Global S-8500 Operating Manual Download

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- Do not store or use gasoline or other flammable

vapors and liquids in the vicinity of this or any

other appliance.

- WHAT TO DO IF YOU SMELL GAS:

• Do not try to light any appliance.

• Do not touch any electrical switch; do not 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.

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 and maintenance

instructions thoroughly before installing

or servicing this equipment.

WARNING:

For Outdoor Use Only

Summary of Contents for S-8500

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 changement le service ou l entretien peuvent cau ser des dommages ou des dégâts matériaux Lisez les instructions d ins tallation d opération et d entretien complètement avant d installer ou entretenir cet équipement AVERTISSEMENT Pour l ...

Page 3: ...0 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 64131 Rev 2 CSA T I L R 10 Thermoelectric Generators ...

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Page 5: ... POWER CURVE 13 4 3 TARGET SET UP POWER CALCULATION 15 4 4 CUSTOMER POWER OUTPUT 16 5 PERFORMANCE 17 5 1 FUEL SYSTEM 17 5 2 BURNER MAINTENANCE 18 5 3 SI SYSTEM MAINTENANCE 19 5 4 COOLING SYSTEM 21 6 TROUBLESHOOTING 23 APPENDIX 25 APPENDIX A TERMS DEFINITIONS 25 APPENDIX B TECHNICAL SPECIFICATIONS 26 APPENDIX C UNPACKING INSTALLATION CLARIFICATIONS 30 APPENDIX D ELECTRICAL SCHEMATICS CONNECTIONS 31...

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Page 7: ... 5 kPa 1 2 psi The Thermoelectric Generator must be isolated from the gas supply pip ing system by closing its individual manual shut off valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 3 5 kPa 1 2 psi WARNING Keep the Thermoelectric Generator area clear and free from combustible materials gasoline and other flammable vapors and liquids Mai...

Page 8: ...y and a low tipping angle of 11 degrees from vertical The Generator must be securely bolted to a mounting pad or platform when assembled See Appendix B WARNING Inspect and check all gas connections for leaks using a commercially available liquid leak detection fluid after installation or service to any part of the fuel system Remedy any fuel system leaks prior to starting the Thermoelectric Genera...

Page 9: ...ment See Appendix B Overall Weight Dimensions for mounting hole locations WARNING Maintain a minimum clearance horizontally of 46 cm 18 inches from the TEG on all four sides to combustible walls DO NOT use a combustible roof above the TEG Consult with GPT for using non combustible roofing and its required clearances 2 2 UNPACKING Unpack the TEG from its shipping crate keep the crate until the TEG ...

Page 10: ... two lifting lugs lift the TEG 4 Line up the holes on the stand with the holes on the TEG Use specified fasteners to assemble the TEG on the stand A17 through A19 in Appendix F Figure 14 5 If removed reinstall the exhaust rope gasket B3 inside the groove in the exhaust assembly B2 Refit the exhaust assembly B2 B3 and fit the rain cap B1 in Appendix F Figure 14 with fasteners B10 through B13 in App...

Page 11: ... use of an additional primary regulator is recommended to hold the input pressure relatively constant Propane LPG 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 juri...

Page 12: ...m of the Electrical Assembly using appropriate cable connectors for the wire or cable being used Allow enough wire to connect to the terminal block TB 1 terminals 3 and 4 Grounding and bonding connections may be made to TB 1 terminal 5 Refer to Appendix D Figure 12 WARNING Use supply wires with a minimum wire gauge of 8 AWG copper wire and a minimum temperature rating of 90 ºC ...

Page 13: ...ating position 6 Check that the TEG has been properly grounded and bonded to the site ground 7 Remove the left and right cabinet panels by turning the 1 4 turn fasteners counter clockwise 8 Inspect the air shutter for cleanliness and open to 50 9 Open the main electrical enclosure and prop open the door using the slide latches on the top of the enclosure 10 Check that the internal battery has been...

Page 14: ...de 8 60 seconds after successful ignition of the pilot burner the main burner solenoid valve is turned on as indicated by LED L2 on the SI Controller and the TEG will rapidly heat up and start to produce power Note The ignition system contains a single 6 V 5 0 Amp hour monobloc rechargeable battery and a battery charger A new fully charged battery provides approximately 120 minutes of operating ti...

Page 15: ...reading 27 0V d If the output voltage reading is the desired output voltage proceed to step 5 e If the output voltage reading is not the desired output voltage press switch S1 DN to decrease the setting or switch S2 UP to increase the setting in steps of 0 05V as needed to set the desired voltage 5 Measuring the power a Connect the DC voltmeter leads to M1 M2 measurement points of the HPL b Press ...

Page 16: ...power greater than the target set up power 11 Re adjusting Air Shutter a Decrease the air shutter in increments of 5 to 10 and allow the TEG to stabilize for 15 minutes between power measurements and adjustments This will cause the power to increase between adjustments b When the power starts to decrease slightly reverse the last air shutter adjustment This should be the optimum setting NOTE Optim...

Page 17: ...obal Power Technologies 11 S 8500 3 5 SHUT DOWN Shut off the manual fuel shut off valve If the TEG Controller Remote Start option has been installed refer to Appendix I Options for shut down instructions ...

Page 18: ...formation Serial Number is the unique identifier for the individual TEG and is date coded Fuel Type NATURAL GAS or PROPANE IMPORTANT Each time of fuel requires a specific system configuration therefore use only the fuel indicated Fuel Input Rating is the nominal energy content of the fuel expressed in kilowatts kW Inlet Pressure is the maximum permitted fuel supply pressure in kilopascals kPa Desi...

Page 19: ...TEG is primarily dependent on the heat input and the cooling system The heat input is fixed via combustion of fuel and the cooling is provided by the fin base fins and fin duct all of which work together Cooling is affected by ambient temperature humidity wind and altitude The following chart shows the gross power output of the thermoelectric power unit prior to power conditioning and without cons...

Page 20: ...ts will need to be made to the air intake shutter opening more with increased altitude to provide sufficient oxygen to the burner for full combustion of the fuel GPT s manufacturing facility sits at 750 m above sea level Performance will increase at lower altitudes At sea level the performance will improve by about 5 545W output At 3000 m the performance may be up to 15 lower 450 W output The foll...

Page 21: ...mple Target Power of a matched load of 1 3 Ohms 555 W at 55oC and sea level 0 m ASL 555 W x 0 925 x 1 05 539W Note Customer available power is the target setup power minus the power losses of the system 0 85 0 90 0 95 1 00 1 05 1 10 0m 500m 1000m 1500m 2000m 2500m 3000m Altitude Performance Multiplication Factor Altitude ASL 64260 rev0 Figure 6 Thermoelectric Power Unit Altitude Derate Curve ...

Page 22: ...ement parts and service instructions The power expected at the output of the TEG needs to account for the power losses within the system Power losses come from interconnections as well as power required to run the High Power Limiter the solenoid valves the spark ignitor module and controller and any additional options that may have been added These electronics have been designed to draw as little ...

Page 23: ...ions explain the required basic maintenance for TEG sub systems 5 1 FUEL SYSTEM Follow these steps to drain the Sediment Bowl 1 Shut off the fuel supply and allow TEG to cool approximately 1 hour 2 Open the drain cock located on the underside of the TEG cabinet any impurities will drain through the cock 3 Close drain cock 4 Leak check the drain cock WARNING Check for fuel leaks after any fuel syst...

Page 24: ...nger tight when reassembling the parts CAUTION Always use the same size orifice as was removed See Appendix F Parts list 7 Connect the fuel line to solenoid valve and orifice then tighten the fuel line fittings 8 Leak check all connections using a commercial leak detector 5 2 BURNER MAINTENANCE Burner internals are maintenance free for most applications If the required power still cannot be achiev...

Page 25: ...mbling the parts 10 Before re starting the TEG leak check all fuel connections 5 3 SI SYSTEM MAINTENANCE CAUTION 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 See Appendix G Figure 22 5 3 1 Follow these steps to check the spark electrode 1 Remove the spark electrode by loosening...

Page 26: ...llow these steps to check the pressure switch 1 Remove the two wires from the pressure switch and connect a multi meter across the pressure switch terminals set to measure resistance ohms 2 If there is no fuel pressure in the system check the resistance measured across the switch is near infinity which indicates the switch is open 3 Provide fuel pressure to the switch by opening the manual shut of...

Page 27: ...e main solenoid valve turns on 60 seconds after the pilot valve The same process can be used for the main valve Reference Appendix F Figure 16 item C5 and Figure 2 5 3 6 Battery Follow these steps to check the battery voltage 1 Open the front of the electronics box 2 Locate the battery see Appendix F Figure 18 3 Disconnect the connector with the brown and white wires from the battery to remove the...

Page 28: ...Global Power Technologies 22 S 8500 This page is purposely left blank ...

Page 29: ... incorrect Replace the fuel orifice Maintenance Air shutter adjustment incorrect Adjust the air shutter Operation Performance SI system faulty Maintain the SI system Maintenance Burner will ignite but will not continue to burn Supply gas pres sure too low Increase the gas supply pressure to the TEG Installation Fuel filter dirty Drain the regulator sediment bowl Maintenance Replace the fuel filter...

Page 30: ...aintenance Fuel pressure adjustment incorrect Adjust TEG fuel pressure Operation Performance Air shutter adjustment incorrect Adjust air shutter Performance High Power Limiter damaged Replace the High Power Limiter electronics Contact GPT Power unit damaged Contact GPT Contact GPT Output power is too high Fuel pressure adjustment incorrect Adjust the TEG fuel pressure Operation Performance Output ...

Page 31: ...onnected breaking the circuit to the load the volt age measured across the power unit leaps up to a new value This is known as the momen tary open circuit voltage Voc Power Unit PU The hermetically sealed portion of the TEG that contains the thermoelec tric materials Rated Power Model S 8500 TEG produces 520 W when operating in an ambient tempera ture of 20 ºC 68 ºF Set up Voltage Vset Voltage fro...

Page 32: ... 9 in Height 2466 mm 97 1 in Net Weight 273 kg 603 lbs Shipping Weight 415 kg 916 lbs Mounting Holes 689 mm 689 mm 27 12 in 27 12 in Figure 9 Overall Dimensions Centre of Mass and Anchor bolt pattern Table 1 Overall Dimensions Weight and Anchor bolt pattern 29 9 37 0 97 1 27 12 ANCHOR BOLT CENTERS 64120 rev0 32 9 58 1 40 2 39 0 27 12 ANCHOR BOLT CENTERS 62 843 CENTER OF MASS ...

Page 33: ...imum Ratings CAUTION Under severe wind loading conditions some damage to sheet metal parts can be expected In such cases inspect for damage prior to being returned to opera tion If excessive damage is found contact GPT Parameter Value Notes Output Power 520 W 24 V At 20oC 750m ASL at output terminals includ ing reverse current diode losses at beginning of life Start up time 15 Minutes to 80 Rated ...

Page 34: ... 5 mV ºC 240cell Nominal factor Voltage Sense Relay VSR Two Each with single Nor mally Open NO Nor mally Closed NC con tacts 16 28 AWG Wire VSR1 Adjust 20 to 32 V Factory set to 23 0 V VSR2 Adjust 20 to 32 V Factory set to 28 5 V VSR Contact Rating 1 A 30 VDC Voltage Limiter User Interface Yes Via Digital Multimeter Voltage Measurement Accu racy 1 5 of Set point Current Measurement Accu racy 2 0 o...

Page 35: ...han 0 ºC 32 ºF at 170 kPag 25 psig 3 Shall have less than 115 mg m3 approx 170 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 of water vapor 8 Shall have less than 1 by ...

Page 36: ...ation of hoisting points Figure 10 Locating resistor assembly APPENDIX C UNPACKING ASSEMBLY CLARIFICATIONS 64125 rev0 HOISTING LOCATIONS OPERATING POSITION MAINTENANCE SHIPPING AND 64126 rev0 POSITION J HOOKS RETAINING BANDS DATA PLATE BEHIND THIS LEG ...

Page 37: ...Global Power Technologies 31 S 8500 APPENDIX D ELECTRICAL SCHEMATICS CONNECTIONS Figure 12 Basic wiring diagram ...

Page 38: ... T153 BRN 10 RESISTOR ASSY CHASSIS STUD TGND6 GRN 10 2 TEG HIGH VOLTAGE CABLE P0WER UNIT W B 8 W R 8 TGND3 GRN 8 PRESSURE SWITCH T204 T205 TGND2 T210 T211 TGND5 3 3 3 3 6V BATTERY YEL ORG BLU 20 T314 T316 T422 T130 WHT RED 10 T131 WHT BLK 10 T133 WHT BLK 10 BASE ELECTRICAL ASSY GRN 20 SOLEINOID START SOLEINOID RUN 4 CUSTOMER LOAD SWRL3 SWRL1 SWRL2 RVL2 T144 T146 T148 T149 T145 T147 T151 T153 T152 ...

Page 39: ...1 7 8 wrench 1 1 wrench 2 Adjustable wrenches that will open to 16 mm 5 8 in 1 Flat head screwdriver 1 Phillips head screwdriver 1 1 8 m 6 ft step ladder for any service requiring inspection of the rain cap or exhaust Additional tools required for installation 1 Lifting device capable of lifting 273kg 603lbs under expected weather conditions 2 shackles 1 Lifting strap chain or cable 4 Bolts nuts 1...

Page 40: ...A9 62349 FIN DUCT OUTER HEM OVERLAP S 8500 A10 62348 FIN DUCT INNER HEM S 8500 A11 62350 CLAMP BAND 0 75 WIDE 36 00 36 35 DIA A12 62351 J HOOK 304 SS MOUNTING HOOK FIN DUCT S 8500 A13 3094 SCREW HEX HD 20 X 0 75 LG SS A14 557 WASHER FLAT SS A15 541 WASHER LOCK SPRING SS A16 611 NUT HEX 20 SS A17 62789 SCREW HEX HD 7 16 14 X 1 0 LG SS A18 63336 WASHER FLAT 7 16 HARDENED SS A19 62790 NUT HEX 7 16 14...

Page 41: ...NG 1 4 SS B11 266 SCREW CAP SOC 1 4 20 X 1 2 SS B12 63457 STANDOFF RAIN CAP S 8500 B13 1835 SCREW CAP SOC 1 4 20 X 1 25 SS B14 5578 WASHER FLAT 5 16 SS B15 5576 SPRING SPAE NAUR 610 403 B16 63459 BRACKET STIFFENER FIN BASE S 8500 B17 3094 SCREW CAP HEX HD 1 4 20 X 3 4 LG SS B18 62360 FIN BASE ASSY S 8500 B19 100108 CLAMP FIN BASE S 8500 B20 300230 NUT HEX LOCK FLEX TOP 1 4 20 SS B21 100141 WASHER ...

Page 42: ...B 1 6 0 5 C9 59564 GAUGE PRESSURE 0 30 PSI HIGH TEMP C10 21109 TEE STREET 1 8 NPT SS SS 2 ST C11 51600 REDUCER 1 4 FNPT X 1 8 MNPT SS 4 RA 2 SS C12 50289 ELBOW STREET 1 8 NPT SS SS 2 SE C13 58949 PLUG 1 4 NPT X 7 8 STEEL UMBRAKO 1105766 C14 21569 ELBOW STREET 1 4 NPT B 4 SE C15 63181 BREATHER VENT 1 4 NPT 316 SS C16 72322 CABLE PLUG SOLENOID VALVE TYPE 2518 DIN Figure 16 Fuel system overview 64121...

Page 43: ... FLAT 1 4 SS D12 63070 MOUNTING BRACKET FUEL SYSTEM S 8500 D13 24498 SCREW HEX HD 1 4 20 UNC X 0 75 316 SS D14 68098 FUEL LINE SNUBBER TO SPARK POST S 8500 D15 22520 SCREW HEX HD 1 4 20 X 3 75 SS D16 62823 SCREW HEX HD 5 16 18 X 1 0 LG SS D17 5578 WASHER FLAT 5 16 SS D18 25648 WASHER LOCK SPRING 5 16 SS D19 5579 NUT HEX 5 16 18 SS D20 62951 ELECTRODE ASSY SI S 8500 D21 63454 ORIFICE ASSY 0 056 S 8...

Page 44: ...LE CLEAR E7 62416 LABEL LAMACOID BREAKER S 8500 E8 29722 SHUNT 50 mV 50 AMP LA 50 50 E9 29141 TERMINAL BLOCK 5 POSITION KULKA 603 5 E10 62422 BATTERY 2V 5 0 AH E11 62587 PCB ASSY X CELL BATT INTERCONNECT 6V E12 69005 SI MODULE FENWALL S 1100 E13 300065 PCBM FENWALL SI INTERFACE S 8500 E14 66222 FUSE 3 AMP 32V VIOLET MINI ATM NOT 56980 SENSOR TEMPERATURE TRISTAR TS RTS OPTION SHOWN Figure 18 Main e...

Page 45: ... F2 62733 FIN BANK 1 S 8500 F3 62734 FIN BANK 2 S 8500 F4 62735 FIN BANK 3 S 8500 F5 62736 FIN BANK 4 S 8500 F6 2390 SCREW HEX HD 3 8 16 x 1 5 SS F7 100082 WASHER DISC SPRING 3 8 4822LB 17 7 PH Figure 19 Cooling Sub System Item Part No Description F1 F2 F2 F2 F2 F5 F4 F3 F3 F2 F2 F3 F2 F2 64124 rev1 F6 F7 ...

Page 46: ...LE LOWER STAND S 8500 G3 62822 SCREW HEX HD 5 16 18 X 0 875 LG SS G4 5578 WASHER FLAT 5 16 SS G5 5579 NUT HEX 5 16 18 SS G6 62789 SCREW HEX HD 7 16 14 X 1 0 LG SS G7 63336 WASHER FLAT 7 16 HARDENED SS G8 62790 NUT HEX 7 16 14 SS Figure 20 Lower stand assembly Item Part No Description 64129 rev0 G1 G2 G3 G4 G5 G8 G6 G7 ...

Page 47: ...3 SCREW HEX HD 1 4 20 X 1 0 LG 316 SS D 22023 WASHER FLAT 1 4 316 SS E 64173 CONVERTER ASSY DC DC 24 12 S 8500 BAP 419 12V Q3293 64166 CONVERTER ASSY DC DC 24 48 S 8500 BAP 419 48V Q7140 F 611 NUT HEX 1 4 20 SS NOT SHOWN 64105 CONDUIT ASSY TEG TO CP PANEL S 8500 64106 CONDUIT ASSY TEG TO DC DC CONVERTER S 8500 64107 CONDUIT ASSY DC DC CONVERTER TO CP PANEL S 8500 Figure 21 Options assembly Item Pa...

Page 48: ...t Start Solenoid valve indicator Fig F 3 Solenoid valve C5 A L2 Indicator Green Main Run Solenoid valve indicator Fig F 3 Solenoid valve C5 B L3 Indicator Green SI module power indicator L4 Indicator Yellow SI Module No Combustion signal indicator L5 Indicator Red Lockout indicator L6 Indicator Red Voltage supply blown fuse indicator L7 Indicator Red Battery supply blown fuse indicator Blinks diml...

Page 49: ... parameters from the analog voltage meter port the user will need a multimeter or a DC voltage meter with a minimum range of 30 Vdc and a minimum accuracy of 1 Analog voltage meter port 2 voltage measurement points and Analog voltage meter port voltage signal range 0 0 V to 9 9 V The multimeter will read a DC voltage which is scaled as 1 Voltage 0 1 V Volt e g a 27 0 Volt output will read as 2 70 ...

Page 50: ...djustment active L3 Indicator Green VSR2 Solid Meter output displays VSR2 voltage set point Blinking VSR2 set point adjustment active L4 Indicator Green OP Solid Meter output displays TEG power L5 Indicator Green OC Solid Meter output displays TEG current L6 Indicator Green Heart beat LED Blinks to indicate HPL is running L7 Indicator Green Solid Indicates output voltage is above VSR1 set point an...

Page 51: ...d and flashing 5 Press switch S1 DN to decrease setting and switch S2 UP to increase setting in steps of 0 05 V as needed to the required voltage reminder e g a 27 Volt output voltage will read as 2 7 V on the multimeter 6 If setup is complete turn the Customer Load circuit breaker to the ON position CAUTION Be aware the High Power Limiter input and output voltage will follow operator s adjustment...

Page 52: ...put voltage set point will be automatically adjusted according to the battery temperature An optional temperature sensor must be connected to the socket on the High Power Limiter see Figure 23 in order for temperature compensation mode to work correctly The temperature sensor should also be attached to one of the posts of the station battery WARNING TCBC opertation for 24V system only Always disco...

Page 53: ...500N 12 RS 8535 S 8500N 24 RS 8531 S 8500N 48 RS 8539 S 8500N 12 CP 8542 S 8500N 24 CP 8544 S 8500N 48 CP 8546 S 8500L 12 8536 S 8500L 24 8532 S 8500L 48 8540 S 8500L 12 RS 8537 S 8500L 24 RS 8533 S 8500L 48 RS 8541 S 8500L 12 CP 8543 S 8500L 24 CP 8545 S 8500L 48 CP 8547 Table 7 S 8500 Standard Part Numbers Where N Natural Gas L LPG or Propane 12 Nominal 12 V Output via DC DC Converter 24 Nominal...

Page 54: ...uests be attempted If an ignition request is received with no fuel pressure the 7 segment display will show nPS to indicate the pressure switch has not closed Ignition The Remote Start Board provides an ignition signal to the spark ignition control system SI Controller when it has been requested to start and removes the ignition signal when it is requested to stop During the time it is requesting ...

Page 55: ...rature compensation logic on voltage measurements when a temperature sensor is connected to the TEMP pins of connector A1 This ensures the accuracy of the Auto Start and Auto Stop voltage thresholds regardless of the environment The temperature sensor should be attached to one of the posts of the station battery and is recommended for all Auto mode systems If not connected the Remote Start Board d...

Page 56: ...he SI System failed to start after three spark attempts Up to 36V 200mA contact closure SO4 SCADA Auto output Signal to the SCADA system that the Auto functionality is ON Up to 36V 200mA contact closure SO5 SCADA Local output Signal to the SCADA system that the TEG is operating in the Local mode SCADA start signals are ignored until Lo cal mode timeout Up to 36V 200mA contact closure S1 button Sta...

Page 57: ...eshold adjustment Adjust Mode L7 Indicator Reserved for future use L8 Indicator Remains lit when system voltage is being displayed Display Mode L9 Indicator Reserved for future use L10 Indicator Blinks during Auto Stop threshold adjustment Adjust Mode Remains lit when measured voltage on the V2 input is being dis played Display Mode L11 Indicator Remains lit when external temperature from the TEMP...

Page 58: ...he external voltage level is displayed Vext ii L10 Indicator The voltage read on input V2 is displayed V2 This will be near zero if input V2 is unused iii L11 Indicator The temperature of the optional external temperature sensor input is displayed TEMP If no temperature sensor is connected it will display ERR instead 2 Further presses of S5 Display will exit Display mode When running off battery p...

Page 59: ...iables listed below The corresponding LED indicator above the display will also blink i L6 Indicator The external voltage level at which the TEG will start if in Auto and Remote modes Astrt ii L10 Indicator The external voltage level at which the TEG will stop if in Auto and Remote modes Astop 2 Press S7 Up or S8 Down to make changes to the displayed variable 3 Further presses of S6 Adjust will ex...

Page 60: ...K 10 BASE ELECTRICAL ASSY GRN 20 2 SOLEINOID START SOLEINOID RUN 4 CUSTOMER LOAD SWRL3 SWRL1 SWRL2 RVL2 T144 T146 T148 T149 T145 T147 T151 T153 T152 WHT 10 T150 WHT 10 TOP BOTTOM HIGH POWER LIMITER SUB ASSY GRN RED BLK SURGE PROTECTOR DEVICE T128 RED 10 T200 T106 RED 10 TB1 T141 WHT BRN T143 GRN BRN T137 GRN BRN T136 WHT T138 RED T139 BLK T134 RED T135 BLK 6300 63005 6300 62398 OPTIONAL TEG CONTRO...

Page 61: ...rface Panel APPENDIX I2 CATHODIC PROTECTION CP INTERFACE SYSTEM INTRODUCTION The Cathodic Protection Interface System provides for adjustment and monitoring of power to the CP load The anode and cathode cables enter the cabinet at the bottom and connect directly to the heavy duty terminal block Refer to Figure 26 for locations and descriptions of the major components of the CP interface cabinet ...

Page 62: ...oil voltage controlled 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 PARALLEL By connecting the large power resistor in parallel with the TEG smaller levels of power may be delivered to the CP load with the current and hence pipe to soil voltage controlled and sometimes required to reduce hot spots on the CP anode With...

Page 63: ...Global Power Technologies 57 S 8500 Figure 29 CP Panel wiring schematic ...

Page 64: ... F Figure 21 To connect the DC DC Converter to the TEG Install the Conduit and connect wires as per Figures 30 and 31 To Connect the user load to output and as shown in Figure 30 The connection requires a Ring Terminal for a 10 Stud The GND Connection is a 10 Screw on the Left hand side of the unit WARNING Use supply wires with a minimum wire gauge of 8 AWG copper wire and a minimum temperature ra...

Page 65: ...Global Power Technologies 59 S 8500 Figure 30 DC DC Converter Connections ...

Page 66: ...Global Power Technologies 60 S 8500 Figure 31 DC DC Converter with CP Panel wiring schematic ...

Page 67: ...r TCBC to be effective See Appendix H for the location to connect the sensor to the power electronics The TCBC mode can only be used for lead acid batteries Note that there are multiple types of lead acid batteries which may require different charging voltages for the given application WARNING Always refer to battery manufacturer specifications for the re quired application s charging voltages dep...

Page 68: ...en the TEG Controller board is in the remote mode see Appendix I1 for more operation details WARNING If the second temperature sensor is not used which will adjust the auto stop voltage then the battery may not be ideally charged according to the manufacturer s specifications The TEG can be either the primary charger in a TEG only system or it may be the secondary charger in hybrid system The TEG ...

Page 69: ...ted stop voltage then the TEG will run continuously until the temperature rises to undo this condition This is often the case at cooler temperatures see table 12 for the effect of temperature compensation An example of cycle charging would be when the TEG is a secondary charger in a hybrid system and provides backup charging in when the primary charging system is unable to charge the bat tery WARN...

Page 70: ...rs 48V One temperature sensor to Remote Start Absolute Maximums 12 6 24 32 30 48 57 60 TCBC Temperature Compensated Battery Charging n a Not Applicable S 8500 12V Not applicable for battery charging it is intended for CP applications The 12V DC DC converter is a tightly regulated converter with minimal adjustment Ensure Auto functionality is OFF S 8500 48V The DC DC converter has no temperature co...

Page 71: ...29 5 58 7 62 2 59 0 15 29 6 31 4 29 8 59 4 62 9 59 7 Table 14 Effects of Temperature Compensation CAUTION If Auto is turned off reset the output voltage to the float charging voltage See the effect of temperature compensation in table 12 Effects of temperature compensation The following table shows the effects of temperature compensation on a nominal set point at 25ºC dependent upon the changing a...

Page 72: ...Global Power Technologies 66 S 8500 Figure 32 Flowchart Battery Charging Application Setup ...

Page 73: ... 8500 APPENDIX K TEG PERFORMANCE LOG MODEL NO TEG SERIAL NO FUEL TYPE HPL SERIAL NO CP INTERFACE SERIAL NO DATE TIME AMBIENT TEMP ºC CORE TEMPERATURE o C TARGET POWER FUEL PRESSURE psi VOLTAGE V CURRENT A POWER W MAINTENANCE REMARK ...

Page 74: ... 8500 APPENDIX K TEG PERFORMANCE LOG MODEL NO TEG SERIAL NO FUEL TYPE HPL SERIAL NO CP INTERFACE SERIAL NO DATE TIME AMBIENT TEMP ºC CORR TMEPERATURE o C TARGET POWER FUEL PRESSURE psi VOLTAGE V CURRENT A POWER W MAINTENANCE REMARK ...

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