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Global 5120 Operating Manual

Thermoelectric generator
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5120
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
01556 REV 5

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  • Page 1 5120 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 01556 REV 5...
  • Page 3 5120 Quick Start Procedure 5120-SI-SO • Turn on gas supply to TEG. Hold down the button on Shut Off (SO) valve. The spark igni- tion system (SI) should begin clicking and the sound of combustion heard within 15 seconds. Continue holding the button for 90 seconds then release it. The SO valve should remain open and the TEG should continue to operate. • Adjust the fuel pressure to 10-15% less than noted on Data Nameplate. • Install the jumper clip between terminals 3 & 4 of TB-1 • After one hour measure the voltage, V , between terminals 2(+) and 4(-) of TB-1. The V should be approximately 6.7 volts. See Section 2.6 to adjusting for ambient temperature. • Return the jumper clip to between terminals 1 and 2 of TB-1 • Apply Customer load Fuel Pressure •...

  • Page 5: Table Of Contents

    5120 Performance Log . . . . . . . . . . . . . . . . . . . .
  • Page 7 Figure 5 Wiring Diagram 5120 TEG with no Limiter/Converter . . . . . . . . . . . . . . . . . . .

  • Page 9: Introduction

    Introduction This manual provides installation, operation and maintenance instructions for the Global Power Technologies Model 5120 Thermoelectric generators. 1.1 General Description and Specifications The Model 5120 Thermoelectric Generator contains no moving parts. It is a reliable, low main- tenance source of DC electrical power for any application where regular utilities are unavailable or unreliable. Power Specifications 120 Watts @ 6.7 Volts Power Ratings 108 Watts @ 12 Volts 20ºC, 750 m above sea level 108 Watts @ 24 Volts 108 Watts @ 48 Volts Electrical 6.7 V Up to 11 Volts 12 V 12-18 Volts Adjustment 24 V 24-30 Volts 48 V 48-60 Volts Reverse Current Protection Terminal block which accepts up to 8 AWG wire. Output Opening for 3/4 in. conduit in the base of the cabi- Fuel 8.8 m /day (311 ft /day) of Std. 1000 BTU/SCF Natural Gas (37.7MJ/Sm ) gas Propane 11.4 l/day (3.0 US gal/day) Maximum Supply Pressure 172 kPa (25 psi)
  • Page 10 Global Power Technologies 5120...

  • Page 11: Standard Features And Options

    Standard Features and Options 1 .2 .1 Standard Features The TEG comes standard with a fuel pressure regulator capable of accepting up to 172 kPa (25 psi) and a built in fuel filter, an Automatic Spark Ignition System (SI), and low voltage alarm contacts (Voltage Sensing Relay or VSR) 1 .2 .2 Options Available options for the 5120 Thermoelectric Generator are as follows: Automatic Shut-Off Option (SO): The Automatic Gas Shut-Off option (SO) is designed to turn off the gas supply to the burner if the flame in the TEG is extinguished and cannot be subse- quently re-ignited by the automatic SI system within approximately three to five minutes. Corrosive Environment Fuel System Option (SS): The Corrosive Environment Fuel System is specially constructed with increased corrosion resistant components. All of the standard...

  • Page 12: Definition Of Terms

    Flame Arrestor Option: Most of Global Power Technologies’ (GPT) standard TEG’s fall under the definition of “flame type equipment” as defined in the regulations of The Oil And Gas Conservation Act Alberta (Section 8.090). GPT has developed a flame arrestor system for use as an option on the Model 5120 TEG to meet the EUB requirements. It has been designed to allow its installation on both new or existing TEGs. Please note that although GPT’s engineers have designed the flame arrestor following CSA standards and have tried to satisfy regulatory requirements with the design, the flame arrestor is not CSA approved. It is the responsibility of the end user to determine the suitability of GPT’s flame arrestor system to meet the requirements of their specific installations including, but not limited to: a) the suitability of EUB’s definition of equipment location and b) the suitability of GPT’s air intake flame arrestor design as an “adequate flame arrestor”.

  • Page 13: Theory Of Operation

    Figure 1 illustrates how this is done in the model 5120 TEG. A thermocouple is formed by P type and N type thermoelectric elements joined together at one end by a hot electrode. Adjacent thermocouples are joined at the other end by cold electrodes. Eighty thermocouples, each producing 84 mV are connected in series so that the TEG produces 120 V at 6.7 V and 18 Amps.
  • Page 14 The electrical output of the 5120 TEG changes as the ambient temperatures changes; the power increases as the temperature decreases. The term rated-power is used when the maximum ambient temperature is 65ºC. • The 5120 TEG’s power unit produces 120 Watts gross at 20ºC at the beginning of its service life. • Power decreases at a rate of 0.288% per ºC rise in Temperature (0.16% per ºF) see Figure 7 on page 2-7.
  • Page 15 Global Power Technologies 5120...

  • Page 16: Operation

    4 #1/4-20 bolts & nuts for mounting. • 1 Phillips Screwdriver. Unpack the 5120 TEG from its shipping crate. Keep the crate until the TEG is operational. Check the TEG for damage which may have occurred during shipping. Any damage must be reported as soon as possible. The damage may make the generator inoperable therefore, Check with Global Power Technologies (GPT) Customer Service before starting a dam- aged TEG . Locate and identify the following items that were shipped with the 5120 TEG.
  • Page 17 7-2, for mounting hole locations. The base must be level and sturdy enough to support the 41 kg (90 lb) TEG. The TEG should be mounted high enough to avoid direct flooding or heavy snowfall interfering with the flow of cooling air. Allow a minimum of 150 mm (6 in.) clearance under the cooling fins. WARNING: Operation of the TEG in locations where cooling air flow may be obstructed will cause overheating of the TEG . Global Power Technologies 5120...

  • Page 18: Data Plate

    2 .3 Data Plate The data plate is located on the inside of the TEG cabinet door and indicates the following: Fuel Type: An X is stamped in the appropriate box for Natural gas or Propane. Each fuel type requires a different orifice, therefore the TEG must be used with the fuel indicated. Model Number: The model number is interpreted as follows: Serial Number: Unique to each TEG. 5120 - ( ) - ( ) Fuel Type: L = Propane N = Natural Gas Limiter Converter Voltage: 12 or 24 Volts Fuel System: SI = Spark Ignition Only SI-SO = Spark Ignition & Auto Shut Off Power, Fuel Pressure, Voltage: These were measured during the factory performance test and are for reference only. The operating power, fuel pressure and voltage are determined and...

  • Page 19: Start-Up

    Figure 4 Wiring Diagram 5120 TEG with Limiter Converter A fuel shut-off valve MUST be installed between the TEG and the fuel supply. All fuel piping must be in accordance with local regulations. Inspect the fuel lines and fittings to be sure they are free of foreign material. Purge fuel lines of all air. The TEG has a 1/4 in. NPT, male fuel inlet. Remove the plastic protective cap and apply thread sealant, see Figure 3. Connect the fuel line and test all joints for leaks using a commercial leak detector. 2 .5 Start Up System Performance Logs are located at the back of this manual, Appendix 7.5, page 7-5. Use of these logs is recommended each time the site is visited. This information is valuable for future reference. Move the jumper on TB-1 from between terminals 1 and 2 to between terminals 3 and 4, see Figure 4 or Figure 5.. Connect a DC Voltmeter to terminals 2(+) and 4(-) of TB-1. This will be measuring V Make sure that all of the connections in the fuel system are tight and have been checked for leaks. Check the ignition system, see Figure 6. Loosen the ignitor rod wing-nut. Global Power Technologies...

  • Page 20: Figure 5 Wiring Diagram 5120 Teg With No Limiter/Converter

    Figure 5 Wiring Diagram 5120 TEG with no Limiter/Converter Push the ignitor rod in as far as it will go, (it should extend about 25mm (1 in.) past the holding screw), then pull it back 3 mm (1/8 in.). Tighten the wing-nut, DO NOT over tighten as the ignitor rod will crack. 2 .5 .1 SI-SO Start Turn on the fuel supply. Push in the button on top of shut-off valve. The spark ignitor should begin clicking and the sound of combustion will begin. In some cases it may be necessary to bleed air from the fuel line before combustion will begin. Continue to hold the button down for at least 90 seconds after combustion begins, then release the button . If the sound of combustion stops, push the button again until combustion is sustained. Note: It is necessary to fully depress the button before releasing it. 2 .5 .2 Manual Start If the TEG’s SI system is malfunctioning, one can manually start the generator. It should be noted that the malfunctioning SI be repaired as soon as possible as the TEG will not be able to reignite itself in the event that the TEG’s burner goes out because of fuel interruptions. Global Power Technologies 5120...

  • Page 21: Evaluation

    Repair and replace SI system as soon as possible. 2 .6 Evaluation 2 .6 .1 Set-Up Power and V The power in the 5120 TEG is produced by the difference in temperature between the burner and the cooling fins. This means that the power output of the 5120 TEG will be affected by the ambient temperature at the generator site. The rated power is the power that the 5120 TEG should produce at a specific ambient tem- perature, up to a maximum temperature of 45ºC (115ºF). The 5120 TEG is rated at 120 Watts gross power (power from the power unit) when operating at an ambient temperature of 20ºC (75ºF). As the ambient temperature rises the gross power will decrease and as the ambient temperature decreases the gross power will increase. For every rise in temperature of 1ºC the 5120 TEG will drop 0.36 Watts in gross power output. Global Power Technologies 5120...
  • Page 22 Figure 7 Rated Gross Power of Power Unit vs. Ambient Temperature at Beginning of Life To determine the required Set-up Power see graph in Figure 7 and consider the following example: The present site temperature is 40ºC Find 40ºC on the horizontal axis. Read vertically until intersecting the rated power curve. Read horizontally to the vertical axis to find the set-up power. Which is 113 Watts , the voltage across the precision load, is a measure of power. The value of the precision load (0.375 ohm) is selected to provide the optimum load condition for the TEG. The relation- ship between V (V) and power (P) is: P = (V 0.375 This relationship is shown in Figure 8. To determine the rated V see the graph in Figure 8: The required power is 116 Watts Locate 116 Watts on the horizontal axis. Read vertically until intersecting the curve. Read horizontally to the vertical axis to determine rated V Which is 6.6 volts. Global Power Technologies 5120...

  • Page 23: Figure 8 V

    Figure 8 V Vs Set Up Power 2 .6 .2 V (Power) Check After ignition has occurred the voltage between terminals 2(+) and terminals 4(-), that is, V will begin to climb as shown on the graph in Figure 9. The V will rise quickly at first then begin to level out. It will take at least one hour for the V to stabilize. When V no longer changes (±0.2 V in ten minutes) compare this value with rated as determined in section 2.6.1, these should be within 0.2 Volts of each other. If the measured V is greater than rated V then the fuel pressure needs to be reduced. If the measured V is less than rated V then proceed as follows. 2 .6 .3 Elevation Adjustment Check the fuel gauge pressure. It should be near to the pressure indicated on the data plate. If the TEG is located at a different altitude than the factory, (750 m or 2460 ft.) the pressure will also be different. See Figure 10. Global Power Technologies 5120...

  • Page 24: Figure 10 Fuel Gauge Pressure Vs Elevation

    If the fuel system and burner appear to be operating correctly, the fuel pressure may be slightly adjusted to match the TEG’s voltage with the rated V value. Figure 12 can be used to determine how much to adjust the fuel pressure . EXAMPLE: Rated V = 6.5 V Measured V = 6.8 V Difference = -0.3 V As seen on the graph, the fuel pressure must Figure 10 Fuel Gauge Pressure vs Elevation be increased 8.5 kPa (1.2 psi). Global Power Technologies 5120...

  • Page 25: Customer Load Wiring

    WARNING: Do not exceed the following values: Natural Gas: 31 kPa (4 .5 psi) Propane: 45 kPa (6 .5 psi) Wait at least 10 minutes before measuring V . If the TEG still does not reach V value then a problem exists with one of the TEG’s systems. See section 3.3, trouble shooting, for evaluation. Replace the cover on the fuel regulator. 2 .7 Customer Load Wiring Use only copper wire, properly sized for the load current. Bring the customer load wires through the strain relief bushing (located on the TEG cab- inet floor). Allow enough wire to connect to the terminal block TB-1. Tighten the screws on the strain relief bushing. Connect the customer load wires to terminals 5(-) and 6(+). Global Power Technologies 2-10 5120...

  • Page 26: Figure 12 Change In V

    Figure 12 Change in V vs Fuel Pressure Adjustment Move the jumper clip to between terminals 1 and 2 of TB-1, see wiring diagram Figure 13. Check the Voltmeter and ammeter readings on the limiter converter. WARNING: Before leaving the site make sure that the button on the shut-off valve has been released . Global Power Technologies 2-11 5120...

  • Page 27: Figure 13 Wiring Diagram 5120 Teg

    Figure 13 Wiring Diagram 5120 TEG Global Power Technologies 2-12 5120...

  • Page 28: Service And Maintenance

    Service and Maintenance Before attempting to service the Model 5120 TEG you should be thoroughly familiar with the operation of this generator. It is suggested that you review Sections 1 and 2 before attempting to service this TEG. 3 .1 Suggested Periodic Maintenance The TEG is a solid-state high-reliability device that requires very little maintenance. However, it does require periodic service checks in order to provide the years of trouble free service of which it is capable. The maintenance interval depends on the site conditions (fuel purity, weather, etc.) and must be established based on site experience. Field experience indicates...
  • Page 29 If the above causes have been ruled out the TEG may require more than just the basic service. Refer to Section 3.3 for further procedures to isolate the cause of the low V condition but keep the TEG operating for now. Unless other service is indicated above, the following basic service is all that is required. 3 .1 .2 TEG Basic Service Schedule Replace the fuel filter (Part# 3400-22363) in the pressure regulator once per year (see Section 3.2.2.2). Drain the pressure regulator sediment bowl (see Section 3.2.2.1) Check the fuel orifice for clogging and replace if necessary (see Section 3.2.2.3). Propane Orifice (#7) Part# 4200-00689 Natural Gas Orifice (#8) Part# 4200-00690 Remove any debris, sand or dust from the cooling fins, air filter stabilizer and cabinet interior. Check all bolts and wire connections for tightness. Restart TEG as per Section 2.5. Record service and current operation parameters in the System Performance Log in Appendix 7.5, page 7-5. Global Power Technologies 5120...

  • Page 30: System Components

    3 .2 System Components The main parts of the 5120 TEG are as follows (see Figure 14): Power Unit: The power unit includes the thermopile and the cooling fins. The thermopile consists of the N and P elements (thermocouples) placed in a sealed compartment to prevent oxidation and surrounded by insulation to prevent heat loss. Cooling Fins: Cooling of the thermopile is done by the free movement of ambient air through the cooling fins. Check that the cooling fins are clear of leaves and other debris. There should be enough space around the fins for air movement. Burner: Gas is expanded through an orifice and then flows through a venturi where it draws in air needed for combustion. This mixture passes through the burner screen and burns at the back of the combustion chamber (next to the thermopile). Fuel System: The power output of the generator is controlled by adjusting the amount of fuel sent to the burner. The fuel system contains a pressure regulator which allows adjustment of fuel flow, a pressure gauge, and a pressure switch which signals the spark ignition system that fuel is present. An optional Shut-Off (SO) valve may also be present which closes when heat is no longer present in the exhaust stack, thereby stopping the flow of gas. Spark Ignition (SI) Module: When the fuel is turned on, the gas pressure causes the pressure switch (located on fuel system) to close. This signals the SI module to generate 12 kV sparks,...

  • Page 31: Figure 14 Teg Main Parts

    Figure 14 TEG Main Parts Place the jumper in V position between terminals 3 and 4 of TB-1. Connect a volt meter to terminals 2(+) and 4(-) Open the circuit by quickly removing the jumper from the terminal block. Record the voltage within 2 seconds. It will increase quickly and should be approximately 13 volts. Immediately replace the jumper. If the momentary open circuit voltage is below 12 volts, then the TEG is operating cold and the fuel system and burner should be thoroughly checked and/or adjusted. If the momentary open circuit voltage appears reasonable, but V remains below 6.7 volts, then the power unit is damaged and will need to be replaced. WARNING: Do not let the open circuit voltage exceed 13 .5 Volts Global Power Technologies 5120...

  • Page 32: Figure 15 Si-So Fuel System Service

    Figure 15 SI-SO Fuel System Service 3 .2 .2 Fuel System The fuel system includes a FISHER 67CFR regulator which controls the fuel pressure to the orifice. The regulator contains both a sediment bowl with a manual drain cock and a fuel filter. The outlet of the pressure regulator leads to a manifold on which is mounted a pressure gauge to monitor the fuel pressure. The fuel flows through the manifold to the fuel line which connects to a orifice mounted on front of the burner. The orifice contains a jewel with a precisely drilled hole to control the fuel flow into the burner. An SO valve is located between the manifold and fuel line, and the SI pressure switch is mounted on the SO valve, see Figure15. 3 .2 .2 .1 Draining the Sediment Bowl The sediment bowl will collect impurities in the fuel. Drain the regulator as follows: Shut off the fuel supply to the TEG. Open the drain cock located on the under side of the TEG cabinet. Any impurities will drain through the cock. Close drain cock. Global Power Technologies 5120...

  • Page 33: Figure 16 Pressure Regulator

    Carefully replace the bottom of the regulator making sure that the gasket is in its proper position. Replace the four bolts and tighten. Figure 16 Pressure Regulator 10) Before re-installing the regulator check the orifice, Section 3.2.2.3 and air supply, Section 3.2.3. 11) Re-install the pressure regulator. With the fuel pressure on, leak check all joints. 3.2.2.3 Fuel Orifice Check or replace the fuel orifice as follows: Shut off the fuel supply to the TEG. Disconnect the flexible fuel line from the front of the burner. Remove the orifice fitting. Visually check the orifice hole. It should be free from any obstructions. • Replace if necessary. Re-assemble the fuel line, tightening all connections. Leak check all connections using a commercial leak detector. Note: Always use the same size orifice as was removed. For propane service use orifice #7 part 4200-00689 For natural gas use orifice #8 part 4200-00690. WARNING: After any fuel system service, check for fuel leaks . Global Power Technologies 5120...

  • Page 34: Figure 17 Venturi Location

    (Figure 18) Check the venturi assembly. If it looks severely corroded it should be replaced. Make sure the venturi is properly located in the venturi tube (1.50” from end, Figure 17), and that the venturi is facing the proper direction. Figure 17 Venturi Location Global Power Technologies 5120...

  • Page 35: Figure 18 Burner Assembly

    Figure 18 Burner Assembly Global Power Technologies 5120...
  • Page 36 WARNING: To prevent high voltage shock remove the orange wire from the pres- sure switch and make sure it can not come into contact with other electrical connections . Check the operation of the SI system as follows: Remove the Spark Electrode by loosening the wing-nut and sliding the electrode out . Inspect the electrode for any cracks in the ceramic rod. If any cracks are found the electrode must be replaced. Slide the electrode back into position until it stops, then pull it back 3 to 6mm (1/8 to1/4”). The ceramic rod should extend about 25mm (1”) from the holding screw. Tighten the wing-nut only until it is snug. DO NOT over tighten or the ceramic rod will crack. Loosen the orange and brown wire connectors from the terminals on the pressure switch and then short the circuit between the two terminals. Arcing should occur in the combustion chamber (making a clicking noise) at the rate of one per sec- ond . If arcing occurs the system is functioning well. Check the pressure switch. It should close at a pressure of 13.8 kPa (2 psig) and open at 6.9 kPa (1 psig). Replace the pressure switch if necessary. Global Power Technologies 5120...

  • Page 37: Figure 19 Spark Ignitor Wiring Diagram

    Check the battery voltage as follows: Measure the voltage between the brown lead and terminal 4 of TB-1. The voltage should be greater than 2 volts. If the voltage is less than 2 volts the battery needs recharging or replacing. Make sure all wire connections are secure. Check the battery charger and spark generator as follows: Manually light the TEG by placing a lighted match at the port of the SI electrode. After twenty minutes of operation check the battery voltage as per step 3. The voltage should be 2.35 volts. Perform step 1 again. If sparking does not occur the control module needs to be replaced. Check if the battery will hold charge as follows: Remove the thin white/red wire from terminal 2 of TB-1. Connect the orange wire to the brown wire. Measure battery voltage between the orange wire and terminal 4 of TB-1. If the voltage is less than 2.0 volts, replace the battery. To replace the battery open the control module. Disconnect the battery leads. Install a new battery, taking note of polarity. Figure 19 Spark Ignitor Wiring Diagram Global Power Technologies 3-10 5120...
  • Page 38 Connect one lead of an ohm meter to the end of the thermocouple fitting. Connect the other lead of the ohm meter to the casing of the thermocouple cable. If an ohm reading registers on the meter then the thermocouple is okay. If the resistance is equal to infinity then the thermocouple is damaged and must be replaced. Check the Shut-Off Valve. Remove the thermocouple fitting from the bottom of the SO valve. Connect one lead of an ohm meter to the SO valve at the point where the tip of the thermocouple was in contact with the valve. Connect the other lead of the ohm meter to the casing of the SO valve. If an ohm reading registers on the meter then the SO valve is okay. If the resis- tance is equal to infinity then the SO valve is damaged and must be replaced. Global Power Technologies 3-11 5120...

  • Page 39: Troubleshooting Guide

    Orifice plugged. Replace orifice. Section 3.2.2.3. Air adjustment incorrect Adjust air supply. Section 2.6.4. Clean air screen. Section 3.2.3. SI system not working. Check SI System. Section 3.2.5. Burner will ignite but Minimum supply gas pressure is 69 Supply gas pressure to low . will not continue to kPa (10 psig). Section 2.4. burn . Incorrect pressure regulator Adjust pressure. Section 2.6.5 setting. Drain regulator sediment bowl. Section 3.2.2.1. Dirty fuel filter. Replace fuel filter. Section 3.2.2.2. Orifice plugged. Replace orifice. Section 3.2.2.3. SO Thermocouple not work- Check thermocouple. Section 3.2.6. ing. SO Valve not working. Check SO Valve. Section 3.2.6. Adjust air supply. Section 2.6.4. Air adjustment incorrect Clean air screen. Section 3.2.3 Global Power Technologies 3-12 5120...
  • Page 40 Low output power or low Incorrect set-up voltage for Determine required V voltage. site temperature. for present conditions. Section 2.6.1. Insufficient cooling around Clear fins of any debris. fins. Drain regulator sediment bowl. Section 3.2.2.1. Dirty fuel filter Change filter. Section 3.2.2.2. Orifice plugged. Change orifice. Section 3.2.2.3. SO valve malfunctioning. Check SO valve. Section 3.2.6 Adjust air supply. Section 2.6.4. Incorrect air supply. Clean air screen. Section 3.2.3 Incorrect fuel adjustment. Adjust fuel regulator. Section 2.6.5 Check switch settings. Limiter Converter needs adjusting or repair. Check output voltage adjustment Pot. Power unit faulty. Check momentary open circuit voltage, section 3.2.1 Output power or voltage Incorrect fuel adjustment. Lower fuel pressure. Section 2.6.5 is too high. Incorrect Limiter Converter Re-adjust the output voltage adjust- adjustment. ment Pot. Global Power Technologies 3-13 5120...

  • Page 41: 5120 Teg Parts List

    3 .4 5120 TEG Parts List Figure 20 5120 TEG Parts Illustration Item Part No . Description 4100-01029 Cover Assy, Upper Fin Duct 4100-01033 Fin Duct, Upper 4100-01035 Fin Duct, Lower 7900-08900 Power Unit, 5120-12/24 7900-08901 Power Unit, 5120-48 or CP5120 6100-01051 Burner 2708-00600 Nut, Wing, 8-32, SS 4200-00689 Orifice, 7, Propane 4200-00690 Orifice, 8, Natural Gas 4200-05286 Fuel Line Kit, 10” 4200-23005 Fuel Line Kit with Elbow, 8” for TEG without Flame Arrestor 4500-00979 Exhaust Stack, Inner 4500-01025 Exhaust Stack Assembly, Outer A10...
  • Page 42 3 .4 5120 TEG Parts List Figure 20 5120 TEG Parts Illustration Item Part No . Description A13 6400-22367 Fuel System, SI 6400-22368 Fuel System, SI-SO 6400-22369 Fuel System, SI-SO, SS Option A14 2200-02110 Terminal Block, 8 Position A15 6300-20144 Control Module, SI II A16 4100-01019 Leg, Left 4100-01020 Leg, Right A17 2514-20535 Screw, Mach, Hex hd, 1/4 - 20 S 5/8 SS A18 2710-00601 Nut, Wing, 10-32, SS A19 4900-07004 Pin, Mounting, SI Electrode...

  • Page 43: Burner Parts List

    3 .5 5120 Burner Parts List Figure 21 5120 Burner Parts Illustration Item Part No . Description 4000-00983 Burner Back Assembly 4000-01004 Insulation Block Support 4000-00701 Spacer, Insulation 4000-00693 Screen Holder 4000-00873 Burner Screen 4000-00694 Insert Ring 4000-00998 Insulation Block 4000-00971 Venturi 4000-00999 Venturi Tube Assembly B10 2506-00479 Screw, Set, Soc. HD, 6-32 x 1/8, SS B11 4000-00985 Combustion Chamber Assembly B12 4000-01005 Spacer, Burner...
  • Page 44 3 .6 5120 Burner with Flame Arrestor Parts Figure 22 5120 Burner with Flame Arrestor Item Part # Description 4000-00983 Burner Back Assembly 4000-01004 Insulation Block Support 4000-00701 Spacer, Insulation 4000-00693 Screen Holder 4000-00873 Burner Screen 4000-00694 Insert Ring 4000-00998 Insulation Block 4000-00971 Venturi 4000-00999 Venturi Tube Holder B10 2506-00479 Screw, Set, Soc. HD, 6-32 x 1/8, SS B11 4000-00985 Burner Cover Assembly B12 4900-27148...

  • Page 45: Burner With Flame Arrestor Parts

    3 .6 Burner with Flame Arrestor Parts (Cont’d) Figure 22 5120 Burner with Flame Arrestor Item Part # Description B15 4000-00990 Air Shutter B16 2810-00569 Washer, Flat, #10, SS B17 2900-07267 E-Ring, Bowed, SS, Spaenaur 251-802 B18 4000-00700 Venturi Adjustment Screw B19 4000-00747 Venturi Plate Assembly B20 4900-07683 Screen, Flame Arrestor B21 4000-00758 Lock Nut, Venturi Adjustment Screw B22 2710-07798 Nut, Coupling, 10-32 x ¾ B23 4900-07797 Stud, Extension, Flame Arrestor B24 4200-23004...

  • Page 46: So Fuel System Parts List

    3044-00376 Nipple, Close, 1/4 NPT X 2” LG. Brass 3041-07291 Nipple, 1/4 NPT X 2.00, SS 4900-02100 Manifold Block 3400-06471 Pressure Switch, Hobbs 76056 16 NO 3200-00691 Gauge, 0-15 PSI 3200-07289 Gauge, Pressure, 0-15 PSI, SS 3021-22790 Connector, Male, 1/4 TB X 1/4 NPT, SS 4200-07981 Vent Tube Assy 3044-02154 Nipple, Hex, 1/4 NPT X 3” LG, Brass 3041-02358 Nipple, Hex, 1/4 NPT X 3 in. LG, SS C10 3031-20071 Elbow, 1/4 Tube X 1/4 NPT, SS C11 3400-00177 Thermocouple (order separately) C12 3090-00176 Valve, Shut Off, Basco C13 3054-00432 Plug, Brass 1/8 - 27 NPT 3051-07290 Plug, 1/8-27 NPT, SS n/a 4200-22888 Fuel Filter Kit Global Power Technologies 3-19 5120...
  • Page 47 Global Power Technologies 3-20 5120...

  • Page 48: Limiter Converter

    Limiter Converter 4 .1 .1 Product Application This manual contains information pertaining to the 220 Watt L/C series limiter converter which is designed for use with a 5120 requiring 12 or 24 Volt outputs. 4 .1 .2 Product Description The 220 Watt L/C consists of two separate circuits operating together. The first is a shunt type voltage limiter that regulates the output of the generator. The second circuit is a DC to DC converter that switches the input voltage to a different output voltage. See Figure 24 for physical description. 4 .1 .3 Product Specifications Overload Protection triggers when the load draws excess current. The result is a proportional drop in output voltage (fold back current limiting).

  • Page 49: Operation

    Connect the 220 Watt L/C to the terminal block as per Figure 25. Remote mounting of the limiter converter is accept- able, but allow for 17 Amps between the generator and the limiter converter when sizing wire. Figure 25 5120 Wiring Diagram The limiter converter must always be mounted in an upright position to allow air to pass freely over the heat sink section. 4 .2 .3 Output Voltage Adjustment The 220 Watt limiter converter 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 26.
  • Page 50 Figure 26 220 Watt L/C Connection and Adjustment Details Global Power Technologies 5120...
  • Page 51 Global Power Technologies 5120...

  • Page 52: Cathodic Protect Interface System

    Refer to Figure 27 for locations and description of the major components of the CP Interface Cabinet. 5 .1 .1 Meter The dual scale meter displays voltage at the terminal block, and current when the PUSH TO READ AMPS button is depressed. The meter is accurate to +/- 3% of full scale. Figure 27 Cathodic Protection Interface Cabinet Global Power Technologies 5120...
  • Page 53 The current shunt rating corresponds to the ampere scale on the meter. 5 .1 .3 Adjustments A 0 to 1 ohm, 300 Watt variable resistor located inside the cabinet may be used to adjust the output power of the CP interface. This resistor may be connected in series or parallel with the TEG. See Figure 28 for series connection and Figure 29 for parallel Connections. 5 .1 .4 Series By connecting the 300 Watt resistor in series with the TEG the maximum allowable power may be delivered to the CP load. This is achieved by moving the tap to the bottom of the resistor. 5 .1 .5 Parallel By connecting the 300 Watt resistor in parallel with the TEG smaller levels of power may be delivered to the CP load. This may be required when hot spots occur on the anode. With the tap located at the top of the resistor the output power will be zero. As the tap is moved down, the power to the CP load is increased. Figure 28 Wiring Diagram, CP Interface in Figure 29 Wiring Diagram, CP Interface in Series Connection Parallel Connection Global Power Technologies 5120...
  • Page 54 Series and Parallel configurations are made by moving the wire at the top of the 300 Watt resis- tor from the left position to the center position of the heavy duty terminal block. Complete parts listings are given in the next five pages for the various Cathodic Protection Interface System available. The suggested system for various TEGs are listed below. TEG Item System Description 5120 6300-06222 CP Interface System Assy, 0-15V, 0-30A 5120-12 6300-06223 CP Interface System Assy, 0-20V, 0-10A 5120-24 6300-06224 CP Interface System Assy, 0-30V, 0-5A Global Power Technologies 5120...
  • Page 55 Figure 30 Cathodic Protection System Parts Identification Global Power Technologies 5120...
  • Page 56 2 8 4900-02134 Meter Panel, CP, Brushed 2 9 2420-06226 Meter, GE/TCA, 251-324-ECXS 3 0 2510-00255 Screw, Mach, P-H-P, 10-32 x 3/8, SS 2510-00256 Screw, Mach, P-H-P, 10-32 x 1/2, SS 3 2 2510-00243 Screw, Mach, P-H-S, 10-32 x 1/4, SS 3 3 2808-00469 Washer, Lock Spring, #8, SS 3 4 2810-00539 Washer, Lock, Spring, #10, CAD 3 5 2508-00254 Screw, Mach, P-H-P, 8-32 x 3/8, SS 3 6 2808-00468 Washer, Lock, Int, #8, SS 3600-04795 Label, Cathodic Protection Interface Part of Item 29 Button, Red, 61F-675, For ALCO Switch Global Power Technologies 5120...
  • Page 57 Global Power Technologies 5120...

  • Page 58: Flame Arrestor Kit Installation And Operation

    Flame Arrestor Kit Installation and Operation 6 .1 IMPORTANT WARNING The Model 5120 TEG with Flame Arrestor Kit has been tested in compliance with API Recommended Practice 12N, for the Operation, Maintenance and Testing of Firebox Flame Arrestors as it applies to continuously run, gas fired, natural draft burners. The Flame Arrestor Kit includes a flame arrestor on the air intake, which has been tested in compliance with CSA standard Z343-98. Global Power Technologies (GPT) considers compli- ance with API 12N and CSA Z343-98 as evidence that the Flame Arrestor Kit is adequate for use in unclassified areas.
  • Page 59 TEGs suitable for installation in these hazardous areas. The addition of a flame arrestor kit does not make the Model 5120 suitable for use in a hazardous area. For hazardous area use, TEGs require reduced surface temperatures (below hazardous gas ignition temperatures), addition of air intake and exhaust flame arrestors, and other modifications.

  • Page 60: Figure 31 Flame Arrestor Kit - Installed

    6 .2 INTRODUCTION The flame arrestor kit for the model 5120 Thermoelectric Generators consists of three main sub-assemblies. These are: An Air Intake Flame Arrestor Kit, GPT P/N 4900-23043. A Flame Arrestor Stack Assembly, GPT P/N 4500-50221, plus Gasket, GPT P/N 4500- 50198 and stack spacer, GPT P/N 4900-50196. A Rain Cap Assembly, GPT P/N 4500-51516 & Flange, Exhaust Stack P/N 4500-28376 A Label to apply to the front door of the TEG, GPT P/N 3600-50232 Please refer to Figure 31 to identify these major sub-assemblies as installed on a Model 5120 Thermoelectric Generator. Figure 31 Flame Arrestor Kit - Installed Global Power Technologies 5120...

  • Page 61: Disassembly

    6 .3 .1 Remove Stacks: Figure 33 shows the removal of the inner and outer exhaust stacks. Remove the outer exhaust stack assembly by loosening the band clamp inside the top of the TEG cabinet. Leave the intake stack assembly in place. Remove the S.I. electrode by loosening the large wing nut on the front of the inner exhaust stack and pulling the electrode straight out. Inspect the electrode carefully. If it is damaged, or the ceramic insulator is cracked it MUST be replaced with GPT P/N 4200-02032. Remove the inner exhaust stack assembly by removing the smaller 10-32 wing nut on the front of the exhaust stack, then gently pulling the inner stack assembly straight back. Save the wing nut for the installation of the new inner stack. 6 .3 .2 Remove Fuel Line and Thermocouple: Figure 34 shows the removal of the fuel line, fuel orifice and thermocouple. Disconnect the flexible fuel line from the fuel manifold using a 9/16 wrench. Global Power Technologies 5120...
  • Page 62 Figure 32 Items for Removal from the base of the SO valve with a 3/8 wrench, and replace the thermocouple with GPT P/N 3400-00177. 6 .3 .3 Remove Air Intake Assembly: Figure 35 shows the removal of the Air Intake and Air Shutter assemblies. Attach the Flame Arrestor Kit label, GPT P/N 3600-50232 to either front door of the TEG. Loosen the air shutter lock nut on the front of the air filter stabilizer assembly. Using a flat blade screwdriver, close the air shutter by turning the air shutter adjustment screw counter-clockwise. Count the number of turns required to close the air shutter. Remove the 10-32 wing nuts and air shutter lock nut from the front of the air filter stabi- lizer assembly. Save these fasteners for installation of the flame arrestor intake. Remove the air filter stabilizer assembly. Global Power Technologies 5120...

  • Page 63: Figure 33 Exhaust Stack Removal

    Figure 33 Exhaust Stack Removal Global Power Technologies 5120...

  • Page 64: Installation

    Failure to follow these instructions exactly, using worn or damaged parts, or installing items incorrectly may result in personal inju- ry or death and possible damage to the equipment and/or property. Global Power Technologies 5120...

  • Page 65: Figure 35 Air Intake And Air Shutter Removal

    Install the burner orifice through the flame arrestor screen and tighten only hand tight into the venturi tube assembly inlet. Caution: Always use the correct size burner orifice, 5120 Natural Gas Orifice (#8), GPT P/N 4200-00690. The flame arrestor kit is not approved for use on a 5120 generator operating on propane fuel . Install the two (2) flame arrestor extension studs into the coupling nuts and place the flame arrestor can spacer over the studs.

  • Page 66: Figure 36 Intake Flame Arrestor Installation

    Rotate the fuel line elbow and flame arrestor can spacer so that the notch in the can aligns with the groove of the grommet on the fuel line elbow. Make sure that the fuel line fitting points away from the combustion chamber exhaust tubes, then tighten the fuel line fitting onto the fuel orifice with two 9/16 wrenches. See Figure 36. Connect one end of the flexible fuel line to the fuel manifold. Connect and tighten the free end of the flexible fuel line to the fitting on the fuel line elbow kit using a 9/16 wrench. WARNING: Check the system for fuel leaks at this point! Rotate the flame arrestor element holder so that the notch in the can aligns with the groove of the grommet on the fuel line elbow. Slide the flame arrestor element holder inside the flame arrestor can spacer. Global Power Technologies 5120...
  • Page 67 First, tighten the thermocouple lock nut finger tight only. Then, support the mounting boss with a 5/8 wrench and snug the thermocouple lock nut with a 7/16 wrench. WARNING: Do not twist the inner stack assembly when installing the thermocou- ple, or the gasket may be damaged. Loosely install the electrode mounting pin and large wing nut into the electrode bracket on the front of the inner stack assembly. Global Power Technologies 6-10 5120...

  • Page 68: Figure 38 Rain Cap Installation

    Adjust the spark gap as directed in the appropriate section of the TEG operating manual. Tighten the wing nut only until it is snug. Caution: Do not over tighten the wing nut or the ceramic rod will crack. Connect the high voltage spark wire to the electrode. 6 .4 .3 Install Rain Cap Assembly: Figure 38 shows the installation of the Rain Cap Assembly. Using the mounting flange as a template, drill 4 holes (9/16 diameter) in the top of the cabinet. Install the rain cap assembly in the large hole in the cabinet top, centered over the flame arrestor inner stack. Install the mounting flange from inside the cabinet. Use the 1/4-20 Hex head screws, washers and nuts to fasten in place. Figure 38 Rain Cap Installation Global Power Technologies 6-11 5120...

  • Page 69: Set Up

    Note: Proper combustion can be determined using a carbon monoxide (CO) meter. When properly adjusted, a model 5120 TEG produces less than 100 ppm as measured inside the top of the flame arrestor inner stack. Measuring carbon monoxide inside the rain cap assembly will give a false reading.

  • Page 70: Maintenance

    6 .6 Maintenance A 5120 TEG with the flame arrestor kit requires periodic maintenance. The maintenance interval depends on the site conditions, fuel cleanliness, weather, dust, insects and other contaminant concentrations etc., and must be established based upon expe- rience at each site. Follow the service and maintenance instructions in the 5120 TEG Operating Manual. Since there are two “screens” in the intake flame arrestor assembly, both the screens (see Figure 39 item B20 and B26), must be cleaned when directed to clean the “air filter” in the 5120 Operating Manual. Global Power Technologies 6-13 5120...

  • Page 71: Parts List

    6 .7 Parts List Figure 39 5120 Burner with Flame Arrestor Item Part No . Description 4200-00690 Orifice, 8, Natural Gas 4000-00983 Burner Back Assembly 4000-01004 Insulation Block Support 4000-00701 Spacer, Insulation 4000-00693 Screen Holder 4000-00873 Burner Screen 4000-00694 Insert Ring 4000-00998 Insulation Block 4000-00698 Venturi 4000-00999 Venturi Tube Holder B10 2506-00479 Screw, Set, Soc. HD, 6-32 x 1/8, SS B11 4000-00985 Burner Cover Assembly B12 4900-27148...
  • Page 72 6 .7 Parts List Figure 39 5120 Burner with Flame Arrestor Item Part No . Description B14 4000-01005 Spacer, Burner B15 4000-00990 Air Shutter B16 2810-00569 Washer, Flat, #10, SS B17 2900-07267 E-Ring, Bowed, SS, Spaenaur 251-802 B18 4000-00700 Venturi Adjustment Screw B19 4000-00747 Venturi Plate Assembly B20 4900-07683 Screen, Flame Arrestor B21 4000-00758 Lock Nut, Venturi Adjustment Screw B22 2710-07798 Nut, Coupling, 10-32 x 3/4 B23 4900-07797 Stud, Extension, Flame Arrestor B24...
  • Page 73 Figure 40 Flame Arrestor Parts Item Part No . Description 4500-51516 Exhaust Stack Assembly, w/Rain Cap, 5060/5120 4500-28376 Flange, Exhaust Stack 2514-00258 Screw, Mach, P-H-P, 1/4-20 x 5/8, SS 2814-00557 Washer, Flat, 1/4”, SS 2714-00611 Nut, Hex, 1/4-20, SS 4500-50221 Exhaust Stack Assembly, Inner, 5120 Flame Arrestor 4500-50198 Gasket, Stack Seal, Flame Arrestor 4500-50196 Spacer, Stack Assembly, Flame Arrestor 4500-50225 Coupling, Extension, 10-32 x 3/4” Global Power Technologies 6-16 5120...

  • Page 74: Appendix

    Appendix 7 .1 Electrical Output Characteristics The electrical output of a Model 5120 TEG is shown on the graph in Figure 41. Note that the power goes through a broad maximum between 0.3 and 0.5 ohms. The rated power of 120 Watts can be obtained only if the load resistance is within this range. Figure 41 Gross Power Unit Electrical Output Characteristics @ 20°C, Beginning of Life Global Power Technologies 5120...

  • Page 75: Physical Dimensions

    7 .2 Physical Dimensions Figure 42 Physical Description Global Power Technologies 5120...

  • Page 76: Gas Specifications

    5. Shall not contain more than 200 mg/Sm (approx. 294 ppm) of total Sulphur. 6. Shall not contain more than 10% [CO 2 ] and/or [N 2 ] by volume, nor vary more than +/- 1% [CO 2 ] and/or [N 2 ] 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/Sm3 (1000 BTU/cu.ft.) Propane/LPG: 93 MJ/Sm3 (2500 BTU/cu.ft.) Butane: 108 MJ/Sm3 (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 5120...
  • Page 77 Global Power Technologies 5120...

  • Page 78: 5120 Performance Log

    7 .5 5120 Performance Log MODEL NO: TEG SERIAL NO: FUEL TYPE: LIMITER/CONVERTER SERIAL NO: Maintenance Repair Notes Global Power Technologies 5120...
  • Page 79 7 .5 5120 Performance Log MODEL NO: TEG SERIAL NO: FUEL TYPE: LIMITER/CONVERTER SERIAL NO: Maintenance Repair Notes Global Power Technologies 5120...

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