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.

Gentherm Global Power Technologies 2-1
P-5050 62553 Rev.8
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 Gentherm Global Power
Technologies’ (GPT) 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 operational.
Locate and identify the following items that were shipped with the P-5050 TEG:
• 1 Fin Duct
• 1 Rain Cap
• 1 Exhaust Stack with Clamp
• 1 Thread Sealing Compound
• 7 Screws, #8-32 × 1/4 in. long, one spare
• 7 Washer, #8 External Lock
CAUTION: Inspect the TEG for damage which 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 3 and mount it on a firm and stable base, suf-
ficiently high above ground level to prevent the TEG from being inundated with water.
c) Connect the fuel supply to the manual shut off valve, 1/4” FNPT, using the thread
sealant provided. Leak check the complete fuel supply system from the fuel supply
line to the burner inlet using a commercial leak detector fluid such as Snoop®.
d) Connect the customer load:
I) connect the load to terminals 7 (+) and 8 (-);
II) C/L 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) Ensure the battery is connected
b) Open the manual SO valve.
Note: Once the TEG is started re-closing the manual SO valve will stop it.

Gentherm Global Power Technologies 2-2
P-5050 62553 rev.8
If the optional TEG Controller board is installed:
Press the Start (S1) button or send a SCADA Start signal to the TEG Controller board
Note: Once the TEG is started pressing the Stop (S2) button or sending a SCADA Stop
signal to the TEG Controller board will stop it.
c) 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 lockout mode - see the Spark Ignition Control System section 4.1.2.
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.
2.3 Adjustment
Follow these steps to adjust the TEG:
a) Disconnect the customer load from the TEG, terminals 7 (+) and 8 (-) of TB-1 and
allow to stabilize for 15 minutes.
b) Measure the Vset voltage between terminals 5 (+) and 6 (-).
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 C/L and CP interface systems, if applicable, are located in
section 8, Adjustment.
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 maintenance
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 manual.
Note: Servicing requirements are given in the Maintenance section.

Gentherm Global Power Technologies 3-1
P-5050 62553 Rev.8
3 TECHNICAL SPECIFICATIONS
This section gives the technical specifications for the Gentherm Global Power Technologies
(GPT) Model P-5050 Thermoelectric generator.
3.1 Overview
The Model P-5050 Thermoelectric Generator (TEG) converts heat directly into electricity
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 P-5050 Thermoelectric Generator provides 67 Watts of electrical power from
the power unit at the beginning of life and at an ambient temperature of 20ºC. This power
is generated at a nominal 6 Volts, which can then be converted to other voltages using the
voltage converter. The converter is 83% efficient which provides 54 Watts of net electrical
power with a 12 Volt/24 Volt converter.
If the generator is to be operated at load conditions that force the output voltage to vary sig-
nificantly from 5.5 Volts, then less than the rated power will be available to the load. Figure
6 identifies the electrical parameters of the P-5050’s power unit as a function of the load
resistance.
3.2 Options
Mounting Stand: The P-5050 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 GPT.
Cathodic Protection Interface (CP): The Cathodic Protection Interface option provides a
termination point of 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.
Remote Start system (TEG Controller board): The Remote Start option provides a
method of starting and stopping the TEG either locally or remotely, using on-board buttons,
SCADA signal interface or system measurements.
Optional VSR Terminal Block: The optional VSR terminal block is an additional wiring har-
ness that provides the VSR and current measurement connection on a terminal block inside
the TEG Cabinet as opposed to directly connecting to the electronic circuit board
Note: Specifications shown are for standard configurations. Gentherm Global Power
Technologies’s Integrated Systems Engineering Department is available to design
installations meeting different specifications including custom voltages, fuel supply
systems and nonstandard operating temperatures.

Gentherm Global Power Technologies 3-2
P-5050 62553 rev.8
Power output
Power Ratings at the beginning of life,
20º C, 750 m above sea level, available at the
terminal strip including reverse current diode.
50 Watts @ 6.7 Volts
50 Watts @ 14.1 Volts
50 Watts @ 28 Volts
Electrical
Adjustment
6.7 V 4 - 11 Volts
12 V 12 - 18 Volts
24 V 24 - 30 Volts
Reverse Current Protection Yes, diode board is standard
Output
Terminal block which accepts up to 8 AWG
wire. Opening for 3/4” conduit in the base
of the cabinet.
Fuel
Natural Gas 4.9 m3/day (173 ft3/day) of Std. 1000 BTU/
SCF (37.7 MJ/Sm3) gas
Propane 6.4 l/day (3.2 US gal/day)
Maximum Supply Pressure 344 kPa (50 psig)
Minimum Supply Pressure 103 kPa (15 psig)
Fuel Connection 1/4” MNPT
Environmental
Ambient Operating Temperature
Continuously Running TEG
Max. 55º C (130º F)
Min. -40º C (-40º F)
Operating Conditions Unsheltered Operation
Materials of construction
Cabinet 304 Stainless Steel
Cooling Type Natural Convection
Burner Meeker type, Inconel 600
Fuel System Brass, Aluminum & Stainless Steel

Gentherm Global Power Technologies 3-3
P-5050 62553 Rev.8
12.03 306
12.06 306
10.53 267
MOUNTING
HOLES
CP PANEL
(OPTIONAL)
62588 rev1
FUEL INLET
1/4 FNPT
39.01 991
26.99 686
18.00 457
2.96 75
18.00 457
MOUNTING HOLES
FUEL INLET
1/4 FNPT
Figure 1 Overall Dimensions of the P-5050 TEG
Depth 686 mm (26.99 in.)
Width 306 mm (12.06 in.)
Height 991 mm (39.01 in.)
Net Weight 41 kg (90 lb)
Shipping Weight 75 kg (165 lb)
Mounting Holes 267 mm wide × 457 mm deep (10.50 in. × 18.00 in.)
3.3 Weights and Measures
The following table gives the overall dimensions and weights of the TEG.

Gentherm Global Power Technologies 3-4
P-5050 62553 rev.8
3.4 SI System
The following table gives the technical specifications for the SI system.
3.5 Data Plate
The data plate is on the inside of the cabinet door and includes vital information about the
generator, see Figure 2.
Model Number: The model number on the Data Plate is interpreted as follows:
Fuel Type: an “X” will be marked in the appropriate box to show whether the generator 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 conditions achieved
at the Gentherm Global Power Technologies Factory before shipping. Note that the fuel
pressure is recorded in kPa and the pressure gauge must be adjusted for the altitude as
described in Section 8.1.1.
Fuel Type: L = Propane
N = Natural Gas
Output Voltage:12 or 24 Volts
SS = Stainless Steel Fuel System:
CP = Cathodic Protection Interface:
RS = Remote Start:
P-5050 - ( ) - ( ) - ( ) - ( )
Electrical SI
Power Supply
Input Voltage Minimum 5.5 V DC
Maximum 35.0 V DC
Power Input 8 Watts
Output Voltage 14.0 VDC
SI
Spark Rate 10/second
Trial For Ignition 7 seconds
Number of tries for Ignition 3 trials until lockout
Inter-Purge Time 10 seconds
Spark Gap
Nominal 4.8 mm (0.19 in.)
Minimum 3.3 mm (0.13 in.)
Maximum 6.3 mm (0.25 in.)
Continuous Operating Time Without Charge 120 minutes with full charged 6V, 5 A.h
battery @ 25°C (75°F)

Gentherm Global Power Technologies 3-5
P-5050 62553 Rev.8
3.6 Fuel Consumption
The P-5050 is certified to operate on commercial propane and natural gas.
The fuel consumption of the P-5050 at rated power is listed in the table below for various
fuels.
Fuel Consumption
at Rated Power Propane Natural Gas
lb/hr* 0.3 -
gal/hr* 0.08 -
kg/hr* 0.15 -
L/hr* 0.29 -
ft3/hr** 2.88 7.2
m3/hr** 0.081 0.205
* At 20ºC (68ºF)
** At atmospheric pressure and 20ºC (68ºF), assuming an energy content of 37.3 MJ/m3or
1000 BTU/ft3
Figure 2 Data Plate

Gentherm Global Power Technologies 3-6
P-5050 62553 rev.8
3.7 Gentherm Global Power Technologies (GPT) Standard Specification for Gaseous
Fuel
Note: Fuel considered is for standard configurations.
Gaseous fuel supplied to GPT’s Thermoelectric Generators:
1. Shall not contain any particulates larger than 30 µm diameter, including but not lim-
ited to sand, dust, gums, crude oil, and impurities.
2. Shall have a hydrocarbon dew point of less than 0ºC (32ºF) at 170 kPag(25psig).
3. Shall have less than 115 mg/m3* (approx. 150 ppm) of H2S.
4. Shall have less than 60 mg/m3* (approx. 88 ppm) of Mercaptan Sulphur.
5. Shall have less than 200 mg/m3* (approx. 294 ppm) of total Sulphur.
6. Shall have less than 10% [CO2] and/or [N2] by volume, nor vary more than +/- 1%
[CO2] and/or [N2] during operation.
7. Shall have less than 120 mg/m3(5 g/100 cu.ft.) of water vapour.
8. Shall have less than 1% by volume of free oxygen.
9. Shall have a nominal gross heating value of:
Natural Gas: 37 MJ/m3(1000 BTU/cu.ft.)
Propane: 93 MJ/m3(2500 BTU/cu.ft.)
Butane: 122 MJ/m3(3300 BTU/cu.ft.)
10. Fuel temperature of less than 60ºC (140º F).
*at 1 atm and 15ºC.

Gentherm Global Power Technologies 4-1
P-5050 62553 Rev.8
4 PROCESS DESCRIPTION
This section describes the function of the equipment, the process of generating power and
available options.
FIN DUCT
RAIN CAP
ASSEMBLY
EXHAUST
LINER
EXHAUST TUBE
ASSEMBLY
CATHODIC
PROTECTION
SYSTEM
(OPTIONAL)
LEG
CABINET
& POWER UNIT
BURNER
ASSEMBLY
EXHAUST
ASSEMBLY
SPARK
ELECTRODE
BAFFLE
FUEL SYSTEM
62589 rev3
DATA PLATE
INSTRUCTION
LABEL
Figure 3 P-5050 TEG General Assembly
4.1 Model P-5050 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 combus-
tion.
c) Cool the cold-end of the thermoelectric power unit using cooling fins.

Gentherm Global Power Technologies 4-2
P-5050 62553 rev.8
d) Generate electrical power from the temperature difference created across thermo-
electric materials housed within the power unit
e) Make the electrical power available to the load
The main parts of the model P-5050 TEG, with CP attached, are shown in Figure 3.
4.1.1 Fuel System
Components making up
the fuel system control
the input of fuel to the
burner. The primary con-
trol is a pressure regulator
that modulates fuel mani-
fold pressure to a meter-
ing orifice. The pressure
regulator includes a sedi-
ment bowl with a manual
drain cock and fuel filter
to remove fuel impurities.
The fuel filter has a resin
impregnated cellulose
element which prevents
solid particles from dam-
aging the regulator and
downstream parts.
The outlet of the pressure
regulator leads to a mani-
fold 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 an 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 plumbed between
the manifold and fuel line.
The solenoid valve is controlled by the Ignition Control System. The Ignition Control 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 the fuel system are
shown in Figure 4.
An optional NACE compliant stainless steel fuel system is available as an option.
EXHAUST ASSEMBLY
ORIFICE FITTING
REGULATOR
CAP
REGULATOR
PRESSURE GAUGE
MANIFOLD
SOLENOID VALVE
FUEL INLET
MANUAL SHUT-OFF
VALVE
FUEL LINE
DRAIN COCK
SPARK ELECTRODE
VENT LINE
62590 rev 0
Figure 4 P-5050 Fuel System General Assembly