Global 5030 Operating Manual Download

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5030

THERMOELECTRIC GENERATOR

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

01953 REV 13

Summary of Contents for 5030

Page 1: ...5030 THERMOELECTRIC GENERATOR 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 01953 REV 13 ...

Page 2: ......

Page 3: ...ry 3 1 3 4 5030 TEG Parts List 3 2 3 5 Burner Parts 3 4 3 6 Fuel System SI SO Parts List 3 6 3 7 Troubleshooting 3 7 4 Limiter Converter Option 30 Watt 4 1 4 1 General Description 4 1 4 2 Operation 4 4 5 Appendix 5 1 5 1 Appendix 1 Gas Specifications 5 1 5 2 Appendix 2 Performance Log 5 3 Table of Figures Figure 1 5030 Dimensions 1 2 Figure 2 Wiring Details 2 2 Figure 3 Wiring Diagram 5030 TEG 2 3...

Page 4: ......

Page 5: ...ff includes a valve in the gas line that is held open by a thermocouple in the exhaust stream In the event that the flame goes out the thermocou ple allows the valve to close preventing the accumulation of gas vapors Fuel Filter When clean commercial fuel is used a fuel filter is not required but for applications where dirty fuel is a possibility an in line fuel filter is recommended 1 2 Physical ...

Page 6: ...rnal resistance of the generator 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 analyze gen erator electrical performance 1 4 Data Plate The data plate is located on the inside of the cabinet door and includes vital information about the generator Fuel Type An X will be mark...

Page 7: ... While the use of sweet line or well head gas is common fluctuating heating values or condensates may damage the generator This may invalidate the warranty The fuel consumption of the 5030 at rated power is listed in the table below for various fuels NOTES a Fuel consumption of liquid propane is assuming measurement of the fuel at 15ºC 60ºF b Fuel consumption of gases in ft3 hr and m3 hr are at at...

Page 8: ...ted then a customer supplied in line fuel filter is recommended Low Temperatures When using propane C3H8 at temperatures below 35ºC 30ºF special consideration must be given to vaporization of the fuel Supply Pressure A minimum gas supply pressure of 105 kPa 15 psi must be supplied to the regulator inlet of the generator A maximum of 172 kPa 25 psi the rating of the pressure regulator is allowed ...

Page 9: ...eak detector fluid such as Snoop 2 2 Set Up Before setting up the generator it must first be determined how much electrical power is required If less than full power is required then the generator can be set up for this lower power level resulting in some savings in fuel consumption To ensure reliable combustion the 5030 should not be set for less than 20 watts gross output If the generator is pro...

Page 10: ...Global Power Technologies 2 2 5030 Figure 2 Wiring Details ...

Page 11: ...o the resistance of the load used The converter limiter included with the 5030 can trigger alarms or other processes in the event of a low voltage Low voltages can be caused by overloads lack of fuel or a faulty generator This detection is achieved by a Voltage Sensing Relay VSR The use of the voltage sensing relay is described in the 30 WATT CONVERTER LIMITER manual TEG Operating Normally LED Ind...

Page 12: ...mbient temperature decreases the gross power will increase 2 6 Start Up 2 6 1 With the fuel pressure turned off record the ambient temperature the rated Voc as noted on data plate located on inside of cover on the PERFORMANCE LOG provided at the back of this manual 2 6 2 Referring to Figure 2 disconnect the TEG lead from the terminal post Connect a voltmeter capable of reading to at least two deci...

Page 13: ...ressure is still close to where it was set at the factory This pressure is marked on the front cabinet see section 1 4 The pressure gauge reading will vary with alti tude due to changes in atmospheric pressure and so it may be necessary to correct the factory reading for altitude Figure 4 shows the correction for variation from the factory altitude of 750 m 2460 ft If the fuel pressure reading dif...

Page 14: ...er depending on which direction caused a rise in voltage until the point resulting in maximum voltage is found The generator should be allowed to stabilize for 15 minutes between each adjustment 2 6 12 After the air shutter is adjusted then adjust the fuel up or down until rated Voc is achieved The fuel should be adjusted in 1 4 kpa 0 2 psi increments allowing the generator to stabilize for 15 min...

Page 15: ...00 00687 Propane Check every 10 000 hours annually Replace every 25 000 hours 3 years To check the orifice remove the flexible fuel line from the back of the burner using two 9 16 open ended wrenches Remove the orifice and visually check it for any obstructions When clean fuel is used or a fuel filter the orifice should be good for several years WARNING When replacing the orifice make sure the con...

Page 16: ...ck Assy 5030 A5 6100 00872 Burner Assy 5030 see Figure 6 A6 4200 00687 Orifice Assy Propane 5 0 0105 4200 00686 Orifice Assy Natural Gas 4 0 0145 A7 2708 00606 Nut Hex 8 32 SS A8 4900 06768 Electrode Spark Ignitor A9 4200 23005 Fuel Line Kit 5030 A10 6400 22381 Fuel System Assy SI SO SS Option see Figure 7 6400 22382 Fuel System Assy SI SO SS Option Item Part DESCRIPTION Figure 5 5030 Base TEG Par...

Page 17: ...A11 4100 00794 Leg 5030 A12 2514 07323 Screw P H P 1 4 20 X 1 1 2 SS A13 2714 00611 Nut Hex 1 4 20 SS A14 6300 06782 Converter Limiter 12V 6300 06758 Converter Limiter 24 V A15 2514 02105 Screw Cap HEX HD 1 4 20 X 3 1 2 LG SS A16 2814 00473 Washer Lock EXT 1 4 SS A17 2900 60391 SPACER 1 4 LG 0 192 ID X 3 8 OD 18 8 SS ...

Page 18: ...ulation Block B3 4000 00701 Spacer Insulation B4 4000 00693 Screen Holder B5 4000 01008 Burner Screen Assy 5030 B6 4000 00694 Insert Ring Burner B7 4000 00864 Venturi Tube Holder 5030 B8 4000 00863 Venturi 5030 B9 2506 00479 Screw Set SOC HD 6 32 X 1 8 SS B10 4000 00828 Insulation Block B11 4000 00827 Burner Cover Figure 6 Burner Parts ...

Page 19: ... 00990 Air Shutter B15 2810 00569 Washer Flat 10 SS B16 4000 00700 Venturi Adjusting Screw 5030 B17 4000 00871 Venturi Plate Assy 5030 B18 4000 07230 Air Filter Assy 5030 B19 4000 00758 Nut Lock Venturi Adjust Screw B20 2710 00601 Nut Wing 10 32 SS B21 2756 07005 Nut Wing 5 16 18 SS B22 4900 07004 Pin Mounting Electrode Figure 6 Burner Parts ...

Page 20: ...bow Street 1 4 NPT BRASS 3031 02356 Elbow Street 1 4 NPT SS C6 3021 00380 Connector Male 1 4 TUBE TO 1 4 NPT 316SS C7 4200 02100 Manifold Block C8 6400 06471 Pressure Switch Hobbs 76056 C9 3200 00691 Pressure Gauge 0 15 PSI 3200 07289 Pressure Gauge 0 15 PSI SS C10 3054 00432 Plug HEX HD 1 8 27 BRASS 3051 07290 Plug HEX HD 1 8 27 SS C11 3090 00176 Valve Shutoff BASCO H19T1 3 C12 3400 00177 Thermoc...

Page 21: ...ower Technologies 3 7 5030 3 7 Troubleshooting The following flow chart is designed to isolate problems that can occur with the generator For further explanation of the comments refer to the appropriate section ...

Page 22: ...Global Power Technologies 3 8 5030 ...

Page 23: ...Global Power Technologies 3 9 5030 ...

Page 24: ...tion is worn then the wire should be replaced If the electrode ceramic is cracked then this is often a path for a spark to ground Replace elec trode 3 7 5 Spark Ignitor Battery The most common reason for a faulty spark ignitor is a dead battery This can occur during long periods of storage from a faulty charging circuit or if the generator is allowed to run open circuit for more than a few hours T...

Page 25: ...ve the two nuts holding the burner in place A7 Figure 5 then remove the burner See Figure 6 Inspect the parts for any tears holes or corrosion and replace them if they are defective Check the venturi if it looks corroded it should be replaced 3 7 11 Open Circuit Voltage The unloaded voltage from the thermopile is an indication of the tem perature difference between the cold side and the hot side A...

Page 26: ...utput of the limiter converter as follows 3 7 14 1 Measure the output voltage between terminals 1 2 and ensure that it is in the 24 to 30 volt range Adjust the voltage as described in the converter limiter manual until the output voltage is about 27 volts If this can be achieved then the converter limiter is probably fine To actually measure the power produced proceed as follows 3 7 14 2 Connect t...

Page 27: ...C A momentary short circuit will not damage the generator or the converter limiter If extended short circuit durations are anticipat ed an in line fuse should be placed on the output of the converter limiter Use 3 Amp slow blow for both the 12 and 24 volt configurations Reverse Current Protection is standard on all 30 Watt Converter Limiter A diode in series with the output prevents current from f...

Page 28: ...Global Power Technologies 4 2 5030 Figure 8 30 Watt Converter Limiter Physical Description ...

Page 29: ...Global Power Technologies 4 3 5030 Figure 9 30 Watt Converter Limiter Connection Adjustment Details ...

Page 30: ...ir to pass freely over the heat sink section Spacers may be required on the back of the 30 Watt L C to allow for clearance between the cabinet and the mounting surface for adequate air flow 4 2 3 Protective Limiter A protective limiter circuit is incorporated into the 30 Watt L C to limit the input voltage This setting can be measured across the TEG Positive and TEG Negative terminals with no load...

Page 31: ... pmm of Mercaptan Sulphur 5 Shall not contain more than 200 mg Sm3 approx 294 ppm of total Sulphur 6 Shall not contain more than 10 CO2 and or N2 by volume nor vary more than 1 CO2 and or N2 during operation 7 Shall not contain more than 120 mg Sm3 of water vapour 8 Shall not contain more than 1 by volume of free oxygen 9 Shall have a nominal gross heating value of Natural Gas 37 MJ Sm3 1000 BTU c...

Page 32: ...Global Power Technologies 5 2 5030 ...

Page 33: ...RFORMANCE LOG MODEL NO TEG SERIAL NO FUEL TYPE LIMITER CONVERTER SERIAL NO Maintenance Repair Notes Date Time Ambient Temp ºC Rated Power Watts Rated V set volts Open Circuit Voltage Measured V out Converter Limiter Fuel Pressure KPa Measured V oc volts ...

Page 34: ...RFORMANCE LOG MODEL NO TEG SERIAL NO FUEL TYPE LIMITER CONVERTER SERIAL NO Maintenance Repair Notes Date Time Ambient Temp ºC Rated Power Watts Rated V set volts Measured V out Converter Limiter Fuel Pressure KPa Open Circuit Voltage Measured V oc volts ...

Page 35: ...Global Power Technologies 5 5 5030 ...

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