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All Power Labs Power Pallet PP20 Technician's Handbook

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1 0 1 0 Mu r r a y S t r e e t B e r k e l e y , C A 9 4 7 1 0 , T e l . 5 1 0 - 8 4 5 - 1 5 0 0 T o l l F r e e 8 8 8 - 2 5 2 - 5 3 2 4
s u p p o r t @a l l p o w e r l a b s . c o m w w w . a l l p o w e r l a b s . c o m

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  • Page 1 1 0 1 0 Mu r r a y S t r e e t B e r k e l e y , C A 9 4 7 1 0 , T e l . 5 1 0 - 8 4 5 - 1 5 0 0 T o l l F r e e 8 8 8 - 2 5 2 - 5 3 2 4 s u p p o r t @a l l p o w e r l a b s .
  • Page 2 Section 1 - Introduction to the Power Pallet Section 1 Introduction to the Power Pallet PP20 v1.08, v1.09 (PP20-GT 1.09 displayed) Page 1-1 770-00084 Section 1_Introduction to the Power Pallet (PP20) Rev B 770-00083 Power Pallet Technician's Handbook (PP20/v1.09) Rev B...

  • Page 3: Table Of Contents

    Section 1 - Introduction to the Power Pallet Table of Contents 1. Overview 1.1 Conceptual overview 1.2 Sequence of Processes Graphic A: The Five Processes of Gasification Graphic B: The Five Processes and the GEK TOTTI Graphic C: The Five Processes and the GEK TOTTI–photo overlay 2.

  • Page 4: Overview

    Section 1 - Introduction to the Power Pallet 1. Overview Conceptual overview The Power Pallet system is comprised of the GEK TOTTI series gasifier integrated with automation system and an engine coupled to a generator. The purpose of the gasifier is to refine biomass feedstocks into a clean-burning gaseous fuel (producer gas) that is compatible with internal combustion engines.
  • Page 5 Section 1 - Introduction to the Power Pallet The processes of gasification converts biomass into a clean burning gas which can fuel an internal combustion engine. Gasification involves subjecting biomass to the processes of drying, pyrolysis, combustion, cracking, and reduction. Tar cracking breaks down tar gases into carbon monoxide, hydrogen, and other light gases by exposure to high temperatures, and reduction converts charcoal into carbon monoxide and hydrogen by percolating the carbon dioxide and water vapor produced during combustion through hot charcoal.

  • Page 6: Graphic B: The Five Processes And The Gek Totti

    Section 1 - Introduction to the Power Pallet Graphic B: The Five Processes and the GEK TOTTI Schematic of the GEK TOTTI gasifier system Page 1-6 770-00084 Section 1_Introduction to the Power Pallet (PP20) Rev B 770-00083 Power Pallet Technician's Handbook (PP20/v1.09) Rev B...

  • Page 7: Graphic C: The Five Processes And The Gek Totti-Photo Overlay

    Section 1 - Introduction to the Power Pallet Graphic C: The Five Processes and the GEK TOTTI–photo overlay Overlay of the processes on a photo of the GEK TOTTI system Page 1-7 770-00084 Section 1_Introduction to the Power Pallet (PP20) Rev B 770-00083 Power Pallet Technician's Handbook (PP20/v1.09) Rev B...

  • Page 8: Flow Of Solids

    Section 1 - Introduction to the Power Pallet 2. Flow of Solids Within the gasifier the solids flow downward by gravity, while the gases are pulled through the system by the vacuum produced by either the engine or the gas blowers of the flare system during start-up.

  • Page 9: Combustion And Tar Cracking

    Section 1 - Introduction to the Power Pallet Pyrolysis is the charring process by which the feedstock is converted into charcoal and large quantities of flammable tar gases. The dry feedstock is pushed from the drying bucket into the pyrolysis zone of the PyroReactor by the auger until the reactor is full, as regulated by the fuel switch.

  • Page 10: Reduction

    Section 1 - Introduction to the Power Pallet Combustion is the main exothermic (heat releasing) reaction in the gasification process. Drying, pyrolysis, reduction, and tar cracking are all endothermic (heat consuming). The Power Pallet’s use of recovered heat from the exiting hot producer gas and engine exhaust improves the heat balance of the overall process thus increasing conversion efficiency.

  • Page 11: Purging Char Ash

    Section 1 - Introduction to the Power Pallet 2.5 Purging char ash In the course of the reduction reactions, the charcoal pieces are consumed to produce CO gas and shrink and break apart until they pack densely and are rich in ash and minerals, inhibiting the flow of gases through the hearth.

  • Page 12: Flow Of Gases

    Section 1 - Introduction to the Power Pallet 3. Flow of Gases 3.1 First stage of waste heat recovery: Preheating intake air At the end of the reduction reaction, the producer gas is at a very high temperature and contains a lot of recoverable heat.
  • Page 13 Section 1 - Introduction to the Power Pallet Page 1-13 770-00084 Section 1_Introduction to the Power Pallet (PP20) Rev B 770-00083 Power Pallet Technician's Handbook (PP20/v1.09) Rev B...

  • Page 14: Second Stage Of Waste Heat Recovery: Drying The Feedstock

    Section 1 - Introduction to the Power Pallet A view of the internal parts of the reactor. The air lines that pre-heat intake air using heat recovered from fresh producer gas. Removing particulates: Cyclonic dust separation Producer gas entrains charcoal dust and ash as it passes through the reduction zone.

  • Page 15: Gas Filtration

    Section 1 - Introduction to the Power Pallet Despite the heat recycled into the air lines and the heat dissipated in the cyclone, the producer gas retains enough useful heat such that this heat can be recovered by routing the gas into the space between the double walls of the drying bucket.

  • Page 16: Combustion Of Producer Gas In The Engine

    Section 1 - Introduction to the Power Pallet λ (lambda) reading; lambda is the quotient of the detected air:fuel ratio and the stoichiometric air:fuel ratio. The control loop tries to maintain a lambda of 1.05, which we have found to result in the best combination of power and clean emissions.

  • Page 17: Note: Unique Combustion Characteristics Of Producer Gas

    Because the Power Pallet’s spark timing is advanced too far to be operated with gasoline, propane or natural gas without risk of engine knocking, ALL Power Labs does not currently support multi-fuel use.

  • Page 18: Flow Of Exhaust

    Section 1 - Introduction to the Power Pallet 4. Flow of Exhaust 4.1 Third stage of waste heat recovery: Exhaust-heat assisted pyrolysis The engine's exhaust gases are in the range of 400˚-600˚C, which is ideal for driving pyrolysis while not being so high as to cause the formation of refractory tars that are difficult to crack. Rather than let this energy go to waste, the Power Pallet routes the exhaust between the double walls of the PyroReactor so that this exhaust heat can be used to pyrolyze the feedstock at the desired temperatures.

  • Page 19: Automation

    Section 1 - Introduction to the Power Pallet 5. Automation The Power Pallet’s automation system has a series of pressure, temperature, current, and oxygen sensors, and other sensors that are monitored by the Process Control Unit (PCU). The PCU runs on the open-source Arduino software platform. The PCU automatically controls the various physical functions required to keep the system running smoothly.

  • Page 20: Identifying Power Pallet Components

    Section 1 - Introduction to the Power Pallet 6. Identifying Power Pallet components Exhibit A: Front view Label Description Label Description Hopper Operation panel Valves to flare and engine Generator PCU panel Wiring configuration box Ash collection vessel Grid tie controler Gas filter Page 1-20 770-00084 Section 1_Introduction to the Power Pallet (PP20) Rev B...

  • Page 21: Exhibit B: Reactor Side View

    Section 1 - Introduction to the Power Pallet Exhibit B: reactor side view Label Description Label Description Flare Cyclone Exhaust stack Filter condensate drain bung PyroReactor access port Filter lid locking lever Gasifier Drying bucket Air inlet check valve Page 1-21 770-00084 Section 1_Introduction to the Power Pallet (PP20) Rev B 770-00083 Power Pallet Technician's Handbook (PP20/v1.09) Rev B...

  • Page 22: Exhibit C: Engine Corner View

    Section 1 - Introduction to the Power Pallet Exhibit C: Engine corner view Label Description Label Description Back-pressure relief valve Reactor access door and ash system motor Engine governor Central wiring conduit Condensate vessel Air blower Page 1-23 770-00084 Section 1_Introduction to the Power Pallet (PP20) Rev B 770-00083 Power Pallet Technician's Handbook (PP20/v1.09) Rev B...

  • Page 23: Exhibit D: Detailed Views

    Section 1 - Introduction to the Power Pallet Engine starter Gas blowers Oil filter Flare igniter Exhibit D: Detailed Views Page 1-24 770-00084 Section 1_Introduction to the Power Pallet (PP20) Rev B 770-00083 Power Pallet Technician's Handbook (PP20/v1.09) Rev B...
  • Page 24 Section 1 - Introduction to the Power Pallet Page 1-25 770-00084 Section 1_Introduction to the Power Pallet (PP20) Rev B 770-00083 Power Pallet Technician's Handbook (PP20/v1.09) Rev B...

  • Page 25: Exhibit E: Pcu And Control Panel

    Section 1 - Introduction to the Power Pallet Exhibit E: PCU and control panel The following is the interface to the automation system of the Power Pallet. Please see Section 4 for more information on the automation system. Note: The control panel shown below is for a grid-tied system. The grid-tied systems do not have a keyed engine start.
  • Page 26 Section 2 - Biomass Feedstock Requirements Section 2 Biomass Feedstock Requirements Page 2-1 770-00085 Section 2 Biomass Feedstock Requirements (PP20/PP25) Rev B 770-00083 Power Pallet Technician's Handbook (PP20/v1.09) Rev B...
  • Page 27 Section 2 - Biomass Feedstock Requirements Table of Contents 1. Feedstock related terms 1.1 Feedstock, Fuel 1.2 Oversized, Undersized, and Fines 1.3 Fuel Jams: Bridging, Rat-holing, Binding 2. Feedstock Qualifications 2.1 Physical compatibility 2.1.1 Upper size limit 2.1.2 Lower size limit 2.1.3 Correct shape 2.1.4 Correct surface texture 2.1.5 Friability...

  • Page 28: Feedstock Related Terms

    Section 2 - Biomass Feedstock Requirements 1. Feedstock related terms 1.1 Feedstock, Fuel The GEK TOTTI Gasifier onboard the Power Pallet is a refinery that takes crude biomass in the hopper and refines it into a clean-burning gaseous fuel for the engine, while producing char-ash as a waste product.
  • Page 29 Section 2 - Biomass Feedstock Requirements Bridging refers to when the feedstock forms an arch or a dome held together by friction, compression, or entanglement, and does not flow as the material below it is emptied away; surface friction and bad feedstock geometry are the primary culprits behind this phenomenon. Bridging is most likely to happen where the hopper narrows down as the material is wedged together by the walls of the hopper.

  • Page 30: Feedstock Qualifications

    Section 2 - Biomass Feedstock Requirements Binding refers to the problem of feedstocks forming compression resistant piles or stacks rather than freely flowing or falling when pushed by the auger or by the weight of material above it. When such a formation occurs, transport of the feedstock from the hopper to the reactor halts. Any of the above problems may require operator intervention to resolve;...

  • Page 31: Correct Surface Texture

    Section 2 - Biomass Feedstock Requirements compatible even if they are of the right size because these shapes tend to cause binding and cause severe jams in the drying bucket and at the interface of the auger and the PyroReactor. Also, long stringy particles must be separated from the feedstock;...

  • Page 32: Flow Characteristics

    Section 2 - Biomass Feedstock Requirements 2.1.7 Flow Characteristics The flow characteristics of a feedstock are a function of their shape, size, and texture, and have a major impact on how practical a feedstock will be. The two characterizations of how solid materials flow are funnel flow and mass flow.

  • Page 33: Angle Of Repose

    Section 2 - Biomass Feedstock Requirements 2.1.8 Angle of repose The angle of repose of the feedstock correlates with the flow characteristic of the feedstock. The angle repose is the angle at which the a large heap of the feedstock will settle to when pulled by nothing but gravity.

  • Page 34: 11Feedstock Particle Size And Char-Ash Byproduct Percentage

    Section 2 - Biomass Feedstock Requirements macadamia nut shells. Because there is so much variation in feedstock availability, the optimal blend must be determined by experimentation on a case by case basis. 2.1.10 Void spaces and physical compatibility The aspect that the size and shape qualifications are trying to control is the average void- space size in the feedstock—the average size of the spaces between the pieces of feedstock.

  • Page 35: Volatile Content

    Section 2 - Biomass Feedstock Requirements 2.2.2 Volatile content The rest of the carbon content of lignocellulosic biomass is contained in the volatile chemicals that contain hydrogen, oxygen, and other elements; these volatiles come off of the feedstock during pyrolysis as tar gases (wood smoke) during pyrolysis. The reactor combusts a portion of these gases to provide heat to drive the rest of the reactions, and cracks the rest of these tar gases into CO and H gas by exposing them to temperatures in excess of 800˚C.

  • Page 36: Feedstock Preparation

    Section 2 - Biomass Feedstock Requirements Feedstock HHV [MJ/kg] Alkali Index [kg/GJ] Hybrid Poplar wood 18.95 0.29 Switchgrass 18.08 0.60 Rice Straw 18.91 1.31 Rice Husks 15.84 0.50 Almond Hulls 18.90 1.74 Sugarcane Bagasse 18.99 0.01 Sunflower Shells 18.64 0.80 Alkali index of example feedstocks Alkali index is only one of several factors that determine the likelihood of slagging and clinker formation.

  • Page 37: Chipping

    Section 2 - Biomass Feedstock Requirements 3.1 Chipping When processing feedstock such as tree limbs, logs, and canes, it will be necessary to chip the material. There are three major styles of chippers, two of which operate on the same principle: ●...

  • Page 38: Pelletizing And Briquetting

    Section 2 - Biomass Feedstock Requirements 3.3 Pelletizing and Briquetting Feedstocks that have incompatibly small particle sizes (such as saw dust) can potentially be made usable by being pressed into briquettes or pellets, especially if they are subsequently torrefied. Pellet mills compress the raw feedstock through a plate under extremely high pressure, often resulting in enough heat to fuse the lignin content of wood.

  • Page 39: Blending Undersized Pieces And Used Filter Media With Feedstock

    Section 2 - Biomass Feedstock Requirements Sifting with the ½” screen to remove undersized pieces and fines. These fall through the screen. For feedstock, you want to isolate the pieces which are smaller than 1” and larger than ½” for the bulk of your feedstock, and then blend in fines as needed.

  • Page 40: Drying Feedstock To Correct Moisture Levels

    Section 2 - Biomass Feedstock Requirements 3.7 Drying feedstock to correct moisture levels The GEK TOTTI gasifier system onboard the Power Pallet operates best with feedstocks that have a moisture content no higher than 30%, and no lower than 10%, as measured on a dry weight basis.

  • Page 41: Moisture Testing

    Section 2 - Biomass Feedstock Requirements 3.8 Moisture Testing To determine the moisture content of your feedstocks, we recommend the following methods: 3.8.1 Moisture Meter The Power Pallet user kit comes with a battery powered moisture meter that can detect moisture levels up to 40%.

  • Page 42: Table Of Feedstocks

    Section 2 - Biomass Feedstock Requirements Note: you can also use an oven, but be sure not to burn the sample. 4. Table of Feedstocks The following table of feedstocks shows the most common feedstocks that are known to work, and what feedstocks are known to be problematic.
  • Page 43 Section 2 - Biomass Feedstock Requirements Caution: Risk of high temperatures May work if blended with Palm Kernel Shells feedstocks that burn cooler Larger pellets have better void spaces Wood Pellets Caution: Pellets crumble due to humidity on shutdown. Caution: Too fine, not physically Saw Dust compatible.

  • Page 44: Biomass Consumption Table

    Section 2 - Biomass Feedstock Requirements Slag risk; heavy metals; plastic content not Municipal Solid suitable, especially PVC. Waste / Trash Burns too hot; processes not designed to Coal handle sulfur and other contaminants. Melts and fouls auger/reactor; does not Plastics have good fixed carbon content.
  • Page 45 Section 2 - Biomass Feedstock Requirements 19.2 21.6 24.0 26.4 28.8 Page 2-20 770-00085 Section 2 Biomass Feedstock Requirements (PP20/PP25) Rev B 770-00083 Power Pallet Technician's Handbook (PP20/v1.09) Rev B...
  • Page 46 Section 3 - GEK TOTTI Gasifier System Section 3 GEK TOTTI Gasifier System Version 5.x series Page 3-1 770-00086 Section 3_GEK TOTTI Gasifier System (PP20) Rev B 770-00083 Power Pallet Technician's Handbook (PP20/v1.09) Rev B...
  • Page 47 Section 3 - GEK TOTTI Gasifier System Page 3-2 770-00086 Section 3_GEK TOTTI Gasifier System (PP20) Rev B 770-00083 Power Pallet Technician's Handbook (PP20/v1.09) Rev B...
  • Page 48 Section 3 - GEK TOTTI Gasifier System Table of Contents 1. Overview 1.1 Notes about nomenclature and terms 1.1.1 Feedstock, Fuel 1.1.2 Syngas, Wood gas, Producer gas 1.1.3 TOTTI, Pyrocoil, Pyroreactor 1.1.4 Gasifier, Reactor 1.1.5 Hearth, Reduction Bell 2. Feedstock Feed System 2.1 Hopper 2.2 Cyclone and Drying Bucket 2.3 Auger and Fuel Level Switch...

  • Page 49: Overview

    Section 3 - GEK TOTTI Gasifier System 8.1 Blowers 8.2 Igniter 1. Overview The GEK TOTTI (Gasifier Experimenter’s Kit, Tower of Total Thermal Integration) is the gasifier system at the heart of the Power Pallet. This document will introduce the major subsystems of the v5.x series GEK TOTTI gasifier in the sequence that starts from the feedstock hopper, proceeding through the drying bucket and reactor, and ends with the gas filter.

  • Page 50: Totti, Pyrocoil, Pyroreactor

    Section 3 - GEK TOTTI Gasifier System ● wood gas refers to gas produced by the gasification of wood. Wood gas is also rich in CO and H , but may also contain tar gases, and may be diluted with nitrogen gas if the gasifier was aspirated with atmospheric air.

  • Page 51: Gasifier, Reactor

    Section 3 - GEK TOTTI Gasifier System distinct component, the TOTTI is no longer a distinct part of the gasifier. The name GEK TOTTI is now used as a brand. 1.1.4 Gasifier, Reactor The reactor is the component of the gasifier that actually produces gas. When speaking of the structure circled in the image of the Power Pallet below, the terms gasifier and reactor are sometimes used interchangeably in our literature.
  • Page 52 Section 3 - GEK TOTTI Gasifier System bell became integrated with another truncated cone that contained the combustion zone. This combined combustion/reduction structure was known as the hearth, which was used interchangeably with the term reduction bell. The old hearth is shown below, next to the new hearth.

  • Page 53: Feedstock Feed System

    Section 3 - GEK TOTTI Gasifier System 2. Feedstock Feed System 2.1 Hopper The Power Pallet comes with a hopper barrel for holding feedstock. The hopper is attached to the top of the drying bucket with a silicone gasket and bolts. The hopper barrel lid is sealed at the top with a lever lock.

  • Page 54: Auger And Fuel Level Switch

    Section 3 - GEK TOTTI Gasifier System heat exchange stage recovers waste heat to dry the feedstock while simultaneously cooling the producer gas to temperatures suitable for the filter and engine. This specialized drying stage enables the Power Pallet to tolerate feedstocks with moisture contents as high as 30% when powering a high load.
  • Page 55 Section 3 - GEK TOTTI Gasifier System 3. Bolt on Top Flange. 4. Screw in Reed Switch Assembly until the brass stud gently contacts the top of the magnet rod. 5. Unscrew the reed switch assembly 1/2 turn and tighten the stainless jam nut to prevent further movement.

  • Page 56: Annotated Figures

    Section 3 - GEK TOTTI Gasifier System 3. Annotated Figures Exhibit A: GEK TOTTI Gasifier with ash collection vessel Page 3-11 770-00086 Section 3_GEK TOTTI Gasifier System (PP20) Rev B 770-00083 Power Pallet Technician's Handbook (PP20/v1.09) Rev B...
  • Page 57 Section 3 - GEK TOTTI Gasifier System Label Description Label Description Fuel Level Switch Ash removal system motor Inlet from drying bucket Reactor access door Exhaust inlet to Pyroreactor Air inlet with check valve Grate basket shaker motor Ash collection vessel Page 3-12 770-00086 Section 3_GEK TOTTI Gasifier System (PP20) Rev B 770-00083 Power Pallet Technician's Handbook (PP20/v1.09) Rev B...

  • Page 58: Exhibit B: Gek Totti Gasifier With Ash Collection Vessel, Cont

    Section 3 - GEK TOTTI Gasifier System Exhibit B: GEK TOTTI Gasifier with ash collection vessel, cont. Label Description Label Description Ignition port (shown with extension) Pyroreactor viewport Outlet to exhaust stack Cyclone Ash removal port Cyclone ash can Page 3-13 770-00086 Section 3_GEK TOTTI Gasifier System (PP20) Rev B 770-00083 Power Pallet Technician's Handbook (PP20/v1.09) Rev B...

  • Page 59: Exhibit C: Gas Cowling And Pyroreactor

    Section 3 - GEK TOTTI Gasifier System Exhibit C: Gas Cowling and Pyroreactor The Pyroreactor fits into the gas cowling in the assembled gasifier. Label Description Label Description Gas cowling (inner vessel) Inlet from drying bucket Gas cowling insulation shroud Air lines Ash-out auger Projected hearth...
  • Page 60 Section 3 - GEK TOTTI Gasifier System Grate basket shaker motor Page 3-15 770-00086 Section 3_GEK TOTTI Gasifier System (PP20) Rev B 770-00083 Power Pallet Technician's Handbook (PP20/v1.09) Rev B...

  • Page 61: Exhibit D: Gasifier Cross Section

    Section 3 - GEK TOTTI Gasifier System Exhibit D: Gasifier cross section Label Description Label Description Pcomb pressure barb Air lines Lighting tube Projected hearth Pyrolysis column Grate basket Air nozzles Ash scroll Page 3-16 770-00086 Section 3_GEK TOTTI Gasifier System (PP20) Rev B 770-00083 Power Pallet Technician's Handbook (PP20/v1.09) Rev B...

  • Page 62: Exhibit E: Detail Of Hearth And Grate Basket

    Section 3 - GEK TOTTI Gasifier System Exhaust inlet to Pyroreactor Exhibit E: Detail of Hearth and Grate Basket Label Description Label Description Page 3-17 770-00086 Section 3_GEK TOTTI Gasifier System (PP20) Rev B 770-00083 Power Pallet Technician's Handbook (PP20/v1.09) Rev B...

  • Page 63: Gek Gasifier Reactor Components

    Section 3 - GEK TOTTI Gasifier System Reactor access door Activator cone Ash-out auger Scroll plate Grate basket Ash collection vessel 4. GEK Gasifier Reactor components Please refer to the annotated figures on the prior pages for images of the parts described below. 4.1 Air inlet (See Annotated Figure A) The air inlet is a check valve allows air to enter the system when the gasifier is operating and...

  • Page 64: Thermocouples Of The Power Pallet

    Section 3 - GEK TOTTI Gasifier System Combustion occurs in the area above the restriction in the projected hearth; a portion of the tar gases and charcoal are combusted by the introduction of preheated air. The restriction in the hearth funnels all of the combustion gases and unburned tar gases together to homogenize the temperature while causing the tar gases to flow through a concentrated hot spot of about 800˚- 900˚C, resulting in efficient tar cracking—the thermal decomposition of these tars into CO and gas.

  • Page 65: Table Of Thermocouples

    Section 3 - GEK TOTTI Gasifier System The Power Pallet comes with three ungrounded type K thermocouples to monitor the reactor and engine coolant temperature. The following table indicates the location, temperature ranges during normal operation, and other technical specifications. 4.7 Table of Thermocouples Display Variable: Trst...

  • Page 66: Grate Basket Shaker And Pratio

    Section 3 - GEK TOTTI Gasifier System ¼” dia See the troubleshooting guide at the end of the Section for instructions on how to test the thermocouples. 5. Grate Basket Shaker and P ratio Onboard the Power Pallet, the only direct influence the PCU exerts on the gasifier is the timing and triggering of the grate basket shaker.
  • Page 67 Section 3 - GEK TOTTI Gasifier System When P is too low, it indicates flow restriction due to small char pieces; to correct for this flow ratio restriction, the programming accelerates the countdown timer to trigger grate shaking sooner in order to purge the small pieces of char. When P is too high, it indicates that bridging is ratio occurring inside the reactor, and is preventing char from filling the grate basket.

  • Page 68: Reading Pressure Values On The Pcu

    Section 3 - GEK TOTTI Gasifier System combustion zone. cyclone. See Annotated Figure D. PCU barb 5.1 Reading pressure values on the PCU The numbers the PCU uses to represent the magnitude of vacuum for its pressure readings stand for measurements in a rather unusual unit: tenths of an inch of water column. The use of this unit of vacuum pressure comes from the legacy of the manually operated GEK gasifiers, which had water filled manometer tubes indicating the level of vacuum, as measured off of a scale marked off in inches.

  • Page 69: Pressure Ratio Ranges And Conditions For Grate Shaker Control

    Section 3 - GEK TOTTI Gasifier System 5.2 Pressure Ratio Ranges and Conditions for Grate Shaker Control Condition Pressure Ratio (Pratio) Lower boundary: gas flow when Pratio is <30 is likely to be restricted due to fine <30 char accumulating in the grate basket. This condition may also be caused by clinkers.

  • Page 70: Ash-Out Auger Motor, And Clearing Jams

    Section 3 - GEK TOTTI Gasifier System ● the auger pushes the char up the tube toward the ash collection vessel, where it accumulates. The ash collection vessel has enough capacity to store the char ash from approximately 24 hours of Power Pallet operation, with variation due to load and feedstock qualities. 6.1 Ash-out Auger Motor, and clearing jams Both the ash-out auger and the scroll plate are driven by the ash-out auger motor.

  • Page 71: Packed Bed Filter

    Section 3 - GEK TOTTI Gasifier System After the producer gas leaves the gasifier, it is directed into the cyclone, where it cools and spins to separate out particles of charcoal dust and condensation from the temperature drop. The condensate and particulates descend and accumulate in the cyclone ash can at the bottom. (See Annotated Figure B) The can, which has enough capacity to support 24 hours of operation, should be emptied each time before starting the Power Pallet.
  • Page 72 Section 3 - GEK TOTTI Gasifier System Condensate may be drained through the gas inlet at the bottom of the filter. 2. Add the layers of sifted biomass as shown in the image above. Page 3-27 770-00086 Section 3_GEK TOTTI Gasifier System (PP20) Rev B 770-00083 Power Pallet Technician's Handbook (PP20/v1.09) Rev B...
  • Page 73 Section 3 - GEK TOTTI Gasifier System 3. Insert the black (coarse, 45 dpi) foam disc, then the green (fine, 65 dpi) foam disc, and then gently insert the perforated steel screen on top. Be careful to not damage the gasket around the upper lip of the filter drum when inserting and removing the screen.

  • Page 75: Flare

    Section 3 - GEK TOTTI Gasifier System 8. Flare The gases produced during the startup process are too rich in tar to be burned in an engine, so they are cleanly burned off in the flare until the reactor is hot enough to produce clean gas.
  • Page 76 Section 3 - GEK TOTTI Gasifier System During startup, water vapor and some smoke will initially emit from the top of the flare until the igniter lights it. Once the smoke starts burning, the user should adjust the AIR setting so that the combustion descends into the flare.
  • Page 78 Section 4 - Automation Assembly Table of Contents 1. Process Control Unit (PCU) 1.1 Introduction 1.2 PCU Power Cable 1.3 Display and input controls 1.4 Analog Inputs 1.5 FET Outputs 1.6 Thermocouple Connectors 1.7 Table of Thermocouples 1.8 Differential Pressure Sensors 1.9 ARD Jumper Settings 1.10 Firmware Upload 1.10.1 Uploading the Firmware...

  • Page 79: Process Control Unit (Pcu)

    Section 4 - Automation Assembly 1. Process Control Unit (PCU) 1.1 Introduction The PCU is a printed circuit board (PCB) that serves as the digital control unit that automates and provides data logging for the Power Pallet. The PCU’s processor is an Atmel ATmega1280, the 8-bit RISC microcontroller of the AVR family.

  • Page 80: Display And Input Controls

    Section 4 - Automation Assembly 1.3 Display and input controls The PCU displays information on a 4-row, 20-column text screen, which accepts user input from the keypad on the front panel, or through the four input buttons directly below the display on the PCB.

  • Page 81: Thermocouple Connectors

    Section 4 - Automation Assembly 1.6 Thermocouple Connectors The PCU’s T0–T6 thermocouple connections are K-type mini thermocouple plugs, and connections T7–T14 are K-type screw terminal connections. The thermocouple that measures the gas temperature at the reactor’s hearth restriction is connected to T0 and displayed as Trst, the thermocouple measuring the gas temperature of the end of the reduction zone (at the top of the grate basket) is connected to T1 and is displayed as Tred, and the thermocouple measuring the engine’s coolant temperature is connected to T2.

  • Page 82: Firmware Upload

    Section 4 - Automation Assembly ● The ARD jumper must be set (both pins connected) in order to communicate with the PCU through the USB serial connection. When the ARD jumper is set, any serial connection to the PCU will reset it; therefore, we recommend that the jumper remain unset (connected to one pin only) during normal operation of the Power Pallet.
  • Page 83 Section 4 - Automation Assembly 2. Connect computer to programming port on the front control door using USB cable (provided in the user kit). Page 4-7 770-00087 Section 4_Automation Assembly (PP20/PP25) Rev B 770-00083 Power Pallet Technician's Handbook (PP20/v1.09) Rev B...
  • Page 84 Section 4 - Automation Assembly 3. Start the Arduino software and load “KS_PowerPallet.pde” (only for versions prior to 1.2). 4. Turn on the Power Pallet using the power switch on the front control door. 5. Select the correct board type using the menu, “Tools> Board> Arduino Mega (ATmega1280)”...
  • Page 85 Section 4 - Automation Assembly The Arduino interface showing that PCU program KS_PowerPallet is uploaded. Page 4-9 770-00087 Section 4_Automation Assembly (PP20/PP25) Rev B 770-00083 Power Pallet Technician's Handbook (PP20/v1.09) Rev B...

  • Page 86: Relay Board

    Section 4 - Automation Assembly 2. Relay Board 2.1 Introduction The Relay Board receives the power and data through the wiring harnesses, and manages input/output signals to the various subsystems and the PCU. Please refer to this diagram for the descriptive sections on the following pages.

  • Page 87: Power Terminals

    Section 4 - Automation Assembly Fuses Main battery power Engine starter Fuel auger forward/reverse Flare ignitor Ash auger (v1.08 or newer) Oxygen sensor reset – previously Aux Grate shaker ATX power input Engine ignition, governor, Blowers hour meter 2.2 Power Terminals 12V DC and ground connections power the entire automation system.

  • Page 88: Atx Power Supply Module

    Section 4 - Automation Assembly 2.4 ATX Power Supply Module Most automated subsystems draw current from the on-board 12V DC battery supply, including some motors with large current requirements, which significantly reduce the instantaneous voltage in the system as they come on. To prevent voltage drops from resetting the PCU, or power spikes from damaging the PCU, the ATX power supply unit provides clean 12V DC power to the PCU.

  • Page 89: Relay Board Configuration Jumpers

    Section 4 - Automation Assembly The ATX power supply unit 2.5 Relay Board Configuration Jumpers JP1: Oil Pressure Sensor/Sender 3 pin jumper ● Jump Pins 1 (leftmost) & 2 (middle) = PP20 configuration (indicated on board) ● Jump Pins 2 (middle) & 3 (rightmost) = PP10 configuration (discontinued) JP2: Alarm Enable &...

  • Page 90: Max-232 Ttl Converter

    Section 4 - Automation Assembly 4 pin jumper Jump bottom 2 pins 2.6 Max-232 TTL converter This integrated circuit provides an electrical buffer for serial communication with the engine governor. 2.7 Analog Connections from Relay Board to PCU These connectors output various analog signals from the Relay Board to the PCU. 2.8 Oxygen Sensor Controller This connector powers the oxygen sensor (lambda) meter, which enables proper functioning of the air/fuel mixing system, and relays the analog signal (0.25-5V analog, 51-1023 digital value)

  • Page 91: Main Power Switch

    Section 4 - Automation Assembly support@allpowerlabs.org if you require detailed diagrams and pinouts, as the harnesses are consistently upgraded. 3.1 Main Power Switch A 30A breaker is used as the main power switch for the Power Pallet’s automation system, providing protection from over-current events. When it is flipped up into the “on” position, it powers the automation assembly with 12V DC from the main battery.
  • Page 92 Section 4 - Automation Assembly Page 4-16 770-00087 Section 4_Automation Assembly (PP20/PP25) Rev B 770-00083 Power Pallet Technician's Handbook (PP20/v1.09) Rev B...
  • Page 93 Section 5 - Software Section 5 Software v1.3 Page 5-1 770-00088 Section 5_Software (PP20/PP25) 770-00083 Power Pallet Technician's Handbook (PP20/v1.09) Rev B...
  • Page 94 Section 5 - Software Table of Contents 1. Component Control Logic 1.1 Notes about Component Control Logic 1.1.1 Filter 1.1.3 Blowers 1.1.4 Feedstock Auger 1.1.5 Grate Shaker 1.1.6 Governor 1.1.7 Mixture Control 1.1.8 Reactor Conditions 1.1.9 Engine Oil Pressure 1.1.10 Oxygen Sensor and Mixture Control 1.1.11 Automatic Shutdown 1.1.12 Mixture on Shutdown 1.2 Displayed Alarms and System Responses...

  • Page 95: Component Control Logic

    Section 5 - Software 1. Component Control Logic 1.1 Notes about Component Control Logic The PCU control logic monitors the reactor temperature and pressure, oxygen sensor reading, and engine state. It also controls fuel feed, char bed agitation, and ash removal. If any critical issue occurs, the control system will sound an alarm to alert the user to the state of the machine.
  • Page 97 Section 5 - Software 1.1.8 Automatic Shutdown When there is an automatic shutdown, the cause remains on display and the system will not resume until reset by the user via the control panel. Shutdown causes are persistent on the display after automatic shutdown for the user to view. 1.2 Displayed Alarms and System Responses Below is a table of the errors that are displayed and the action taken by the system.
  • Page 98 Section 5 - Software High P_comb Check Air Intake Combustion vacuum No alarm Immediate > 300 units High Coolant High Coolant Temp Greater than 0 sec Engine shutdown 3 sec Temp 98°C default (user configurable) Reduction Engine shutdown 7 sec Increase Load Engine on and 3 sec Temp Low...

  • Page 101: System Information

    Section 5 - Software <Component>: <MODE> NEXT ADV MODE Values Component Grate Shaker, Fuel Auger, or Ash Auger <Mode> Grate Shaker ● Auto: Grate shaker will turn on at intervals according to parameters. ● ON: Grate shaker on continuously ● OFF: Grate shaker disabled. Fuel Auger ●...

  • Page 102: Testing

    Section 5 - Software 2.6 Testing Test Relay: FETX Name [state] State: NEXT ADV Tests 0. Fuel Auger Fwd Turns on/off auger forward relay (FET0) 1. Grate Turns on/off grate shaker relay (FET1) 2. Engine/Governor Turns on/off engine ignition relay (FET2) 3.

  • Page 103: Analog Inputs

    Section 5 - Software 2.7 Analog Inputs Analog Input: ANAX FET Name [state] State: NEXT ADV Analog Input FET Name ANA0 ANA_Lambda ANA1 ANA_Fuel_Switch ANA2 ANA_Eng_Switch ANA3 ANA_Oil ANA4 ANA_Aug_current ANA5 ANA_Throttle_Pos ANA6 ANA_Coolant_Temp (Currently shows ash auger current) ANA7 Unused Page 5-11 770-00088 Section 5_Software (PP20/PP25)

  • Page 104: Air Servo

    Section 5 - Software 2.8 Air Servo ServoMin Careful of Sides! NEXT ADV Values Servo Minimum (Closed)— minimum servo mixer angle (degrees) Servo Maximum (Open)— maximum servo mixer angle (degrees) Keypad NEXT Go to next menu Go to next menu item Increase item value Decrease item value 2.9 Calibrate Pressure Sensors...

  • Page 105: Configuration

    Section 5 - Software 2.10 Configuration Configurations [Configuration name:Value] ADV to save choice NEXT Keypad NEXT Go to next menu Go to next Text depends Text depends configuration on configuration on configuration submenu submenu. submenu. See Configuration See Configuration Menu and Options Menu and Options below.
  • Page 106 Section 5 - Software (Units: 0.1 Amps) Low Oil(PSI) + : increase value - : decrease value (Units: 1 PSI) Datalog SD card YES: command to datalog to SD card (if present). NO:command to not datalog to SD card Pratio Accum# +5 : increase value - 5: decrease value (Units: 5)
  • Page 107 Section 5 - Software Modbus Baud + : increase value - : decrease value (Units: 1) Modbus Parity + : increase value - : decrease value (Units: 1) Modbus Address + : increase value - : decrease value (Units: 1) Grid Tie? YES: Grid tie configuration (with Factory default matches...

  • Page 108: Alarm

    Section 5 - Software 2.12 Alarm [current] [total] ALARM [Alarm Name] [Alarm Advice] NEXT QUIET RESET Keypad NEXT QUIET RESET Go to next menu Show next alarm Silence alarm (will be Reset conditions turn on again if a new causing the alarm alarm occurs) Note: If the alarm caused a shutdown of the engine or auger, the alarm MUST be reset or acknowledged for the system to operate correctly...

  • Page 109: Data Logging Outputs

    Section 5 - Software 4. Data Logging Outputs When data logging with the PCU, a table of values is output with the following variable headings and information. Variable Value Units Time since PCU is powered on Seconds Time Temperature at the restriction of the reduction bell (0˚- ˚C T_tred 1250˚C)
  • Page 110 Section 5 - Software Engine oil pressure ANA3 Feedstock auger current ANA4 Throttle position (enabled since 11/2013) enumerated ANA5 0.75v-4.25v DC, quantized into integer between 0-1023 T_Eng_coolant Coolant Temperature, same as ˚C ANA6 (not used) governor auxiliary signal (not used) ANA7 Grate shaking state, enumerated (1=ON, 2=OFF) enumerated...
  • Page 111 Section 5 - Software Engine air premix/oxygen sensor D value for Lambda_D PID loop Reactor State enumerated P_reactorLevel (0= OFF, 1= LOW, 2= MEDIUM, 3= HIGH) Temperature state enumerated T_tredLevel (0=COLD, 1= COOL, 2=WARM, 3=HOT) Temperature state enumerated T_bredLevel (0=COLD, 1= COOL, 2=WARM, 3=HOT) Engine state (1=ON, 2=OFF) enumerated Engine...

  • Page 112: Serial Commands

    Section 5 - Software 5. Serial Commands The following commands are available over a serial connection made at 115600 baud: Symbol Action Device info Rewrite specified EEPROM space (give number followed by ';') Add 0.02 to p Subtract 0.02 from p Add 0.02 to i Subtract 0.02 from i d or D...
  • Page 113 Section 6 - Engine Section 6 Engine Page 6-1 770-00089 Section 6_Engine (PP20/PP25) Rev B 770-00083 Power Pallet Technician's Handbook (PP20/v1.09) Rev B...
  • Page 114 Section 6 - Engine Table of Contents 1. Engine 1.1 Power Pallet Engines 1.2 Engine Specifications 2. Mixing System 2.1 Overview 2.2 Condensate Vessel (PP20 only) 2.3 Oxygen Sensor and Lambda Meter 2.4 Programming the Lambda Meter 2.5 Air Servo 2.5.1 Calibration 3.

  • Page 115: Engine

    Section 6 - Engine 1. Engine The Power Pallet engine is a spark-ignition engine, similar to those found in most automobiles, with some minor differences: a special-purpose mixing system provides the appropriate fuel/ air mixture, and spark timing is advanced significantly to compensate for the slow flame propagation of producer gas.

  • Page 116: Mixing System

    Section 6 - Engine 2. Mixing System 2.1 Overview The system immediately preceding the engine is the mixing system, which mixes producer gas with air to the correct ratio. The intake of air is regulated by an air servo controlled by a PID (proportional integral derivative) loop run from the PCU based on input from the oxygen sensor reading the oxygen concentration in the exhaust.
  • Page 117 Section 6 - Engine The condensate vessel has a sight glass that indicates when the condensate should be drained. The condensation vessel should be drained regularly, before there is enough liquid in the vessel to be visible through the sight glass. You should not wait until the sight glass is submerged to drain the vessel;...

  • Page 118: Oxygen Sensor And Lambda Meter

    Section 6 - Engine 2.3 Oxygen Sensor and Lambda Meter The Power Pallet uses a wideband oxygen sensor (model MTX-L) and digital lambda meter manufactured by Innovate Motorsports to monitor the oxygen content of the exhaust. The oxygen sensor is located in the engine exhaust stream and detects the amount of free oxygen ) in the exhaust to determine if the fuel mixture is lean (proportion of oxygen exceeds the stoichiometric ratio) or rich (proportion of combustibles exceed the stoichiometric ratio).

  • Page 119: Programming The Lambda Meter

    Note: this section requires the use of the Bosch Oxygen Sensor LogWorks Program, or LM Programmer, found on the USB drive that comes with the user kit Every lambda meter must be programmed before the first use. ALL Power Labs performs this programming on every Power Pallet before shipping. The following directions outline this process of re-programming the lambda meter in the field.
  • Page 120 Section 6 - Engine Lambda Meter serial cable, inside the podium on the left wall. 3. Launch LM Programmer 4. Select the “Display” tab and set the values below. Setting Value Setting Value Green Min Red Max Green Max Numeric Min Yellow Max Numeric Max Display in...
  • Page 121 Section 6 - Engine 5. Set the same options for the "Analog Out 1" tab using table below: Volts Lambda 0.25 0.55 6. Enter the “Advanced” dialog box on the “Analog Out 1” tab and make sure that the response speed is set to sec and that both the Warmup Output and Error Outputs are set to 0.00V: 7.

  • Page 122: Air Servo

    Section 6 - Engine 2.5 Air Servo The air mixture servo valve has a small indicator line on the end of the shaft so one can visually see the valve positioning. Attached to the inlet of the air mixture servo valve is an oiled air filter.

  • Page 123: Programming The Electronic Governor

    Before the governor can be used for the first time it must be programmed and calibrated. The engine governors are calibrated by ALL Power Labs prior to commissioning. In the rare condition that the governor must be entirely reprogrammed and calibrated, the following instructions outline these procedures.

  • Page 124: Grid-Tie Systems

    Section 6 - Engine Turn on the Power Pallet. The PCU will boot and show the system status screen. Press the left- most button under the display until the Testing screen appears. Press the button labeled TEST until the ENGINE test mode is activated. The governor should now be powered on, and should emit a soft electronic humming noise.

  • Page 125: Loading A Configuration File

    Section 6 - Engine 3.1.4 Loading a Configuration File 1. In the L-series Tool select: File → Load Configuration File to Control... Select the configuration file that corresponds with the specification of the Power Pallet. Page 6-13 770-00089 Section 6_Engine (PP20/PP25) Rev B 770-00083 Power Pallet Technician's Handbook (PP20/v1.09) Rev B...

  • Page 126: Calibrating The Electronic Governor

    Section 6 - Engine 3.1.5 Calibrating the Electronic Governor 1. To calibrate the governor position use the menu: Tools →Position Calibration → Automatic 2. Click the box for “The preceding has been followed” to continue. 3. Follow the on-screen instructions. All settings can be left at their defaults.

  • Page 127: Mpu

    Section 6 - Engine 4. MPU The MPU (magnetic pick-up) is a sensor installed in the engine flywheel housing which outputs a 3V pulsed signal as the teeth on the flywheel pass near it. The frequency of these pulses are used by the engine governor to determine the rotation speed of the engine.
  • Page 129 Section 6 - Engine The MPU is essentially as close as possible without actually touching the teeth; the separation is only a few thousandths of an inch. This close positioning enables the MPU to produce a 3V signal for the governor by induction from the teeth of the flywheel. To adjust the MPU: 1.
  • Page 130 Section 7 - Generator Section 7 Generator Page 7-1 770-00090 Section 7_Generator (PP20/PP25) Rev B 770-00083 Power Pallet Technician's Handbook (PP20/v1.09) Rev B...
  • Page 131 Section 7 - Generator Table of Contents Disclaimer 1. Generators 1.1 Frequency 2. Wiring Configurations 2.1 Series Star 2.2 Parallel Star 2.3 Series Delta 2.4 Parallel Delta 2.5 Double Delta 2.6 1 Phase Zig-Zag 2.7 Load Imbalance 3. Automatic Voltage Regulator (AVR) 3.1 AVR Adjustment Page 7-2 770-00090 Section 7_Generator (PP20/PP25) Rev B...

  • Page 132: Disclaimer

    It is recommended that power conditioning be used for the operation of sensitive equipment. ALL Power Labs is not responsible for any damages due to inappropriate wiring or output connections, variations in voltage, or otherwise.
  • Page 133 Section 7 - Generator equipment that it will power. The generator is driven synchronously with the engine, meaning the generator turns at the same rate as the engine, and the frequency of the alternating current (AC) produced by the generator is a multiple of the engine speed. A 2-pole generator unit will produce current frequency that is the same as the engine speed;...

  • Page 134: Wiring Configurations

    Section 7 - Generator 2. Wiring Configurations The generator’s stator unit contains six independent windings. Each winding is wired to a numbered ring terminal at either end. To change the configuration of the generator, the terminals must be connected the appropriate studs on the terminal block inside the housing on the top of the generator.
  • Page 135 Section 7 - Generator terminal block diagrams. Page 7-6 770-00090 Section 7_Generator (PP20/PP25) Rev B 770-00083 Power Pallet Technician's Handbook (PP20/v1.09) Rev B...

  • Page 136: Series Star

    Section 7 - Generator 50Hz: 400 VOLT (L-L), 3 PHASE 2.1 Series Star 60Hz: 480 VOLT (L-L), 3 PHASE Legs Voltages 50hz 380 3Φ 400 3Φ 415 3Φ 440 3Φ L1-L2-L3 60hz 415 3Φ 440 3Φ 460 3Φ 480 3Φ 50hz 60hz 50hz...

  • Page 137: Parallel Star

    Section 7 - Generator 50Hz: 200 VOLT, 3 PHASE; 115 VOLT, 1 PHASE 2.2 Parallel Star 60Hz: 208 VOLT, 3 PHASE; 120 VOLT, 1 PHASE Legs Voltages 50hz 190 3Φ 200 3Φ 208 3Φ 220 3Φ L1-L2-L3 60hz 208 3Φ 220 3Φ...

  • Page 138: Series Delta

    Section 7 - Generator 50Hz: 230 VOLT, 3 PHASE; 115/230 VOLT 1 PHASE 2.3 Series Delta 60Hz: 240 VOLT, 3 PHASE; 120/240 VOLT 1 PHASE Legs Voltages 50hz 220 3Φ 230 3Φ 240 3Φ 254 3Φ L1-L2-L3 60hz 240 3Φ 254 3Φ...

  • Page 139: Parallel Delta

    Section 7 - Generator 50Hz: 115 VOLT, 3 PHASE; 115 VOLT, 1 PHASE (L1-L2) 2.4 Parallel Delta 60Hz: 120 VOLT, 3 PHASE; 120 VOLT, 1 PHASE (L1-L2) Legs Voltages 50hz 110 3Φ 115 3Φ 120 3Φ 127 3Φ L1-L2-L3 60hz 120 3Φ...

  • Page 140: Double Delta

    Section 7 - Generator 50Hz: 115/230 VOLT, 1 PHASE 60Hz: 120/240 VOLT, 1 PHASE 2.5 Double Delta Note: purely 1 phase configurations are not compatible with the grid-tie system Legs Voltages 50hz 60hz 50hz 60hz Page 7-11 770-00090 Section 7_Generator (PP20/PP25) Rev B 770-00083 Power Pallet Technician's Handbook (PP20/v1.09) Rev B...

  • Page 141: Phase Zig-Zag

    Section 7 - Generator 50Hz: 115/230 VOLT, 1 PHASE 60Hz: 120/240 VOLT, 1 PHASE 2.6 1 Phase Zig-Zag Note: purely 1 phase configurations are not compatible with the grid-tie system Legs Voltages 50hz 60hz 50hz 60hz Page 7-12 770-00090 Section 7_Generator (PP20/PP25) Rev B 770-00083 Power Pallet Technician's Handbook (PP20/v1.09) Rev B...

  • Page 142: Load Imbalance

    Section 7 - Generator 2.7 Load Imbalance While the maximum load imbalance for three-phase loads is not specifically stated in the relevant literature, it is generally accepted that three-phase motor loads are not tolerant of voltage imbalance of more than 2% between phases. Therefore, it is advisable to ensure that, when single-phase loads attached to a generator wired for three-phase current, the loads should be evenly distributed among each phase.

  • Page 143: Avr Adjustment

    Section 7 - Generator 3.1 AVR Adjustment This procedure should be performed if changing the stator wiring or if the voltage is outside of the desired range. In order to measure and adjust the voltage, the generator must be running at the target operating frequency and any load must be disconnected.
  • Page 144 Section 7 - Generator Page 7-15 770-00090 Section 7_Generator (PP20/PP25) Rev B 770-00083 Power Pallet Technician's Handbook (PP20/v1.09) Rev B...
  • Page 145 Section 8 - Maintenance Section 8 Technician Level Maintenance Page 8-1 770-00091 Section 8_Maintenance (PP20) Rev B 770-00083 Power Pallet Technician's Handbook (PP20/v1.09) Rev B...
  • Page 146 Section 8 - Maintenance Table of Contents 1. Warning: Maintenance Hazards 1.3 Scope of this Section 2. Gasifier 2.1 Overhaul Gasifier 2.2 Overhaul Hopper 2.3 Replace Gasifier 3. Engine 3.1 Governor Deep Clean Procedure 3.2 Cleaning the Air Filter 3.4 Spark Plug Inspection 3.5 Overhaul Engine 3.6 Turbo 3.6.1 Turbo Maintenance...

  • Page 148: Scope Of This Section

    Section 8 - Maintenance 1.3 Scope of this Section Please see the Power Pallet Operation Manual for the schedule of maintenance and all operator level maintenance procedures. The following are maintenance instructions that should be conducted by trained technicians only. 2.

  • Page 149: Replace Gasifier

    Section 8 - Maintenance 2.3 Replace Gasifier Remove the gasifier as described in 2.1 Overhaul Gasifier section above. Insert the new gasifier. Assembly is the reverse of disassembly. Page 8-5 770-00091 Section 8_Maintenance (PP20) Rev B 770-00083 Power Pallet Technician's Handbook (PP20/v1.09) Rev B...

  • Page 150: Engine

    Section 8 - Maintenance 3. Engine 3.1 Governor Deep Clean Procedure The daily servicing of the governor is explained in the Power Pallet Operation Manual. These instructions for the deep cleaning of the governor are provided in the case that disassembly may be required.
  • Page 151 Section 8 - Maintenance Remove governor and throttle Disconnect the governor from Remove the two screws that body from intake runner. the throttle body. hold on the throttle plate. Remove the end cap. Remove the retaining screw. Note the orientation of the spring.

  • Page 152: Cleaning The Air Filter

    Section 8 - Maintenance bearings. installed. in retaining ring. The ring should be installed with the chamfered edge oriented inward. Cleaning Clean all metal components in denatured or isopropyl alcohol. Tough deposits may require soaking components overnight. A wire brush may aid in faster cleaning. Bearings should turn smoothly.

  • Page 153: Spark Plug Inspection

    Section 8 - Maintenance 3.4 Spark Plug Inspection The spark plugs of the Power Pallet may gradually accumulate mineral fouling when mineral rich feedstocks are used: Examples of fouled spark plugs that caused malfunction. At the recommended engine tune-up interval, be sure to inspect the spark plugs, and either clean the with a wire brush or replace them.
  • Page 154 Section 8 - Maintenance Page 8-10 770-00091 Section 8_Maintenance (PP20) Rev B 770-00083 Power Pallet Technician's Handbook (PP20/v1.09) Rev B...
  • Page 155 Section 9 - Troubleshooting Chapter 9 Troubleshooting Page 9-1 770-00093 Section 9_Troubleshooting (PP20/PP25) Rev B 770-00083 Power Pallet Technician's Handbook (PP20/v1.09) Rev B...
  • Page 156 Section 9 - Troubleshooting Table of Contents 1. Most Common Problems 2. Gasifier Troubleshooting 2.1 Testing the fuel level switch 2.1.1 Paddle Switch 2.1.2 Flex Reed Switch Troubleshooting 2.2 Testing the Thermocouples 2.3 Testing for leaks 2.4 Tables of Symptoms 2.4.1 Hopper 2.4.2 Auger 2.4.3 Cyclone...

  • Page 157: Most Common Problems

    Section 9 - Troubleshooting 1. Most Common Problems The most common problems that cause failures to start are: ● Starter not turning over: Insufficient battery charge— during the flaring process, the air and gas blowers, igniter, grate shaker, and all of the electronics are being powered by the battery.

  • Page 158: Gasifier Troubleshooting

    Section 9 - Troubleshooting 2. Gasifier Troubleshooting 2.1 Testing the fuel level switch 2.1.1 Paddle Switch To test the fuel level switch, access the testing mode screen on the PCU. In the fuel level switch test mode, it should give the following values: ●...
  • Page 159 Section 9 - Troubleshooting Air leaks constitute an entire class of problems that can arise anywhere there is a joint or interface or even a faulty hose. Because the entire gas circuit is under vacuum pressure when the machine is operating if there is a leak, air will leak into the gas circuit rather gas leaking out. Because of this, testing for leaks is not always easy.
  • Page 160 Section 9 - Troubleshooting An example of localized overheating due to an internal fire caused by an air leak from a poorly re-sealed interface. ● Scanning for leaks with a mechanic’s stethoscope, or other detection methods— The most reliable way to detect leaks is to use one of the detection methods listed below to detect air rushing out of a leak as a little bit of positive pressure is applied to the gas circuit while the machine is fully cooled down.

  • Page 161: Tables Of Symptoms

    Section 9 - Troubleshooting 2.4 Tables of Symptoms 2.4.1 Hopper Symptom Possible root cause Solution Air leaks around hopper 1) Damaged lid gasket Align or replace lid gasket 2) Misaligned bolts or Align or replace drying bucket flange flange gasket gasket.

  • Page 162: Cyclone

    Section 9 - Troubleshooting 3) Fuel level switch is Replace. damaged. 4) Tar build-up holds Unscrew the entire fuel switch switch in off-position. fixture and clean out all tar with solvents. Low current state for 1) Bridging in the hopper or Check the two forward and reverse auger drying bucket.

  • Page 163: Flare

    Section 9 - Troubleshooting 2.4.5 Flare Symptom Possible root cause Solution Too much air Air blower gasket stuck in Adjust the gasket so that it seats properly allowed into flare housing. in the gasket housing. stack at low flows Flame seen above Flare does not have Increase air blower output using the knob the flare stack...
  • Page 164 Section 9 - Troubleshooting Symptom Possible root cause Solution Ignition port melted Torch being applied to Lighting the reactor should take no longer from heat ignition port for too long than 10 minutes. If feedstock does not by operator trying to light seem to light, see the row below.

  • Page 165: Temperature Related Problems

    Section 9 - Troubleshooting fouled with clinkers clinker-prone feedstock with lower-mineral feedstock. If the gasifier operates well in spite of 5) Pratio is below 15 for the low Pratio, this is not a problem, and most all of the run alarm threshold needs to be adjusted.
  • Page 166 Section 9 - Troubleshooting 6) Fault connection on the Switch Trst and Tred to see if each PCU board. connector gives the same reading, replace if needed. Temperatures are 1) Insufficient feedstock in Turn off the system by closing the gas or too high (above pyrolysis zone (pyrolysis engine...

  • Page 167: Engine Troubleshooting

    Section 9 - Troubleshooting 3. Engine Troubleshooting 3.1.1 Engine Symptom Possible Cause Corrections/Solutions Engine cranks but 1) If first starting the Cranking the engine will purge the air does not start. system up, there will be until wood gas and the correct air mixture air in the gas filter and the reaches the engine.
  • Page 168 Section 9 - Troubleshooting 5) Air mixture servo not Check lambda meter for error code. opening properly Use air servo adjustment menu to verify operation of the air servo. 6) Grid Tie Systems: Mixture on grid-tie systems is controlled by “Engine On”...

  • Page 169: Troubleshooting For The Air Servo

    Section 9 - Troubleshooting leaks. 2) Poor gas quality Switch to flare. See troubleshooting section in Chapter 3. 3) Wrong spark timing Confirm spark plugs are wired for correct engine firing order. Engine pre-ignition Poor spark plug wire Confirm wires are well seated. when starting seating Engine speed...

  • Page 170: Troubleshooting For The Oxygen Sensor And Lambda Meter

    Section 9 - Troubleshooting connect to governor mode, listen for governor "whine" 2) Serial cable not connected Verify all cable connections, ensure use of correct port on automation assembly. 3) Harness connections mis- Verify governor and key switch wired harness RS-232 connections at relay board.
  • Page 171 Section 9 - Troubleshooting 3) No serial port Obtain USB serial adapter or use computer with serial port Lambda meter display Power cycle lambda meter. unintelligible after Replace if issue continues. programming "E2" error on lambda meter Oxygen sensor not connected Check all oxygen sensor cable display connections and ensure plugs are fully engaged to their...

  • Page 172: Generator Troubleshooting

    Section 9 - Troubleshooting 4. Generator Troubleshooting Symptom Possible Root Cause Solution Heavy load step High instant torque on Adjust STAB pot (this will cause causes frequency drop engine voltages to dip, but allow larger loads to be placed on the engine with minimized frequency impact).

  • Page 173: Automation Assembly Troubleshooting

    Section 9 - Troubleshooting 5. Automation Assembly Troubleshooting 5.1 Troubleshooting FETs To test operation of a FET output, use a voltmeter on the low-resistance or diode-check setting. The meter should read a low resistance to ground when the FET is switched, on and infinite resistance when it is switched off.
  • Page 174 Section 9 - Troubleshooting ends of the harnesses are fully plugged into their mates. Use visual inspection and continuity test with volt-meter 3) Circuit boards, Check all connections in terminals harnesses, or subsystems inside the enclosure and at incorrectly wired subsystems against Wiring Harness Documents (found in appendices to Technician’s...

  • Page 175: Troubleshooting The Pcu

    Section 9 - Troubleshooting 5.4 Troubleshooting the PCU Symptom Possible Cause Solution Unable to read LCD 1) Contrast non-ideal for Adjust the blue contrast knob or screen/ nothing on LCD lighting conditions. cover the LCD screen to shade screen from direct sun. 2) Display connection not Check and secure connections.
  • Page 177 Section 10 - Grid Tie Table of Contents Warnings/Hazards Reference Materials Use Cases Use Cases and Available Features Connection to a Utility for Mains Paralleling Part of a Microgrid Stand-Alone Operation Commissioning Procedure PCU Configuration Deep Sea Configurations AVR Tuning Configure DSE SCADA Settings AVR Bias Tuning Procedure Governor Bias Tuning Procedure...
  • Page 178 Section 10 - Grid Tie Brief Explanation of the Grid Tie System The Power Pallet Grid Tie module uses a Deep Sea 8610 controller to synchronize the Power Pallet with and export power to the grid. It is configurable through the Deep Sea Configuration Suite Software with many settings also accessible through the controller interface.
  • Page 179 Section 10 - Grid Tie III. Reference Materials Deep Sea Electronics has a full listing of manuals and quick start guides available in several languages on their website available for download. Please visit: http://www.deepseaplc.com/support/product-software/dse-genset/synchronising-load-sharing- controllers/dse8610. This document may occasionally refer you to one of the following technical manuals. DSE8610 Quick Start Guide DSE8610 Control Module (User Manual) Page 10-4...
  • Page 180 Section 10 - Grid Tie DSE Configuration Suite PC Software DSE8600 Configuration Suite Software Manual Installation & Operation Manual Load Share System Design and Commissioning Guide to Synchronising and Load Sharing Guide to Synchronising and Load Sharing Part 1 Part 2 Page 10-5 770-00092 Section 10_Grid Tie (PP20/PP25) Rev A 770-00083 Power Pallet Technician's Handbook (PP20/v1.09) Rev B...
  • Page 181 Section 10 - Grid Tie IV. Use Cases A. Use Cases and Available Features The following features sets are available: Feature Mains Paralleling Part of a Microgrid Stand Alone Operation Fixed export control No Break transfer Islanding Load sharing Close to dead bus Earth fault detection Mains decoupling Yes*...
  • Page 182 An example of this is a diesel generator and Power Pallet supplying load to the microgrid. c. Stand-Alone Operation Note: ALL Power Labs does not support stand-alone operation of the Power Pallet Grid-Tied models. However, instructions are provided for troubleshooting purposes only that are only to be done by an APL certified technician.
  • Page 183 Section 10 - Grid Tie Commissioning Procedure Please note that the Grid Tie Power Pallets are already configured when shipped. The commissioning procedure listed here is offered for reference only. 1. PCU Configuration Enable ‘Grid Tie’ mode on the PCU. Navigate to the view for this configuration setting by using the buttons on the control panel.
  • Page 184 Section 10 - Grid Tie 3. AVR Tuning a. Disconnect the two (orange and black) bias wires on the generator’s AVR (automatic voltage regulator). See wiring diagram. b. Make sure that the tiny arrow on the AVR VOLT potentiometer is centered within the tick marks.
  • Page 185 Section 10 - Grid Tie Figure x. Location of VOLT and STAB potentiometer on generator AVR. 4. Configure DSE SCADA Settings The following procedure is designed to confirm that the DSE is able to accurately control genset output voltage (through the AVR) and the frequency (controlled by the governor) via the DSE program’s supervisory control and data acquisition (SCADA) interface.
  • Page 186 Section 10 - Grid Tie A. AVR Bias Tuning Procedure CAUTION: For bias voltages exceeding 2.5V, the AVR’s default behavior is to reject the bias input. This can lead to unexpected behavior of the generator. For more information, consult the AVR manual. CAUTION: Bias voltages outside the range of -5V to +5V may damage the AVR.
  • Page 187 Section 10 - Grid Tie Governor Bias Tuning Procedure ● Disconnect governor bias wires from back of DSE controller ● Initial Governor SW1 = See Value In Configurations Table ● Initial Governor SW2 = See Value In Configurations Table ● The generator should be kept running without load ●...
  • Page 188 Section 10 - Grid Tie VI. Dynamic Tuning Grid Operation Each utility grid or microgrid has unique dynamics and the Power Pallet’s generator must be “tuned” to properly synchronize and maintain stable power export. The figure below shows the hardware configuration of the Deep Sea Module and the Power Pallet: Figure x.
  • Page 189 Section 10 - Grid Tie The Deep Sea control module has SCADA settings that determine how the AVR and governor bias control loops react dynamically to fluctuations in the grid in an effort to maintain a stable, synchronized connection between the Power Pallet and the grid. These settings are called gain and stability and, during synchronization, the frequency synchronizer and voltage matcher are controlled by their gain, while, when the Power Pallet is exporting power, gain and stability control load share and reactive power control.
  • Page 190 Section 10 - Grid Tie generator frequency, the bar will consistently move to the right across the screen, while frequency variation will show as inconsistent movement back and forth across the screen. 2. Voltage Matcher During the synchronization process,the voltage matcher adjusts the AVR bias in order to synchronize the generator’s voltage to that of the grid.
  • Page 191 Section 10 - Grid Tie to see the targets for various critical variables, such as load level, reactive power, power factor, and biases displayed as percentages and up once more to see their absolute values. ● Target Power The Power Pallet target power output for fixed export can be adjusted through the SCADA settings in the DSE Configuration Suite software, under Multiset ->Load Levels ->Maximum.
  • Page 192 Section 10 - Grid Tie IX. Troubleshooting The troubleshooting provided in this table is only for a trained APL technician only or if directed by a trained APL technician or APL support team. Please do not conduct any troubleshooting below before contacting APL support. Symptom Possible Root Cause Solution...
  • Page 193 Section 10 - Grid Tie Over-voltage Incorrect DSE wire-topology Incorrect AVR potentiometer settings setting or bias Under-voltage Incorrect DSE wire-topology settings “E-stop alarm” Ignition circuit fuse blown Replace fuse (#3?) “E-stop alarm” Bad wiring Confirm wiring Unexpected engine shutdown Outside pre-set parameters Operate with in pre-set parameters or change parameters.

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