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TABLE OF FIGURES

Figure 1: Overall Dimensions of the P-5050 TEG   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Figure 2: Data Plate   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Figure 3 P-5050 TEG General Assembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Figure 4 P-5050 Fuel System General Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Figure 5 Burner General Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Figure 6 Model P-5050 Power Unit Electrical Output Characteristics   . . . . . . . . . . . . . . . . . . 4-5

Figure 7 C/L General Assembly   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Figure 8 CP Interface System General Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Figure 9 TEG Controller Assembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Figure 10 Assembling the P-5050 TEG   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Figure 11 Model P-5050 Mounting Dimensions   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Figure 12 Applying Thread Sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Figure 13 Setting-up the P-5050 TEG   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Figure 14 Wiring Diagram P-5050 TEG for 12 or 24 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Figure 15 Wiring Diagram P-5050 TEG for 12 or 24V with optional TEG Controller  . . . . . . . 5-8

Figure 16 Wiring Diagram P-5050 TEG for 6.7V   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

Figure 17 Customer Load Connections   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Figure 18 CP Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Figure 19 Vset and Setup Power Versus Ambient Temperature . . . . . . . . . . . . . . . . . . . . . . . 7-3

Figure 20 Vset Versus Time After Ignition, Typical Response   . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Figure 21 Change in Fuel Gauge Pressure Versus Elevation Above Mean Sea Level, 

            Typical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Figure 22 Change in Vset Versus Air-Shutter Adjustment, Typical . . . . . . . . . . . . . . . . . . . . . 8-2

Figure 23 Change in Vset Versus Fuel Pressure Adjustment, Typical  . . . . . . . . . . . . . . . . . . 8-5

Figure 24 CP Interface System, Series Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8

Figure 25 CP Interface System, Parallel Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8

Figure 26 Pressure Regulator  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

Figure 27 Burner Assembly Cross Section  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7

Figure 28 Electrode Protrusion From Air Box Lid  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9

Figure 29 Momentary Open Circuit Diagram   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13

Figure 30 Model P-5050 TEG  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2

Figure 31 Model P-5050 Burner  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5

Figure 32 Model P-5050 Fuel System   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6

Figure 33 Model P-5050 SS Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  11-7

Figure 34 Model P-5050 Electrical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-8

Figure 35 Cathodic Protection Interface Cabinet  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1

Figure 36 CP Interface System, Series Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2

Figure 37 CP Interface System, Parallel Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4

Figure 38 Cathodic Protection System Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4

Figure 39 HRS Option Overview.  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1

Figure 40 Model P5050 HRS Configuration  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3

Figure 41 Model P5050 HRS, Burner  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-4

Summary of Contents for P-5050

Page 1: ...Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department WARNING If the information in this manual is not followed exactly a fire or explosion may result causing property damage personal injury or loss of life WARNING Improper installation adjustment alteration service or maintenance can cause injury or property damage Read the installation operating an...

Page 2: ... du fournisseur de gaz Si vous ne pouvez pas atteindre votre fournisseur de gaz appelez le service d incendie AVERTISSEMENT L installation inexacte l ajustement le change ment le service ou l entretien peuvent causer des dommages ou des dégâts matériaux Lisez les instructions d installation d opération et d entretien complètement avant d installer ou entretenir cet équipement AVERTISSEMENT Pour l ...

Page 3: ...nit 16 7875 57th Street SE Calgary Alberta Canada T2C 5K7 Phone 1 403 236 5556 Fax 1 403 236 5575 www genthermglobalpower com For latest version download from website NOTICE TO INSTALLER These instructions shall be left with the consumer to retain them for future reference GLOBAL POWER TECHNOLOGIES ...

Page 4: ......

Page 5: ...ESCRIPTION 4 1 4 1 Model P 5050 Thermoelectric Generator 4 1 4 2 Converter Limiter 4 6 4 3 Temperature Compensation 4 7 4 4 Blocking Diode 4 8 4 5 Optional Cathodic Protection Interface System 4 9 4 6 Optional Remote Start System TEG Controller board 4 9 4 7 Intake and Exhaust Flame Arrestors 4 13 4 8 Optional VSR Terminal Block 4 13 5 INSTALLATION 5 1 5 1 Precautions 5 1 5 2 Tools Required 5 1 5 ...

Page 6: ...ommended Periodic Maintenance 9 1 9 2 Fuel System Maintenance 9 4 9 3 Burner Maintenance 9 6 9 4 SI System Maintenance 9 9 9 5 C L Examination 9 11 9 6 Power Unit Examination 9 12 10 TROUBLESHOOTING 10 1 11 PART LIST 11 1 11 1 Model P 5050 TEG 11 2 11 2 Model P 5050 Burner 11 5 11 3 Model P 5050 Fuel System 11 6 11 4 Model P 5050 Optional Steel Fuel System 11 7 11 5 Model P 5050 Electrical 12 CATH...

Page 7: ... Vset Versus Time After Ignition Typical Response 7 4 Figure 21 Change in Fuel Gauge Pressure Versus Elevation Above Mean Sea Level Typical 8 1 Figure 22 Change in Vset Versus Air Shutter Adjustment Typical 8 2 Figure 23 Change in Vset Versus Fuel Pressure Adjustment Typical 8 5 Figure 24 CP Interface System Series Wiring Diagram 8 8 Figure 25 CP Interface System Parallel Wiring Diagram 8 8 Figure...

Page 8: ......

Page 9: ... damage to the equipment 1 1 3 Trained Operators Personnel performing installation operation and maintenance work should be properly trained in such functions 1 2 Technical Terms An operator should be familiar with technical terminology Terms of particular significance defined for the model P 5050 are as follows Thermoelectric Generator TEG A device that produces electrical power through the direc...

Page 10: ...Vset measured across the precision load on the output of the electronics without a customer load connected using a voltmeter Required Vset Vset needed to achieve rated power for the present ambient temperature CP Cathodic Protection Thermoelectric generators are used in impressed current sys tems for cathodic corrosion protection of metallic structures such as pipelines CP Interface System An asse...

Page 11: ...Lock CAUTION Inspect the TEG for damage which may have occurred during shipping Please report any damage as soon as possible as it may make the gener ator inoperable Check with the factory before starting a damaged TEG b Assemble the TEG as shown in Figure 3 and mount it on a firm and stable base suf ficiently high above ground level to prevent the TEG from being inundated with water c Connect the...

Page 12: ... the TEG a Disconnect the customer load from the TEG terminals 7 and 8 of TB 1 and allow to stabilize for 15 minutes b Measure the Vset voltage between terminals 5 and 6 c Check the measured Vset value rises to that required as per Power Output Evaluation section Measured Vset will level off after 1 hour from ignition If the measured value is not in its normal operating range then adjust the power...

Page 13: ...stance 3 2 Options Mounting Stand The P 5050 can be conveniently mounted on any platform with four holes spaced as shown in Figure 11 It is important to mount the TEG at a height sufficient to prevent direct flooding or heavy snowfall from interfering with the flow of cooling air A mounting stand is available from GPT Cathodic Protection Interface CP The Cathodic Protection Interface option provid...

Page 14: ...lock which accepts up to 8 AWG wire Opening for 3 4 conduit in the base of the cabinet Fuel Natural Gas 4 9 m3 day 173 ft3 day of Std 1000 BTU SCF 37 7 MJ Sm3 gas Propane 6 4 l day 3 2 US gal day Maximum Supply Pressure 344 kPa 50 psig Minimum Supply Pressure 103 kPa 15 psig Fuel Connection 1 4 MNPT Environmental Ambient Operating Temperature Continuously Running TEG Max 55º C 130º F Min 40º C 40º...

Page 15: ...0 457 2 96 75 18 00 457 MOUNTING HOLES FUEL INLET 1 4 FNPT Figure 1 Overall Dimensions of the P 5050 TEG Depth 686 mm 26 99 in Width 306 mm 12 06 in Height 991 mm 39 01 in Net Weight 41 kg 90 lb Shipping Weight 75 kg 165 lb Mounting Holes 267 mm wide 457 mm deep 10 50 in 18 00 in 3 3 Weights and Measures The following table gives the overall dimensions and weights of the TEG ...

Page 16: ...d have been included for reference only These are the conditions achieved at the Gentherm Global Power Technologies Factory before shipping Note that the fuel pressure is recorded in kPa and the pressure gauge must be adjusted for the altitude as described in Section 8 1 1 Fuel Type L Propane N Natural Gas Output Voltage 12 or 24 Volts SS Stainless Steel Fuel System CP Cathodic Protection Interfac...

Page 17: ...The fuel consumption of the P 5050 at rated power is listed in the table below for various fuels Fuel Consumption at Rated Power Propane Natural Gas lb hr 0 3 gal hr 0 08 kg hr 0 15 L hr 0 29 ft3 hr 2 88 7 2 m3 hr 0 081 0 205 At 20ºC 68ºF At atmospheric pressure and 20ºC 68ºF assuming an energy content of 37 3 MJ m3 or 1000 BTU ft3 Figure 2 Data Plate ...

Page 18: ...ºC 32ºF at 170 kPag 25psig 3 Shall have less than 115 mg m3 approx 150 ppm of H2S 4 Shall have less than 60 mg m3 approx 88 ppm of Mercaptan Sulphur 5 Shall have less than 200 mg m3 approx 294 ppm of total Sulphur 6 Shall have less than 10 CO2 and or N2 by volume nor vary more than 1 CO2 and or N2 during operation 7 Shall have less than 120 mg m3 5 g 100 cu ft of water vapour 8 Shall have less tha...

Page 19: ... POWER UNIT BURNER ASSEMBLY EXHAUST ASSEMBLY SPARK ELECTRODE BAFFLE FUEL SYSTEM 62589 rev3 DATA PLATE INSTRUCTION LABEL Figure 3 P 5050 TEG General Assembly 4 1 Model P 5050 Thermoelectric Generator The TEG generates electrical power from heat energy The overall process is a Provide fuel mix it with air and ignite making heat available b Warm the hot end of a thermoelectric power unit using the av...

Page 20: ... pressure gauge to monitor the fuel pressure and a pressure switch for the SI module The fuel flows through the manifold to the fuel line which connects to an orifice mounted on the front of the burner The orifice contains a jewel with a precisely sized hole to meter the fuel flow into the burner A solenoid valve SV is plumbed between the manifold and fuel line The solenoid valve is controlled by ...

Page 21: ... second purge period and then make another attempt at ignition The SI will attempt 3 ignition trials and if flame detection cannot be maintained the SI will go into Lockout mode The Lockout light on the SI Controller board will turn on and the SI will be powered down The SI Controller board will have to be reset for another attempt at ignition see Section 4 1 2 1 Resetting the SI Controller board ...

Page 22: ...W 8 32 X 1 2 NUT 10 32 316 SS AIR BOX ASSY W INTAKE ARRESTORS Figure 5 Burner General Assembly 4 1 3 Burner The burner conveys gas from the fuel system mixes it with air and transports the mixture to the combustion zone Air passes through a flame arrestor screening out insects and dust and then through a venturi and air shutter assembly allowing for adjustment of the air fuel mixture This mixture ...

Page 23: ...e free movement of ambient air through the cooling fins A fin duct acts as a chimney causing ambient air to rise through the cooling fins thus helping transfer heat away from the thermopile CAUTION Keep cooling fins clean and duct work inlets and outlets clear of obstruc tions Restricting the free flow of cooling air may cause damage to the power unit 4 1 6 Cabinet The power unit burner and fuel s...

Page 24: ...vides a protective load for the power unit Voltage Converter The voltage converter switches the input voltage to another level suit able for the load Nominal 12 or 24 V settings can be selected and the exact output voltage can be fine tuned A B C SW1 TEMP COMP OUTPUT VOLTAGE ADJUSTMENT POT VSR1 ADJUSTMENT POT VSR2 ADJUSTMENT POT 6V BATTERY SI CONTROLLER BOARD AND SI MODULE RESET SWITCH LOCKOUT IND...

Page 25: ...M is open If the generator is below the trip voltage then the connection between NO and COM is open and the connections between NC and COM is closed The trip voltage is adjusted by the pot labeled VSR 1 and VSR 2 adjust on the Limiter board as shown in Figure 7 On Board Current Sense The C L includes an onboard current sense that measures the customer load current The output is across pin 3 and pi...

Page 26: ... TEG without the blocking diode then the TEG will draw power from the station battery if the TEG is off 4 4 Blocking Diode A Blocking Diode is integrated into the C L to allow multiple generators to be connected together in parallel or to allow one or more generators to be combined with alternative energy sources It is connected in series with the output to prevent current from flowing back into t...

Page 27: ...available for use with the TEG The TEG Controller board provides a method of starting and stopping the TEG either locally or remotely using on board buttons SCADA signal interface or system measurements The pressure switch is connected to the TEG Controller when it is added to the system Only if there is fuel available by the closed pressure switch will any requests to start be attempted The TEG C...

Page 28: ...H OPTIONAL TEMPERATURE SENSOR The TEG Controller board has a heartbeat one of three L1 L2 or L3 indicators blinks when it is powered and operating with a supply voltage above 10Vdc The board also has a low power sleep mode when there is no supply voltage it is connected to the battery and sitting in standby or Lockout the heartbeat is very short and less frequent to save battery power Pressing the...

Page 29: ...output Signal to the SCADA system that the SI System failed to start Up to 36V 200mA con tact closure SO4 SCADA Auto output Signal to the SCADA system that the Auto functionality is on Up to 36V 200mA con tact closure SO5 SCADA Local output Signal to the SCADA system that the TEG is operating in the Local mode SCADA start signals are ignored till the mode time out switches back to Remote Up to 36V...

Page 30: ... the adjust able values Up and Down buttons can be used to make changes to adjustable values S7 button Up Operator button for incrementing an adjust ment S8 button Down Operator button for decrementing an adjust ment L4 Indicator Future current measurement display L5 Indicator Future current measurement display L6 Indicator Future current measurement display Blinking for Auto Start adjustment L7 I...

Page 31: ...e Measurement Display on TEG Controller a Press S5 Display to enter the Display mode Each press of S5 Display toggles through the available measurements the corresponding indicator above the display will turn on b Press S5 Display until the display goes off to exit the Display mode It will also automati cally time out and exit Display mode Note The Adjustment mode is not available until the Displa...

Page 32: ...s hazardous i e may contain hazardous gas es such as in a Class 1 Division 2 area then TEG models 1120 1500 are the only GPT TEGs suitable for installation in these hazardous areas The addition of a flame arrestors does not make the Models P 5050 N P 5100 N and P 5100 L TEGs suitable for use in a hazardous area For hazardous area use TEGs require reduced surface temperatures below hazardous gas ig...

Page 33: ...nd Handling The TEG must be kept clear and free from combustible materials gasoline and other flammable vapors and liquids Maintain 900 mm 36 in mini mum clearances from combustible construction to the top sides and back and install over a noncombustible floor WARNING Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appli anc...

Page 34: ... which may have occurred during shipping Please report any damage as soon as possible as it may make the generator inoperable Check with the factory before starting a damaged TEG 5 4 Assembling Follow these steps to assemble the TEG see Figure 10 a Attach the fin duct using the 8 screws and washer supplied inserting the exhaust shield tap into the duct b Attach the rain cap to the top of the cabin...

Page 35: ...ructed will cause overheating of the TEG Allow a minimum of 150 mm 6 in clearance under the cooling fins and 600 mm 36 in above the top of the fin duct Locate the TEG to avoid flooding interfering with the flow of cooling air 5 6 Supplying Fuel This topic describes how to connect the fuel supply and gives background information for consideration when providing fuel to the P 5050 TEG 12 06 306 10 5...

Page 36: ...olated from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at pressures less than 3 5 kPa 0 5 psig d Inspect the fuel lines and fittings to be sure they are free of foreign material e Purge fuel lines of all air WARNING All fuel piping must be in accordance with local regulations 5 6 2 Fuel Considerations Fuel...

Page 37: ...553 Rev 8 Figure 13 Setting up the P 5050 TEG REGULATOR CAP SOLENOID VALVE PRESSURE SWITCH SPARK ELECTRODE PRESSURE GAUGE PRESSURE REGULATOR FUEL INLET VALVE VENT LINE POWER UNIT FUEL LINE REGULATOR ADJUSTING SCREW 62954 rev1 VENTURI ADJUSTMENT SCREW ...

Page 38: ...PG Gas Supply Considerations If remote Propane LPG gas supply system is used consider the following Location Propane LPG tanks and cylinders must be located outdoors in a well ventilated area at least 3 meters 10 ft from the TEG unless directed otherwise by the local authority having jurisdiction Mounting Each tank or cylinder must be set on a firm level water proof base located on consolidated gr...

Page 39: ...Gentherm Global Power Technologies 5 7 P 5050 62553 Rev 8 Figure 14 Wiring Diagram P 5050 TEG for 12 or 24 V ...

Page 40: ...Gentherm Global Power Technologies 5 8 P 5050 62553 rev 8 Figure 15 Wiring Diagram P 5050 TEG for 12 or 24V with optional TEG Controller ...

Page 41: ...Gentherm Global Power Technologies 5 9 P 5050 62553 Rev 8 Figure 16 Wiring Diagram P 5050 TEG for 6 7V ...

Page 42: ...wires to TB 1 terminals 7 and 8 6 7 V see Figure 14 The load is connected directly to the power unit 12 or 24 V see Figure 15 or Figure 16 if TEG Controller present 5 8 Installation of Optional CP Interface System The CP interface is normally shipped ready for operation attached to the TEG If it was shipped separately install as follows Note Before installing inspect for obvious dents and broken c...

Page 43: ...iagram for your application b Run the CP interface system wires to the TEG as per Figure 14 15 or 16 as appro priate and terminate to TB 1 5 8 3 Connection of CP Load Wire the CP load directly to the CP interface system Feed the CP anode and cathode load cables into the CP box and terminate TYPICAL P5050 TEG CATHODIC PROTECTION BOX OPENING FOR 1 INCH CONDUIT TERMINAL ACCEPTS UP TO 9mm 00AWG WIRE A...

Page 44: ...Gentherm Global Power Technologies 5 12 P 5050 62553 rev 8 ...

Page 45: ...ve Note Once the TEG is started re closing the manual shut off valve will stop it If the optional TEG Controller board is installed Press the Start S1 button or send a SCADA Start signal to the TEG Controller board Note Once the TEG is started pressing the Stop S2 button or sending a SCADA Stop signal to the TEG Controller board will stop it WARNING When the TEG is operating surface temperatures i...

Page 46: ...Gentherm Global Power Technologies 6 2 P 5050 62553 rev 8 ...

Page 47: ...f the TEG is affected by the ambient temperature surrounding the generator at site Power output increases when temperature falls and decreases when temperature climbs A temperature drop of 1ºC from the ambient temperature as indicated on the data plate effects a power increase of 0 2 W and similarly a temperature climb of 1ºC from the ambi ent temperature as indicated on the data plate effects a p...

Page 48: ...W and Vset of 5 88 V for a temperature of 22ºC is marked on the TEG Vset Vsetref Tref T 0 006 5 88 22 35 0 006 5 88 13 0 006 5 88 0 078 5 88 0 078 5 61 V Similarly power from the power unit at begining of life is Pset Psetref Tref T 0 184 67 22 35 0 184 67 22 35 0 184 67 13 0 184 67 2 39 67 2 39 64 61 W 7 1 2 Determining Vset and Rated Power Graphically A good approximation to Vset and rated power...

Page 49: ...or for the reference Vset voltage and determine the required Vset for the present ambient temperature See Working out Required Vset or Setup Power topic above or Alternative Method of Working out Required Vset or Setup Power c Connect a voltmeter between terminals 5 and 6 This is the measured Vset and should tend towards the required Vset It will climb as shown in Figure 20 Caution Do not allow me...

Page 50: ...r some time a Disconnect the customer load from the TEG terminals 7 and 8 of TB 1 and allow to stabilize for 15 minutes b Consult the data plate inside TEG door for the reference Vset voltage and determine the required Vset for the present ambient temperature See Working out Required Vset or Setup Power topic above or Alternative Method of Working out Required Vset or Setup Power c Connect a voltm...

Page 51: ...41 to 48 kPa 6 0 to 7 0 psi for natural gas and 48 to 55 kPa 7 0 to 8 0 psi for propane Note Good record keeping is necessary for long term follow up Use the TEG Performance Log located at the end of this manual for recording details each time adjustments are made or servicing is carried out Figure 21 Change in Fuel Gauge Pressure Versus Elevation Above Mean Sea Level Typical ...

Page 52: ...r Elevation Confirm the fuel gauge pressure is at or below the pressure indicated on the data plate If the TEG is located at a different altitude than the factory 792 m 2600 ft the pressure will also be different Use Figure 21 to determine how much to adjust the fuel pressure Example If the site elevation is 1000 m 3281 ft then 2 5 kPa 0 36 psig must be added to the pressure on the data plate Figu...

Page 53: ...l it is free from the Air Lid This will completely close off air intake ii Turn air adjustment screw clockwise 1 2 to 2 5 turns for natural gas 2 4 5 to 5 turns for propane This is generally a good starting point for air adjustment After voltage has risen to a stable point further adjustments can be made with 1 4 turn adjustments d Close the doors wait ten minutes then measure and record Vset If V...

Page 54: ...Oppm For Natural Gas when using as measured CO2 percentage and COppm When using as measured O2 percentage and COppm Where COAFppm Carbon monoxide air free ppm COppm As measured combustion gas carbon monoxide ppm O2 Percentage of oxygen in combustion gas as a percentage CO2 Percentage of carbon dioxide in combustion gas as a percent age The model P 5050 does not produce excessive concentrations of ...

Page 55: ...sult Data Plate Label Located on inner door for Reference Factory Fuel Pressure c Wait ten minutes then measure Vset and record If the TEG can not be adjusted to match required Vset value then a problem exists with one of the TEG s systems If necessary see Troubleshooting section for guidance d Tighten the lock nut and replace the cover on the fuel regulator 8 2 Adjustment of C L A C L is availabl...

Page 56: ...the bottom of the TEG cabinet and follow the main wiring harness around the loop and into the lower hole of the Electronics enclosure door Continue to route the wires along the bottom of the electronics enclosure and then connect to the VSR terminals on the left side of the limiter board Refer to Figure 7 for the connector pinout Note Due to the integrated blocking diode set the no load trip point...

Page 57: ...ompensation for adjustment of the output voltage a Switch 1 ON b Switch 2 OFF c Connect a DC Voltmeter to the customer Load Terminals d Turn the output voltage adjustment pot until the desired voltage is reached per bat tery manufacturer s recommended charging voltage for 25ºC with no temperature compensation e Set SW1 on the Limiter board to the following configuration to enable temperature compe...

Page 58: ...eter to easily see the change in power when adjusting the variable resistor Once the resistor has been adjusted to give the desired power output check that all electrical connections are tight and lastly recheck that the desired power output has not changed Note TEG fuel pressure may be adjusted to fine tune the CP output Fuel pressure within 10 of that marked on the data plate is recommended to p...

Page 59: ...ptional Remote Start System TEG Controller The TEG Controller has an on board 3 digit 7 segment display It is used to display mea sured values as well as make adjustments to some variables 8 5 1 Measurement Display on TEG Controller a Press S5 Display button to enter the Display mode Each press of the Display but ton toggles through the available measurements the corresponding indicator above the ...

Page 60: ...Gentherm Global Power Technologies 8 10 P 5050 62553 rev 8 ...

Page 61: ...interval depends on the site conditions fuel purity environment etc and must be established based on site records Field experience indicates that a properly installed TEG usually requires maintenance only once a year At least once a year evaluate Vset as per the procedure below This should be the first pro cedure during any service visit and will determine what further service may be needed 9 1 1 ...

Page 62: ... is functioning well and requires only a routine service Proceed with Routine Service per topic below III If measured voltage is more than 0 1 V below required Vset The cause must be determined Refer to the last entry in the TEG Performance Log In the log check if the TEG was left operating at the correct Vset during the last service visit Remember that Vset changes with ambient conditions If the ...

Page 63: ...that is required unless other maintenance is indicated by the Vset evaluation Follow these steps to perform a routine annual service a Stop the TEG and pause to let cool See Startup and Shutdown Section 6 b Drain the pressure regulator sediment bowl See Draining the Sediment Bowl Section 9 2 1 c Replace the fuel filter in the pressure regulator See Fuel Filter Replacement Section 9 2 2 d Check the...

Page 64: ...he cock Place empty container beneath drain cock to prevent spillage inside the cabinet c Close drain cock d Leak check the drain cock WARNING Check for fuel leaks after any fuel system service 9 2 2 Fuel Filter Replacement Follow these steps to remove the fuel filter a Shut off the fuel supply to the TEG and allow to cool b Drain the sediment bowl by opening the drain cock Place empty con tainer ...

Page 65: ...ce 9 2 3 Fuel Orifice Inspection Follow these steps to inspect the fuel orifice a Shut off the fuel supply to the TEG and allow to cool b Disconnect the fuel line from the solenoid valve c Disconnect the other end of the fuel line from the orifice from the lid of the air box d Remove the orifice fitting from the lid of the air box e Visually check the orifice hole It should be free from any obstru...

Page 66: ...ws from each side of the cabinet baffle and remove baffle from cabinet Note Try not to disturb the air shutter setting g Remove the 2 wing nuts and 4 screws from air box lid h Clean the screens by forcing air through it or washing in water i Replace Air Box lid cabinet baffle fuel system and fittings Note If the air shutter setting was disturbed turn the venturi adjusting screw counterclock wise u...

Page 67: ...connection and the orange wire connections of the pressure switch electrical connections d Remove fuel line between the solenoid valve and orifice fitting e Remove the 2 bolts mounting the fuel regulator to the cabinet wall and remove the fuel system f Remove the 2 screws from each side of the cabinet baffle and remove baffle from cabinet Note Try not to disturb the air shutter setting 62596 rev 0...

Page 68: ... Slide the burner assembly out of the burner chamber Follow these steps to inspect the burner a Check the venturi assembly If it looks severely corroded it should be replaced Make sure the venturi is properly located in the venturi tube see Figure 5 and that the ven turi is facing the proper direction b Check the air screens for any dust and debris If any are found it should be cleaned c Check the...

Page 69: ...ck the Spark Electrode WARNING Remove the 2 position screw connector from the SI Controller board plugged into the header labeled IGN to prevent accidental high voltage shock from the igniter cable Follow these steps to check the spark electrode a Remove the spark electrode by loosening the wing nut and sliding the electrode out see Figure 13 b Inspect the electrode for any cracks in the ceramic r...

Page 70: ...ance measured across the switch is near zero which indicates the switch being closed Replace the pressure switch if necessary Note Switch should close at pressures above 13 8 kPa 2 psig e Remove fuel pressure from the switch by closing the manual gas valve and use a wire to join the two removed pressure switch wires together This will cause the system to attempt a start which will release the trap...

Page 71: ...onics assembly and the spark return connection near the high voltage coil on the SI Controller board b Verify that the TEG bonding wire is connected between the electronics assembly and the TEG cabinet Both connections are required for the SI module to properly detect flame recognition Refer to Figure 14 15 or 16 9 4 6 Check Solenoid Valve a If at the beginning of sparking the solenoid is not hear...

Page 72: ... it still will not provide expected lower to the load then the power unit should be checked 9 6 Power Unit Examination The power unit normally requires no maintenance If after maintaining and adjusting all other systems TEG will not produce required power consider examining the power unit Use the procedures below to help determine if the power unit could be damaged 9 6 1 Check for Internal Short F...

Page 73: ...t if the TEG was just started from cold e Record Vset f While observing the voltmeter display remove the Connection from Terminal 1 of TB1 creating an open circuit condition and note the momentary voltage On a digi tal multi meter this will be the first number displayed after removing the connection within 2 seconds of removing the connection Record the number as the momentary open circuit voltage...

Page 74: ... voltages were measured as 5 88 V and 10 8 V respectively and the precision load resistance was 0 75 ohms then IL 1 38 VL RL 1 38 5 88 0 75 10 59 A RINT Voc VL IL 10 8 5 88 10 59 4 92 10 59 0 46 ohms Internal resistance is acceptable 0 58 ohms For further information or assistance please contact the Customer Service Department at Gentherm Global Power Technologies Figure 29 Momentary Open Circuit ...

Page 75: ...ce Air filter dirty Clean the air filter Maintenance Air shutter adjustment incorrect Adjust the air shutter Adjustment SI system faulty Maintain the SI system Maintenance Burner will ignite but will not continue to burn Supply gas pressure too low Increase the gas supply pressure to the TEG Installation Fuel filter dirty Drain the regulator sediment bowl Maintenance Replace the fuel filter Mainte...

Page 76: ... Fuel orifice size incorrect Replace the orifice Maintenance Fuel pressure adjustment incorrect Adjust TEG fuel manifold pressure Adjustment Safety SOV valve malfunctioning Check the Safety SOV valve Maintenance Air screen dirty Clean the air screen Maintenance Air shutter adjustment incorrect Adjust air shutter Adjustment L C damaged Examine the L C Maintenance L C adjustment incorrect Adjust the...

Page 77: ...ntact Gentherm Global Power Technologies s Customer Service Department at Gentherm Global Power Technologies Customer Service Department Direct 001 403 720 1190 Fax 001 403 236 5575 Switchboard 001 403 236 5556 E mail customer service gentherm com Web www genthermglobalpower com GLOBAL POWER TECHNOLOGIES Unit 16 7875 57th SE Calgary Alberta Canada T2C 5K7 ...

Page 78: ...FLE INNER CABINET P 5050 P 5100 A8 4200 00688 ORIFICE 6 0 0185 5060 N A9 4200 00686 ORIFICE 4 0 0145 5060 L A10 2508 07410 SCREW MACH P H P 8 32 X 1 4 SS A11 2808 00472 WASHER LOCK EXT 8 SS A12 2810 00569 WASHER FLAT 10 SS A13 2810 29696 WASHER LOCK SPRING 10 316 SS A14 2510 00255 SCREW MACH P H P 10 32 X 3 8 SS A15 4900 61984 EXHAUST ASSY P 5050 P 5100 A16 4500 61569 GASKET EXHAUST P 5050 P 5100 ...

Page 79: ...LY P 5050 5100 A24 4900 62113 COVER ASSY UPPER FIN DUCT P 5050 P 5100 A25 4100 61552 FIN DUCT UPPER P 5050 A26 4100 61551 FIN DUCT LOWER P 5050 A27 2514 20535 SCREW HEX HD 1 4 20 X 5 8 SS A28 7000 61555 POWER UNIT SEAT IN P 5050 A29 4900 62114 LEG P 5050 P 5100 A30 2514 00266 SCREW CAP SOC 1 4 20 X 1 2 SS A31 2708 00600 NUT WING 8 32 SST A32 4900 58496 ELECTRODE ASSY FLAME SENSING SI Figure 30 Mod...

Page 80: ...TER CONVERTER ASSY 24V RS P 5050 P 5100 OPTIONAL A37 6300 65206 CP INTERFACE ASSEMBLY P 5050 6 7V NOT SHOWN OPTIONAL A38 6300 65207 CP INTERFACE ASSEMBLY P 5050 12V NOT SHOWN OPTIONAL A39 6300 65245 CP INTERFACE ASSEMBLY P 5050 24V NOT SHOWN OPTIONAL 2400 56980 SENSOR TEMPERATURE TRISTAR TS RTS NOT SHOWN OPTIONAL Figure 30 Model P 5050 TEG A17 A27 A5 A2 A7 62628 rev3 A10 A11 A15 A16 A20 A10 A22 A2...

Page 81: ... 4000 61870 BURNER COVER P 5050 P 5100 B11 4500 62118 AIR BOX ASSY W INTAKE ARRESTORS P 5050 P 5100 B12 4900 63988 AIR BOX ASSY NON FA P 5050 P 5100 B13 4900 07004 PIN MOUNTING SI ELECTRODE B14 2756 07005 NUT WING 5 16 18 SS B15 2710 00601 NUT WING 10 32 SS B16 4500 61862 AIR BOX MACHINED P 5050 P 5100 B17 2710 63957 NUT LOCK HEX 10 32 316SS McMASTER CARR 95885A420 B18 4900 63954 AIR SHUTTER ASSY ...

Page 82: ... P 5100 C8 3200 00691 GAUGE Pressure 0 15 PSI C9 3041 07996 NIPPLE HEX 1 8 NPT 316 SS SS 2 HN C10 3094 27927 VALVE Solenoid Burkert 6013 463305 2mm ORIFICE 2WAY NC 1 8FNPT Brass C11 3021 20977 CONNECTOR 1 4 TB X 1 8 MNPT SS 400 1 2 C12 3400 06471 SWITCH PRESSURE 1 6 PSI 76056 DB 1 6 0 5 C13 3021 00380 CONNECTOR 1 4 TB X 1 4 MNPT 316 SS SS 400 1 4 C14 4200 61865 VENT TUBE ASSY REGULATOR SS P 5050 P...

Page 83: ...NPT X 1 5 LG 316 SS D7 4200 61991 MANIFOLD BLOCK FUEL SYSTEM P 5050 P 5100 D8 3200 00691 GAUGE Pressure 0 15 PSI D9 3041 07996 NIPPLE HEX 1 8 NPT 316 SS SS 2 HN D10 3091 62558 VALVE SOLENOID BURKERT 6013 6013 A02 0BBVANM81 5 012 DC 02 PD02 2mm ORIFICE 2WAY NC 1 8 FNPT SS D11 3021 20977 CONNECTOR 1 4 TB X 1 8 MNPT SS 400 1 2 D12 3400 61849 SWITCH PRESSURE 1 6 PSI NO PLATED STEEL HOBBS 76056 0000001...

Page 84: ...NYLON 0 8125 LG 6 HOLE DIGIKEY 492 1112 ND E19 2706 00604 NUT Hex 6 32 SST E20 2506 54087 SCREW MACH P H P 6 32 X 1 4 SS E21 2900 63960 WASHER RETAINING SOUTHCO 09 6 1 E22 2900 63959 SCREW FAST LEAD KNURLED SS SOUTHCO 09 13 102 26 E23 4900 63039 DEAD FRONT ELECTRICAL ASSY P 5050 P 5100 E24 2400 63126 PCB ASSY LC DC DC CONVERTER MEDIUM POWER P 5050 P 5100 E25 2400 64879 PCB ASSY LC DC DC LIMITER ME...

Page 85: ...athode cables enter the cabinet at the bottom and connect directly to the heavy duty terminal block Refer to Figure 35 for locations and description of the major components of the CP Interface Cabinet 12 1 1 Meter The duel 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 35 Cathodic Protect...

Page 86: ...nnecting 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 12 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 o...

Page 87: ...m for various TEGs are listed below GPT TEG Item System Description P 5050 6 7 6300 65206 CP Interface Assembly P 5050 6 7V P 5050 12 6300 65207 CP Interface Assembly P 5050 12V P 5050 24 6300 65245 CP Interface Assembly P 5050 24V P 5100 6 7 6300 65208 CP Interface Assembly P 5100 6 7V P 5100 12 6300 65209 CP Interface Assembly P 5100 12V P 5100 24 6300 65246 CP Interface Assembly P 5100 24V ...

Page 88: ...Gentherm Global Power Technologies 12 4 P 5050 62553 rev 8 Figure 38 Cathodic Protection System Parts Identification ...

Page 89: ... to Read AMPS 1 7 2900 03192 Plug Bumper 1 8 2900 01947 Grommet Rubber 1 4 x 1 8 5 9 4400 02284 CP Meter Adjust Assy 1 10 1600 01851 Weather Stripping 3 8 x 1 8 THK 39 11 2514 00258 Screw mach P H P 1 4 x 20 x 5 8 SS 4 12 2814 00473 Washer Lock ext 1 4 SS 8 13 2714 00611 Nut Hex 1 4 20 SS 8 14 2708 00606 Nut Hex 8 32 SS 3 15 2010 00208 Term Ring Yellow 10 3 16 2010 00201 Term Ring Yellow 1 4 3 17 ...

Page 90: ...69 Washer Lock Spring 8 SS 6 34 2810 00539 Washer Lock Spring 10 CAD 2 35 2508 00254 Screw Mack P H P 8 32 x 3 8 SS 7 36 2808 00468 Washer Lock Int 8 SS 10 37 3600 04795 Label Cathodic Protection Interface 1 38 Part of Item 29 Button Red 61F 675 For ALCO Switch 11 Item Part No Description QTY Figure 38 Parts Table Cont ...

Page 91: ...aust tube as sembly and burner configuration The ducts and legs are replaced with mounting bars for mount ing to the HRS option see Figure 40 Item G37 13 2 Installation Each HRS kit is provided with an installation manual to provide instruction for mounting the HRS to the exterior wall of the building Refer to the Heat Recovery System HRS Installation Manual part number 3900 66683 to complete the ...

Page 92: ...Gentherm Global Power Technologies 13 2 P 5050 62553 rev 8 13 3 TEG Operation Refer to Sections 2 10 of this manual for TEG operations ...

Page 93: ...508 07410 SCREW MACH P H P 8 32X1 4 SS G18 See Fig 30 G19 3600 62570 ELECTRODE ASSY FLAME SENSING SI OR 4900 58496 ELECTRODE ASSY SI 5220 G20 G25 See Fig 30 G26 4900 65709 RAIN DEFLECTOR HRS P 5050 P 5100 G27 2514 65724 SCREW HEX HD 1 4 20 X 2 SS G28 3600 62131 MOUNTING BAR HRS P 5050 P 5100 Figure 40 Model P 5050 HRS Configuration Item Part No Description 66660 rev0 G1 G26 G17 G7 G4 G28 G27 G29 G...

Page 94: ... P 5100 J8 J9 See Fig 31 J10 4000 66631 BURNER COVER TOP ELECTRODE P 5050 P 5100 J11 4500 66635 AIR BOX ASSY TOP ELECTRODE P 5050 P 5100 J12 J17 See Fig 31 J18 4900 66632 LID W ARRESTORS ASSEMBLY TOP ELECTRODE P 5050 P 5100 J19 J23 See Fig 31 Figure 41 Model P 5050 HRS Burner Item Part No Description B15 B22 B14 B11 67104 rev 0 J1 J2 J3 J4 J5 J6 J7 J8 J9 J10 B16 B17 B25 B18 B20 B20 B24 B19 B17 B13...

Page 95: ...8 14 TEG PERFORMANCE LOG MODEL NO TEG SERIAL NO FUEL TYPE LIMITER CONVERTER SERIAL NO CP INTERFACE SERIAL NO DATE TIME AMBIENT TEMP ºC REQUIRED POWER W REQUIRED v SET V MEASURED v SET V MEASURED POWER W FUEL PRESSURE OPEN CIRCUIT VOLTAGE V MAINTENANCE REMARK ...

Page 96: ...8 14 TEG PERFORMANCE LOG MODEL NO TEG SERIAL NO FUEL TYPE LIMITER CONVERTER SERIAL NO CP INTERFACE SERIAL NO DATE TIME AMBIENT TEMP ºC REQUIRED POWER W REQUIRED v SET V MEASURED v SET V MEASURED POWER W FUEL PRESSURE OPEN CIRCUIT VOLTAGE V MAINTENANCE REMARK ...

Page 97: ...8 14 TEG PERFORMANCE LOG MODEL NO TEG SERIAL NO FUEL TYPE LIMITER CONVERTER SERIAL NO CP INTERFACE SERIAL NO DATE TIME AMBIENT TEMP ºC REQUIRED POWER W REQUIRED v SET V MEASURED v SET V MEASURED POWER W FUEL PRESSURE OPEN CIRCUIT VOLTAGE V MAINTENANCE REMARK ...

Page 98: ...Gentherm Global Power Technologies 14 4 P 5050 62553 rev 8 ...

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