Global 5030 User manual

5030
THERMOELECTRIC GENERATOR
Operating Manual
#16, 7875 - 57th Street SE
Calgary, Alberta
Canada T2C 5K7
Main: [phone]
Fax: [phone]
www.globalte.com
01953 REV 13

Table of Contents
1 General Information ......................................................1 - 1
1.1 Introduction ........................................................1 - 1
1.2 Physical Description .................................................1 - 1
 1.3 DenitionofTerms...................................................1 - 1
1.4 Data Plate .........................................................1 - 2
 1.5 FuelConsumption ...................................................1 - 3
1.6 Fuel Considerations..................................................1 - 4
2 Operations..............................................................2 - 1
 2.1 Assembly ..........................................................2 - 1
2.2 Set Up ............................................................2 - 1
2.3 Wiring.............................................................2 - 1
2.4 Electrical Properties..................................................2 - 3
 2.5 AmbientTemperatureandRatedPower..................................2 - 4
2.6 Start Up ...........................................................2 - 4
3 Service ................................................................3 - 1
 3.1 MaintenanceandRepair ..............................................3 - 1
 3.2 Orice.............................................................3 - 1
3.3 Battery ............................................................3 - 1
 3.4 5030TEGPartsList .................................................3 - 2
3.5 Burner Parts........................................................3 - 4
 3.6 FuelSystem-SI-SO,PartsList ........................................3 - 6
 3.7 Troubleshooting .....................................................3 - 7
4 Limiter Converter Option, 30 Watt ..........................................4 - 1
 4.1 GeneralDescription ..................................................4 - 1
4.2 Operation ..........................................................4 - 4
5 Appendix ...............................................................5 - 1
 5.1 Appendix1,GasSpecications.........................................5 - 1
 5.2 Appendix2,PerformanceLog .........................................5 - 3
Table of Figures
Figure1 5030Dimensions................................................1 - 2
Figure 2 Wiring Details...................................................2 - 2
Figure3 WiringDiagram,5030TEG ........................................2 - 3
Figure4 AltitudeAdjustments .............................................2 - 4
Figure5 5030BaseTEGParts ............................................3 - 2
Figure 6 Burner Parts....................................................3 - 4
Figure7 FuelSystem,SI-SO..............................................3 - 6
Figure8 ConverterLimiterPhysicalDescription ...............................4 - 2
Figure9 20WattL/CAdjustmentDetails ....................................4 - 3

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5030
1 GENERAL INFORMATION
1.1 Introduction
The5030isa highly reliable, low maintenance power sourcethatconvertsheatdirectlyinto
electricitywithoutanymovingparts.
The5030generatorusespropane(C3H8)ornaturalgas(CH4)asafuelandwillautomatically
ignitewhenevergaspressureispresent.Itgenerates30wattsofDCpowerat2.0volts.The
limiterconverter(L/C)convertsthe2.0voltstoamoreuseful12or24voltsandmaintainsthe
voltageatanadjustablelevel.
Featuresofthe5030includethefollowing:
Spark Ignition (SI)The5030comesstandardwiththesparkIgnition(SI)feature.Thispro-
videsasparktoignitetheburnerwheneverfuelpressureispresent.TheSIusesarecharge-
ableleadacidbattery.Thebatterychargeismaintainedbythe5030.
Automatic Shuto (SO)Theautomaticshuto󰀨includesavalveinthegaslinethatisheldopen
byathermocoupleintheexhauststream.Intheeventthattheamegoesoutthethermocou-
pleallowsthevalvetoclosepreventingtheaccumulationofgasvapors.
Fuel FilterWhencleancommercialfuelisusedafuellterisnotrequiredbutforapplications
wheredirtyfuelisapossibilityaninlinefuellterisrecommended.
1.2 Physical Description
Figure1showsthe5030withitsdimensionslabeled.Theoveralldimensionsofthe5030are
asfollows:
Specicationsanddimensionssubjecttochangewithoutnotice.
1.3 DenitionofTerms
Thermoelectric Generator (TEG):Adevicethatproduceselectricalpowerthroughthedirect
conversionofheatenergytoelectricalenergy.
Power Unit:Thehermeticallysealedportionofthegeneratorthatcontainsthethermoelectric
materialsandthecoolingns.
Length 348mm 13.7 in.
Width 356mm 14.0 in.
Height 450mm 17.7 in.
Weight 20kg 44.5lb
Shipping Weight 45kg 102lb
Mounting Holes 203mmwidex70mmdeep 8in.widex2.75in.deep

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Figure 1 5030Dimensions
Limiter-Converter (L/C):  A specic electronic device attached between the generator and
loadthatconvertsonelevelofDCvoltagetoanother,andlimitsthevoltagelevel.
Matched Load: Aconditionofloadwheretheloadvoltageofthegeneratorisone-halfofthe
opencircuitvoltageandtheloadresistanceisequaltotheinternalresistanceofthegenerator.
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gen-
eratorelectricalperformance.
1.4 Data Plate
Thedataplateislocatedontheinsideofthecabinetdoorandincludesvitalinformationabout
the generator.
Fuel Type:An“X”willbemarkedintheappropriateboxtoindicatewhetherthegeneratoris
conguredtoburnnaturalgas(CH4)orpropane(C3H8).Suitableoricesareavailableifitis
necessarytochangethefueltype.

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Fuel Pressure, Power, Voltage:Thefuelpressure,grosspoweroutputandopencircuitsetup
voltagehavebeenincludedforreferenceonly.Thesearetheconditionsthatwereachievedat
theGlobalPowerTechnologies(GPT)factorypriortoshipping.Notethatthefuelpressureis
recordedinkPa(psi)andthatthepressuregaugemustbeadjustedforaltitudeasdescribed
in section 2.6.8.
1.5 Fuel Consumption
The5030isdesignedtooperateoncommercialpropane(C3H8)orcleandrynaturalgas(CH4)
with an un-uctuating heating value of not less than 28 megajoules/m3 (750 BTU/ft3).  (See
Appendix 1, Gas Specications.)  While the use of sweet line or well head gas is common,
uctuatingheatingvaluesorcondensatesmaydamagethegenerator.Thismayinvalidatethe
warranty.
Thefuelconsumptionofthe5030atratedpowerislistedinthetablebelowforvariousfuels.
 NOTES:
a. Fuelconsumptionofliquidpropaneisassumingmeasurementofthefuelat15ºC
(60ºF).
b. Fuelconsumptionofgases,inft3/hrandm3/hrareatatmosphericpressureand
15ºC(60ºF).
c. Naturalgasisassumedtohaveanenergycontentof37.3GJ/m3or1000BTU/ft3.
      5030()-()SI-()
FUELTYPE:
 L=Propane
 N=NaturalGas
OUTPUTVOLTAGE:
 12or24Volts
FACTORYOPTIONS:
 SO=AutomaticShuto󰀨
FuelConsumptionat
RatedPower
Propane
(C3H8)
NaturalGasc
(CH4)
lb/hra0.14 -
gal/daya0.8 -
kg/daya1.5 -
L/daya3.0 -
ft3/dayb28.4 74.4
m3/dayb0.8 2.1
Model Number:ThemodelnumberontheDataPlateisinterpretedasfollows:

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1.6 Fuel Considerations
Clean FuelThefuelusedtooperatetheGPTmodel5030mustbeclean.Seethegasspec-
icationinsection4.1.Ifdirtyfuelisanticipatedthenacustomersuppliedinlinefuellteris
recommended.
Low Temperatures Whenusingpropane(C3H8)attemperaturesbelow-35ºC(-30ºF)special
considerationmustbegiventovaporizationofthefuel.
Supply Pressure A minimum gas supply pressure of 105 kPa (15 psi) must be supplied to
theregulatorinletofthegenerator.Amaximumof172kPa(25psi),theratingofthepressure
regulator,isallowed.

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2 OPERATION
2.1 Assembly
The5030ispackagedreadytooperaterequiringminorassembly.Nospecialtoolsarerequired
beyondstandardscrewdriversandwrenches.Four1/4inchboltsarerequiredtotthroughthe
platformontowhichthe5030istobemounted.Thefuelconnectionismadetothemale1/4
MNPTttingprovided.
2.1.1 The5030canbemountedonanystandwithfour5/16”holesspaced203mm(8.00in.)wide
X70mm(2.75inch)deep.Thestandshouldbesturdyenoughtokeepthe20kg(44.5lb)
5030stableintheenvironmentalconditionsthatmaybeexpectedandallowaminimumof15
cm(6inch)clearanceunderthecoolingns.Thestandrequiresfour1/4”boltslongenough
totthroughthemountingplates.Setthegeneratoronthestandsothattheholeslineupand
insertandtightenthebolts.
2.1.2 ConnectthefuelsupplytotheTEGfuelinlet(1/4MNPT)usingproperproceduresandthread
sealant.Pleasenotethatallfuelinstallationsshouldbedoneinaccordancewithlocalregula-
tions.
2.1.3 CheckallgasconnectionsforleakswithacommercialleakdetectoruidsuchasSnoop.
2.2 Set Up
Before setting up the generator it must rst be determined how much electrical power is
required.Iflessthanfullpowerisrequiredthenthegeneratorcanbesetupforthislowerpower
levelresultinginsomesavingsinfuelconsumption.To ensure reliable combustion the 5030
should not be set for less than 20 watts gross output.Ifthegeneratorisproducingmore
electricalpowerthanisbeingusedthentheexcesspowerwillbedisposedofwithinthecon-
verterlimiter.Tosetupthegeneratoravoltmetercapableofreadingtoatleasttwodecimal
placeswillberequired.Ametercapableofreadingtothreedecimalplacesispreferred.
2.3 Wiring
Allelectricalconnectionstothe5030aremadeatasevenpositionterminalstriplocatedinside
theconverterlimiteratthebottomofthecircuitboardasshowninFigure2.Figure3showsthe
wiringofthe5030.The5030isshippedwiththepowerunitconnectedtotheconverterlimiter
and electrical power is available at terminals 1 & 2.  To disconnect the power unit from the
converterlimiter,removethecoveranddisconnecttheTEG(-)leadfromthecommonterminal
post.TheTEG(+)leadisconnectedtotheVIN+terminalpost.Theopencircuitvoltagecan
nowbereadfromthenegativeandpositiveleads.

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Figure 2 Wiring Details

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Figure 3 WiringDiagram,5030TEG
2.4 Electrical Properties
Theelectricalpropertiesofthe5030generatorareverydependentontheresistanceoftheload
towhichitisconnected.Maximumpowerisgeneratedataloadof0.11ohms.Thisiscalled
matchedload.Theconverterlimiterincludedwiththegeneratorisdesignedtoalwayspresent
aloadof0.11ohmstothegenerator.Ifforanyreasonthisconverterlimiterisnotusedthen
considerationmustbegiventotheresistanceoftheloadused.
Theconverterlimiterincludedwiththe5030cantriggeralarmsorotherprocessesintheevent
ofalowvoltage.Lowvoltagescanbecausedbyoverloads,lackoffuelorafaultygenerator.
ThisdetectionisachievedbyaVoltageSensingRelay(VSR).Theuseofthevoltagesensing
relayisdescribedinthe30WATTCONVERTERLIMITERmanual.
TEGOperatingNormallyLEDIndicatorworksinconjunctionwiththevoltagesensingrelayand
turnsonproviding a visual indication when theoutputvoltageisabovethepresetminimum.
Notethatduringtheopencircuitvoltagetest,thisgreenLEDremainso󰀨asthepowerunithas
beendisconnectedfromthepowerelectronicsunit.

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2.5 Ambient Temperature and Rated Power
Thepoweroutputfromthe 5030willbe slightlya󰀨ectedbytheambienttemperature(theair
temperature)aroundthegenerator.
Theratedpoweristhepowerthatthe5030shouldproduceataspecicambienttemperature.
The5030isratedat30wattsgrosspowerwhenoperatingatanambienttemperatureof24ºC
(75ºF).Astheambienttemperaturerises,thegrosspowerwilldecrease,andastheambient
temperaturedecreases,thegrosspowerwillincrease.
2.6 Start Up
2.6.1 Withthefuelpressureturnedo󰀨,recordtheambienttemperature,theratedVoc(asnotedon
dataplatelocatedoninsideofcover)onthe“PERFORMANCELOG”,providedatthebackof
thismanual.
2.6.2 ReferringtoFigure2,disconnecttheTEG(-)leadfromtheterminalpost.Connectavoltmeter
capableofreadingtoatleasttwodecimalplacestotheTEG(-)andTEG(+)leads.
2.6.3 Makesurethatalloftheconnectionsinthefuelsystemarestilltight,checkingforleakswitha
commercialleakcheckuid.
WARNING: Do not test for fuel leaks with a match or any open ame.
Figure 4 Altitudeadjustments

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2.6.4 Ensurethatthesparkignitorcontactwiresareconnectedtothepressureswitch(C8,Figure7).
Loosentheignitorrodwingnutandpushtheignitorrod(A8,Figure5)inuntilittouchesthe
powerunitandthenpullitoutabout5mm(1/4inch).Testthesparkignitorbyshortingthe
contactsonthepressureswitchandlistenforthesoundofthespark.
2.6.5 Conrmthattheregulatorinletpressureisbetween105kPa(15psi)and172kPa(25psi).
2.6.6 Turnonthegaspressureandthenfullypushinthebuttonontheshuto󰀨valve(C11,Figure7)
tosupplypressuretothepressurevalveandgauge.Thesparkignitorshouldbeginclicking
andthesoundofcombustionshouldbegin.Insomecasesitisnecessarytoallowthefuelline
tobleedoutalloftheair.Holdthebuttondownforaboutoneminuteaftercombustionbegins
andthenrelease.Ifthesoundofcombustionquitsthenpushthebuttondownagainuntilcom-
bustionissustained.
NOTE:Itisnecessarytopushthebuttonrmlybeforereleasingit.
2.6.7 Checkthatthegaspressureisstillclosetowhereitwassetatthefactory.Thispressureis
markedonthefrontcabinet(seesection1.4).Thepressuregaugereadingwillvarywithalti-
tudeduetochangesinatmosphericpressureandsoitmaybenecessarytocorrectthefactory
readingforaltitude.Figure4showsthecorrectionforvariationfromthefactoryaltitudeof750
m(2460ft).Ifthefuelpressurereadingdi󰀨ersfromthevalueshownonthecabinetandafter
correctingforaltitudethenadjustittobeclosetotheindicatedpressureorslightlylower.
2.6.8 Afterignitionoftheburner,recordthetimeonthePerformanceLog,atthebackofthismanual.
Thevoltagewillbegintoriseandatnotimeshouldthisvoltageexceed4.0volts.
WARNING: Should these values ever exceed these limits then overheating may
cause irreparable damage to the power unit invalidating the warranty.
2.6.9 Afterignition,allowthetemperatureofthegeneratortostabilizeforonehourandthenrecord
theVocvoltageinthePerformanceLog.
CAUTION: When the TEG is operating, surface temperatures in the vicinity of the
thermopile, burner, exhaust stack and around the cooling ns may be in
excess of 100ºC. Avoid contact of skin and clothing with these areas when
operating in and around the TEG.

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2.6.10Atthispointitmaybenecessarytoadjusttheairshutterforoptimumcombustion.Theburner
shouldbestable,withtheVocvoltagereadingveryconstant.Loosenthelockingnutandturn
theairadjustingscrew1/2turnclockwise.Thiswillincreasetheamountofairintheair/fuel
mixture.Allowthegeneratortostabilizeforabout15minutes.Ifthevoltageincreasedduring
thistimeproceedtosection2.6.12.Ifthevoltagedecreasedduringthistimethisindicatesan
airrichcondition,andtheairshuttershouldbereturnedtotheoriginalpositionuntilthevoltage
beginsto rise again.Nowturnthe airadjustingscrew1/2turncounterclockwise. Allowthe
generatortostabilizeforabout15minutes.Ifthevoltageincreasedduringthistimeproceedto
section 2.6.12.
NOTE: Ifthevoltagemeterusedisonlycapableofreading2decimalplacesthenitmay
takeafewminutestoseeachangeinvoltage.
Ifbothactionsresultedinadropinvoltagethentheoriginalpositionwasalreadyclosetoopti-
mumandtheairadjustingscrewshouldbetightenedinthatpositionandproceedtosection
2.6.13.
2.6.11Afterthevoltagehasstabilized,continuetoopenorclosetheairshutter(dependingonwhich
directioncausedariseinvoltage)untilthepointresultinginmaximumvoltageisfound.The
generatorshouldbeallowedtostabilizefor15minutesbetweeneachadjustment.
2.6.12Aftertheairshutterisadjusted,thenadjustthefuelupordownuntilratedVocisachieved.The
fuelshouldbeadjustedin1.4kpa(0.2psi)incrementsallowingthegeneratortostabilizefor15
minutesbetweenadjustments.Aftertheregulatorisadjustedre-tightenthelocknut.
2.6.13OnceVocisobtainedthen:
ReconnecttheTEG(-)leadtotheterminalpost.
Connectthevoltmetertotheoutputterminals1&2markedcustomerload.SeeFigure2.This
voltageshouldread10to18voltsforthe12voltoptionor22to30voltsforthe24voltoption.
Theconverterlimiterhasbeenfactorysetat14.1voltsor27.0voltsrespectivelybutcanbe
adjustedasdescribedinthe30WATTCONVERTERLIMITERmanual.
2.6.14The5030isnowreadytobeconnectedtotheload.Connecttheloadacrossterminals1&2.
 OncetheloadisconnectedandtheTEGisstartedandallowedtowarmup,useavoltmeter
tomeasurethevoltagebetweenVolt+andVolt-ontheMeterTB(terminalblock).Recordthis
result.Now measure the voltagebetweenAmp+andAmp-onthe Meter TBandrecordthis
result.Thepowerbeingdeliveredtotheloadcanbecalculatedasfollows:
  Power=Voltreading*Ampreading(involts)dividedby0.01
  iePower=14.2*0.015dividedby0.01=21.3W

GlobalPowerTechnologies  3-1
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3 SERVICE
3.1 Maintenance and Repair
The 5030 Generator is designed to require a minimum amount of maintenance when using
commercialfuel.Sections3.2and3.3describethepreventativemaintenancerequiredfortrou-
blefreeoperation.Shouldmorethanthesekeyitemsrequiremaintenanceorrepairacomplete
parts list is included.
3.2 Orice
Partnumber4200-00686(NaturalGas)or4200-00687(Propane)
Checkevery10,000hours(annually)
Replaceevery25,000hours(3years)
Tochecktheoriceremovetheexiblefuellinefromthebackoftheburnerusingtwo9/16”
openendedwrenches.Removetheoriceandvisuallycheckitforanyobstructions.When
cleanfuelisused(orafuellter)theoriceshouldbegoodforseveralyears.
WARNING: When replacing the orice make sure the connections are well tight-
ened to prevent any leakage.
3.3 Battery
Partnumber2400-27019
Replaceevery50,000hours(Approximately5years)
Replacetherechargeable“D”sizeleadacidbatteryinthelimiterconverterenclosure.

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3.4 5030 TEG Parts List
A1 7900-08904 PowerUnit,5030
A2 6200-06424 CoverAssy,5030(IncludesItemA3&A4)
A3 4500-00790 ExhaustStackAssy,5030
A4 4500-00755 IntakeStackAssy,5030
A5 6100-00872 BurnerAssy,5030(seeFigure6)
A6 4200-00687 OriceAssy,Propane,#5,0.0105
 4200-00686 OriceAssy,NaturalGas,#4,0.0145
A7 2708-00606 Nut,Hex,8-32,SS
A8 4900-06768 Electrode,SparkIgnitor
A9 4200-23005 FuelLineKit,5030
A10 6400-22381 FuelSystemAssy,SI-SO,SSOption(seeFigure7)
 6400-22382 FuelSystemAssy,SI-SO,SSOption
Item Part # DESCRIPTION
Figure 55030BaseTEGParts

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3.4 5030 TEG Parts List (cont’d)
Item Part # DESCRIPTION
Figure 55030BaseTEGParts
A11 4100-00794 Leg,5030
A12 2514-07323 Screw,P-H-P,1/4-20X11/2,SS
A13 2714-00611 Nut,Hex,1/4-20,SS
A14 6300-06782 ConverterLimiter,12V
 6300-06758 ConverterLimiter,24V
A15 2514-02105 Screw,Cap,HEX-HD,1/4-20X31/2LG.,SS
A16 2814-00473 Washer,Lock,EXT,1/4,SS
A17 2900-60391 SPACER,1/4”LG,0.192IDX3/8OD,18-8SS

GlobalPowerTechnologies  3-4
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3.5 Burner Parts
Item Part # DESCRIPTION
B1 4000-07440 BurnerBackAssy,5030
B2 4000-00829 Support,InsulationBlock
B3 4000-00701 Spacer,Insulation
B4 4000-00693 Screen Holder
B5 4000-01008 BurnerScreenAssy,5030
B6 4000-00694 InsertRing,Burner
B7 4000-00864 VenturiTubeHolder,5030
B8 4000-00863 Venturi,5030
B9 2506-00479 Screw,Set,SOC.HD,6-32X1/8,SS
B10 4000-00828 InsulationBlock
B11 4000-00827 Burner Cover
Figure 6 Burner Parts

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3.5 Burner Parts (cont’d)
Item Part # DESCRIPTION
B12 4000-01005 Spacer
B13 2900-07267 E-Ring,Bowed,SS
B14 4000-00990 Air Shutter
B15 2810-00569 Washer,Flat,#10,SS
B16 4000-00700 VenturiAdjustingScrew,5030
B17 4000-00871 VenturiPlateAssy5030
B18 4000-07230 AirFilterAssy,5030
B19 4000-00758 Nut,Lock,VenturiAdjustScrew
B20 2710-00601 Nut,Wing,10-32,SS
B21 2756-07005 Nut,Wing,5/16-18,SS
B22 4900-07004 Pin,Mounting,Electrode
Figure 6 Burner Parts

GlobalPowerTechnologies  3-6
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3.6 Fuel System - SI-SO, Parts List
Item Part # DESCRIPTION
C1 3100-22360 Regulator,Fisher,67CFR,0-20PSI
 3100-22365 Regulator,Fisher67CFR,0-20PSI,SOURGAS
C2 3031-20071 Elbow,1/4TUBEX1/4MNPT,SS
C3 4200-20122 VentTubeAssy,5030
C4 3044-00501 Nipple,Hex,1/4NPTX11/2,BRASS
 3041-02359 Nipple,Hex,1/4NPTX11/2,SS
C5 3034-00384 Elbow,Street,1/4NPT,BRASS
 3031-02356 Elbow,Street,1/4NPT,SS
C6 3021-00380 Connector,Male,1/4TUBETO1/4NPT,316SS
C7 4200-02100 ManifoldBlock
C8 6400-06471 PressureSwitch,Hobbs76056
C9 3200-00691 PressureGauge,0-15PSI
 3200-07289 PressureGauge,0-15PSI,SS
C10 3054-00432 Plug,HEX-HD,1/8-27,BRASS
 3051-07290 Plug,HEX-HD,1/8-27,SS
C11 3090-00176 Valve,Shuto󰀨,BASCOH19T1-3
C12 3400-00177 Thermocouple,JohnsonK16RA-24C(orderseparately)
C13 4200-22888 FuelFilterKit(notshown)
Note:AlternatepartsareforStainlessversionoffuelsystem.
Figure 7FuelSystem,SI-SO