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Global Power Technologies

CATHODIC PROTECTION INTERFACE OPTION

302954 rev0 | Model 8550-RU

Page 49 of 53

9.4

PARTS LIST – CATHODIC PROTECTION INTERFACE

Figure 29 – Cathodic Protection Interface Assembly Parts

Item

Part No.

Description

5014

Bushing, Universal, 1, Nylon, 0.125 PNL

6594

Cover Assembly, Resistor, 8550 CP Panel

21899

Mounting Bracket, Resistor

6226

Meter, 0-50 mV DC, 2.5” Custom Scale*

6221

Meter Face, 30V, 30A*

3192

Plug, Bumper, 0.875 x 0.250

6608

Slide, Resistor, 1 Ω, 1000

6566

Resister, 1.0R, 100W, 31.6A, Adjustable

6217

Shunt, Type 766, 30 Amp, 50mV, Holloway SW w/ Base

6714

Terminal Block, 3P, 14/2/0 AWG, 175A

7941

Terminal Block, POS

NOTE: *

Panel Meter (6226) comes with a blank face plate. Always order the Meter Face (6221)

when replacing the Panel Meter.

Summary of Contents for 8550-RU

Page 1: ...Global Power Technologies www globalte com Model 8550 RU Thermoelectric Generator OPERATING MANUAL ...

Page 2: ......

Page 3: ...NTENANCE 21 5 1 POWER CHECK 21 5 2 BASIC SERVICE 23 5 3 COOLING SYSTEM 24 5 4 FUEL SYSTEM 26 5 5 BURNER SYSTEM 28 5 6 SPARK IGNITION SI 30 5 7 OVERTEMPERATURE SHUTDOWN SYSTEM 32 5 8 AUTOMATIC SHUT OFF SO 34 5 9 POWER UNIT TESTING 35 6 TROUBLESHOOTING 37 7 PARTS LISTS 39 7 1 FUEL SYSTEM PARTS LIST 42 7 2 ELECTRONICS ASSEMBLY PARTS LIST 43 8 6720 VOLTAGE LIMITER FOR MODEL 8550 RU TEG 44 8 1 PRODUCT ...

Page 4: ...ponents 29 Figure 16 Spark Ignition System Wiring 30 Figure 17 Spark Ignition Components 31 Figure 18 Overtemperature Shutdown System 33 Figure 19 Automatic Shut off Components 34 Figure 20 Model 8550 RU TEG Parts 1 of 2 39 Figure 21 Model 8550 RU TEG Parts 2 of2 40 Figure 22 Fuel System Parts 42 Figure 23 Electronics Assembly Parts 43 Figure 24 6720 Voltage Limiter 44 Figure 25 6720 Limiter Main ...

Page 5: ...hermoelectric Generator is designed to combust gaseous fuels which will result in combustion products including heat carbon dioxide and water vapour and may contain traces of carbon monoxide unburnt hydrocarbons and nitrous oxides Emissions from combustion will depend on generator set up and operation as well as the composition of the gas feed Ensure that gas supplied meets Global Power Technologi...

Page 6: ...ll rights reserved No part of this manual may be reproduced without permission in writing from GPT except by a reviewer who may quote brief passages or reproduce illustrations in a review with appropriate credit nor may any part of this manual be reproduced stored in a retrieval system or transmitted in any form or by any means electronic photocopying recording or otherwise without prior permissio...

Page 7: ...ion of heat energy to electrical energy GPT Global Power Technologies Power Unit The hermetically sealed portion of the generator that contains the thermoelectric materials Matched Load A condition of load where the load voltage of the generator is one half of the open circuit voltage Optimum Load A condition of load where the power output of the generator is maximized Power Conditioner A broad te...

Page 8: ...e inside of the cabinet door When contacting GPT indicate both the complete Model Number and Serial Number of your TEG Figure 1 Data Plate The information indicated on the data plate are as follows Design Altitude Maximum permitted altitude that the TEG should be operated at Fuel Input Rating Maximum permitted energy rate to the generator Inlet Pressure Minimum and maximum levels of inlet fuel pre...

Page 9: ...r and temperature recorded during the factory acceptance test This is the maximum power unit power that can be expected from the TEG under similar conditions Voltage Power unit voltage recorded during factory acceptance test Burner Fuel Pressure Burner fuel pressure recorded during factory acceptance test The Model 8550 RU TEG s model number can be interpreted as follows Figure 2 Model Number Expl...

Page 10: ...bstruct the flow of wind choose a site on the windward side at least 45 feet 14 m away from the building or object or on the roof if possible Always follow local regulations when placing the TEG near buildings and fuel tanks 3 1 3 FUEL SUPPLY The fuel system on each TEG unit is designed for either propane or natural gas Check the Data Plate on inside of the TEG cabinet to verify the type of fuel t...

Page 11: ...oint in excess of 0 C 32 F at 170 kPag 25 psig 3 Shall not contain more than 115 mg Sm3 2 approx 170 ppm of H2S 3 4 Shall not contain more than 60 mg Sm3 approx 88 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 by more than 1 CO2 and or N2 during operation 7 Shall not contain more t...

Page 12: ...ate 1 Check the TEG for any damage that may have occurred during shipping If the TEG shows any sign of damage contact Global Power Technologies to report it Do not proceed with the installation 2 Check and re tighten any bolts that may have loosened 3 Remove the tie wraps that clamp the ends of the heat pipes to the support ring CAUTION Failure to remove the tie wraps can cause the heat pipes to c...

Page 13: ...ore than 3 then proceed to the next step Figure 4 TEG Stand WARNING Operation of TEG on an unstable or non level base or in locations where cooling air flow may be obstructed will cause overheating of the TEG 3 3 INSTALLING THE RELAY ASSEMBLY The Shutdown Relay Assembly is shipped inside the TEG cabinet To install 1 Thread the male end of the Relay Assembly into the bottom of the Shut off Valve on...

Page 14: ... Spark Igniter Electrode through the fitting on the bottom of the burner until it touches inside then pull back by approximately 1 8 inch 3 mm This should leave 2 63 to 2 75 inches 67 to 70 mm extruding beyond the fitting refer to Figure 5 2 Gently tighten the nut on the fitting to maintain the position of the electrode 3 Connect the terminal lug of the high voltage cable to the end of the Spark I...

Page 15: ...f all air 3 6 ADJUSTING FOR ALTITUDE The burner fuel pressure supplied on the TEG and marked on the data plate is set for the factory altitude or site elevation of 2460 ft 750 m At the factory s elevation the fuel pressure should be in the range of 16 to 22 psi 110 to 150 kPa for propane or 6 to 10 psi 41 to 69 kPa for natural gas If the TEG s installation site is at a similar altitude check the b...

Page 16: ...that adjustment is required for your site s altitude by counting vertically from the Factory Elevation mark at 0 psi kPa Enter this number on the Start up Data Sheet For example If your TEG will be installed at a site with an altitude of 7970 ft 2429 m increase your burner fuel pressure by 2 61 psi 18 kPa from the factory setting Figure 7 Altitude Adjustment ...

Page 17: ... This will also need to be done for power adjustments NOTE Use the Start up Data Sheet located at the end of this manual during the start up process It helps simplify starting heating up and making power adjustments 4 1 1 DETERMINE SET POWER Determine the required Set Power before proceeding with Start up Set Power is the power to which the TEG must be set at your ambient conditions so that it gen...

Page 18: ...0 26 11 0 10 21 30 39 50 59 70 79 90 99 109 12 4 42 31 20 6 7 18 27 36 46 55 66 75 86 95 106 15 5 47 35 24 9 3 14 23 32 42 52 63 72 82 91 100 18 6 51 38 27 13 0 10 19 30 39 48 59 68 79 88 99 21 7 53 40 29 15 2 9 18 28 37 46 57 66 77 86 97 24 8 56 44 3 8 4 7 16 27 35 45 55 64 75 84 95 Table 2 Corrected Air Temperature for Wind in miles per hour and F 2 Using the corrected air temperature as determi...

Page 19: ...wer Unit voltage during start up Connect the second voltmeter across Terminals 6 and 7 of TB 1 This will measure the Power Unit current 1 mV 1 Amp Follow these steps to start up the Model 8550 RU TEG 1 Turn on the fuel supply to the TEG and observe the fuel pressure at the fuel pressure gauge Refer to the Start up Data Sheet and compare the observed fuel pressure to the adjusted fuel pressure as d...

Page 20: ...hoot the system as indicated in Section 5 6 3 Check that the Burner Run Valve is closed 4 Open the Automatic Shut Off valve by pressing the button with one hand Keep this button pressed Do not release until instructed Step 8 The Spark Igniter should start clicking followed by a series of popping sounds from the unit as the burner ignites The Power Unit voltage will start to rise slightly 5 Continu...

Page 21: ...at the external valve Then close the Burner Run Valve The Automatic Shut off Valve will close when the burner thermocouple cools down WARNING Proceed to the Heat Up and Power Adjustment section as soon as the automatic shut off valve remains open Failure to do so may overheat the Power Unit 4 1 3 HEAT UP AND POWER ADJUSTMENT It is normal for the heat pipes to make a crackling sound as they start t...

Page 22: ... pressure change to stabilize Record any changes in fuel pressure on the Start Up Data Sheet If the power level is less than 70 of Set Power after 30 minutes the fuel pressure may be too low Wait until the power level has stabilized and make the necessary adjustment NOTE Keep the cabinet door closed as much as possible during the warm up period until the Power Unit output power stabilizes It takes...

Page 23: ...g and compare it to the previous reading If the new power reading is higher than the previous reading close the air shutter by another 1 8 inch 3 mm wait 10 minutes and then take another power reading Continue closing the air shutter by 1 8 inch 3 mm and checking the power every ten minutes until the power no longer rises then proceed to the next step If the new power reading is lower than the ini...

Page 24: ...rrect power level Before applying the customer load ensure that all wire connections are tight and adjust the power conditioner output to the desired customer voltage as outlined in Section 8 To apply customer load 1 Connect the customer load to the TEG at terminals 2 and 4 of terminal block TB 1 2 Turn the circuit breaker on the power conditioner to the ON position 3 Close and latch the cabinet W...

Page 25: ...Power and the System Performance Log to make sure that the TEG was left operating at Set Power during the last maintenance visit Perform a power check by doing the following 1 Check the Power Unit voltage at Terminals 6 and 4 of TB 1 2 Check the Power Unit current at terminals 6 and 7 of TB 1 The Current Shunt rating is 50 Amps 50 mV 3 Calculate the Power Unit output power by multiplying the Power...

Page 26: ...it is essential that the TEG be supplied with a fuel of constant heating value Poor cooling by heat pipes Check to make sure that the Heat Pipe fins are not obstructed by debris or dust Check that the Heat Pipe ends are warm Test the cooling system as outlined in Sections 5 3 Change in customer load An overloaded TEG can see a minor to severe decline in output power and voltage Verify that the con...

Page 27: ...e complete Burner System for obstructions and damage as outlined on Section 5 5 If after servicing and restarting the Power Unit still does not come to Set Power a change in the fuel quality is likely the cause Increase the fuel pressure to obtain Set Power being careful not to exceed the maximum VOC and RINT as determined in Section 5 9 It will take 10 minutes for a change in fuel pressure to tak...

Page 28: ...ng the life of the TEG If you find any evidence of a poorly functioning heat pipe please contact GPT 5 3 1 HAND INSPECTION Before performing this inspection ensure that the TEG has been operating for at least one hour If possible choose a day that is calm and not windy This method involves touching the heat pipes with bare hands Be cautious when touching the heat pipes Do not keep your hand in con...

Page 29: ...he requirements of the hand temperature inspection i e heat pipes that are not noticeably warm up to 2 inches 50 mm from the tip Tool required thermocouple meter range up to 150 C 300 F example Digital Multimeter with K type thermocouple adapter surface temperature probe 50mm 2 in long 5 mm 0 2 in diameter K type thermocouple probe Keep the TEG operating for at least an hour in calm weather condit...

Page 30: ...TC TD A problem should be suspected with any heat pipe that is operating at a temperature much lower than the rest of the heat pipes Replacement of heat pipes should only be done by a factory trained technician consult GPT for heat pipes replacement Remove and replace any heat pipe that is visually damaged CAUTION Do not operate the TEG if it has a damaged heat pipe 5 4 FUEL SYSTEM WARNING Turn of...

Page 31: ... the flow of fuel to the burner Figure 13 Fuel System Components 5 4 1 DRAINING THE PRESSURE REGULATOR SEDIMENT BOWL To drain the pressure regulator sediment bowl 1 Open the drain cock located under the pressure regulator 2 Using a small container collect any liquid impurities that may have collected in the bowl 3 After the bowl has drained close the drain cock ...

Page 32: ...assemble and check for leaks WARNING Check for leaks after performing any fuel system service 5 5 BURNER SYSTEM The Burner System should be disassembled only if a problem with burner operation is suspected The Burner System consists of the following components The burner venturi and air shutter assembly which mixes combustion air and fuel The burner plate assembly where combustion takes place The ...

Page 33: ... If these parts are obstructed clean them with a stiff wire brush If they are corroded the burner must be repaired or replaced With the burner plate assembly removed examine the exhaust stack through the Power Unit remove any obstructions and check for corrosion If the exhaust stack is corroded it must be replaced as follows 1 Remove the converter shroud which covers the lower portion of the heat ...

Page 34: ...e fuel system The SI Control Module which generates the high voltage pulse for the Spark Electrode and controls the function of the system Whenever there is adequate fuel pressure in the Fuel System the Pressure Switch is closed With the Pressure Switch closed the SI Control Module will generate 12 kV pulses which will arc from the Spark Electrode The SI Control Module will continue to generate th...

Page 35: ...tions to prevent high voltage shock 3 Carefully remove the spark igniter electrode assembly loosen the fitting and slide out the electrode 4 Inspect the spark igniter electrode for cracks in the ceramic tube Check the rod that runs through the ceramic tube for continuity Replace the spark igniter electrode if it is damaged 5 To test the function of the SI Control Module position the spark igniter ...

Page 36: ...tings or from heat pipe failure The Overtemperature Shutdown system consists of the following main components Six Shutdown Thermostats Each thermostat is installed in a heat pipe block and protects two heat pipes During an overtemperature event the thermostat will cause the respective shutdown fuse to blow in the Shutdown Module NOTE Thermostats produced after September 2021 will come paired with ...

Page 37: ...wn occurs check the thermal cut off and six shutdown fuses for continuity If any of them have opened then follow these maintenance steps 1 Inspect all the heat pipes for damage and clean any debris 2 Inspect the thermostat wiring for loose or broken wires If the thermostat is paired with an adaptor board ensure that both quick connect terminals are tight ...

Page 38: ...ikely damaged and should be replaced 5 8 AUTOMATIC SHUT OFF SO The Automatic Shut Off system is designed to turn off the fuel supply to the TEG in the event of a flame outage The thermocouple will hold open the shut off valve as long as good burner combustion is maintained The thermocouple also interfaces with the Overtemperature Shutdown System and is interrupted if an overtemperature event occur...

Page 39: ...ay need replacement to prevent nuisance shutdowns 4 If no voltage can be observed at all then check the shutdown relay power Refer to Section 3 3 5 If the shutdown module is outputting at least 12 Volts and the thermal cut off has not opened then the shutdown relay is faulty and should be replaced 6 If no problems have been detected with the thermocouple signal but the shut off valve still cannot ...

Page 40: ...wer Unit power was below Set Power see Section 5 1 1 for test result diagnostic If the Power Unit is producing Set Power the open circuit voltage Voc should be in the range of 52 to 56 Volts and the internal resistance RINT should be in the range of 1 10 to 1 35 Ohms NOTE If the TEG has just been started in the last 10 hours or has been stopped and restarted several times in the past days its inte...

Page 41: ...ing Close burner Run valve 4 1 2 Fuel filter dirty Drain the regulator sediment 5 4 Replace the fuel filter 5 4 2 Fuel pressure adjustment incorrect Adjust the burner fuel pressure 4 1 2 Fuel orifice plugged Replace the fuel orifice 5 4 3 Fuel orifice size incorrect 5 4 3 Air shutter adjustment incorrect Tune the air shutter 4 1 4 Incorrect spark electrode depth Adjust spark electrode depth 3 4 5 ...

Page 42: ...ower or output voltage Set Power incorrect Determine proper Set Power for ambient conditions 4 1 1 Heat pipes not adequately cooling power unit Maintain and or replace heat pipes 5 3 Fuel pressure adjustment incorrect Adjust burner fuel pressure 4 1 2 Air shutter adjustment incorrect Adjust air shutter 4 1 4 Output voltage adjustment incorrect Adjust the output voltage screw on the power condition...

Page 43: ...Global Power Technologies PARTS LISTS 302954 rev0 Model 8550 RU Page 39 of 53 7 PARTS LISTS Figure 20 Model 8550 RU TEG Parts 1 of 2 ...

Page 44: ...ption 1 6462 Block Heat Pipe 2 6397 Bracket Support 3 22490 Burner Assembly 4 300329 Cabinet Assembly 8550 RS 5 6991 Clamp Stepless 12 6 6931 Clamp Stepless 9 7 6396 Clip Heat Pipe 8 6645 Converter Mounting Ring 9 6398 Converter Shroud 10 20184 Cover Assembly Limiter 11 6768 Electrode Assembly 6 4 Long 12 301413 Electronics Assembly 8550 RU 13 5545 Exhaust Gasket 14 5406 Exhaust Stack Assembly ...

Page 45: ...hread SS 33 5574 Screw Self Tap PHP 6 x 0 625 SS 34 21646 Shoe Heat Pipe with 1 4 NPT 35 6978 Shutdown Relay Assembly 36 6986 Spiral Wrap Φ 0 125 Teflon 37 5576 Spring Wire 302 SS 38 6968 Standoff 1 2 Hex 1 4 20 X 5 8 SS 39 6958 Stiffener Assembly Lower Heat Pipe 40 6395 Support Arm Lower Heat Pipe 41 6394 Support Arm Upper Heat Pipe 42 6393 Support Ring Heat Pipe Sanded 43 6431 Support Upright 44...

Page 46: ...3 51548 Adapter 0 25 Tube X 0 25 MNPT 316 Ss 54 68147 Connector Port 0 25 Tube 316 SS 55 302835 Elbow 90 Union 0 25 Tube Brass 56 20743 Elbow 90 Union 0 25 Tube 316 SS 57 29216 Ferrule Set 0 25 316 Ss 58 301421 Tubing 0 25 OD X 0 035 Wall 304 SS 59 301420 Tubing 0 25 OD X 0 035 Wall 304 SS 60 301422 Tubing 0 25 OD X 0 035 Wall 304 SS 61 302833 Tubing 0 25 OD X 0 035 Wall 304 SS 62 406 Gauge Pressu...

Page 47: ...essure 1 6 psi 69 5551 Tee Union 0 25 Tube Brass 70 5554 Union 0 25 Tube Brass 71 176 Valve Shut off 72 302836 Valve Toggle Needle 0 25 Tube Brass 73 20122 Vent Tube Assembly Regulator SS 7 2 ELECTRONICS ASSEMBLY PARTS LIST Figure 23 Electronics Assembly Parts Item Part No Description 74 67289 Spark Igniter Module Assembly 76 5238 Shunt 50 Amp 50V 77 6963 Overtemperature Shutdown Module 78 2110 Te...

Page 48: ...se current protection from customer load connections Provide a Voltage Sensing Relay VSR that can be used for Low Voltage Alarm and or Voltage Good contacts in customer applications 8 2 OPERATION 8 2 1 OUTPUT VOLTAGE ADJUSTMENT Do not adjust the voltage limiter output voltage until the TEG is set up and operating in accordance with Section 4 of this manual 1 Ensure that the TEG has been running fo...

Page 49: ...the following procedure 1 Ensure the TEG has been running for at least an hour to stabilize 2 Disconnect all customer load connections from terminals 2 and 4 of TB 1 3 Connect a voltmeter across terminal 2 and terminal 4 of TB 1 4 Connect a multimeter across the COM and NC terminals of the VSR Control Board within the 6720 Limiter Set the multimeter to measure continuity or resistance 5 Using a sm...

Page 50: ...PARTS LIST Figure 25 6720 Limiter Main Parts Item Part No Description 1 20184 Cover Assembly Limiter 8550 not shown order separately 2 3154 Heat Sink Assembly 3 116 Resistor 2 Ohm 300 Watts 10 4 59056 Control VSR Board 24 Volt 5 61042 Driver Board 6 284 Circuit Breaker 30 Amp 7 6714 Terminal Block 3 Pole Heavy Duty 8 2580 Output Diode ...

Page 51: ...athodic protection load to exceed 30 Amps as this will trip the circuit breaker The Model CP8550 RU generator is not rated to supply more than 30 amps of current to the load If total circuit resistance is less than 0 5 ohms then the 1000 watt variable resistor in the CP box should be wired in series with the circuit and adjusted so that current does not exceed 30 amps 9 1 METER The dual scale mete...

Page 52: ...ad This is achieved by moving the tap to the left side of the resistor To reduce power to the CP load slide the tap to the right 9 3 2 PARALLEL By connecting the 1000 Watt resistor parallel to the TEG smaller levels of power may be delivered to the CP load This is sometimes required to reduce hot spots on the anode With the tap located at the right side of the resistor the output power will be zer...

Page 53: ...ver Assembly Resistor 8550 CP Panel 3 21899 Mounting Bracket Resistor 4 6226 Meter 0 50 mV DC 2 5 Custom Scale 5 6221 Meter Face 30V 30A 6 3192 Plug Bumper 0 875 x 0 250 7 6608 Slide Resistor 1 Ω 1000 8 6566 Resister 1 0R 100W 31 6A Adjustable 9 6217 Shunt Type 766 30 Amp 50mV Holloway SW w Base 10 6714 Terminal Block 3P 14 2 0 AWG 175A 11 7941 Terminal Block POS NOTE Panel Meter 6226 comes with a...

Page 54: ...ons are listed below Figure 30 Model 8550 RU TEG Dimensions WEIGHT AND DIMENSIONS Diameter of Top 61 in 155 cm Overall Height 40 in 102 cm Length of Lower Cabinet 18 in 46 cm Width of Lower Cabinet 18 in 46 cm Height of Lower Cabinet 17 in 44 cm Weight with Power Conditioner 225 lb 102 kg ELECTRICAL SPECIFICATIONS Power Rating at 20 C Output Adjustment Range 480 Watts 12 Volts 12 Volt Models 11 4 ...

Page 55: ...gas The cold junction of the thermocouples is maintained at 235 F 163 C by an array of heat pipes that transfer the heat to the ambient air The cold junction of the thermocouples is maintained at a lower temperature 163 C or 235 F by an array of heat pipes that transfer the heat to the ambient air by natural convection Each heat pipe is hermetically sealed and contains a measured amount of fluid i...

Page 56: ... Operating voltages outside the nominal 24 to 30 Volt range are best achieved by connecting a DC to DC Converter to the output of the TEG Nominal 12 Volt and 48 Volt DC DC Converter options are available for the Model 8550 RU TEG Consult GPT for assistance with finding the best system to suit your application The available power of a Model 8550 RU TEG is also a function of the amount of cooling su...

Page 57: ...Global Power Technologies APPENDIX C SYSTEM WIRING DIAGRAM 302954 rev0 Model 8550 RU Page 53 of 53 APPENDIX C SYSTEM WIRING DIAGRAM Figure 33 Model 8550 RU TEG Wiring Diagram ...

Page 58: ...t Temperature Ignition Fuel Pressure Corrected Air Temperature Operating Fuel Pressure Wind Speed Site Elevation Set Power at Corrected Temperature Corrected Fuel Pressure for Elevation POWER LEVELS Time Burner Fuel Pressure Voltage V Current A Power W Start Time Start 15 minutes 30 minutes 40 minutes 50 minutes 60 minutes ...

Page 59: ...302954 rev0 Model 8550 RU TEG Performance Log MODEL NO SERIAL NO FUEL TYPE ...

Page 60: ...302954 rev0 Model 8550 RU TEG Performance Log MODEL NO SERIAL NO FUEL TYPE ...

Page 61: ...2 20 C 36 F Good TC TD TA TC 20 C 36 F Replace TC TD 1 2 3 4 5 6 7 8 9 10 11 12 Hand temperature inspection of Model 8550 RU TEG heat pipes is done to check that the heat pipe is warm up to 2 inches 50 mm from the tip If the inspection satisfies the hand inspection as per Section 3 5 1 the detailed inspection described in Section 3 5 2 is not required Heat Pipe Geographic Orientation Map and Wind ...

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