Gentherm P-5100 User Manual

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

Gentherm P-5100 Specifications

General

Brand	Gentherm
Model	P-5100
Category	Inverter
Language	English

Summary

About This Manual

Health and Safety

Ensures proper operation and maintenance for equipment safety and function.

Technical Terms

Defines key terminology used in the manual for operator understanding.

Quick Start Procedure

Installation

Provides step-by-step instructions for setting up the TEG unit.

Start Up

Details the sequence of steps for initiating TEG operation.

Adjustment

Outlines the procedure for initial TEG power output adjustments.

Performance Log

Recommends recording TEG performance and maintenance history.

Technical Specifications

Overview

Provides a general description of the TEG's function and capabilities.

Options

Details available optional features for the TEG system.

Weights and Measures

Lists the physical dimensions and weight specifications of the TEG.

System

Specifies technical details for the Spark Ignition (SI) system.

Data Plate

Explains the interpretation of information found on the generator's data plate.

Fuel Consumption

Lists fuel consumption rates for various fuel types at rated power.

Standard Specification for Gaseous Fuel

Defines the required standards for gaseous fuels used with the TEG.

Process Description

Model P-5100 Thermoelectric Generator

Describes the basic process of how the TEG generates electrical power.

Fuel System

Details the components and function of the fuel system.

Spark Ignition Control System

Explains the operation of the ignition control system and spark generation.

Burner

Describes the burner's function in mixing fuel and air for combustion.

Cooling Fins and Fin Duct

Explains the role of cooling fins and fin duct in heat dissipation.

Cabinet

Describes the enclosure protecting the TEG's internal components.

Optional TEG Mounting Stands

Details the available mounting stand options for the TEG.

Converter Limiter

Describes the Converter/Limiter (C/L) and its function.

Temperature Compensation

Explains how temperature compensation affects output voltage.

Blocking Diode

Describes the function of the integrated blocking diode.

Optional Cathodic Protection Interface System

Details the optional CP interface system for cathodic protection.

Optional Remote Start System (TEG Controller Board)

Describes the TEG controller for remote start and stop functionality.

Intake and Exhaust Flame Arrestors

Discusses the function and compliance of flame arrestors.

Optional VSR Terminal Block

Describes the optional terminal block for voltage sensing relay connections.

Installation

Precautions

Lists critical safety and installation precautions to follow.

Tools Required

Lists the necessary tools for performing the TEG installation.

Unpacking

Provides instructions for unpacking the TEG and identifying components.

Assembling

Details the steps for assembling the TEG components.

Mounting

Provides guidance on securely mounting the TEG to a stable base.

Supplying Fuel

Describes how to connect the fuel supply to the TEG.

Connecting the Fuel Supply

Details the procedure for connecting the fuel line to the TEG.

Fuel Considerations

Discusses important factors regarding fuel type and supply.

Propane/Natural Gas Supply Considerations

Provides guidance for Propane/LPG gas supply system setup.

Connecting Customer Load

Explains how to connect the external electrical load to the TEG.

Installation of Optional CP Interface System

Instructions for installing the optional Cathodic Protection interface system.

Attaching the CP Interface System To TEG

Details the physical attachment of the CP interface to the TEG cabinet.

TEG Wiring Interconnection

Describes wiring the CP interface system directly to the TEG.

Connection of CP Load

Explains how to connect the CP load cables to the interface box.

Startup and Shutdown

Before Starting

Lists essential checks and preparations before starting the TEG.

TEG Start-Up

Details the procedure for starting the TEG using the ignition control system.

Shutdown

Provides instructions for safely shutting down the TEG.

Power Output Evaluation

Required Vset or Setup Power at Site

Explains how ambient temperature affects TEG power output and how to calculate required Vset.

Working-out Required Vset or Setup Power

Details formulas for calculating required Vset based on ambient temperature.

Determining Vset And Rated Power Graphically

Shows how to graphically determine Vset and rated power from ambient temperature.

Checking Vset or Setup Power

Outlines procedures to check the stable setup voltage (Vset) of the power unit.

Examining Vset Immediately after Ignition

Describes how to check Vset shortly after ignition as the unit warms up.

Examining Vset after Running for Some Time

Explains how to check Vset after the TEG has been running for an extended period.

Adjustment

Power Output Adjustment

Details procedures for adjusting TEG power output via air and fuel flow.

Adjustment for Elevation

Explains how to adjust fuel pressure based on site elevation.

Air-shutter Adjustment

Describes how to adjust the air shutter for optimal air-fuel mixture.

Fuel Pressure Adjustment

Details fine-tuning fuel pressure to match measured Vset.

Adjustment of Converter/Limiter

Explains how to adjust the Converter/Limiter (C/L) settings.

Output Voltage Adjustment

Procedure for adjusting the C/L output voltage.

Voltage Sensing Relay (VSR) Adjustment

Details how to adjust the Voltage Sensing Relay set points.

Enabling Temperature Compensation

Instructions on how to enable temperature compensation for output voltage.

Adjustment of Optional CP Interface System

Describes how to adjust the optional CP interface system.

CP Power Output Adjustment

Details how to adjust output power via the CP interface variable resistor.

Adjustment of the Optional Remote Start System (TEG Controller)

Explains how to adjust settings on the TEG Controller.

Maintenance

Recommended Periodic Maintenance

Outlines routine service checks for long-term TEG reliability.

Tools and Parts Recommended for Routine Servicing

Lists essential tools and parts for performing periodic maintenance.

Evaluate Vset

Procedure to evaluate Vset to determine necessary servicing.

Routine Service

Details the steps for performing basic annual servicing.

Fuel System Maintenance

Provides procedures for servicing the TEG's fuel system.

Draining the Sediment Bowl

Instructions for draining the sediment bowl in the fuel regulator.

Fuel Filter Replacement

Describes the steps for replacing the fuel filter.

Fuel Orifice Inspection

Details how to inspect and clean the fuel orifice.

Burner Maintenance

Provides procedures for servicing the TEG's burner components.

Air Lid Screens Cleaning

Instructions for cleaning the air lid screens on the burner's air box.

Inspection of Burner Components

Details how to inspect the internal components of the burner.

SI System Maintenance

Describes maintenance procedures for the Spark Ignition (SI) system.

Check the Spark Electrode

Procedure to inspect the spark electrode for proper function and condition.

Check the Pressure Switch

Details how to test the pressure switch for correct operation.

Check the Battery Voltage

Instructions for checking the voltage of the TEG's battery.

Check the Operation of the Ignition Control Module and Spark Generation

Verifies the ignition control module and spark generation are functioning correctly.

Check the spark return path for the SI module

Ensures the correct spark return path connection for SI module operation.

Check Solenoid Valve

Details how to test the solenoid valve for proper electrical and mechanical function.

Converter/Limiter Examination

Procedures to check the Converter/Limiter (C/L) for potential damage.

Check Converter/Limiter Switch Settings

Verifies the correct setting of C/L selector switches for desired output voltage.

Check Output Voltage from the Converter/Limiter

Describes how to measure and adjust the output voltage from the C/L.

Power Unit Examination

Provides steps to examine the power unit if required power is not produced.

Check for Internal Short

Details how to check the power unit for internal electrical shorts.

Check Internal Resistance

Explains how to measure and evaluate the power unit's internal resistance.

Troubleshooting

Burner does not ignite

Identifies probable causes and solutions for burner ignition failure.

Burner will ignite but will not continue to burn

Troubleshoots issues where the burner ignites but fails to sustain combustion.

Low output power or low voltage

Addresses causes and solutions for low power output or voltage.

Output power is too high

Troubleshoots causes for excessive output power.

Output voltage is too high

Addresses causes for excessively high output voltage.

Part List

Model P-5100 TEG

Lists parts for the main P-5100 TEG assembly.

Model P-5100 Burner

Lists parts specific to the P-5100 burner assembly.

Model P-5100 Fuel System

Lists parts for the standard P-5100 fuel system.

Model P-5100 Optional Stainless-Steel Fuel System

Lists parts for the optional stainless-steel fuel system.

Model P-5100 Electrical

Lists parts for the electrical components of the P-5100.

Cathodic Protection Option

Introduction

Provides an overview of the Cathodic Protection interface system.

Meter

Describes the dual-scale meter for voltage and current monitoring.

Current Shunt

Explains the function of the current shunt for measurement.

Adjustments

Details how to adjust output power using the variable resistor.

Series

Describes the series connection configuration for the resistor.

Parallel

Describes the parallel connection configuration for the resistor.

Heat Recovery System (HRS) Option

Introduction

Introduces the HRS option for waste heat recovery.

Installation

Refers to a separate manual for HRS and TEG installation.

TEG Operation

Refers to general TEG operation sections for HRS usage.

Model P-5100 HRS Configuration Parts

Lists specific parts required for the P-5100 HRS configuration.

TEG Performance Log