Gentherm P-5050 User manual

- Do not store or use gasoline or other flammable
vapors and liquids in the vicinity of this or any
other appliance.
- WHAT TO DO IF YOU SMELL GAS:
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use
any phone in your building.
• Immediately call your gas supplier from a
neighbour’s phone. Follow the gas supplier’s
instructions.
• If you cannot reach your gas supplier, call the
fire department.
WARNING: If the information in this manual
is not followed exactly, a fire or explosion
may result causing property damage, personal
injury or loss of life.
WARNING: Improper installation,
adjustment, alteration, service or
maintenance can cause injury
or property damage. Read the
installation, operating and maintenance
instructions thoroughly before installing
or servicing this equipment.
WARNING: For Outdoor Use Only

- 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
fournisseur de gaz, appelez le service
d’incendie.
AVERTISSEMENT:L’installation
inexacte, l’ajustement, le change-
ment, le service ou l’entretien peuvent
causer des dommages ou des dégâts
matériaux. Lisez les instructions
d’installation, d’opération et d’entretien
complètement avant d’installer ou
entretenir cet équipement.
AVERTISSEMENT: Pour l’usage extérieur seulement
AVERTISSEMENT: si l’information de ce man-
uel n’est pas suivie exactement, un incendie
ou une explosion peut resulter entraînant des
dégâts matériaux, des blessures ou la perte de
vie.

P-5050
THERMOELECTRIC
GENERATOR
Operating Manual
62553 Rev 8
Gentherm Global Power Technologies
Unit 16, 7875 - 57th Street SE
Calgary, Alberta
Canada, T2C 5K7
Phone: [phone]
Fax: [phone]
www.genthermglobalpower.com *
* For latest version download from website
NOTICE TO INSTALLER: These instructions shall be left with the consumer
to retain them for future reference.
GLOBAL POWER TECHNOLOGIES

TABLE OF CONTENTS
1 ABOUT THIS MANUAL ..................................................1-1
1.1 Health and Safety ....................................................1-1
1.2 Technical Terms ......................................................1-1
2 QUICK START PROCEDURE..............................................2-1
2.1 Installation ..........................................................2-1
2.2 Start-up ............................................................2-1
2.3 Adjustment ..........................................................2-2
2.4 Performance Log .....................................................2-2
3 TECHNICAL SPECIFICATIONS ............................................3-1
3.1 Overview ...........................................................3-1
3.2 Options.............................................................3-1
3.3 Weights and Measures ................................................3-3
3.4 SI System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.5 Data Plate ..........................................................3-4
3.6 Fuel Consumption ....................................................3-5
3.7 Gentherm Global Power Technologies Standard Specification for
Gaseous Fuel...........................................................3-6
4 PROCESS DESCRIPTION ................................................4-1
4.1 Model P-5050 Thermoelectric Generator ..................................4-1
4.2 Converter Limiter .....................................................4-6
4.3 Temperature Compensation ............................................4-7
4.4 Blocking Diode.......................................................4-8
4.5 Optional Cathodic Protection Interface System..............................4-9
4.6 Optional Remote Start System (TEG Controller board) .......................4-9
4.7 Intake and Exhaust Flame Arrestors ....................................4-13
4.8 Optional VSR Terminal Block...........................................4-13
5 INSTALLATION .........................................................5-1
5.1 Precautions .........................................................5-1
5.2 Tools Required .......................................................5-1
5.3 Unpacking ..........................................................5-2
5.4 Assembling..........................................................5-2
5.5 Mounting ...........................................................5-3
5.6 Supplying Fuel .......................................................5-3
5.7 Connecting Customer Load ............................................5-10
5.8 Installation of Optional CP Interface System...............................5-10
6 STARTUP AND SHUTDOWN ..............................................6-1
6.1 Before Starting.......................................................6-1
6.2 TEG Start-Up ........................................................6-1
6.3 Shutdown ...........................................................6-1

7 POWER OUTPUT EVALUATION ...........................................7-1
7.1 Required Vset or Setup Power at Site.....................................7-1
7.2 Checking Vset or Setup Power ..........................................7-2
8 ADJUSTMENT..........................................................8-1
8.1 Power Output Adjustment ..............................................8-2
8.2 Adjustment of C/L.....................................................8-5
8.3 Enabling Temperature Compensation .....................................8-7
8.4 Adjustment of Optional CP Interface System ...............................8-7
8.5 Adjustment of the optional Remote Start System (TEG Controller) ..............8-9
9 MAINTENANCE.........................................................9-1
9.1 Recommended Periodic Maintenance.....................................9-1
9.2 Fuel System Maintenance ..............................................9-4
9.3 Burner Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
9.4 SI System Maintenance................................................9-9
9.5 C/L Examination.....................................................9-11
9.6 Power Unit Examination ..............................................9-12
10 TROUBLESHOOTING...................................................10-1
11 PART LIST............................................................11-1
11.1 Model P-5050 TEG .................................................11-2
11.2 Model P-5050 Burner................................................11-5
11.3 Model P-5050 Fuel System ...........................................11-6
11.4 Model P-5050 Optional Steel Fuel System ...............................11-7
11.5 Model P-5050 Electrical
12 CATHODIC PROTECTION ...............................................12-1
11.1 Introduction .......................................................12-1
13 HEAT RECOVERY SYSTEM OPTION ......................................13-1
13.1 Introduction ..........................................................13-1
13.2 Installation ...........................................................13.1
13.3 TEG Operation .......................................................13.2
14 TEG PERFORMANCE LOG ..............................................14-1

TABLE OF FIGURES
Figure 1: Overall Dimensions of the P-5050 TEG .................................3-3
Figure 2: Data Plate ........................................................3-5
Figure 3 P-5050 TEG General Assembly ........................................4-1
Figure 4 P-5050 Fuel System General Assembly..................................4-2
Figure 5 Burner General Assembly.............................................4-4
Figure 6 Model P-5050 Power Unit Electrical Output Characteristics ..................4-5
Figure 7 C/L General Assembly ...............................................4-6
Figure 8 CP Interface System General Assembly..................................4-8
Figure 9 TEG Controller Assembly ............................................4-10
Figure 10 Assembling the P-5050 TEG .........................................5-2
Figure 11 Model P-5050 Mounting Dimensions ...................................5-3
Figure 12 Applying Thread Sealant.............................................5-4
Figure 13 Setting-up the P-5050 TEG ..........................................5-5
Figure 14 Wiring Diagram P-5050 TEG for 12 or 24 V..............................5-7
Figure 15 Wiring Diagram P-5050 TEG for 12 or 24V with optional TEG Controller .......5-8
Figure 16 Wiring Diagram P-5050 TEG for 6.7V ..................................5-9
Figure 17 Customer Load Connections ........................................5-10
Figure 18 CP Installation....................................................5-11
Figure 19 Vset and Setup Power Versus Ambient Temperature.......................7-3
Figure 20 Vset Versus Time After Ignition, Typical Response ........................7-4
Figure 21 Change in Fuel Gauge Pressure Versus Elevation Above Mean Sea Level,
Typical ...........................................................8-1
Figure 22 Change in Vset Versus Air-Shutter Adjustment, Typical .....................8-2
Figure 23 Change in Vset Versus Fuel Pressure Adjustment, Typical ..................8-5
Figure 24 CP Interface System, Series Wiring Diagram.............................8-8
Figure 25 CP Interface System, Parallel Wiring Diagram............................8-8
Figure 26 Pressure Regulator .................................................9-4
Figure 27 Burner Assembly Cross Section .......................................9-7
Figure 28 Electrode Protrusion From Air Box Lid ..................................9-9
Figure 29 Momentary Open Circuit Diagram ....................................9-13
Figure 30 Model P-5050 TEG ................................................11-2
Figure 31 Model P-5050 Burner ..............................................11-5
Figure 32 Model P-5050 Fuel System .........................................11-6
Figure 33 Model P-5050 SS Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-7
Figure 34 Model P-5050 Electrical.............................................11-8
Figure 35 Cathodic Protection Interface Cabinet .................................12-1
Figure 36 CP Interface System, Series Wiring Diagram............................12-2
Figure 37 CP Interface System, Parallel Wiring Diagram...........................12-4
Figure 38 Cathodic Protection System Parts Identification..........................12-4
Figure 39 HRS Option Overview. .............................................13-1
Figure 40 Model P5050 HRS Configuration .....................................13-3
Figure 41 Model P5050 HRS, Burner ..........................................13-4

Gentherm Global Power Technologies 1-1
P-5050 62553 Rev.8
1 ABOUT THIS MANUAL
This manual provides instructions for the operation and maintenance of the model P-5050
Thermoelectric Generator.
1.1 Health and Safety
Correct operation and maintenance according to this manual is critical for proper equipment
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 significance,
defined for the model P-5050, 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 thermoelec-
tric materials and cooling fins.
Rated Power: Model P-5050 TEG produces 50 W when operating in an ambient tempera-
ture of 20ºC (68ºF). With the fuel flow held constant TEGs operating in ambient tempera-
tures higher than 20ºC (68ºF) will see power output efficiency reduce, 0.2 W per ºC (0.1
W per ºF) of temperature change up to a maximum ambient temperature of 55ºC (130ºF).
Conversely for temperatures lower than 20ºC (68ºF) power output efficiency will increase
by 0.2 W per ºC (0.1 W per ºF) of temperature change.

Gentherm Global Power Technologies 1-2
P-5050 62553 rev.8
Set-up Voltage: Vset: Voltage from the power unit for a specific ambient temperature when
the power unit is connected to a precision load, which is proportional to set-up power. Fuel
flow to the burner is adjusted so that proper voltage exists, necessary temperature differ-
ence within the power unit maintained, to deliver required power.
Open Circuit Voltage: Voltage at the terminals of the power unit when no current is flow-
ing through the power unit, 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 volt-
age measured across the power unit leaps up to a new value. This is known as the momen-
tary open circuit voltage (Voc).
Measured Vset:Vset measured across the precision load on the output of the electronics
without a customer load connected 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 sys-
tems for cathodic corrosion protection of metallic structures such as pipelines.
CP Interface System: An assembly of electrical components system that acts as an inter-
face between the TEG and the CP load, which also provides for adjustment and monitoring
of power to the CP load.
Converter/Limiter (C/L): 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 com-
pletely 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.