Related Manuals for Global 8550-RU
Summary of Contents for Global 8550-RU
- Page 1 Model 8550-RU Thermoelectric Generator PERATING ANUAL Global Power Technologies www.globalte.com...
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Page 3: Table Of Contents
TROUBLESHOOTING ......................37 PARTS LISTS ......................... 39 FUEL SYSTEM PARTS LIST ......................42 ELECTRONICS ASSEMBLY PARTS LIST ..................43 6720 VOLTAGE LIMITER FOR MODEL 8550-RU TEG .............. 44 PRODUCT APPLICATION ......................44 OPERATION ..........................44 SERVICE ............................. 45 6720 VOLTAGE LIMITER PARTS LIST ..................46 CATHODIC PROTECTION INTERFACE OPTION ............... - Page 4 Figure 18 – Overtemperature Shutdown System .................. 33 Figure 19 – Automatic Shut-off Components ..................34 Figure 20 – Model 8550-RU TEG Parts (1 of 2) ..................39 Figure 21 – Model 8550-RU TEG Parts (2 of2) ..................40 Figure 22 – Fuel System Parts ....................... 42 Figure 23 –...
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Page 5: Important Safety Instructions
Thermoelectric Generator and to replace any part of the control system and any gas control that has been under water. 5. The Model 8550-RU Thermoelectric Generator contains electrical and gas related safety devices as identified throughout this manual. Tampering or rendering inoperative any of these safety devices may result in personal injury or death and possible damage to the equipment and is not permitted under any circumstances. -
Page 6: Manual Icons And Safety Banners
Canada T2C 5K7 Customer Service/Technical Support: 1-403-720-1190 Copyright© 2022 by Global Power Technologies (GPT). All rights reserved. No part of this manual may be reproduced without permission in writing from GPT, except by a reviewer who may quote brief passages or reproduce illustrations in a Copyright review with appropriate credit;... -
Page 7: General Information
It is a reliable, low-maintenance source of DC electrical power for applications where regular utilities are unavailable or unreliable. The Model 8550-RU TEG comes equipped with a 6720 Voltage Limiter and can be field upgraded with remote-start capability. Contact GPT for information on upgrading your TEG. -
Page 8: Data Plate
TEG Model Number explanation of the model number. The type of fuel that the TEG’s fuel system is designed for and was tested with. Fuel Type L = Propane, N = Natural Gas 302954 rev0 | Model 8550-RU Page 4 of 53... -
Page 9: Figure 2 - Model Number Explanation
Burner fuel pressure recorded during factory acceptance test. Burner Fuel Pressure The Model 8550-RU TEG’s model number can be interpreted as follows: Figure 2 – Model Number Explanation Use only the type of fuel that is indicated on the data plate. -
Page 10: Installation
3° (0.5 inch per foot or 50 mm per meter). The Model 8550-RU TEG has an optional stand that allows optimal airflow around the TEG and convenience for operators to perform service checks. If you opted not to purchase the stand, prepare a platform or stand to mount the TEG on. - Page 11 122 MJ/m (3300 BTU/cu.ft.) Shall not exceed 60°C (140°F) in temperature. NOTES: (1) For gaseous fuels outside of these specifications, please contact Global Power Technologies. (2) At 1 atm and 15°C (59°F). (3) Contact local representative or Global Power Technologies if H S concentration is greater than 170 ppm.
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Page 12: Unpacking And Mounting
Wire strippers Teflon thread sealant tape Check the TEG for any signs of damage before beginning assembly and installation. Some damages can make the TEG inoperable. Consult Global Power Technologies before operating a TEG with any signs of damage. WARNING! Do not discard the shipping crate until the TEG is fully operational. -
Page 13: Installing The Relay Assembly
Position the Relay with the female end of the assembly pointed towards the back of the cabinet. Carefully fit the male end of the thermocouple into the female end on the Relay Assembly. Tighten the threads using a 3/8-inch wrench, being CAREFUL NOT TO OVERTIGHTEN. 302954 rev0 | Model 8550-RU Page 9 of 53... -
Page 14: Installing The Spark Igniter Electrode
WARNING! Before connecting the fuel supply to the TEG, review Section 3.1.3 and ensure that all necessary precautions have been made based on the fuel supply used and the environmental conditions. 302954 rev0 | Model 8550-RU Page 10 of 53... -
Page 15: Adjusting For Altitude
From the marked altitude on step a), follow the line vertically towards the curve and stop when you touch the curve. This is the point to where you will adjust your fuel pressure for your TEG site’s altitude. 302954 rev0 | Model 8550-RU Page 11 of 53... -
Page 16: Figure 7 - Altitude Adjustment
If your TEG will be installed at a site with an altitude of 7970 ft (2429 m), increase your burner fuel pressure by 2.61 psi (18 kPa) from the factory setting. Figure 7 – Altitude Adjustment 302954 rev0 | Model 8550-RU Page 12 of 53... -
Page 17: Start-Up And Operation
6720 Voltage Limiter input. WARNING! Before attempting to start the Model 8550-RU TEG, make sure to review and understand the Electrical Output Characteristics in Figure 32 and the Terms and Acronyms in Section 2.1. Before starting the TEG: ... - Page 18 Continuing with the previous example, if the corrected air temperature is 27°F (-3°C), based on the graph on Figure 8, the Set Power is 620 W. Enter this number in the Start-Up Data Sheet. Do not operate the TEG beyond this number. 302954 rev0 | Model 8550-RU Page 14 of 53...
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Page 19: Figure 8 - Power As A Function Of Ambient Temperature
Connect the second voltmeter across Terminals 6 (+) and 7 (-) of TB-1. This will measure the Power Unit current (1 mV = 1 Amp). Follow these steps to start-up the Model 8550-RU TEG: Turn on the fuel supply to the TEG and observe the fuel pressure at the fuel pressure gauge. -
Page 20: Figure 9 - Fuel System Components
Confirm that the fuel lines were purged of air. If fuel is reaching the burner, refer to Section 5.6 troubleshoot the Ignition System. As soon as combustion begins, slowly open the Burner Run Valve. 302954 rev0 | Model 8550-RU Page 16 of 53... - Page 21 If it’s too cold or too windy to assess the temperature of the heat pipes, check the NOTE: cooling fins instead. If all the fins on a heat pipe are at about the same temperature, then the heat pipe is working well. 302954 rev0 | Model 8550-RU Page 17 of 53...
- Page 22 Once the Power Unit output power has stabilized to within 5 Watts of Set Power and stayed there for at least 15 minutes, proceed to the next section for Air Shutter Adjustment. 302954 rev0 | Model 8550-RU Page 18 of 53...
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Page 23: Figure 10 - Air Shutter Adjustment
The Air Shutter is now optimally tuned for your ambient conditions and fuel supply. Close the cabinet door and wait another 10 minutes for the TEG to stabilize. Take a final power reading. 302954 rev0 | Model 8550-RU Page 19 of 53... -
Page 24: Applying Customer Load
This information is valuable for future reference. If the site is a multiple TEG installation, keep the log in a common maintenance area where service technicians can access it easily during maintenance checks. 302954 rev0 | Model 8550-RU Page 20 of 53... -
Page 25: Service And Maintenance
Global Power Technologies SERVICE AND MAINTENANCE SERVICE AND MAINTENANCE Before attempting to service the Model 8550-RU TEG, review Sections 2, 4.1, 4.1.3, and the Power Conditioner manual in Section 8. Do not attempt to service the TEG unless you are thoroughly familiar with its operation. - Page 26 There are three basic reasons for the Set Power to be low. These are: • low or inefficient heating by the burner and fuel system, poor or inefficient cooling, or • • a faulty or damaged Power Unit. 302954 rev0 | Model 8550-RU Page 22 of 53...
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Page 27: Basic Service
56 Volts and R is above 1.40 Ohms, the Power Unit is likely faulty. The Power Unit may still be able to operate at reduced output. Consult Global Power Technologies to determine the safe operating level for the Power Unit under your conditions. -
Page 28: Cooling System
If a poorly functioning heat pipe is not identified, it can result in the accelerated degradation of that pipe as well as the surrounding heat pipes. Heat pipes on the TEG Model 8550-RU are serviceable components and should be replaced to prolong the life of the TEG. If you find any evidence of a poorly functioning heat pipe, please contact GPT. -
Page 29: Figure 11 - Hand Temperature Inspection
Make sure to take the surface temperature of the tube, not the fins or the air around the tube. Refer to Figure 12 for inspection points. Figure 12 – Heat Pipe Condenser Tube Temperature Inspection Points 302954 rev0 | Model 8550-RU Page 25 of 53... -
Page 30: Fuel System
Manifold and pressure gauge – monitors the fuel pressure to the fuel orifice. Automatic shut-off valve, sometimes referred to as safety shut-off valve 302954 rev0 | Model 8550-RU Page 26 of 53... -
Page 31: Figure 13 - Fuel System Components
Open the drain cock located under the pressure regulator. Using a small container, collect any liquid impurities that may have collected in the bowl. After the bowl has drained, close the drain cock. 302954 rev0 | Model 8550-RU Page 27 of 53... -
Page 32: Burner System
Remove the air shutter from the venturi by closing the air shutter completely and removing the four screws located in the openings on the air shutter plate. 302954 rev0 | Model 8550-RU Page 28 of 53... -
Page 33: Figure 15 - Burner System Components
Remove the four nut-and-spring assemblies that hold down the converter mounting ring. Before removing the converter mounting ring, mark its position so that it can be reinstalled in the same position. 302954 rev0 | Model 8550-RU Page 29 of 53... -
Page 34: Spark Ignition (Si)
A completely discharged battery requires 16 hours of charging to fully recharge. Figure 16 shows the Spark Ignition system wiring and Figure 17 shows the location of the Spark Ignition system components. 302954 rev0 | Model 8550-RU Page 30 of 53... -
Page 35: Figure 17 - Spark Ignition Components
Do not touch the tip of the orange wire or allow it to come in contact with other electrical connections. WARNING! Check the Pressure Switch. The switch should close at fuel pressures greater than 16 kPa (2.5 psi). Replace the Pressure Switch if necessary. 302954 rev0 | Model 8550-RU Page 31 of 53... -
Page 36: Overtemperature Shutdown System
While the six thermostats protect the heat pipes and power unit, the thermal cut-off protects the cabinet interior from overtemperature. If the cabinet gets too hot, this fuse will open and cause the shutdown relay to de-energize. 302954 rev0 | Model 8550-RU Page 32 of 53... -
Page 37: Figure 18 - Overtemperature Shutdown System
Inspect all the heat pipes for damage and clean any debris. Inspect the thermostat wiring for loose or broken wires. If the thermostat is paired with an adaptor board, ensure that both quick-connect terminals are tight. 302954 rev0 | Model 8550-RU Page 33 of 53... -
Page 38: Automatic Shut-Off (So)
Figure 19 – Automatic Shut-off Components If your Model 8550-RU TEG is experiencing intermittent shutdowns or does not start reliably, follow these steps to troubleshoot the Automatic Shut-Off system. Check that the thermocouple sensor is installed correctly in the Burner Plate assembly. -
Page 39: Power Unit Testing
Attach a voltmeter to read the Power Unit voltage at terminals 6(+) and 4(-) of TB-1. The voltmeter leads must be attached to these terminals because you will need both hands free to do the open circuit test. Measure and record the Power Unit loaded voltage (V 302954 rev0 | Model 8550-RU Page 35 of 53... - Page 40 In some cases, the Power Unit may be operated at derated power, consult GPT for NOTE: further information. Do not operate the Power Unit above Set Power, maximum open circuit voltage, or maximum internal resistance. WARNING! 302954 rev0 | Model 8550-RU Page 36 of 53...
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Page 41: Troubleshooting
Fuel filter dirty not continue to Replace the fuel filter 5.4.2 burn Fuel pressure adjustment Adjust the burner fuel pressure 4.1.2, 4.1.3 incorrect Fuel orifice plugged Replace the fuel orifice 5.4.3 302954 rev0 | Model 8550-RU Page 37 of 53... - Page 42 Output voltage adjustment Adjust the output voltage screw on Output 8.2.1 incorrect the power conditioner voltage is too high Power conditioner is faulty Replace the power conditioner 302954 rev0 | Model 8550-RU Page 38 of 53...
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Page 43: Parts Lists
Global Power Technologies PARTS LISTS PARTS LISTS Figure 20 – Model 8550-RU TEG Parts (1 of 2) 302954 rev0 | Model 8550-RU Page 39 of 53... -
Page 44: Figure 21 - Model 8550-Ru Teg Parts (2 Of2)
Global Power Technologies PARTS LISTS Figure 21 – Model 8550-RU TEG Parts (2 of2) Refer to Figure 20 and Figure 21 for the following parts: Item Part No. Description 6462 Block, Heat Pipe 6397 Bracket, Support 22490 Burner Assembly 300329... - Page 45 Medium Ambient uses 12 each of 22896. • Check the colour of the tip of the Heat Pipe to determine which type to use. **Parts must be ordered separately from the remainder of the fuel system. 302954 rev0 | Model 8550-RU Page 41 of 53...
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Page 46: Fuel System Parts List
301422 Tubing, 0.25 OD X 0.035 Wall, 304 SS 302833 Tubing, 0.25 OD X 0.035 Wall, 304 SS Gauge, Pressure, 0-30 Psi, 1/4 MNPT 22820 Nut, 0.25 Tube Fitting, 316 SS 302954 rev0 | Model 8550-RU Page 42 of 53... -
Page 47: Electronics Assembly Parts List
Spark Igniter Module Assembly 5238 Shunt, 50 Amp-50V 6963 Overtemperature Shutdown Module 2110 Terminal Strip, 8P 27019 Non-spillable battery, 2V D size, lead acid (not shown) 6982 Fuse, 0.5A, 250VAC, 0.25x1.25", AGC-1/2 (not shown) 302954 rev0 | Model 8550-RU Page 43 of 53... -
Page 48: 6720 Voltage Limiter For Model 8550-Ru Teg
Global Power Technologies 6720 VOLTAGE LIMITER FOR MODEL 8550-RU TEG 6720 VOLTAGE LIMITER FOR MODEL 8550-RU TEG Figure 24 – 6720 Voltage Limiter PRODUCT APPLICATION The 6720 Voltage Limiter is an electronic device connected to the output of the TEG’s Power Unit. It is a shunt regulator that is essential for power unit health. -
Page 49: Service
Normally Open (NO) contact. From the factory, the Model 8550-RU TEG VSR will be set so that the VSR will energize when the power unit voltage climbs above 23 Volts. The VSR also incorporates approximately 0.5 Volts of hysteresis, meaning once the VSR is energized the voltage would need to drop 0.5 Volts below the... -
Page 50: 6720 Voltage Limiter Parts List
Global Power Technologies 6720 VOLTAGE LIMITER FOR MODEL 8550-RU TEG 6720 VOLTAGE LIMITER PARTS LIST Figure 25 – 6720 Limiter Main Parts Item Part No. Description 20184 Cover Assembly, Limiter, 8550 (not shown, order separately) 3154 Heat Sink Assembly Resistor, 2 Ohm, 300 Watts, 10% 59056 Control &... -
Page 51: Cathodic Protection Interface Option
A shunt is used to measure the current to the terminal block. The voltage drop across the shunt is proportional to the current flowing through it. The current shunt is rated at 30 Amps = 50 mV. 302954 rev0 | Model 8550-RU Page 47 of 53... -
Page 52: Adjustment
The change from series to parallel configuration is made by moving the wire coming from the right side of the 1000-Watt resistor, from the left position to the center position of the heavy-duty terminal block. For further information on Cathodic Protection applications, please contact Global Power Technologies CAUTION! -
Page 53: Parts List - Cathodic Protection Interface
Terminal Block, 3P, 14/2/0 AWG, 175A 7941 Terminal Block, POS NOTE: *Panel Meter (6226) comes with a blank face plate. Always order the Meter Face (6221) when replacing the Panel Meter. 302954 rev0 | Model 8550-RU Page 49 of 53... -
Page 54: Appendix A - Weight, Dimensions, And Electrical Specifications
APPENDIX A — WEIGHT, DIMENSIONS, AND ELECTRICAL SPECIFICATIONS Figure 30 shows the Model 8550 TEG in its normal operating configuration. Weight, dimensions, and electrical specifications are listed below. Figure 30 – Model 8550-RU TEG Dimensions WEIGHT AND DIMENSIONS Diameter of Top... -
Page 55: Appendix B - Process Description
The operation of the TEG is controlled by the fuel pressure supplied to the burner. 302954 rev0 | Model 8550-RU Page 51 of 53... -
Page 56: Figure 32 - Gross Power Unit Electrical Output Characteristics At 20°C, Beginning Of Life (Without Power Conditioner)
Model 8550-RU TEG. Consult GPT for assistance with finding the best system to suit your application. The available power of a Model 8550-RU TEG is also a function of the amount of cooling supplied by the heat pipes, and this cooling is affected by both the ambient air temperature and the wind speed. -
Page 57: Appendix C - System Wiring Diagram
Global Power Technologies APPENDIX C — SYSTEM WIRING DIAGRAM APPENDIX C — SYSTEM WIRING DIAGRAM Figure 33 – Model 8550-RU TEG Wiring Diagram 302954 rev0 | Model 8550-RU Page 53 of 53... - Page 58 FORMS AND LOGS 8550 Thermoelectric Generator Start-Up Data Sheet Model #: Serial #: Fuel Type: Start-Up By: Date: Ambient Temperature: Ignition Fuel Pressure: Corrected Air Temperature: Operating Fuel Pressure: Wind Speed: Site Elevation Set Power at Corrected Temperature: Corrected Fuel Pressure for Elevation: POWER LEVELS Burner Fuel Time...
- Page 59 Model 8550-RU TEG Performance Log MODEL NO: SERIAL NO: FUEL TYPE: 302954 rev0...
- Page 60 Model 8550-RU TEG Performance Log MODEL NO: SERIAL NO: FUEL TYPE: 302954 rev0...
- Page 61 Replace Detailed Inspection) Good *Hand temperature inspection of Model 8550-RU TEG heat pipes is done to check that the heat pipe is warm, up to 2 inches (50 mm) from the tip. If the inspection satisfies the hand inspection as per Section 3.5.1, the detailed inspection described in...