Teg 5220 Manual

- Do not store or use gasoline or other flamma-
ble vapors and liquids in the vicinity of this or

any other appliance.
- WHAT TO DO F YOU SMELL GAS:
Do not try to light any appliance.
Do not touch any electrical switch; do not
use any phone in your building.
mmediately call your gas supplier from a
neighbour's phone. Follow the gas suppli-
er's instructions.
f you cannot reach your gas supplier, call
the fire department.
- nstallation and service must be performed by
a qualified installer, service agency or the gas
supplier
)A$IG: f the information in this manual is
not followed exactly, a fire or explosion may
result causing property damage, personal
injury or loss of life.
)A$IG: mproper installation,
adjustment, alteration, service or
maintenance can cause injury or
property damage. Read the installa-
tion, operating and maintenance
instructions thoroughly before
installing or servicing this equipment.
)A$IG: F8; !>=-88; '<. !75B
- Ne pas entreposer ou utiliser de l'essence,
d'autres liquides ou vapeurs inflammables
proximit de cet appareil ou d'aucun autre
appareil.
- QUE FARE S VOUS SENTEZ LE GAZ:
N'allumez aucun appareil
Ne touchez aucun commutateur lectrique;
n'utilisez pas le tlphone de votre btiment
Appelez immdiatement votre fournisseur
de gaz d'un tlphone dans un btiment
voisin, si possible. Suivez les instructions
du fournisseur de gaz.
Si vous ne pouvez pas atteindre votre four-
nisseur de gaz, appelez le service d'in-
cendie.
- L'installation et le service doivent tre effec-
tus par une personne qualife, une compag-
nie de service ou le fournisseur de gaz.
A(E$&I%%EME&:L'installation
inexacte, l'ajustement, le change-
ment, le service ou l'entretien peu-
vent causer des dommages ou des
dgts matriaux. Lisez les instruc-
tions d'installation, d'opration et
d'entretien compltement avant d'in-
staller ou entretenir cet quipement.
A(E$&I%%EME&: Pour l'usage extrieur seulement
A(E$&I%%EME&: si l'information de ce
manuel n'est pas suivie exactement, un
incendie ou une explosion peut resulter entra-
nant des dgts matriaux, des blessures ou la
perte de vie.
5220
&HE$M!ELEC&$IC
GEE$A&!$
Operating Manual
28142 rev. 5
Global Thermoelectric
#9, 3700 - 78
th
Ave. S.E.
Calgary, Alberta
Canada T2C 2L8
TEL: 1-403-236-5556
FAX: 1-403-236-5575
WEB: www.globalte.com
NOTCE TO NSTALLER: These instructions shall be left with the consumer to
retain them for future reference.
&*+5. 8/ C87=.7=<
1 A+8>= =12< M*7>*5................................................................................................1
1.1 Health and Safety .......................................................................................1
1.1.1 Warnings ..........................................................................................1
1.1.2 Cautions ...........................................................................................1
1.1.3 Trained Operators ............................................................................1
1.2 Technical Terms ..........................................................................................1
2 #>2,4 %=*;= ";8,.->;..........................................................................................3
2.1 nstallation ...................................................................................................3
2.2 Start Up .......................................................................................................3
2.3 Adjustment ..................................................................................................4
2.4 Performance Log.........................................................................................4
3 &.,172,*5 %9.,2/2,*=287< .....................................................................................5
3.1 Overview.....................................................................................................5
3.2 Options........................................................................................................5
3.3 Weights and Measures ...............................................................................7
3.4 gnitor Control System ...............................................................................8
3.5 Data Plate ...................................................................................................8
3.6 Fuel Consumption.......................................................................................9
3.7 Standard Specification for Gaseous Fuel..................................................10
4 ";8,.<< D.<,;29=287 ..........................................................................................11
4.1 Model 5220 Thermoelectric Generator .....................................................11
4.1.1 Fuel System....................................................................................12
4.1.2 Spark gnition Control System........................................................13
4.1.2.1 Resetting The Power Supply ............................................13
4.1.3 Burner ............................................................................................13
4.1.4 Power Unit ......................................................................................15
4.1.5 Cooling Fins and Fin Duct ..............................................................16
4.1.6 Cabinet............................................................................................16
4.1.7 Optional TEG Mounting Stands ......................................................16
4.2 Optional 220 Watt Limiter ........................................................................17
4.3 Optional 220 Watt Limiter Converter.........................................................19
4.4 Optional Cathodic Protection nterface System........................................20
5 I7<=*55*=287 .......................................................................................................21
5.1 Precautions ...............................................................................................21
5.2 Tools Required ..........................................................................................21
5.3 Unpacking .................................................................................................21
5.4 Assembling................................................................................................22
5.5 Mounting ...................................................................................................23
5.6 Supplying Fuel ..........................................................................................24
5.6.1 Connecting the Fuel Supply............................................................24
5.6.2 Fuel Considerations........................................................................24
5.7 Connecting Customer Load ......................................................................26
5.8 nstallation of Optional L/C........................................................................27
5.8.1 Attaching the L/C to TEG................................................................27
5.8.2 TEG Wiring nterconnection............................................................27
5.9 nstallation of Optional CP nterface System............................................28
5.9.1 Attaching the CP nterface System to TEG ....................................28
5.9.2 TEG Wiring nterconnection............................................................30
5.9.3 Connection of CP Load...................................................................30
6 %=*;= '9 *7- %1>=-8@7 .....................................................................................31
6.1 Before Starting..............................................................................................31
6.2 TEG Start-Up ................................................................................................31
6.3 Shutdown......................................................................................................31
7 "8@.; !>=9>= E?*5>*=287..................................................................................33
7.1 Required V
=/>
or Setup Power at Site .......................................................33
7.1.1 Working-out Required V
=/>
or Setup Power ....................................33
7.1.2 Determining V
=/>
and Rated Power Graphically..............................35
7.2 V
=/>
and Rated Power................................................................................35
7.2.1 V
=/>
Shortly after gnition .................................................................36
7.2.2 Examining V
=/>
When Going From Run To Set Up Position ...........37
8 A-><=6.7= .......................................................................................................39
8.1 Power Output Adjustment .........................................................................40
8.1.1 Adjustment for Elevation.................................................................40
8.1.2 Air-shutter Adjustment.....................................................................41
8.1.2.1 Measuring CO Emissions Levels......................................42
8.1.3 Fuel Pressure Adjustment...............................................................43
8.2 Adjustment of Optional L/C.......................................................................44
8.2.1 Output Voltage Adjustment .............................................................44
8.2.2 Voltage Sensing Relay (VSR) Adjustment ......................................44
8.3 Adjustment of Option CP nterface System..............................................45
8.3.1 CP Power Output Adjustment .........................................................45
8.3.1.1 Series Wiring.....................................................................46
8.3.1.2 Parallel Wiring...................................................................46
9 M*27=.7*7,. .......................................................................................................47
9.1 Recommended Periodic Maintenance......................................................47
9.1.1 Tools and Parts Recommended for Routine Servicing...................47
9.1.2 Evaluate V
=/>
...................................................................................48
9.1.3 Routine Service...............................................................................49
9.2 Fuel System Maintenance ........................................................................49
9.2.1 Draining the Sediment Bowl ...........................................................49
9.2.2 Fuel Filter Replacement..................................................................50
9.2.3 Fuel Orifice nspection....................................................................51
9.4.7 Check Solenoid Valve.....................................................................56
10 &;8>+5.<188=270.................................................................................................61
10.1 Burner Maintenance..................................................................................55
10.1.1 Air Filter Cleaning .........................................................................55
10.1.2 nspection of Burner Components ................................................55
10.2 gnition Control System Maintenance .......................................................57
10.2.1 Check the Spark Electrode ...........................................................57
10.2.2 Check the Pressure Switch...........................................................58
10.2.3 Check the Battery Voltage ............................................................58
10.2.4 Check the Power Supply ..............................................................58
10.2.5 Check if the Battery will Hold Charge...........................................59
10.2.6 Check the Operation of the gnition Controller ............................59
10.2.7 Check Solenoid Valve...................................................................59
10.3 L/C Examination........................................................................................60
10.3.1 Check L/C Switch Settings ...........................................................60
10.3.2 Check nput Voltage to the L/C.....................................................60
10.3.3 Check Output from the L/C...........................................................60
10.4 Power Unit Examination .............................................................................61
10.4.1 Check for nternal Short................................................................61
10.4.2 Check nternal Resistance............................................................61
11 "*;= L2<= .......................................................................................................63
11.1 Model 5220 TEG.........................................................................................65
11.2 Model 5220 Burner .....................................................................................68
11.3 Model 5220 Fuel System............................................................................69
12 &EG ".;/8;6*7,. L80.......................................................................................71
LI%& !F FIG'$E%
Figure 1 Overall Dimensions of the 5220 TEG . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Figure 2 5220 TEG General Assembly, shown with L/C Option . . . . . . . . . . . . . . .11
Figure 3 5220 Fuel System General Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Figure 4 Burner General Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Figure 5 Cut-away of a Model 5220 Thermopile . . . . . . . . . . . . . . . . . . . . . . . . . .15
Figure 6 Electrical Output Characteristics (no Power Conditioner) . . . . . . . . . . . .16
Figure 7 220 Watt Limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Figure 8 220 Watt L/C General Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Figure 9 CP nterface System General Assembly . . . . . . . . . . . . . . . . . . . . . . . . .20
Figure 10 Assembling the 5220 TEG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Figure 11 Model 5220 Mounting Dimensions, shown with L/C Option . . . . . . . . . .23
Figure 12 Applying Thread - Sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Figure 13 Setting-up the 5220 TEG, shown with L/C Option . . . . . . . . . . . . . . . . . .25
Figure 14 Wiring Diagram 5220 TEG, shown with 12 V Limiter Option . . . . . . . . . .26
Figure 15 Wiring Diagram 5220 TEG, Shown W/ L/C Option . . . . . . . . . . . . . . . . .27
Figure 16 CP nstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Figure 17 CP Wiring for Model 5220-12 V DC, with Limiter Option . . . . . . . . . . . . .29
Figure 18 CP Wiring for Model 5220-24 V DC, with L/C Option . . . . . . . . . . . . . . .29
Figure 19 V
=/>
and Rated Power versus Ambient Temperature . . . . . . . . . . . . . . . .35
Figure 20 V
=/>
versus Time After gnition, Typical Response . . . . . . . . . . . . . . . . . .36
Figure 21 Change in Fuel Gauge Pressure vs Elevation Above Mean Sea Level,
Typical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Figure 22 Air Shutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Figure 23 Change in V
=/>
versus Air-Shutter Adjustment, Typical . . . . . . . . . . . . . . .42
Figure 24 Change in V
=/>
versus Fuel Pressure Adjustment, Typical . . . . . . . . . . . .43
Figure 25 CP nterface System, Series Wiring Diagram . . . . . . . . . . . . . . . . . . . . .46
Figure 26 CP nterface System, Parallel Wiring Diagram . . . . . . . . . . . . . . . . . . . .46
Figure 27 Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Figure 28 S Module Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Figure 29 gnition Control Module Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Figure 30 Momentary Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Figure 31 Model 5220 TEG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Figure 32 Model 5220 Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
Figure 33 Model 5220 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Global Thermoelectric 1
28142 Rev. 5
1 AB!'& &HI% MA'AL
This manual provides instructions for the operation and maintenance of the model 5220
Thermoelectric generator.
1.1 H.*5=1 *7- %*/.=B
Correct operation and maintenance according to this manual is critical for proper equip-
ment function and safety. Keep the following in mind when using these instructions.
1.1.1 )*;7270<
Throughout this manual you will notice paragraphs preceded by the text Warning. t is
imperative that the advice in these paragraphs be adhered to, as failure to do so may
result in personal injury or death and possible damage to the equipment.
1.1.2 C*>=287<
Throughout this manual you will notice paragraphs preceded by the text Caution. t is
imperative that the advice in these paragraphs be adhered to, as failure to do so may
result in damage to the equipment.
1.1.3 &;*27.- !9.;*=8;<
Personnel performing installation, operation, and maintenance work should be properly
trained in such functions.
1.2 &.,172,*5 &.;6<
An operator should be familiar with technical terminology. Terms of particular signifi-
cance, defined for the model 5220, are as follows:
T*'4/1'.'%64+% G'0'4#614 (TEG): A device that produces electrical power through the
direct conversion of heat energy to electrical energy.
P19'4 0+6 (P): The hermetically sealed portion of the TEG that contains the thermo-
electric materials and cooling fins.
R#6'& P19'4: Model 5220 TEG power unit produces 220 W when operating in an ambi-
ent temperature of 20C (68F). With the fuel flow held constant, TEGs operating in
ambient temperatures higher than 24C (75F) will see power output efficiency reduce,
0.8 W per C (0.44 W per F) of temperature change up to a maximum ambient temper-
ature of 65.5C (150F). Conversely for temperatures lower than 20C (68F) power out-
put efficiency will increase by 0.8 W per C (0.44 W per F) of temperature change.
S'6-72 P19'4: Power from the power unit for a specific ambient temperature. t is
derived from voltage across a precision load, also known as V
=/>
.
28142 Rev. 5
S'6-72 !1.6#)': V
=/>
Voltage from the power unit for a specific ambient temperature,
which is proportional to set-up power. Fuel flow to the burner is adjusted so that proper
voltage exists, necessary temperature difference within the power unit maintained, to
deliver required power.
O2'0 C+4%7+6 !1.6#)': Voltage at the terminals of the power unit when no current is
flowing, i.e. open circuit, which is related to the temperature across the thermoelectric
materials inside the power unit.
When a power unit lead is suddenly disconnected, breaking the circuit to the load, the
voltage measured across the power unit leaps up to a new value. This is known as the
momentary open circuit voltage (V
9-
). The voltage will continue to climb from that level.
n the case of the model 5220 do not allow V
oc
to exceed 27.0 volts, otherwise, the TEG
can be damaged.
M'#574'& !
5'6
: V
=/>
measured across the power unit using a voltmeter.
R'37+4'& !
5'6
: V
=/>
needed to achieve rated power for the present ambient temperature.
CP (C#6*1&+% P416'%6+10): Thermoelectric generators are used in impressed current
systems for Cathodic corrosion protection of metallic structures such as pipelines.
CP I06'4(#%' S;56'/: An assembly of electrical components system that acts as an
interface between the TEG and the CP load, which also provides for adjustment and
monitoring of power to the CP load.
L+/+6'4/C108'46'4 (L/C): A specific electronic device attached between the generator
and the load that converts one level of DC voltage to another, and limits the power unit
voltage.
M#07#. S*761(( !#.8': A manually operated valve in the gas line for the purpose of
completely turning on or shutting off the gas supply to the TEG.
S1.'01+& !#.8' (S!): A electrically actuated valve that controls the gas supply to the
burner. This Valve is operated by the gnition Control Module.
28142 Rev. 5
2 #'ICK %&A$& "$!CED'$E
This section gives the key steps for setting up the TEG. t is for the operator who is
already familiar with operating the TEG, having successfully completed Global
Thermoelectric's TEG training course, and being a qualified service person with reason-
able knowledge and experience with industrial fuel and electrical equipment.
2.1 I7<=*55*=287
Follow these steps to install the TEG:
a) Unpack the TEG from its shipping crate, keep the crate until the TEG is opera-
tional. Locate and identify the following items that were shipped with the 5220
TEG:
1 Fin Duct
1 Cover Plate
1 Thread Sealing Compound
17 Screws, #8-32 1/4 in. long, one spare
17 Washers, #8 External Lock , one spare
9>/: I8=:/-> >2/ %EG 09< .+7+1/ >2+> 7+C 2+@/ 9--?<</. .?<381 =23::381.
"6/+=/ </:9<> +8C .+7+1/ += =998 += :9==3,6/ += 3> 7+C 7+5/ >2/ 1/8/<-
+>9< 389:/<+,6/. C2/-5 A3>2 >2/ 0+->9<C ,/09</ =>+<>381 + .+7+1/. %EG.
b) Assemble the TEG as shown in Figure 10 and mount it on a firm and stable base,
sufficiently high above ground level to prevent the TEG from being inundated with
water. See Section 5, nstallation, for details.
c) Connect the fuel supply to the manual shutoff valve, 1/4" FNPT, using the thread
sealant provided. See Section 5.6, Supplying Fuel, for details
d) Connect the customer load:
) in the case of an optional L/C being fitted connect the load to terminals 5
(-) and 6 (+);
) in the case of no L/C option connect the load to terminals 4 (-) and 5 (+);
) for CP applications connect the cathode and anode wires to the external
CP interface box.
2.2 %=*;= '9
Follow these steps to start the TEG:
a) Open the manual shutoff valve.
9>/: !8-/ >2/ %EG 3= =>+<>/. </--69=381 >2/ 7+8?+6 =2?>900 @+6@/ A366 =2?> 3> 900.
28142 Rev. 5
b) The Spark gnition (S) system should begin clicking after one second and the
sound of combustion heard within 7 seconds. f the burner does not ignite wait 25
seconds for a second or third ignition trial. After a third trial the ignition control
system will go into stand by mode - see the gnition control section 4.1.2.
c) Leak check the complete fuel supply system from the fuel supply line to the burn-
er inlet using a commercial leak detector fluid such as Snoop.
"ARNING: "*'0 6*' TEG +5 12'4#6+0), 574(#%' 6'/2'4#674'5 +0 6*' 8+%+0-
+6; 1( 6*' 6*'4/12+.', $740'4, ':*#756 56#%- #0& #4170& 6*'
%11.+0) (+0 &7%6 /#; $' +0 ':%'55 1( 100= C. A81+& %106#%6 1(
5-+0 #0& %.16*+0) 9+6* 6*'5' #4'#5 9*'0 12'4#6+0) +0 #0&
#4170& 6*' TEG.
2.3 A-3><=6.7=
Follow these steps to adjust the TEG:
a) Move the jumper clip on terminal block TB-1 to the SETUP position between ter-
minals 2 and 3, see Figure 14 or 15.
b) Measure the V
=/>
voltage between terminals 2 (+) and 4 (-).
c) Check the measured Vset value rises to that required, as per Power Output
Evaluation section. Measured V
=/>
will level off after 1-hour from ignition. f the
measured value is not in its normal operating range then adjust the power output
as per the Adjustment section.
C#76+10: D1 016 #..19 /'#574'& !
5'6
61 ':%''& 4'37+4'& !
5'6
, &'6'4/+0'&
+0 6*' P19'4 O76276 E8#.7#6+10 5'%6+10, 16*'49+5' 18'4*'#6+0)
/#; %#75' +44'2#4#$.' &#/#)' 61 6*' 219'4 70+6.
9>/: D/>+36= 09< +.4?=>381 >2/ 9:>398+6 L/C +8. C" 38>/<0+-/ =C=>/7=, 30 +::63-+,6/, +</
69-+>/. 38 >2/ A.4?=>7/8> =/->398.
2.4 ".;/8;6*7,. L80
Your TEG is now operating successfully, making available continuous electrical power to
the load. t is recommended that a record be kept of the TEG's performance and main-
tenance 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 manu-
al.
9>/: $/<@3-381 </;?3</7/8>= +</ 13@/8 38 >2/ M+38>/8+8-/ =/->398.
28142 Rev. 5
3 &ECHICAL %"ECIFICA&I!%
This section gives the technical specifications for the Global Model 5220 Thermoelectric
generator.
3.1 !?.;?2.@
Global's Model 5220 Thermoelectric Generator (TEG) converts heat directly into elec-
tricity with no moving parts. t is a reliable, low maintenance source of DC electrical
power for any application where regular utilities are unavailable or unreliable.
The model 5220 Thermoelectric Generator provides 220 Watts of electrical power from
the power unit at an ambient temperature of 20C. This power is generated at a nomi-
nal 15 Volts, which can then be converted to other voltages using an optional voltage
converter. The converter is 80% efficient, which provides 175 Watts of net electrical
power with a 24 Volt converter.
f the generator is to be operated at load conditions that force the output voltage to vary
significantly from 15 Volts, then less than the rated power will be available to the load.
Figure 6 identifies the electrical parameters of the 5220 as a function of the load resist-
ance.
The 5220 generator uses Propane (C
3
H
8
), or Natural Gas (CH
4
) as a fuel and with an
ignition control module (S) will automatically ignite whenever gas pressure is present.
The output voltage from the generator is adjustable from 12 to 18 Volts or from 24 to 30
Volts with the optional DC/DC converter. The 5220 includes a voltage sensing relay
(VSR) that can be used to trigger alarms or other processes when an abnormally low
voltage is detected.
3.2 !9=287<
Mounting Stand: The 5220 can be conveniently mounted on any platform with four holes
spaced as shown in Figure 11. t 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. A
mounting stand is available from Global Thermoelectric.
Cathodic Protection nterface (CP): The Cathode Protection nterface option provides a
termination point for cathode and anode cables up to 9 mm (00 AWG) in size, a meter
to monitor the voltage and current of the CP circuit and an adjustable resistor to control
the output power.
Current Split (CS): The Current Splitting variation of the CP nterface is also available.
The CS version allows two CP circuits to be controlled individually from one CP nterface
unit.
28142 Rev. 5
P19'4 176276
Power Ratings
20 C, 750 m above sea level
220 Watts @ 12 Volts
176 Watts @ 24 Volts
E.'%64+%#.
Adjustment
12 V 1218 Volts
24 V 2430 Volts
Reverse Current Protection Yes
Output
Terminal block which accepts up to 8 AWG
wire. Opening for 3/4 conduit in the base of
the cabinet.
F7'.
Natural Gas
19.7 m
3
/day (698 ft
3
/day) of Std. 1000
BTU/SCF (37.7 MJ/Sm
3
) gas
Propane 27.8 L/day (7.405 gal/day)
Maximum Supply Pressure 413 kPa (60 psig)
Minimum Supply Pressure 241 kPa (35 psig)
Fuel Connection 1/4 FNPT connection
E08+410/'06#.
Ambient Operating Temperature
Continuously Running TEG
Max. 55 C (130 F)
Min. -55 C (-67 F)
Operating Conditions Unsheltered Operation
M#6'4+#.5 1( C105647%6+10
Cabinet 304 Stainless Steel
Cooling Type Natural Convection
Thermopile
Hermetically Sealed Lead Tin-Telluride
(PbSnTe)
Burner Meeker type, nconel 600
Fuel System Brass, Aluminum & Stainless Steel
9>/: $:/-303-+>398= =29A8 +</ 09< =>+8.+<. -98031?<+>398=. G69,+6 %2/<79/6/-><3-H=
A::63-+>398= E8138//<381 D/:+<>7/8> 3= +@+36+,6/ >9 ./=318 38=>+66+>398= 7//>381
.300/</8> =:/-303-+>398= 38-6?.381 -?=>97 @96>+1/=. 0?/6 =?::6C =C=>/7= +8. 898-
=>+8.+<. 9:/<+>381 >/7:/<+>?</=.
28142 Rev. 5
3.3 ).201=< *7- M.*<>;.<
The following table gives the overall dimensions and weights of the TEG.
Depth 794 mm (31.24 in.)
Width 479 mm (18.85 in.)
Height 1275 mm (50.19 in.)
Net Weight 97 kg (214 lb)
Shipping Weight 140 kg (308 lb)
Mounting Holes 267 mm A3./ 457 mm .//: (10.50 in. 18.00 in.)
Mounting Hole Diameter 8 mm (0.312 in.)
F20>;. 1 Overall Dimensions of the 5220 TEG
28142 Rev. 5
3.4 I072=287 C87=;85 %B<=.6
The following table gives the technical specifications for the gnition Control System.
Electrical S
Power Supply
nput Voltage
Minimum 5.0 V DC
Maximum 35.0 V DC
Power nput 4.16 Watts
Output Voltage 13.8 VDC
S
Spark Rate 10/second
Trial For gnition 7 seconds
Number of tries for gnition 3 trials until lockout
nter-Purge Time 25 seconds
Spark Gap
Nominal 4.8 mm (0.19 in.)
Minimum 3.3 mm (0.13 in.)
Maximum 6.3 mm (0.25 in.)
Continuous Operating Time Without Charge
120 minutes with full charged batteries @
25C (75F)
3.5 D*=* "5*=.
The data plate is on the inside of the cabinet door and includes vital information about
the generator.
M1&'. N7/$'4: The model number on the Data Plate is interpreted as follows:
C" = Cathodic Protection nterface
F>.5 &B9.:
L = Propane
N = Natural Gas
!>=9>= (85=*0.:
12 or 24 Volts
%9*;4 I072=287 (%I):
( ) 5220 ( ) - ( ) - %I - C
28142 Rev. 5
F7'. T;2': an "X will be marked in the appropriate box to show whether the genera-
tor is set to burn natural gas (CH
4
) or propane (C
3
H
8
). Suitable orifices are available if
changing the fuel type is necessary.
F7'. P4'5574', P19'4, !1.6#)': The fuel pressure, gross power output and voltage
across the precision load have been included for reference only. These are the condi-
tions achieved at the Global Thermoelectric factory before shipping. Note that the fuel
pressure is recorded in kPa and that the pressure gauge must be adjusted for the alti-
tude as described in Section 8.1.1.
3.6 F>.5 C87<>69=287
The 5220 is certified to operate on commercial propane, or commercial natural gas.
The Fuel Consumption of the 5220 at rated power is listed in the table below for various
Fuels.
F>.5 C87<>69=287
*= $*=.- "8@.;
";89*7. *=>;*5 G*<
lb/hr* 1.30 -
gal/hr* 0.31 -
kg/hr* 0.60 -
L/hr* 1.16 -
ft
3
/hr** 11.10 29
m
3
hr** 0.31 0.82
* At 15C (60F)
** At atmospheric pressure and 15C (60F), assuming an energy content of 37.3 MJ/m
3
or 1000 BTU/ft
3
.
28142 Rev. 5
3.7 %=*7-*;- %9.,2/2,*=287 /8; G*<.8>< F>.5
9>/: F?/6 -98=3./</. 3= 09< =>+8.+<. -98031?<+>398=.
G+=/9?= 0?/6 =?::63/. >9 >2/ %EG =2+66 2+@/:
a. No sand, dust, gums, crude oil, impurities or other objectionable substances in
quantities which are likely to clog fuel filters or regulators.
b. A hydrocarbon dew point of less than 0C (32F) at the supply pressure.
c. Less than 115 mg/Sm
3
* (approx. 169 ppm) of H
2
S.
d. Less than 60 mg/Sm
3
* (approx. 88 ppm) of Mercaptan Sulphur.
e. Less than 200 mg/Sm
3
* (approx. 294 ppm) of total Sulphur.
f. Less than 2% by volume of CO
2
.
g. Less than 120 mg/Sm
3
(5 g/100 cu.ft.) of water vapour.
h. Less than 1% by volume of free oxygen.
9>/: F?/6 9<303-/= +8. =/>>381= +</ +@+36+,6/ 09< 8+>?<+6 1+= +8. :<9:+8/.
i. Fuel temperature of less than 65C (150 F).
*Sm
3
- Standard cubic meter of gas at 101.325 kPa at 15C.
28142 Rev. 5
4 "$!CE%% DE%C$I"&I!
This section describes the function of the equipment, the process of generating power
and available options.
4.1 M8-.5 5220 &1.;68.5.,=;2, G.7.;*=8;
The TEG generates electrical power from heat energy. The overall process is:
a) Provide fuel, mix it with air and ignite making heat available
b) Warm the hot-end of a thermoelectric power unit using the available heat of com-
bustion
c) Cool the cold-end of the thermoelectric power unit using cooling fins
F20>;. 2 5220 TEG General Assembly, shown with L/C Option
28142 Rev. 5
d) Generate electrical power from the temperature difference created across ther-
moelectric materials housed within the power unit
e) Make the electrical power available to the load
The main parts of the model 5220 TEG, with optional Limiter/Converter (L/C) attached,
are shown in Figure 2.
4.1.1 F>.5 %B<=.6
Components making
up the fuel system
control the input of
fuel to the burner. The
primary control is a
pressure regulator
that modulates fuel
manifold pressure to
a metering orifice.
The pressure regula-
tor includes a sedi-
ment bowl with a
manual drain cock
and fuel filter to
remove fuel impuri-
ties. The fuel filter has
a resin impregnated
cellulose element
which prevents solid particles from damaging the regulator and downstream parts.
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 S module . The fuel
flows through the manifold to the fuel line which connects to a orifice mounted on the
front of the burner. The orifice contains a jewel with a precisely sized hole to meter the
fuel flow into the burner. A solenoid valve (SV) is located beneath the cabinet and
plumbed between the manifold and fuel line.
The solenoid valve is controlled by the gnitionControl System. The gnitionControl
System opens the solenoid valve when the fuel pressure switch is Closed (fuel pressure
is present), and closes the solenoid valve when fuel pressure switch is open (no fuel
pressure) or the gnition Control System does not detect combustion. The main parts of
fuel system are shown in Figure 3.
F20>;. 3 5220 Fuel System General Assembly
28142 Rev. 5
4.1.2 %9*;4 I072=287 C87=;85 %B<=.6
The gnition Control System consists of the following parts:
Spark electrode
Pressure switch
gnition control module (S)
Solenoid valve
S Power Supply
Battery pack
When the manual ball valve is opened, fuel pressure causes the pressure switch (locat-
ed in the fuel system) to close. This, combined with the absence of flame sensed at the
spark electrode, signals the ignition control module (S) to generate sparks from the
electrode to the combustion chamber plate, as well as open the solenoid valve allowing
gas to flow into the burner chamber, causing ignition to occur. Once combustion is
detected, the S will stop sparking and the S will continue to monitor the presence of
flame at the electrode. f the S did not detect combustion for a period of 7 seconds, it
will stop sparking and close the solenoid valve, wait for a 25 second purge period and
then make another attempt at ignition. The S will attempt 3 ignition trials and if flame
detection cannot be maintained, the S will go into standby mode and the power supply
board will go into sleep mode after 60 seconds. The power supply will have to be reset
for another attempt at ignition, see Section 4.1.2.1, Resetting the Power Supply.
4.1.2.1 $.<.==270 =1. "8@.; %>995B
To reset the power supply, the closed signal from the pressure must be reset. The sim-
plest method is to pull one of the orange wire spade connectors off of the pressure sen-
sor, wait 10 seconds and replace. This is necessary because the fuel pressure switch
is closed and the pressure cannot be relieved easily. The power supply will energize the
S and the S will begin another three start trials. See Figure 28 and 29.
9>/: %2/ -97,?=>398 -98><96 =C=>/7 -98>+38= 3 D-=3D/. 2 @96>, 2.5 +7:-29?<, </-
-2+<1/+,6/ ,+>>/<3/= +8. + -98=>+8> :9>/8>3+6 ,+>>/<C -2+<1/<. A 8/A 0?66C
-2+<1/. ,+>>/<C :<9@3./= +::<9B37+>/6C 240 738?>/= 90 9:/<+>381 >37/ +> 25GC.
%2/ :9A/< =?::6C =A3>-2/= 0<97 ,+>>/<C @96>+1/ >9 1/8/<+>9< :9A/< ?83> @96>+1/
38 6/== >2+8 15 738?>/= +0>/< =>+<>-?:. C97:6/>/6C .3=-2+<1/. ,+>>/<3/= A366 >+5/
+::<9B37+>/6C 14 .+C= %EG 9:/<+>398 >9 </1+38 100% -2+<1/.
4.1.3 B>;7.;
The burner receives gas from the fuel system, mixes it with air and transports the mix-
ture to the combustion zone. Air passes through an air-shutter assembly allowing for
adjustment of the air/fuel mixture. A downstream venturi provides the necessary suction
to draw in the air. This mixture leaves the venturi and passes through a burner screen
that anchors the flame. The design of the combustion chamber produces uniform heat-
ing of the power unit hot-end.
The main parts of the burner are shown in Figure 4.
28142 Rev. 5
F20>;. 4 Burner General Assembly
28142 Rev. 5
4.1.4 "8@.; '72=
The power unit generates electric
power from the direct conversion
of heat energy into electrical
energy. t operates on similar
principles as thermocouples that
are used for applications such as
temperature measurement.
However, it utilizes high perform-
ance semi-conducting thermo-
electric materials housed inside a
hermetically sealed casing.
9>/: %2/<79-9?:6/= -98=3=> 90
>A9 6/81>2= 90 .3==3736+<
7+>/<3+6= 4938/. >91/>2/<
+> 98/ /8.. H/+>381 >2+>
4?8->398 >9 + 2312/< >/7-
:/<+>?</ >2+8 >2/ 9:/8
/8.= </=?6>= 38 + @96>+1/
+-<9== >2/ 9:/8 /8.=.
C?<</8> A366 069A 30 >2/
9:/8 /8.= +</ -988/->/. >9 +8 /6/-><3-+6 69+. +8. :9A/< A366 ,/ -98>38?9?=6C
./63@/</. += 6981 += >2/ >/7:/<+>?</ .300/</8-/ 3= 7+38>+38/.. $38-/ >2/ @96>+1/
3= </6+>3@/6C =7+66 + %EG ?=/= 7+8C >2/<79-9?:6/= 38 =/<3/= >9 38-</+=/ >2/ @96>-
+1/ 9?>:?> >9 + ?=+,6/ 6/@/6, 09<7381 + >2/<79:36/.
Figure 5 illustrates how this is done in a model 5220 TEG. A thermocouple is formed by
P type and N type thermoelectric elements joined together at one end by a hot-junction
electrode. Adjacent elements are joined at the other end by cold-junction electrodes.
One hundred and eighty one thermocouples, each producing 75 mV are connected in
series to total 14 V. This is the matched load voltage.
Temperature difference maintained across the thermocouple junction effects voltage,
and power output. A burner maintains the hot side of the thermocouples at a tempera-
ture of around 538C (1000F). Cooling fins, which transfer the heat to the surrounding
air, maintain the cold side of the thermocouples at a lower temperature of around 163C
(325F). Adjusting the amount of fuel supplied to the burner varies the temperature dif-
ference and controls the power output.
Electrical output characteristics are shown in Figure 6. Power peaks in a broad load
resistance range of 0.8 - 1.5 W. Rated power of 220 W is obtained when the power unit
load resistance is within this range.
F20>;. 5 Cut-away of a Model 5220 Thermopile
28142 Rev. 5
F20>;. 6 Electrical Output Characteristics (no Power Conditioner)
4.1.5 C885270 F27< *7- F27 D>,=
Cooling of the thermopile is done by the free movement of ambient air through the cool-
ing fins. A fin duct acts as a chimney, causing ambient air to rise through the cooling
fins, thus helping transfer heat away from the thermopile.
"#40+0): K''2 %11.+0) (+05 %.'#0 #0& &7%6 914- +0.'65 #0& 176.'65 %.'#4 1(
1$5647%6+105. R'564+%6+0) 6*' (4'' (.19 1( %11.+0) #+4 /#; %#75' &#/-
#)' 61 6*' 219'4 70+6.
4.1.6 C*+27.=
The power unit, burner and fuel system are enclosed in a stainless steel cabinet.
4.1.7 !9=287*5 &EG M8>7=270 %=*7-< ("85. 8; B.7,1 &B9.)
The Pole Stand consists of a 76 in. long piece of 3 in. diameter pipe with an "H" shaped
bracket welded to one end which the TEG can be firmly attached to using 1/4 in. fasten-
ers (not included). The Bench Stand consists of 3 in. by 3 in. and 2 in. by 2 in. aluminum
angle sections that are assembled together to provide a sturdy structure to support the
TEG.
28142 Rev. 5
4.2 !9=287*5 220 )*== L262=.;
The minimum requirement for the 5220 is a limiter operating at a nominal voltage of 14 V.
This limiter is a shunt type voltage limiter that regulates the output voltage of the genera-
tor. The main components of the Limiter are shown in Figure 7, and explained below:
P416'%6+8' (!1.6#)') L+/+6'4: A voltage limiting circuit is incorporated into the 220 W
Limiter, which limits input voltage helping achieve optimal performance from the TEG. t is
factory set to activat at 14.1 V for the model 5220 TEG. Unless the generator is equipped
with an optional CP System. n this case, the voltage is factory set at 17.5 V.
C744'06 L+/+6'4: Over load protection triggers when the load draws excess current. The
result is a proportional drop in output voltage, fold-back current limiting.
Short circuit protection is also designed into the 220 W Limiter. A diode in series with the
positive output prevents current from flowing back through the converter when the gener-
ator is shut off.
C#76+10: I( ':6'0&'& 5*146 %+4%7+6 &74#6+105 #4' #06+%+2#6'&, #0 +0-.+0' (75'
5*17.& $' 2.#%'& 10 6*' 176276 1( 6*' .+/+6'4 %108'46'4.
F20>;. 7 220 Watt Limiter
28142 Rev. 5
B.1%-+0) D+1&': Reverse current protection is standard on the 220 W Limiter. A diode
in series with the positive output prevents current from flowing back through the convert-
er when the generator is shut off.
!1.6#)' S'05+0) R'.#;: Voltage Sensing Relay (VSR) provides a set of contacts to
indicate an alarm condition when the output voltage drops below a preset minimum. Low
voltages, due to overloads, lack of fuel or a faulty generator, are detected by a voltage
sensing circuit incorporated into the voltage limiter. When a low voltage condition is
detected, the Voltage Sensing Relay (VSR) with connections NC(normally closed),
NO(normally open) and COM (common) can be used to trigger an alarm or other
processes. When the generator is above the trip voltage the connection between NO
and COM is closed and the connection between NC and COM is open. f the generator
is below the trip voltage then the connection between NO and COM is open and the con-
nections between NC and COM is closed. The trip voltage is adjusted by the pot labeled
VSR adjust on the VSR board as shown if Figure 7.
!1.6 #0& A/2 M'6'45: The volt and amp meters provide indication of voltage and cur-
rent respectively, output by the L/C.
P19'4 R'5+5614: When no load, or a very small load, is connected the TEG has more
power available than needed by the load. This excess power is directed into a power
resistor by the voltage limiter.
F20>;. 8 220 Watt L/C General Assembly
28142 Rev. 5
4.3 !9=287*5 220 )*== L262=.; C87?.;=.;
An optional 220 W Limiter/Converter (L/C) is available for use with the model 5220 TEG.
t is intended for use with a model 5220 applications requiring 24 V DC nominal output.
t consists of two separate circuits operating together. The first is a shunt type voltage
limiter that regulates the output of the generator. The second circuit is a DC-DC convert-
er that switches the input voltage to a different output voltage. t includes over load, short
circuit and reverse current protection and a set of low voltage alarm contacts.
The main parts of the 220 W L/C are shown in Figure 8.
P416'%6+8' (!1.6#)') L+/+6'4: A voltage limiting circuit is incorporated into the 220 W
L/C, which limits input voltage helping achieve optimal performance from the TEG. t is
factory set at 16.0 V for the model 5220 TEG.
!1.6#)' C108'46'4: The voltage converter switches the input voltage to nominal 24 V
setting.
C744'06 L+/+6'4: Over load protection triggers when the load draws excess current.
The result is a proportional drop in output voltage, fold-back current limiting.
Short circuit protection is also designed into the 220 W L/C. A 15-second short circuit will
not damage the generator or the L/C.
C#76+10: I( ':6'0&'& 5*146 %+4%7+6 &74#6+105 #4' #06+%+2#6'&, #0 +0-.+0' (75'
5*17.& $' 2.#%'& 10 6*' 176276 1( 6*' .+/+6'4 %108'46'4. 5' # 15 A
5.19 $.19 (14 6*' /1&'. 5220-24 TEG.
B.1%-+0) D+1&': Reverse current protection is standard on the 220 W L/C. A diode in
series with the positive output prevents current from flowing back through the converter
when the generator is shut off.
!1.6#)' S'05+0) R'.#;: Voltage Sensing Relay (VSR) provides a set of contacts to
indicate an alarm condition when the output voltage drops below a preset minimum.
Low voltages, due to overloads, lack of fuel or a faulty generator, are detected by a volt-
age sensing circuit incorporated into the voltage limiter. When a low voltage condition is
detected, the Voltage Sensing Relay (VSR) with connections NC (normally closed), NO
(normally open) and COM (common) can be used to trigger an alarm or other process-
es. When the generator is above the trip voltage the connection between NO and COM
is closed. f the generator is below the trip voltage then the connection between NO and
COM is open and the connection between NC and COM is closed. The trip voltage is
adjusted by the pot labeled VSR adjust on the VSR board as shown in Figure 8.
!1.6 #0& A/2 M'6'45: The volt and amp meters provide indication of voltage and cur-
rent respectively, output by the L/C.
P19'4 R'5+5614: When no load, or a very small load, is connected the TEG has more
power available than needed by the load. This excess power is directed into a power
resistor by the voltage limiter.
28142 Rev. 5
4.4 !9=287*5 C*=18-2, ";8=.,=287 I7=.;/*,. %B<=.6
An optional cathodic protection interface system is available for use with the model 5220
TEG. t 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 direct-
ly to a heavy-duty terminal block. A 0 to 1 W 300 watt variable resistor is provided for
adjusting the output power
applied to the CP system.
The main parts of the CP inter-
face system are shown in
Figure 9.
E0%.1574': The CP interface
system is enclosed within a
weather resistant 304 SS
enclosure. Enclosure features
include a lock-able cabinet
door, 1 in. conduit opening on
the bottom for customer CP
wires, and separate area within
the enclosure for the variable
power resistor.
M'6'4: The dual 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.
Available standard meter face for the 5220 TEG is 0-30 V, 0-30 A.
C744'06 S*706: A shunt located in the CP nterface enclosure is used to measure the
current to the terminal block. The voltage drop across the shunt is proportional to the
current flowing through it. The current shunt rating corresponds to the ampere scale on
the meter.
T'4/+0#. B.1%-: Customer terminal block, is a heavy duty terminal block that will
accept customer anode & cathode wire up to 9 mm dia. (00 AWG).
!#4+#$.' R'5+5614: A 300 W variable 0 to 1 ohms resistor located inside the enclosure
may be used to adjust the output power of the CP interface. This resistor may be wired
in series or parallel with the customers CP load, depending on the application.
F20>;. 9 CP nterface System General Assembly
28142 Rev. 5
5 I%&ALLA&I!
This section provides installation instructions for the Model 5220 Thermoelectric gener-
ator.
5.1 ";.,*>=287<
The installation must conform with local codes or, in the absence of local codes, with the
CSA-B149.1 Natural Gas and Propane nstallation Code and CSA-B149.2, Propane
Storage and Handling. The TEG must be kept clear and free from combustible materi-
als, gasoline and other flammable vapours and liquids. Maintain 900 mm (36 in.) mini-
mum clearances from combustible construction, to the top, sides and back, and install
over a non-combustible floor.
Do not use this appliance if any part has been under water. mmediately call a qualified
service technician to inspect the appliance and to replace any part of the control system
and any gas control which has been underwater.
The TEG, when installed must be electrically grounded in accordance with local codes,
or in the absence of local codes, with the applicable provisions of the Canadian
Electrical Code CSA C22.1. A grounding lug is provided on the sidewall of the cabinet
for this purpose.
5.2 &885< $.:>2;.-
The following tools are required for installing the TEG:
1 DC Voltmeter, accurate to 0.1 V.
2 Adjustable Wrenches, that will open to 16 mm (5/8 in.)
1 Screwdriver, flat-head
1 Screwdriver, Phillips
4 Bolts & nuts, #1/4-20 for mounting
5.3 '79*,4270
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 5220 TEG:
1 Fin Duct
1 Cover Plate
1 Thread Sealing Compound
17 Screws, #8-32 1/4 in. long, one spare
17 Washers, #8 External Lock, one spare
9>/: I8=:/-> >2/ %EG 09< .+7+1/ A23-2 7+C 2+@/ 9--?<</. .?<381 =23::381. "6/+=/
</:9<> +8C .+7+1/ += =998 += :9==3,6/ += 3> 7+C 7+5/ >2/ 1/8/<+>9< 389:/<+,6/.
C2/-5 A3>2 >2/ 0+->9<C ,/09</ =>+<>381 + .+7+1/. %EG.
28142 Rev. 5
5.4 A<<.6+5270
Follow these steps to assemble the TEG, see Figure 10:
a) Attach the fin duct and cover using the #8 screws and lockwashers supplied.
b) f not already installed, insert the exhaust stack into the top of the cabinet. Slide
the clamp over the bottom of the stack and tighten the clamp screw.
F20>;. 10 Assembling the 5220 TEG
28142 Rev. 5
5.5 M8>7=270
Mount the TEG to a firm and stable base, using 1/4-20 bolts of material suitable for the
environment. See Figure 11 for mounting hole locations. The base must be level and
sturdy enough to support the 83 kg (183 lb) mass of the TEG. Various stands are avail-
able from the factory. Contact your sales rep for more information.
C#76+10: O2'4#6+10 1( 6*' TEG +0 .1%#6+105 9*'4' %11.+0) #+4 (.19 /#; $'
1$5647%6'& 9+.. %#75' 18'4*'#6+0) 1( 6*' TEG. A..19 # /+0+/7/ 1(
150 // (6 +0.) %.'#4#0%' 70&'4 6*' %11.+0) (+05 #0& 600 // (3 (6.)
#$18' 6*' 612 1( 6*' (+0 &7%6. L1%#6' 6*' TEG 61 #81+& (.11&+0) +06'4-
('4+0) 9+6* 6*' (.19 1( %11.+0) #+4.
F20>;. 11 Model 5220 Mounting Dimensions, shown with L/C Option
28142 Rev. 5
5.6 %>995B270 F>.5
This topic describes how to connect the fuel supply and gives background information
for consideration when providing fuel to the 5220 TEG.
5.6.1 C877.,=270 =1. F>.5 %>995B
The TEG has a 1/4 in. female NPT
fuel inlet, i.e. connection to the
TEG's manual shutoff valve.
Follow these steps to connect the
fuel supply:
a) Remove the any protective
cap or plugs.
b) Apply thread sealant to the
fuel line threads as per Figure
12.
9>/: %2</+. =/+6+8> 3= </-97-
7/8./.. $/+6+8> 7?=> ,/
+::<9@/. 09< ?=/ A3>2
1+=/9?= 0?/6=. %+:/ 3= 89> </-977/8./..
c) Connect the fuel line and test all joints for leaks using a commercial leak detec-
tor fluid such as Snoop.
9>/: %2/ %EG +8. 3>= 7+8?+6 =2?>900 @+6@/ 7?=> ,/ .3=-988/->/. 0<97 >2/ 1+= =?::6C
:3:381 =C=>/7 .?<381 +8C :</==?</ >/=>381 90 >2/ 1+= =?::6C :3:381 =C=>/7 +> >/=>
:</==?</= 38 /B-/== 90 3.5 5"+ (0.5 :=31).
The TEG must be isolated from the gas supply piping system by closing its individual
manual shutoff valve during any pressure testing of the gas supply piping system at test
pressures less than 3.5 kPa (0.5 psig).
d) nspect the fuel lines and fittings to be sure they are free of foreign material.
e) Purge fuel lines of all air.
9>/: A66 0?/6 :3:381 7?=> ,/ 38 +--9<.+8-/ A3>2 69-+6 </1?6+>398=.
5.6.2 F>.5 C87<2-.;*=287<
F7'. T;2'5: Fuel must be either natural gas or propane vapour . Check the TEG data
plate for the fuel type, see Figure 22. Do not use a different type of fuel than indicated.
F20>;. 12 Applying Thread Sealant
28142 Rev. 5
F20>;. 13 Setting-up the 5220 TEG, shown with L/C option
S722.; P4'5574': Make sure that fuel pressure is at least 241 kPa (35 psig) and will not
exceed 413 kPa (60 psig). f it is expected that the fuel supply pressure will vary great-
ly, the use of an additional primary regulator is recommended. This will hold the input
pressure relatively constant.
C.'#0 F7'.: The fuel used to operate the 5220 TEG must be clean and dry. See
Technical Specifications section for full gas specifications. f dirty fuel is anticipated then
a customer supplied in-line fuel filter is recommended.
L19 T'/2'4#674': Regulator freeze-off can be minimized by regulating the incoming
supply pressure to 138 kPa (20 psig). When using propane (C
3
H
8
) at temperatures
below -30C (-22F) special consideration must be given to the vaporization of the fuel.
28142 Rev. 5
5.7 C877.,=270 C><=86.; L8*-
Connect the customer load directly to the TEG using the following procedure. f an
optional CP interface system is applicable then see nstallation of Optional CP nterface
System topic below.
Follow these steps to connect the customer load:
a) Bring the customer load wires through the strain relief bushing (located on the LC/
Limiter enclosure). Allow enough wire to connect to the terminal block TB-1.
9>/: &=/ 986C -9::/< A3</, :<9:/<6C =3D/. 09< >2/ 69+. -?<</8>.
b) Tighten the screws on the strain relief bushing.
c) Connect the customer load wires to TB-1:
12 !: C988/-> >2/ 69+. +> >/<738+6= 5(+) +8. 4 (-) =// F31?</ 14. %2/ 5220 12
'96> 3= 3=96+>/. 0<97 9>2/< :9A/< =?::63/= 9< ,+>>/<3/= ,C + .39./ 38 =/<3/=
A3>2 >2/ 9?>:?>. %2/ .39./ .9/= -98=?7/ +,9?> 2 A+>>= 90 :9A/< +8. -+8
,/ ,C:+==/. ,C -988/->381 >2/ 69+. >9 >/<738+6 1(+) +8. >/<738+6 4 (-).
9>/ >2+> =38-/ >2/ 6373>/< 3= ,/381 ,C:+==/. >2/ +77/>/< A366 </+. D/<9.
24 !: C988/-> >2/ 69+. +> >/<738+6= 7 (+) +8. 6(-) =// F31?</ 15. A </@/<=/ -?<-
</8> :<9>/->398 .39./ 3= :<9@3./. 98 >2/ :9=3>3@/ 9?>:?> >/<738+6 90 >23= ?83>.
F20>;. 14 Wiring Diagram 5220 TEG, Shown with 12 V Limiter Option
28142 Rev. 5
F20>;. 15 Wiring Diagram 5220 TEG, Shown with L/C Option
5.8 I7<=*55*=287 8/ !9=287*5 L262=.;/C87?.;=.; (L/C)
The L/C is normally shipped ready for operation, attached to the TEG. f it was shipped
separately install as follows.
9>/: B/09</ 38=>+66381 38=:/-> 09< 9,@39?= ./8>= +8. ,<95/8 -97:98/8>= +8. +.@3=/
G69,+6 %2/<79/6/-><3- =/<@3-/ ./:+<>7/8> 30 .+7+1/ 3= 89>/..
5.8.1 A==*,1270 =1. L/C =8 &EG
The standard mounting location is on the right side of the generator cabinet. To attach
the L/C remove the four nuts and lock washers provided and bolt it to the outside of the
TEG cabinet, See Figure 16
9>/: A6A+C= 79?8> >2/ L/C 38 +8 ?:<312> :9=3>398 +8. +669A >2/ 0<// 069A 90 +3< >2<9?12
>2/ ?83>. #/79>/ 79?8>381 90 >2/ L/C 3= +--/:>+,6/.
5.8.2 &EG )2;270 I7=.;,877.,=287
Wire the L/C directly to the TEG using the following procedure:
a) Feed the wires from the L/C into the TEG cabinet through the hole provided.
28142 Rev. 5
F20>;. 16 CP nstallation
9>/: I0 </79>/6C 79?8>381 >2/ L/C, =3D/ >2/ 38>/<-988/->381 A3</= ,/>A//8 >2/ 1/8/<-
+>9< +8. >2/ L/C 09< 17 A, +8. ?=/ 89 6/== >2+8 A(G 89. 10.
b) Before connecting the input or output wires to the TEG terminal block check the
selector switch setting, Figure 8, is correct for the required voltage and model
5220 TEG.
c) Connect the L/C wires to TB-1 as per Figure 15.
5.9 I7<=*55*=287 8/ !9=287*5 C" I7=.;/*,. %B<=.6
The CP interface is normally shipped ready for operation, attached to the TEG. f it was
shipped separately install as follows.
9>/: B/09</ 38=>+66381 38=:/-> 09< 9,@39?= ./8>= +8. ,<95/8 -97:98/8>= +8. +.@3=/
G69,+6 %2/<79/6/-><3- =/<@3-/ ./:+<>7/8> 30 .+7+1/ 3= 89>/..
5.9.1 A==*,1270 =1. C" I7=.;/*,. %B<=.6 =8 &EG
The standard mounting location is on the left side of the generator cabinet. To attach the
CP interface system, remove the four nuts and lock washers provided and bolt it to the
outside of the TEG, see Figure 16.
28142 Rev. 5
F20>;. 17 CP Wiring for Model 5220-12 V DC, with Limiter Option
F20>;. 18 CP Wiring for Model 5220-24 V DC, With Limiter/Converter Option
28142 Rev. 5
9>/: A6A+C= 79?8> >2/ C" 38>/<0+-/ =C=>/7 38 +8 ?:<312> :9=3>398 +8. +669A >2/ 0<//
069A 90 +3< >2<9?12 >2/ ?83>.
5.9.2 &EG )2;270 I7=.;,877.,=287
Wire the CP interface system directly to the TEG using the following procedure:
a) Check the wiring diagram, Figure 17 or 18 as applicable, and choose the wiring
diagram for your application.
b) Run the CP interface system wires to the TEG as per Figure 17 or 18, as appro-
priate, and terminate to TB-1.
5.9.3 C877.,=287 8/ C" L8*-
Wire the CP load directly to the CP interface system. Feed the CP anode and cathode
load cables into the CP box and terminate.
28142 Rev. 5
6 %&A$&'" AD %H'&D!)
This section describes how to startup and shutdown the model 5220 TEG.
6.1 B./8;. %=*;=270
Before starting the TEG perform these steps:
a) Move the jumper on TB-1 from the RUN position to the SETUP position, i.e. from
between terminals 1 and 2 to between terminals 3 and 4 respectively. See Figure
14 or 15.
b) Connect a DC voltmeter to terminals 2 (+) and 3 (-) of TB-1. This will be measur-
ing V
=/>
.
c) Make sure that all of the connections in the fuel system are tight and have been
checked for leaks.
6.2 &EG %=*;=-'9
Follow these steps to start the TEG using the gnitionControl System:
a) Supply fuel and open the manual shut-off valve. The spark ignitor should begin
clicking and the sound of combustion will begin. n some cases it may be neces-
sary to bleed air from the system. f combustion is not maintained after three tri-
als, see section 4.1.2 gnition Control System of this manual.
9>/: !8-/ >2/ %EG 3= =>+<>/., </--69=381 >2/ 7+8?+6 =2?>-900 @+6@/ A366 =>9: 3>.
"ARNING: "*'0 6*' TEG +5 12'4#6+0), 574(#%' 6'/2'4#674'5 +0 6*' 8+%+0+6; 1(
6*' 6*'4/12+.', $740'4, ':*#756 56#%- #0& #4170& 6*' %11.+0) (+0 &7%6
/#; $' +0 ':%'55 1( 100=C. A81+& %106#%6 1( 5-+0 #0& %.16*+0) 9+6*
6*'5' #4'#5 9*'0 12'4#6+0) +0 #0& #4170& 6*' TEG.
6.3 %1>=-8@7
Thermoelectric generators are intended for continuous operation where reliable power
is required without interruption. n case the TEG must be shutdown temporarily for serv-
icing or an emergency close the TEG manual shutoff valve.
28142 Rev. 5
28142 Rev. 5
7 "!)E$ !'&"'& E(AL'A&I!
Output power is the primary indication of correct setup, adjustment and operation of the
TEG. This section describes how to determine if the TEG is providing rated power.
Power output should be evaluated:
during initial setup at site;
adjusting a TEG;
before and after servicing a TEG, and
whenever altering the fuel's heat of combustion.
9>/: %C:3-+6 =/>>381= +</ 130-144 5"A (18.5 - 21. :=31) 09< 8+>?<+6 1+= +8. 125-140 5"+
(18.0 - 20.0 :=31) 09< :<9:+8/.
9>/: G99. </-9<. 5//:381 3= 8/-/==+<C 09< 6981 >/<7 09669A-?:. &=/ >2/ %EG
"/<09<7+8-/ L91, 69-+>/. +> >2/ /8. 90 >23= 7+8?+6, 09< </-9<.381 ./>+36= /+-2
>37/ +.4?=>7/8>= +</ 7+./ 9< =/<@3-381 3= -+<<3/. 9?>.
7.1 A6+2.7= &.69.;*=>;. E//.,=< 87 (
5'6
*7- $*=.- "8@.;
Power from the 5220 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.
For every 1C temperature drop from the ambient temperature indicated on the data
plate effects a power increase of 0.8 W and similarly, a temperature climb of 1C from
the ambient temperature as indicated on the data plate effects a power decrease of 0.8
W. This effect needs to be considering when setting-up the TEG.
7.1.1 D.=.;627270 (
5'6
*7- $*=.- "8@.;
V
=/>
, proportional to rated power, must be adjusted for actual ambient temperature at site
as described below. Figure 19 is used to determine the appropriate V
=/>
and expected
rated power at various ambient temperatures, through calculations.
Factory test data for rated power and voltage are marked on the data plate that is locat-
ed inside the TEG cabinet door. These values are for a specific ambient temperature
that is also indicated on the data plate. They require correction for ambient temperatures
different to that indicated. The following formulas apply:
28142 Rev. 5
V
=/>
= V
=/> </0
. + [(T
</0.
- T) 0.026] E;?+>398 1.
Where: T = Ambient temperature, at site (C)
T
</0.
= Reference ambient temperature, marked on Data Plate (C)
V
=/></0.
= Reference set-up voltage, marked on Data Plate (V)
V
=/>
= Set-up voltage, at site (V)
P
=/>
= P
=/></0.
+ [(T
</0
- T) 0.8] E;?+>398 2.
Where: T = Ambient temperature, at site (C)
T
ref.
= Reference ambient temperature, marked on Data Plate (C)
P
=/></0
= Reference power marked on TEG Data Plate (W)
P
=/>
= Rated power at new ambient (W)
9>/: A@93. =/>>381-?: >2/ %EG >9 <?8 +> 2312/< '
=/>
9< <+>/. :9A/< @+6?/=, += 3>= 630/
7+C ,/ +00/->/.. %23= 7/>29. 3= =?3>+,6/ 09< +7,3/8> >/7:/<+>?</= 90 ?: >9
65.5GC (150GF). I0 38 .9?,> -98>+-> G69,+6 %2/<79/6/-><3-'= C?=>97/< $/<@3-/
D/:+<>7/8> 09< 1?3.+8-/.
Example : Ambient temperature at site is 35C. Set-up power of 220 W and V
=/>
of
14.3 V, 22C is marked on the TEG Data Plate.
V
set
= V
=/></0.
+ [(T
</0.
- T) 0.026]
= 14.9 + [(22 - {35}) 0.026]
= 14.9 + [(22 - 35) 0.026]
= 14.9 + [-13 0.026]
= 14.9 + [-0.3338]
= 14.9 - 0.338
= 14.56 V
similarly,
P
=/>
= P
=/></0.
+ [(T
</0.
- T) 0.8]
= 220 + [(22 - {35}) 0.8]
= 220 + [(22 - 35) 0.8]
= 220 + [-13 0.8]
= 220 + [-10.4]
= 220 - 10.4
= 209.6 W
28142 Rev. 5
7.1.2 D.=.;627270 (
5'6
*7- $*=.- "8@.; G;*912,*55B
A good approximation to V
=/>
and rated power can be obtained from the chart shown in
Figure 19. Knowing the ambient temperature, move up vertical to the line. Read the
V
=/>
from the right side of the graph and rated power from the left side.
7.2 (
<.=
*7- $*=.- "8@.;
To determine the electrical power that the generator is producing a precision resistor is
provided within the generator. This resistor is called the V
=/>
resistor. By connecting the
generator to this resistor and measuring the voltage across it, the power produced by
the generator can be calculated as follows:
Where: P = Power (watts)
V = Voltage (Volts)
R = Resistance (Ohms)
F20>;. 19 V
=/>
and Rated Power versus Ambient Temperature
" = (
2
$
28142 Rev. 5
As R = 4.0 Ohms the power calculation may be simplified to:
P = (V
=/>
)
2
/4 E;?+>398 3
V
=/>
voltage, is measured across terminals 2 and 4, with the jumper clip in the setup posi-
tion across terminals 2 and
3, as shown in Figure 14
and 15.
7.2.1 (
5'6
%18;=5B */=.; I072=287
mmediately after ignition
the power unit warms and
the resulting temperature
rise produces power.
Follow these steps to check
V
=/>
after ignition:
a) Consult the data
plate inside TEG
door for the reference
V
=/>
voltage and
determine the
required V
=/>
for the
present ambient tem-
perature. See
Sections 7.1.1, or
7.1.2.
b) Move the jumper clip
on the terminal block TB-1 to the SETUP position, i.e. between terminals 2 and
3. See Figure 14 or 15.
c) Connect a voltmeter between terminals 2 (+) and 4 (-). This is the measured V
=/>
,
and should tend towards the required V
=/>
(determined in "a). t will climb as
shown in Figure 20.
C#76+10: D1 016 #..19 6*' /'#574'& !
5'6
61 ':%''& 6*' 4'37+4'& !
5'6
.
O8'4*'#6+0) 9+.. 4'57.6 #0& /#; %#75' +44'2#4#$.' &#/#)' 61 6*'
219'4 70+6.
d) The measured V
=/>
will rise quickly at first then begin to level out. t will take at
least one hour for this voltage to level out. When the measured V
=/>
no longer
changes (0.2 V in ten minutes) compare this value with required V
=/>
. The
measured V
=/>
should be within 0.2 V of the required V
=/>
F20>;. 20 V
=/>
versus Time After gnition, Typical
Response
28142 Rev. 5
9>/: %C:3-+66C, 30 >2/ 7/+=?</. '
=/>
3= 1</+>/< >2+8 </;?3</. '
=/>
>2/8 >2/ 0?/6 :</==?</
8//.= >9 ,/ </.?-/..
7.2.2 (
5'6
A/=.; &EG 1*< %=*+252C.-
Once the TEG has been running for some time, typically more than an hour, the power
unit will be up to operating temperature.
Follow these steps to check V
=/>
:
a) Consult the data plate inside TEG door for the reference V
=/>
voltage and deter-
mine the required V
=/>
for the present ambient temperature. See Sections 7.1.1,
or 7.1.2.
b) Move the jumper clip on the terminal block TB-1 to the SETUP position, i.e.
between terminals 2 and 3. This connects the TEG to an internal load required for
V
=/>
. See Figure 14 or 15.
c) Connect a voltmeter between terminals 2 (+) and 4 (-). The measured V
=/>
, and
should match the required V
=/>
for the present temperature.
C#76+10: D1 016 #..19 6*' /'#574'& !
5'6
61 ':%''& 6*' 4'37+4'& !
5'6
.
O8'4*'#6+0) 9+.. 4'57.6 #0& /#; %#75' +44'2#4#$.' &#/#)' 61 6*'
219'4 70+6.
d) Pause approximately 10-45 minutes and when the measured voltage is stable
compare it to required V
=/>
. Measured V
=/>
should be within 0.2 V of the required
V
=/>
.
9>/: "+?=381 3= 8/-/==+<C >9 +669A >2/ %EG @96>+1/ >9 =>+,363D/ >9 >2/ 8/A 69+. -98.3-
>398=. (C2+81381 0<97 -?=>97/< 69+. >9 >2/ 98-,9+<. 1 927 </=3=>9<).
28142 Rev. 5
28142 Rev. 5
8 ADJ'%&ME&
This section describes how to adjust the Model 5220 Thermoelectric generator.
9>/: %C:3-+6 =/>>381= +</ 130-144 5"A (18.5 - 21. :=31) 09< 8+>?<+6 1+= +8. 125-140 5"+
(18.0 - 20.0 :=31) 09< :<9:+8/.
9>/: G99. </-9<. 5//:381 3= 8/-/==+<C 09< 6981 >/<7 09669A-?:. &=/ >2/ %EG
"/<09<7+8-/ L91, 69-+>/. +> >2/ /8. 90 >23= 7+8?+6, 09< </-9<.381 ./>+36= /+-2
>37/ +.4?=>7/8>= +</ 7+./ 9< =/<@3-381 3= -+<<3/. 9?>.
F20>;. 21 Change in Fuel Gauge Pressure versus Elevation Above Mean Sea Level, Typical
28142 Rev. 5
F20>;. 22 Air Shutter
8.1 "8@.; !>=9>= A-3><=6.7=
TEG output power is controlled by the flow of air and fuel into the TEG. Use the follow-
ing procedures to adjust the TEG's power output in sequence given.
8.1.1 A-3><=6.7= /8; E5.?*=287
Confirm the fuel gauge pressure is near to the pressure indicated on the data plate
located on the inside of the cabinet doors. f the TEG is located at a different altitude
than the factory, 792 m (2600 ft.), the fuel pressure will need to be different to obtain the
same results also be different. Use Figure 21 to determine how much to adjust the fuel
pressure.
Example: f the site elevation is 1000m (3281ft.) then 2.5 kPa (0.36 psig) must be
added to the pressure on the data plate.
9>/: %C:3-+6 =/>>381= +</ 130-144 5"A (18.5 - 21. :=31) 09< 8+>?<+6 1+= +8. 125-140 5"+
(18.0 - 20.0 :=31) 09< :<9:+8/.
28142 Rev. 5
Follow these steps to adjust fuel pressure:
a) Remove the cover on the regulator and loosen the lock nut.
b) Turn the adjusting screw (clockwise to increase pressure) until the required
change in pressure is obtained.
9>/: C98=?6> D+>+ "6+>/ L+,/6 L9-+>/. 98 388/< .99< 09< #/0/</8-/ F+->9<C F?/6
"</==?</. $// F31?</ 22 09< D+>+ "6+>/ 69-+>398.
c) Tighten the lock nut and replace the cover on the fuel regulator.
8.1.2 A2;-<1>==.; A-3><=6.7=
At this point, adjusting the air shutter for optimum combustion may be necessary (see
Figure 22). The generator should be stable, with the V
=/>
voltage constant.
"ARNING: A+4 5*766'4 %1/210'065 #4' *16 #0& 9+.. $740 5-+0. M#-' #.. #+4 5*76-
6'4 #&,756/'065 75+0) 611.5 10.;, 016 $#4' 5-+0.
a) Mark the original position of te air shutter with a felt pen against the burner cover.
b) Loosen the four screws mounting the air screen against the air shutter, leaving
the air shutter still in place.
c) Open the air shutter slightly by rotating the shutter to enlarge the opening. Adjust
the shutter only a small amount at a time. There will be a slight resistance to air
shutter movement as the air shutter is still being held against the venturi by four
inner wave washers.
d) Close the doors and let the unit stabilize for 10 minutes and measure V
=/>
.
I/ (
5'6
2< 0;.*=.; =1*7 =1. 8;2027*5 ?*5>. repeat step c). Continue to enlarge the
shutter opening until V
=/>
decreases then rotate the shutter to the position that
gave the highest V
=/>,
and tighten screws A and B and measure CO, see section
8.1.2.1.
I/ (
5'6
2< 5.<< =1*7 =1. 8;2027*5 ?*5>. return air shutter to the original position
and then close slightly. Let the unit stabilize for 10 minutes and then measure
V
=/>
. Repeat until V
=/>
decreases, then return to the position that gave the high-
est V
=/>
, and tighten screws A and B and measure CO, see section 8.1.2.1.
9>/: I> 7+C >+5/ =/@/<+6 738?>/= >9 =// + -2+81/ 38 @96>+1/ 30 986C 2 ./-37+6 :6+-/=
+</ .3=:6+C/. 98 >2/ @96>7/>/<.
e) Tighten screws A and B, replace air screen and verify V
=/>
did not change.
28142 Rev. 5
8.1.2.1 M.*<>;270 C! E62<<287< L.?.5<
The model 5220 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. n
a free air measurement, the allowable CO rate is 800 ppm. n order to be able to deter-
mine the levels of air-free CO ppm, a combustion analyzer capable of measuring CO
ppm and either CO
2
percentage, or O
2
percentage, is needed.
The equations used to calculate the air-free stage of CO are:
E F9< +>?<+6 G+= A2/8 ?=381 += 7/+=?</. C!
2
:/<-/8>+1/, +8. C!
::7
:
E F9< "<9:+8/ A2/8 ?=381 += 7/+=?</. C!
2
:/<-/8>+1/, +8. C!
::7
:
)1*, )2*, )3* += :/< C$A
F20>;. 23 Change in V
=/>
versus Air-Shutter Adjustment, Typical
[1]
[2]
[3]
28142 Rev. 5
F20>;. 24 Change in V
=/>
Versus Fuel Pressure Adjustment, Typical
E (2/8 ?=381 += 7/+=?</. !
2
:/<-/8>+1/, +8. C!
::7
:
Where: CO
AFppm
= Carbon monoxide, air-free ppm.
CO
ppm
= As-measured combustion gas carbon monoxide ppm.
O
2
= Percentage of oxygen in combustion gas, as a percentage.
CO
2
= Percentage of carbon dioxide in combustion gas, as a per-
centage.
The model 5220 does not produce excessive concentrations of CO if adjusted properly.
8.1.3 F>.5 ";.<<>;. A-3><=6.7=
Once the air is adjusted, and if the fuel system and burner appear to be operating cor-
rectly, the fuel pressure may be slightly adjusted to match the measured V
=/>
voltage with
the required V
=/>
value. Use Figure 24 to determine how much to adjust the fuel pres-
sure.
28142 Rev. 5
Example: Required V
=/>
= 14.1 V
Measured V
=/>
= 13.5 V
Difference = +0.6 V
Based on Figure 24 the fuel pressure must then be increased 3.6 kPa (0.52 psig).
Follow these steps to adjust fuel pressure:
a) Remove the cover on the regulator and loosen the lock nut.
b) Turn the adjusting screw (clockwise to increase pressure) until the required
change in pressure is obtained.
9>/: C98=?6> D+>+ "6+>/ L+,/6 L9-+>/. 98 I88/< D99< 09< #/0/</8-/ F+->9<C F?/6
"</==?</.
c) Wait ten minutes then measure V
=/>
and record. f the TEG can not be adjusted
to match required V
=/>
value then a problem exists with one of the TEG's systems.
f necessary see Troubleshooting section for guidance.
d) Tighten the lock nut and replace the cover on the fuel regulator.
8.2 A-3><=6.7= 8/ !9=287*5 L/C
An optional L/C is available for use with the model 5220 TEG. This text describes how
to adjust the L/C, if applicable.
8.2.1 !>=9>= (85=*0. A-3><=6.7=
The L/C is factory set at 14.1 V to 27.0 V depending on the output ordered. (Model 5220-
24). f this requires adjusting use the following procedure.
Follow these steps to adjust the L/C output voltage:
a) Disconnect the customer load from the TEG, terminals 6 (-) and 7 (+) of TB-1.
b) Move the jumper clip on the terminal block TB-1 to the RUN position, i.e. between
terminals 1 and 2.
c) Connect a voltmeter between terminals 6 and 7 of TB-1 and measure the output
voltage.
d) Adjust the output voltage by turning the output voltage adjustment pot shown in
Figure 8.
8.2.2 (85=*0. %.7<270 $.5*B ((%$) A-3><=6.7=
The VSR provides a set of contacts to indicate an alarm condition when the output volt-
age drops below a pre-set minimum. t is factory set at 23.0 V (Model 5220-24) or 11.5
V (Model 5220-12). The VSR is rated for 2 A at 30 V DC and will take up to wire size no.
16 AWG.
28142 Rev. 5
9>/: B/-+?=/ >2/ =/8=381 :938> 09< >2/ </6+C ><3: 3= +2/+. 90 + ,69-5381 .39./, =/> >2/
89-69+. ><3:-:938> 0.5 ' 2312/< >2+8 >2/ </;?3</. ><3:-:938>. F9< /B+7:6/, -98=3./<
+8 +6+<7 3= </;?3</. A2/8 >2/ 9?>:?> @96>+1/ .<9:= >9 23.0 ' +> >2/ -?=>97/< 69+.
>/<738+6=. (2/8 7+5381 >2/ ><3:-:938> +.4?=>7/8> +> 89-69+. -98.3>398= =/> 3> >9
><3: +> 23.5 ', += 7/+=?</. +> >2/ -?=>97/< 69+. >/<738+6=. &8./< 69+. -98.3>398=
A2/8 >2/ @96>+1/ .<9:= >9 23.0 ', += 7/+=?</. +> >2/ -?=>97/< 69+. >/<738+6=,
>2/ </6+C A366 ><3:.
Follow these steps to adjust the VSR set point:
a) Remove both the positive and negative wires from the customer load terminals.
b) Connect a DC voltmeter to the customer load terminals.
c) Remove cover from the L/C.
d) Set the output voltage to the desired alarm point value.
e) Place an ohmmeter between the common and normally open contact of the VSR.
f) Turn the VSR adjustment pot until the contacts open (the normally open contacts
are closed when output voltage is above VSR trip-point).
g) Using the output voltage adjustment, raise output voltage to a value where the
VSR will reset.
h) To re-check the trip-point, lower output voltage and monitor opening of the VSR
contacts. Fine tune as required to achieve desire trip value.
i) Reset output voltage to the desired normal operating value. Factory setting is
either 14.1 or 27.0 V.
8.3 A-3><=6.7= 8/ !9=287*5 C" I7=.;/*,. %B<=.6
An optional CP interface system is available for use with the model 5220 TEG. This text
describes how to adjust the CP interface system, if applicable.
8.3.1 C" "8@.; !>=9>= A-3><=6.7=
The 0-1W 300 W variable resistor, located inside the CP cabinet, may be used to adjust
the output power from the CP interface. This resistor may be connected in series or par-
allel with the customer load. See Figure 25 for series connection and Figure 26 for par-
allel connection.
Adjusting the variable resistor can be done simply while the system is running, by loos-
ening the slide ring on the resistor and moving it up or down on the resistor. Check the
power changes by using the meters provided in the enclosure or using a hand held
multi-meter to easily see the change in power when adjusting the variable resistor. Once
the resistor has been adjusted to give the desired power output, check that all electrical
connections are tight, and lastly recheck that the desired power output has not changed.
28142 Rev. 5
F20>;. 25 CP nterface System, Series Wiring
Diagram
F20>;. 26 CP nterface System, Parallel
Wiring Diagram
9>/: %EG 0?/6 :</==?</ 7+C ,/ +.4?=>/. >9 038/ >?8/ >2/ C" 9?>:?>. F?/6 :</==?</ A3>2
38 10% 90 >2+> 7+<5/. 98 >2/ .+>+ :6+>/ 3= </-977/8./. >9 :</@/8> 06+7/ 9?>.
8.3.1.1 %.;2.< )2;270
Series connection is achieved by connecting the 300 W resistor in series with the cus-
tomer load as shown with the dark line. The maximum allowable power may be deliv-
ered to the CP load by moving the tap to the bottom of the resistor. To reduce power to
the CP load, slide the tap upward.
8.3.1.2 "*;*55.5 )2;270
Parallel connection is achieved by connecting the 300 W resistor in parallel with the cus-
tomer load as shown with the dark line, smaller levels of power may be delivered to the
CP load. This may be required when hot spots occur on the anode of the CP circuit. 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.
Change from a series to parallel configuration by moving the wire running from the top
of the 300 W resistor from the centre terminal of the heavy duty terminal block to the left
terminal.
28142 Rev. 5
9 M*27=.7*7,.
This section describes how to maintain the model 5220 TEG. Before attempting to main-
tain the TEG the qualified service person should be thoroughly familiar with its:
technical specifications;
process description;
installation;
startup and shutdown;
power output evaluation, and
adjustment.
9>/: G99. </-9<. 5//:381 3= 8/-/==+<C 09< 6981 >/<7 09669A-?:. &=/ >2/ %EG
"/<09<7+8-/ L91, 69-+>/. +> >2/ /8. 90 >23= 7+8?+6, 09< </-9<.381 ./>+36= /+-2
>37/ +.4?=>7/8>= +</ 7+./ 9< =/<@3-381 3= -+<<3/. 9?>.
9.1 $.,866.7-.- ".;28-2, M*27=.7*7,.
The TEG is a solid-state high-reliability device that requires very little maintenance.
However, it does require periodic service checks in order to provide the years of trouble
free service of which it is capable. The maintenance interval depends on the site condi-
tions (fuel purity, environment, etc.) and must be established based on site records.
Field experience indicates that a properly installed TEG usually requires maintenance
only once a year.
At least once a year Evaluate V
=/>
as per the procedure below. This should be the first
procedure during any service visit and will determine what further service may be need-
ed.
9.1.1 &885< *7- "*;=< $.,866.7-.- /8; $8>=27. %.;?2,270
The following tools and parts should be available for routine servicing:
1 Multi-meter, including DC voltmeter accurate to 0.1 V (and
Ohmmeter*)
1 Flat-head screwdriver
1 Phillips screwdriver
1 Wrench, 9/16 in.
1 Wrench, 1/2 in.
1 Adjustable wrench, that will open to 16 mm (5/8 in.)
1 Fuel filter kit, P/N 3400-22363
1 Fuel orifice: for natural gas use orifice #8, P/N 4200-00690,
for propane use orifice #10, P/N 4200-06251.
1 S gnition Control Battery pack assembly, P/N 2400-27906*
*not usually required, but could be convenient for troubleshooting.
28142 Rev. 5
9.1.2 E?*5>*=. (
5'6
This procedure describes how to evaluate V
=/>
and determine what further servicing
could be needed. Follow these steps to evaluate V
=/>
:
a) Check V
=/>
, see Power Output Evaluation Section 7, and record.
b) Compare measured voltage with required V
=/>
for present ambient temperature
and act as follows:
) I( /'#574'& 81.6#)' +5 /14' 6*#0 0.2 ! #$18' 4'37+4'& !
5'6
:
The fuel pressure must be reduced. Proceed with Routine Service,
Section 9.1.3. Remember to adjust the fuel pressure during restart or
before leaving the site. See Adjustment Section 8.
C#76+10: D1 016 %106+07' 12'4#6+0) 6*' TEG 9+6* /'#574'& !
5'6
':%''&-
+0) 6*#6 4'37+4'& !
5'6
, (14 24'5'06 #/$+'06 6'/2'4#674', 16*'4-
9+5' 18'4*'#6+0) /#; %#75' +44'2#4#$.' &#/#)' 61 6*' 219'4
70+6.
) I( /'#574'& 81.6#)' +5 9+6*+0 0.2 ! 1( 4'37+4'& !
5'6
:
The TEG is functioning well and requires only a routine service. Proceed
with Routine Service, Section 9.1.3.
) I( /'#574'& 81.6#)' +5 /14' 6*#0 0.2 ! $'.19 4'37+4'& !
5'6
:
The cause must be determined. Refer to the last entry in the TEG
Performance Log. From the log, check if the TEG was left operating at the
correct V
=/>
during the last service visit. Remember that V
=/>
changes with
ambient conditions. f the TEG was not left operating at the correct V
=/>
dur-
ing the last visit, determine the reason for this. f the TEG was left operat-
ing at the correct V
=/>
during the last visit and is now not, consider the fol-
lowing possible causes:
i) C1*70. 27 F>.5 ";.<<>;.
Refer back to the last entry in the log and determine if the fuel pres-
sure has changed. f the fuel pressure has changed, re-adjust the
fuel pressure to the last entry. f this returns the measured voltage
to within 0.2 V of required V
=/>
proceed with Routine Service,
Section 9.1.3.
9>/: A .3<>C 0?/6 036>/< 7+C -+?=/ + .<9: 38 0?/6 :</==?</. A :6?11/. 0?/6
9<303-/ A366 -2+81/ 0?/6 069A A3>29?> + -2+81/ 38 0?/6 :</==?</.
ii) C1*70. 27 A2; F58@
Check for obstructions at the cooling fins and the air filter stabilizer.
Adjust the air shutter, see Adjustment section. f this returns the
measured voltage to within 0.2 V of required V
=/>
proceed with
Routine Service, Section 9.1.3.
28142 Rev. 5
iii) C1*70. 27 F>.5 #>*52=B
n order to maintain a constant output power it is essential that the
TEG be supplied with a constant heating value fuel. Proceed with
Routine Service, Section 9.1.3.
f the above causes have been ruled out the TEG may require more
than just routine servicing. Keep the TEG operating for now and see
the Troubleshooting, Section 10, for guidance.
9.1.3 $8>=27. %.;?2,.
Basic annual servicing is all that is required unless other maintenance is indicated by the
V
=/>
evaluation.
Follow these steps to perform a routine annual service:
a) Stop the TEG and pause to let cool. See Startup and Shutdown Section 6.
b) Drain the pressure regulator sediment bowl. See Draining the Sediment Bowl
Section 9.2.1.
c) Replace the fuel filter (Part# 3400-22361) in the pressure regulator, if necessary.
See Fuel Filter Replacement Section 9.2.2.
d) Check the fuel orifice for clogging and replace if necessary. See Fuel Orifice
Replacement Section 9.2.3.
e) Remove any debris, sand or dust from the cooling fins, air filter stabilizer and cab-
inet interior. See Air Filter Cleaning Section 10.1.1.
f) Check all bolts and wire connections for tightness.
g) Start the TEG. See Startup and Shutdown section.
h). Check V
=/>
, record and adjust if necessary. See Power Output Evaluation Section
7 and Adjustment Section 8, as applicable. Record the final setup in the TEG
Performance Log before leaving site.
9.2 F>.5 %B<=.6 M*27=.7*7,.
This text gives procedures for servicing the fuel system.
9.2.1 D;*27270 =1. %.-26.7= B8@5
Follow these steps to drain the regulator sediment bowl:
a) Shut off the fuel supply to the TEG and allow to cool.
28142 Rev. 5
b) Open the drain cock located on the under side of the TEG cabinet, any impurities
will drain through the cock.
c) Close drain cock.
d) Leak check the drain cock.
"ARNING: C*'%- (14 (7'. .'#-5 #(6'4 #0; (7'. 5;56'/ 5'48+%'.
9.2.2 F>.5 F25=.; $.95*,.6.7= (2/ 7.,.<<*;B)
Follow these steps to remove the fuel filter:
a) Shut off the fuel supply to the TEG and
allow to cool.
b) Remove the wires from the pressure
switch.
c) Drain the sediment bowl by opening
the drain cock.
d) Disconnect the flexible fuel line from
the SV valve.
e) Disconnect the vent hose from the
cabinet base.
f) Remove the two bolts which hold the
regulator to the cabinet.
g) Mark the regulator body and sediment
bowl, for proper orientation during re-assembly.
h) Turn the regulator upside down and remove the four screws from the bottom.
i) Remove the filter, and Viton gasket. See Figure 27.
Follow these steps to install the fuel filter:
a) nstall the filter, and Viton gasket onto the sediment bowl. See Figure 27.
b) Carefully replace the bottom of the regulator making sure the filter and gasket are
in their proper position.
c) Align the sediment bowl with the regulator body and replace the four screws and
tighten.
F20>;. 27 Pressure Regulator
28142 Rev. 5
9>/: (236/ >2/ </1?6+>9< 3= </79@/. 3> 3= + + -98@/83/8> >37/ >9 -2/-5 >2/ 9<303-/ +8.
-6/+8 >2/ +3<-036>/<. $// F?/6 !<303-/ I8=:/->398, $/->398 8.2.3 +8. A3< F36>/<
C6/+8381, $/->398 10.1.1.
d) nstallation of the pressure regulator into the TEG is the reverse of removal. With
the fuel pressure on, leak check all regulator joints and fuel connections.
"ARNING: C*'%- (14 (7'. .'#-5 #(6'4 #0; (7'. 5;56'/ 5'48+%'.
9.2.3 F>.5 !;2/2,. I7<9.,=287
Follow these steps to inspect the fuel orifice:
a) Shut off the fuel supply to the TEG and allow to cool.
b) Remove the air screen by undoing the 4 mounting screws.
c) Disconnect the flexible fuel line from the safety SV valve.
d) Disconnect the other end of the flexible fuel line and attached orifice from the cen-
ter of the air shutter.
e) Remove the orifice fitting from the flexible fuel line.
f) Visually check the orifice hole. t should be free from any obstructions. Replace it
if necessary. t is recommended a magnifying glass is used to aid with visual
inspection.
g) Connect the orifice fitting to the flexible fuel line then thread the orifice back
through the center of the air shutter. This only needs to be finger tight.
C#76+10: A.9#;5 75' 6*' 5#/' 5+<' 14+(+%' #5 9#5 4'/18'&.
Propane orifice (#10) - Part# 4200-06251
Natural gas orifice (#8) - Part# 4200-00690
h) Connect the free end of the flexible fuel line to safety SV valve.
i) Leak check all connections using a commercial leak detector.
"ARNING: C*'%- (14 (7'. .'#-5 #(6'4 #0; (7'. 5;56'/ 5'48+%'.
28142 Rev. 5
28142 Rev. 5
10 &$!'BLE%H!!&IG
";8+5.6 ";8+*+5. C*><. "8<<2+5. %85>=287 L884>9 %.,=287
Burner does not
ignite
Air in fuel line Purge fuel lines of air I8=>+66+>398
Supply gas pressure
too low
ncrease the gas supply
pressure to the TEG
I8=>+66+>398
Fuel filter dirty
Drain the regulator
sediment
M+38>/8+8-/
Replace the fuel filter M+38>/8+8-/
Fuel pressure
adjustment incorrect
Adjust the TEG fuel
manifold pressure
A.4?=>7/8>
Fuel orifice plugged Replace the fuel orifice M+38>/8+8-/
Fuel orifice size
incorrect
Replace the fuel orifice M+38>/8+8-/
Air filter dirty Clean the air filter M+38>/8+8-/
Air-shutter adjustment
incorrect
Adjust the air-shutter A.4?=>7/8>
S system faulty Maintain the S system M+38>/8+8-/
Burner will ignite
but will not
continue to burn
Supply gas pressure
too low
ncrease the gas supply
pressure to the TEG
I8=>+66+>398
Fuel filter dirty Drain the regulator
sediment bowl.
M+38>/8+8-/
Replace the fuel filter M+38>/8+8-/
Fuel pressure
Adjust the TEG fuel
manifold pressure
A.4?=>7/8>
Fuel orifice size
incorrect
Replace the orifice with
one of the correct size
M+38>/8+8-/
Safety SV valve
malfunctioning
Check the safety SV
valve
%<9?,6/=299>381
Air filter dirty Clean the air filter %<9?,6/=299>381
Air shutter adjustment
incorrect
Adjust the air-shutter A.4?=>7/8>
28142 Rev. 5
&$!'BLE%H!!&IG, -98>38?/.
";8+5.6 ";8+*+5. C*><. "8<<2+5. %85>=287 L884>9 %.,=287
Low output
power or low
voltage
V
=/>
adjustment
incorrect
Determine required V
=/>
for present ambient tem-
perature at site and adjust
"9A/< !?>:?>
E@+6?+>398 +8.
A.4?=>7/8>
Airflow past cooling fins
insufficient
Clean the cooling fins of
any debris
M+38>/8+8-/
Fuel filter dirty
Drain the regulator
sediment bowl
M+38>/8+8-/
Fuel orifice size
incorrect
Replace the orifice M+38>/8+8-/
Fuel pressure
Adjust TEG fuel manifold
pressure
A.4?=>7/8>
Safety SV valve
malfunctioning
Check the safety SV valve %<9?,6/=299>381
Air filter dirty Clean the air filter %<9?,6/=299>381
Air-shutter adjustment
incorrect
Adjust air-shutter A.4?=>7/8>
L/C* damaged Examine the L/C %<9?,6/=299>381
L/C* adjustment
incorrect
Adjust the L/C A.4?=>7/8>
Power unit damaged Examine the power unit %<9?,6/=299>381
Output power
is too high
Fuel pressure
Adjust the TEG fuel
manifold pressure
A.4?=>7/8>
Output
voltage is too
high
L/C* damaged Adjust the L/C A.4?=>7/8>
L/C* adjustment
incorrect
Adjust the L/C A.4?=>7/8>
28142 Rev. 5
10.1 B>;7.; &;8>+5.<188=270
This text gives procedures for servicing the burner.
10.1.1 A2; F25=.; C5.*7270
The air-filter stabilizer screen at the front of the burner may become clogged with dust
and insects thereby preventing the proper flow of air into the burner.
Follow these steps to clean the air filter:
a) Shut-off the fuel supply to the TEG and allow to cool.
b) Remove the air screen by undoing the 4 mounting screws
c) Clean the air-filter screen by forcing air through it or washing in water.
d) Replace screen and mounting screws.
9>/: I0 >2/ +3< =2?>>/< =/>>381 A+= .3=>?<,/.. $/> >2/ +3< =2?>>/< >2/ -9<</-> <+81/ >9
,/138 ,+6+8-381 >2/ +3<-0?/6 73B>?</ A2/8 </-=>+<>381, += :/< A3< $2?>>/<
A.4?=>7/8>, $/->398 8.1.2.
10.1.2 I7<9.,=287 8/ B>;7.; C86987.7=<
Burner internals are maintenance free for most applications. f the required V
=/>
still can-
not be achieved after servicing the fuel system, air filter and checking the cooling fins
and air duct then it may be necessary to check and service the burner internals. The pro-
cedures below give the steps for inspecting the burner components.
Follow these steps to remove the burner:
a) Shut-off the fuel supply to the TEG and allow to cool.
b) Disconnect the ignition wire from the spark electrode.
c) Slide the spark electrode out. See Figure 2 and 3.
"ARNING: I( TEG *#5 016 %11.'& 57((+%+'06.; +6 %#0 $' 8'4; *16.
d) Remove the air screen.
e) Disconnect the flexible fuel line from the safety SV valve.
f) Disconnect the other end of the flexible fuel line and attached orifice from the cen-
ter of the air shutter.
9>/: I> 7+C ,/ -98@/83/8> >9 .3=-988/-> +8. </79@/ >2/ 0?/6 =C=>/7.
28142 Rev. 5
F20>;. 28 S Module Wiring
h) Remove the four hex-nuts holding the burner in place and slide the burner out.
See Figure 4.
Follow these steps to inspect the burner:
a) Check the air filter screen for any tears or holes. f any are found it should be
replaced.
b) Check the burner screen.
c) Check the ceramic spacer.
Follow these steps to install the burner:
a) Reassembly is the reverse of disassembly.
9>/: %2/ 9<303-/ 03>>381 986C 8//.= >9 ,/ 0381/< >312> A2/8 >2</+./. ,+-5 >2<9?12 >2/
0<98> 90 >2/ +3< =-<//8.
b) Before re-starting the TEG, leak check all fuel connections.
"ARNING: C*'%- (14 (7'. .'#-5 #(6'4 #0; (7'. 5;56'/ 5'48+%'.
28142 Rev. 5
F20>;. 29 gnition Control Module Schematic
10.2 I072=287 C87=;85 %B<=.6 &;8>+5.<188=270
The S system may require occasional maintenance. f the gniting Control system fails
to ignite it must be checked and serviced as necessary. Use the procedures below to
maintain the S system.
"ARNING: R'/18' 6*' 14#0)' 9+4' %100'%614 (41/ 6*' 24'5574' 59+6%* #0&
/#-' 574' +6 %#0 016 %1/' +061 %106#%6 9+6* 16*'4 '.'%64+%#. %100'%-
6+105 61 24'8'06 *+)* 81.6#)' 5*1%-.
10.2.1 C1.,4 =1. %9*;4 E5.,=;8-.
Follow these steps to check the spark electrode:
a) nspect the electrode for any cracks in the ceramic rod. f any cracks are found
the electrode must be replaced.
b) Slide the electrode back into position through the burner back until it stops, then
pull it back 3 to 6 mm (1/8 to 1/4 in.). The ceramic rod should extend about 25
mm (1.5 in.) from the holding screw.
c) Unplug the orange wire connectors from the terminals on the pressure switch and
then short the circuit between the two connectors. Arcing should occur in the
combustion chamber (making a clicking noise) at the rate of ten per second.
d) f arcing occurs the S system is functioning well.
28142 Rev. 5
10.2.2 C1.,4 =1. ";.<<>;. %@2=,1
Follow these steps to check the pressure switch:
a) Remove the two wires from the pressure switch and connect a multi-meter across
the pressure switch terminals, set to measure resistance (ohms). See Figure 28
and 29.
b) With no fuel pressure in the fuel manifold, check the resistance measured across
the switch is near infinity, which indicates the switch being opened. Replace the
pressure switch if necessary.
9>/: $A3>-2 =29?6. 9:/8 +> :</==?</= ,/69A 6.9 5"+ (1 :=31).
c) Provide fuel pressure to the switch by opening the manual shutoff valve.
d) Check the resistance measured across the switch is near zero, which indicates
the switch being closed. Replace the pressure switch if necessary.
9>/: $A3>-2 =29?6. -69=/ +> :</==?</= +,9@/ 13.8 5"+ (2 :=31).
e) Remove fuel pressure from the switch by closing the manual gas valve.
10.2.3 C1.,4 =1. B*==.;B (85=*0.
Follow these steps to check the battery voltage:
a) Open the door of the S enclosure mounted on the left door of the generator cab-
inet.
b) Locate the battery wiring harness connector plugged into the power supply, see
Figure 28 and 29.
c) Probe the back of connector, measuring the voltage between the red and black
terminals of the battery wiring harness connector. The voltage should be greater
than 6 V.
d) f the voltage is less than 6 V the battery assembly needs recharging or replac-
ing.
10.2.4 C1.,4 =1. "8@.; %>995B
Follow these steps to check the power supply voltage to the ignition controller:
a) Start the TEG, it should have been allowed to cool beforehand .
b) Upon start up, probe and measure the voltage between the Red and Black wires
of the gnition controller plug, see Figure 28 and 29. Voltage should be 13.7 V or
greater.
28142 Rev. 5
c) Pause and after 20 minutes, check the voltage as in b), voltage should again be
13.7 V or greater.
Follow these steps to check the Power Supply Battery Charging Circuit and gnition
Controller voltage Supply:
a) Start the TEG.
b) Pause and after twenty minutes of operation Check Battery Voltage, Section
10.2.3.
c) Voltage should be 6.5 V or greater.
10.2.5 C1.,4 2/ =1. B*==.;B @255 H85- C1*;0.
Follow these steps to check if the battery will hold charge:
a) With the TEG Cold and manual shutoff valve off, remove the two orange wires
from the terminals of the pressure switch and short circuit between the two wires.
b) Measure the battery Voltage, Section 10.2.3, within 60 seconds. f battery volt-
age is less than 6 V, replace battery assembly.
10.2.6 C1.,4 =1. !9.;*=287 8/ =1. I072=287 C87=;855.;
Follow these steps to verify operation of the ignition controller correct.
a) Verify electrode gap (1/8 - 1/4), Section 10.2.1.
b) Start the TEG.
c) f arcing occurs, the ignition control module is functioning.
d) f no arcing occurs, verify power supply voltage to ignition controller, Section
10.2.4. f it is as specified, replace ignition module.
10.5.7 C1.,4 %85.782- (*5?..
Follow these steps to check if the Solenoid Valve Operation:
a) f at the beginning of sparking, the solenoid is not heard to click open, unplug
solenoid valve connector inside the cabinet, see Fig 3. Measure resistance over
solenoid plug, if resistance is infinity, replace solenoid valve.
b) Start the TEG. While S is sparking, measure voltage of the solenoid valve plug.
f voltage is less than 13.5 V, check power supply to ignition controller as per topic
above. f it is ok, replace the ignition controller.
28142 Rev. 5
10.3 L/C EA*627*=287
The L/C normally requires no maintenance. f the TEG is producing required V
=/>
but it
is not supplying expected power to the load then the operation of the L/C should be
checked and serviced as necessary. Use the procedures below to help determine if the
L/C could be damaged.
10.3.1 C1.,4 L/C %@2=,1 %.==270<
Check the selector switches are set correctly for the required output voltage, as per
Figure 8.
9>/: $A3>-2 1 =29?6. ,/ ! 09< 12 ' 9< !FF 09< 24 ' 89738+6 9?>:?>. $A3>-2 2 =29?6.
,/ !FF.
10.3.2 C1.,4 I79>= (85=*0. =8 =1. L/C
Follow these steps to check the input voltage to the L/C:
b) Place the jumper clip between terminals 1 and 2 of TB-1, i.e. in the RUN position.
c) Connect a voltmeter between terminals 2 and 4 of TB-1 and measure the input
voltage.
d) Wait for the TEG to reach operating temperature and a stable voltage measure-
ment between terminal 2 and 4, 15 minutes maybe sufficient if the TEG was
already warm. Allow 1 hour if the TEG was just started from cold.
e) Unloaded input voltage, between terminals 2 and 4 of TB-1, should be about 16
V. Check the measured voltage is about 14 volts, if not suspect an electrical short,
damaged limiter or power unit.
10.3.3 C1.,4 !>=9>= (85=*0. /;86 =1. L/C
Follow these steps to check the output voltage from the L/C:
b) Place the jumper clip between terminals 1 and 2 of TB-1, i.e. in the RUN posi -
tion.
c) Connect a voltmeter between terminals 5 and 6 of TB-1 and measure the o u t -
put voltage.
28142 Rev. 5
d) Alter the output voltage by turning the output voltage adjustment pot shown in
Figure 8. f the unloaded output voltage, measured across terminals 5 and 6, does
not change when the adjustment pot is altered the L/C needs replacing.
9>/: I0 >2/ %EG :<9.?-/= </;?3</. '
=/>
, >2/ L/C 3= 9:/<+>381 :<9:/<6C +8. 3> =>366 A366 89>
:<9@3./ /B:/->/. 69A/< >9 >2/ 69+. >2/8 >2/ :9A/< ?83> =29?6. ,/ -2/-5/..
10.4 "8@.; '72= EA*627*=287
The power unit normally requires no maintenance. f after maintaining and adjusting all
other systems and TEG will not produce required power consider examining the power
unit. Use the procedures below to help determine if the power unit could be damaged.
10.4.1 C1.,4 /8; I7=.;7*5 %18;=
Follow these steps to check for an internal short:
a) Start the TEG.
b) Free-up terminals 2 (+) and 4 (-), i.e. remove all wires from these terminals except
the white/red power unit lead connected to terminal 2 and the white/black power
unit lead connected to terminal 4.
c) Connect a voltmeter to terminals 2 and 4.
C#76+10: T*' (1..19+0) 56'25 /#; %#75' 52#4-+0). I( #0 +06'40#. 5*146 +5 24'5-
'06 6*' ,7/2'4 9+4', 5'' $'.19, /#; #4% 61 6*' %*#55+5.
d) Run a jumper wire from terminal 4 to the TEG chassis and watch the voltage
reading. Remove the jumper wire. Any fluctuation in voltage may indicate an inter-
nal short within the power unit.
e) Run a jumper wire from terminal 2 to the TEG chassis and watch the voltage
reading. Remove the jumper wire. Any fluctuation in voltage may indicate an inter-
nal short within the power unit.
f an internal short is confirmed, with no other equipment connected, the power
unit is damaged and will need replacing. f not and the TEG appears to be fully
functional check the customer load is functioning correctly and is grounded prop-
erly.
10.4.2 C1.,4 I7=.;7*5 $.<2<=*7,.
Follow these steps to check the power unit's internal resistance:
a) Start the TEG.
b) Move the jumper clip to the SETUP position, i.e. between terminals 2 and 3 of TB-
1.
28142 Rev. 5
c) Connect a voltmeter between terminals 2 (+) and 4 (-).
9>/: A6>/<8+>3@/ </=3=>9< @+6?/= +</ +--/:>+,6/ =9 6981 += >2/ </=3=>+8-/ 3= -69=/ >9 1
W +8. +--?<+-C -6+== ,/>>/< >2+8 F 1%.
d) Wait for the TEG to reach operating temperature and a stable voltage measure-
ment between terminal 2 and 4, 15 minutes maybe sufficient if the TEG was
already warm. Allow 1 hour if the TEG was just started from cold.
e) Measure V
=/>
with the voltmeter connected between terminals 2 and 4 and record.
f) While observing the voltmeter display remove the jumper clip, creating an open
circuit condition, and note the momentary voltage. On a digital multi-meter this will
be the first number displayed after removing the clip, within 2 seconds of remov-
ing the clip. Record the number as the momentary open circuit voltage (V
9-
). f
this was not recorded quickly enough replace the jumper clip and repeat steps d)
to g) above.
9>/: (2/8 >2/ 4?7:/< -63: 3= =?../86C </79@/. >2/ 7/+=?</. @96>+1/ 6/+:= ?: >9 +
@+6?/, 589A8 += >2/ 797/8>+<C 9:/8 -3<-?3> @96>+1/ ('
9-
). M/+=?</. @96>+1/ -98-
>38?/= >9 -637,.
"#40+0): D1 016 #..19 !
1%
61 ':%''& 691 5'%10&5 16*'49+5' 6*' TEG %#0 $'
&#/#)'&.
F20>;. 30 Momentary Open Circuit Diagram
28142 Rev. 5
h) Calculate the internal resistance using the equations 5 and 6 below.
L
= V
=/>
/ R
L
E;?+>398 6
R
3
= (V
9-
- V
L
) /
L
E;?+>398 7
Where: R
3
= internal resistance (W)
V
9-
= momentary open circuit voltage (V)
V
=/>
= setup voltage (V)
L
= load current (A)
R
L
= precision load resistance (W) 1.0 W
i) Check the internal resistance, R
3
, is less than 1.0 W. f not the power unit may be
damaged.
Example: f the V
=/>
voltage and momentary open circuit voltages were measured as
14.9 V and 28 V respectively and the precision load resistance was 1.0 W
then:
L
= V
=/>
/ R
L
= 14.9 / 1.0
= 14.9 A
R
I%
= (V
9-
- V
=/>
) /
L
= (28 - 14.9) / 14.9
= 13.1 / 14.9
= 0.88 W
nternal resistance is acceptable, < 1.1 W .
For further information or assistance, please contact the Customer Service Department
at Global Thermoelectric.
28142 Rev. 5
28142 Rev. 5
11 "A$& LI%&
This section lists the parts that form the equipment.
For parts and service please contact Global's Customer Service Department at:
Global Thermoelectric
Customer Service Department
Direct: (403) 720-1190
Fax: (403) 236-5575
Main: (403) 236-5556
Web: www.globalte.com
#9, 3700 - 78 Avenue SE
Calagary, Alberta T2C 2L8
28142 Rev. 5
11.1 M8-.5 5220 &EG
I=.6 "*;= 8. D.<,;29=287
A1 7900-08908 Power Unit
A2 4100-22947 Fin Duct, Lower
A3 4100-22875 Fin Duct, Upper
A4 4100-22906 Cover Assy, Upper Fin Duct
A5 6100-27902 Burner Assy
A6 4500-06011 Exhaust Stack Assy
A7 4900-06170 Rod, Burner Mounting
A8 4900-27837 Electrode Assy, Spark gnitor, Fenwal
A9 2514-20535 Screw, Cap, Hex, HD, 1/4-20 x 5/8, SS
A10 4100-22946 Leg, Cabinet, Right
A11 6200-27917 Cabinet Assy
A12 3600-27888 Label, Data Plate
A13 2514-22520 Screw, Cap, Hex Hd, 1/4-20 x 3.75, SS
A14 2814-00473 Washer, Lock, Ext, 1/4, SS
A15 2714-00611 Nut, Hex, 1/4-20, SS
A16 2814-00557 Washer, Flat, 1/4, SS
A17 2510-07412 Screw, Mach, P-H-P, 10-32 x 3/4, SS
A18 2200-02110 Terminal Block, 8 Position
F20>;. 31 Model 5220 TEG
28142 Rev. 5
11.1 M8-.5 5220 &EG (C87=D-)
I=.6 "*;= 8. D.<,;29=287
A19 2400-02109 Marker Strip
A20 2400-04552 Connector, Straight, 2 Screw, 3/4
A21 2508-07410 Screw, Mach, P-H-P, 8-32 x 1/4, SS
A22 2808-00472 Washer, Lock, Ext, #8, SS
A23 2400-52968 S Board Assy Channel Products 50N-12-3-3-7-10-0-E23062
A24 2400-27907 Power Convertor, 4VDC n, 13.8VDC Out, 6V Batt. Charge
A25 2400-24559 Battery 6V, 5.0 Ahr, MonoBloc
A26 2900-00283 Bushing, Universal, 1/8 Heyco
A27 4000-05586 Air Screen Assy
A28 4100-22945 Leg, Cabinet, Left
A29 2010-00208 Terminal, Ring, #10 Yellow
A30 2900-00523 Clamp, 5 1/4 Dia., SS
A31 6400-27905 Fuel system, W/ Burkert Valve, 5220
A32 4200-06251 Orifice Assy, Propane
4200-00690 Orifice Assy, Natural Gas
A33 3600-27892 Label, nstruction
A34 4900-22372 Spacer, Fuel System w/67CFR Regulator
A35 4000-27900 Air Shutter, Profiled, 5220
F20>;. 31 Model 5220 TEG
28142 Rev. 5
11.2 M8-.5 5220 B>;7.;
B1 4000-05606 Burner Back Assy
B2 4000-05605 Holder, Screen nsulator
B3 4000-05390 Screen Assy
B4 4000-06086 nsulation Block
B5 4000-06186 Burner Can, Exhaust
B6 4000-05375 Venturi Tube ntake Assy
B7 4000-05378 Burner Top Assy
B8 2710-00601 Nut, Wing, 10-32, SS
B9 2508-05047 Screw, Truss-Hd-P, 8-32 x 3/8:, SS
B10 4000-06631 Rope, 1/4 Kaotex 2000
B11 2810-27901 Washer, Bowed, 5mm, AZ SS, Spaenaur 681-821
B12 4000-27900 Air Shutter, Profiled, 5220
B13 4900-07004 Pn, Mounting, S HOlder
B14 2789-07005 Nut, Wing, 5/16-18, SS
B15 4900-05586 Air Screen Assembly
I=.6 "*;= 8. D.<,;29=287
F20>;. 32 Model 5220 Burner
28142 Rev. 5
11.3 M8-.5 5220 F>.5 %B<=.6
tem Part No. Description
C1 3100-22361 Regulator, Fisher 67CFR, 0-35 PS, UL144, UL252, 5220
C2 3044-00501 Nipple, Hex, 1/4 NPT X 1 1/8, Brass(Fairview)
C3 4200-02100 Manifold Block, Fuel System
C4 3400-06471 Switch, Pressure 1.6 PS, 76056-DB 1.6-0.5
C5 3034-21569 Elbow, Street 1/4 NPT, B-4-SE
C6 3044-02154 Nipple, Hex, 1/4 x 3, Brass
C7 3094-24653 Valve, 1/4 NPT, Brass, 1/4 Turn, Q11F-600TB2.N
C8 3200-00406 Gauge, Pressure, 0-30 PS
C9 3031-20071 Elbow, 1/4 TB X 1/4 MNPT, SS, SS-400-2-4
C10 4200-07981 Vent Tube Assy, Regulator, SS, 5060/5120/5220
C11 3021-00380 Connector, 1/4 TB X 1/4 MNPT, 316SS, SS-40-1-4
C12 4200-27904 Fuel Line, Manifold, 5220
C13 3031-26518 Elbow, 1/4 TB X 1/4 MNPT, SS
F20>;. 33 Model 5220 Fuel System
28142 Rev. 5
11.3 M8-.5 5220 F>.5 %B<=.6
C14 3094-27927 Valve, Solenoid, Burkert, 6013, CD04933, 2 Way NC 1/8 FNPT, Brass
C15 4200-05286 Kit, Fuel Line, 10in.
C16 4900-22372 Spacer 3/8, Fuel System W/CFR Regulator
C17 4200-27844 Bracket, Solenoid Valve, 5120/5220
C18 2514-22520 Screw, Hex HD, 1/4 - 20 X 3.75 SS
C19 2808-00473 Washer, Lock, Ext. 1/4, SS
C20 2714-00611 Nut, Hex, 1/4-20, SS
C21 2808-00538 Washer, Lock, Spring, #8, SS
C22 2508-23438 Screw, MACH, P-H-P, M4 X 12mm, SS
C23 3400-22363 Filter Kit, Fisher 67CFR, (Not Shown)
C24 2100-22810 Cable, 3 Wire, 18 AWG Black, Silflex (part of Limiter or L/C)
tem Part No. Description
F20>;. 33 Model 5220 Fuel System
28142 Rev. 5
12 &EG "E$F!$MACE L!G
MODEL NO:
TEG SERAL NO:
FUEL TYPE:
LMTER/CONVERTER SERAL NO:
CP NTERFACE SERAL NO:
D
A
T
E
T
M
E
A
M
B
E
N
T

T
E
M
P
C
R
E
Q
U
R
E
D

P
O
W
E
R

(
W
)
R
E
Q
U
R
E
D

v
$
E
%
(
V
)
M
E
A
S
U
R
E
D

v
$
E
%
(
V
)
M
E
A
S
U
R
E
D

P
O
W
E
R
(
W
)
F
U
E
L

P
R
E
S
S
U
R
E
O
P
E
N

C
R
C
U
T
V
O
L
T
A
G
E

(
V
)
MANTENANCE
REMARK
28142 Rev. 4
12 &EG "E$F!$MACE L!G
MODEL NO:
TEG SERAL NO:
FUEL TYPE:
LMTER/CONVERTER SERAL NO:
CP NTERFACE SERAL NO:
D
A
T
E
T
M
E
A
M
B
E
N
T

T
E
M
P
C
R
E
Q
U
R
E
D

P
O
W
E
R

(
W
)
R
E
Q
U
R
E
D

v
$
E
%
(
V
)
M
E
A
S
U
R
E
D

v
$
E
%
(
V
)
M
E
A
S
U
R
E
D

P
O
W
E
R
(
W
)
F
U
E
L

P
R
E
S
S
U
R
E
O
P
E
N

C
R
C
U
T
V
O
L
T
A
G
E

(
V
)
MANTENANCE
REMARK

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