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Gentherm P-5100, Operating Manual

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Gentherm P-5100 Operating Manual Download Page 38

 

 

INSTALLATION 

Gentherm Global Power Technologies  

 

Page 31 

 

 

Figure 15 - Wiring Diagram P-5100 TEG for 12 or 24V with optional TEG Controller 

 
Connect the customer load directly to the TEG using the following procedure. If an optional 
CP interface system is applicable, then see Installation of Optional CP Interface System topic 

in section 5.8. 
 
Follow these steps to connect the customer load: 

1.

 

Bring the customer load wires through the provided hole in the bottom of the TEG 
cabinet  using  appropriate  cable  connectors  for  the  wire  or  cable  being  used.  Allow 

enough wire to connect to the terminal block TB-1. See Figure 16. 

2.

 

Connect the customer load wires to TB-1 terminals 7(+) and 8(-): 
12 or 24 V: see Figure 15 if TEG Controller present. 

Summary of Contents for P-5100

Page 1: ...t use any phone in your building Immediately call your gas supplier from a neighbour s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department Insta...

Page 2: ...z imm diatement votre fournisseur de gaz d un t l phone dans un b timent voisin si possible Suivez les instructions du fournisseur de gaz Si vous ne pouvez pas atteindre votre fournisseur de gaz appel...

Page 3: ...57th Street SE Calgary Alberta Canada T2C 5K7 Main 1 403 236 5556 Fax 1 403 236 5575 www genthermglobalpower com NOTICE TO INSTALLER These instructions shall be left with the consumer to retain them...

Page 4: ......

Page 5: ...SS DESCRIPTION 11 4 1 MODEL P 5100 THERMOELECTRIC GENERATOR 11 4 2 CONVERTER LIMITER 16 4 3 TEMPERATURE COMPENSATION 17 4 4 BLOCKING DIODE 18 4 5 OPTIONAL CATHODIC PROTECTION INTERFACE SYSTEM 19 4 6 O...

Page 6: ...C MAINTENANCE 49 9 2 FUEL SYSTEM MAINTENANCE 51 9 3 BURNER MAINTENANCE 54 9 4 SI SYSTEM MAINTENANCE 56 9 5 C L EXAMINATION 60 9 6 POWER UNIT EXAMINATION 60 10 TROUBLESHOOTING 63 11 PART LIST 65 11 1 M...

Page 7: ...19 Vset Versus Time After Ignition Typical Response 38 Figure 20 Change in Fuel Gauge Pressure Versus Elevation Above Mean Sea Level 40 Figure 21 Change in Vset Versus Air Shutter Adjustment 41 Figur...

Page 8: ...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...

Page 9: ...ion 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 Protectio...

Page 10: ...one spare NOTE Inspect the TEG for damage that 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 sta...

Page 11: ...the TEG 1 Disconnect the customer load from the TEG terminals 7 and 8 of TB 1 and allow to stabilize for 15 minutes 2 Measure the Vset voltage between terminals 5 and 6 3 Check the measured Vset valu...

Page 12: ...ted 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...

Page 13: ...he cabinet Fuel Natural Gas 9 4 m3 day 332 ft3 day of Std 1000 BTU SCF 37 7 MJ Sm3 gas High BTU Natural Gas 6 3 m3 day 222 ft3 day of 1500 BTU SCF 56 5 MJ Sm3 gas 7 8 m3 day 277 ft3 day of 1200 BTU SC...

Page 14: ...ives the overall dimensions and weights of the TEG Depth 790 mm 31 11 in Width 309 mm 12 17 in Height 991 mm 39 12 in Net Weight 60 kg 132 lb Shipping Weight 83 kg 183 lb Mounting Holes 267 mm wide 45...

Page 15: ...t Inter Purge Time 10 seconds Spark Gap Nominal 4 8 mm 0 19 in Minimum 3 3 mm 0 13 in Maximum 6 3 mm 0 25 in Continuous Operating Time Without Charge 120 minutes with full charged 6V 5 Ah batteries 25...

Page 16: ...the conditions achieved at the Gentherm Global Power Technologies GPT factory before shipping Note that the fuel pressure is recorded in kPa and that the pressure gauge must be adjusted for the altit...

Page 17: ...re than 0 C 32 F at 170 kPag 25 psig 3 Shall not contain more than 115 mg Sm3 approx 170 ppm of H2S 4 Shall not contain more than 60 mg Sm3 approx 88 pmm of Mercaptan Sulphur 5 Shall not contain more...

Page 18: ...t energy The overall process is 1 Provide fuel mix it with air and ignite making heat available 2 Warm the hot end of a thermoelectric power unit using the available heat of combustion 3 Cool the cold...

Page 19: ...to a manifold on which is mounted a 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 orifi...

Page 20: ...e SI will stop sparking and the SI will continue to monitor the presence of flame at the electrode If the SI did not detect combustion for a period of 7 seconds it will stop sparking and close the sol...

Page 21: ...then through a venturi and air shutter assembly allowing for adjustment of the air fuel mixture This mixture leaves the venturi and passes through a burner screen that anchors the flame Combustion cha...

Page 22: ...Cooling Fins and Fin Duct Cooling of the thermopile is done by the free movement of ambient air through the cooling fins A fin duct acts as a chimney causing ambient air to rise through the cooling f...

Page 23: ...el P 5050 or P 5100 TEG requiring either 12 or 24 V DC nominal output It consists of two separate circuits operating together The first is a DC DC Converter that converts the input to 12 or 24V The se...

Page 24: ...larm or other processes When the generator is above the trip voltage the connection between NO and COM is closed and the connection between NC and COM is open If the generator is below the trip voltag...

Page 25: ...ller board is installed and system measurements desired to be used for start stop control an optional external temperature sensor can be attached to one of the posts of the battery Note there is no ef...

Page 26: ...EG Controller when it is added to the system Only if there is fuel available by the closed pressure switch will any requests be attempted The TEG Controller provides an ignition request signal to the...

Page 27: ...PROCESS DESCRIPTION Gentherm Global Power Technologies Page 20 Figure 9 TEG Controller Assembly...

Page 28: ...t output Signal to the SCADA system that the SI System failed to start Up to 36V 200mA contact closure SO4 SCADA Auto output Signal to the SCADA system that the Auto functionality is on Up to 36V 200m...

Page 29: ...perature measurement display L12 Indicator Negative value displayed on 7 segments L13 Indicator Local mode indicator L14 Indicator Future option display L15 Indicator Auto mode indicator FE Fuse Volta...

Page 30: ...to the variable 3 Press S6 Adjust until the display goes off to exit the Adjustment mode It will also automatically time out and exit Adjustment mode All variable changes are saved upon exit of the Ad...

Page 31: ...ignition temperatures addition of air intake and exhaust flame arrestors and other modifications It is the customers responsibility concerning the installed location and operation of a TEG with or wi...

Page 32: ...d 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 appliance and to replace any par...

Page 33: ...ernal Lock one spare NOTE Inspect the TEG for damage 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...

Page 34: ...must be level and sturdy enough to support the 83 kg 183 lb mass of the TEG CAUTION Operation of the TEG in locations where cooling air flow may be obstructed will cause overheating of the TEG Allow a...

Page 35: ...t must be approved for use with gaseous fuels Tape is not recommended 3 Connect the fuel line and test all joints for leaks using a commercial leak detector fluid such as Snoop NOTE The TEG and its ma...

Page 36: ...se of an additional primary regulator is recommended This will hold the input pressure relatively constant Clean Fuel The fuel used to operate the P 5100 TEG must be clean and dry See Technical Specif...

Page 37: ...ng jurisdiction Mounting Each tank or cylinder must be set on a firm level water proof base located on consolidated ground at grade level The base must extend at least 300mm 1 ft from all sides of the...

Page 38: ...hen see Installation of Optional CP Interface System topic in section 5 8 Follow these steps to connect the customer load 1 Bring the customer load wires through the provided hole in the bottom of the...

Page 39: ...lecting and connecting a solar charge controller 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 separat...

Page 40: ...G using the following procedure Follow these steps to wire the CP interface system to the TEG 1 Check the wiring diagram Figure 14 or Figure 15 as applicable and choose the wiring diagram for your app...

Page 41: ...off valve NOTE Once the TEG is started re closing the manual shut off valve will stop it 2 If the optional TEG Controller board is installed Press the Start S1 button or send a SCADA Start signal to t...

Page 42: ...ling fins This means the power output of the TEG is affected by the ambient temperature surrounding the generator at site Power output increases when temperature falls and decreases when temperature c...

Page 43: ...herm Global Power Technologies GPT Customer Service Department for guidance Example Ambient temperature at site is 35 C Set up power of 127 W and Vset of 6 8 V 22 C is marked on the TEG Data Plate Vse...

Page 44: ...nit warms and the resulting temperature rise produces power Follow these steps to check Vset after ignition 1 Disconnect the customer load from the TEG terminals 7 and 8 of TB 1 and allow to stabilize...

Page 45: ...reater than required Vset then the fuel pressure needs to be reduced Figure 19 Vset Versus Time After Ignition Typical Response 7 2 2 Examining Vset after Running for Some Time Once the TEG has been r...

Page 46: ...ed Vset and should match the required Vset for the present temperature CAUTION Do not allow measured Vset to exceed that required Vset for present ambient temperature otherwise overheating may cause i...

Page 47: ...l gas P 5100N 48 to 55 kPa 7 0 to 8 0 psi for high BTU natural gas P 5100H ONLY 41 to 48 kPa 6 0 to 7 0 psi for propane P 5100L NOTE Good record keeping is necessary for long term follow up Use the TE...

Page 48: ...is located at a different altitude than the factory 792 m 2600 ft the fuel pressure will need to be different to obtain the same results also be different Use Figure 20 to determine how much to adjus...

Page 49: ...nts 5 Close the doors wait ten minutes then measure and record Vset a If Vset is greater than the original value or did not change the burner adjustment is air rich see Figure 21 turn the adjusting sc...

Page 50: ...n combustion gas as a percentage CO2 Percentage of carbon dioxide in combustion gas as a percentage The model P 5100 does not produce excessive concentrations of CO if adjusted properly 8 1 3 Fuel Pre...

Page 51: ...ock nut 2 Turn the adjusting screw clockwise to increase pressure until the required change in pressure is obtained NOTE Consult Data Plate Label Located on Inner Door for Reference Factory Fuel Press...

Page 52: ...ect to the VSR outputs route the wire in through the hole provided in the bottom of the TEG cabinet and follow the main wiring harness around the loop and into the lower hole of the Electronics enclos...

Page 53: ...voltage for 25 C with no temperature compensation 14 Set SW1 on the Limiter board to the following configuration to enable temperature compensation a Switch 1 OFF b Switch 2 ON 8 4 ADJUSTMENT OF OPTIO...

Page 54: ...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 prevent flame out Figure 23 CP Interface System Series Wiring Di...

Page 55: ...E OPTIONAL REMOTE START SYSTEM TEG CONTROLLER The TEG Controller has an on board 3 digit 7 segment display It is used to display measured values as well as adjust some variables 8 5 1 Measurement Disp...

Page 56: ...d 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 procedu...

Page 57: ...is more than 0 1 V below required Vset The cause must be determined Refer to the last entry in the TEG Performance Log From the log check if the TEG was left operating at the correct Vset during the...

Page 58: ...t Section 9 2 2 4 Check the fuel orifice for clogging and replace if necessary See Fuel Orifice Replacement Section 9 2 3 5 Remove any debris sand or dust from the cooling fins air lid screens and cab...

Page 59: ...cabinet 3 Remove the four screws from the bottom of the regulator 4 Remove the filter and gasket See Figure 25 Figure 25 Pressure Regulator Follow these steps to install the fuel filter 1 Install the...

Page 60: ...e air box 4 Remove the orifice fitting from the lid of the air box 5 Visually check the orifice hole It should be free from any obstructions Replace it if necessary It is recommended a magnifying glas...

Page 61: ...orange wire connections of the pressure switch electrical connections 4 Remove fuel line between the solenoid valve and orifice fitting 5 Remove the fuel system same as section 9 3 2 5 6 Remove the 2...

Page 62: ...re 26 Burner Assembly Cross Section Follow these steps to remove the burner 1 Shut off the fuel supply to the TEG and allow to cool WARNING If TEG has not cooled sufficiently it can be very hot 2 Disc...

Page 63: ...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 venturi is facing the proper direction 2 Check the air screens...

Page 64: ...the wing nut and sliding the electrode out see Figure 13 2 Inspect the electrode for any cracks in the ceramic rod If any cracks are found the electrode must be replaced 3 Slide the electrode back in...

Page 65: ...e 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 5 Remove fuel pressure from the switc...

Page 66: ...s turn on If it is on check that the two boards are connected with good contact otherwise replace the SI module 9 4 5 Check the spark return path for the SI module Follow these steps to check the spar...

Page 67: ...tput voltage adjustment pot shown in Figure 8 If the unloaded output voltage measured across terminals 7 and 8 does not change when the adjustment pot is altered the C L needs replacing NOTE If the TE...

Page 68: ...e Follow these steps to check the power unit s internal resistance 1 Start the TEG 2 Disconnect the customer load from terminals 7 and 8 of TB 1 3 Connect a voltmeter between terminals 5 and 6 4 Pause...

Page 69: ...uit voltage V VL Load voltage V IL Load current A RL Precision load resistance OHM Vset Voltage measured across terminals 5 and 6 V Example If the load voltage and momentary open circuit voltages were...

Page 70: ...irty 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...

Page 71: ...uel 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 Ma...

Page 72: ...hat form the equipment For parts and service please contact Gentherm Global Power Technologies Customer Service Department at 16 7875 57th Street SE Calgary Alberta T2C 5K7 Direct 403 720 1190 Fax 403...

Page 73: ...1 4 20 X 3 1 2 SS 1 1 2 THREAD A3 557 WASHER FLAT 1 4 SS A4 62064 BAFFLE INNER CABINET P 5050 P 5100 A5 7324 SCREW Mach P H P 8 32 X 1 2 SS A6 472 WASHER Lock EXT 8 SS A7 62124 EXHAUST SHIELD OUTER B...

Page 74: ...SS A19 63985 EXHAUST TUBE ASSY NON FA P 5050 P 5100 A20 62126 EXHAUST TUBE ASSY P 5050 P 5100 A21 62065 LINER EXHAUST P 5050 P 5100 A22 62067 RAIN CAP ASSEMBLY P 5050 5100 A23 62113 COVER ASSY UPPER F...

Page 75: ...P 5050 P 5100 A35 611 NUT HEX 1 4 20 SS A36 65176 LIMITER CONVERTER ASSY 12V P 5050 P 5100 OPTIONAL A37 65175 LIMITER CONVERTER ASSY 24V P 5050 P 5100 OPTIONAL A38 63515 LIMITER CONVERTER ASSY 12V RS...

Page 76: ...015 5030 5060 5120 1120 B5 873 SCREEN BURNER 5120 1120 B6 694 INSERT RING BURNER 5120 5060 5030 1120 B7 61869 INSULATION BLOCK P 5050 P 5100 B8 61871 SPACER VENTURI P 5050 P 5100 B9 62056 VENTURI P 51...

Page 77: ...ure 30 Model P 5100 Burner Item Part No Description B17 27901 WASHER BOWED 5 MM A2 SS Spaenaur 681 821 B18 61990 LID W ARRESTORS ASSEMBLY P 5050 P 5100 B19 00472 WASHER Lock EXT 8 SS B20 7324 SCREW Ma...

Page 78: ...0 C5 58949 PLUG 1 4 NPT X 7 8 STEEL UMBRAKO 1105766 C6 501 NIPPLE HEX 1 4 NPT X 1 1 8 BRASS C7 61991 MANIFOLD BLOCK FUEL SYSTEM P 5050 P 5100 C8 691 GAUGE Pressure 0 15 PSI C9 7996 NIPPLE HEX 1 8 NPT...

Page 79: ...D4 22364 REGULATOR FISHER 67CFR 0 20 PSI SOUR GAS D5 20428 PLUG 1 4 NPT HEX 316 SS SS 4 P D6 2359 NIPPLE HEX 1 4 NPT X 1 5 LG 316 SS D7 61991 MANIFOLD BLOCK FUEL SYSTEM P 5050 P 5100 D8 691 GAUGE Pres...

Page 80: ...P 5100 OPTIONAL STAINLESS STEEL FUEL SYSTEM Cont d Figure 32 Model P 5100 SS Fuel System Item Part No Description D13 380 CONNECTOR 1 4 TB X 1 4 MNPT 316 SS SS 400 1 4 D14 61865 VENT TUBE ASSY REGULAT...

Page 81: ...4 SCREW MACH P H P 8 32 X 1 2 SS E7 63136 STANDOFF 6 32 M F 1 4 HEX ALUM 1 12 LG E8 63096 SI BOARD CHANNEL PROD 2021 90 MICRO 50N 12 3 3 7 10 0 E9 254 SCREW MACH P H P 8 32 X 3 8 SS E10 472 WASHER LOC...

Page 82: ...102 26 E23 63039 DEAD FRONT ELECTRICAL ASSY P 5050 P 5100 E24 63126 PCB ASSY LC DC DC CONVERTER MEDIUM POWER P 5050 P 5100 E25 64879 PCB ASSY LC DC DC LIMITER MEDIUM POWER P 5050 P 5100 E26 58437 SCR...

Page 83: ...nd cathode cables enter the cabinet at the bottom and connect directly to the heavy duty terminal block Refer to Figure 34 for locations and description of the major components of the CP Interface Cab...

Page 84: ...or parallel with the TEG See Figure 35 for series connection and Figure 36 for parallel Connections 12 1 4 Series By connecting the 300 Watt resistor in series with the TEG the maximum allowable powe...

Page 85: ...enter position of the heavy duty terminal block Complete parts listings are given in the next five pages for the various Cathodic Protection Interface Systems available The required system for various...

Page 86: ...CATHODIC PROTECTION OPTION Gentherm Global Power Technologies Page 79 Figure 37 Cathodic Protection System Parts Identification...

Page 87: ...R 8 OHM 300 WATT ADJUSTABLE 65247 RESISTOR 12 OHM 300 WATT ADJUSTABLE 65248 RESISTOR 50 OHM 300 WATT ADJUSTABLE 6 1931 LABEL PUSH TO READ AMPS 1 7 3192 PLUG BUMPER 1 8 1947 GROMMET RUBBER 1 4 X 1 8 5...

Page 88: ...4 ECXS 1 BUTTON RED 61F 675 FOR ALCO SWITCH 11 30 255 SCREW MACH P H P 10 32 X 3 8 SS 2 31 256 SCREW MACH P H P 10 32 X 1 2 SS 6 32 25071 SCREW MACH P H P 10 32 X 1 4 SS 6 33 00469 WASHER LOCK SPRING...

Page 89: ...er configuration The ducts and legs are replaced with mounting bars for mounting to the HRS option see Figure 39 Item G37 Figure 39 HRS Option Overview 13 2 INSTALLATION Each HRS kit is provided with...

Page 90: ...2121 BURNER ASSEMBLY W INTAKE ARRESTOR P 5100 G3 See Figure 29 G4 65697 RAIN CAP ASSEMBLY HRS P 5050 5100 G5 G16 See Figure 29 G17 7410 SCREW MACH P H P 8 32X1 4 SS G18 See Figure 29 G19 62570 ELECTRO...

Page 91: ...Description J1 62117 BURNER BACK ASSY P 5050 P 5100 J2 J6 See Figure 30 J7 66630 INSULATION BLOCK TOP ELECTRODE P 5050 P 5100 J8 J9 See Figure 30 J10 66631 BURNER COVER TOP ELECTRODE P 5050 P 5100 J1...

Page 92: ...85 14 TEG PERFORMANCE LOG MODEL NO TEG SERIAL NO FUEL TYPE LIMITER CONVERTER SERIAL NO CP INTERFACE SERIAL NO DATE TIME AMBIENT TEMP C REQUIRED POWER W REQUIRED v SET V MEASURED v SET V MEASURED POWE...

Page 93: ...86 14 TEG PERFORMANCE LOG MODEL NO TEG SERIAL N FUEL TYPE LIMITER CONVERTER SERIAL NO CP INTERFACE SERIAL NO DATE TIME AMBIENT TEMP C REQUIRED POWER W REQUIRED v SET V MEASURED v SET V MEASURED POWER...

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