Mec PM-798-A User manual

MEC-PM-798 MEC Starter Kit ManualMEC-PM-798 MEC Starter Kit ManualMEC-
PM-798 MEC Starter Kit Manual
Page 1
TDSP BV
Fabriekstraat 34
7005 AR Doetinchem
THE NETHERLANDS
Phone [phone]
Fax [phone]
This material may not in whole or part be copied, stored electronically, or communicated to third
parties without prior agreement in writing from Thermo Dynamic Solution Provider BV.
Owned by .......................................................
Prepared by.................................. B. Westerdijk
Reviewed by....................................................
Approved by ....................................................
.....................................................................
.....................................................................
Date…… 9 April 2021
MEC-PM-798-A
MEC Starter Kit Manual

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CONTENTS
1Revision History...................................................................................................................................................3
1.1 Abbreviations ....................................................................................................................................................3
2Introduction..........................................................................................................................................................4
3Installation............................................................................................................................................................5
4Stirling Engine electrical connections ................................................................................................................7
5Controls box Electrical Connections ..................................................................................................................8
5.1 Controls Box connections shown in fig.5.1 explained.......................................................................................9
5.1.1 Absorber Over-Travel Switches ..............................................................................................................9
5.1.2 Coolant in- and outlet thermistors............................................................................................................9
5.1.3 RS485 Communications interface .........................................................................................................10
5.1.4 Head Thermocouples.............................................................................................................................10
5.1.5 Flow Meter.............................................................................................................................................10
5.1.6 Mains Power ..........................................................................................................................................11
5.1.7 Cooled Seal and Inner Iron Protection Thermostats ..............................................................................11
5.1.8 Grounding..............................................................................................................................................11
5.1.9 Engine Power.........................................................................................................................................11
5.2 Controls Box functions explained....................................................................................................................11
5.2.1 Demand On/Off button and Heat Source Enable Indicator....................................................................11
5.2.2 Emergency Stop Button.........................................................................................................................12
5.2.3 User Reset Button..................................................................................................................................12
5.2.4 Mains On/Off Switch.............................................................................................................................12
5.2.5 Engine Running Indicator......................................................................................................................12
6Outline of Operating Sequence.........................................................................................................................13
7Errors..................................................................................................................................................................14
7.1 Error Code List ...............................................................................................................................................14
7.2 Clearing Errors...............................................................................................................................................15
7.2.1 Automatic Reset.....................................................................................................................................15
7.2.2 User Reset..............................................................................................................................................15
7.3 Troubleshooting an error................................................................................................................................16
8Diagnostics..........................................................................................................................................................17
8.1 Engine Control States......................................................................................................................................17
9Engine Specification, Connections and Operation..........................................................................................17
Appendix A LCD Data Monitor –User Manual................................................................................................18
Appendix B Error list ..........................................................................................................................................20

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1REVISION HISTORY
Version
Name
Date
Comments
A
B. Westerdijk
9 April 2021
Change document name & number
(from TM-744)
Cover all engine-types
Update for Control Box with LCD
1.1 Abbreviations
AC Alternating Current
BC (Hardware) Blocking Chain
DC Direct Current
LCD Liquid Cristal Display
MEC Microgen Engine Corporation (brand)
PCBA Printed Circuit Board Assembly
SW SoftWare
TDSP Thermo Dynamic Solution Provider B.V.
USA United States of America
VI Voltage and current(I) (monitoring)
WCS Water Cooled Seal

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2INTRODUCTION
TDSP provides MEC Starter Kits that make the first-time integration of a Stirling Engine
in a customer’s Application quite easy. A Starter Kit consists of a Stirling Engine, a
Controls Box, and several other parts, as indicated on the provided quotation
document. The Control Box is prewired to connect to the Engine and its provided
internal and externally mounted sensors. This document provides information on
connecting the Box to a heating system with a Stirling Engine. Also, information about
how to run, control and troubleshoot such a system, is provided.
TDSP can provide Stirling Engines with the following Engine-head variants:
Figure 2.1 Available Engine-head-type options
The Biomass and Solar Engines weigh around 60 kg, and around 70kg when packaged
and should be lifted and handled in accordance with any local handling requirements.
A Gas Engine weighs 10kg less.
Ceramic collar: to prevent excessive heat loss from the burner it is necessary to
provide thermal insulation between the heated area and the burner seal plate. This
function is provided by the ceramic collars that are mounted on all MEC Stirling
Engines.
CAUTION:Once the engine has been fired, the ceramic collars are potentially
hazardous. See the Engine manual PS-V1-01 for details.
Round Biomass
Head
Bullet Biomass
Head
Diamond
Biomass Head
Solar Head
Finned Gas
Head

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3INSTALLATION
To be able to operate and generate electrical power, the Stirling Engine must be
heated, cooled, and connected to an electrical AC-grid. This can be the local available
230VAC 50Hz or the 240VAC 60Hz single-phase state- or national-grid, or a locally
generated 230V-50Hz/240V-60Hz single-phase AC-grid provided from a bi-directional
inverter-charger set-up with batteries. Specifically, related to split-phase systems as
available in e.g., the USA, to receive proper powering, the Engine must be connected
across the two hot wires.
PLEASE NOTE: the MEC Stirling Engine can only act as a “grid-slave”, it is not able
act as a “grid-master”, as a stand-alone generator.
An overview of a typical Engine installation is shown in fig. 3.1 on the next page.
The mechanical aspects related to the installation are:
-Heating of the Engine-head and heat-protection of the rest of the Engine and
Application: the application of heat must be limited to the Engine-head only. As
an option, the heating of the head should be mechanically regulated, to avoid
overheating, or be completely removed in an emergency-stop-situation.
-The coolant-flow: the engine must be cooled sufficiently. The connections to
the engine must be made through flexible hoses and the burner seal plate (when
used) can be sealed via a flexible connection such as a polymer seal (note:
there may be a temperature protection requirement).
-Mounting of the Engine: it can be mounted standing or hanging (option: up-
side-down). Horizontal mounting or mounting under any angle is also possible.
A bracket must be used to minimize vibrations. Approved mounting materials
are available via TDSP.
The electrical part of the installation and the use of the provided Controls Box is
described in detail in Chapters 4 and 5.

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Figure 3.1 Engine Installation Schematic
The Stirling Engine comes with the following built-in sensors:
-K-type thermocouple for measuring the head-temperature, 2 pcs
-Inner-iron thermostat, 1 pc
-Over-travel switch, 2 pcs
-Water-Cooled Seal thermostat, 2 pcs
The following sensors are provided separately or connected to the Control Box wiring:
-Coolant flow temperature sensors for pipe-mounting, 2 pcs
-Coolant flow meter, 1 pc
-Ambient temperature sensor (inside the Controls Box)
Biomass and Solar
Gas and Biomass

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4STIRLING ENGINE ELECTRICAL CONNECTIONS
A simple schematic of the electrical connections to the Stirling Engine is shown below:
DAOT
DAOT
TC1 TC2
ENG L
ENG N
WCS
WCS
STAT
STAT
Heater
Head
IGN+
IGN-
FLAME
Figure 4.1 Engine electrical connections
TC1, TC2 : Engine head thermocouples connections,
ENG L, N : Engine AC power cable connections, locking-type connectors are
required,
IGN +, - : Ignition probe connections, IGN - must be connected to GND,
DAOT : Dynamic Absorber Over-Travel switch connections,
WCS, STAT : Water Cooled Seal (mounted on the engine plate), Inner Engine
thermostat connections,
FLAME : Flame detection (ionization) probe connection.

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5CONTROLS BOX ELECTRICAL CONNECTIONS
The Controls Box comes with the following cables/wires and connectors:
Figure 5.1 Control Box electrical connections
•The mains power connection must be hard-wired in accordance with local
regulations.
•The ambient temperature thermistor is located inside the enclosure.
Flow Meter
Connector
USB to
RS485
Engine
Power
Engine
GND
Coolant Inlet
Thermistor
Engine Over-
travel Switches
Head
Thermocouples
Mains Power *
Coolant Outlet
Thermistor
Cooled seal stats
Inner iron stat

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The front panel of the Controls Box has the following indicators and buttons:
1. User Reset button
2. Emergency Stop button
3. Demand on/off switch
4. LCD
5. Heat Enable Signal active indicator
6. Mains On/Off switch/isolator
7. Engine Running indicator
Figure 5.2 Control Box front panel
On this inside of the Box, the following parts can be seen:
1. Terminal block connectors
2. Engine Capacitor
3. Raspberry Pi and LCD
4. MEC Engine Control board
5. Start and Stop resistors
6. Ambient thermistor
7. 24V/5V PSU (Power supply)
Figure 5.3 Control Box internals
5.1 Controls Box connections shown in fig.5.1 explained
5.1.1 Absorber Over-Travel Switches
Connect the four connectors present on this cable onto the two Absorber Over-Travel
switches that are incorporated into the Engine: when the Engine over-travels this will
be detected immediately, and the Engine will be emergency-stopped.
5.1.2 Coolant in- and outlet thermistors
The coolant temperature sensors are already connected onto the cable, the clips fit
onto a pipe with and outer diameter of 22mm.

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5.1.3 RS485 Communications interface
This cable is provided to enable the use of the STIRLING ENGINE DATA VIEWER
software:
Figure 5.4 STRILING ENGINE DATA VIEWER
For details, please consult the Data Viewer User Manual MEC-WI-584.
Additionally, via the RS485 communication-bus, data can be provided to your
Application which can be used to help control the heat source in running the Engine
optimally and safe. Please contact TDSP for more information.
5.1.4 Head Thermocouples
Connect these two cables with connector to the two mating connectors of the two K-
type thermocouples that are incorporated into the engine head. The values provided
by these thermocouples are used as part of the Engine control and protection
algorithms.
5.1.5 Flow Meter
Connect this cable with connector to the provided HUBA 200.915101N (DN15) vortex
flow sensor, this sensor must be used to allow for measuring the coolant flow-rate.