendix F, Figure 14). 8. Install and tighten the fuel line kit to 1/4 NPT elbow (C14 in Appendix F, Figure 16) in the fuel system. Global Power Technologies S-8500... -
Page 11: Connecting The Fuel Supply
Connection: Tanks and cylinders are to be equipped with flexible connections to offset any movement affecting the piping or tubing. Global Power Technologies S-8500... -
Page 12: Connecting Customer Load
TB-1, terminals 3(+) and 4(-). Grounding and bonding connections may be made to TB-1, terminal 5. Refer to Appendix D, Figure 12 WARNING: Use supply wires with a minimum wire gauge of 8 AWG copper wire, and a minimum temperature rating of 90 ºC. Global Power Technologies S-8500... -
Page 13: Installation
(page 65). 2. Inspect the TEG for mechanical damage and remedy if found. If excessive damage is found contact Global Power Technologies (GPT). 3. Check that the fuel system connections are tight and have been checked for leaks. - Page 14 Customer Load circuit breaker is “ON”. The battery will NOT charge if the Customer Load circuit breaker is in the “OFF” position.” The highlighted portion inside the note shall be removed as it is not true. POWER 64228 Rev2 Figure 2 SI Controller Interface Global Power Technologies S-8500...
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Page 15: Power Output Evaluation
The TEG has stabilized once there is about 5 Watts difference between two 15 minute readings. This is typically about an hour after starting. NOTE: The TEG power will likely have not reached the target setup power at this point Global Power Technologies S-8500... -
Page 16: Leaving The Site
Make sure the Customer Load circuit breaker is in the “ON” position. Close the main electrical panel lid. Replace the pyramid stand panels using the 1/4 turn fasteners (1/4 turn clockwise). Ensure there are no combustible materials within 46 cm (18 inches) from the TEG. Global Power Technologies S-8500... -
Page 17: Shut-Down
3.5 SHUT-DOWN Shut off the manual fuel shut-off valve If the TEG Controller (Remote Start) option has been installed, refer to Appendix I Options for shut-down instructions. Global Power Technologies S-8500... -
Page 18: Operation
Figure 3 Data Plate Where: • Model No. is the model number and options. This is the model S-8500. See Appendix I for further released configuration information. • Serial Number is the unique identifier for the individual TEG and is date coded. -
Page 19: Power Unit Power Curve
TEG or checking performance as the maximum power that can be achieved will vary. The following chart should be used to determine the expected maximum power under the given ambient temperature condition. Global Power Technologies S-8500... - Page 20 Performance will increase at lower altitudes. At sea level, the performance will improve by about 5% (545W output). At 3000 m, the performance may be up to 15% lower (450 W output). The following chart shows the power multiplication factor as a function of altitude above sea level. Global Power Technologies S-8500...
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Page 21: Target Set-Up Power Calculation
Target Power of a matched load of 1.3 Ohms (555 W) at 55 o C and sea level (0 m ASL) = 555 W x 0.925 x 1.05 = 539W Note: Customer available power is the target setup power minus the power losses of the system. Global Power Technologies S-8500... -
Page 22: Customer Power Output
4.4 CUSTOMER POWER OUTPUT The S-8500 TEG incorporates protective electronics modules designed to maintain optimum conditions, protect the power unit and regulate the output voltage. If no customer load is attached to the TEG or the Customer Load circuit breaker is “OFF”... -
Page 23: Performance
4.3 prior to basic periodic maintenance. Additional maintenance might be required if the output power is significantly lower than the target power in which case contact the Customer Service Department at Global Power Technologies (GPT). Following sections explain the required basic maintenance for TEG sub-systems. -
Page 24: Burner Maintenance
Always be cautious when beginning maintenance since parts may not yet have cooled sufficiently to handle. 2. Disconnect the supply fuel line and fuel inlet valve. 3. Disconnect the solenoid wire terminal connections and the pressure switch wire connections. Global Power Technologies S-8500... -
Page 25: System Maintenance
(1.05”). Check the TEG data plate for the fuel type, see Figure 3. 67960 rev1 4. Tighten the fitting nut only until it is snug. Ensure the ceramic rod remains at the previously specified Figure 8 :S-8500 Electrode distance. Position Global Power Technologies S-8500... - Page 26 Replace the pressure switch if necessary. Note: Switch should open at pressures below 6.9 kPa (1 psi). 8. The SI controller must recognize that there is fuel available by the closed pressure switch condition before it will power the SI module. Global Power Technologies S-8500...
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Page 27: Cooling System
Should the fins become caked with dust or mud, it may be necessary to remove the dust and mud by the most appropriate method at hand, such as using compressed air, a long soft brush or use of water spray. Global Power Technologies S-8500... - Page 28 This page is purposely left blank. Global Power Technologies S-8500...
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Page 29: Troubleshooting
TROUBLESHOOTING Global Power Technologies S-8500... - Page 30 Contact GPT adjustment incorrect high High Power Limiter Replace the High Power Contact GPT damaged Limiter electronics Low output High Power Limiter Adjust the Hgh Power voltage Operation adjustment incorrect Limiter Overloaded TEG Reduce customer load Performance Global Power Technologies S-8500...
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Page 31: Appendix
(V Power Unit (PU): The hermetically sealed portion of the TEG that contains the thermoelec- tric materials. Rated Power: Model S-8500 TEG produces 520 W when operating in an ambient tempera- ture of 20 ºC (68 ºF). Set-up Voltage: V : Voltage from the power unit for a specific ambient temperature when the power unit is operated in a known state, which is proportional to set-up power. -
Page 32: Appendix B: Technical Specifications
2466 mm (97.1 in.) Net Weight 273 kg (603 lbs) Shipping Weight 415 kg (916 lbs) Mounting Holes 689 mm × 689 mm (27.12 in. × 27.12 in.) Table 1 Overall Dimensions, Weight and Anchor bolt pattern Global Power Technologies S-8500... - Page 33 Via output diode Overload Protection Voltage fold-back Maximum Output Current 28 A Protected by 30 A Circuit Breaker Output Connections Screw type terminal block, #10 Studs. Up to 8 AWG wires. Hole for up to 1” conduit connector. Global Power Technologies S-8500...
- Page 34 Rated Zone 4 Primary Materials of Con- Cabinet & Duct 304 SS struction Cooling system 1100 & 6061 Series Aluminum Fuel System contains Stainless and Brass fittings Table 3 Absolute Maximum & Minimum Ratings (24V model) Global Power Technologies S-8500...
- Page 35 Global Power Technologies (GPT) Standard Specification for Gaseous Fuel Note: Fuel considered is for standard, non-custom TEG and fuel system configurations. Gaseous fuel supplied to GPT’s Thermoelectric Generators: 1. Shall not contain any particulates larger than 30 μm diameter, including but not limited to sand, dust, gums, crude oil, and impurities.
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Page 36: Appendix C: Unpacking & Installation Clarifications
APPENDIX C UNPACKING & ASSEMBLY CLARIFICATIONS Global Power Technologies S-8500... -
Page 37: Appendix Delectrical Schematics & Connections
APPENDIX D ELECTRICAL SCHEMATICS & CONNECTIONS Figure 12: Basic wiring diagram Global Power Technologies S-8500... - Page 38 Figure 13: Detailed wiring diagram - Base TEG Global Power Technologies S-8500...
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Page 39: Appendix E: Service & Installation Tools
Additional tools required for installation: • Lifting device capable of lifting 273kg (603lbs) under expected weather conditions • shackles • Lifting strap, chain or cable • Bolts & nuts, #1/2-13 for mounting • Tape measure Global Power Technologies S-8500... -
Page 40: Appendix F: Parts List
62348 FIN DUCT, INNER HEM, S-8500 62350 CLAMP, BAND, 0.75” WIDE, 36.00-36.35” DIA 62351 J-HOOK, 304 SS, MOUNTING HOOK, FIN DUCT, S-8500 3094 SCREW, HEX HD, ¼-20 X 0.75” LG, SS WASHER, FLAT, ¼”, SS WASHER, LOCK, SPRING, ¼, SS NUT, HEX, ¼-20, SS... - Page 41 Appendix F Model S-8500 Parts List B9 B10 B11 64123 rev2 Figure 15: Major sub-assemblies overview Item Part No. Description 62340 RAIN CAP ASSY, S-8500 61915 EXHAUST STACK ASSY, S-8500 300461 EXHAUST STACK ASSY, N, S-8500 5545 EXHAUST GASKET, 8550...
- Page 42 Appendix F Model S-8500 Parts List NOTES: 1. FOR TEG PRIOR TO JAN 2020, REPLACE ITEM C5, BRASS VALVES WITH FIELD REPLACEMENT KIT 300279, STAINLESS STEEL VALVES WITH FIELD REPLACEMENT KIT 300280. LPG OPTION NATURAL GAS OPTION 64121 rev2 Figure 16: Fuel system overview Item Part No.
- Page 43 MOUNTING BRACKET, FUEL SYSTEM, S-8500 24498 SCREW, HEX HD, 1/4-20 UNC X 0.75, 316 SS 68098 FUEL LINE, SNUBBER TO SPARK POST, S-8500 22520 SCREW, HEX HD, 1/4-20 X 3.75” SS 62823 SCREW, HEX HD, 5/16-18 X 1.0” LG, SS 5578 WASHER, FLAT, 5/16”, SS...
- Page 44 Appendix F Model S-8500 Parts List 64128 rev1 Figure 18 Main electrical enclosure Item Part No. Description 62963 ENCLOSURE ASSY, ELECTRONICS, S-8500 56828 SCREW, CAP, HEX, 1/4-20 X 1/2” LG, SS WASHER, LOCK, INT, 1/4”, SS 62398 HIGH POWER LIMITER ASSY, S-8500,...
- Page 45 Appendix F Model S-8500 Parts List 64124 rev1 Figure 19 Cooling Sub-System Item Part No. Description 62353 FIN BASE, MACHINED, S-8500 62733 FIN BANK 1, S-8500 62734 FIN BANK 2, S-8500 62735 FIN BANK 3, S-8500 62736 FIN BANK 4, S-8500 2390 SCREW, HEX HD, 3/8”-16 x 1.5”,SS...
- Page 46 Appendix F Model S-8500 Parts List 64129 rev0 Figure 20 Lower stand assembly Item Part No. Description 62338 LEG, STAND, S-8500 62337 MOUNTING ANGLE, LOWER, STAND, S-8500 62822 SCREW, HEX HD, 5/16-18 X 0.875” LG, SS 5578 WASHER, FLAT, 5/16”, SS...
- Page 47 CONVERTER ASSY, DC/DC 24/48, S-8500, BAP-419-48V-Q7140 NUT, HEX, 1/4-20, SS NOT SHOWN: 64105, CONDUIT ASSY, TEG TO CP PANEL, S-8500 64106 CONDUIT ASSY, TEG TO DC/DC CONVERTER, S-8500 64107 CONDUIT ASSY, DC/DC CONVERTER TO CP PANEL, S-8500 Global Power Technologies S-8500...
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Page 48: Appendix G: Spark Ignition System
Battery supply blown fuse indicator (Blinks dimly) FE Fuse TEG supply fuse FB Fuse SI battery supply fuse V1 Connections Pilot/Start Solenoid valve connector (pos/neg/chassis) V2 Connections Main/Run Solenoid valve connector (pos/neg/chassis) Table 4 SI Controller Interface Global Power Technologies S-8500... -
Page 49: Appendix Hhigh Power Limiter Electronics
The status LED will flash quickly if the output voltage is more than 1.0V above the output voltage set point. (High Output Voltage) See section 7 – Troubleshooting, for possible causes of high or low output voltage. Global Power Technologies S-8500... - Page 50 Solid: Indicates output voltage is above VSR2 set point and VSR2 is energized L9, L10 Indicators (Red) Solid: Protective Limiter is engaged. Indicates a failure state L11, L12, L13 Indicator (Yellow) Switched resistor 1, 2, and 3 respectively are active Table 5 HPL INTERFACE Global Power Technologies S-8500...
- Page 51 0.1 V, as needed to the required voltage (reminder, e.g., a 27 Volt output voltage will read as 2.7 V on the multimeter). CAUTION: Be aware the VSR relays might energize or de-energize with adjustment. Global Power Technologies S-8500...
- Page 52 25ºC. It is factory set to charge 12 cells (24V nominal) lead acid battery system (factory set to 27.0V at 25 o C). Please contact Global Power Technologies (GPT) for more information on custom solutions.
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Page 53: Appendix Ioptions
APPENDIX I OPTIONS The following standard Model S-8500 configurations have been released. Please consult your GPT representative for customized reliable remote power solutions not listed here. Description Part Number S-8500N-12 8534 S-8500N-24 8530 S-8500N-48 8538 S-8500N-12-RS 8535 S-8500N-24-RS 8531 S-8500N-48-RS... - Page 54 Lockout state will cause [LOC] to flash on the 7-segment display. A reset must be performed either locally with the Reset pushbutton or remotely through a SCADA input before any start requests will be reattempted. Figure 24 Remote Start Board – Diagram Global Power Technologies S-8500...
- Page 55 Auto Start and Auto Stop voltage thresholds. In order to ensure correct Auto functionality for S-8500 TEGs that have a 12V or 48V DC/DC Converter, the external sense dipswitch must be turned ON and the external sense connector should be connected to both V2 on the Remote Start board and your external 12V/48V system battery.
- Page 56 Operator button for incrementing an ad- justment. S8 button – Down Operator button for decrementing an adjustment. Note: All SCADA inputs and outputs accept 16-28 AWG wire. Table 8 Remote Start Board – Inputs, Outputs, & Switches Global Power Technologies S-8500...
- Page 57 Indicates that Auto functionality is ON. FE Fuse Voltage supply 2A fuse and adjacent fuse blown indicator. FB Fuse Battery supply 2A fuse and adjacent fuse blown blinking indicator. Table 10 Remote Start Board – LED Indicators Global Power Technologies S-8500...
- Page 58 Note: After making changes to these dipswitches, ensure the board is power cycled for at least five seconds, as the dipswitch settings are only scanned during powerup. Table 11 Remote Start Board – Dipswitch Settings for S-8500 Remote Start Board – Instructions for Use...
- Page 59 3. Further presses of S6 (Adjust) will exit Adjustment mode. When running off battery power it will also automatically time-out and exit Adjustment mode after a moment of inactivity. All variable changes are always saved upon exit of the Adjustment mode. Global Power Technologies S-8500...
- Page 60 Figure 25 Detailed wiring diagram - 24V Remote Start Global Power Technologies S-8500...
- Page 61 CP interface cabinet. RESISTOR COVER RESISTOR METER PUSH TO READ AMPS TERMINAL BLOCK SHUNT CABINET TEG + TEG - MOUNTING +ANODE PLATE -CATHODE 64238 rev0 Figure 26 Cathodic Protection Interface Panel Global Power Technologies S-8500...
- Page 62 FOR PARTS LIST - SEE APPENDIX F, Figure 21 Figure 27 CP Interface System, Figure 28 CP Interface System, Series Wiring Diagram Parallel Wiring Diagram Global Power Technologies S-8500...
- Page 63 Figure 29 CP Panel wiring schematic Global Power Technologies S-8500...
- Page 64 To adjust the output voltage of the DC/DC Converter measure the voltage across Output (+) and (–) then adjust the voltage adjustment pot until the desired voltage is reached. See Figure 30. FOR PARTS LIST- SEE APPENDIX F- FIGURE 21 Global Power Technologies S-8500...
- Page 65 Figure 30 DC/DC Converter Connections Global Power Technologies S-8500...
- Page 66 Figure 31 DC/DC Converter with CP Panel wiring schematic Global Power Technologies S-8500...
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Page 67: Appendix Jbattery Charging Operation
If the TEG is not in a float or cycle charging application, then the default operation is fixed voltage power supply mode. This is the default factory mode setting; it provides a regulated output voltage. The TEG output charging voltage to be set will depend on either a float charging or cycle charging application. Global Power Technologies S-8500... - Page 68 Global Power Technologies S-8500...
- Page 69 TCBC in combination with the required optional temperature sensor(s) for proper TCBC operation. If left in pow- er supply mode or without the temperature sensor(s), the battery may not be charged according to the manufacturer’s specifications. Global Power Technologies S-8500...
- Page 70 TCBC : Temperature Compensated Battery Charging n/a : Not Applicable * S-8500-12V – Not applicable for battery charging; it is intended for CP applications. The 12V DC/ DC converter is a tightly regulated converter with minimal adjustment. Ensure Auto functionality is OFF.
- Page 71 28.3 30.1 28.5 56.7 60.2 57.0 28.7 30.5 28.9 57.4 60.9 57.7 29.0 30.8 29.2 58.1 61.6 58.4 29.3 31.1 29.5 58.7 62.2 59.0 29.6 31.4 29.8 59.4 62.9 59.7 Table 14 Effects of Temperature Compensation Global Power Technologies S-8500...
- Page 72 Figure 32: Flowchart, Battery Charging Application Setup Global Power Technologies S-8500...
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Page 73: Appendix Kteg Performance Log
APPENDIX K TEG PERFORMANCE LOG MODEL NO: TEG SERIAL NO: FUEL TYPE: HPL SERIAL NO: CP INTERFACE SERIAL NO: MAINTENANCE REMARK Global Power Technologies S-8500... - Page 74 APPENDIX K TEG PERFORMANCE LOG MODEL NO: TEG SERIAL NO: FUEL TYPE: HPL SERIAL NO: CP INTERFACE SERIAL NO: MAINTENANCE REMARK Global Power Technologies S-8500...
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