All Power Labs Power Pallet PP20 Manuals

Manuals and User Guides for All Power Labs Power Pallet PP20. We have 1 All Power Labs Power Pallet PP20 manual available for free PDF download: Technician's Handbook

All Power Labs Power Pallet PP20 Technician's Handbook

All Power Labs Power Pallet PP20 Technician's Handbook (193 pages)

Brand: All Power Labs | Category: Industrial Equipment | Size: 18 MB

Table of Contents

Section 1

3
Section 2

27
- Feedstock Related Terms
  28
- Feedstock, Fuel
  28
- Fuel Jams: Bridging, Rat-Holing, Binding
  28
- Oversized, Undersized, and Fines
  28
- Correct Shape
  30
- Feedstock Qualifications
  30
- Lower Size Limit
  30
- Physical Compatibility
  30
- Upper Size Limit
  30
- Correct Surface Texture
  31
- Friability
  31
- Resistance to Steamed Disintegration
  31
- Flow Characteristics
  32
- Angle of Repose
  33
- Blending Feedstocks to Compensate for Shape and Texture
  33
- 11Feedstock Particle Size and Char-Ash Byproduct Percentage
  34
- Chemical Compatibility
  34
- Fixed Carbon Content
  34
- Alkali Index, Slagging, and Clinker Formation
  35
- Ash Content
  35
- Fixed Carbon to Volatile Ratio
  35
- Volatile Content
  35
- Feedstock Preparation
  36
- Chipping
  37
- Chunking
  37
- Pelletizing and Briquetting
  38
- Sorting
  38
- Blending Undersized Pieces and Used Filter Media with Feedstock
  39
- Recovery of Tars from Condensate
  39
- Drying Feedstock to Correct Moisture Levels
  40
- Microwave Method
  41
- Moisture Meter
  41
- Moisture Testing
  41
- General Requirements for All Feedstocks
  42
- Suitability Key
  42
- Table of Feedstocks
  42
- Biomass Consumption Table
  44
Section 3

48
- Feedstock, Fuel
  49
- Notes about Nomenclature and Terms
  49
- Overview
  49
- Syngas, Wood Gas, Producer Gas
  49
- TOTTI, Pyrocoil, Pyroreactor
  50
- Gasifier, Reactor
  51
- Hearth, Reduction Bell
  51
- Cyclone and Drying Bucket
  53
- Feedstock Feed System
  53
- Hopper
  53
- Auger and Fuel Level Switch
  54
- Annotated Figures
  56
- Exhibit A: GEK TOTTI Gasifier with Ash Collection Vessel
  56
- Exhibit B: GEK TOTTI Gasifier with Ash Collection Vessel, Cont
  58
- Exhibit C: Gas Cowling and Pyroreactor
  59
- Exhibit D: Gasifier Cross Section
  61
- Exhibit E: Detail of Hearth and Grate Basket
  62
- Air Inlet
  63
- Air Lines
  63
- Air Nozzles
  63
- GEK Gasifier Reactor Components
  63
- Lighting Port
  63
- Projected Hearth
  63
- Thermocouples of the Power Pallet
  64
- Table of Thermocouples
  65
- Grate Basket Shaker and Pratio
  66
- Reading Pressure Values on the PCU
  68
- Ash Handling
  69
- Pressure Ratio Ranges and Conditions for Grate Shaker Control
  69
- Ash-Out Auger Motor, and Clearing Jams
  70
- Cyclone
  70
- Gas Filtration System
  70
- Packed Bed Filter
  71
- Packing the Gas Filter
  71
- Flare
  75
Section 4

78
- Introduction
  79
- PCU Power Cable
  79
- Process Control Unit (PCU)
  79
- Analog Inputs
  80
- Display and Input Controls
  80
- FET Outputs
  80
- ARD Jumper Settings
  81
- Differential Pressure Sensors
  81
- Table of Thermocouples
  81
- Thermocouple Connectors
  81
- Firmware Upload
  82
- Uploading the Firmware
  82
- Introduction
  86
- Relay Board
  86
- Ash Auger Motor Driver PCB
  87
- Current Sensor
  87
- Power Terminals
  87
- ATX Power Supply Module
  88
- Relay Board Configuration Jumpers
  89
- Air Servo
  90
- Analog Connections from Relay Board to PCU
  90
- FET Inputs from PCU to Relay Board
  90
- Hour Meter
  90
- Max-232 TTL Converter
  90
- Oxygen Sensor Controller
  90
- Wiring Harnesses
  90
- Engine Start Key Switch
  91
- Main Power Switch
  91
- PWM Blower Controls
  91
- USB Port
  91
Section 5 Software V1.3

94
- Component Control Logic
  95
- Feedstock Auger
  95
- Filter
  95
- Notes about Component Control Logic
  95
- System Information
  101
- Testing
  102
- Analog Inputs
  103
- Air Servo
  104
- Calibrate Pressure Sensors
  104
- Configuration
  105
- Configuration Menu and Options
  105
- Alarm
  108
- Data Logging Outputs
  109
- Serial Commands
  112
Section 6 Engine

114
- Engine
  115
- Engine Specifications
  115
- Power Pallet Engines
  115
- Condensate Vessel (PP20 Only)
  116
- Mixing System
  116
- Overview
  116
- Oxygen Sensor and Lambda Meter
  118
- Programming the Lambda Meter
  119
- Air Servo
  122
- Calibration
  122
- Engine Governor
  122
- Programming the Electronic Governor
  123
- Standalone Systems
  123
- Connecting to the Governor
  124
- Grid-Tie Systems
  124
- Loading a Configuration File
  125
- Calibrating the Electronic Governor
  126
- Mpu
  127
Section 7 Generator

131
- Disclaimer
  132
- Frequency
  132
- Generators
  132
- Wiring Configurations
  134
- Series Star
  136
- Parallel Star
  137
- Series Delta
  138
- Parallel Delta
  139
- Double Delta
  140
- Phase Zig-Zag
  141
- Automatic Voltage Regulator (AVR)
  142
- Load Imbalance
  142
- AVR Adjustment
  143
Section 8 Technician Level Maintenance

146
- Gasifier
  148
- Overhaul Gasifier
  148
- Overhaul Hopper
  148
- Scope of this Section
  148
- Replace Gasifier
  149
- Engine
  150
- Governor Deep Clean Procedure
  150
- Cleaning the Air Filter
  152
- Overhaul Engine
  153
- Replace Turbo
  153
- Spark Plug Inspection
  153
- Turbo
  153
- Turbo Maintenance
  153
Troubleshooting

156
- Most Common Problems
  157
- Flex Reed Switch Troubleshooting
  158
- Gasifier Troubleshooting
  158
- Paddle Switch
  158
- Testing for Leaks
  158
- Testing the Fuel Level Switch
  158
- Testing the Thermocouples
  158
- Auger
  161
- Hopper
  161
- Tables of Symptoms
  161
- Cyclone
  162
- Gas Filter
  162
- Air Inlet
  163
- Difficulty Starting and Operational Problems
  163
- Flare
  163
- Temperature Related Problems
  165
- Engine
  167
- Engine Troubleshooting
  167
- Troubleshooting for the Air Servo
  169
- Troubleshooting for the Governor
  169
- Troubleshooting for the Oxygen Sensor and Lambda Meter
  170
- Generator Troubleshooting
  172
- Automation Assembly Troubleshooting
  173
- Firmware Upload Troubleshooting
  173
- Relay Board Troubleshooting
  173
- Troubleshooting Fets
  173
- Troubleshooting the PCU
  175

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