Gentherm P-5100 Operating Manual
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Gentherm P-5100 Operating Manual

Thermoelectric generator
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WARNING:
If the information in this
manual is not followed exactly, a fire or
explosion
may
damage, personal injury or loss of life.
Do not store or use gasoline or other
flammable vapors and liquids near this or
any other appliance.
WHAT TO DO IF YOU SMELL GAS:
Do not try to light any appliance.
•
•
Do not touch any electrical switch; do not
use any phone in your building.
•
Immediately call your gas supplier from a
neighbour's
phone.
supplier's instructions.
•
If you cannot reach your gas supplier, call
the fire department.
Installation and service must be performed
by a qualified installer, service agency or the
gas supplier.
WARNING:
adjustment, alteration, service or maintenance
can cause injury or property damage. Read the
installation,
operating
instructions thoroughly before installing or
servicing this equipment.
WARNING:
For Outdoor Use Only.
result
causing
Follow
the
Improper
installation,
and
maintenance
property
gas

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  • Page 1 WARNING: If the information in this manual is not followed exactly, a fire or explosion result causing property damage, personal injury or loss of life. Do not store or use gasoline or other flammable vapors and liquids near this or any other appliance.
  • Page 2 AVERTISSEMENT: Si l’information de ce manuel n’est pas suivie exactement, un incendie ou une explosion peut résulter entraînant dégâts matériaux, blessures ou la perte de vie. Ne pas entreposer ou utiliser de l’essence, d’autres liquides ou vapeurs inflammables à proximité de cet appareil ou d’aucun autre appareil.
  • Page 3 #16, 7875 - 57 Street SE Calgary, Alberta Canada T2C 5K7 Main: +1 403 236 5556 Fax: +1 403 236 5575 www.genthermglobalpower.com NOTICE TO INSTALLER: These instructions shall be left with the consumer to retain them for future reference. 62128 Rev 10...

  • Page 5: Table Of Contents

    DATA PLATE ......................8 FUEL CONSUMPTION ....................9 STANDARD SPECIFICATION FOR GASEOUS FUEL ............10 PROCESS DESCRIPTION ....................11 MODEL P-5100 THERMOELECTRIC GENERATOR ............11 CONVERTER LIMITER ....................16 TEMPERATURE COMPENSATION................. 17 BLOCKING DIODE ....................18 OPTIONAL CATHODIC PROTECTION INTERFACE SYSTEM ..........19 OPTIONAL REMOTE START SYSTEM (TEG CONTROLLER BOARD) ........
  • Page 6 MODEL P-5100 TEG ....................66 11.2 MODEL P-5100 BURNER ................... 69 11.3 MODEL P-5100 FUEL SYSTEM ..................71 11.4 MODEL P-5100 OPTIONAL STAINLESS STEEL FUEL SYSTEM .......... 72 11.5 MODEL P-5100 ELECTRICAL ..................74 12 CATHODIC PROTECTION OPTION..................76 12.1 INTRODUCTION ....................... 76 13 HEAT RECOVERY SYSTEM (HRS) OPTION .................
  • Page 7 Figure 13 – Setting up the P-5100 TEG ..............29 Figure 14 - Wiring Diagram P-5100 for 12 or 24 V ............30 Figure 15 - Wiring Diagram P-5100 TEG for 12 or 24V with optional TEG Controller ..31 Figure 16 - Customer Load Connections ..............32 Figure 17 –...

  • Page 8: About This Manual

    ABOUT THIS MANUAL ABOUT THIS MANUAL This manual provides instructions for the operation and maintenance of the model P-5100 Thermoelectric generator. 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.
  • Page 9 Manual Shutoff Valve: A manually operated valve in the gas line for completely turning on or shutting off the gas supply to the TEG. Solenoid Valve (SV): A electrically actuated valve that controls the gas supply to the burner. This Valve is operated by the Ignition Control Module. Gentherm Global Power Technologies Page 2...

  • Page 10: Quick Start Procedure

    Follow these steps to install the TEG: 1. Unpack the TEG from its shipping crate, keep the crate until the TEG is operational. Locate and identify the following items that were shipped with the P-5100 TEG: • 1 Fin Duct.

  • Page 11: Adjustment

    It is recommended that a record be kept of the TEG’s performance and maintenance history. Each time adjustments are made, or servicing is carried out the details should be recorded. A blank TEG Performance Log is provided at the end of this manual. Gentherm Global Power Technologies Page 4...

  • Page 12: Technical Specifications

    5.5 Volts, then less than the rated power will be available to the load. OPTIONS Mounting Stand: The P-5100 can be conveniently mounted on any platform with four holes spaced as shown in Figure 11. It is important to mount the TEG at a height sufficient to prevent direct flooding or heavy snowfall from interfering with the flow of cooling air.
  • Page 13 Max. 55º C (130º F) Min. -40º C (-40 ºF) Continuously Running TEG Operating Conditions Unsheltered Operation Materials of Construction Cabinet 304 Stainless Steel Cooling Type Natural Convection Burner Meeker type, Inconel 600 Fuel System Brass, Aluminum & Stainless Steel Gentherm Global Power Technologies Page 6...

  • Page 14: Weights And Measures

    83 kg (183 lb.) Mounting Holes 267 mm wide × 457 mm deep (10.50 in. × 18.00 in.) Mounting Hole Diameter 790 mm (31.11 in.) Figure 1 – Overall Dimensions of the P-5100 TEG Gentherm Global Power Technologies Page 7...

  • Page 15: System

    The data plate is on the inside of the cabinet door and includes vital information about the generator. Model Number: The model number on the Data Plate is interpreted as follows: P-5100 ( ) - ( ) – ( ) – ( ) Fuel Type: L = Propane...

  • Page 16: Fuel Consumption

    FUEL CONSUMPTION The P-5100 is certified to operate on commercial propane, or natural gas as described in the table below. The Fuel Consumption of the P-5100 at rated power is listed in the table below for various Fuels. Fuel Consumption...

  • Page 17: Standard Specification For Gaseous Fuel

    Natural Gas: 37 MJ/Sm3 (1000 BTU/cu. ft). b) High BTU Natural Gas: 45.2 – 56.5 MJ/Sm3 (1200 - 1500 BTU/cu. ft). c) Propane/LPG: 93 MJ/Sm3 (2500 BTU/cu. ft). 10. Shall not exceed 60ºC (140ºF) in temperature. Gentherm Global Power Technologies Page 10...

  • Page 18: Process Description

    5. Make the electrical power available to the load. The main parts of the model P-5100 TEG, with CP attached, are shown in Figure 3. Gentherm Global Power Technologies Page 11...

  • Page 19: Figure 4 - P-5100 Fuel System General Assembly

    The fuel filter has a resin impregnated cellulose element which prevents solid particles from damaging the regulator and downstream parts. Figure 4 – P-5100 Fuel System General Assembly The outlet of the pressure regulator leads to a manifold on which is mounted a pressure gauge to monitor the fuel pressure, and a pressure switch for the SI module.
  • Page 20 25ºC. The SI Controller switches from battery voltage to generator power unit voltage after the output voltage exceeds 10 VDC. Completely discharged batteries will take approximately 20 hours TEG operation to regain 100% charge as long as the output load is not overloading the TEG. Gentherm Global Power Technologies Page 13...

  • Page 21: Figure 5 - Burner General Assembly

    (1000ºF). Cooling fins, which transfer the heat to the surrounding air, maintain the cold side at a lower temperature of around 163ºC (325ºF). Adjusting the amount of fuel supplied to the burner varies the temperature difference and controls the power output. Gentherm Global Power Technologies Page 14...

  • Page 22: Figure 6 - Model P-5100 Power Unit Electrical Output Characteristics

    0.30-0.60 Ω. Rated power of 127 W gross is obtained when the power unit load resistance is within this range, at the beginning of the service life of the TEG. Figure 6 – Model P-5100 Power Unit Electrical Output Characteristics 4.1.5...

  • Page 23: Converter Limiter

    A Converter/Limiter (C/L) is available for use with the model P-5100 TEG. It is intended for use with a model P-5050, or P-5100 TEG requiring either 12 or 24 V DC nominal output. It consists of two separate circuits operating together. The first is a DC/DC Converter that converts the input to 12 or 24V.

  • Page 24: Temperature Compensation

    CAUTION! limiter converter. Use 10 A slow blow for the model P-5100-12 or a 5 A slow blow for the model P-5100- 24 TEG. Voltage Sensing Relay: Two independent Voltage Sensing Relays (VSRs) provide a set of contacts to indicate an alarm condition when the output voltage drops below a preset minimum.

  • Page 25: Blocking Diode

    It is connected in series with the output to prevent current from flowing back into the electronics from another power source. Figure 8 - CP Interface System General Assembly Gentherm Global Power Technologies Page 18...

  • Page 26: Optional Cathodic Protection Interface System

    PROCESS DESCRIPTION OPTIONAL CATHODIC PROTECTION INTERFACE SYSTEM An optional cathodic protection interface system is available for use with the model P-5100 TEG. It provides 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 terminal block.

  • Page 27: Figure 9 - Teg Controller Assembly

    PROCESS DESCRIPTION Figure 9 - TEG Controller Assembly Gentherm Global Power Technologies Page 20...
  • Page 28 Up and Down buttons can be used to make changes to adjustable values Operator button for incrementing an adjustment S7 button – Up Operator button for decrementing an adjustment S8 button – Down Gentherm Global Power Technologies Page 21...
  • Page 29 10 seconds 4.6.1.2 Stop the TEG using the TEG Controller Board 1. Press S2 (Stop) or apply a remote SCADA Stop signal across SI2 of the TEG Controller for a minimum of 10 seconds Gentherm Global Power Technologies Page 22...

  • Page 30: Intake And Exhaust Flame Arrestors

    The Adjustment mode is not available until the Display mode is exited. INTAKE AND EXHAUST FLAME ARRESTORS The Model P-5050 and P-5100 are provided with flame arrestors (FA). The natural gas fueled Model P-5050N TEG and natural gas and propane fueled Models P-5100N, P-5100H and P-...

  • Page 31: Optional Vsr Terminal Block

    The addition of a flame arrestors does not make the Models P-5050 N, P-5100 N, P-5100 H and P-5100 L TEGs suitable for use in a hazardous area. For hazardous area use, TEGs require reduced surface temperatures (below hazardous gas ignition temperatures), addition of air intake and exhaust flame arrestors, and other modifications.

  • Page 32: Installation

    INSTALLATION INSTALLATION This section provides installation instructions for the Model p-5100 Thermoelectric Generator. PRECAUTIONS The installation must conform with local codes or, in absence of local codes, with the CSA-B149.1 Natural Gas and Propane Installation Code and CSA B149.2, Propane Storage and Handling. The TEG...

  • Page 33: Unpacking

    INSTALLATION UNPACKING Unpack the TEG from its shipping crate, keep the crate until the TEG is operational. Locate and identify the following items that were shipped with the P-5100 TEG: • 1 - Fin Duct • 1 - Rain Cap •...

  • Page 34: Mounting

    900 mm (3 ft.) above the top of the fin duct. Locate the TEG to avoid flooding interfering with the flow of cooling air. Figure 11 – Model P-5100 Mounting Dimensions Gentherm Global Power Technologies Page 27...

  • Page 35: Supplying Fuel

    INSTALLATION SUPPLYING FUEL This topic describes how to connect the fuel supply and gives background information for consideration when providing fuel to the P-5100 TEG. 5.6.1 Connecting the Fuel Supply The TEG has a 1/4 in. female NPT fuel inlet, i.e. connection to the TEG’s manual shutoff valve.

  • Page 36: Figure 13 - Setting Up The P-5100 Teg

    This will hold the input pressure relatively constant. Clean Fuel: The fuel used to operate the P-5100 TEG must be clean and dry. See Technical Specifications section for full gas specifications. If dirty fuel is anticipated, then a customer supplied in-line fuel filter is recommended.

  • Page 37: Connecting Customer Load

    Connection: Tanks and cylinders are to be equipped with flexible connections to offset any movement affecting the piping or tubing. CONNECTING CUSTOMER LOAD Figure 14 - Wiring Diagram P-5100 for 12 or 24 V Gentherm Global Power Technologies Page 30...

  • Page 38: Figure 15 - Wiring Diagram P-5100 Teg For 12 Or 24V With Optional Teg Controller

    INSTALLATION Figure 15 - Wiring Diagram P-5100 TEG for 12 or 24V with optional TEG Controller Connect the customer load directly to the TEG using the following procedure. If an optional CP interface system is applicable, then see Installation of Optional CP Interface System topic in section 5.8.

  • Page 39: Installation Of Optional Cp Interface System

    AWG copper wire, and a minimum temperature rating of 90 ºC. Connecting to some types of solar charge controllers may damage the TEG. Please contact Gentherm Global Power CAUTION! Technologies for advice on selecting and connecting a solar charge controller.

  • Page 40: Figure 17 - Cp Installation

    TB-1. 5.8.3 Connection of CP Load Wire the CP load directly to the CP interface system. Feed the CP anode and cathode load cables into the CP box and terminate. Gentherm Global Power Technologies Page 33...

  • Page 41: Startup And Shutdown

    STARTUP AND SHUTDOWN STARTUP AND SHUTDOWN This section describes how to startup and shutdown the model P-5100 TEG. BEFORE STARTING Before starting the TEG perform these steps: 1. Make sure that all the connections in the fuel system are tight and have been checked for leaks.

  • Page 42: Power Output Evaluation

    REQUIRED V OR SETUP POWER AT SITE Power from the P-5100 TEG is produced by the difference in temperature between the burner and the cooling fins. This means the power output of the TEG is affected by the ambient temperature surrounding the generator at site. Power output increases when temperature falls and decreases when temperature climbs.
  • Page 43 This method is suitable for ambient temperatures of up NOTE: to 65.5ºC (150ºF). If in doubt contact Gentherm Global Power Technologies’ (GPT) Customer Service Department for guidance. Example: Ambient temperature at site is 35ºC. Set-up power of 1 27 W and V 6.8 V, 22ºC is marked on the TEG Data Plate.

  • Page 44: Set Or Setup Power

    Setup Power topic above, or Alternative Method of Working-out Required V Setup Power. 3. Connect a voltmeter between terminals 5 (+) and 6 (-). This is the measured V should tend towards the required V . It will climb as shown in Figure 19. Gentherm Global Power Technologies Page 37...

  • Page 45: Figure 19

    2. Consult the data plate inside TEG door for the reference V voltage and determine the required V for the present ambient temperature. See Working-out Required V or Setup Power topic above, or Alternative Method of Working-out Required V Setup Power. Gentherm Global Power Technologies Page 38...
  • Page 46 , for present ambient temperature, otherwise CAUTION! overheating may cause irreparable damage to the power unit. 4. When the V measurement is completed, reattach the customer load to terminals 7 (+) and 8 (-) of TB-1. Gentherm Global Power Technologies Page 39...

  • Page 47: Adjustment

    ADJUSTMENT ADJUSTMENT This section describes how to adjust the Model P-5100 Thermoelectric generator. Typical settings are: • 28 to 34 kPa (4.0 to 5.0 psi) for natural gas (P-5100N), NOTE: • 48 to 55 kPa (7.0 to 8.0 psi) for high BTU natural gas (P-5100H ONLY), •...

  • Page 48: Power Output Adjustment

    Follow these steps to adjust fuel pressure: 1. Remove the cover on the regulator and loosen the lock nut. 2. Turn the adjusting screw (clockwise to increase pressure) until the required change in pressure is obtained. Gentherm Global Power Technologies Page 41...
  • Page 49 Tighten the lock-nut. 8.1.2.1 Measuring CO Emissions Levels The model P-5100 will not produce excessive amounts of CO if properly adjusted. Due to the open exhaust system of TEG, the CO measurement must be in the free air state. In a free air measurement, the allowable CO rate is 800 ppm however a correctly adjusted P-5100 will produce less than 120 ppm CO air free.
  • Page 50 = As-measured combustion gas carbon monoxide ppm = Percentage of oxygen in combustion gas, as a percentage = Percentage of carbon dioxide in combustion gas, as a percentage The model P-5100 does not produce excessive concentrations of CO if adjusted properly. 8.1.3 Fuel Pressure Adjustment...
  • Page 51 V value, then a problem exists with one of the TEG’s systems. If necessary, see Troubleshooting section for guidance. 4. Tighten the lock nut and replace the cover on the fuel regulator. Gentherm Global Power Technologies Page 44...

  • Page 52: Adjustment Of C/L

    It is factory set at 23.0V and 28.5V (Model P-5100-24) or 11.5V and 14.3V (Model P-5100-12). The VSR is rated for 2A at 30V DC and will take up to 14 AWG stripped wire. The Remote VSR Terminal Option will allow for a wire size of 10AWG with a ring or fork terminal termination.

  • Page 53: Enabling Temperature Compensation

    Switch 1 OFF b. Switch 2 ON ADJUSTMENT OF OPTIONAL CP INTERFACE SYSTEM An optional CP interface system is available for use with the model P-5100 TEG. This text describes how to adjust the CP interface system, if applicable. 8.4.1 CP Power Output Adjustment The 0-1Ω...

  • Page 54: Figure 23 - Cp Interface System, Series Wiring Diagram

    NOTE: within 10% of that marked on the data plate is recommended to prevent flame out. Figure 23 - CP Interface System, Series Wiring Diagram Figure 24 - CP Interface System, Parallel Wiring Diagram Gentherm Global Power Technologies Page 47...

  • Page 55: Adjustment Of The Optional Remote Start System (Teg Controller)

    3. Press the Adjust button until the display goes off to exit the Adjustment mode. It will also automatically timeout and exit Adjustment mode. All variable changes are saved upon exit of the Adjust mode. NOTE: The Adjustment mode is not available until the Display mode is exited. Gentherm Global Power Technologies Page 48...

  • Page 56: Maintenance

    MAINTENANCE MAINTENANCE This section describes how to maintain the model P-5100 TEG. Before attempting to maintain the TEG the qualified service person should be thoroughly familiar with its: • technical specifications; • process description; • installation; • startup and shutdown;...

  • Page 57: Figure 22 - Change In

    Check for obstructions at the cooling fins and the air filter stabilizer. Adjust the air shutter, see Adjustment section. If this returns the measured voltage to within 0.1 V of required V proceed with Routine Service. Gentherm Global Power Technologies Page 50...

  • Page 58: Fuel System Maintenance

    2. Open the drain cock located on the underside of the TEG cabinet, any impurities will drain through the cock. (Place empty container beneath drain cock to prevent spillage inside the cabinet.) 3. Close drain cock. 4. Leak check the drain cock. Gentherm Global Power Technologies Page 51...

  • Page 59: Figure 25 - Pressure Regulator

    3. Align the sediment bowl with the regulator body, replace the four screws and tighten. 4. With the fuel pressure on, leak checks all regulator joints and fuel connections using a commercial leak detector. Gentherm Global Power Technologies Page 52...
  • Page 60 7. Connect the fuel line to SV valve and orifice, then tighten the fuel line fittings. 8. Leak check all connections using a commercial leak detector. WARNING! Check for fuel leaks after any fuel system service. Gentherm Global Power Technologies Page 53...

  • Page 61: Burner Maintenance

    If the air shutter setting was disturbed turn the venturi adjusting screw as NOTE: described in Section 8.1.2. This will set the adjustment in the correct range to begin balancing the air-fuel mixture when re-starting. Before re-starting the TEG, leak check all fuel connections. Gentherm Global Power Technologies Page 54...

  • Page 62: Figure 26 - Burner Assembly Cross Section

    5. Remove the 2 bolts mounting the fuel regulator to the cabinet wall and remove the fuel system. 6. Remove the 2 screws from each side of the cabinet baffle and remove baffle from cabinet. Gentherm Global Power Technologies Page 55...

  • Page 63: Si System Maintenance

    The SI system may require occasional maintenance. If the SI system fails to ignite it must be checked and serviced as necessary. Use the procedures below to maintain the SI system. If arching occurs the SI system is functioning well. See wiring diagrams Figure 14 or Figure Gentherm Global Power Technologies Page 56...
  • Page 64 5. Loosen the orange wire connectors from the terminals on the pressure switch and then short the circuit between the two terminals. Arcing should occur in the combustion chamber (making a clicking noise) at the rate of one per second. Gentherm Global Power Technologies Page 57...

  • Page 65: Figure 27 - Electrode Protrusion From Air Box Lid

    Switch should open at pressures below 6.9 kPa (1 psig). 8. The SI controller must recognize that there is fuel available by the closed pressure switch condition before it will power the SI module. Gentherm Global Power Technologies Page 58...
  • Page 66 SI module is sparking, and the SI valve indicator is on. If it is, replace the solenoid wiring harness. If it isn’t, replace the SI module. Gentherm Global Power Technologies Page 59...

  • Page 67: C/L Examination

    2. 3. Connect a voltmeter to terminals 1 and 2. The following steps may cause sparking. If an internal WARNING! short is present the jumper wire, see below, may arc to the chassis. Gentherm Global Power Technologies Page 60...

  • Page 68: Figure 28 - Momentary Open Circuit Diagram

    Record the number as the momentary open circuit voltage (Voc). If this was not recorded quickly enough replace the connection and repeat steps 4 to 6 above. Figure 28 - Momentary Open Circuit Diagram Gentherm Global Power Technologies Page 61...
  • Page 69 = (12.2-6.7) / 17.87 = 5.5 / 17.87 = 0.308 OHM Internal resistance is acceptable, < 0.308 OHM. For further information or assistance, please contact the Customer Service Department at Gentherm Global Power Technologies. Gentherm Global Power Technologies Page 62...

  • Page 70: Troubleshooting

    Replace the orifice with Maintenance incorrect one of the correct size Safety SOV valve Check the safety SOV Maintenance malfunctioning valve Air filter dirty Clean the air filter Maintenance Air shutter adjustment Adjust the air-shutter Adjustment incorrect Gentherm Global Power Technologies Page 63...
  • Page 71 Adjust the TEG fuel Adjustment adjustment incorrect manifold pressure is too high L/C* damaged Adjust the L/C Adjustment Output voltage is too high L/C* adjustment Adjust the L/C Adjustment incorrect *applicable for L/C option only Gentherm Global Power Technologies Page 64...

  • Page 72: Part List

    PART LIST PART LIST This section lists the parts that form the equipment. For parts and service please contact Gentherm Global Power Technologies’ Customer Service Department at: #16, 7875 - 57th Street SE Calgary, Alberta T2C 5K7 Direct: (403) 720-1190...

  • Page 73: 11.1 Model P-5100 Teg

    PART LIST 11.1 MODEL P-5100 TEG Figure 29 - Model P-5100 TEG Item Part No. Description 61864 FUEL SYSTEM, P-5050/P-5100 62557 FUEL SYSTEM, SS, P-5050/P-5100 2105 SCREW, CAP, HEX-HD, 1/4-20 X 3-1/2, SS, 1-1/2” THREAD WASHER, FLAT, 1/4” SS 62064...
  • Page 74 PART LIST 11.1 MODEL P-5100 TEG (Cont’d) Figure 29 - Model P-5100 TEG Item Part No. Description SCREW, CAP, SOC, 1/4-20 X 1/2 SS 61993 CABINET ASSEMBLY, P-5050/P-5100 62122 RAIN GUARD, P-5050/P-5100 7410 SCREW, Mach, P-H-P, 8-32 X 1/4, SS...

  • Page 75: Figure 29 - Model P-5100 Teg

    LIMITER/CONVERTER ASSY, 12V, RS, P-5050/P-5100 (OPTIONAL) 63516 LIMITER/CONVERTER ASSY, 24V, RS, P-5050/P-5100 (OPTIONAL) 65209 CP INTERFACE ASSEMBLY P-5100 12 V (NOT SHOWN) (OPTIONAL) 65246 CP INTERFACE ASSEMBLY P-5100 24 V (NOT SHOWN) (OPTIONAL) 56980 SENSOR, TEMPERATURE, TRISTAR TS-RTS (NOT SHOWN)

  • Page 76: 11.2 Model P-5100 Burner

    INSULATION BLOCK, P-5050/P-5100 61871 SPACER, VENTURI, P-5050/P-5100 62056 VENTURI, P-5100 61870 BURNER COVER, P-5050/P-5100 62118 AIR BOX ASSY, W INTAKE ARRESTORS, P-5050/P-5100 7004 PIN, MOUNTING, SI ELECTRODE 7005 NUT, WING, 5/16-18, SS NUT, WING, 10-32, SS 63957 NUT, LOCK, HEX, 10-32, 316SS...

  • Page 77: Figure 30 - Model P-5100 Burner

    PART LIST 11.2 MODEL P-5100 BURNER (Cont’d) Figure 30 - Model P-5100 Burner Item Part No. Description 27901 WASHER, BOWED, 5 MM, A2 SS, Spaenaur 681-821 61990 LID W/ ARRESTORS, ASSEMBLY, P-5050/P-5100 00472 WASHER, Lock, EXT. #8, SS 7324 SCREW, Mach, P-H-P, 8-32 X 1/2, SS...

  • Page 78: 11.3 Model P-5100 Fuel System

    PART LIST 11.3 MODEL P-5100 FUEL SYSTEM Figure 31 - Model P-5100 Fuel System Item Part No. Description 24653 VALVE, BALL, 1/4 NPT, BRASS, CG/CSA/UL APP’D, 600# WOG 62069 NIPPLE, 1/4 NPT X 6” LG. BRASS 21569 ELBOW, Street 1/4 NPT, B-4-SE REGULATOR, FISHER 67CFR, 0-20 PSI, UL 144 &...

  • Page 79: 11.4 Model P-5100 Optional Stainless-Steel Fuel System

    PART LIST 11.4 MODEL P-5100 OPTIONAL STAINLESS-STEEL FUEL SYSTEM Figure 32 - Model P-5100 SS Fuel System Item Part No. Description 21689 VALVE, BALL, 1/4” 2000 LB, 316 SS, V-TEK V2 62559 NIPPLE, 1/4 NPT X 6” L, SS 2356...
  • Page 80 PART LIST 11.4 MODEL P-5100 OPTIONAL STAINLESS-STEEL FUEL SYSTEM (Cont’d) Figure 32 - Model P-5100 SS Fuel System Item Part No. Description CONNECTOR, 1/4 TB X 1/4 MNPT, 316 SS, SS-400-1-4 61865 VENT TUBE ASSY, REGULATOR, SS P-5050/P-5100 22363 FILTER KIT, FISHER 67 CFR (Not Shown)

  • Page 81: 11.5 Model P-5100 Electrical

    PART LIST 11.5 MODEL P-5100 ELECTRICAL Figure 33 - Model P-5100 Electrical Item Part No. Description 63035 BACK PAN, ELECTRICAL ENCLOSURE, P-5050/P-5100 56227 SCREW, MACH, P-H-P, 6-32 X 1.5” LG, SS 24554 NUT, LOCK, HEX, 8-32, NYLON INSERT, 316 SS...

  • Page 82: Figure 33 - Model P-5100 Electrical

    SCREW, FAST LEAD, KNURLED, SS, SOUTHCO 09-13-102-26 63039 DEAD FRONT, ELECTRICAL ASSY, P-5050/P-5100 63126 PCB ASSY, LC DC/DC CONVERTER, MEDIUM POWER, P-5050/P-5100 64879 PCB ASSY, LC DC/DC LIMITER, MEDIUM POWER, P-5050/P-5100 58437 SCREW, CAP, HEX SOCKET, 8-32 x 3/8”, 18.8 SS 24559 BATTERY, 6V, 5.0Ahr, MONOBLOC, AEI 108539...

  • Page 83: Cathodic Protection Option

    The duel Scale meter displays voltage at the terminal block, and current when the PUSH TO READ AMPS button is depressed. The meter is accurate to +/- 3% of full scale. Figure 34 - Cathodic Protection Interface Cabinet Gentherm Global Power Technologies Page 76...

  • Page 84: Figure 35 - Cp Interface System, Series Wiring Diagram

    With the tap located at the top of the resistor the output power will be zero. As the tap is moved down, the power to the CP load is increased. Figure 35 - CP Interface System, Series Wiring Diagram Gentherm Global Power Technologies Page 77...

  • Page 85: Figure 36 - Cp Interface System, Parallel Wiring Diagram

    Interface Systems available. The required system for various TEGs are listed below. GPT TEG Part No. System Description P-5050-12 65207 CP Interface Assembly, P-5050-12V P-5050-24 65245 CP Interface Assembly, P-5050-24V P-5100-12 65209 CP Interface Assembly, P-5100-12V P-5100-24 65246 CP Interface Assembly, P-5100-24V Gentherm Global Power Technologies Page 78...

  • Page 86: Figure 37 - Cathodic Protection System Parts Identification

    CATHODIC PROTECTION OPTION Figure 37 - Cathodic Protection System Parts Identification Gentherm Global Power Technologies Page 79...

  • Page 87: Figure 38 - Parts Table

    MOUNTING HARDWARE, 300 W RESISTOR WIRE, #10, WHT/BLK, TIN-PLT-COP WIRE, #10, WHT/BLK, TIN-PLT-COP 2041 WIRE, #10, BRN, TIN-PLT-COP11 WIRE, #10, WHT/RED, TIN-PLT-COP WIRE, #10, WHT/RED, TIN-PLT-COP WIRE, #10, WHT/RED, TIN-PLT-COP 4.25 WIRE, #10, RED, TIN-PLT-COP Gentherm Global Power Technologies Page 80...
  • Page 88 SCREW, MACH, P-H-P, 10-32 X 1/4, SS 00469 WASHER, LOCK SPRING, #8, SS WASHER, LOCK, SPRING, #10, CAD SCREW, MACK, P-H-P, 8-32 X 3/8, SS WASHER, LOCK, INT, #8, SS 4795 LABEL, CATHODIC PROTECTION INTERFACE Gentherm Global Power Technologies Page 81...

  • Page 89: Heat Recovery System (Hrs) Option

    HEAT RECOVERY SYSTEM (HRS) OPTION 13.1 INTRODUCTION The Heat Recovery System (HRS) Option is available for P-5050 and P-5100. This option allows for waste heat recover, to warm building interiors where required, see Figure 38. The TEG configured for the HRS application includes an HRS specific rain cap, exhaust tube assembly, and burner configuration.

  • Page 90: 13.4 Model P-5100 Hrs Configuration Parts

    HEAT RECOVERY SYSTEM (HRS) OPTION 13.4 MODEL P-5100 HRS CONFIGURATION PARTS Figure 40 - HRS Configuration Item Part No. Description See Figure 29 66634 BURNER ASSEMBLY, W/INTAKE ARRESTOR, HRS, P-5100 62121 BURNER ASSEMBLY, W/INTAKE ARRESTOR, P-5100 See Figure 29 65697...

  • Page 91: 13.5 Model P-5100 Hrs Burner Parts

    HEAT RECOVERY SYSTEM (HRS) OPTION 13.5 MODEL P-5100 HRS BURNER PARTS Figure 41 - Model P-5100 HRS, Burner Item Part No. Description 62117 BURNER BACK ASSY, P-5050/P-5100 J2-J6 See Figure 30 66630 INSULATION BLOCK, TOP ELECTRODE, P-5050/P-5100 J8-J9 See Figure 30...

  • Page 92: Teg Performance Log

    TEG PERFORMANCE LOG TEG PERFORMANCE LOG MODEL NO: TEG SERIAL NO: FUEL TYPE: LIMITER/CONVERTER SERIAL NO: CP INTERFACE SERIAL NO: MAINTENANCE REMARK Gentherm Global Power Technologies Page 85...
  • Page 93 TEG PERFORMANCE LOG TEG PERFORMANCE LOG MODEL NO: TEG SERIAL N FUEL TYPE: LIMITER/CONVERTER SERIAL NO: CP INTERFACE SERIAL NO: MAINTENANCE REMARK Gentherm Global Power Technologies Page 86...

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