Global 1120 User manual

1120 THERMOELECTRIC GENERATOR
CLASS I, DIVISION 2, GROUP D, T3
Operating Manual
#16, 7875 - 57th Street SE
Calgary, Alberta
Canada T2C 5K7
Main: [phone]
Fax: [phone]
www.globalte.com
22786 REV 9

TABLE OF CONTENTS
1 GENERAL ............................................................1
1.1 General Information ..................................................1
 1.2 DenitionofTerms...................................................1
 1.3 TheoryofOperation..................................................3
 1.4 PhysicalDescription .................................................4
 1.5 ElectricalOutputCharacteristics ........................................6
 1.6 AmbientTemperatureE󰀨ects ..........................................6
1.7 Rated Power .......................................................6
 1.8 FuelConsumption ...................................................9
 1.9 BoilingTemperatureofFuel ...........................................9
 1.10 Installation .........................................................9
 1.11 MechanicalInspection ................................................10
 1.12 ElectricalConnection .................................................12
 1.13 FuelSupplyConnection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 .
1.14 StartupPreparation ............................................13
2 OPERATION ............................................................15
2.1 Data Plate .........................................................15
 2.2 Start-UpDataSheets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
 2.3 StartingGenerator ...................................................17
 2.4 HeatUpToRatedPower .............................................18
2.5 VsetVersusTime ...................................................18
2.6 VsetVersusPower ..................................................18
 2.7 DeterminingRequiredVset ...........................................19
 2.8 FuelandAiradjustment ..............................................20
 2.9 AirShutterAdjustment................................................21
 2.10 FuelPressureAdjustment .............................................22
 2.11 ApplyingcustomerLoad ..............................................24
3 SERVICE ............................................................25
 3.1 1120TEG .........................................................25
 3.2 PowerUnit .........................................................27
 3.3 BurnerAssembly ....................................................27
 3.4 FuelAssembly ......................................................28
 3.5 IgniterHousingAssembly .............................................28
 3.6 ConduitAssembly ...................................................29
 3.7 ElectronicsAssembly.................................................29
 3.8 Service............................................................34
 3.9 FieldTroubleshooting ................................................35
 3.10 1120TEGPartsLists ................................................39
 3.11 IgnitorDetails.......................................................41
 3.12 BurnerPartsList ....................................................42
 3.13 FuelSystemPartsList................................................44
 3.14 ConduitAssemblyPartsList ...........................................45
 3.15 IgnitorHousingAssemblyPartsList .....................................46
 3.16 ElectronicsBoxL/CPartsList .........................................47
 3.17 ElectronicsBoxLidL/CPartsList .......................................48
I

TABLE OF CONTENTS
4 Appendix ............................................................49
 4.1 GasSpecications ...................................................49
4.2 TEGStartUpDataSheet .............................................50
4.3 SystemPerformanceLog .............................................52
II

List of Figures
Figure1 TEGDesign ........................................................3
Figure2 PhysicalDescription,1120TEG ........................................5
Figure3 ElectricalOutputCharacteristics ........................................7
Figure4 PowerVs.AmbientTemperature ........................................8
Figure5 TEGMounting .....................................................10
Figure6 MechanicalInspection ...............................................11
Figure7 RecommendedConnections ..........................................12
Figure8 ApplyingThreadSealant .............................................13
Figure9 ChangeinFuelPressureVs.Elevation ..................................16
Figure10 TEGStartUp ......................................................17
Figure11 VsetVs.Time.......................................................18
Figure12 VsetVs.SetUpPower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Figure13 ChangeinVsetVs.AirShuttingSetting ..................................21
Figure14 FuelPressureVs.Vset ...............................................23
Figure15 TEGSubsystems ...................................................25
Figure16 PowerUnit ........................................................26
Figure17 AutoShutO󰀨......................................................27
Figure18 SchematicDiagram,1120TEG(sheet1of2).............................30
Figure19 SchematicDiagram,1120TEG(sheet2of2).............................31
Figure20 ElectronicsDiagram,1120TEG........................................32
Figure21 RemovingFuelSystem ..............................................35
Figure22 FuelRegulator .....................................................35
Figure23 1120TEGPartsIllustration ...........................................39
Figure24 IgnitorDetail .......................................................41
Figure25 BurnerParts .......................................................42
Figure26 FuelSystemParts ..................................................44
Figure27 ConduitAssemblyParts ..............................................45
Figure28 IgnitorHousingParts................................................46
Figure29 ElectronicsBox.....................................................47
Figure30 ElectronicsBoxLid..................................................48
III

IV

MODEL1120
HAZARDOUSAREAGENERATINGSYSTEM
DESIGNEDFOR
CLASSI,DIVISION2,GROUPD
T3OPERATION
SPECIFICATIONS
Output Voltage
Nominal  12-18VDC
     24-30VDC
Power Output  100WattsMinimum
Special Features  DigitalPanelMeter,LED,VoltageandCurrent
     IntegralBlockingDiode
     VoltageSensingAlarmwithdrycontacts
     AutoShuto󰀨
     SparkIgnition
     AutoRe-ignition
Fuel Consumption NaturalGas:8.8m3perday,(311Sft3 perday)
     Propane:11.4Lperday,(30USgalperday)
Inlet Fuel Supply Pressure Max172kPa(25psi)
      Min69kPa(10psi)NaturalGas
      Min103kPa(15psi)Propane
Dimensions
Width  61cm(24.0in.)withelectronicsboxclosed
     92cm(36.0in.)withelectronicsboxopen
Depth  80cm(31.6in.)
Height  115cm(45.3in.)withdripcap
     126cm(49.4in.)withrainshroud
Weight  123kg.(270lbs.)
Operating Temperature -20ºC(-4ºF)to+40ºC(105ºF)
Storage Temperature -65ºC(-85ºF)to+65ºC(149ºF)
V

Global Power Technologies
1120 - Class I, Division 2, Group D, T3
1 GENERAL
1.1 General Information
Thismanualprovidesinstallation,operationandmaintenanceinstructionsfortheGlobalPower
Technologies(GPT)Model1120ThermoelectricGeneratorSystem.
Special Customer Option: If the Generator System was ordered with specially engineered
options,theyarecompletelydescribedintheredSpecialCustomerOptionsectionoftheman-
ual.
1.2 DenitionofTerms
Tocorrectlyusethismanualthereadermustinterpretthemeaningofthefollowingwordsas
hereindened:
Thermoelectric Generator:Adevicethatproduceselectricalpowerthroughthedirectconver-
sionofheatenergytoelectricalenergy.
Power Unit:Thehermeticallysealedportionofthegeneratorthatcontainsthethermoelectric
materialsandthecoolingns.
TEG:Athermoelectricgenerator.
Matched Load:Aconditionofloadwhere:
a) theloadvoltageofthegeneratorisone-halfoftheopencircuitvoltage.
b) theloadresistanceisequaltotheinternalresistanceofthegenerator.
Optimum Load:Aconditionofloadwherethepoweroutputofthegeneratorismaximized.
Precision Load:Theprecisionresistorcontainedonthegeneratorthatprovidestheoptimum
loadcondition.ThevoltageacrosstheresistorisdenedasVsetandisusedtoanalyzegener-
atorelectricalperformance.
Power Conditioner:Abroadtermusedtodescribeanelectronicdeviceattachedtothegen-
eratoroutputthatconverts,adjusts,limitsorotherwiseconditionspower.
AutoShuto󰀨:The1120generatorisequippedwithathermocouplecontrolledsolenoidvalve
thatcanbemanuallyreset.Intheeventofextendedamefailurethethermocoupleoutputwill
bereducedsu󰀩cientlytoreleasethesolenoidandstopfuelgasowtotheburner.
Converter:Aspecicelectronicdeviceattachedbetweenthegeneratorandloadthatconverts
onelevelofDCvoltagetoanother.
Limiter:Aspecicelectronicdeviceattachedacrossthegeneratoroutputthatlimitsthevolt-
agelevel.
1

Global Power Technologies
1120 - Class I, Division 2, Group D, T3
Generator System:Thesystemconsistingofthegeneratorincludingitsfactoryoptions,the
powerconditionerincludingitsfactoryoptions,andthespecialcustomeroptions.
Safe Operation, Operate Safely, Operating Safely:Thesearetermsusedtodescribethe
operationofthe1120GeneratingSystem,whenitsoperatingareaorzone,shouldsuddenlyor
graduallygohazardoustowardsorbeyondthelowerexplosivelimit(LEL).Thegeneratorwill
eitheroperateatreducedpowerorextinguishcompletelyduetolackofoxygen.Thegenerator
systemwillnot,eitherwhilerunningorattemptingtobeignited,ignitethesurroundinghazard-
ousatmosphere.Iftheoperatingareashouldclearwithinashortperiodoftimethegenerator
willattempttoreigniteitself.Seeshorttermautoignition.
Short Term Auto Ignition:  The generators high voltage ignition system will automatically
comeontoreigniteitselfintheeventofaamefailureduetoeitherablowoutorshortdura-
tiongasfailure.Fuelgasmustbepresentandtheshuto󰀨valvemustnothaveoperatedfor
theautoreignitiontooccur.
Hazardous Area:(denitionperCanadianElectricalCode,Part1,Section18)
18-002Classication:Hazardouslocationsshallbeclassiedaccordingtothenatureofthe
hazard,asfollows:
a) ClassIlocationsarethoseinwhichammablegasesorvapoursareormaybesu󰀩cient
toproduceexplosiveorignitiblemixtures;
b) ClassIIlocationsarethosewhicharehazardousbecauseofthepresenceofcombusti-
bleorelectricallyconductivedusts;
c) Class III locations are those which are hazardous because of the presence of easily
ignitiblebersoryings,butinwhichsuchbersoryingsarenotlikelytobeinsuspen-
sioninairinquantitiessu󰀩cienttoproduceignitiblemixtures.
18-004DivisionofClassIlocations:ClassIlocationsshallbefurtherdividedintotwodivisions
asfollows:
a) Division1,comprisingClassIlocationsinwhich:
(i) Hazardous concentrations of ammable gases or vapours exist continuously,
intermittently,orperiodicallyundernormaloperatingconditions;or
(ii) Hazardousconcentrationsofammablegasesorvapoursmayexistfrequently
becauseofrepairormaintenanceoperationorbecauseofleakage;or
(iii) Equipmentisoperatedorprocessescarriedonofsuchnaturethatbreakdownor
faultyoperationthereofcouldresultinthereleaseofhazardousconcentrationsof
ammablegasesorvapoursandsimultaneousfailureofelectricalequipment;
b) Division2,comprisingClassIlocationsinwhich:
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Global Power Technologies
1120 - Class I, Division 2, Group D, T3
(i) Flammablevolatileliquids,ammablegasesorvapoursarehandled,processed,
orused,butinwhichtheliquids,gases,orvapoursarenormallyconnedwithin
closedcontainersorclosedsystemsfromwhichtheycanescapeonlyasaresult
ofaccidentalruptureorbreakdownofthecontainersorsystemsortheabnormal
operationoftheequipmentbywhichtheliquidsorgasesarehandled,processed,
orusedor;
(ii) Hazardousconcentrationofgasesorvapoursarenormallypreventedbypositive
mechanicalventilation,butwhichmaybecomehazardousastheresultoffailure
orabnormaloperationoftheventilationequipmentor;
(iii) ThelocationisadjacenttoaClassI,Division1location,fromwhichahazardous
concentrationofgasesorvapourscouldbecommunicated,unlesssuchcommu-
nicationispreventedbyadequatepositivepressureventilationfromasourceof
cleanair,ande󰀨ectivesafeguardsagainstventilationfailureareprovided.
c) GroupDincludespropane,methane,butane.
NOTE: Throughoutthis manualthe wordsGenerator,Thermoelectric Generator,TEGand
GeneratorSystemwillbeusedinterchangeably.
1.3 Theory of Operation
A TEG produces electrical power through
the direct conversion of heat energy into
electricalenergy.Itoperatesonthesame
principle as the thermocouples that are
used for measuring temperatures and in
safetyshuto󰀨controlsforgaswater heat-
ers, home furnaces, etc..  However, the
TEG utilizes semiconducting thermoelec-
tricmaterialsthat are much more e󰀩cient
and thus permit practical thermoelectric
power sources.  A thermocouple consists
oftwodissimilar materials (usually in wire
form) which are joined together at one
end. If this junction is heatedto a higher
temperaturethantheotherendofthewire,
a voltage will exist across the cooler end.
Further,electricalpowerwillbedeliveredto
aloadplacedinthecircuit.Thisprocesswillcontinueprovidedthatthetemperaturedi󰀨erence
ismaintained.ATEGisasystemwhichprovidesthemeanstomaintaintheserequiredcon-
ditions.
Figure1illustrateshowthisisaccomplishedinthemodel1120TEG.Athermocoupleisformed
byaPtypeandanNtypethermoelectricelementjoinedtogetherelectricallybyahotjunction
electrode.Adjacentthermocouplesarejoinedtogetherelectricallybycoldjunctionelectrodes.
Eightythermocouples,eachproducing84mVareconnectedinseriessothepowerunitproduc-
es120Wattsat6.7Voltsand18Amperes.
Figure1TEGDesign
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Global Power Technologies
1120 - Class I, Division 2, Group D, T3
Thehotjunctionofthethermocouplesismaintainedatahightemperature(538ºCor1000ºF)by
aburnerwhichoperatesongaseousfuelssuchaspropaneornaturalgas.Thecoldjunctionof
thethermocouplesismaintainedatalowertemperature(163ºCor325ºF)byanarrayofcooling
nswhichtransfertheheattoambientairbynaturalconvection.Thethermocouplesarecon-
tainedinahermeticallysealedenclosurebecausetheyareadverselya󰀨ectedwhenexposedto
airatoperatingtemperatures.Theyaresurroundedbythermalinsulationtominimizeheatloss.
Maximumpowerisdeliveredtotheloadwhen:(a)theloadvoltageisone-halfoftheopencircuit
voltageand(b)theloadresistanceisequaltotheinternalresistance.Thisconditioniscalled
thematched-loadpower(alsomaximume󰀩ciency)whentheloadvoltageisslightlyhigherthan
one-half(approx.55%)oftheopencircuitvoltage.
TheTEGissuppliedwithaprecisionloadresistorthatprovidesaknownload.Thisresistor
isusedbothinadjustingtheTEGforproperoperationandinevaluatingitsperformance.The
fuelowtotheburnerisadjustedsothatthepropervoltageexistsacrossthisprecisionresistor.
Atthis condition the TEG isoperatingattheintended junction temperature and isdelivering
maximumpower.
The TEG is supplied with a protective device which prevents its output voltage from rising
beyond11.4Volts.Thisisrequiredbecauseunderextendedopencircuit(orslightlyloaded)
conditionsthehotjunctiontemperaturecouldincreasebeyondthesafeoperatingrange.
The burner operates at moderate pressures from 28 to 70 kPa (4 to 10 psi).  The gas is
expandedthroughanoriceandthenowsthroughaventuriwhereitdrawsinairneededfor
combustion.Thefuelowiscontrolledbyapressureregulatorandisadjustedbytheoperator
toobtainthedesiredpoweroutput.
Insummary,theTEGproduceselectricalpowerwhenatemperaturedi󰀨erenceismaintained
betweenthehotandcoldjunctionsofthethermoelectricmaterials.Thetemperaturedi󰀨erence,
andthereforetheamountofpowerproduced,dependsontherateatwhichfuelissuppliedto
theburner.TheoperationoftheTEGissimplythecontrolofthefuelpressuretotheburner
whichresultsinthedesiredpoweroutput.
1.4 Physical Description
Figure2showsthegeneratorinitsnormaloperatingposition.
4

Global Power Technologies
1120 - Class I, Division 2, Group D, T3
1120 TEG w/ Drip Cap
1120 TEG w/ Rain Shroud
Figure 2 PhysicalDescription
5

Global Power Technologies
1120 - Class I, Division 2, Group D, T3
1.5 Electrical Output Characteristics
Figure3showstheelectricaloutputcharacteristicsoftheModel1120powerunit,whichgives
thepower,currentandvoltageasafunctionoftheloadresistance.TheTEGwilloperateat
anyloadconditionfromshortcircuittoopencircuit.Observethatthepowergoesthrougha
broadmaximumbetween0.3and0.5ohms.Ratedpower(120Watts)canbeobtainedonly
iftheloadresistanceiswithinthisrange.Thegraphisusefulindeterminingpower,current
andvoltageatvariouscustomerloadconditions.Refertothegraphandconsiderthefollowing
example:
1) You are installing a Model 1120 TEG at a gas wellhead to cathodically protect the
well-casingfromcorrosion.
2) Youhavemeasuredanddeterminedyourtotalgroundbedresistancetobe1.0ohm.
3) Find1.0ohmonthehorizontalaxis.
4) Readverticallyuntilintersectingthepower,current,andvoltagecurves.
5) Readhorizontallytotheverticalaxistodeterminethevaluesofpower,currentandvolt-
age.
6) Whichare106Watts,10.2Ampsand10.3Volts.
1.6 AmbientTemperatureE󰀨ects
TheelectricaloutputoftheTEGisdependentonambienttemperatureasshowninFigure4.
Observethatthepowerdecreasesasambienttemperatureincreases.
Statement of Rated Power
1) ThePowerUnitproduces120Wattswhenoperatedatanambienttemperatureof20ºC.
2) Withthefuelowheldconstant,thepowerchangesatarateof0.288%perºC(0.16%per
ºF)oftemperaturechange.
3) TheTEGcanbeoperatedatratedpowertoamaximumambienttemperatureof40ºC
(105ºF).ConsultGPTifambienttemperaturesexceed40ºC.
1.7 Rated Power
TheTEGcanbeadjustedforratedpoweratanambienttemperaturebyusingtheratedpower
curveasshowninFigure4.Considerthefollowingexample:
1) Thepresentsitetemperatureis40ºC.
2) Find40ºConthehorizontalaxis.
3) Readverticallyuntilintersectingtheratedpowercurve.
4) Readhorizontallytotheverticalaxistondtheset-uppower.
5) Whichis114watts.
6

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1120 - Class I, Division 2, Group D, T3
Figure 3 PowerUnitElectricalOutputCharacteristics@20°
7

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1120 - Class I, Division 2, Group D, T3
Figure 4 GrossPowerfrom1120PowerUnitVsAmbientTemperature
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1120 - Class I, Division 2, Group D, T3
1.8 Fuel Consumption
ThefuelconsumptionoftheTEGoperatedatratedpowerisshownbelow.TheTEGcanbe
operatedatlessthanratedpower,downto75%or90Watts.
1.9 Boiling Temperature of Fuel
Boilingpointofliqueedfuelsatatmosphericpressureare:
methane -166.5ºC(-258.7ºF)
propane -42.1ºC(-43.7ºF)
butane -0.5ºC(+31.1ºF)
1.10 Installation
Thisgeneratormustbeinstalledbyqualiedpersonnelinaccordancewithinternationaland/or
localelectricalcodes.
CarefullyunpacktheTEGfromshippingcontainer.RetaintheshippingcontaineruntiltheTEG
isoperational.
Identifyandlocatethefollowingitemsfromtheshippingcontainer:
A. GeneratorSystemComplete.
B. CustomerAssyKit.
MounttheTEGonageneratorstand,ifastandhasnotbeenprepared,aeldprovenmount-
ingarrangement is showninFigure 5. Ensurethat the TEGismounted in accordancewith
followingnotes:
A. TheTEGmustbemountedwiththenductinaverticalposition.
B. Theairowthroughthecoolingnsmustnotbeobstructed.
C. TheTEG should bemountedata height su󰀩cienttoprevent direct ooding orheavy
snowfallfrominterferingwiththeowofcoolingorintakeair.
D. Whenthegeneratorisinstallednearabuilding,eldexperiencehasshownthatthebest
locationsareontherooforonthewindwardside,withaminimumdistanceof3.0meters
(10feet)fromthebuilding.BesurethattheTEGlocationrelativetobuildingsandfuel
containersareinaccordancewithlocalregulations.
FUELCONSUMPTION
ATRATEDPOWER
PROPANE
C3H8
BUTANE
C4H10
NATURALGAS
METHANECH4
LB/HR 0.54 0.54 -
GAL/HR 0.13 0.13 -
KG/HR 0.25 0.25 -
L/HR 0.48 0.42 -
CUFT/HR 4.70 3.52 13.0
CUM/HR 0.133 0.099 0.368
9

Global Power Technologies
1120 - Class I, Division 2, Group D, T3
Removetherainshroud(iftheTEGc/warainshroud),thenductfrontcover,thedripcap(if
theTEGc/wadripcap).WithasuitableliftingdeviceandtheLiftingLug(showninFigure6),
gentlyliftandmovetheTEGtoplace.WhentheTEGhasbeenmountedonthestand,proceed
withacompletemechanicalinspection.
1.11 Mechanical Inspection (see Figure 6)
Ensure the exhaust ame arrestor assembly is screwed tight to the exhaust stack, and all
screwsontheamearrestorassemblyaretight.Visuallyinspecttheamearrestorelementby
lookingdowntheexhaustpipetoensurethatthereisnovisualdamageorfractures.Replace
thedripcap(iftheTEGc/wadripcap),thenductfrontcover,therainshroud(iftheTEGc/w
arainshroud).
Openthefrontdoorsofthecabinetandlocatetheburnermountingbolts,tightenthecapnuts,
andlocatetheairintakeamearrestorassemblies.Ensurethattheyaretightlysecured.
LocatetheIgniterhousingassembly,removethecapandvisuallyinspecttheignitorconnec-
tions, re-installing the cap securely.  Check that all conduit connections are secure and the
mountingsaretight.
Locatethefuelsystemassemblyandensurethatalltheconnectionsaretight.
Check that all hardware and mountings are secure and tighten as necessary.  When the
mechanicalinspectioniscomplete,proceedtoelectricalconnection.
Figure 5 TEGMounting
10

Global Power Technologies
1120 - Class I, Division 2, Group D, T3
Figure 6MechanicalInspection,
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 
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
 

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 
 
 
1120 TEG w/ Drip Cap
1120 TEG w/ Rain Shroud
11

Global Power Technologies
1120 - Class I, Division 2, Group D, T3
1.12 Electrical Connection
NOTE: ThisTEGincorporatesahighvoltageignitionsystemthatoperatesfromaninternal
2Voltbattery.ThisbatteryischargedbytheTEG.Disconnectoneendofthe2Volt
ignitor battery and proceed with connection of the customer wiring (see Figure 7).
Proceedtofuelconnection.
Ensurethatcircuitbreakersordisconnectsareusedattheloadendofthewiringandthatthe
circuitisopenpriortoconnectiontotheTEG(seeFigure7).Ifthe2Voltbatteryandthedis-
connectsarenotopenthentheignitionsystemisstillliveandcouldcauseanexplosion.
Provision has been made in the electronics housing for two 3/4” NPT rigid conduit entries.
Sealingofthesettingsmustbeusedtomaintainthesystemintegrity.Foraccesstotheelec-
tronicsassembly,removethe twenty 3/8-16 bolts installed in the lid and swing the lid open.
Terminal blocks have been factory installed for customer connection.  TB2-2 is +24 Volts,
TB2-3is-24Volts.ThevoltagesensingrelayterminalsarelocatedontheLimiterConverter
boardmountedonthelid.
1.13 Fuel Supply Connection
AlthoughtheTEGfuelregulatorincorporatesaliquidtrapand40-50micronstainlesssteellter,
thegeneratorsystemhasbeendesignedtooperateonsalesorinstrumentqualityfuel.Dueto
sitespecicfuelcharacteristics,ensurethatnecessarypre-ltrationhasbeeninstalledpriorto
connectiontoTEGfuellines.
Figure 7RecommendedConnections
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