Teg 5220 Manual

- Do not store or use gasoline or other flamma-

ble 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 suppli-

er’s instructions.

• If you cannot reach your gas supplier, call

the fire department.

- Installation and service must be performed by

a qualified installer, service agency or the gas

supplier

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 installa-

tion, operating and maintenance

instructions thoroughly before

installing or servicing this equipment.

WARNING: For Outdoor Use Only

- Ne pas entreposer ou utiliser de l'essence,

d'autres liquides ou vapeurs inflammables à

proximité de cet appareil ou d'aucun autre

appareil.

- QUE FAIRE SI VOUS SENTEZ LE GAZ:

• N'allumez aucun appareil

• Ne touchez aucun commutateur électrique;

n'utilisez pas le téléphone de votre bâtiment

• Appelez immédiatement votre fournisseur

de gaz d'un téléphone dans un bâtiment

voisin, si possible. Suivez les instructions

du fournisseur de gaz.

• Si vous ne pouvez pas atteindre votre four-

nisseur de gaz, appelez le service d'in-

cendie.

- L’installation et le service doivent être effec-

tués par une personne qualifée, une compag-

nie de service ou le fournisseur de gaz.

AVERTISSEMENT:L'installation

inexacte, l'ajustement, le change-

ment, le service ou l'entretien peu-

vent causer des dommages ou des

dégâts matériaux. Lisez les instruc-

tions d'installation, d'opération et

d'entretien complètement avant d'in-

staller ou entretenir cet équipement.

AVERTISSEMENT: Pour l'usage extérieur seulement

AVERTISSEMENT: si l'information de ce

manuel n'est pas suivie exactement, un

incendie ou une explosion peut resulter entraî-

nant des dégâts matériaux, des blessures ou la

perte de vie.

5220

THERMOELECTRIC

GENERATOR

Operating Manual

28142 rev. 5

Global Thermoelectric

#9, 3700 - 78th Ave. S.E.

Calgary, Alberta

Canada T2C 2L8

TEL: 1-403-236-5556

FAX: 1-403-236-5575

WEB: www.globalte.com

NOTICE TO INSTALLER: These instructions shall be left with the consumer to

retain them for future reference.

Table of Contents

1 About this Manual................................................................................................1

1.1 Health and Safety .......................................................................................1

1.1.1 Warnings ..........................................................................................1

1.1.2 Cautions ...........................................................................................1

1.1.3 Trained Operators ............................................................................1

1.2 Technical Terms ..........................................................................................1

2 Quick Start Procedure .........................................................................................3

2.1 Installation ...................................................................................................3

2.2 Start Up .......................................................................................................3

2.3 Adjustment ..................................................................................................4

2.4 Performance Log.........................................................................................4

3 Technical Specifications .....................................................................................5

3.1 Overview .....................................................................................................5

3.2 Options........................................................................................................5

3.3 Weights and Measures ...............................................................................7

3.4 Ignitor Control System ...............................................................................8

3.5 Data Plate ...................................................................................................8

3.6 Fuel Consumption .......................................................................................9

3.7 Standard Specification for Gaseous Fuel..................................................10

4 Process Description ..........................................................................................11

4.1 Model 5220 Thermoelectric Generator .....................................................11

4.1.1 Fuel System....................................................................................12

4.1.2 Spark Ignition Control System ........................................................13

4.1.2.1 Resetting The Power Supply ............................................13

4.1.3 Burner ............................................................................................13

4.1.4 Power Unit ......................................................................................15

4.1.5 Cooling Fins and Fin Duct ..............................................................16

4.1.6 Cabinet............................................................................................16

4.1.7 Optional TEG Mounting Stands ......................................................16

4.2 Optional 220 Watt Limiter ........................................................................17

4.3 Optional 220 Watt Limiter Converter.........................................................19

4.4 Optional Cathodic Protection Interface System ........................................20

5 Installation .......................................................................................................21

5.1 Precautions ...............................................................................................21

5.2 Tools Required ..........................................................................................21

5.3 Unpacking .................................................................................................21

5.4 Assembling................................................................................................22

5.5 Mounting ...................................................................................................23

5.6 Supplying Fuel ..........................................................................................24

5.6.1 Connecting the Fuel Supply............................................................24

5.6.2 Fuel Considerations ........................................................................24

5.7 Connecting Customer Load ......................................................................26

5.8 Installation of Optional L/C........................................................................27

5.8.1 Attaching the L/C to TEG................................................................27

5.8.2 TEG Wiring Interconnection............................................................27

5.9 Installation of Optional CP Interface System ............................................28

5.9.1 Attaching the CP Interface System to TEG ....................................28

5.9.2 TEG Wiring Interconnection............................................................30

5.9.3 Connection of CP Load...................................................................30

6 Start Up and Shutdown .....................................................................................31

6.1 Before Starting ..............................................................................................31

6.2 TEG Start-Up ................................................................................................31

6.3 Shutdown......................................................................................................31

7 Power Output Evaluation ..................................................................................33

7.1 Required Vset or Setup Power at Site .......................................................33

7.1.1 Working-out Required Vset or Setup Power ....................................33

7.1.2 Determining Vset and Rated Power Graphically..............................35

7.2 Vset and Rated Power................................................................................35

7.2.1 Vset Shortly after Ignition .................................................................36

7.2.2 Examining Vset When Going From Run To Set Up Position ...........37

8 Adustment .......................................................................................................39

8.1 Power Output Adjustment .........................................................................40

8.1.1 Adjustment for Elevation .................................................................40

8.1.2 Air-shutter Adjustment.....................................................................41

8.1.2.1 Measuring CO Emissions Levels ......................................42

8.1.3 Fuel Pressure Adjustment...............................................................43

8.2 Adjustment of Optional L/C .......................................................................44

8.2.1 Output Voltage Adjustment .............................................................44

8.2.2 Voltage Sensing Relay (VSR) Adjustment ......................................44

8.3 Adjustment of Option CP Interface System ..............................................45

8.3.1 CP Power Output Adjustment .........................................................45

8.3.1.1 Series Wiring.....................................................................46

8.3.1.2 Parallel Wiring ...................................................................46

9 Maintenance .......................................................................................................47

9.1 Recommended Periodic Maintenance ......................................................47

9.1.1 Tools and Parts Recommended for Routine Servicing ...................47

9.1.2 Evaluate Vset ...................................................................................48

9.1.3 Routine Service...............................................................................49

9.2 Fuel System Maintenance ........................................................................49

9.2.1 Draining the Sediment Bowl ...........................................................49

9.2.2 Fuel Filter Replacement..................................................................50

9.2.3 Fuel Orifice Inspection ....................................................................51

9.4.7 Check Solenoid Valve .....................................................................56

10 Troubleshooting .................................................................................................61

10.1 Burner Maintenance..................................................................................55

10.1.1 Air Filter Cleaning .........................................................................55

10.1.2 Inspection of Burner Components ................................................55

10.2 Ignition Control System Maintenance .......................................................57

10.2.1 Check the Spark Electrode ...........................................................57

10.2.2 Check the Pressure Switch...........................................................58

10.2.3 Check the Battery Voltage ............................................................58

10.2.4 Check the Power Supply ..............................................................58

10.2.5 Check if the Battery will Hold Charge...........................................59

10.2.6 Check the Operation of the Ignition Controller ............................59

10.2.7 Check Solenoid Valve ...................................................................59

10.3 L/C Examination........................................................................................60

10.3.1 Check L/C Switch Settings ...........................................................60

10.3.2 Check Input Voltage to the L/C.....................................................60

10.3.3 Check Output from the L/C...........................................................60

10.4 Power Unit Examination .............................................................................61

10.4.1 Check for Internal Short................................................................61

10.4.2 Check Internal Resistance............................................................61

11 Part List .......................................................................................................63

11.1 Model 5220 TEG.........................................................................................65

11.2 Model 5220 Burner .....................................................................................68

11.3 Model 5220 Fuel System ............................................................................69

12 TEG Performance Log .......................................................................................71

LIST OF FIGURES

Figure 1 Overall Dimensions of the 5220 TEG . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Figure 2 5220 TEG General Assembly, shown with L/C Option . . . . . . . . . . . . . . .11

Figure 3 5220 Fuel System General Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Figure 4 Burner General Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Figure 5 Cut-away of a Model 5220 Thermopile . . . . . . . . . . . . . . . . . . . . . . . . . .15

Figure 6 Electrical Output Characteristics (no Power Conditioner) . . . . . . . . . . . .16

Figure 7 220 Watt Limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Figure 8 220 Watt L/C General Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Figure 9 CP Interface System General Assembly . . . . . . . . . . . . . . . . . . . . . . . . .20

Figure 10 Assembling the 5220 TEG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Figure 11 Model 5220 Mounting Dimensions, shown with L/C Option . . . . . . . . . .23

Figure 12 Applying Thread - Sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Figure 13 Setting-up the 5220 TEG, shown with L/C Option . . . . . . . . . . . . . . . . . .25

Figure 14 Wiring Diagram 5220 TEG, shown with 12 V Limiter Option . . . . . . . . . .26

Figure 15 Wiring Diagram 5220 TEG, Shown W/ L/C Option . . . . . . . . . . . . . . . . .27

Figure 16 CP Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Figure 17 CP Wiring for Model 5220-12 V DC, with Limiter Option . . . . . . . . . . . . .29

Figure 18 CP Wiring for Model 5220-24 V DC, with L/C Option . . . . . . . . . . . . . . .29

Figure 19 Vset and Rated Power versus Ambient Temperature . . . . . . . . . . . . . . . .35

Figure 20 Vset versus Time After Ignition, Typical Response . . . . . . . . . . . . . . . . . .36

Figure 21 Change in Fuel Gauge Pressure vs Elevation Above Mean Sea Level,

Typical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Figure 22 Air Shutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Figure 23 Change in Vset versus Air-Shutter Adjustment, Typical . . . . . . . . . . . . . . .42

Figure 24 Change in Vset versus Fuel Pressure Adjustment, Typical . . . . . . . . . . . .43

Figure 25 CP Interface System, Series Wiring Diagram . . . . . . . . . . . . . . . . . . . . .46

Figure 26 CP Interface System, Parallel Wiring Diagram . . . . . . . . . . . . . . . . . . . .46

Figure 27 Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

Figure 28 SI Module Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

Figure 29 Ignition Control Module Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

Figure 30 Momentary Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62

Figure 31 Model 5220 TEG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66

Figure 32 Model 5220 Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

Figure 33 Model 5220 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69

Global Thermoelectric 1

28142 Rev. 5

1 ABOUT THIS MANUAL

This manual provides instructions for the operation and maintenance of the model 5220

Thermoelectric generator.

1.1 Health and Safety

Correct operation and maintenance according to this manual is critical for proper equip-

ment function and safety. Keep the following in mind when using these instructions.

1.1.1 Warnings

Throughout this manual you will notice paragraphs preceded by the text Warning. It is

imperative that the advice in these paragraphs be adhered to, as failure to do so may

result in personal injury or death and possible damage to the equipment.

1.1.2 Cautions

Throughout this manual you will notice paragraphs preceded by the text Caution. It is

imperative that the advice in these paragraphs be adhered to, as failure to do so may

result in damage to the equipment.

1.1.3 Trained Operators

Personnel performing 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 signifi-

cance, defined for the model 5220, are as follows:

Thermoelectric Generator (TEG): A device that produces electrical power through the

direct conversion of heat energy to electrical energy.

Power Unit (PU): The hermetically sealed portion of the TEG that contains the thermo-

electric materials and cooling fins.

Rated Power: Model 5220 TEG power unit produces 220 W when operating in an ambi-

ent temperature of 20ºC (68ºF). With the fuel flow held constant, TEGs operating in

ambient temperatures higher than 24ºC (75ºF) will see power output efficiency reduce,

0.8 W per ºC (0.44 W per ºF) of temperature change up to a maximum ambient temper-

ature of 65.5ºC (150ºF). Conversely for temperatures lower than 20ºC (68ºF) power out-

put efficiency will increase by 0.8 W per ºC (0.44 W per ºF) of temperature change.

Set-up Power: Power from the power unit for a specific ambient temperature. It is

derived from voltage across a precision load, also known as Vset.


28142 Rev. 5

Set-up Voltage: Vset Voltage from the power unit for a specific ambient temperature,

which is proportional to set-up power. Fuel flow to the burner is adjusted so that proper

voltage exists, necessary temperature difference within the power unit maintained, to

deliver required power.

Open Circuit Voltage: Voltage at the terminals of the power unit when no current is

flowing, i.e. open circuit, which is related to the temperature across the thermoelectric

materials inside the power unit.

When a power unit lead is suddenly disconnected, breaking the circuit to the load, the

voltage measured across the power unit leaps up to a new value. This is known as the

momentary open circuit voltage (Voc). The voltage will continue to climb from that level.

In the case of the model 5220 do not allow Voc to exceed 27.0 volts, otherwise, the TEG

can be damaged.

Measured Vset: Vset measured across the power unit using a voltmeter.

Required Vset: Vset needed to achieve rated power for the present ambient temperature.

CP (Cathodic Protection): Thermoelectric generators are used in impressed current

systems for Cathodic corrosion protection of metallic structures such as pipelines.

CP Interface System: An assembly of electrical components system that acts as an

interface between the TEG and the CP load, which also provides for adjustment and

monitoring of power to the CP load.

Limiter/Converter (L/C): A specific electronic device attached between the generator

and the load that converts one level of DC voltage to another, and limits the power unit

voltage.

Manual Shutoff Valve: A manually operated valve in the gas line for the purpose of

completely turning on or shutting off the gas supply to the TEG.

Solenoid Valve (SV): A electrically actuated valve that controls the gas supply to the

burner. This Valve is operated by the Ignition Control Module.


28142 Rev. 5

2 QUICK START PROCEDURE

This section gives the key steps for setting up the TEG. It is for the operator who is

already familiar with operating the TEG, having successfully completed Global

Thermoelectric's TEG training course, and being a qualified service person with reason-

able knowledge and experience with industrial fuel and electrical equipment.

2.1 Installation

Follow these steps to install the TEG:

a) Unpack the TEG from its shipping crate, keep the crate until the TEG is opera-

tional. Locate and identify the following items that were shipped with the 5220

TEG:

� 1 × Fin Duct

� 1 × Cover Plate

� 1 × Thread Sealing Compound

� 17 × Screws, #8-32 × 1/4 in. long, one spare

� 17 × Washers, #8 External Lock , 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 gener-

ator inoperable. Check with the factory before starting a damaged TEG.

b) Assemble the TEG as shown in Figure 10 and mount it on a firm and stable base,

sufficiently high above ground level to prevent the TEG from being inundated with

water. See Section 5, Installation, for details.

c) Connect the fuel supply to the manual shutoff valve, 1/4" FNPT, using the thread

sealant provided. See Section 5.6, Supplying Fuel, for details

d) Connect the customer load:

I) in the case of an optional L/C being fitted connect the load to terminals 5

(-) and 6 (+);

II) in the case of no L/C option connect the load to terminals 4 (-) and 5 (+);

III) for CP applications connect the cathode and anode wires to the external

CP interface box.

2.2 Start Up

Follow these steps to start the TEG:

a) Open the manual shutoff valve.

Note: Once the TEG is started re-closing the manual shutoff valve will shut it off.


28142 Rev. 5

b) The Spark Ignition (SI) system should begin clicking after one second and the

sound of combustion heard within 7 seconds. If the burner does not ignite wait 25

seconds for a second or third ignition trial. After a third trial the ignition control

system will go into stand by mode - see the Ignition control section 4.1.2.

c) Leak check the complete fuel supply system from the fuel supply line to the burn-

er inlet using a commercial leak detector fluid such as Snoop®.

WARNING: When the TEG is operating, surface temperatures in the vicin-

ity of the thermopile, burner, exhaust stack and around the

cooling fin duct may be in excess of 100º C. Avoid contact of

skin and clothing with these areas when operating in and

around the TEG.

2.3 Adjustment

Follow these steps to adjust the TEG:

a) Move the jumper clip on terminal block TB-1 to the SETUP position between ter-

minals 2 and 3, see Figure 14 or 15.

b) Measure the Vset voltage between terminals 2 (+) and 4 (-).

c) Check the measured Vset value rises to that required, as per Power Output

Evaluation section. Measured Vset will level off after 1-hour from ignition. If the

measured value is not in its normal operating range then adjust the power output

as per the Adjustment section.

Caution: Do not allow measured Vset to exceed required Vset, determined

in the Power Output Evaluation section, otherwise overheating

may cause irreparable damage to the power unit.

Note: Details for adjusting the optional L/C and CP interface systems, if applicable, are

located in the Adjustment section.

2.4 Performance Log

Your TEG is now operating successfully, making available continuous electrical power to

the load. It is recommended that a record be kept of the TEG's performance and main-

tenance history. Each time adjustments are made or servicing is carried out the details

should be recorded. A blank TEG Performance Log is provided at the end of this manu-

al.

Note: Servicing requirements are given in the Maintenance section.


28142 Rev. 5

3 TECHNICAL SPECIFICATIONS

This section gives the technical specifications for the Global Model 5220 Thermoelectric

generator.

3.1 Overview

Global's Model 5220 Thermoelectric Generator (TEG) converts heat directly into elec-

tricity with no moving parts. It is a reliable, low maintenance source of DC electrical

power for any application where regular utilities are unavailable or unreliable.

The model 5220 Thermoelectric Generator provides 220 Watts of electrical power from

the power unit at an ambient temperature of 20°C. This power is generated at a nomi-

nal 15 Volts, which can then be converted to other voltages using an optional voltage

converter. The converter is 80% efficient, which provides 175 Watts of net electrical

power with a 24 Volt converter.

If the generator is to be operated at load conditions that force the output voltage to vary

significantly from 15 Volts, then less than the rated power will be available to the load.

Figure 6 identifies the electrical parameters of the 5220 as a function of the load resist-

ance.

The 5220 generator uses Propane (C3H8), or Natural Gas (CH4) as a fuel and with an

ignition control module (SI) will automatically ignite whenever gas pressure is present.

The output voltage from the generator is adjustable from 12 to 18 Volts or from 24 to 30

Volts with the optional DC/DC converter. The 5220 includes a voltage sensing relay

(VSR) that can be used to trigger alarms or other processes when an abnormally low

voltage is detected.

3.2 Options

Mounting Stand: The 5220 can be conveniently mounted 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 cooling air. A

mounting stand is available from Global Thermoelectric.

Cathodic Protection Interface (CP): The Cathode Protection Interface option provides a

termination point for cathode and anode cables up to 9 mm (00 AWG) in size, a meter

to monitor the voltage and current of the CP circuit and an adjustable resistor to control

the output power.

Current Split (CS): The Current Splitting variation of the CP Interface is also available.

The CS version allows two CP circuits to be controlled individually from one CP Interface

unit.


28142 Rev. 5

Power output

Power Ratings

20º C, 750 m above sea level

220 Watts @ 12 Volts

176 Watts @ 24 Volts

Electrical

Adjustment12 V 12–18 Volts

24 V 24–30 Volts

Reverse Current Protection Yes

Output

Terminal block which accepts up to 8 AWG

wire. Opening for 3/4” conduit in the base of

the cabinet.

Fuel

Natural Gas19.7 m3/day (698 ft3/day) of Std. 1000

BTU/SCF (37.7 MJ/Sm3) gas

Propane 27.8 L/day (7.405 gal/day)

Maximum Supply Pressure 413 kPa (60 psig)

Minimum Supply Pressure 241 kPa (35 psig)

Fuel Connection 1/4” FNPT connection

Environmental

Ambient Operating Temperature

Continuously Running TEG

Max. 55º C (130º F)

Min. -55º C (-67 ºF)

Operating Conditions Unsheltered Operation

Materials of Construction

Cabinet 304 Stainless Steel

Cooling Type Natural Convection

ThermopileHermetically Sealed Lead Tin-Telluride

(PbSnTe)

Burner Meeker type, Inconel 600

Fuel System Brass, Aluminum & Stainless Steel

Note: Specifications shown are for standard configurations. Global Thermoelectric’s

Applications Engineering Department is available to design installations meeting

different specifications including custom voltages. fuel supply systems and non-

standard operating temperatures.


28142 Rev. 5

3.3 Weights and Measures

The following table gives the overall dimensions and weights of the TEG.

Depth 794 mm (31.24 in.)

Width 479 mm (18.85 in.)

Height 1275 mm (50.19 in.)

Net Weight 97 kg (214 lb)

Shipping Weight 140 kg (308 lb)

Mounting Holes 267 mm wide × 457 mm deep (10.50 in. × 18.00 in.)

Mounting Hole Diameter 8 mm (0.312 in.)

Figure 1 Overall Dimensions of the 5220 TEG


28142 Rev. 5

3.4 Ignition Control System

The following table gives the technical specifications for the Ignition Control System.

Electrical SI

Power SupplyInput Voltage

Minimum 5.0 V DC

Maximum 35.0 V DC

Power Input 4.16 Watts

Output Voltage 13.8 VDC

SISpark Rate 10/second

Trial For Ignition 7 seconds

Number of tries for Ignition 3 trials until lockout

Inter-Purge Time 25 seconds

Spark GapNominal 4.8 mm (0.19 in.)

Minimum 3.3 mm (0.13 in.)

Maximum 6.3 mm (0.25 in.)

Continuous Operating Time Without Charge120 minutes with full charged batteries @

25ºC (75ºF)

3.5 Data Plate

The data plate is on the inside of the cabinet door and includes vital information about

the generator.

Model Number: The model number on the Data Plate is interpreted as follows:

CP = Cathodic Protection Interface

Fuel Type:

L = Propane

N = Natural Gas

Output Voltage:

12 or 24 Volts

Spark Ignition (SI):

( ) 5220 ( ) - ( ) - SI - C


28142 Rev. 5

Fuel Type: an “X” will be marked in the appropriate box to show whether the genera-

tor is set to burn natural gas (CH4) or propane (C3H8). Suitable orifices are available if

changing the fuel type is necessary.

Fuel Pressure, Power, Voltage: The fuel pressure, gross power output and voltage

across the precision load have been included for reference only. These are the condi-

tions achieved at the Global Thermoelectric factory before shipping. Note that the fuel

pressure is recorded in kPa and that the pressure gauge must be adjusted for the alti-

tude as described in Section 8.1.1.

3.6 Fuel Consumption

The 5220 is certified to operate on commercial propane, or commercial natural gas.

The Fuel Consumption of the 5220 at rated power is listed in the table below for various

Fuels.

Fuel Consumption

at Rated PowerPropane Natural Gas

lb/hr* 1.30 -

gal/hr* 0.31 -

kg/hr* 0.60 -

L/hr* 1.16 -

ft3/hr** 11.10 29

m3hr** 0.31 0.82

* At 15ºC (60ºF)

** At atmospheric pressure and 15ºC (60ºF), assuming an energy content of 37.3 MJ/m3

or 1000 BTU/ft3.


28142 Rev. 5

3.7 Standard Specification for Gaseous Fuel

Note: Fuel considered is for standard configurations.

Gaseous fuel supplied to the TEG shall have:

a. No sand, dust, gums, crude oil, impurities or other objectionable substances in

quantities which are likely to clog fuel filters or regulators.

b. A hydrocarbon dew point of less than 0ºC (32ºF) at the supply pressure.

c. Less than 115 mg/Sm3 * (approx. 169 ppm) of H2S.

d. Less than 60 mg/Sm3 * (approx. 88 ppm) of Mercaptan Sulphur.

e. Less than 200 mg/Sm3 * (approx. 294 ppm) of total Sulphur.

f. Less than 2½% by volume of CO2.

g. Less than 120 mg/Sm3 (5 g/100 cu.ft.) of water vapour.

h. Less than 1% by volume of free oxygen.

Note: Fuel orifices and settings are available for natural gas and propane.

i. Fuel temperature of less than 65ºC (150º F).

*Sm3 - Standard cubic meter of gas at 101.325 kPa at 15ºC.


28142 Rev. 5

4 PROCESS DESCRIPTION

This section describes the function of the equipment, the process of generating power

and available options.

4.1 Model 5220 Thermoelectric Generator

The TEG generates electrical power from heat energy. The overall process is:

a) Provide fuel, mix it with air and ignite making heat available

b) Warm the hot-end of a thermoelectric power unit using the available heat of com-

bustion

c) Cool the cold-end of the thermoelectric power unit using cooling fins

Figure 2 5220 TEG General Assembly, shown with L/C Option


28142 Rev. 5

d) Generate electrical power from the temperature difference created across ther-

moelectric materials housed within the power unit

e) Make the electrical power available to the load

The main parts of the model 5220 TEG, with optional Limiter/Converter (L/C) attached,

are shown in Figure 2.

4.1.1 Fuel System

Components making

up the fuel system

control the input of

fuel to the burner. The

primary control is a

pressure regulator

that modulates fuel

manifold pressure to

a metering orifice.

The pressure regula-

tor includes a sedi-

ment bowl with a

manual drain cock

and fuel filter to

remove fuel impuri-

ties. The fuel filter has

a resin impregnated

cellulose element

which prevents solid particles from damaging the regulator and downstream parts.

The outlet of the pressure regulator leads 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 a orifice mounted on the

front of the burner. The orifice contains a jewel with a precisely sized hole to meter the

fuel flow into the burner. A solenoid valve (SV) is located beneath the cabinet and

plumbed between the manifold and fuel line.

The solenoid valve is controlled by the IgnitionControl System. The IgnitionControl

System opens the solenoid valve when the fuel pressure switch is Closed (fuel pressure

is present), and closes the solenoid valve when fuel pressure switch is open (no fuel

pressure) or the Ignition Control System does not detect combustion. The main parts of

fuel system are shown in Figure 3.

Figure 3 5220 Fuel System General Assembly


28142 Rev. 5

4.1.2 Spark Ignition Control System

The Ignition Control System consists of the following parts:

• Spark electrode

• Pressure switch

• Ignition control module (SI)

• Solenoid valve

• SI Power Supply

• Battery pack

When the manual ball valve is opened, fuel pressure causes the pressure switch (locat-

ed in the fuel system) to close. This, combined with the absence of flame sensed at the

spark electrode, signals the ignition control module (SI) to generate sparks from the

electrode to the combustion chamber plate, as well as open the solenoid valve allowing

gas to flow into the burner chamber, causing ignition to occur. Once combustion is

detected, the 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 solenoid valve, wait for a 25 second purge period and

then make another attempt at ignition. The SI will attempt 3 ignition trials and if flame

detection cannot be maintained, the SI will go into standby mode and the power supply

board will go into sleep mode after 60 seconds. The power supply will have to be reset

for another attempt at ignition, see Section 4.1.2.1, Resetting the Power Supply.

4.1.2.1 Resetting the Power Supply

To reset the power supply, the closed signal from the pressure must be reset. The sim-

plest method is to pull one of the orange wire spade connectors off of the pressure sen-

sor, wait 10 seconds and replace. This is necessary because the fuel pressure switch

is closed and the pressure cannot be relieved easily. The power supply will energize the

SI and the SI will begin another three start trials. See Figure 28 and 29.

Note: The combustion control system contains 3 D-sized 2 volt, 2.5 amp-hour, re-

chargeable batteries and a constant potential battery charger. A new fully

charged battery provides approximately 240 minutes of operating time at 25ºC.

The power supply switches from battery voltage to generator power unit voltage

in less than 15 minutes after start-up. Completely discharged batteries will take

approximately 14 days TEG operation to regain 100% charge.

4.1.3 Burner

The burner receives gas from the fuel system, mixes it with air and transports the mix-

ture to the combustion zone. Air passes through an air-shutter assembly allowing for

adjustment of the air/fuel mixture. A downstream venturi provides the necessary suction

to draw in the air. This mixture leaves the venturi and passes through a burner screen

that anchors the flame. The design of the combustion chamber produces uniform heat-

ing of the power unit hot-end.

The main parts of the burner are shown in Figure 4.


28142 Rev. 5

Figure 4 Burner General Assembly


28142 Rev. 5

4.1.4 Power Unit

The power unit generates electric

power from the direct conversion

of heat energy into electrical

energy. It operates on similar

principles as thermocouples that

are used for applications such as

temperature measurement.

However, it utilizes high perform-

ance semi-conducting thermo-

electric materials housed inside a

hermetically sealed casing.

Note: Thermocouples consist of

two lengths of dissimilar

materials joined together

at one end. Heating that

junction to a higher tem-

perature than the open

ends results in a voltage

across the open ends.

Current will flow if the

open ends are connected to an electrical load and power will be continuously

delivered as long as the temperature difference is maintained. Since the voltage

is relatively small a TEG uses many thermocouples in series to increase the volt-

age output to a usable level, forming a thermopile.

Figure 5 illustrates how this is done in a model 5220 TEG. A thermocouple is formed by

P type and N type thermoelectric elements joined together at one end by a hot-junction

electrode. Adjacent elements are joined at the other end by cold-junction electrodes.

One hundred and eighty one thermocouples, each producing 75 mV are connected in

series to total 14 V. This is the matched load voltage.

Temperature difference maintained across the thermocouple junction effects voltage,

and power output. A burner maintains the hot side of the thermocouples at a tempera-

ture of around 538ºC (1000ºF). Cooling fins, which transfer the heat to the surrounding

air, maintain the cold side of the thermocouples at a lower temperature of around 163ºC

(325ºF). Adjusting the amount of fuel supplied to the burner varies the temperature dif-

ference and controls the power output.

Electrical output characteristics are shown in Figure 6. Power peaks in a broad load

resistance range of 0.8 - 1.5 W. Rated power of 220 W is obtained when the power unit

load resistance is within this range.

Figure 5 Cut-away of a Model 5220 Thermopile


28142 Rev. 5

Figure 6 Electrical Output Characteristics (no Power Conditioner)

4.1.5 Cooling Fins and Fin Duct

Cooling of the thermopile is done by the free movement of ambient air through the cool-

ing fins. A fin duct acts as a chimney, causing ambient air to rise through the cooling

fins, thus helping transfer heat away from the thermopile.

Warning: Keep cooling fins clean and duct work inlets and outlets clear of

obstructions. Restricting the free flow of cooling air may cause dam-

age to the power unit.

4.1.6 Cabinet

The power unit, burner and fuel system are enclosed in a stainless steel cabinet.

4.1.7 Optional TEG Mounting Stands (Pole or Bench Type)

The Pole Stand consists of a 76 in. long piece of 3 in. diameter pipe with an "H" shaped

bracket welded to one end which the TEG can be firmly attached to using 1/4 in. fasten-

ers (not included). The Bench Stand consists of 3 in. by 3 in. and 2 in. by 2 in. aluminum

angle sections that are assembled together to provide a sturdy structure to support the

TEG.


28142 Rev. 5

4.2 Optional 220 Watt Limiter

The minimum requirement for the 5220 is a limiter operating at a nominal voltage of 14 V.

This limiter is a shunt type voltage limiter that regulates the output voltage of the genera-

tor. The main components of the Limiter are shown in Figure 7, and explained below:

Protective (Voltage) Limiter: A voltage limiting circuit is incorporated into the 220 W

Limiter, which limits input voltage helping achieve optimal performance from the TEG. It is

factory set to activat at 14.1 V for the model 5220 TEG. Unless the generator is equipped

with an optional CP System. In this case, the voltage is factory set at 17.5 V.

Current Limiter: Over load protection triggers when the load draws excess current. The

result is a proportional drop in output voltage, fold-back current limiting.

Short circuit protection is also designed into the 220 W Limiter. A diode in series with the

positive output prevents current from flowing back through the converter when the gener-

ator is shut off.

Caution: If extended short circuit durations are anticipated, an in-line fuse

should be placed on the output of the limiter converter.

Figure 7 220 Watt Limiter


28142 Rev. 5

Blocking Diode: Reverse current protection is standard on the 220 W Limiter. A diode

in series with the positive output prevents current from flowing back through the convert-

er when the generator is shut off.

Voltage Sensing Relay: Voltage Sensing Relay (VSR) provides a set of contacts to

indicate an alarm condition when the output voltage drops below a preset minimum. Low

voltages, due to overloads, lack of fuel or a faulty generator, are detected by a voltage

sensing circuit incorporated into the voltage limiter. When a low voltage condition is

detected, the Voltage Sensing Relay (VSR) with connections NC(normally closed),

NO(normally open) and COM (common) can be used to trigger an alarm 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 voltage then the connection between NO and COM is open and the con-

nections between NC and COM is closed. The trip voltage is adjusted by the pot labeled

VSR adjust on the VSR board as shown if Figure 7.

Volt and Amp Meters: The volt and amp meters provide indication of voltage and cur-

rent respectively, output by the L/C.

Power Resistor: When no load, or a very small load, is connected the TEG has more

power available than needed by the load. This excess power is directed into a power

resistor by the voltage limiter.

Figure 8 220 Watt L/C General Assembly


28142 Rev. 5

4.3 Optional 220 Watt Limiter Converter

An optional 220 W Limiter/Converter (L/C) is available for use with the model 5220 TEG.

It is intended for use with a model 5220 applications requiring 24 V DC nominal output.

It consists of two separate circuits operating together. The first is a shunt type voltage

limiter that regulates the output of the generator. The second circuit is a DC-DC convert-

er that switches the input voltage to a different output voltage. It includes over load, short

circuit and reverse current protection and a set of low voltage alarm contacts.

The main parts of the 220 W L/C are shown in Figure 8.

Protective (Voltage) Limiter: A voltage limiting circuit is incorporated into the 220 W

L/C, which limits input voltage helping achieve optimal performance from the TEG. It is

factory set at 16.0 V for the model 5220 TEG.

Voltage Converter: The voltage converter switches the input voltage to nominal 24 V

setting.

Current Limiter: Over load protection triggers when the load draws excess current.

The result is a proportional drop in output voltage, fold-back current limiting.

Short circuit protection is also designed into the 220 W L/C. A 15-second short circuit will

not damage the generator or the L/C.

Caution: If extended short circuit durations are anticipated, an in-line fuse

should be placed on the output of the limiter converter. Use a 15 A

slow blow for the model 5220-24 TEG.

Blocking Diode: Reverse current protection is standard on the 220 W L/C. A diode in

series with the positive output prevents current from flowing back through the converter

when the generator is shut off.

Voltage Sensing Relay: Voltage Sensing Relay (VSR) provides a set of contacts to

indicate an alarm condition when the output voltage drops below a preset minimum.

Low voltages, due to overloads, lack of fuel or a faulty generator, are detected by a volt-

age sensing circuit incorporated into the voltage limiter. When a low voltage condition is

detected, the Voltage Sensing Relay (VSR) with connections NC (normally closed), NO

(normally open) and COM (common) can be used to trigger an alarm or other process-

es. When the generator is above the trip voltage the connection between NO and COM

is closed. If the generator is below the trip voltage then the connection between NO and

COM is open and the connection between NC and COM is closed. The trip voltage is

adjusted by the pot labeled VSR adjust on the VSR board as shown in Figure 8.

Volt and Amp Meters: The volt and amp meters provide indication of voltage and cur-

rent respectively, output by the L/C.

Power Resistor: When no load, or a very small load, is connected the TEG has more

power available than needed by the load. This excess power is directed into a power

resistor by the voltage limiter.


28142 Rev. 5

4.4 Optional Cathodic Protection Interface System

An optional cathodic protection interface system is available for use with the model 5220

TEG. It provides for adjustment and monitoring of power to a Cathodic Protection (CP)

load. The anode and cathode cables enter the cabinet at the bottom and connect direct-

ly to a heavy-duty terminal block. A 0 to 1 W 300 watt variable resistor is provided for

adjusting the output power

applied to the CP system.

The main parts of the CP inter-

face system are shown in

Figure 9.

Enclosure: The CP interface

system is enclosed within a

weather resistant 304 SS

enclosure. Enclosure features

include a lock-able cabinet

door, 1 in. conduit opening on

the bottom for customer CP

wires, and separate area within

the enclosure for the variable

power resistor.

Meter: The dual scale meter

displays voltage at the terminal

block, and current when the

PUSH TO READ AMPS button

is depressed. The meter is accurate to ± 3% of full scale.

Available standard meter face for the 5220 TEG is 0-30 V, 0-30 A.

Current Shunt: A shunt located in the CP Interface enclosure is used to measure the

current to the terminal block. The voltage drop across the shunt is proportional to the

current flowing through it. The current shunt rating corresponds to the ampere scale on

the meter.

Terminal Block: Customer terminal block, is a heavy duty terminal block that will

accept customer anode & cathode wire up to 9 mm dia. (00 AWG).

Variable Resistor: A 300 W variable 0 to 1 ohms resistor located inside the enclosure

may be used to adjust the output power of the CP interface. This resistor may be wired

in series or parallel with the customers CP load, depending on the application.

Figure 9 CP Interface System General Assembly


28142 Rev. 5

5 INSTALLATION

This section provides installation instructions for the Model 5220 Thermoelectric gener-

ator.

5.1 Precautions

The installation must conform with local codes or, in the absence of local codes, with the

CSA-B149.1 Natural Gas and Propane Installation Code and CSA-B149.2, Propane

Storage and Handling. The TEG must be kept clear and free from combustible materi-

als, gasoline and other flammable vapours and liquids. Maintain 900 mm (36 in.) mini-

mum clearances from combustible construction, to the top, sides and back, and install

over a non-combustible floor.

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 part of the control system

and any gas control which has been underwater.

The TEG, when installed must be electrically grounded in accordance with local codes,

or in the absence of local codes, with the applicable provisions of the Canadian

Electrical Code CSA C22.1. A grounding lug is provided on the sidewall of the cabinet

for this purpose.

5.2 Tools Required

The following tools are required for installing the TEG:

� 1 × DC Voltmeter, accurate to ±0.1 V.

� 2 × Adjustable Wrenches, that will open to 16 mm (5/8 in.)

� 1 × Screwdriver, flat-head

� 1 × Screwdriver, Phillips

� 4 × Bolts & nuts, #1/4-20 for mounting

5.3 Unpacking

Unpack the TEG from its shipping crate, keep the crate until the TEG is operational.

Locate and identify the following items that were shipped with the 5220 TEG:

� 1 × Fin Duct

� 1 × Cover Plate

� 1 × Thread Sealing Compound

� 17 × Screws, #8-32 × 1/4 in. long, one spare

� 17 × Washers, #8 External 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 before starting a damaged TEG.


28142 Rev. 5

5.4 Assembling

Follow these steps to assemble the TEG, see Figure 10:

a) Attach the fin duct and cover using the #8 screws and lockwashers supplied.

b) If not already installed, insert the exhaust stack into the top of the cabinet. Slide

the clamp over the bottom of the stack and tighten the clamp screw.

Figure 10 Assembling the 5220 TEG


28142 Rev. 5

5.5 Mounting

Mount the TEG to a firm and stable base, using 1/4-20 bolts of material suitable for the

environment. See Figure 11 for mounting hole locations. The base must be level and

sturdy enough to support the 83 kg (183 lb) mass of the TEG. Various stands are avail-

able from the factory. Contact your sales rep for more information.

Caution: Operation of the TEG in locations where cooling air flow may be

obstructed will cause overheating of the TEG. Allow a minimum of

150 mm (6 in.) clearance under the cooling fins and 600 mm (3 ft.)

above the top of the fin duct. Locate the TEG to avoid flooding inter-

fering with the flow of cooling air.

Figure 11 Model 5220 Mounting Dimensions, shown with L/C Option


28142 Rev. 5

5.6 Supplying Fuel

This topic describes how to connect the fuel supply and gives background information

for consideration when providing fuel to the 5220 TEG.

5.6.1 Connecting the Fuel Supply

The TEG has a 1/4 in. female NPT

fuel inlet, i.e. connection to the

TEG's manual shutoff valve.

Follow these steps to connect the

fuel supply:

a) Remove the any protective

cap or plugs.

b) Apply thread sealant to the

fuel line threads as per Figure

12.

Note: Thread sealant is recom-

mended. Sealant must be

approved for use with

gaseous fuels. Tape is not recommended.

c) Connect the fuel line and test all joints for leaks using a commercial leak detec-

tor fluid such as Snoop®.

Note: The TEG and its manual shutoff valve must be disconnected from the gas supply

piping system during any pressure testing of the gas supply piping system at test

pressures in excess of 3.5 kPa (0.5 psig).

The TEG must be isolated from the gas supply piping system by closing its individual

manual shutoff valve during any pressure testing of the gas supply piping system at test

pressures less than 3.5 kPa (0.5 psig).

d) Inspect the fuel lines and fittings to be sure they are free of foreign material.

e) Purge fuel lines of all air.

Note: All fuel piping must be in accordance with local regulations.

5.6.2 Fuel Considerations

Fuel Types: Fuel must be either natural gas or propane vapour . Check the TEG data

plate for the fuel type, see Figure 22. Do not use a different type of fuel than indicated.

Figure 12 Applying Thread Sealant


28142 Rev. 5

Figure 13 Setting-up the 5220 TEG, shown with L/C option

Supply Pressure: Make sure that fuel pressure is at least 241 kPa (35 psig) and will not

exceed 413 kPa (60 psig). If it is expected that the fuel supply pressure will vary great-

ly, the use of an additional primary regulator is recommended. This will hold the input

pressure relatively constant.

Clean Fuel: The fuel used to operate the 5220 TEG must be clean and dry. See

Technical Specifications section for full gas specifications. If dirty fuel is anticipated then

a customer supplied in-line fuel filter is recommended.

Low Temperature: Regulator freeze-off can be minimized by regulating the incoming

supply pressure to 138 kPa (20 psig). When using propane (C3H8) at temperatures

below -30ºC (-22ºF) special consideration must be given to the vaporization of the fuel.


28142 Rev. 5

5.7 Connecting Customer Load

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 below.

Follow these steps to connect the customer load:

a) Bring the customer load wires through the strain relief bushing (located on the LC/

Limiter enclosure). Allow enough wire to connect to the terminal block TB-1.

Note: Use only copper wire, properly sized for the load current.

b) Tighten the screws on the strain relief bushing.

c) Connect the customer load wires to TB-1:

12 V: Connect the load at terminals 5(+) and 4 (-) see Figure 14. The 5220 12

Volt is isolated from other power supplies or batteries by a diode in series

with the output. The diode does consume about 2 watts of power and can

be bypassed by connecting the load to terminal 1(+) and terminal 4 (-).

Note that since the limiter is being bypassed the ammeter will read zero.

24 V: Connect the load at terminals 7 (+) and 6(-) see Figure 15. A reverse cur-

rent protection diode is provided on the positive output terminal of this unit.

Figure 14 Wiring Diagram 5220 TEG, Shown with 12 V Limiter Option


28142 Rev. 5

Figure 15 Wiring Diagram 5220 TEG, Shown with L/C Option

5.8 Installation of Optional Limiter/Converter (L/C)

The L/C is normally shipped ready for operation, attached to the TEG. If it was shipped

separately install as follows.

Note: Before installing inspect for obvious dents and broken components and advise

Global Thermoelectric service department if damage is noted.

5.8.1 Attaching the L/C to TEG

The standard mounting location is on the right side of the generator cabinet. To attach

the L/C remove the four nuts and lock washers provided and bolt it to the outside of the

TEG cabinet, See Figure 16

Note: Always mount the L/C in an upright position and allow the free flow of air through

the unit. Remote mounting of the L/C is acceptable.

5.8.2 TEG Wiring Interconnection

Wire the L/C directly to the TEG using the following procedure:

a) Feed the wires from the L/C into the TEG cabinet through the hole provided.


28142 Rev. 5

Figure 16 CP InstallationNote: If remotely mounting the L/C, size the interconnecting wires between the gener-

ator and the L/C for 17 A, and use no less than AWG no. 10.

b) Before connecting the input or output wires to the TEG terminal block check the

selector switch setting, Figure 8, is correct for the required voltage and model

5220 TEG.

c) Connect the L/C wires to TB-1 as per Figure 15.

5.9 Installation of Optional CP Interface System

The CP interface is normally shipped ready for operation, attached to the TEG. If it was

shipped separately install as follows.

Note: Before installing inspect for obvious dents and broken components and advise

Global Thermoelectric service department if damage is noted.

5.9.1 Attaching the CP Interface System to TEG

The standard mounting location is on the left side of the generator cabinet. To attach the

CP interface system, remove the four nuts and lock washers provided and bolt it to the

outside of the TEG, see Figure 16.


28142 Rev. 5

Figure 17 CP Wiring for Model 5220-12 V DC, with Limiter Option

Figure 18 CP Wiring for Model 5220-24 V DC, With Limiter/Converter Option


28142 Rev. 5

Note: Always mount the CP interface system in an upright position and allow the free

flow of air through the unit.

5.9.2 TEG Wiring Interconnection

Wire the CP interface system directly to the TEG using the following procedure:

a) Check the wiring diagram, Figure 17 or 18 as applicable, and choose the wiring

diagram for your application.

b) Run the CP interface system wires to the TEG as per Figure 17 or 18, as appro-

priate, and terminate to TB-1.

5.9.3 Connection of CP Load

Wire the CP load directly to the CP interface system. Feed the CP anode and cathode

load cables into the CP box and terminate.


28142 Rev. 5

6 STARTUP AND SHUTDOWN

This section describes how to startup and shutdown the model 5220 TEG.

6.1 Before Starting

Before starting the TEG perform these steps:

a) Move the jumper on TB-1 from the RUN position to the SETUP position, i.e. from

between terminals 1 and 2 to between terminals 3 and 4 respectively. See Figure

14 or 15.

b) Connect a DC voltmeter to terminals 2 (+) and 3 (-) of TB-1. This will be measur-

ing Vset.

c) Make sure that all of the connections in the fuel system are tight and have been

checked for leaks.

6.2 TEG Start-Up

Follow these steps to start the TEG using the IgnitionControl System:

a) Supply fuel and open the manual shut-off valve. The spark ignitor should begin

clicking and the sound of combustion will begin. In some cases it may be neces-

sary to bleed air from the system. If combustion is not maintained after three tri-

als, see section 4.1.2 Ignition Control System of this manual.

Note: Once the TEG is started, re-closing the manual shut-off valve will stop it.

WARNING: When the TEG is operating, surface temperatures in the vicinity of

the thermopile, burner, exhaust stack and around the cooling fin duct

may be in excess of 100ºC. Avoid contact of skin and clothing with

these areas when operating in and around the TEG.

6.3 Shutdown

Thermoelectric generators are intended for continuous operation where reliable power

is required without interruption. In case the TEG must be shutdown temporarily for serv-

icing or an emergency close the TEG manual shutoff valve.


28142 Rev. 5


28142 Rev. 5

7 POWER OUTPUT EVALUATION

Output power is the primary indication of correct setup, adjustment and operation of the

TEG. This section describes how to determine if the TEG is providing rated power.

Power output should be evaluated:

• during initial setup at site;

• adjusting a TEG;

• before and after servicing a TEG, and

• whenever altering the fuel's heat of combustion.

Note: Typical settings are 130-144 kPA (18.5 - 21. psig) for natural gas and 125-140 kPa

(18.0 - 20.0 psig) for propane.

Note: Good record keeping is necessary for long term follow-up. Use the TEG

Performance Log, located at the end of this manual, for recording details each

time adjustments are made or servicing is carried out.

7.1 Ambient Temperature Effects on Vset and Rated Power

Power from the 5220 TEG is produced by the difference in temperature between the

burner and the cooling 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 climbs.

For every 1ºC temperature drop from the ambient temperature indicated on the data

plate effects a power increase of 0.8 W and similarly, a temperature climb of 1ºC from

the ambient temperature as indicated on the data plate effects a power decrease of 0.8

W. This effect needs to be considering when setting-up the TEG.

7.1.1 Determining Vset and Rated Power

Vset, proportional to rated power, must be adjusted for actual ambient temperature at site

as described below. Figure 19 is used to determine the appropriate Vset and expected

rated power at various ambient temperatures, through calculations.

Factory test data for rated power and voltage are marked on the data plate that is locat-

ed inside the TEG cabinet door. These values are for a specific ambient temperature

that is also indicated on the data plate. They require correction for ambient temperatures

different to that indicated. The following formulas apply:


28142 Rev. 5

Vset = Vset ref. + [(Tref. - T) × 0.026] Equation 1.

Where: T = Ambient temperature, at site (ºC)

Tref. = Reference ambient temperature, marked on Data Plate (ºC)

Vsetref. = Reference set-up voltage, marked on Data Plate (V)

Vset = Set-up voltage, at site (V)

Pset = Psetref. + [(Tref - T) × 0.8] Equation 2.

Where: T = Ambient temperature, at site (ºC)

Tref. = Reference ambient temperature, marked on Data Plate (ºC)

Psetref = Reference power marked on TEG Data Plate (W)

Pset = Rated power at new ambient (W)

Note: Avoid setting-up the TEG to run at higher Vset or rated power values, as its life

may be affected. This method is suitable for ambient temperatures of up to

65.5ºC (150ºF). If in doubt contact Global Thermoelectric's Customer Service

Department for guidance.

Example : Ambient temperature at site is 35ºC. Set-up power of 220 W and Vset of

14.3 V, 22ºC is marked on the TEG Data Plate.

Vset = Vsetref. + [(Tref. - T) × 0.026]

= 14.9 + [(22 - {35}) × 0.026]

= 14.9 + [(22 - 35) × 0.026]

= 14.9 + [-13 × 0.026]

= 14.9 + [-0.3338]

= 14.9 - 0.338

= 14.56 V

similarly,

Pset = Psetref. + [(Tref. - T) × 0.8]

= 220 + [(22 - {35}) × 0.8]

= 220 + [(22 - 35) × 0.8]

= 220 + [-13 × 0.8]

= 220 + [-10.4]

= 220 - 10.4

= 209.6 W


28142 Rev. 5

7.1.2 Determining Vset and Rated Power Graphically

A good approximation to Vset and rated power can be obtained from the chart shown in

Figure 19. Knowing the ambient temperature, move up vertical to the line. Read the

Vset from the right side of the graph and rated power from the left side.

7.2 Vset and Rated Power

To determine the electrical power that the generator is producing a precision resistor is

provided within the generator. This resistor is called the Vset resistor. By connecting the

generator to this resistor and measuring the voltage across it, the power produced by

the generator can be calculated as follows:

Where: P = Power (watts)

V = Voltage (Volts)

R = Resistance (Ohms)

Figure 19 Vset and Rated Power versus Ambient Temperature

P = V2

R


28142 Rev. 5

As R = 4.0 Ohms the power calculation may be simplified to:

P = (Vset)2/4 Equation 3

Vset voltage, is measured across terminals 2 and 4, with the jumper clip in the setup posi-

tion across terminals 2 and

3, as shown in Figure 14

and 15.

7.2.1 Vset Shortly after Ignition

Immediately after ignition

the power unit warms and

the resulting temperature

rise produces power.

Follow these steps to check

Vset after ignition:

a) Consult the data

plate inside TEG

door for the reference

Vset voltage and

determine the

required Vset for the

present ambient tem-

perature. See

Sections 7.1.1, or

7.1.2.

b) Move the jumper clip

on the terminal block TB-1 to the SETUP position, i.e. between terminals 2 and

3. See Figure 14 or 15.

c) Connect a voltmeter between terminals 2 (+) and 4 (-). This is the measured Vset,

and should tend towards the required Vset (determined in “a”). It will climb as

shown in Figure 20.

Caution: Do not allow the measured Vset to exceed the required Vset.

Overheating will result and may cause irreparable damage to the

power unit.

d) The measured Vset will rise quickly at first then begin to level out. It will take at

least one hour for this voltage to level out. When the measured Vset no longer

changes (±0.2 V in ten minutes) compare this value with required Vset. The

measured Vset should be within 0.2 V of the required Vset

Figure 20 Vset versus Time After Ignition, Typical

Response


28142 Rev. 5

Note: Typically, if the measured Vset is greater than required Vset then the fuel pressure

needs to be reduced.

7.2.2 Vset After TEG has Stabilized

Once the TEG has been running for some time, typically more than an hour, the power

unit will be up to operating temperature.

Follow these steps to check Vset:

a) Consult the data plate inside TEG door for the reference Vset voltage and deter-

mine the required Vset for the present ambient temperature. See Sections 7.1.1,

or 7.1.2.

b) Move the jumper clip on the terminal block TB-1 to the SETUP position, i.e.

between terminals 2 and 3. This connects the TEG to an internal load required for

Vset. See Figure 14 or 15.

c) Connect a voltmeter between terminals 2 (+) and 4 (-). The measured Vset, and

should match the required Vset for the present temperature.

Caution: Do not allow the measured Vset to exceed the required Vset.

Overheating will result and may cause irreparable damage to the

power unit.

d) Pause approximately 10-45 minutes and when the measured voltage is stable

compare it to required Vset. Measured Vset should be within 0.2 V of the required

Vset.

Note: Pausing is necessary to allow the TEG voltage to stabilize to the new load condi-

tions. (Changing from customer load to the on-board 1 ohm resistor).


28142 Rev. 5


28142 Rev. 5

8 ADJUSTMENT

This section describes how to adjust the Model 5220 Thermoelectric generator.






Figure 21 Change in Fuel Gauge Pressure versus Elevation Above Mean Sea Level, Typical


28142 Rev. 5

Figure 22 Air Shutter

8.1 Power Output Adjustment

TEG output power is controlled by the flow of air and fuel into the TEG. Use the follow-

ing procedures to adjust the TEG's power output in sequence given.

8.1.1 Adjustment for Elevation

Confirm the fuel gauge pressure is near to the pressure indicated on the data plate

located on the inside of the cabinet doors. If the TEG 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 21 to determine how much to adjust the fuel

pressure.

Example: If the site elevation is 1000m (3281ft.) then 2.5 kPa (0.36 psig) must be

added to the pressure on the data plate.




28142 Rev. 5

Follow these steps to adjust fuel pressure:

a) Remove the cover on the regulator and loosen the lock nut.

b) 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

Pressure. See Figure 22 for Data Plate location.

c) Tighten the lock nut and replace the cover on the fuel regulator.

8.1.2 Air-shutter Adjustment

At this point, adjusting the air shutter for optimum combustion may be necessary (see

Figure 22). The generator should be stable, with the Vset voltage constant.

WARNING: Air shutter components are hot and will burn skin. Make all air shut-

ter adjustments using tools only, not bare skin.

a) Mark the original position of te air shutter with a felt pen against the burner cover.

b) Loosen the four screws mounting the air screen against the air shutter, leaving

the air shutter still in place.

c) Open the air shutter slightly by rotating the shutter to enlarge the opening. Adjust

the shutter only a small amount at a time. There will be a slight resistance to air

shutter movement as the air shutter is still being held against the venturi by four

inner wave washers.

d) Close the doors and let the unit stabilize for 10 minutes and measure Vset.

If Vset is greater than the original value repeat step c). Continue to enlarge the

shutter opening until Vset decreases then rotate the shutter to the position that

gave the highest Vset, and tighten screws A and B and measure CO, see section

8.1.2.1.

If Vset is less than the original value return air shutter to the original position

and then close slightly. Let the unit stabilize for 10 minutes and then measure

Vset. Repeat until Vset decreases, then return to the position that gave the high-

est Vset, and tighten screws A and B and measure CO, see section 8.1.2.1.

Note: It may take several minutes to see a change in voltage if only 2 decimal places

are displayed on the voltmeter.

e) Tighten screws A and B, replace air screen and verify Vset did not change.


28142 Rev. 5

8.1.2.1 Measuring CO Emissions Levels

The model 5220 will not produce excessive amounts of CO if properly adjusted. Due to

the open exhaust system of TEG, the CO measurement must be in the free air state. In

a free air measurement, the allowable CO rate is 800 ppm. In order to be able to deter-

mine the levels of air-free CO ppm, a combustion analyzer capable of measuring CO

ppm and either CO2 percentage, or O2 percentage, is needed.

The equations used to calculate the air-free stage of CO are:

• For Natural Gas when using as measured CO2 percentage, and COppm:

• For Propane when using as measured CO2 percentage, and COppm:

[1], [2], [3] as per CSA

Figure 23 Change in Vset versus Air-Shutter Adjustment, Typical

[1]

[2]

[3]


28142 Rev. 5

Figure 24 Change in Vset Versus Fuel Pressure Adjustment, Typical

• When using as measured O2 percentage, and COppm:

Where: COAFppm = Carbon monoxide, air-free ppm.

COppm = As-measured combustion gas carbon monoxide ppm.

O2 = Percentage of oxygen in combustion gas, as a percentage.

CO2 = Percentage of carbon dioxide in combustion gas, as a per-

centage.

The model 5220 does not produce excessive concentrations of CO if adjusted properly.

8.1.3 Fuel Pressure Adjustment

Once the air is adjusted, and if the fuel system and burner appear to be operating cor-

rectly, the fuel pressure may be slightly adjusted to match the measured Vset voltage with

the required Vset value. Use Figure 24 to determine how much to adjust the fuel pres-

sure.


28142 Rev. 5

Example: Required Vset = 14.1 V

Measured Vset = 13.5 V

Difference = +0.6 V

Based on Figure 24 the fuel pressure must then be increased 3.6 kPa (0.52 psig).

Follow these steps to adjust fuel pressure:

a) Remove the cover on the regulator and loosen the lock nut.

b) 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

Pressure.

c) Wait ten minutes then measure Vset and record. If the TEG can not be adjusted

to match required Vset value then a problem exists with one of the TEG's systems.

If necessary see Troubleshooting section for guidance.

d) Tighten the lock nut and replace the cover on the fuel regulator.

8.2 Adjustment of Optional L/C

An optional L/C is available for use with the model 5220 TEG. This text describes how

to adjust the L/C, if applicable.

8.2.1 Output Voltage Adjustment

The L/C is factory set at 14.1 V to 27.0 V depending on the output ordered. (Model 5220-

24). If this requires adjusting use the following procedure.

Follow these steps to adjust the L/C output voltage:

a) Disconnect the customer load from the TEG, terminals 6 (-) and 7 (+) of TB-1.

b) Move the jumper clip on the terminal block TB-1 to the RUN position, i.e. between

terminals 1 and 2.

c) Connect a voltmeter between terminals 6 and 7 of TB-1 and measure the output

voltage.

d) Adjust the output voltage by turning the output voltage adjustment pot shown in

Figure 8.

8.2.2 Voltage Sensing Relay (VSR) Adjustment

The VSR provides a set of contacts to indicate an alarm condition when the output volt-

age drops below a pre-set minimum. It is factory set at 23.0 V (Model 5220-24) or 11.5

V (Model 5220-12). The VSR is rated for 2 A at 30 V DC and will take up to wire size no.

16 AWG.


28142 Rev. 5

Note: Because the sensing point for the relay trip is ahead of a blocking diode, set the

no-load trip-point 0.5 V higher than the required trip-point. For example, consider

an alarm is required when the output voltage drops to 23.0 V at the customer load

terminals. When making the trip-point adjustment at no-load conditions set it to

trip at 23.5 V, as measured at the customer load terminals. Under load conditions

when the voltage drops to 23.0 V, as measured at the customer load terminals,

the relay will trip.

Follow these steps to adjust the VSR set point:

a) Remove both the positive and negative wires from the customer load terminals.

b) Connect a DC voltmeter to the customer load terminals.

c) Remove cover from the L/C.

d) Set the output voltage to the desired alarm point value.

e) Place an ohmmeter between the common and normally open contact of the VSR.

f) Turn the VSR adjustment pot until the contacts open (the normally open contacts

are closed when output voltage is above VSR trip-point).

g) Using the output voltage adjustment, raise output voltage to a value where the

VSR will reset.

h) To re-check the trip-point, lower output voltage and monitor opening of the VSR

contacts. Fine tune as required to achieve desire trip value.

i) Reset output voltage to the desired normal operating value. Factory setting is

either 14.1 or 27.0 V.

8.3 Adjustment of Optional CP Interface System

An optional CP interface system is available for use with the model 5220 TEG. This text

describes how to adjust the CP interface system, if applicable.

8.3.1 CP Power Output Adjustment

The 0-1W 300 W variable resistor, located inside the CP cabinet, may be used to adjust

the output power from the CP interface. This resistor may be connected in series or par-

allel with the customer load. See Figure 25 for series connection and Figure 26 for par-

allel connection.

Adjusting the variable resistor can be done simply while the system is running, by loos-

ening the slide ring on the resistor and moving it up or down on the resistor. Check the

power changes by using the meters provided in the enclosure or using a hand held

multi-meter to easily see the change in power when adjusting the variable resistor. Once

the resistor has been adjusted to give the desired power output, check that all electrical

connections are tight, and lastly recheck that the desired power output has not changed.


28142 Rev. 5

Figure 25 CP Interface System, Series Wiring

Diagram

Figure 26 CP Interface System, Parallel

Wiring Diagram

Note: TEG fuel pressure may be adjusted to fine tune the CP output. Fuel pressure with

in 10% of that marked on the data plate is recommended to prevent flame out.

8.3.1.1 Series Wiring

Series connection is achieved by connecting the 300 W resistor in series with the cus-

tomer load as shown with the dark line. The maximum allowable power may be deliv-

ered to the CP load by moving the tap to the bottom of the resistor. To reduce power to

the CP load, slide the tap upward.

8.3.1.2 Parallel Wiring

Parallel connection is achieved by connecting the 300 W resistor in parallel with the cus-

tomer load as shown with the dark line, smaller levels of power may be delivered to the

CP load. This may be required when hot spots occur on the anode of the CP circuit. With

the tap located at the top of the resistor the output power will be zero. As the tap is

moved down, the power to the CP load is increased.

Change from a series to parallel configuration by moving the wire running from the top

of the 300 W resistor from the centre terminal of the heavy duty terminal block to the left

terminal.


28142 Rev. 5

9 Maintenance

This section describes how to maintain the model 5220 TEG. Before attempting to main-

tain the TEG the qualified service person should be thoroughly familiar with its:

• technical specifications;

• process description;

• installation;

• startup and shutdown;

• power output evaluation, and

• adjustment.




9.1 Recommended Periodic Maintenance

The TEG is a solid-state high-reliability device that requires very little maintenance.

However, it does require periodic service checks in order to provide the years of trouble

free service of which it is capable. The maintenance interval depends on the site condi-

tions (fuel purity, environment, etc.) and 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 procedure below. This should be the first

procedure during any service visit and will determine what further service may be need-

ed.

9.1.1 Tools and Parts Recommended for Routine Servicing

The following tools and parts should be available for routine servicing:

� 1 × Multi-meter, including DC voltmeter accurate to ± 0.1 V (and

Ohmmeter*)

� 1 × Flat-head screwdriver

� 1 × Phillips screwdriver

� 1 × Wrench, 9/16 in.

� 1 × Wrench, 1/2 in.

� 1 × Adjustable wrench, that will open to 16 mm (5/8 in.)

� 1 × Fuel filter kit, P/N 3400-22363

� 1 × Fuel orifice: for natural gas use orifice #8, P/N 4200-00690,

for propane use orifice #10, P/N 4200-06251.

� 1 × SI Ignition Control Battery pack assembly, P/N 2400-27906*

*not usually required, but could be convenient for troubleshooting.


28142 Rev. 5

9.1.2 Evaluate Vset

This procedure describes how to evaluate Vset and determine what further servicing

could be needed. Follow these steps to evaluate Vset:

a) Check Vset, see Power Output Evaluation Section 7, and record.

b) Compare measured voltage with required Vset for present ambient temperature

and act as follows:

I) If measured voltage is more than 0.2 V above required Vset:

The fuel pressure must be reduced. Proceed with Routine Service,

Section 9.1.3. Remember to adjust the fuel pressure during restart or

before leaving the site. See Adjustment Section 8.

Caution: Do not continue operating the TEG with measured Vset exceed-

ing that required Vset, for present ambient temperature, other-

wise overheating may cause irreparable damage to the power

unit.

II) If measured voltage is within 0.2 V of required Vset:

The TEG is functioning well and requires only a routine service. Proceed

with Routine Service, Section 9.1.3.

III) If measured voltage is more than 0.2 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 last service visit. Remember that Vset changes with

ambient conditions. If the TEG was not left operating at the correct Vset dur-

ing the last visit, determine the reason for this. If the TEG was left operat-

ing at the correct Vset during the last visit and is now not, consider the fol-

lowing possible causes:

i) Change in Fuel Pressure

Refer back to the last entry in the log and determine if the fuel pres-

sure has changed. If the fuel pressure has changed, re-adjust the

fuel pressure to the last entry. If this returns the measured voltage

to within 0.2 V of required Vset proceed with Routine Service,

Section 9.1.3.

Note: A dirty fuel filter may cause a drop in fuel pressure. A plugged fuel

orifice will change fuel flow without a change in fuel pressure.

ii) Change in Air Flow

Check for obstructions at the cooling fins and the air filter stabilizer.

Adjust the air shutter, see Adjustment section. If this returns the

measured voltage to within 0.2 V of required Vset proceed with

Routine Service, Section 9.1.3.


28142 Rev. 5

iii) Change in Fuel Quality

In order to maintain a constant output power it is essential that the

TEG be supplied with a constant heating value fuel. Proceed with

Routine Service, Section 9.1.3.

If the above causes have been ruled out the TEG may require more

than just routine servicing. Keep the TEG operating for now and see

the Troubleshooting, Section 10, for guidance.

9.1.3 Routine Service

Basic annual servicing is all that is required unless other maintenance is indicated by the

Vset evaluation.

Follow these steps to perform a routine annual service:

a) Stop the TEG and pause to let cool. See Startup and Shutdown Section 6.

b) Drain the pressure regulator sediment bowl. See Draining the Sediment Bowl

Section 9.2.1.

c) Replace the fuel filter (Part# 3400-22361) in the pressure regulator, if necessary.

See Fuel Filter Replacement Section 9.2.2.

d) Check the fuel orifice for clogging and replace if necessary. See Fuel Orifice

Replacement Section 9.2.3.

e) Remove any debris, sand or dust from the cooling fins, air filter stabilizer and cab-

inet interior. See Air Filter Cleaning Section 10.1.1.

f) Check all bolts and wire connections for tightness.

g) Start the TEG. See Startup and Shutdown section.

h). Check Vset, record and adjust if necessary. See Power Output Evaluation Section

7 and Adjustment Section 8, as applicable. Record the final setup in the TEG

Performance Log before leaving site.

9.2 Fuel System Maintenance

This text gives procedures for servicing the fuel system.

9.2.1 Draining the Sediment Bowl

Follow these steps to drain the regulator sediment bowl:

a) Shut off the fuel supply to the TEG and allow to cool.


28142 Rev. 5

b) Open the drain cock located on the under side of the TEG cabinet, any impurities

will drain through the cock.

c) Close drain cock.

d) Leak check the drain cock.

WARNING: Check for fuel leaks after any fuel system service.

9.2.2 Fuel Filter Replacement (if necessary)

Follow these steps to remove the fuel filter:

a) Shut off the fuel supply to the TEG and

allow to cool.

b) Remove the wires from the pressure

switch.

c) Drain the sediment bowl by opening

the drain cock.

d) Disconnect the flexible fuel line from

the SV valve.

e) Disconnect the vent hose from the

cabinet base.

f) Remove the two bolts which hold the

regulator to the cabinet.

g) Mark the regulator body and sediment

bowl, for proper orientation during re-assembly.

h) Turn the regulator upside down and remove the four screws from the bottom.

i) Remove the filter, and Viton gasket. See Figure 27.

Follow these steps to install the fuel filter:

a) Install the filter, and Viton gasket onto the sediment bowl. See Figure 27.

b) Carefully replace the bottom of the regulator making sure the filter and gasket are

in their proper position.

c) Align the sediment bowl with the regulator body and replace the four screws and

tighten.

Figure 27 Pressure Regulator


28142 Rev. 5

Note: While the regulator is removed it is a a convenient time to check the orifice and

clean the air-filter. See Fuel Orifice Inspection, Section 8.2.3 and Air Filter

Cleaning, Section 10.1.1.

d) Installation of the pressure regulator into the TEG is the reverse of removal. With

the fuel pressure on, leak check all regulator joints and fuel connections.


9.2.3 Fuel Orifice Inspection

Follow these steps to inspect the fuel orifice:

a) Shut off the fuel supply to the TEG and allow to cool.

b) Remove the air screen by undoing the 4 mounting screws.

c) Disconnect the flexible fuel line from the safety SV valve.

d) Disconnect the other end of the flexible fuel line and attached orifice from the cen-

ter of the air shutter.

e) Remove the orifice fitting from the flexible fuel line.

f) Visually check the orifice hole. It should be free from any obstructions. Replace it

if necessary. It is recommended a magnifying glass is used to aid with visual

inspection.

g) Connect the orifice fitting to the flexible fuel line then thread the orifice back

through the center of the air shutter. This only needs to be finger tight.

Caution: Always use the same size orifice as was removed.

Propane orifice (#10) - Part# 4200-06251

Natural gas orifice (#8) - Part# 4200-00690

h) Connect the free end of the flexible fuel line to safety SV valve.

i) Leak check all connections using a commercial leak detector.



28142 Rev. 5


28142 Rev. 5

10 TROUBLESHOOTING

Problem Probable Cause Possible Solution Lookup Section

Burner does not

igniteAir in fuel line Purge fuel lines of air Installation

Supply gas pressure

too low

Increase the gas supply

pressure to the TEGInstallation

Fuel filter dirty

Drain the regulator

sediment Maintenance

Replace the fuel filter Maintenance

Fuel pressure

adjustment incorrect

Adjust the TEG fuel

manifold pressureAdjustment

Fuel orifice plugged Replace the fuel orifice Maintenance

Fuel orifice size

incorrectReplace the fuel orifice Maintenance

Air filter dirty Clean the air filter Maintenance

Air-shutter adjustment

incorrectAdjust the air-shutter Adjustment

SI system faulty Maintain the SI system Maintenance

Burner will ignite

but will not

continue to burn

Supply gas pressure

too low

Increase the gas supply

pressure to the TEGInstallation

Fuel filter dirty Drain the regulator

sediment bowl.Maintenance

Replace the fuel filter Maintenance

Fuel pressure


Adjust the TEG fuel



Fuel orifice size

incorrect

Replace the orifice with

one of the correct sizeMaintenance

Safety SV valve

malfunctioning

Check the safety SV

valveTroubleshooting

Air filter dirty Clean the air filter Troubleshooting

Air shutter adjustment

incorrectAdjust the air-shutter Adjustment


28142 Rev. 5

TROUBLESHOOTING, continued

Problem Probable Cause Possible Solution Lookup Section

Low output

power or low

voltageVset adjustment

incorrect

Determine required Vset

for present ambient tem-

perature at site and adjust

Power Output

Evaluation and

Adjustment

Airflow past cooling fins

insufficient

Clean the cooling fins of

any debrisMaintenance

Fuel filter dirtyDrain the regulator

sediment bowlMaintenance


Fuel orifice size

incorrect Replace the orifice Maintenance

Fuel pressure


Adjust TEG fuel manifold

pressureAdjustment

Safety SV valve

malfunctioningCheck the safety SV valve Troubleshooting

Air filter dirty Clean the air filter Troubleshooting

Air-shutter adjustment

incorrectAdjust air-shutter Adjustment

L/C* damaged Examine the L/C Troubleshooting

L/C* adjustment

incorrectAdjust the L/C Adjustment

Power unit damaged Examine the power unit Troubleshooting

Output power

is too highFuel pressure


Adjust the TEG fuel


Output

voltage is too

highL/C* damaged Adjust the L/C Adjustment

L/C* adjustment

incorrectAdjust the L/C Adjustment


28142 Rev. 5

10.1 Burner Troubleshooting

This text gives procedures for servicing the burner.

10.1.1 Air Filter Cleaning

The air-filter stabilizer screen at the front of the burner may become clogged with dust

and insects thereby preventing the proper flow of air into the burner.

Follow these steps to clean the air filter:

a) Shut-off the fuel supply to the TEG and allow to cool.

b) Remove the air screen by undoing the 4 mounting screws

c) Clean the air-filter screen by forcing air through it or washing in water.

d) Replace screen and mounting screws.

Note: If the air shutter setting was disturbed. Set the air shutter the correct range to

begin balancing the air-fuel mixture when re-starting, as per Air Shutter

Adjustment, Section 8.1.2.

10.1.2 Inspection of Burner Components

Burner internals are maintenance free for most applications. If the required Vset still can-

not be achieved after servicing the fuel system, air filter and checking the cooling fins

and air duct then it may be necessary to check and service the burner internals. The pro-

cedures below give the steps for inspecting the burner components.

Follow these steps to remove the burner:

a) Shut-off the fuel supply to the TEG and allow to cool.

b) Disconnect the ignition wire from the spark electrode.

c) Slide the spark electrode out. See Figure 2 and 3.

WARNING: If TEG has not cooled sufficiently it can be very hot.

d) Remove the air screen.

e) Disconnect the flexible fuel line from the safety SV valve.

f) Disconnect the other end of the flexible fuel line and attached orifice from the cen-

ter of the air shutter.

Note: It may be convenient to disconnect and remove the fuel system.


28142 Rev. 5

Figure 28 SI Module Wiring

h) Remove the four hex-nuts holding the burner in place and slide the burner out.

See Figure 4.

Follow these steps to inspect the burner:

a) Check the air filter screen for any tears or holes. If any are found it should be

replaced.

b) Check the burner screen.

c) Check the ceramic spacer.

Follow these steps to install the burner:

a) Reassembly is the reverse of disassembly.

Note: The orifice fitting only needs to be finger tight when threaded back through the

front of the air screen.

b) Before re-starting the TEG, leak check all fuel connections.



28142 Rev. 5

Figure 29 Ignition Control Module Schematic

10.2 Ignition Control System Troubleshooting

The SI system may require occasional maintenance. If the Igniting Control system fails

to ignite it must be checked and serviced as necessary. Use the procedures below to

maintain the SI system.

WARNING: Remove the orange wire connector from the pressure switch and

make sure it can not come into contact with other electrical connec-

tions to prevent high voltage shock.

10.2.1 Check the Spark Electrode

Follow these steps to check the spark electrode:

a) Inspect the electrode for any cracks in the ceramic rod. If any cracks are found

the electrode must be replaced.

b) Slide the electrode back into position through the burner back until it stops, then

pull it back 3 to 6 mm (1/8 to 1/4 in.). The ceramic rod should extend about 25

mm (1.5 in.) from the holding screw.

c) Unplug the orange wire connectors from the terminals on the pressure switch and

then short the circuit between the two connectors. Arcing should occur in the

combustion chamber (making a clicking noise) at the rate of ten per second.

d) If arcing occurs the SI system is functioning well.


28142 Rev. 5

10.2.2 Check the Pressure Switch

Follow these steps to check the pressure switch:

a) Remove the two wires from the pressure switch and connect a multi-meter across

the pressure switch terminals, set to measure resistance (ohms). See Figure 28

and 29.

b) With no fuel pressure in the fuel manifold, check the resistance measured across

the switch is near infinity, which indicates the switch being opened. Replace the

pressure switch if necessary.

Note: Switch should open at pressures below 6.9 kPa (1 psig).

c) Provide fuel pressure to the switch by opening the manual shutoff valve.

d) Check the resistance measured across the 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).

e) Remove fuel pressure from the switch by closing the manual gas valve.

10.2.3 Check the Battery Voltage

Follow these steps to check the battery voltage:

a) Open the door of the SI enclosure mounted on the left door of the generator cab-

inet.

b) Locate the battery wiring harness connector plugged into the power supply, see

Figure 28 and 29.

c) Probe the back of connector, measuring the voltage between the red and black

terminals of the battery wiring harness connector. The voltage should be greater

than 6 V.

d) If the voltage is less than 6 V the battery assembly needs recharging or replac-

ing.

10.2.4 Check the Power Supply

Follow these steps to check the power supply voltage to the ignition controller:

a) Start the TEG, it should have been allowed to cool beforehand .

b) Upon start up, probe and measure the voltage between the Red and Black wires

of the Ignition controller plug, see Figure 28 and 29. Voltage should be 13.7 V or

greater.


28142 Rev. 5

c) Pause and after 20 minutes, check the voltage as in b), voltage should again be

13.7 V or greater.

Follow these steps to check the Power Supply Battery Charging Circuit and Ignition

Controller voltage Supply:

a) Start the TEG.

b) Pause and after twenty minutes of operation Check Battery Voltage, Section

10.2.3.

c) Voltage should be 6.5 V or greater.

10.2.5 Check if the Battery will Hold Charge

Follow these steps to check if the battery will hold charge:

a) With the TEG Cold and manual shutoff valve off, remove the two orange wires

from the terminals of the pressure switch and short circuit between the two wires.

b) Measure the battery Voltage, Section 10.2.3, within 60 seconds. If battery volt-

age is less than 6 V, replace battery assembly.

10.2.6 Check the Operation of the Ignition Controller

Follow these steps to verify operation of the ignition controller correct.

a) Verify electrode gap (1/8” - 1/4”), Section 10.2.1.

b) Start the TEG.

c) If arcing occurs, the ignition control module is functioning.

d) If no arcing occurs, verify power supply voltage to ignition controller, Section

10.2.4. If it is as specified, replace ignition module.

10.5.7 Check Solenoid Valve.

Follow these steps to check if the Solenoid Valve Operation:

a) If at the beginning of sparking, the solenoid is not heard to click open, unplug

solenoid valve connector inside the cabinet, see Fig 3. Measure resistance over

solenoid plug, if resistance is infinity, replace solenoid valve.

b) Start the TEG. While SI is sparking, measure voltage of the solenoid valve plug.

If voltage is less than 13.5 V, check power supply to ignition controller as per topic

above. If it is ok, replace the ignition controller.


28142 Rev. 5

10.3 L/C Examination

The L/C normally requires no maintenance. If the TEG is producing required Vset but it

is not supplying expected power to the load then the operation of the L/C should be

checked and serviced as necessary. Use the procedures below to help determine if the

L/C could be damaged.

10.3.1 Check L/C Switch Settings

Check the selector switches are set correctly for the required output voltage, as per

Figure 8.

Note: Switch 1 should be ON for 12 V or OFF for 24 V nominal output. Switch 2 should

be OFF.

10.3.2 Check Input Voltage to the L/C

Follow these steps to check the input voltage to the L/C:


b) Place the jumper clip between terminals 1 and 2 of TB-1, i.e. in the RUN position.

c) Connect a voltmeter between terminals 2 and 4 of TB-1 and measure the input

voltage.

d) Wait for the TEG to reach operating temperature and a stable voltage measure-

ment between terminal 2 and 4, 15 minutes maybe sufficient if the TEG was

already warm. Allow 1 hour if the TEG was just started from cold.

e) Unloaded input voltage, between terminals 2 and 4 of TB-1, should be about 16

V. Check the measured voltage is about 14 volts, if not suspect an electrical short,

damaged limiter or power unit.

10.3.3 Check Output Voltage from the L/C

Follow these steps to check the output voltage from the L/C:


b) Place the jumper clip between terminals 1 and 2 of TB-1, i.e. in the RUN pos i -

tion.

c) Connect a voltmeter between terminals 5 and 6 of TB-1 and measure the o u t -

put voltage.


28142 Rev. 5

d) Alter the output voltage by turning the output voltage adjustment pot shown in

Figure 8. If the unloaded output voltage, measured across terminals 5 and 6, does

not change when the adjustment pot is altered the L/C needs replacing.

Note: If the TEG produces required Vset, the L/C is operating properly and it still will not

provide expected lower to the load then the power unit should be checked.

10.4 Power Unit Examination

The power unit normally requires no maintenance. If after maintaining and adjusting all

other systems and TEG will not produce required power consider examining the power

unit. Use the procedures below to help determine if the power unit could be damaged.

10.4.1 Check for Internal Short

Follow these steps to check for an internal short:

a) Start the TEG.

b) Free-up terminals 2 (+) and 4 (-), i.e. remove all wires from these terminals except

the white/red power unit lead connected to terminal 2 and the white/black power

unit lead connected to terminal 4.

c) Connect a voltmeter to terminals 2 and 4.

Caution: The following steps may cause sparking. If an internal short is pres-

ent the jumper wire, see below, may arc to the chassis.

d) Run a jumper wire from terminal 4 to the TEG chassis and watch the voltage

reading. Remove the jumper wire. Any fluctuation in voltage may indicate an inter-

nal short within the power unit.

e) Run a jumper wire from terminal 2 to the TEG chassis and watch the voltage

reading. Remove the jumper wire. Any fluctuation in voltage may indicate an inter-

nal short within the power unit.

If an internal short is confirmed, with no other equipment connected, the power

unit is damaged and will need replacing. If not and the TEG appears to be fully

functional check the customer load is functioning correctly and is grounded prop-

erly.

10.4.2 Check Internal Resistance

Follow these steps to check the power unit's internal resistance:

a) Start the TEG.

b) Move the jumper clip to the SETUP position, i.e. between terminals 2 and 3 of TB-

1.


28142 Rev. 5

c) Connect a voltmeter between terminals 2 (+) and 4 (-).

Note: Alternative resistor values are acceptable so long as the resistance is close to 1

W and accuracy class better than ± 1%.

d) Wait for the TEG to reach operating temperature and a stable voltage measure-

ment between terminal 2 and 4, 15 minutes maybe sufficient if the TEG was

already warm. Allow 1 hour if the TEG was just started from cold.

e) Measure Vset with the voltmeter connected between terminals 2 and 4 and record.

f) While observing the voltmeter display remove the jumper clip, creating an open

circuit condition, and note the momentary voltage. On a digital multi-meter this will

be the first number displayed after removing the clip, within 2 seconds of remov-

ing the clip. Record the number as the momentary open circuit voltage (Voc). If

this was not recorded quickly enough replace the jumper clip and repeat steps d)

to g) above.

Note: When the jumper clip is suddenly removed the measured voltage leaps up to a

value, known as the momentary open circuit voltage (Voc). Measured voltage con-

tinues to climb.

Warning: Do not allow Voc to exceed two seconds otherwise the TEG can be

damaged.

Figure 30 Momentary Open Circuit Diagram


28142 Rev. 5

h) Calculate the internal resistance using the equations 5 and 6 below.

IL = Vset / RL Equation 6

Ri = (Voc - VL) / IL Equation 7

Where: Ri = internal resistance (W)

Voc = momentary open circuit voltage (V)

Vset = setup voltage (V)

IL = load current (A)

RL = precision load resistance (W) 1.0 W

i) Check the internal resistance, Ri, is less than 1.0 W. If not the power unit may be

damaged.

Example: If the Vset voltage and momentary open circuit voltages were measured as

14.9 V and 28 V respectively and the precision load resistance was 1.0 W

then:

IL = Vset / RL

= 14.9 / 1.0

= 14.9 A

RINT = (Voc - Vset) / IL= (28 - 14.9) / 14.9

= 13.1 / 14.9

= 0.88 W

Internal resistance is acceptable, < 1.1 W .

For further information or assistance, please contact the Customer Service Department

at Global Thermoelectric.


28142 Rev. 5


28142 Rev. 5

11 PART LIST

This section lists the parts that form the equipment.

For parts and service please contact Global’s Customer Service Department at:

Global Thermoelectric

Customer Service Department

Direct: (403) 720-1190

Fax: (403) 236-5575

Main: (403) 236-5556

Web: www.globalte.com#9, 3700 - 78 Avenue SE

Calagary, Alberta T2C 2L8


28142 Rev. 5

11.1 Model 5220 TEG

Item Part No. Description

A1 7900-08908 Power Unit

A2 4100-22947 Fin Duct, Lower

A3 4100-22875 Fin Duct, Upper

A4 4100-22906 Cover Assy, Upper Fin Duct

A5 6100-27902 Burner Assy

A6 4500-06011 Exhaust Stack Assy

A7 4900-06170 Rod, Burner Mounting

A8 4900-27837 Electrode Assy, Spark Ignitor, Fenwal

A9 2514-20535 Screw, Cap, Hex, HD, 1/4-20 x 5/8”, SS

A10 4100-22946 Leg, Cabinet, Right

A11 6200-27917 Cabinet Assy

A12 3600-27888 Label, Data Plate

A13 2514-22520 Screw, Cap, Hex Hd, 1/4-20 x 3.75”, SS

A14 2814-00473 Washer, Lock, Ext, 1/4, SS

A15 2714-00611 Nut, Hex, 1/4-20, SS

A16 2814-00557 Washer, Flat, 1/4, SS

A17 2510-07412 Screw, Mach, P-H-P, 10-32 x 3/4, SS

A18 2200-02110 Terminal Block, 8 Position

Figure 31 Model 5220 TEG


28142 Rev. 5

11.1 Model 5220 TEG (Cont’d)


A19 2400-02109 Marker Strip

A20 2400-04552 Connector, Straight, 2 Screw, 3/4”

A21 2508-07410 Screw, Mach, P-H-P, 8-32 x 1/4, SS

A22 2808-00472 Washer, Lock, Ext, #8, SS

A23 2400-52968 SI Board Assy Channel Products 50N-12-3-3-7-10-0-E23062

A24 2400-27907 Power Convertor, 4VDC In, 13.8VDC Out, 6V Batt. Charge

A25 2400-24559 Battery 6V, 5.0 Ahr, MonoBloc

A26 2900-00283 Bushing, Universal, 1/8” Heyco

A27 4000-05586 Air Screen Assy

A28 4100-22945 Leg, Cabinet, Left

A29 2010-00208 Terminal, Ring, #10 Yellow

A30 2900-00523 Clamp, 5 1/4” Dia., SS

A31 6400-27905 Fuel system, W/ Burkert Valve, 5220

A32 4200-06251 Orifice Assy, Propane

4200-00690 Orifice Assy, Natural Gas

A33 3600-27892 Label, Instruction

A34 4900-22372 Spacer, Fuel System w/67CFR Regulator

A35 4000-27900 Air Shutter, Profiled, 5220

Figure 31 Model 5220 TEG


28142 Rev. 5

11.2 Model 5220 Burner

B1 4000-05606 Burner Back Assy

B2 4000-05605 Holder, Screen Insulator

B3 4000-05390 Screen Assy

B4 4000-06086 Insulation Block

B5 4000-06186 Burner Can, Exhaust

B6 4000-05375 Venturi Tube Intake Assy

B7 4000-05378 Burner Top Assy

B8 2710-00601 Nut, Wing, 10-32, SS

B9 2508-05047 Screw, Truss-Hd-P, 8-32 x 3/8:, SS

B10 4000-06631 Rope, 1/4” Kaotex 2000

B11 2810-27901 Washer, Bowed, 5mm, AZ SS, Spaenaur 681-821

B12 4000-27900 Air Shutter, Profiled, 5220

B13 4900-07004 PIn, Mounting, SI HOlder

B14 2789-07005 Nut, Wing, 5/16-18, SS

B15 4900-05586 Air Screen Assembly


Figure 32 Model 5220 Burner


28142 Rev. 5

11.3 Model 5220 Fuel System


C1 3100-22361 Regulator, Fisher 67CFR, 0-35 PSI, UL144, UL252, 5220

C2 3044-00501 Nipple, Hex, 1/4 NPT X 1 1/8, Brass(Fairview)

C3 4200-02100 Manifold Block, Fuel System

C4 3400-06471 Switch, Pressure 1.6 PSI, 76056-DB 1.6-0.5

C5 3034-21569 Elbow, Street 1/4 NPT, B-4-SE

C6 3044-02154 Nipple, Hex, 1/4” x 3”, Brass

C7 3094-24653 Valve, 1/4 NPT, Brass, 1/4 Turn, Q11F-600TB2.N

C8 3200-00406 Gauge, Pressure, 0-30 PSI

C9 3031-20071 Elbow, 1/4 TB X 1/4 MNPT, SS, SS-400-2-4

C10 4200-07981 Vent Tube Assy, Regulator, SS, 5060/5120/5220

C11 3021-00380 Connector, 1/4 TB X 1/4 MNPT, 316SS, SS-40-1-4

C12 4200-27904 Fuel Line, Manifold, 5220

C13 3031-26518 Elbow, 1/4 TB X 1/4 MNPT, SS

Figure 33 Model 5220 Fuel System


28142 Rev. 5

11.3 Model 5220 Fuel System

C14 3094-27927 Valve, Solenoid, Burkert, 6013, CD04933, 2 Way NC 1/8 FNPT, Brass

C15 4200-05286 Kit, Fuel Line, 10in.

C16 4900-22372 Spacer 3/8”, Fuel System W/CFR Regulator

C17 4200-27844 Bracket, Solenoid Valve, 5120/5220

C18 2514-22520 Screw, Hex HD, 1/4 - 20 X 3.75” SS

C19 2808-00473 Washer, Lock, Ext. 1/4, SS

C20 2714-00611 Nut, Hex, 1/4-20, SS

C21 2808-00538 Washer, Lock, Spring, #8, SS

C22 2508-23438 Screw, MACH, P-H-P, M4 X 12mm, SS

C23 3400-22363 Filter Kit, Fisher 67CFR, (Not Shown)

C24 2100-22810 Cable, 3 Wire, 18 AWG Black, Silflex (part of Limiter or L/C)


Figure 33 Model 5220 Fuel System


28142 Rev. 5

12 TEG PERFORMANCE LOG

MODEL NO:

TEG SERIAL NO:

FUEL TYPE:

LIMITER/CONVERTER SERIAL NO:

CP INTERFACE SERIAL NO:

DA

TE

TIM

E

AM

BIE

NT

TE

MP

ºC RE

QU

IRE

D

PO

WE

R (

W)

RE

QU

IRE

D v

SE

T

(V)

ME

AS

UR

ED

vS

ET

(V)

ME

AS

UR

ED

P

OW

ER

(W)

FU

EL P

RE

SS

UR

E

OP

EN

CIR

CU

IT

VO

LTA

GE

(V

)

MAINTENANCE

REMARK


28142 Rev. 4

12 TEG PERFORMANCE LOG

MODEL NO:

TEG SERIAL NO:

FUEL TYPE:

LIMITER/CONVERTER SERIAL NO:

CP INTERFACE SERIAL NO:

DA

TE

TIM

E

AM

BIE

NT

TE

MP

ºC RE

QU

IRE

D

PO

WE

R (

W)

RE

QU

IRE

D v

SE

T

(V)

ME

AS

UR

ED

vS

ET

(V)

ME

AS

UR

ED

P

OW

ER

(W)

FU

EL P

RE

SS

UR

E

OP

EN

CIR

CU

IT

VO

LTA

GE

(V

)

MAINTENANCE

REMARK

Teg 5220 Manual

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