Global 1120 Operating Manual Download

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1120 THERMOELECTRIC GENERATOR

CLASS I, DIVISION 2, GROUP D, T3

Operating Manual

#16, 7875 - 57th Street SE

Calgary, Alberta

Canada T2C 5K7

Main: +1 403 236 5556

Fax: +1 403 236 5575

www.globalte.com

22786 REV 9

Summary of Contents for 1120

Page 1: ...1120 THERMOELECTRIC GENERATOR CLASS I DIVISION 2 GROUP D T3 Operating Manual 16 7875 57th Street SE Calgary Alberta Canada T2C 5K7 Main 1 403 236 5556 Fax 1 403 236 5575 www globalte com 22786 REV 9 ...

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Page 3: ... Up To Rated Power 18 2 5 Vset Versus Time 18 2 6 Vset Versus Power 18 2 7 Determining Required Vset 19 2 8 Fuel and Air adjustment 20 2 9 Air Shutter Adjustment 21 2 10 Fuel Pressure Adjustment 22 2 11 Applying customer Load 24 3 SERVICE 25 3 1 1120 TEG 25 3 2 Power Unit 27 3 3 Burner Assembly 27 3 4 Fuel Assembly 28 3 5 Igniter Housing Assembly 28 3 6 Conduit Assembly 29 3 7 Electronics Assembly...

Page 4: ...TABLE OF CONTENTS 4 Appendix 49 4 1 Gas Specifications 49 4 2 TEG Start Up Data Sheet 50 4 3 System Performance Log 52 II ...

Page 5: ...ure 13 Change in Vset Vs Air Shutting Setting 21 Figure 14 Fuel Pressure Vs Vset 23 Figure 15 TEG Subsystems 25 Figure 16 Power Unit 26 Figure 17 Auto Shut Off 27 Figure 18 Schematic Diagram 1120 TEG sheet 1 of 2 30 Figure 19 Schematic Diagram 1120 TEG sheet 2 of 2 31 Figure 20 Electronics Diagram 1120 TEG 32 Figure 21 Removing Fuel System 35 Figure 22 Fuel Regulator 35 Figure 23 1120 TEG Parts Il...

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Page 7: ... Ignition Auto Re ignition Fuel Consumption Natural Gas 8 8 m3 per day 311 Sft3 per day Propane 11 4 L per day 30 US gal per day Inlet Fuel Supply Pressure Max 172 kPa 25 psi Min 69 kPa 10 psi Natural Gas Min 103 kPa 15 psi Propane Dimensions Width 61 cm 24 0 in with electronics box closed 92 cm 36 0 in with electronics box open Depth 80 cm 31 6 in Height 115 cm 45 3 in with drip cap 126 cm 49 4 i...

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Page 9: ...ltage of the generator is one half of the open circuit voltage b the load resistance is equal to the internal resistance of the generator Optimum Load A condition of load where the power output of the generator is maximized Precision Load The precision resistor contained on the generator that provides the optimum load condition The voltage across the resistor is defined as Vset and is used to anal...

Page 10: ...rical Code Part 1 Section 18 18 002 Classification Hazardous locations shall be classified according to the nature of the hazard as follows a Class I locations are those in which flammable gases or vapours are or may be sufficient to produce explosive or ignitible mixtures b Class II locations are those which are hazardous because of the presence of combusti ble or electrically conductive dusts c ...

Page 11: ...hangeably 1 3 Theory of Operation A TEG produces electrical power through the direct conversion of heat energy into electrical energy It operates on the same principle as the thermocouples that are used for measuring temperatures and in safety shutoff controls for gas water heat ers home furnaces etc However the TEG utilizes semiconducting thermoelec tric materials that are much more efficient and...

Page 12: ...uating its performance The fuel flow to the burner is adjusted so that the proper voltage exists across this precision resistor At this condition the TEG is operating at the intended junction temperature and is delivering maximum power The TEG is supplied with a protective device which prevents its output voltage from rising beyond 11 4 Volts This is required because under extended open circuit or...

Page 13: ...Global Power Technologies 1120 Class I Division 2 Group D T3 1120 TEG w Drip Cap 1120 TEG w Rain Shroud Figure 2 Physical Description 5 ...

Page 14: ...cting the power current and voltage curves 5 Read horizontally to the vertical axis to determine the values of power current and volt age 6 Which are 106 Watts 10 2 Amps and 10 3 Volts 1 6 Ambient Temperature Effects The electrical output of the TEG is dependent on ambient temperature as shown in Figure 4 Observe that the power decreases as ambient temperature increases Statement of Rated Power 1 ...

Page 15: ...Global Power Technologies 1120 Class I Division 2 Group D T3 Figure 3 Power Unit Electrical Output Characteristics 20 7 ...

Page 16: ...Global Power Technologies 1120 Class I Division 2 Group D T3 Figure 4 Gross Power from 1120 Power Unit Vs Ambient Temperature 8 ...

Page 17: ...nerator stand if a stand has not been prepared a field proven mount ing arrangement is shown in Figure 5 Ensure that the TEG is mounted in accordance with following notes A The TEG must be mounted with the fin duct in a vertical position B The air flow through the cooling fins must not be obstructed C The TEG should be mounted at a height sufficient to prevent direct flooding or heavy snowfall fro...

Page 18: ...aust pipe to ensure that there is no visual damage or fractures Replace the drip cap if the TEG c w a drip cap the fin duct front cover the rain shroud if the TEG c w a rain shroud Open the front doors of the cabinet and locate the burner mounting bolts tighten the cap nuts and locate the air intake flame arrestor assemblies Ensure that they are tightly secured Locate the Igniter housing assembly ...

Page 19: ...Group D T3 Figure 6 Mechanical Inspection 7774 Rev5 0 0 0 _ LIFTING LUG IGNITOR HOUSING FUEL SYSTEM v g I _ _ DRIP CAP EXHAUST FLAME ARRESTOR FIN DUCT COVER BURNER MOUNTING BOLTS AIR INTAKE FLAME ARRESTORS 1120 TEG w Drip Cap 1120 TEG w Rain Shroud 11 ...

Page 20: ...on has been made in the electronics housing for two 3 4 NPT rigid conduit entries Sealing of these fittings must be used to maintain the system integrity For access to the elec tronics assembly remove the twenty 3 8 16 bolts installed in the lid and swing the lid open Terminal blocks have been factory installed for customer connection TB2 2 is 24 Volts TB2 3 is 24 Volts The voltage sensing relay t...

Page 21: ...xt if ambient temperatures below 5ºC 41ºF are expected be sure that the fuel contains an additive to prevent any moisture in the fuel from freezing Anhydrous methanol added in the ratio of one litre of methanol to 800 litres of fuel tank capacity is recommended 1 13 2 Apply thread sealant to all pipe connections using the method illustrated in Figure 8 A Union type connection is recommended at the...

Page 22: ...nitor system While pushing the manual ignitor button listen at the ignitor housing A sharp snap should be heard as the ignitor discharges If this is not audible refer to Trouble Shooting section 3 9 for set up of ignitor system and correct 1 14 5 Proceed to Section 2 Operation 14 ...

Page 23: ...ice 2 1 4 Output Rating The output rating is the output voltage range and power to customer load 2 1 5 Design Altitude The design altitude is the maximum design altitude of the TEG 2 1 6 Fuel Input Rating The fuel input rating is the maximum fuel energy input rate of the TEG 2 1 7 Inlet Pressure The inlet pressure is the maximum permitted fuel supply pressure range 2 1 8 Burner Fuel Pressure The b...

Page 24: ...wer output at ambient temperature voltage across the precision load and burner fuel pressure that were measured during factory performance test at elevation of the factory are recorded as factory settings This information is provided for reference only because the fuel pressure is adjusted to obtain the desired power at customer site 16 ...

Page 25: ...additional sheets are needed they can be duplicated 2 3 Starting Generator Perform the following steps see Figure 10 2 3 1 Turn on fuel Loosen the lock nut on the fuel regulator 2 3 2 If required correct the factory set fuel pressure for the elevation as per Figure 9 Change in Fuel Pressure Vs Elevation 2 3 3 Adjust the air shutters to slightly fuel rich from the factory set position Note that the...

Page 26: ... time after ignition This curve is for a TEG set at the fuel pressure that produces rated power During this heat up period measure the Vset and record it as item 2 on the start up data sheet at the time intervals specified To monitor progress during heat up compare your measurements with those shown in Figure11 After 20 minutes of operation observe the Vset and determine the following 1 If Vset is...

Page 27: ...ad horizontally to the vertical axis to determine Vset Which is 6 8 volts 2 7 Determining Required Vset This heat up period is the ideal time to determine the Vset Vset is based on set up power as follows SET UP POWER from Figure 4 Vset from Figure 12 Set up power is found by adjusting the desired power for ambient temperature Vset is deter mined from set up power as shown in Figure 12 1 Estimate ...

Page 28: ...to Figure 12 to determine the related Vset and record as Item 6 2 8 Fuel Air Adjustment After the TEG has been operating for one hour Vset should not be changing with time The readings on the start up data sheet at 40 and 60 minutes should not differ by more than 0 2 volts When you are satisfied that Vset is not changing with time compare the measured value of Vset with the required Vset Item 6 Pr...

Page 29: ...to heat the excess air to exhaust temperature In both cases fuel is being wasted When the air shutter is at its optimum setting neither of above the TEG is operating at maximum efficiency NOTE If available a combustion analyzer will facilitate rapid air shutter optimizing as you need not wait for Vset to change Figure 13 shows change in Vset as a function of air shutter settings Observe that Vset ...

Page 30: ...s the TEG is ready to switch to operate mode 2 10 Fuel Pressure Adjustment To change Vset it is necessary to change the fuel pressure Figure 14 shows the change in Vset as a function of the change in fuel pressure for a typical TEG operating at rated power The following examples will illustrate how this curve can be used 1 Suppose the measured Vset is 6 5 volts but 6 7 volts or a change of 0 2 vol...

Page 31: ...Record the fuel pressure as Item 9 4 Determine the required change in fuel pressure from Figure 14 and record as Item 10 5 Determine the new fuel pressure by adding Item 10 to Item 9 and record as Item 11 EXAMPLE Item 9 37 9 kPa 5 5 psi Item 10 2 1 kPa 0 3 psi New Fuel Pressure 35 8 kPa 5 2 psi 6 Adjust the fuel pressure to the value in Item 11 Close the cabinet doors and record the time Figure 14...

Page 32: ...ully charged if they are too deeply discharged the 1120 TEG will not charge the station battery 2 Set power switch to Run position see Figure 10 The TEG normal light should come on Adjust the voltage control to the desired operating voltage plus 0 7 volts using the Output Voltage Adjust dial on the electronics box and the reading on digital panel meter If a multiple TEG system is in use ensure tha...

Page 33: ...eory of operation on the 1120 generator system only If the system contains any options they are described in the Special Options section The 1120 Generator can be broken down into several subsystems consisting of the following see Figure 15 Power Unit Assembly Burner Assembly Igniter Housing Assembly Fuel System Assembly Conduit Assembly Electronics Electronics Assembly 25 ...

Page 34: ...Global Power Technologies 1120 Class I Division 2 Group D T3 Figure 16 Power Unit Figure 15 TEG Subsystems 1120 w Rain Shroud 26 ...

Page 35: ...elec tric pile in the middle and a combustion chamber on the other end which accepts the burner assembly 3 3 Burner Assembly See Figure 25 The burner assembly consists of the burner components the heat exchanger and flame arres tors air intake and exhaust This assembly performs several functions The orifice introduces fuel at a predetermined pressure to the burner This fuel flows through the ventu...

Page 36: ... to the shut off valve which in conjunction with the thermocouple works as an auto shut off system designed to shut off the gas supply if the TEG burner should go out for an extended period of time Figure 17 shows the electrical operation of the shut off valve and thermocouple NOTE The time required for dropout of the shutoff valve can vary from 1 to 7 minutes This time being determined by the hol...

Page 37: ... It consists of a junction box for distribution and interconnection flexible conduit assemblies with seals for main taining the integrity of assemblies and a digital panel meter for display of voltage and current settings The digital panel meter is not field repairable and requires replacement of both the display section and monitor board located in electronic housing in the event of failure 3 7 E...

Page 38: ...Global Power Technologies 1120 Class I Division 2 Group D T3 Figure 18 Schematic Diagram 1120 TEG sheet 1 of 2 30 ...

Page 39: ...Global Power Technologies 1120 Class I Division 2 Group D T3 Figure 19 Schematic Diagram 1120 TEG Sheet 2 of 2 31 ...

Page 40: ...Global Power Technologies 1120 Class I Division 2 Group D T3 Figure 20 Electronics Diagram 1120 TEG 32 ...

Page 41: ...ed on the PCB attached to the door assembly The DC DC Converter schematic is shown in Figure 18 This converter is a high efficiency switching regulator designed to step the TEG output voltage up to 12 V or 24 V nominal The dip switch settings for the different outputs are shown in Figure 18 Fine tuning of the output voltage is accomplished by adjusting S4 located on the front of the electronics bo...

Page 42: ...splay and the control por tion Figure 29 item F7 which conditions the voltages for the display portion The digital panel meter is a 3 5 digit auto ranging meter When the power switch is in the Set Up position the meter will show the Vset voltage When the power switch is set to the Run position the meter will show the output voltage of the system In addition when the Meter Select switch is pressed ...

Page 43: ...or is first turned OFF Whenever major work or repairs are required other than that called out in field troubleshooting 1 The generator or electronics assembly must be removed to a safe area Or 2 The area in which the generator is being used must be rendered safe in accordance with all regulations governing the operations area 3 9 1 Changing the Fuel Filter Figure 20 Figure 21 3 8 2 Annual Service ...

Page 44: ...ect the flexible fuel line at point B 3 Remove the two nuts holding the regulator to the mounting bracket point D 4 Remove the four socket cap screws from the bottom of the regulator Remove the bot tom complete with the rubber gasket see Figure 22 5 Remove and inspect the filter clean or replace as required 6 Re assemble in reverse order 7 Ensure that all joints are leak checked prior to starting ...

Page 45: ...ll not stabilize sustained combustion note the position of the air shutters and adjust for sustained ignition Reset the air shutters when the unit warms up Burner does not remain ignit ed when shut off valve button is released Replace thermocouple Replace shut off valve Output power or voltage low TEG in Set Up position Incorrect fuel adjustment see section 2 10 Incorrect air adjustment see sectio...

Page 46: ...for testing or make area safe Trouble shoot the electronics TEG Normal light is out voltmeter reading is OK TEG is running TEG lamp burned out Replace the lamp Lamp driver circuit is bad TEG Normal light is out voltmeter is out TEG is running Possible short circuit condition disconnect the load If the lamp lights OK and the voltmeter is OK then trouble shoot the load If the lamp does not light and...

Page 47: ... A4 2446 Burner Assy 1 A5 20954 Screw Mach P H P 1 4 20 X 5 8 316 SS 28 A6 7028 Cabinet Top Assy 1 A7 20828 Thermocouple 24 K16RA 24 Soldered 1 A8 57210 Heat Shield 1120 Meter 1 A9 3322 Cover Digital Panel Meter 1 A10 7336 Bezel Digital Panel Meter 1 A11 29606 Screw Mach P H P 6 32 X 3 8 316 SS 4 A12 2405 Orifice Assy 7 Propane 1 2406 Orifice Assy 8 Natural Gas 1 A13 2394 Washer Disc Spring 8 SS 2...

Page 48: ... 32 X 5 8 316 SS 2 A15 2460 Air Shutter Teflon 2 A16 2311 Ignitor Housing Assy 1 A17 22383 Fuel System Assy W CF Regulator 1 20955 Screw Hex HD 1 4 20 X 3 1 2 316 SS 2 22024 Washer Lock 1 4 316 SS 2 20952 Nut Hex 1 4 20 316 SS 2 A18 21773 Cabinet Assy 1 A19 5286 Fuel Line Kit 1 A20 2218 Leg Left 1 2219 Leg Right 1 Figure 23 1120 Parts Illustration 40 ...

Page 49: ...ssy 1 A27 23566 Screw Cap Hex HD 3 8 16 X 1 1 2 316 SS 20 A28 2266 Mounting Rod Burner 4 A29 21131 Nut Hex 5 16 18 316 SS 4 A30 24368 Screw Mach Hex HD 1 4 20 x 3 8 316 SS 8 A31 24497 Screw Mach P H P 8 32 X 1 4 316 SS 40 A32 23811 Washer Lock Spring 8 316 SS 6 A33 22024 Washer Lock Spring 1 4 316 SS 16 A34 20952 Nut Hex 1 4 20 316 SS 16 A35 2339 Fin Duct Lower 1 A36 8905 Power Unit 1 A37 7625 Con...

Page 50: ...port 1 B3 701 Spacer Insulation 1 B4 693 Screen Holder 1 B5 873 Screen Burner 1 B6 694 Insert Ring Burner 1 B7 2302 Insulation Block 1 B8 2401 Venturi Tube Holder 1 B9 971 Venturi 1 B10 479 Screw Set Soc HD 6 32 X 1 8 SS 1 B11 2389 Burner Cover Assy 1 B12 2454 Flame Arrestor Assy Air Intake 2 3 12 Burner Part List Figure 25 Burner Parts 42 ...

Page 51: ...tem Part No Description QTY B13 609 Nut Hex 10 32 SS 2 B14 469 Washer Int Lock 10 SS 2 B15 2415 Flame Arrestor Assy Exhaust 1 B16 5241 Flame Arrestor Housing Upper 1 B17 2452 Exhaust Stack 1 B18 2413 Screw Hex HD 1 4 20 X 1 00 SS 8 B19 541 Washer Lock Spring 1 4 SS 8 Figure 25 Burner Parts 43 ...

Page 52: ...ff BASCO H19 TA3 1 C6 1429 Pressure Switch H0BBS 78628 1 C7 20071 Elbow 1 4 NPT X 1 4 Tube SS 1 C8 5286 Fuel Line Kit 1 C9 20828 Thermocouple 24 K16RA 24 Soldered order separately 1 C10 2356 Elbow Street 1 4 NPT SS 1 C11 2358 Nipple 1 4 NPT X 3 SS 1 C12 2360 Adaptor 1 4 NPT SS 1 C13 20067 Vent Tube Assy 1120 1 C14 22363 Fuel Filter Kit Fisher 67 CFR not shown Figure 26 Fuel System Parts NOTE Parts...

Page 53: ...f 1 2 NPT 2 D3 2163 Connector 90 3 8 Conduit 1 2 NPT 2 D4 5222 Plug Close Up 1 2 NPT CUP 1 1 D5 2168 Conduit Liquid Tight Flex 3 8 22 D6 2168 Conduit Liquid Tight Flex 3 8 10 D7 20156 Barrier Gland 3 4 NPT 2 20155 Reducer Bushing 3 4 X 1 2 ALUM 2 D8 2456 Cable Assembly 1 D9 6372 Ignitor Cable Conduit Assy 1 D10 51084 Digital Panel Meter Assy 1120 1 Figure 27 Conduit Assembly Parts 45 ...

Page 54: ... E5 60307 Ignitor Board Assy 1 E6 6362 Connector 3 16 1 8 Nylon NY 300 1 2 1 E7 2032 Electrode Assy Spark Ignitor 1 E9 21650 Nut Hex 6 32 SS 1 4 Across Flats 2 E10 Ground Cable SI 1 5205 Female Disconnect DNF18 250Fib 1 137 Wire 20AWG Green 6 1 204 Terminal Ring 1 4 RED PNF18 14R 1 E11 2379 Reducer 1 1 4 X 3 4 NPT ALUM 1 E12 2376 Connector 90 M F 3 4 NPT ALUM 1 NOTE Parts not included if ordering ...

Page 55: ...2 27019 Battery 2V 2 5 AH D Size 1 F3 6527 Shunt 10A 50mV Holloway Type SW w Base 1 F4 2282 Control Board Spark Ignitor 1 F5 2418 Terminal Block 7 Position 2 F6 7329 PCB Voltmeter Control LED 1 F7 6714 Terminal Block 3 Pole Heavy Duty 1 F8 2374 Actuator Potentiometer Adjust 1 F9 2160 Switch Push Button 1 F10 7810 Switch CAM BACO PR 26 225 1 Figure 29 Electronic Box 47 ...

Page 56: ...List Item Part No Description QTY F11 5317 PCB Assy Limiter Converter 220W 1 F12 114 Resistor 0 75 OHM 50W 1 2 F13 2183 Resistor 2 0 OHM 50W 1 2 F14 5350 Heat Sink Limiter Converter 1 F15 6181 Potentiometer 1 turn 2 KOhm 2 Watt 1 F16 29529 LED Green BA9S G 28 Volt 1 Figure 30 Electronic Box Lid 48 ...

Page 57: ... of Mercaptan Sulphur E Shall Not contain more than 200 mg Sm3 approx 294 ppm of total Sulphur F Shall not contain more than 10 CO2 and or N2 by volume nor vary more than 1 CO2 and or N2 during operation G Shall not contain more than 120 mg Sm3 of water vapour H Shall not contain more than 1 by volume of free oxygen I Shall have a gross heating value of Natural Gas 37 MJ Sm3 1000 BTU cu ft 1 Propa...

Page 58: ...et measured 10 minutes afte air shutter adjustment 16 Vset measured final before applying load Date Data By Site TEG Serial No 1 Time of sustained ignition 2 Time minutes after ignition 10 20 30 40 50 60 Vset 3 Temp max ambient expected at site 4 Temp Present ambient at site 5 Set Up Power see Figure 4 6 Vset required to obtain set up power see Figure 12 7 Vset measured one hour after ignition 8 V...

Page 59: ...et measured 10 minutes afte air shutter adjustment 16 Vset measured final before applying load Date Data By Site TEG Serial No 1 Time of sustained ignition 2 Time minutes after ignition 10 20 30 40 50 60 Vset 3 Temp max ambient expected at site 4 Temp Present ambient at site 5 Set Up Power see Figure 4 6 Vset required to obtain set up power see Figure 12 7 Vset measured one hour after ignition 8 V...

Page 60: ... D T3 Date Data By Amperage Customer Load Voltage Customer Load Output Voltage Conv Limiter Set Up Power Watts V set Volts Air Shutter Fuel Pressure Ambient Temp ºC Time Maintenance Repair Notes 1120 System Performance Log Site TEG Serial No TEG Group NO 52 ...

Page 61: ... D T3 Date Data By Amperage Customer Load Voltage Customer Load Output Voltage Conv Limiter Set Up Power Watts V set Volts Air Shutter Fuel Pressure Ambient Temp ºC Time Maintenance Repair Notes 1120 System Performance Log Site TEG Serial No TEG Group NO 53 ...

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