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global thermoelectric 8550 Operating Manual

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8550
Thermoelectric
Generator
Operating Manual
23658 Rev. 4
Global Thermoelectric
Bay 9, 3700 - 78 AVE., S.E.
Calgary, Alberta, Canada
T2C 2L8
Phone: 1-403-236-5556
Fax: 1-403-236-5575
EMAIL: service@globalte.com

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  • Page 1 8550 Thermoelectric Generator Operating Manual 23658 Rev. 4 Global Thermoelectric Bay 9, 3700 - 78 AVE., S.E. Calgary, Alberta, Canada T2C 2L8 Phone: 1-403-236-5556 Fax: 1-403-236-5575 EMAIL: service@globalte.com...
  • Page 3 CURRENT DOES NOT EXCEED 30 AMPS. FOR FURTHER INFORMATION PLEASE CONTACT THE GLOBAL CUSTOMER SER- VICE DEPARTMENT AT THE NUMBER SHOWN BELOW. GLOBAL THERMOELECTRIC BAY 9, 3700 - 78 AVE. S.E. CALGARY, ALBERTA, CANADA T2C 2L8 PHONE: 1-403-236-5556 FAX: 1-403-236-5575 COPYRIGHT (C) 1991 GLOBAL THERMOELECTRIC...

  • Page 5: Table Of Contents

    4.2 8550 Performance Log ........
  • Page 6 Figure 21 Fuel System Parts List, 8550 TEG ....... . .3-21...

  • Page 7: General Information

    Manual Identification 1.1.1 This manual provides installation, operation and maintenance instructions for the Global Model 8550 Thermoelectric Generator. The generator must be used in conjunction with a Power Conditioner. The manual for the operation of this Power Conditioner is included fol- lowing this manual.

  • Page 8: Theory Of Operation

    A TEG is a system which provides the means to maintain these condi- tions. 1.3.2 Figure 1 illustrates how this is accomplished in the Model 8550 TEG. A thermocouple is formed by a P type and an N type thermoelectric element joined together electrically by a hot junction electrode.

  • Page 9: Physical Description

    1.3.3 The cold junctions of the Model 8550 TEG are cooled by series of heat pipes. Each heat pipe is hermetically sealed and contains a measured amount of fluid in equilibrium with its vapour. As heat is applied to the fluid it boils and then re-condenses in the upper portion due to the cooling effect of the cooling fins.

  • Page 10: Electrical Output Characteristics

    Figure 2 Model 8550 Dimensions Electrical Output Characteristics 1.5.1 The typical electrical output characteristics at standard temperature of a Model 8550 power unit without the power conditioner are shown in Figure 3. The power, current and voltage are shown as a function of the power unit load resistance. Note that the output power curve goes through a maximum between 1.00 and 2.00 Ohms and that rated power can only be obtained...

  • Page 11: Figure 3 Power Unit Electrical Output Characteristics (Without Power Conditioner)

    Consult Global Thermoelectric for the system best suited to your application. 1.5.2 The available power of a Model 8550 TEG is also a function of the amount of cooling supplied by the heat pipes. The cooling is a function of both the ambient air temperature and the wind speed.

  • Page 12: Fuel Information

    Figure 4 Power as a Function of Ambient Temperature Fuel Information 1.6.1 The fuel consumption of a Model 8550 TEG operating at rated power under standard temper- ature conditions is given in Table 2. These values are subject to change without notice.
  • Page 13 Table 3 Corrected Air Temperature for Wind Wind Air Temperature (ºC) (ºF) Speed (km/hr) (mile/hr) 104 113 122 104 113 122 108 117 104 115 12.4 15.5 18.6 21.7 24.8 Global Thermoelectric 23658 Rev. 4...
  • Page 14 Global Thermoelectric 23658 Rev. 4...

  • Page 15: Installation And Operation

    INSTALLATION AND OPERATION Unpacking and Mounting 2.1.1 The following tools are required in order to set up and operate the 8550 TEG: • A voltmeter or meters with leads and clips able to measure the following ranges: 0-30 ±0.1 V 0-30 ±0.1 mV...

  • Page 16: Data Plate Information

    Fuel type: An "X" is stamped in the appropriate box for Natural Gas or Propane. Each of these fuels uses several different fuel system components, therefore, the TEG should only be used with the fuel indicated. Global Thermoelectric 23658 Rev. 4...

  • Page 17: Fuel Supply

    Model Number: The model number on the data plate is interpreted as follows: 8550(*) - (**) (***) * Fuel Type: L = Propane N = Natural Gas ** Power Conditioner Nominal Output Voltage: 12, 24 or 48V *** Factory Options:...

  • Page 18: Ignition And Start Procedure

    2.3.5 If it is expected that the fuel may contain moisture or other contamination, a filtering or fuel conditioning system must be used. Consult Global Thermoelectric for more information. 2.3.6 The TEG is equipped with a 1/4 in. NPT male connector. Remove the plastic protective cap and connect the fuel line.

  • Page 19: Figure 8 Wiring Diagram, 8550 Teg

    TB-1 SHUNT BLK/WHT #20 RED/WHT #20 6720 LIMITER TERMINAL BLOCK WHT/RED TO POWER CONDITIONER FROM POWER WHT/RED CONDITIONER WHT/BLK SI HIGH VOLTAGE CABLE MODULE SPARK TO PRESSURE ELECTRODE SWITCH Figure 8 Wiring Diagram, 8550 TEG Global Thermoelectric 23658 Rev. 4...
  • Page 20 WARNING: Do not allow the burner to operate with only the Auto Shut-Off valve open for more than 5 minutes. The Burner Run Valve should be opened as soon as the flame is burning. Global Thermoelectric 23658 Rev. 4...

  • Page 21: Figure 9 Fuel System Components, Si And So

    WARNING: Once the burner is started, you must proceed to the Heat Up and Power Adjustment (section 2.5). Failure to do so may overheat the power unit. Global Thermoelectric 23658 Rev. 4...

  • Page 22: Heat Up And Power Adjustment

    Find the current (or mV measured across the shunt) on the side axis and draw a line horizon- tally across. The power is indicated by the power line nearest the intersection of the two lines, interpolate if necessary. Global Thermoelectric 23658 Rev. 4...
  • Page 23 (0.50 psi), no more than 6.8 kPa (1.00 psi). After 10 minutes determine if further adjustment is needed. Once the Power Unit output power has stabilized to within 5 Watts of Set Power, and stayed there for at least 15 minutes, proceed to section 2.5.8, Air Shutter adjustment. Global Thermoelectric 23658 Rev. 4...
  • Page 24 2.5.9 If the TEG is factory new or has just undergone a major overhaul, the Power Unit output power may drift slightly over the first few weeks of operation. It may be necessary to adjust the fuel pressure slightly to obtain Set Power after this time. Global Thermoelectric 2-10 23658 Rev. 4...

  • Page 25: Applying Customer Load

    This information is valuable for future reference. If this site is a multiple TEG installation, it may be desirable to keep the log in a common maintenance book for the site. Global Thermoelectric 2-11 23658 Rev. 4...
  • Page 26 Global Thermoelectric 2-12 23658 Rev. 4...
  • Page 27 8550 Thermoelectric Generator Start-Up Data Sheet Start-UP By: Date: Model #: Serial #: Fuel Type: Temperature: Wind Speed: Corrected Temperature: Ignition Fuel Pressure: Set Power at Corrected Operating Temperature Fuel Pressure Power Levels Orifice Fuel Time Voltage (V) Current (A)
  • Page 28 8550 Thermoelectric Generator Start-Up Data Sheet Start-UP By: Date: Model #: Serial #: Fuel Type: Temperature: Wind Speed: Corrected Temperature: Ignition Fuel Pressure: Set Power at Corrected Operating Temperature Fuel Pressure Power Levels Orifice Fuel Time Voltage (V) Current (A)

  • Page 29: Service And Maintenance

    TEG. Suggested Periodic Maintenance 3.1.1 The 8550 TEG is a solid-state, highly reliable device that requires very little maintenance. However, it requires periodic service checks in order to provide the years of trouble free serv- ice of which it is capable. The maintenance interval depends on the site conditions (fuel puri- ty, weather, etc.) and must be established on site experience.
  • Page 30 56 Volts and R is above 1.40 Ohms the Power Unit is likely faulty. The Power Unit may still be able to operate at reduced output. Consult Global Thermoelectric Inc. to determine the safe operating level for the Power Unit under your conditions.

  • Page 31: Power Check

    Auto Shut-Off valve, Burner Run valve, Burner Start valve and Burner Start restrictor. The fuel orifice is a precision jewelled orifice which will control the fuel flow to the burner depending on the up stream pressure. Global Thermoelectric 23658 Rev. 4...

  • Page 32: Figure 12 Fuel System Components, Si And So

    Check and replace the gasket if needed. Carefully reassemble the regulator ensuring that the needle valve spring is properly placed over the nee- dle valve centering cup in the regulator body. Check for proper operation and leak check all joints for fuel leaks. Global Thermoelectric 23658 Rev. 4...

  • Page 33: Burner System

    Holder Screen, located in the Venturi mounting fitting on the Burner Plate assembly, and the Burner Mantle for corrosion or obstructions. If these parts are obstructed, clean them with a stiff wire brush. If these parts are corroded, the Burner must be repaired or replaced. Global Thermoelectric 23658 Rev. 4...

  • Page 34: Figure 14 Burner System Components

    5 turns (1/4 in. or 6 mm). 3.4.5 Always apply high temperature anti-seize compound to the threads on the Venturi before installing it. It is not necessary to tighten the Venturi more than hand tight. Global Thermoelectric 23658 Rev. 4...

  • Page 35: Cooling System

    Heat Pipe which is operating at a temperature much lower than the rest of the Heat Pipes. 3.5.4 Replacement of Heat Pipes should only be done by a factory trained technician, consult Global Thermoelectric for this type of work. Global Thermoelectric 23658 Rev. 4...

  • Page 36: Spark Ignition (Si)

    A new fully charged battery provides about 16 hours of continuous starting capability without recharging. Twenty minutes of recharging is sufficient for one start cycle, 15 hours of charging are required to fully recharge a full discharged battery. Figure 15 Spark Ignition System Wiring Global Thermoelectric 23658 Rev. 4...

  • Page 37: Figure 16 Spark Ignition Components

    Inspect the Spark Ignitor Electrode for cracks in the ceramic tube. Check the wire which runs through the ceramic tube for continuity. Replace the Spark Ignitor Electrode if it is damaged. Figure 16 Spark Ignition Components Global Thermoelectric 23658 Rev. 4...
  • Page 38 2700 ºF Spark Electrode: Ceramic Tube (alumina) 1926 ºC or 3500 ºF Control Module Life 5 x 10 Sparks Minimum Continuous Operating Time without Charge 16 hours with Full Charged Battery @ 23ºC (73ºF) Global Thermoelectric 3-10 23658 Rev. 4...

  • Page 39: Automatic Shut-Off (So)

    Burner Plate fitting. 3.7.2.3 If the sensor is functioning and the system still does not hold the Shut-Off Valve open with a hot burner, then the valve must be replaced. Note that in order for Global Thermoelectric 3-11 23658 Rev. 4...

  • Page 40: Power Unit Testing

    ) of the Power Unit from which the internal resistance ) can be calculated. In order for this test to be accurate, the TEG must have been oper- ating for the past 12 hours at 24 to 26 Volts. Global Thermoelectric 3-12 23658 Rev. 4...
  • Page 41 3.8.4 The maximum operating limits are 56.5 Volts for open circuit voltage and 1.45 Ohms for inter- nal resistance. If the Power Unit will not produce Set Power and problems with the Burner System, Fuel System, and Cooling System have been ruled out, the fuel pressure may be Global Thermoelectric 3-13 23658 Rev. 4...

  • Page 42: Over Temperature Shutdown System

    The six shutdown (normally open) thermostats are located in the top heat pipe shoes at 60 degree intervals, around the 8550 power unit. Each thermostat will sense an over tempera- ture condition in an area cooled by two heat pipes. When an over temperature condition is present the thermostat will switch to the closed position.

  • Page 43: Figure 18 Over Temperature Shut Down System

    At this time the button on the SO valve may be released and the TEG adjusted and operated as described section 2. If an over temperature condition occurs the thermostat will close, blowing the associated fuse, and causing the SO value to close, shutting down the TEG. Global Thermoelectric 3-15 23658 Rev. 4...

  • Page 44: Trouble Shooting Guide

    Then isolate the customer load from the Power Conditioner. Refer to Table 6 as a guide to trouble shooting the TEG and consult the indicated sections of this manual for further information. Global Thermoelectric 3-16 23658 Rev. 4...
  • Page 45 Follow evaluation procedure in sections 3.1.2 and 3.1.2 y 3.1.3 3.1.3 Test Power unit Check function of Power conditioner Separate Manual Incorrect Fuel pressure 3.1.2 Power Unit Output Power High Check Function of Power Conditioner Separate Manual Global Thermoelectric 3-17 23658 Rev. 4...

  • Page 46: 8550 Teg Parts List

    3.11 8550 TEG Parts List Figure 19 8550 TEG Parts List Item Part No. Description 6300-03162 Limiter, Model 6720 6200-21611 Cabinet Assy 4900-06431 Support, Upright, Heat Pipe 4900-06394 Support Arm, Upper, Heat Pipe 4900-06395 Support Arm, Lower, Heat Pipe 4900-06393...
  • Page 47 3.12 8550 TEG Parts List Figure 20 8550 TEG Parts List Item Part No. Description 4500-05406 Exhaust Stack Assy, 8550 2400-21647 Thermostat, Shutdown 2510-02104 Screw, Cap, Soc-H-Hex, 10-32 x 1", SS 4900-21646 Shoe, Heat Pipe 4900-06462 Block, Heat Pipe 2900-06991...
  • Page 48 3.12 8550 TEG Parts List Figure 20 8550 TEG Parts List Item Part No. Description 6300-20144 Spark Ignitor Module 2400-27019 Battery, 2V, 2.5 AH, Dsize (inside B12) 2400-05238 Shunt, 50 Amp 50 mV, Bach 6709 2200-02110 Terminal Block, 8 Position...

  • Page 49: Figure 21 Fuel System Parts List, 8550 Teg

    3.13 Fuel System Parts Lists Figure 21 Fuel System Parts List, 8550 TEG Item Part No. Description 4200-06434 Orifice, Propane, 0.040 4200-06433 Orifice, Natural Gas, 0.061 4200-05897 Orifice Tube Assy 3084-05554 Union, 1/4 TB, B-400-6, Brass 4200-05286 Fuel Line Kit...
  • Page 50 3.13 Fuel System Parts Lists Figure 21 Fuel Sytstem Parts List, 8550 TEG Item Part No. Description 3090-00176 Valve, Shut-Off 3400-06471 Switch, Pressure, 1.5 PSI 3044-00501 Nipple, Hex, 1/4 NPT x 1 1/2", Brass 4200-02100 Manifold Block 3200-00406 Gauge, Pressure, 0-30 PSI...

  • Page 51: Appendix

    ) (3260 BTU/cu.ft.) Note: Various orifices and fuel settings are available for Natural Gas, LPG (Propane), Methane or Butane. Shall not exceed 65ºC (150ºF) in temperature. - Standard cubic meter of gas at 101.325 KPa at 15ºC. Global Thermoelectric 23658 Rev. 4...
  • Page 52 Global Thermoelectric 23658 Rev. 4...

  • Page 53: 8550 Performance Log

    8550 Performance Log 8550 Performance Log Model # SERIAL # FUEL Remarks Global Thermoelectric 23658 Rev. 4...
  • Page 54 8550 Performance Log Model # SERIAL # FUEL Remarks Global Thermoelectric 23658 Rev. 4...
  • Page 55 Global Thermoelectric 23658 Rev. 4...
  • Page 56 6720 VOLTAGE LIMITER MODEL 8550 THERMOELECTRIC GENERATOR Global Thermoelectric Bay 9, 3700 - 78 Ave, S.E. Calgary, AB, Canada T2C 2L8 ph. 1-403- 236-5556 fax 1-403- 236-5575...
  • Page 58 Figure 2 6720 Voltage Limiter ..........2-2 Figure 3 Wiring Diagram, 8550 TEG with Voltage Limiter ......2-3 Figure 4 Schematic Diagram, 6720 Voltage Limiter.

  • Page 60: General Information

    Limiter: A specific electronic device attached across the generator output that limits the volt- age level. Generator System: The system consisting of the generator including its factory options, the power conditioner and the special customer options. Global Thermoelectric 21168 rev.4...

  • Page 61: Product Application

    TEG output voltage through a series of resistors and transistors that act to hold the voltage at an adjustable level. Figure 1 shows the dimensions of the 6720 Voltage Limiter. Figure 1 6720 Voltage Limiter Physical Description Global Thermoelectric 21168 rev.4...
  • Page 62 Open Circuit: The open circuit voltage cannot rise above the limiter set voltage. Voltage Sensing Relay (VSR): The limiter is equipped with a standard Voltage Sensing Relay. The VSR provides a set of contacts that indicate an alarm condition when the voltage drops below a preset minimum. Global Thermoelectric 21168 rev.4...
  • Page 63 Global Thermoelectric 21168 rev.4...

  • Page 64: Operation

    Remember the TEG delivers power at 20-30 Amps, therefore select wire size and connection method accordingly. Voltage Sensing Relay Adjustment If using the VSR in your system is necessary, proceed with the following adjustment proce- dure. Refer to Figure 2 and Figure 3. Global Thermoelectric 21168 rev.4...
  • Page 65 Turn the VSR adjustment screw (Figure 2) until the contacts just open (they are closed during normal operation). Reset the voltage limiter output voltage to desired operating level. Connect the customer alarm wiring to the VSR terminal strip (Figure 3). Figure 2 6720 Voltage Limiter Global Thermoelectric 21168 rev.4...
  • Page 66 Figure 3 Wiring diagram, 8550 TEG with voltage limiter Global Thermoelectric 21168 rev.4...
  • Page 67 Global Thermoelectric 21168 rev.4...

  • Page 68: Service

    325 couples in series producing a load voltage of 28 Volts. This voltage is the matched load point in the Model 8550 TEG where maximum power is transferred to the load. In multi gen- erator systems several TEGs are placed in series to obtain the required load voltage.
  • Page 69 Figure 4 SchematicDiagram 6720 Voltage Limiter Global Thermoelectric 21168 rev.4...

  • Page 70: Trouble Shooting

    1.0 and 20 Amps. Slowly increase the power supply output voltage until the current begins to flow. Using the Schematic Diagram check for faulty components and replace. Global Thermoelectric 21168 rev.4...

  • Page 71: 6720 Limiter Parts List

    6720 Limiter Parts List Figure 5 6720 Limiter Main Parts Item Part No. Description 4900-20184 Cover Assy, Limiter, 8550 (not shown) 2400-03154 Heat Sink Assy 2410-00116 Resistor, 2 Ohm, 300 Watt, 10% 4900-20737 Control & VSR Board, 24 Volt 4900-04481...

  • Page 72: 6720 Limiter Electronics Parts

    Diode, Zener, 1N5234B, 6.2 V, ½ Watt Diode, Zener, 1N5234B, 6.2 V, ½ Watt Diode, 1N4005/7 1A Diode, 1N1184A Transistor, TO-92, MPSA56 Transistor, TO-92, MPSA56 Transistor, TO-92, MPSA06 Transistor, TO-92, MPSA06 Q21-Q24 Transistor, TO-3, 2N3772 Q25-Q26 Transistor, TIP120 Global Thermoelectric 21168 rev.4...
  • Page 73 Figure 6 Control & VSR Board Figure 7 Limiter Drive Board Global Thermoelectric 21168 rev.4...
  • Page 74 Global Thermoelectric 21168 rev.4...
  • Page 75 CATHODIC PROTECTION INTERFACE SYSTEM For 8550 Thermoelectric Generator Global Thermoelectric Bay 9, 3700 - 78 AVE., S.E. Calgary, Alberta, Canada T2C 2L8 Phone: 1-403-236-5556 Fax: 1-403-236-5575...
  • Page 77 Parts List, CP interface panel, 8550 ........

  • Page 79: General Information

    CP load. The anode and cathode cables enter the cabinet at the bottom and connect directly to the heavy duty terminal block. Refer to figure 1 for locations and descriptions of the major components of the CP interface cabinet. Figure 1 Cathodic Protection Interface Panel Global Thermoelectric Page 1-1 6624 Rev.4...

  • Page 80: Meter

    CP load. This is achieved by moving the tap to the left side of the resistor. To reduce power to the CP load, slide the tap to the right. Figure 2 Schematic Diagram, Series Connection Global Thermoelectric Page 1-2 6624 Rev.4...

  • Page 81: Parallel

    1000 Watt resistor, from the left position to the center position of the heavy duty terminal block. A complete parts listing is given for the Cathodic Protection Interface Systems on the follow- ing pages. Global Thermoelectric Page 1-3 6624 Rev.4...

  • Page 82: Parts List, Cp Interface Panel, 8550

    PARTS LIST, CP INTERFACE PANEL, 8550 Figure 4 CP Panel Assembly Parts Item Part No. Desctiption 4900-06621 Mounting Plate, 8550 CP 2410-06566 Resistor, 1 ohm, PFE5K1R00 4900-06567 Mounting Bracket, Resistor 4900-06594 Cover Assy, Resistor 4900-06608 Slide, Resistor 2108-02107 Wire, #8 wht/blk, TIN-PLT-COP...
  • Page 83 PARTS LIST, CP INTERFACE PANEL, 8550 Figure 4 CP Panel Assembly Parts Item Part No. Desctiption 2514-07323 Screw, Mach, P-H-P, 1/4-20 x 1.5 2714-00611 Nut, Hex, 1/4-20, SS 2814-00473 Washer, Lock, ext, 1/4, SS 2814-00557 Washer, Flat, 1/4, SS 2510-00255...

  • Page 84: Parts List, Cp Box Assembly

    Parts List, CP Box Assembly Figure 5 CP Box Assembly Parts Item Part No. Desctiption 4900-06634 Box, 8550 CP 2200-01815 Terminal Block, Heavy Duty, 3 Pole 2420-05211 Meter, 0-30V, 0-30A 2400-00568 Shunt, Type 766, 30 Amp, 50mV 3600-01931 Label, Push to Read Amps...
  • Page 85 Washer, Lock, Spring, #10 CAD 2508-00254 Screw, Mach, P-H-P, 8-32 X 3/8, SS 2808-00468 Washer, Lock, Int, #8, SS 2420-06226 Meter Face, 0-15V, 0-30amp Label, Terminal Block 2010-00204 Term, Ring, Red, #20 wire, 1/4 Stud Global Thermoelectric Page 1-7 6624 Rev.4...

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