Global 5120 User manual

5120
THERMOELECTRIC GENERATOR
Operating Manual
#16, 7875 - 57th Street SE
Calgary, Alberta
Canada T2C 5K7
Main: [phone]
Fax: [phone]
www.globalte.com
01556 REV 5

5120 Quick Start Procedure
5120-SI-SO
• Turn on gas supply to TEG. Hold down the button on Shut O󰀨 (SO) valve.  The spark igni-
tionsystem(SI)shouldbeginclickingandthesoundofcombustionheardwithin15seconds.
Continueholdingthebuttonfor90secondsthenreleaseit.TheSOvalveshouldremainopen
andtheTEGshouldcontinuetooperate.
• Adjustthefuelpressureto10-15%lessthannotedonDataNameplate.
• Installthejumperclipbetweenterminals3&4ofTB-1
• Afteronehourmeasurethevoltage,Vset,betweenterminals2(+)and4(-)ofTB-1.TheVset
shouldbeapproximately6.7volts.SeeSection2.6toadjustingforambienttemperature.
• Returnthejumpercliptobetweenterminals1and2ofTB-1
• ApplyCustomerload
Fuel Pressure
• Propanestartup:  41-45kPa 6-6.5psi
• NaturalGasstartup: 24-31kPa 3.5-4.5psi

Table of Contents
1 Introduction .............................................................1-1
 1.1 GeneralDescriptionandSpecications....................................1-1
 1.2 StandardFeaturesandOptions .........................................1-2
 1.3 DenitionofTerms....................................................1-3
 1.4 TheoryofOperation...................................................1-4
2 Operation .............................................................2-1
 2.1 PhysicalDescription ..................................................2-1
 2.2 Unpacking,AssemblyandMounting ......................................2-1
 2.3 DataPlate ..........................................................2-3
 2.4 FuelSupply .........................................................2-3
 2.5 Start-Up ............................................................2-4
 2.6 Evaluation ..........................................................2-6
 2.7 CustomerLoadWiring................................................2-11
3 Service and Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
 3.1 SuggestedPeriodicMaintenance ........................................3-1
 3.2 SystemComponents ..................................................3-3
 3.3 TroubleshootingGuide ...............................................3-12
3.4 5120TEGPartsList .................................................3-14
3.5 BurnerPartsList ....................................................3-16
3.6 BurnerwithFlameArrestorParts .......................................3-17
3.8 SI-SOFuelSystemPartsList ..........................................3-19
4 Limiter Converter .........................................................4-1
 4.1 GeneralDescription ...................................................4-1
 4.2 Operation ...........................................................4-2
5 Cathodic Protect Interface System...........................................5-1
5.1 GeneralDescription ...................................................5-1
6 Flame Arrestor Kit Installation and Operation .................................6-1
 6.1 ImportantWarning ....................................................6-1
 6.2 GeneralDescription ...................................................6-3
 6.3 Disassembly.........................................................6-4
 6.4 Installation ..........................................................6-7
 6.5 SetUp ............................................................6-12
 6.6 Maintenance .......................................................6-13
 6.7 PartsList ..........................................................6-14
7 Appendix .............................................................7-1
 7.1 ElectricalOutputCharacteristics .........................................7-1
 7.2 PhysicalDimensions ..................................................7-2
 7.3 GasSpecications ....................................................7-3
 7.4 5120PerformanceLog ................................................7-5

List of Figures
Figure1 TEGDesign .....................................................1-4
Figure2 AssemblingTEG .................................................2-2
Figure3 ApplyingThreadSealant ...........................................2-3
Figure4 WiringDiagram5120TEGwithLimiter/Converter .......................2-4
Figure5 WiringDiagram5120TEGwithnoLimiter/Converter .....................2-5
Figure6 SI-SOStartUp...................................................2-6
Figure7 RatedPowervs.AmbientTemperature................................2-7
Figure8 VsetVs.SetUpPower .............................................2-8
Figure9 VsetvsTimeAfterIgnition ..........................................2-9
Figure10 FuelGaugePressurevs.Elevation...................................2-9
Figure11 ChangeinVsetvsAirShutterSetting ................................2-10
Figure12 ChangeinVsetvsFuelPressureAdjustment ..........................2-11
Figure13 WiringDiagram5120TEG ........................................2-12
Figure14 TEGMainParts ..................................................3-4
Figure15 SI-SOFuelSystemService.........................................3-5
Figure16 PressureRegulator ...............................................3-6
Figure17 VenturiLocation..................................................3-7
Figure18 BurnerAssembly .................................................3-8
Figure19 SparkIgnitorWiringDiagram ......................................3-10
Figure20 5120TEGParts.................................................3-14
Figure21 BurnerPartsList ................................................3-16
Figure22 5120BurnerwithFlameArrestorParts ...............................3-17
Figure23 SI-SOFuelSystemParts .........................................3-19
Figure24 LimiterConvertPhysicalDescription..................................4-1
Figure25 WiringDiagram,5120withLimiterConverter ...........................4-2
Figure26 220WattL/CAdjustmentDetails.....................................4-3
Figure27 CPInterfaceCabinet ..............................................5-1
Figure28 WiringDiagram,CPInterfaceinSeriesConnection ......................5-2
Figure29 WiringDiagram,CPInterfaceinParallelConnection .....................5-3
Figure30 CPSystemPartsIdentication ......................................5-4
Figure31 FlameArrestorKit-Installed ........................................6-3
Figure32 ItemsForRemoval,FlameArrestorInstallation .........................6-5
Figure33 ExhaustStackRemoval ...........................................6-6
Figure34 FuelLineandThermocoupleRemoval ................................6-7
Figure35 AirIntakeandAirShutterRemoval ...................................6-8
Figure36 IntakeFlameArrestorInstallation ....................................6-9
Figure37 FlameArrestorStackandThermocoupleInstallation ....................6-10
Figure38 RainCapInstallation .............................................6-11
Figure39 BurnerwithFlameArrestor ........................................6-14
Figure40 RainCap/ExhaustStackParts .....................................6-16
Figure41 ElectricalOutputCharacteristics .....................................7-1
Figure42 PhysicalDescription,5120TEG .....................................7-2

GlobalPowerTechnologies  1-1
5120
1 Introduction
Thismanualprovidesinstallation,operationandmaintenanceinstructionsfortheGlobal Power
TechnologiesModel5120Thermoelectricgenerators.
1.1 GeneralDescriptionandSpecications
TheModel5120ThermoelectricGeneratorcontainsnomovingparts.Itisareliable,lowmain-
tenancesourceofDCelectricalpowerforanyapplicationwhereregularutilitiesareunavailable
orunreliable.
PowerSpecications
PowerRatings
20ºC,750mabovesealevel
120Watts@6.7Volts
108Watts@12Volts
108Watts@24Volts
108Watts@48Volts
Electrical
Adjustment
6.7V Upto11Volts
12V12-18Volts
24V 24-30Volts
48V 48-60Volts
ReverseCurrentProtection Yes
Output
Terminalblockwhichacceptsupto8AWGwire.
Openingfor3/4in.conduitinthebaseofthecabi-
net
Fuel
NaturalGas 8.8m3/day(311ft3/day)ofStd.1000BTU/SCF
(37.7MJ/Sm3)gas
Propane 11.4l/day(3.0USgal/day)
MaximumSupplyPressure 172kPa(25psi)
MinimumSupplyPressure 69kPa(10psi)
FuelConnection 1/4in.MNPTconnection
Environmental
AmbientOperatingTemperature Max.45ºC(115ºF)
Min.-40ºC(-40ºF)
OperatingConditions UnshelteredOperation
Materials of Construction
Cabinet 304SS
CoolingType NaturalConvection
Thermopile HermeticallySealedLeadTin-Telluride(PbSnTe)
FuelSystem Brass,Aluminum&SS

GlobalPowerTechnologies  1-2
5120

GlobalPowerTechnologies  1-3
5120
1.1.1 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.
1.1.2 Warnings
ThroughoutthismanualyouwillnoticeparagraphsprecededbythetextWarning.Itisimpera-
tive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and/orproperty.Warningswillbeprinted
inboldtextinitalicswiththetitleWARNINGincapitalletters.
1.1.3 Cautions
ThroughoutthismanualyouwillnoticeparagraphsprecededbythetextCaution.Itisimpera-
tivethattheadviceintheseparagraphsbeadheredtoasfailuretodosomayresultindamage
totheequipment.CautionswillbeprintedinboldtextinitalicswiththetitleCaution.
1.1.4 Notes
Throughoutthismanualyouwillnoticeparagraphsprecededbythe text Note.  These para-
graphsprovideadditionalinformationorreferenceothersectionsofthemanual,whichmaybe
useful.Noteswillbeprintedinitalics.
1.2 Standard Features and Options
1.2.1 Standard Features
TheTEGcomesstandardwithafuelpressureregulatorcapableofacceptingupto172kPa
(25psi)andabuiltinfuellter,anAutomaticSparkIgnitionSystem(SI),andlowvoltagealarm
contacts(VoltageSensingRelayorVSR)
1.2.2 Options
Availableoptionsforthe5120ThermoelectricGeneratorareasfollows:
Automatic Shut-O Option (SO):TheAutomaticGasShut-O󰀨option(SO)isdesignedtoturn
o󰀨thegassupplytotheburneriftheameintheTEGisextinguishedandcannotbesubse-
quentlyre-ignitedbytheautomaticSIsystemwithinapproximatelythreetoveminutes.
Corrosive Environment Fuel System Option (SS):TheCorrosiveEnvironmentFuelSystem
is specially constructed with increased corrosion resistant components.  All of the standard
brassttingsandgaugeinternalsarereplacedwithstainlesssteelequivalentswherepossible
andthefuelregulatorisupgradedtocomplywithNACEstandardMR-01-75(SulphideStress
Cracking Resistant Material For Oileld Equipment).  External components that can not be
replacedarecoatedwithGlyptaltoreducetheirriskofcorrosion.

GlobalPowerTechnologies  1-4
5120
Flame Arrestor Option: Most of Global Power Technologies’ (GPT) standard TEG’s fall
underthedenitionof“ametypeequipment”asdenedintheregulationsofTheOilAndGas
ConservationActAlberta(Section8.090).GPThasdevelopedaamearrestorsystemforuse
asanoptionontheModel5120TEGtomeettheEUBrequirements.Ithasbeendesignedto
allowitsinstallationonbothneworexistingTEGs.
Pleasenote that although GPT’s engineers havedesigned the ame arrestor following CSA
standardsandhavetriedtosatisfyregulatoryrequirementswiththedesign,theamearrestor
isnotCSAapproved.ItistheresponsibilityoftheendusertodeterminethesuitabilityofGPT’s
amearrestorsystemtomeettherequirementsoftheirspecicinstallationsincluding,butnot
limited to: a) the suitability of EUB’s denition of equipment location and b) the suitability of
GPT’sairintakeamearrestordesignasan“adequateamearrestor”.
Cathodic Protection Interface System (CP):TheCathodicProtectionInterfaceSystempro-
videsforadjustmentandmonitoringofpowertoacathodicprotection(CP)load.Theanode
andcathodecablesenterthecabinetatthebottomandconnectdirectlytoaheavydutytermi-
nalblock.A0to1Ohmresistor,300wattvariableresistorisprovidedforadjustingtheoutput
powerappliedtotheCPsystem.
TEG Mounting Stands (Pole and Bench Type):ThePoleStandconsistsofa76”longpiece
of3”diameterpipewithan“H”shapedbracketweldedtooneendwhichtheTEGcanbermly
attachedtousing1/4”fasteners(notincluded).TheBenchStandconsistsof3”by3”and2”
by 2” aluminum angle sections that are assembled together to provide a sturdy structure to
support the TEG.
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.
TEG:AThermoelectricGenerator.
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.
Generator System:Thesystemconsistingofthegenerator,includingitsfactoryoptions,the
limiter-converter,includingitsfactoryoptions,andthespecialcustomeroptions.
Set-up Voltage, Vset:Theset-upvoltageofthegenerator.
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.

GlobalPowerTechnologies  1-5
5120
Rated Power: Theamountofpoweragen-
eratorcanbeoperatedatwhentheambient
temperatureofthesiteisexpectedtopeakat
65ºC.Astheambienttemperatureincreases
therated-powerdecreases.
Rated Vset: TheamountofVset a generator
can be operated at when the ambient tem-
perature of the site is expected to peak at
65ºC.Astheambienttemperatureincreases
theratedVsetdecreases.
Open Circuit Voltage, VOC:  The voltage
attheterminals of a powersourcewhenno
appreciablecurrentisowing.
1.4 Theory of Operation
A thermoelectric generator (TEG) produces
electricalpowerthroughthedirectconversion
ofheatenergyintoelectricalenergy.
This is done by joining two dissimilar, thermoelectric materials at one end and then heating
thejunctionendtoahighertemperaturethantheotherend.Thiscreatesavoltageacrossthe
coolerend.Sincethisvoltageisrelativelysmall,thejunctionsarejoinedinseriestoachieve
ausefulelectricaloutput.Ifthetemperaturedi󰀨erenceismaintained,electricalpowercanbe
deliveredtoaloadplacedinthiscircuit.
Figure 1 illustrates how this is done in the model 5120 TEG.  A thermocouple is formed by
P type and N type thermoelectric elements joined together at one end by a hot electrode.
Adjacentthermocouplesarejoinedattheotherendbycoldelectrodes.Eightythermocouples,
eachproducing84mVareconnectedinseriessothattheTEGproduces120Vat6.7Vand
18Amps.
TheTEGvoltagevariesaccordingtothetemperaturedi󰀨erenceatthethermocouplejunction.
Thehotsideofthethermocouplesismaintainedatatemperaturearound538ºC(1000ºF)by
aburnerwhich operates onpropane,ornaturalgas. The coldsideofthe thermocouples is
maintainedatalowertemperature,around163ºC(325ºF),bythecoolingnswhichtransferthe
heattothesurroundingair.Thistemperaturedi󰀨erenceiscontrolledbyadjustingtheamount
offuelsuppliedtotheburner.
The TEG is supplied with a precision load resistorthatprovidestheoptimumloadcondition.
ThisresistorisusedbothinadjustingtheTEGforproperoperationandinevaluatingitsper-
formance.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.
Figure 1TEGDesign

GlobalPowerTechnologies  1-6
5120
The TEG is supplied with a protective device which prevents its output voltage from rising
beyond12V.Thisisrequiredbecauseunderextendedopencircuit(orslightlyloaded)condi-
tionsthehotjunctiontemperaturecouldincreasebeyondthesafeoperatingrange.
Insummary,theTEGproduceselectricalpowerwhenatemperaturedi󰀨erenceismaintained
between the hot and cold junctions of the thermocouples.  This temperature di󰀨erence, and
thereforetheamountofpowerproduced,dependsontherateatwhichfuelissuppliedtothe
burnerandtheambienttemperature.
The electrical output of the 5120 TEG changes as the ambient temperatures changes; the
powerincreasesasthetemperaturedecreases.
 Thetermrated-powerisusedwhenthemaximumambienttemperatureis65ºC.
• The5120 TEG’spowerunitproduces 120 Wattsgrossat 20ºCatthebeginning of its
servicelife.
• Power decreases at a rate of 0.288% per ºC rise in Temperature (0.16% per ºF) see
Figure7onpage2-7.
• Maximumallowableambienttemperatureforoperationis45ºC(115ºF).

GlobalPowerTechnologies  1-7
5120

GlobalPowerTechnologies  2-1
5120
2 Operation
2.1 Physical Description
5120 Dimension Chart
Length 757mm(29.8in.)
Width 370mm(14.6in.)
Height 987mm(38.9in.)
Weight 60kg(132lb)
ShippingWeight 79kg(175lb)
MountingHoles 267mmX457mm(10.50wideX18.00deep)
2.2 Unpacking, Assembly and Mounting
ToolsRequired:
• 1  DCVoltmeteraccurateto0.1V.
• 2  Smalladjustablewrenchesthatwillopento16mm(5/8inch).
• 1  Flatheadscrewdriver.
• 4  #1/4-20bolts&nutsformounting.
• 1  PhillipsScrewdriver.
Unpack the 5120 TEG from its shipping crate.  Keep the crate until the TEG is operational.
ChecktheTEGfordamagewhichmayhaveoccurredduringshipping.Anydamagemustbe
reportedassoonaspossible.Thedamagemaymakethegeneratorinoperabletherefore,
Check with Global Power Technologies (GPT) Customer Service before starting a dam-
aged TEG.
 Locateandidentifythefollowingitemsthatwereshippedwiththe5120TEG.
• 1  1FinDuct.
• 1  IntakeStackwithClamp.
• 1  ExhaustStackwithClamp.
• 1  ThreadSealingCompound.
• 7  #8-32x¼inchlongScrews(1spare).
• 7  #8Washers,externallock.
AssembletheTEGasfollows(seeFigure2):
1) Attachthenductusingthe#8screwsandwasherssupplied.
2) Inserttheintakeandexhauststacksintothetopofthecabinet.
3) Slidetheclampsoverthebottomsofeachstackandtightentheclampscrews.

GlobalPowerTechnologies  2-2
5120
MounttheTEGtoarmandstablebase,using1/4-20bolts,SeeAppendixFigure42,page
7-2,for mounting holelocations.The basemustbelevel and sturdyenoughtosupport the
41kg(90lb)TEG.TheTEGshouldbemountedhighenoughtoavoiddirectoodingorheavy
snowfallinterferingwiththeowofcoolingair.Allowaminimumof150mm(6in.)clearance
underthecoolingns.
WARNING:  Operation of the TEG in locations where cooling air ow may be
obstructed will cause overheating of the TEG.
Figure 2AssemblingTEG

GlobalPowerTechnologies  2-3
5120
2.3 Data Plate
ThedataplateislocatedontheinsideoftheTEGcabinetdoorandindicatesthefollowing:
Fuel Type:AnXisstampedintheappropriateboxforNaturalgasorPropane.Eachfueltype
requiresadi󰀨erentorice,thereforetheTEGmustbeusedwiththefuelindicated.
Model Number:Themodelnumberisinterpretedasfollows:
Serial Number: UniquetoeachTEG.
Power, Fuel Pressure, Voltage:Theseweremeasuredduringthefactoryperformancetest
andareforreferenceonly.Theoperatingpower,fuelpressureandvoltagearedeterminedand
adjustedasperSection2.6.
2.4 Fuel Supply
Fuel Considerations
Clean Fuel:Thefuelusedtooperatethe5120TEGmustbeclean(seegasspecicationsin
Appendix,page7-3).Ifdirtyfuelisanticipatedthenacustomersupplied,in-linefuellteris
recommended.
Low Temperature:  When using propane (C3H8) at
temperaturesbelow-30ºC(-22ºF)specialconsideration
mustbegiventothelowvapourpressureofthefuel.
Pressure:Makesurethatfuelpressureisatleast69
kPa (10 psig) and will not exceed 172 kPa (25 psig).
Ifit isexpectedthatthefuelsupplypressure willvary
greatly,theuseofanadditionalprimaryregulatorisrec-
ommended.Thiswillholdtheinputpressurerelatively
constant.
ChecktheTEGdataplateforthefueltype.DONOT
useadi󰀨erenttypeoffuelthanindicated.
DONOTAPPLYSEALANTON
THEFIRSTTWOTHREADS
APPLYTHREADSEALANT
OVERTHISAREA
07193rev1
Figure 3ApplyingThreadSealant
Fuel Type: L= Propane
  N= NaturalGas
Limiter Converter Voltage:
12or24Volts
Fuel System:
SI =SparkIgnitionOnly
SI-SO =SparkIgnition&AutoShutO󰀨
5120 - ( ) - ( ) ( )

GlobalPowerTechnologies  2-4
5120
Afuelshut-o󰀨valveMUSTbeinstalledbetweentheTEGandthefuelsupply.Allfuelpiping
mustbeinaccordancewithlocalregulations.
1) Inspectthefuellinesandttingstobesuretheyarefreeofforeignmaterial.
2) Purgefuellinesofallair.
TheTEGhasa1/4in.NPT,malefuelinlet.Removetheplasticprotectivecapandapplythread
sealant,seeFigure3.Connectthefuellineandtestalljointsforleaksusingacommercialleak
detector.
2.5 Start Up
SystemPerformanceLogsarelocatedatthebackofthismanual,Appendix7.5,page7-5.Use
of these logs is recommended each time the site is visited.  This information is valuable for
futurereference.
1) MovethejumperonTB-1frombetweenterminals1and2tobetweenterminals3and
4,seeFigure4orFigure5..
2) ConnectaDCVoltmetertoterminals2(+)and4(-)ofTB-1.ThiswillbemeasuringVset.
3) Makesurethatalloftheconnectionsinthefuelsystemaretightandhavebeenchecked
forleaks.
Checktheignitionsystem,seeFigure6.
1) Loosentheignitorrodwing-nut.
Figure 4WiringDiagram5120TEGwithLimiterConverter

GlobalPowerTechnologies  2-5
5120
2) Pushtheignitorrodinasfarasitwillgo,(itshouldextendabout25mm(1in.)pastthe
holdingscrew),thenpullitback3mm(1/8in.).
3) Tightenthewing-nut,DONOTovertightenastheignitorrodwillcrack.
2.5.1 SI-SO Start
1) Turnonthefuelsupply.
2) Pushinthebuttonontopofshut-o󰀨valve.Thesparkignitorshouldbeginclickingand
thesoundofcombustionwillbegin.Insomecasesitmaybenecessarytobleedairfrom
thefuellinebeforecombustionwillbegin.
3) Continuetoholdthebuttondownforatleast90secondsaftercombustionbegins,then
release the button.
4) Ifthesoundofcombustionstops,pushthebuttonagainuntilcombustionissustained.
Note:Itisnecessarytofullydepressthebuttonbeforereleasingit.
2.5.2 Manual Start
IftheTEG’sSIsystemismalfunctioning,onecanmanuallystartthegenerator.Itshouldbe
notedthatthemalfunctioningSIberepairedassoonaspossibleastheTEGwillnotbeableto
reigniteitselfintheeventthattheTEG’sburnergoesoutbecauseoffuelinterruptions.
Figure 5WiringDiagram5120TEGwithnoLimiter/Converter