Gentherm P-5100 User manual

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.
Do not store or use gasoline or other
flammable vapors and liquids near 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.
Installation and service must be performed
by a qualified installer, service agency or the
gas supplier.
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.

AVERTISSEMENT: Si l’information de ce
manuel n’est pas suivie exactement, un
incendie ou une explosion peut résulter
entraînant des dégâts matériaux, des
blessures ou la perte de vie.
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.
L'installation et le service doivent être
effectués par un installateur qualifié, une
agence de service ou le fournisseur de gaz.
AVERTISSEMENT: L’installation inexacte,
l’ajustement, le changement, 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.

62128 Rev 10
#16, 7875 - 57th Street SE
Calgary, Alberta Canada T2C 5K7
Main: [phone]
Fax: [phone]
www.genthermglobalpower.com
NOTICE TO INSTALLER: These instructions shall be left with the consumer
to retain them for future reference.

Gentherm Global Power Technologies I
TABLE OF CONTENTS
1ABOUT THIS MANUAL......................................................................................................1
1.1 HEALTH AND SAFETY .................................................................................................1
1.2 TECHNICAL TERMS ....................................................................................................1
2QUICK START PROCEDURE ..............................................................................................3
2.1 INSTALLATION ..........................................................................................................3
2.2 START UP .................................................................................................................3
2.3 ADJUSTMENT ............................................................................................................4
2.4 PERFORMANCE LOG ...................................................................................................4
3TECHNICAL SPECIFICATIONS...........................................................................................5
3.1 OVERVIEW................................................................................................................5
3.2 OPTIONS ..................................................................................................................5
3.3 WEIGHTS AND MEASURES..........................................................................................7
3.4 SYSTEM....................................................................................................................8
3.5 DATA PLATE..............................................................................................................8
3.6 FUEL CONSUMPTION..................................................................................................9
3.7 STANDARD SPECIFICATION FOR GASEOUS FUEL ........................................................10
4PROCESS DESCRIPTION ................................................................................................11
4.1 MODEL P-5100 THERMOELECTRIC GENERATOR........................................................... 11
4.2 CONVERTER LIMITER ...............................................................................................16
4.3 TEMPERATURE COMPENSATION................................................................................. 17
4.4 BLOCKING DIODE....................................................................................................18
4.5 OPTIONAL CATHODIC PROTECTION INTERFACE SYSTEM .............................................. 19
4.6 OPTIONAL REMOTE START SYSTEM (TEG CONTROLLER BOARD) ...................................19
4.7 INTAKE AND EXHAUST FLAME ARRESTORS .................................................................23
4.8 OPTIONAL VSR TERMINAL BLOCK ..............................................................................24
5INSTALLATION .............................................................................................................25
5.1 PRECAUTIONS.........................................................................................................25
5.2 TOOLS REQUIRED.................................................................................................... 25
5.3 UNPACKING ............................................................................................................26
5.4 ASSEMBLING .......................................................................................................... 26
5.5 MOUNTING .............................................................................................................27
5.6 SUPPLYING FUEL ..................................................................................................... 28
5.7 CONNECTING CUSTOMER LOAD ................................................................................ 30
5.8 INSTALLATION OF OPTIONAL CP INTERFACE SYSTEM ..................................................32
6STARTUP AND SHUTDOWN ............................................................................................34
6.1 BEFORE STARTING ..................................................................................................34
6.2 TEG START-UP ........................................................................................................34

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6.3 SHUTDOWN ............................................................................................................34
7POWER OUTPUT EVALUATION ........................................................................................ 35
7.1 REQUIRED Vset OR SETUP POWER AT SITE ..................................................................35
7.2 CHECKING Vset OR SETUP POWER ..............................................................................37
8ADJUSTMENT ............................................................................................................... 40
8.1 POWER OUTPUT ADJUSTMENT ..................................................................................41
8.2 ADJUSTMENT OF C/L................................................................................................ 45
8.3 ENABLING TEMPERATURE COMPENSATION ................................................................. 46
8.4 ADJUSTMENT OF OPTIONAL CP INTERFACE SYSTEM .................................................... 46
8.5 ADJUSTMENT OF THE OPTIONAL REMOTE START SYSTEM (TEG CONTROLLER) ............... 48
9MAINTENANCE .............................................................................................................49
9.1 RECOMMENDED PERIODIC MAINTENANCE..................................................................49
9.2 FUEL SYSTEM MAINTENANCE ....................................................................................51
9.3 BURNER MAINTENANCE............................................................................................ 54
9.4 SI SYSTEM MAINTENANCE........................................................................................ 56
9.5C/L EXAMINATION ................................................................................................... 60
9.6 POWER UNIT EXAMINATION ..................................................................................... 60
10 TROUBLESHOOTING .....................................................................................................63
11 PART LIST ................................................................................................................... 65
11.1 MODEL P-5100 TEG .................................................................................................66
11.2 MODEL P-5100 BURNER ...........................................................................................69
11.3 MODEL P-5100 FUEL SYSTEM.................................................................................... 71
11.4 MODEL P-5100 OPTIONAL STAINLESS STEEL FUEL SYSTEM .......................................... 72
11.5 MODEL P-5100 ELECTRICAL...................................................................................... 74
12 CATHODIC PROTECTION OPTION.................................................................................... 76
12.1 INTRODUCTION....................................................................................................... 76
13 HEAT RECOVERY SYSTEM (HRS) OPTION.........................................................................82
13.1 INTRODUCTION....................................................................................................... 82
13.2 INSTALLATION ........................................................................................................82
13.3 TEG OPERATION......................................................................................................82
13.4 MODEL P-5100 HRS CONFIGURATION PARTS ..............................................................83
13.5 MODEL P-5100 HRS BURNER PARTS ..........................................................................84
14 TEG PERFORMANCE LOG ............................................................................................... 85

Gentherm Global Power Technologies III
TABLE OF FIGURES
Figure 1 –Overall Dimensions of the P-5100 TEG ......................................................... 7
Figure 2 - Data Plate................................................................................................. 9
Figure 3 - P-5100 TEG General Assembly ...................................................................11
Figure 4 –P-5100 Fuel System General Assembly .......................................................12
Figure 5 –Burner General Assembly ..........................................................................14
Figure 6 –Model P-5100 Power Unit Electrical Output Characteristics.............................15
Figure 7 - C/L General Assembly ...............................................................................16
Figure 8 - CP Interface System General Assembly .......................................................18
Figure 9 - TEG Controller Assembly............................................................................20
Figure 10 –Assembling the P-5100 TEG .....................................................................26
Figure 11 –Model P-5100 Mounting Dimensions..........................................................27
Figure 12 –Applying Thread Sealant..........................................................................28
Figure 13 –Setting up the P-5100 TEG ......................................................................29
Figure 14 - Wiring Diagram P-5100 for 12 or 24 V .......................................................30
Figure 15 - Wiring Diagram P-5100 TEG for 12 or 24V with optional TEG Controller .........31
Figure 16 - Customer Load Connections .....................................................................32
Figure 17 –CP Installation........................................................................................33
Figure 18 - Vset and Setup Power Versus Ambient Temperature .....................................37
Figure 19 - Vset Versus Time After Ignition, Typical Response ........................................38
Figure 20 - Change in Fuel Gauge Pressure Versus Elevation Above Mean Sea Level ........40
Figure 21 - Change in Vset Versus Air-Shutter Adjustment.............................................41
Figure 22 - Change in Vset Versus Fuel Pressure Adjustment..........................................44
Figure 23 - CP Interface System, Series Wiring Diagram ..............................................47
Figure 24 - CP Interface System, Parallel Wiring Diagram.............................................47
Figure 25 –Pressure Regulator .................................................................................52
Figure 26 - Burner Assembly Cross Section.................................................................55
Figure 27 - Electrode Protrusion from Air Box Lid.........................................................58
Figure 28 - Momentary Open Circuit Diagram..............................................................61
Figure 29 - Model P-5100 TEG...................................................................................66
Figure 30 - Model P-5100 Burner...............................................................................69
Figure 31 - Model P-5100 Fuel System .......................................................................71
Figure 32 - Model P-5100 SS Fuel System ..................................................................72
Figure 33 - Model P-5100 Electrical............................................................................74
Figure 34 - Cathodic Protection Interface Cabinet ........................................................76
Figure 35 - CP Interface System, Series Wiring Diagram ..............................................77
Figure 36 - CP Interface System, Parallel Wiring Diagram.............................................78
Figure 37 - Cathodic Protection System Parts Identification ..........................................79
Figure 38 - Parts Table.............................................................................................80
Figure 39 - HRS Option Overview ..............................................................................82
Figure 40 - HRS Configuration...................................................................................83
Figure 41 - Model P-5100 HRS, Burner .......................................................................84

ABOUT THIS MANUAL
Gentherm Global Power Technologies Page 1
1ABOUT THIS MANUAL
This manual provides instructions for the operation and maintenance of the model P-5100
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-5100, 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
thermoelectric materials and cooling fins.
Rated Power: Model P-5100 TEG produces 100 W when operating in an ambient
temperature of 20ºC (68ºF). With the fuel flow held constant TEGs operating in ambient
temperatures higher than 20ºC (68ºF) will see power output efficiency reduce, 0.4 W per ºC
(0.2 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 0.4 W per ºC (0.2 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.

ABOUT THIS MANUAL
Gentherm Global Power Technologies Page 2
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).
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
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.
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 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.

QUICK START PROCEDURE
Gentherm Global Power Technologies Page 3
2QUICK 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 reasonable
knowledge and experience with industrial fuel and electrical equipment.
2.1 INSTALLATION
Follow these steps to install the TEG:
1. 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-5100 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 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 generator inoperable. Check
with the factory before starting a damaged TEG.
2. Assemble the TEG as shown in Figure 3 and mount it on a firm and stable base,
sufficiently high above ground level to prevent the TEG from being inundated with
water.
3. Connect the fuel supply to the manual shutoff 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®.
4. Connect the customer load:
•connect the load to terminals 7 (+) and 8 (-);
•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:
1. Ensure the battery is connected.
2. Open the manual shutoff valve.
NOTE:
Once the TEG is started re-closing the manual shutoff valve will shut it off.