global thermoelectric 5060 Operating instructions

5060

Thermoelectric

Generator

Operating Manual

Global Thermoelectric

Bay 9, 3700 - 78 AVE., S.E.

Calgary, Alberta

Canada, T2C 2L8

Phone: 1 (403) 236-5556

Fax: 1 (403) 236-5575

5060 Quick Start Procedure

5060-SI

• Turn on gas supply to TEG. The spark ignition system (SI) should begin clicking and the sound

of combustion heard within 15 seconds.

• 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, V

set

, between terminals 2(+) and 4(-) of TB-1. The V

set

should be approximately 13.8 volts.

• Return the jumper clip to between terminals 1 and 2 of TB-1.

• Apply customer load.

5060-SI-SO

• Turn on gas supply to TEG. Hold down the button on Shut Off (SO) valve. The spark ignition

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, V

set

, between terminals 2(+) and 4(-) of TB-1. The V

set

should be approximately 13.8 volts.

• Return the jumper clip to between terminals 1 and 2 of TB-1

• Apply Customer load

Fuel Pressure

• Propane start up: 40-48 kPa 6-7 psi

• Natural Gas start up: 35-40 kPa 5-6 psi

Table of Contents

1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.1 General Description and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.2 Standard Features and Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1.2.1 Standard Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1.2.2 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1.3 Definition of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1.4 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

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

2.5.1 SI Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

2.5.2 SI-SO Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

2.5.3 Manual Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

2.6 Elevation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

2.6.1 Set-Up Power & V

set

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

2.6.2 V

set

(Power) Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9

2.6.3 Elevation Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9

2.6.4 Air-Shutter Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10

2.6.5 Fuel Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11

2.7 Customer Load Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12

3 Service and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3.1 Suggested Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3.1.1 Power Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3.1.2 TEG Basic Service Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

3.2 System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

3.2.1 Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

3.2.2 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

3.2.3 Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7

3.2.4 Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8

3.2.5 Spark Ignition (SI) System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8

3.2.6 Automatic Shut-Off (SO) System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12

3.3 Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13

3.4 5060 TEG Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15

3.5 Burner Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17

3.6 Burner with Flame Arrestor Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18

3.7 SI Fuel System Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20

3.8 SI-SO Fuel System Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21

4 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

4.1 Electrical Output Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

4.2 Physical Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

4.3 Gas Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

4.4 5060 Performance Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

List of Figures

Figure 1 TEG Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

Figure 2 Assembling 5060 TEG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

Figure 3 Applying Thread Sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3

Figure 4 Wiring Diagram 5060 TEG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

Figure 5 SI Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

Figure 6 V

set

& Rated Power vs. Ambient Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7

Figure 7 SI-SO Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

Figure 8 V

set

vs Time After Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9

Figure 9 Fuel Gauge Pressure vs. Elevation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9

Figure 10 Change in V

set

vs Air Shutter Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10

Figure 11 Change in V

set

vs Fuel Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11

Figure 12 Wiring Diagram 5060 TEG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12

Figure 13 Teg Main Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

Figure 14 SI Fuel System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

Figure 15 Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

Figure 16 SI-SO Fuel System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7

Figure 17 Venturi Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8

Figure 18 Burner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9

Figure 19 Spark Ignitor Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10

Figure 20 5060 TEG Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15

Figure 21 Burner Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17

Figure 22 5060 Burner with Flame Arrestor Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18

Figure 23 SI Fuel System Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20

Figure 24 SI-SO Fuel System Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21

Figure 25 Electrical Output Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

Figure 26 Physical Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

Global Thermoelectric 1-1

Reference Copy - For Sales Use Only

1 Introduction

This manual provides installation, operation and maintenance instructions for the Global

Model 5060 Thermoelectric generators.

1.1 General Description and Specifications

Global's Model 5060 Thermoelectric Generator contains no moving parts. It is a reliable, low

maintenance source of DC electrical power for any application where regular utilities are

unavailable or unreliable.

Power Specifications

Power Ratings

20ºC, 750 m above sea level

60 Watts @ 6.7 Volts

54 Watts @ 12 Volts

54 Watts @ 24 Volts

54 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 cabinet

Fuel

Natural Gas

4.4m

3

/day (155 ft

3

/day) of Std. 1000 BTU/SCF

(37.7MJ/Sm

3

) gas

Propane 5.7 l/day (1.5 US gal/day)

Maximum Supply Pressure 1750 kPa (250 psi)

Minimum Supply Pressure 100 kPa (15 psi)

Fuel Connection 1/4 in. MNPT connection

Environmental

Ambient Operating Temperature

Max. 55ºC (130ºF)

Min. -55ºC (-67ºF)

Operating Conditions Unsheltered Operation

Materials of Construction

Cabinet 304 SS

Cooling Type Natural Convection

Thermopile Hermetically Sealed Lead Tin-Telluride (PbSnTe)

Burner Meeker type/Inconel 600

Fuel System Brass, Aluminum & SS

Global Thermoelectric 1-2

Reference Copy - For Sales Use Only

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 1720 kPa

(250 psi) and a built in fuel filter, an Automatic Spark Ignition System (SI), and low voltage

alarm contacts (Voltage Sensing Relay or VSR)

1.2.2 Options

Available options for the 5060 Thermoelectric Generator are as follows:

Automatic Shut-Off Option (SO): The Automatic Gas Shut-Off option (SO) is designed to

turn off the gas supply to the burner if the flame in the TEG is extinguished and cannot be sub-

sequently re-ignited by the automatic SI system within approximately three to five 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 fittings 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 Oilfield Equipment). External components

that can not be replaced are coated with Glyptal to reduce their risk of corrosion.

Flame Arrestor Option: Most of Global's standard TEG's fall under the definition of "flame

type equipment" as defined in the regulations of The Oil And Gas Conservation Act Alberta

(Section 8.090). Global has developed a flame arrestor system for use as an option on the

Model 5060 TEG to meet the EUB requirements. It has been designed to allow its installa-

tion on both new or existing TEGs.

Please note that although Global's engineers have designed the flame arrestor following CSA

standards and have tried to satisfy regulatory requirements with the design, the flame arrestor

is not CSA approved. It is the responsibility of the end user to determine the suitability of

Global's flame arrestor system to meet the requirements of their specific installations includ-

ing, but not limited to: a) the suitability of EUB's definition of equipment location and b) the

suitability of Global's air intake flame arrestor design as an "adequate flame 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 ter-

minal block. A 0 to 1 Ohm resistor, 300 watt variable resistor is provided for adjusting the out-

put 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 firm-

ly 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.

Global Thermoelectric 1-3

Reference Copy - For Sales Use Only

1.3 Definition of Terms

Thermoelectric Generator: A device that produces electrical power through the direct con-

version of heat energy to electrical energy.

Power Unit: The hermetically sealed portion of the generator that contains the thermoelec-

tric materials and the cooling fins.

TEG: A Thermoelectric Generator.

Limiter-Converter (L/C): A specific 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, V

set

: The set-up voltage of the generator. In the 5060 generator V

set

equals

open circuit voltage.

Rated Power: The amount of power 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-power decreases.

Rated V

set

: The amount of V

set

a generator can be operated at when the ambient tempera-

ture of the site is expected to peak at 65ºC. As the ambient temperature increases the rated

V

set

decreases.

Open Circuit Voltage, V

OC

: The voltage at the terminals of a power source when no appre-

ciable current is flowing.

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 difference is maintained, electrical power

can be delivered to a load placed in this circuit.

Figure 1 illustrates how this is done in the model 5060 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 thermocou-

ples, each producing 84 mV are connected in series to total 6.7 Volts. This is the matched

load voltage. At 9 Amps the generator then produces 60 Watts.

The TEG voltage varies according to the

temperature difference 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 fins which transfer the heat to

the surrounding air. This temperature differ-

ence is controlled by adjusting the amount

of fuel supplied to the burner.

In summary, the TEG produces electrical

power when a temperature difference is

maintained between the hot and cold junc-

tions of the thermocouples. This tempera-

ture difference, 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 5060 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 5060 TEG produces 60 Watts at 24ºC.

• Power decreases 0.18W per ºC rise in temperature (0.1W per ºF) see Figure 6.

• Maximum allowable ambient temperature for operation is 65ºC (150ºF).

Global Thermoelectric 1-4

Reference Copy - For Sales Use Only

Figure 1 TEG Design

Global Thermoelectric 2-1

23520 rev. 0

2 Operation

2.1 Physical Description

5060 Dimension Chart

Length 629 mm (24.75 in.)

Width 372 mm (14.64 in.)

Height 988 mm (38.89 in.)

Weight 41 kg (90 lb)

Shipping Weight 75 kg (165 lb)

Mounting Holes 267 mm X 457 mm (10.50 wide X 18.00 deep)

2.2 Unpacking, Assembly and Mounting

Tools Required:

• 1 x DC Voltmeter accurate to 0.1V.

• 2 x Small adjustable wrenches that will open to 16mm (5/8 inch).

• 1 x Flat head screwdriver.

• 4 x #1/4-20 bolts & nuts for mounting.

• 1 x Phillips Screwdriver.

Unpack the 5060 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 Customer Service before starting a damaged TEG.

Locate and identify the following items that were shipped with the 5060 TEG.

• 1 x 1Fin Duct.

• 1 x Intake Stack with Clamp.

• 1 x Exhaust Stack with Clamp.

• 1 x Thread Sealing Compound.

• 7 x #8 - 32 x ¼ inch long Screws (1 spare).

• 7 x #8 Washers, external lock.

Assemble the TEG as follows (see Figure 2):

1) Attach the fin 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 Thermoelectric 2-2

Reference Copy - For Sales Use Only

Mount the TEG to a firm and stable base, using 1/4-20 bolts, See Appendix Figure 26, page

5-2, 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 flooding or heavy

snowfall interfering with the flow of cooling air. Allow a minimum of 150 mm (6 in.) clearance

under the cooling fins.

WARNING: Operation of the TEG in locations where cooling air flow may be obstruct-

ed will cause overheating of the TEG.

Figure 2 Assembling TEG

Global Thermoelectric 2-3

Reference Copy - For Sales Use Only

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 different orifice, therefore the TEG must be used with the fuel indicated.

Model Number: The model number is interpreted as follows:

FUEL TYPE:

L = Propane

N = Natural Gas

LIMITER CONVERTER VOLTAGE:

12 or 24 Volt

FUEL SYSTEM:

SI = Spark Ignition Only

SI-SO = Spark Ignition & Auto Shut Off

5060 ( ) - ( ) ( )

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 5060 TEG must be clean (see gas specifications

in Appendix, page 4-3). If dirty fuel is anticipated then a customer supplied, in-line fuel filter

is recommended.

Low Temperature: When using propane (C

3

H

8

)

at temperatures below -30ºC (-22ºF) special con-

sideration must be given to the low vapour pres-

sure of the fuel.

Pressure: Make sure that fuel pressure is at

least 100 kPa (15 psig) and will not exceed 1720

kPa (250 psig). If it is expected that the fuel sup-

ply pressure will vary greatly, the use of an addi-

tional primary regulator is recommended. This

will hold the input pressure relatively constant.

Figure 3 Applying Thread Sealant

Global Thermoelectric 2-4

Reference Copy - For Sales Use Only

Check the TEG data plate for the fuel type. DO NOT use a different type of fuel than indicat-

ed.

A fuel shut-off 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 fittings 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 com-

mercial leak detector.

2.5 Start Up

System Performance Logs are located at the back of this manual, Appendix 4.4. Use of these

logs is recommended each time the site is visited. This information is valuable for future ref-

erence.

The starting procedure depends on whether the TEG has the SI (Spark Ignition) or SI-SO

(Spark Ignition/Shut-Off) fuel system. Check the data plate to confirm which of these the TEG

has.

Figure 4 Wiring Diagram 5060 TEG

Global Thermoelectric 2-5

Reference Copy - For Sales Use Only

1) Move the jumper on TB-1 from between terminals 1 and 2 to between terminals 3 and

4, see Figure 4.

2) Connect a DC Voltmeter to terminals 2(+) and 4(-) of TB-1. This will be measuring V

set

.

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 5.

1) Loosen the ignitor rod wing-nut.

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 Start

Turn on the fuel supply. 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 combus-

tion will begin. If combustion does not begin refer to Section 3.3 for trouble shooting.

2.5.2 SI-SO Start

1) Turn on the fuel supply.

2) Push in the button on top of shut-off 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.

2.5.3 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.

1) Remove the SI electrode from the burner

2) If the TEG has a SI-SO fuel system push in the button on top of shut-off valve.

3) Place a lighted match or similar flame source to the electrode port. Ignition should

occur quickly and the sound of combustion will begin. For SI-SO fuel system continue

to hold the button on the shut-off valve for 90 seconds.

4) Repair and replace SI system as soon as possible.

Global Thermoelectric 2-6

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2.6 Evaluation

2.6.1 Set-Up Power and V

set

The power in the 5060 TEG is produced by the difference in temperature between the burn-

er and the cooling fins. This means that the power output of the 5060 TEG will be affected by

the ambient temperature at the generator site.

The rated power is the power that the 5060 TEG should produce at a specific ambient tem-

perature, up to a maximum temperature of 65ºC (150ºF). The 5060 TEG is rated at 60 Watts

gross power (power from the power unit) 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. For every rise in temperature of 1ºC

the 5060 TEG will drop 0.18 Watts in gross power output.

Figure 5 SI Start Up

Global Thermoelectric 2-7

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Figure 6 V

set

& Rated Power vs. Ambient Temperature

Global Thermoelectric 2-8

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To determine the set-up voltage V

set

and set-up power use the graph in Figure 6. For exam-

ple if the ambient temperature is 10 C then V

set

will be 13.7 Volts and set-up power will be

62.5 Watts.

To calculate the set-up power use the formula:

P = 60 + [ (24º - T) x 0.18]

where: T = Ambient temperature ºC

P = Set-Up Power (Watts)

EXAMPLE: The ambient temperature is 10ºC

P = 60 + [(24º - 10º) x 0.18]

= 62.52 Watts

Figure 7 SI-SO Start Up

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