1. Manuals
  2. Brands
  3. Global Manuals
  4. Portable Generator
  5. 5030
  6. Operating manual

Global 5030 Operating Manual

Thermoelectric generator
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
5030
THERMOELECTRIC GENERATOR
Operating Manual
#16, 7875 - 57th Street SE
Calgary, Alberta
Canada T2C 5K7
Main: +1 403 236 5556
Fax: +1 403 236 5575
www.globalte.com
01953 REV 13

Advertisement

Table of Contents
loading

Related Manuals for Global 5030

Summary of Contents for Global 5030

  • Page 1 5030 THERMOELECTRIC GENERATOR Operating Manual #16, 7875 - 57th Street SE Calgary, Alberta Canada T2C 5K7 Main: +1 403 236 5556 Fax: +1 403 236 5575 www.globalte.com 01953 REV 13...

  • Page 3: Table Of Contents

    Wiring Diagram, 5030 TEG ........

  • Page 5: General Information

    GENERAL INFORMATION 1 .1 Introduction The 5030 is a highly reliable, low maintenance power source that converts heat directly into electricity without any moving parts. The 5030 generator uses propane (C ) or natural gas (CH ) as a fuel and will automatically ignite whenever gas pressure is present. It generates 30 watts of DC power at 2.0 volts. The limiter converter (L/C) converts the 2.0 volts to a more useful 12 or 24 volts and maintains the voltage at an adjustable level. Features of the 5030 include the following: Spark Ignition (SI) The 5030 comes standard with the spark Ignition (SI) feature. This pro- vides a spark to ignite the burner whenever fuel pressure is present. The SI uses a recharge- able lead acid battery. The battery charge is maintained by the 5030. Automatic Shutoff (SO) The automatic shutoff includes a valve in the gas line that is held open by a thermocouple in the exhaust stream. In the event that the flame goes out the thermocou- ple allows the valve to close preventing the accumulation of gas vapors. Fuel Filter When clean commercial fuel is used a fuel filter is not required but for applications where dirty fuel is a possibility an in line fuel filter is recommended.

  • Page 6: Data Plate

    Figure 1 5030 Dimensions Limiter-Converter (L/C): A specific electronic device attached between the generator and load that converts one level of DC voltage to another, and limits the voltage level. Matched Load: A condition of load where the load voltage of the generator is one-half of the open circuit voltage and the load resistance is equal to the internal resistance of the generator. Precision load: The precision resistor contained on the generator that provides the optimum load condition. The voltage across the resistor is defined as Vset and is used to analyze gen- erator electrical performance. 1 .4 Data Plate The data plate is located on the inside of the cabinet door and includes vital information about the generator. Fuel Type: An “X” will be marked in the appropriate box to indicate whether the generator is configured to burn natural gas (CH ) or propane (C ). Suitable orifices are available if it is necessary to change the fuel type. Global Power Technologies 5030...

  • Page 7: Fuel Consumption

    Model Number: The model number on the Data Plate is interpreted as follows: 5030 ( ) - ( ) SI-( ) FUEL TYPE: L = Propane N = Natural Gas OUTPUT VOLTAGE: 12 or 24 Volts FACTORY OPTIONS: SO = Automatic Shutoff Fuel Pressure, Power, Voltage: The fuel pressure, gross power output and open circuit setup voltage have been included for reference only. These are the conditions that were achieved at the Global Power Technologies (GPT) factory prior to shipping. Note that the fuel pressure is recorded in kPa (psi) and that the pressure gauge must be adjusted for altitude as described in section 2.6.8. 1 .5 Fuel Consumption The 5030 is designed to operate on commercial propane (C ) or clean dry natural gas (CH with an un-fluctuating heating value of not less than 28 megajoules/m (750 BTU/ft ). (See Appendix 1, Gas Specifications.) While the use of sweet line or well head gas is common,...

  • Page 8: Fuel Considerations

    1 .6 Fuel Considerations Clean Fuel The fuel used to operate the GPT model 5030 must be clean. See the gas spec- ification in section 4.1. If dirty fuel is anticipated then a customer supplied in line fuel filter is recommended. Low Temperatures When using propane (C ) at temperatures below -35ºC (-30ºF) special consideration must be given to vaporization of the fuel. Supply Pressure A minimum gas supply pressure of 105 kPa (15 psi) must be supplied to the regulator inlet of the generator. A maximum of 172 kPa (25 psi), the rating of the pressure regulator, is allowed. Global Power Technologies 5030...

  • Page 9: Operations

    2 .2 Set Up Before setting up the generator it must first be determined how much electrical power is required. If less than full power is required then the generator can be set up for this lower power level resulting in some savings in fuel consumption. To ensure reliable combustion the 5030 should not be set for less than 20 watts gross output . If the generator is producing more electrical power than is being used then the excess power will be disposed of within the con- verter limiter. To set up the generator a voltmeter capable of reading to at least two decimal places will be required. A meter capable of reading to three decimal places is preferred.

  • Page 10: Figure 2 Wiring Details

    Figure 2 Wiring Details Global Power Technologies 5030...

  • Page 11: Electrical Properties

    Figure 3 Wiring Diagram, 5030 TEG 2 .4 Electrical Properties The electrical properties of the 5030 generator are very dependent on the resistance of the load to which it is connected. Maximum power is generated at a load of 0.11 ohms. This is called matched load. The converter limiter included with the generator is designed to always present a load of 0.11 ohms to the generator. If for any reason this converter limiter is not used then consideration must be given to the resistance of the load used. The converter limiter included with the 5030 can trigger alarms or other processes in the event of a low voltage. Low voltages can be caused by overloads, lack of fuel or a faulty generator. This detection is achieved by a Voltage Sensing Relay (VSR). The use of the voltage sensing relay is described in the 30 WATT CONVERTER LIMITER manual. TEG Operating Normally LED Indicator works in conjunction with the voltage sensing relay and turns on providing a visual indication when the output voltage is above the preset minimum. Note that during the open circuit voltage test, this green LED remains off as the power unit has been disconnected from the power electronics unit. Global Power Technologies 5030...

  • Page 12: Ambient Temperature And Rated Power

    2 .5 Ambient Temperature and Rated Power The power output from the 5030 will be slightly affected by the ambient temperature (the air temperature) around the generator. The rated power is the power that the 5030 should produce at a specific ambient temperature. The 5030 is rated at 30 watts gross power when operating at an ambient temperature of 24ºC (75ºF). As the ambient temperature rises, the gross power will decrease, and as the ambient temperature decreases, the gross power will increase. 2 .6 Start Up 2.6.1 With the fuel pressure turned off, record the ambient temperature, the rated V (as noted on data plate located on inside of cover) on the “PERFORMANCE LOG”, provided at the back of this manual. 2.6.2 Referring to Figure 2, disconnect the TEG(-) lead from the terminal post. Connect a voltmeter capable of reading to at least two decimal places to the TEG(-) and TEG(+) leads. 2.6.3 Make sure that all of the connections in the fuel system are still tight, checking for leaks with a commercial leak check fluid. WARNING: Do not test for fuel leaks with a match or any open flame.
  • Page 13 When the TEG is operating, surface temperatures in the vicinity of the thermopile, burner, exhaust stack and around the cooling fins may be in excess of 100ºC. Avoid contact of skin and clothing with these areas when operating in and around the TEG. Global Power Technologies 5030...
  • Page 14 2.6.13. 2.6.11 After the voltage has stabilized, continue to open or close the air shutter (depending on which direction caused a rise in voltage) until the point resulting in maximum voltage is found. The generator should be allowed to stabilize for 15 minutes between each adjustment. 2.6.12 After the air shutter is adjusted, then adjust the fuel up or down until rated V is achieved. The fuel should be adjusted in 1.4 kpa (0.2 psi) increments allowing the generator to stabilize for 15 minutes between adjustments. After the regulator is adjusted re-tighten the lock nut. 2.6.13 Once V is obtained then: Reconnect the TEG(-) lead to the terminal post. Connect the voltmeter to the output terminals 1 & 2 marked customer load. See Figure 2. This voltage should read 10 to 18 volts for the 12 volt option or 22 to 30 volts for the 24 volt option. The converter limiter has been factory set at 14.1 volts or 27.0 volts respectively but can be adjusted as described in the 30 WATT CONVERTER LIMITER manual. 2.6.14 The 5030 is now ready to be connected to the load. Connect the load across terminals 1 & 2. Once the load is connected and the TEG is started and allowed to warm up, use a voltmeter to measure the voltage between Volt+ and Volt - on the Meter TB (terminal block). Record this result. Now measure the voltage between Amp+ and Amp- on the Meter TB and record this result. The power being delivered to the load can be calculated as follows: Power = Volt reading * Amp reading (in volts) divided by 0.01 ie Power = 14.2 * 0.015 divided by 0.01 = 21.3W Global Power Technologies 5030...

  • Page 15: Service

    SERVICE 3 .1 Maintenance and Repair The 5030 Generator is designed to require a minimum amount of maintenance when using commercial fuel. Sections 3.2 and 3.3 describe the preventative maintenance required for trou- ble free operation. Should more than these key items require maintenance or repair a complete parts list is included. 3.2 Orifice Part number 4200-00686 (Natural Gas) or 4200-00687 (Propane) Check every 10,000 hours (annually) Replace every 25,000 hours (3 years) To check the orifice remove the flexible fuel line from the back of the burner using two 9/16” open ended wrenches. Remove the orifice and visually check it for any obstructions. When clean fuel is used (or a fuel filter) the orifice should be good for several years. WARNING: When replacing the orifice make sure the connections are well tight- ened to prevent any leakage.

  • Page 16: 5030 Teg Parts List

    3 .4 5030 TEG Parts List Figure 5 5030 Base TEG Parts Item Part # DESCRIPTION 7900-08904 Power Unit, 5030 6200-06424 Cover Assy, 5030 (Includes Item A3 & A4) 4500-00790 Exhaust Stack Assy, 5030 4500-00755 Intake Stack Assy, 5030 6100-00872 Burner Assy, 5030 (see Figure 6) 4200-00687 Orifice Assy, Propane, #5, 0.0105 4200-00686 Orifice Assy, Natural Gas, #4, 0.0145 2708-00606 Nut, Hex, 8-32, SS 4900-06768 Electrode, Spark Ignitor 4200-23005 Fuel Line Kit, 5030 A10 6400-22381 Fuel System Assy, SI-SO, SS Option (see Figure 7) 6400-22382 Fuel System Assy, SI-SO, SS Option Global Power Technologies 5030...
  • Page 17 3 .4 5030 TEG Parts List (cont’d) Figure 5 5030 Base TEG Parts Item Part # DESCRIPTION A11 4100-00794 Leg, 5030 A12 2514-07323 Screw, P-H-P, 1/4-20 X 1 1/2, SS A13 2714-00611 Nut, Hex, 1/4-20, SS A14 6300-06782 Converter Limiter, 12V 6300-06758 Converter Limiter, 24 V A15 2514-02105 Screw, Cap, HEX-HD, 1/4-20 X 3 1/2 LG., SS A16 2814-00473 Washer, Lock, EXT, 1/4, SS A17 2900-60391 SPACER, 1/4” LG, 0.192 ID X 3/8 OD, 18-8 SS Global Power Technologies 5030...

  • Page 18: Burner Parts

    3 .5 Burner Parts Figure 6 Burner Parts Item Part # DESCRIPTION 4000-07440 Burner Back Assy, 5030 4000-00829 Support, Insulation Block 4000-00701 Spacer, Insulation 4000-00693 Screen Holder 4000-01008 Burner Screen Assy, 5030 4000-00694 Insert Ring, Burner 4000-00864 Venturi Tube Holder, 5030 4000-00863 Venturi, 5030 2506-00479 Screw, Set, SOC. HD, 6-32 X 1/8, SS B10 4000-00828 Insulation Block B11 4000-00827 Burner Cover Global Power Technologies 5030...
  • Page 19 Figure 6 Burner Parts Item Part # DESCRIPTION B12 4000-01005 Spacer B13 2900-07267 E-Ring, Bowed, SS B14 4000-00990 Air Shutter B15 2810-00569 Washer, Flat, #10, SS B16 4000-00700 Venturi Adjusting Screw, 5030 B17 4000-00871 Venturi Plate Assy 5030 B18 4000-07230 Air Filter Assy, 5030 B19 4000-00758 Nut, Lock, Venturi Adjust Screw B20 2710-00601 Nut, Wing, 10-32, SS B21 2756-07005 Nut, Wing,5/16-18, SS B22 4900-07004 Pin, Mounting, Electrode...

  • Page 20: Fuel System - Si-So, Parts List

    Fuel System - SI-SO, Parts List Figure 7 Fuel System, SI-SO Note: Alternate parts are for Stainless version of fuel system. Item Part # DESCRIPTION C1 3100-22360 Regulator, Fisher, 67CFR, 0-20 PSI 3100-22365 Regulator, Fisher 67CFR, 0-20 PSI, SOUR GAS C2 3031-20071 Elbow, 1/4 TUBE X 1/4 MNPT, SS C3 4200-20122 Vent Tube Assy, 5030 C4 3044-00501 Nipple, Hex, 1/4 NPT X 1 1/2, BRASS 3041-02359 Nipple, Hex, 1/4 NPT X 1 1/2, SS C5 3034-00384 Elbow, Street, 1/4 NPT, BRASS 3031-02356 Elbow, Street, 1/4 NPT, SS C6 3021-00380 Connector, Male, 1/4 TUBE TO 1/4 NPT, 316SS C7 4200-02100 Manifold Block...

  • Page 21: Troubleshooting

    3 .7 Troubleshooting The following flow chart is designed to isolate problems that can occur with the generator. For further explanation of the comments refer to the appropriate section. Global Power Technologies 5030...
  • Page 22 Global Power Technologies 5030...
  • Page 23 Global Power Technologies 5030...
  • Page 24 3.7.4 Shorted Ignitor Wire: If the sound of a spark can be heard but no spark is formed at the electrode tip then the high voltage spark wire is shorting to the cabinet. Even if no spark can be heard a short may still exist. With the pressure switch contacts closed listen and look for a spark along the length of the wire. If possible, reposition the wire away from the cabinet or position a non-conductive obstacle in between the wire and the cabinet. Strips of electrician’s tape work well to isolate the wire. If the insulation is worn then the wire should be replaced. If the electrode ceramic is cracked then this is often a path for a spark to ground. Replace elec- trode. 3.7.5 Spark Ignitor Battery: The most common reason for a faulty spark ignitor is a dead battery. This can occur during long periods of storage, from a faulty charging circuit or if the generator is allowed to run open circuit for more than a few hours. The battery can be removed and charged at 300 milliamps or the generator can be manually ignited and allow the generator to charge the battery automatically. The converter limiter must be connected to the generator to charge the battery (TEG(-) and TEG(+) leads connected to terminal posts). If the battery does not charge while the generator is operating then either the charging circuit is faulty or the battery should be replaced. The charging circuit can be checked by measuring the voltage on the battery leads with the battery disconnected. If the measured voltage is not close to 2.3 volts try adjusting the charging voltage using the pot shown in Figure 2. If the voltage is still not 2.3 volts then the converter limiter should be returned to the factory for repair. 3.7.6 Electrode: To adjust the position of the electrode loosen the wing nut to allow the electrode to be pushed in freely. Push the electrode in until it touches the burner plate. Next pull the electrode about 5 millimeters (1/4 inch) out and re-tighten the wing nut. 3.7.7 Fuel/Air Mixture: The mixture of the fuel to the air is adjusted with the air adjustment screw protruding from the burner cover. To adjust the air shutter loosen the locking nut and turn the adjusting screw. If the generator is having difficulty igniting it is sometimes easier to ignite in a fuel rich condition or in other words with the air shutter fully closed or almost fully closed. Global Power Technologies 3-10 5030...
  • Page 25 (A8, Figure 5) and remove the two nuts holding the burner in place (A7, Figure 5) then remove the burner. See Figure 6. Inspect the parts for any tears, holes or corrosion and replace them if they are defective. Check the venturi, if it looks corroded it should be replaced. 3.7.11 Open Circuit Voltage: The unloaded voltage from the thermopile is an indication of the tem- perature difference between the cold side and the hot side. At normal operating conditions the open circuit voltage should be about 4.0 volts. Values lower than 3.8 volts generally indicate that the thermopile is not hot enough and values higher than 4.0 volts generally indicate that the thermopile is too hot. NEVER ALLOW THE VOLTAGE TO EXCEED 4.0 VOLTS. 3.7.12 Cooling: The fin base temperature is measured by inserting a thermocouple between the cool- ing fins near the centre of the thermopile. In a 25ºC (77ºF) ambient the fin base temperature is typically 120ºC (248ºF) but it should never exceed 170ºC (338ºF). If the temperature is too high then the generator cooling fins are obstructed. Ensure that the fins are not blocked with debris or other obstructions and that at least 15 cm (6 inch) of clearance is present below and above the fins. 3.7.13 Converter Limiter analysis (12 VOLT): After V is at the correct voltage, connect the TEG(-) lead to the terminal post and measure the power on the output of the limiter converter as fol- lows: 3.7.13.1 Measure the output voltage between terminals 1 & 2 and ensure that it is in the 10 to 18 volt range. Adjust the voltage as described in the limiter converter manual until the output voltage is above 14.0 volts. If this can be achieved, then the converter limiter is probably fine. To actually measure the power produced proceed as follows. Global Power Technologies 3-11 5030...
  • Page 26 3.7.14 Converter Limiter Analysis (24 VOLT): After V is at the correct voltage, connect the TEG(-) lead to the terminal post and measure the power on the output of the limiter converter as follows: 3.7.14.1 Measure the output voltage between terminals 1 & 2 and ensure that it is in the 24 to 30 volt range. Adjust the voltage as described in the converter limiter manual until the output voltage is about 27 volts. If this can be achieved, then the converter limiter is probably fine. To actually measure the power produced proceed as follows. 3.7.14.2 Connect the output from the converter limiter across a resistor (capable of dissipating 30 watts) in the 20 to 24 ohm range. Measure the voltage across the output, and calculate the power as follows: P = V P = Power (watts) V = Measured voltage across resistor (VDC) R = Resistor value (ohms) As long as the limiter converter is producing 21 watts (or 70% of rated power) then the limiter converter is working. Global Power Technologies 3-12 5030...

  • Page 27: Limiter Converter Option, 30 Watt

    Limiter Convert Option, 30 Watt 4 .1 General Information 4 .1 .1 Product Application This manual contains information pertaining to the 30 Watt L/C series converter limiter which is designed for use with a model 5030 thermoelectric generator. 4 .1 .2 Product Description The 30 Watt L/C consists of two separate circuits operating together. The first is a DC to DC converter that switches the input voltage to a different output voltage. The second circuit is a shunt type voltage limiter that regulates the output of the generator. See figure 8 for physical description. 4.1.3 Product Specifications Short Circuit Protection is designed into the 30 Watt L/C. A momentary short circuit will not damage the generator or the converter limiter. If extended short circuit durations are anticipat- ed, an in-line fuse should be placed on the output of the converter limiter. Use 3 Amp slow blow for both the 12 and 24 volt configurations. Reverse Current Protection is standard on all 30 Watt Converter Limiter. A diode in series with the output prevents current from flowing back through the converter when the generator is shut off. Voltage Sensing Relay provides a set of contact to indicate an alarm condition when the output voltage drops below a preset minimum.
  • Page 28 Figure 8 30 Watt Converter Limiter Physical Description Global Power Technologies 5030...
  • Page 29 Figure 9 30 Watt Converter Limiter Connection & Adjustment Details Global Power Technologies 5030...

  • Page 30: Operation

    4 .2 .3 Protective Limiter A protective limiter circuit is incorporated into the 30 Watt L/C to limit the input voltage. This setting can be measured across the TEG Positive and TEG Negative terminals with no load connected. The 30 Watt Converter Limiter is factory set at 1.8 Volts. 4 .2 .4 Output Voltage Adjustment The 30 Watt Converter Limiter is factory set at 14.1 Volts or 27.0 Volts depending on the output ordered. To trim the output voltage use the output voltage adjustment pot shown in figure 9. The output voltage range cannot be switched between 12 and 27 Volts. 4 .2 .5 Voltage Sensing Relay Adjustment The VSR is factory set at 10.5 Volts for 14.1 Volt output and at 21 Volts for a 27.0 Volt output. Should this require adjustment, use the VSR adjustment pot in figure 9. Global Power Technologies 5030...

  • Page 31: Appendix

    2. Shall not have a hydrocarbon dew point in excess of 0ºC (32ºF) at 170 kPa (25 psi 3 (2) 3. Shall not contain more than 115 mg/Sm (approx. 170 ppm) of H 4. Shall not contain more than 60 mg/Sm (approx. 88 pmm) of Mercaptan Sulphur. 5. Shall not contain more than 200 mg/Sm (approx. 294 ppm) of total Sulphur. 6. Shall not contain more than 10% [CO ] and/or [N ] by volume, nor vary more than +/- 1% ] and/or [N ] during operation. 7. Shall not contain more than 120 mg/Sm of water vapour. 8. Shall not contain more than 1% by volume of free oxygen. 9. Shall have a nominal gross heating value of: Natural Gas: 37 MJ/Sm (1000 BTU/cu.ft.) Propane/LPG: 9 3 MJ/Sm (2500 BTU/cu.ft.) Butane: 108 MJ/Sm (2900 BTU/cu.ft) 10. Shall not exceed 60ºC (140ºF) in temperature. Notes: (1) - For gaseous fuels outside of these specifications, please contact Global Power Technologies (GPT). (2) - Sm = Standard cubic meter of gas at 101.325 kPa at 20ºC (NIST). Global Power Technologies 5030...
  • Page 32 Global Power Technologies 5030...

  • Page 33: Appendix 2, Performance Log

    5 .2 APPENDIX 2, PERFORMANCE LOG MODEL NO: TEG SERIAL NO: FUEL TYPE: LIMITER/CONVERTER SERIAL NO: Maintenance Repair Notes Global Power Technologies 5030...
  • Page 34 5 .2 APPENDIX 2, PERFORMANCE LOG MODEL NO: TEG SERIAL NO: FUEL TYPE: LIMITER/CONVERTER SERIAL NO: Maintenance Repair Notes Global Power Technologies 5030...
  • Page 35 Global Power Technologies 5030...

Table of Contents