Gentherm 5220 User 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 inju-
ry or loss of life.
WARNING: Improper installation,
adjustment, alteration, service or
maintenance can cause injury or
property damage. Read the instal-
lation, operating and maintenance
instructions thoroughly before install-
ing 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’incend-
ie.
- 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 changement, le service ou
l’entretien peuvent causer des dommages ou
des dégâts matériaux. Lisez les instructions
d’installation, d’opération et d’entretien com-
plètement 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.

GLOBAL POWER TECHNOLOGIES
5220
THERMOELECTRIC
GENERATOR
Operating Manual
28142 rev. 14
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.

Table of Contents
1 About this Manual ............................................................................................1-1
1.1 Health and Safety ....................................................................................1-1
1.1.1 Warnings.......................................................................................1-1
1.1.2 Cautions........................................................................................1-1
1.1.3 Trained Operators.........................................................................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 Ignitor Control System ............................................................................3-4
3.5 Data Plate ................................................................................................3-4
3.6 Fuel Consumption....................................................................................3-5
3.7 Standard Specification for Gaseous Fuel................................................3-6
4 Process Description.........................................................................................4-1
4.1 Model 5220 Thermoelectric Generator....................................................4-1
4.1.1 Fuel System...................................................................................4-2
4.1.2 Spark Ignition Control System.......................................................4-3
4.1.2.1 Resetting The Power Supply ...........................................4-3
4.1.3 Burner ...........................................................................................4-3
4.1.4 Power Unit .....................................................................................4-5
4.1.5 Cooling Fins and Fin Duct.............................................................4-6
4.1.6 Cabinet ..........................................................................................4-6
4.1.7 Optional TEG Mounting Stands.....................................................4-6
4.2 Optional 220 Watt Limiter .......................................................................4-7
4.3 Optional 220 Watt Limiter Converter .......................................................4-9
4.4 Optional Cathodic Protection Interface System.....................................4-10
5 Installation ......................................................................................................5-1
5.1 Precautions..............................................................................................5-1
5.2 Tools Required ........................................................................................5-1
5.3 Unpacking................................................................................................5-1
5.4 Assembling ..............................................................................................5-2
5.5 Mounting ..................................................................................................5-3
5.6 Supplying Fuel .........................................................................................5-4
5.6.1 Connecting the Fuel Supply ..........................................................5-4
5.6.2 Fuel Considerations.......................................................................5-4
5.7 Connecting Customer Load.....................................................................5-6
5.8 Installation of Optional L/C ......................................................................5-7

5.8.1 Attaching the L/C to TEG ..............................................................5-7
5.8.2 TEG Wiring Interconnection ..........................................................5-7
5.9 Installation of Optional CP Interface System...........................................5-8
5.9.1 Attaching the CP Interface System to TEG...................................5-8
5.9.2 TEG Wiring Interconnection ........................................................5-10
5.9.3 Connection of CP Load ...............................................................5-10
6 Start Up 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
7.1.1 Working-out Required Vset or Setup Power...................................7-1
7.1.2 Determining Vset and Rated Power Graphically ............................7-2
7.2 Vset and Rated Power ..............................................................................7-3
7.2.1 Vset Shortly after Ignition................................................................7-4
7.2.2 Examining Vset When Going From Run To Set Up Position .........7-5
8 Adjustment ......................................................................................................8-1
8.1 Power Output Adjustment........................................................................8-2
8.1.1 Adjustment for Elevation................................................................8-2
8.1.2 Air-shutter Adjustment ...................................................................8-3
8.1.2.1 Measuring CO Emissions Levels.....................................8-4
8.1.3 Fuel Pressure Adjustment .............................................................8-5
8.2 Adjustment of Optional L/C......................................................................8-6
8.2.1 Output Voltage Adjustment............................................................8-6
8.2.2 Voltage Sensing Relay (VSR) Adjustment ....................................8-6
8.3 Adjustment of Option CP Interface System.............................................8-7
8.3.1 CP Power Output Adjustment .......................................................8-7
8.3.1.1 Series Wiring ...................................................................8-8
8.3.1.2 Parallel Wiring..................................................................8-8
9 Maintenance......................................................................................................9-1
9.1 Recommended Periodic Maintenance.....................................................9-1
9.1.1 Tools and Parts Recommended for Routine Servicing .................9-1
9.1.2 Evaluate Vset ..................................................................................9-2
9.1.3 Routine Service .............................................................................9-3
9.2 Fuel System Maintenance .......................................................................9-3
9.2.1 Draining the Sediment Bowl ..........................................................9-3
9.2.2 Fuel Filter Replacement ................................................................9-4
9.2.3 Fuel Orifice Inspection...................................................................9-5
10 Troubleshooting .............................................................................................10-1
10.1 Burner Maintenance ..............................................................................10-3
10.1.1 Air Filter Cleaning......................................................................10-3
10.1.2 Inspection of Burner Components.............................................10-3

10.2 Ignition Control System Maintenance....................................................10-5
10.2.1 Check the Spark Electrode........................................................10-5
10.2.2 Check the Pressure Switch .......................................................10-6
10.2.3 Check the Battery Voltage.........................................................10-6
10.2.4 Check the Power Supply ...........................................................10-6
10.2.5 Check if the Battery will Hold Charge........................................10-7
10.2.6 Check the Operation of the Ignition Controller .........................10-7
10.2.7 Check Solenoid Valve ...............................................................10-7
10.3 L/C Examination ....................................................................................10-8
10.3.1 Check L/C Switch Settings ........................................................10-8
10.3.2 Check Input Voltage to the L/C .................................................10-8
10.3.3 Check Output from the L/C........................................................10-8
10.4 Power Unit Examination..........................................................................10-9
10.4.1 Check for Internal Short ............................................................10-9
10.4.2 Check Internal Resistance.........................................................10-9
11 Part List ....................................................................................................11-1
11.1 Model 5220 TEG .....................................................................................11-2
11.2 Model 5220 Burner..................................................................................11-4
11.3 Model 5220 Fuel System ........................................................................11-5
12 TEG Performance Log....................................................................................12-1

LIST OF FIGURES
Figure 1 Overall Dimensions of the 5220 TEG ...........................3-3
Figure 2 5220 TEG General Assembly, shown with L/C Option ..............4-1
Figure 3 5220 Fuel System General Assembly ...........................4-2
Figure 4 Burner General Assembly ....................................4-4
Figure 5 Cut-away of a Model 5220 Thermopile ..........................4-5
Figure 6 Gross Power from Power Unit @ 20°C ..........................4-6
Figure 7 220 Watt Limiter............................................4-7
Figure 8 220 Watt L/C General Assembly ...............................4-8
Figure 9 CP Interface System General Assembly ........................4-10
Figure 10 Assembling the 5220 TEG....................................5-2
Figure 11 Model 5220 Mounting Dimensions, shown with L/C Option ..........5-3
Figure 12 Applying Thread - Sealant ....................................5-4
Figure 13 Setting-up the 5220 TEG, shown with L/C Option .................5-5
Figure 14 Wiring Diagram 5220 TEG, shown with 12 V Limiter Option .........5-6
Figure 15 Wiring Diagram 5220 TEG, Shown W/ L/C Option ................5-7
Figure 16 CP Installation .............................................5-8
Figure 17 CP Wiring for Model 5220-12 V DC, with Limiter Option ............5-9
Figure 18 CP Wiring for Model 5220-24 V DC, with L/C Option ...............5-9
Figure 19 Vset and Gross Power from Power Unit versus Ambient Temperature ..7-3
Figure 20 Vset versus Time After Ignition, Typical Response..................7-4
Figure 21 Change in Fuel Gauge Pressure vs Elevation Above Mean Sea Level,
Typical ...................................................8-1
Figure 22 Air Shutter ................................................8-2
Figure 23 Change in Vset versus Air-Shutter Adjustment, Typical ..............8-4
Figure 24 Change in Vset versus Fuel Pressure Adjustment, Typical ...........8-5
Figure 25 CP Interface System, Series Wiring Diagram .....................8-8
Figure 26 CP Interface System, Parallel Wiring Diagram ....................8-8
Figure 27 Pressure Regulator .........................................9-4
Figure 28 SI Module Wiring ..........................................10-4
Figure 29 Ignition Control Module Schematic ............................10-5
Figure 30 Momentary Open Circuit ...................................10-10
Figure 31 Model 5220 TEG ..........................................11-2
Figure 32 Model 5220 Burner ........................................11-4
Figure 33 Model 5220 Fuel System....................................11-5