1

Introducing
the GEK Gasifier Systems

Updated: 09/16/2012

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Table of Contents
I. Overview and Specifications
a. GEK Gasifier System sizes
b. GEK Gasifier models, levels, and features
c. Biomass requirements of the GEK Gasifier Systems
II. Identifying the GEK System Components
III. Identifying the PowerPallet Control Panel and PCU Components
IV. Description of the GEK Gasifier process flows
V. Description of GEK Gasifier Components
VI. Description of Control Panel and PCU Components
VII. Datalogging with the PCU

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I. Overview and Specifications

ALL Power Labs offers downdraft gasifier systems in various sizes: 10kW, 20kW, and 100kW.
These kWe ratings reference the potential of electrical power capable in a gasifier/ICE/generator
system at the gasifier's maximum gas flow capacity. The GEK PowerPallet integrates an internal
combustion engine and a generator with automated controls with the ability to utilize the gas for other
purposes, while the GEK Gasifier comes as an assemble-yourself kit that provides stand-alone wood
gas for a variety of end uses. Below are the specifications of the systems provided by ALL Power Labs.

GEK Gasifier System Sizes provided by ALL Power Labs

10kW GEK 20kW GEK 100kW GEK
electrical capacity range (kW) 2 - 10 4 - 20 20 - 100
gas flow range (m^2/hr) 5 -27 11 - 53 53 - 267
gas heat flow at max (BTU/hr) 168,993 331,727 8,355,765
biomass consumption rate (kg/day) 160 - 320 320 - 640 640 - 3200
gasifier system footprint (excluding hopper) (ft) 2x4 2x4 4x7

The GEK Systems are offered at various integration stages as well as at different kit levels to
make the equipment accessible at various price points. The kit 'Levels' refer to the completeness of the
offered product. The levels are as follows:
• Level I: free CAD files available online
• Level III: Weld-It-Yourself kit (mild steel only)
• Level IV: Assemble-It-Yourself kit (stainless steel only)
• Level V: Completely Assembled and Integrated

GEK Gasifier Models, Levels and Features Offered

Model Sizes Levels Included Features
(kW) Available
Basic GEK 10, 20 I, III, IV Reactor, gas filter only. Gas drive system: ejector venturi
GEK TOTTI 10, 20, III, IV Basic GEK with Pyrocoil and Drying Bucket. Gas drive system:
100 ejector venturi
GEK 10, 20 V GEK TOTTI, PCU, logic and components for automation, engine
PowerPallet and generator. Gas drive system: blowers. Integrated on a 4x4
pallet. Available in 120V/208/240V AC, 60/50Hz, and in single,
split, or three phase configurations.
PowerTainer 100 IV, V Pyrocoil, Drying Auger, PCU, logic and components for
automation, open hopper with air lock, engine and generator.
Integrated inside a shipping container

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Biomass Requirements of the GEK Gasifier Systems

Most downdraft gasifier systems require specified feedstock characteristics and can be sensitive
to feedstocks that lie outside of the required specifications for the given equipment. Across all of the
GEK Models above, ALL Power Labs has implemented designs in both the reactor and the bulk
handling systems that broaden the allowed feedstock characteristic requirements of typical systems of
its size. Below are the suggested ranges for given feedstock characteristics to be used in the GEK
systems.
Biomass Requirements
particle size (in) .5 - 1.5
moisture content (% by dry weight) <25
fixed to volatile ratio >0.25
ash content (%) >5
Please refer to the Feedstock Requirements and Preparation Guide for more information.

The GEK Systems are designed for raw biomass and organic-based feedstocks. Experimental
feedstocks lying outside of the suggested ranges may require modification of the equipment and testing
of the gas quality produced. For experimental and research, ALL Power Labs offers a Research
Experimenters Kit with test and control equipment valuable for gas testing or further development off
of the base systems. Contact [email protected] for more information.

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II. Identifying the GEK System Components

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GEK System Components con't

1. Feedstock Hopper 26. Engine Radiator Coolant Port

2. Drying Bucket 27. Engine Alternator
3. Fuel Level Switch 28. 12V DC Car Battery (not included)
4. Pyrocoil Exhaust Port 29. Fuel Level Switch
5. Reactor 30. Pyrocoil and Exhaust Insulation Jacket
6. Auxiliary Port 31. Engine Exhaust
7. Gas Cowling 32. Engine Gas Valve
8. Manual Grate Shaker 33. Packed Bed Gas Filter Lid Access
9. Ash Port 34. Filter Condensate Drain Port
10. Dual Channel Manometer and Thermocouple 35. Automatic Flare Igniter
Port 36. Air Blower
11. Cyclone Condensate Jar 37. Air Filter
12. Air Inlet Check Valve 38. System Safety Relief Valve
13. Lighting Port 39. Generator and Electrical Connection Box
14. Cyclone 40. Engine Starter Motor
15. Gas Service Connection Port 41. Engine Condensate Trap
16. Biomass Feed Auger 42. Engine Oil Filter
17. Ejector Compressed Air Connection 43. Governor and Engine Throttle
18. Ejector Venturi Gas Drive 45. Oxygen Sensor
19. Swirl Burner 46. Automated Grate Shaker
20. Manual Air-Premix Valve 47. Feedstock Hopper View Port
21. Gas Shut-off Valve 48. Dual Gas Blower
22. Packed Bed Gas Filter 49. Pyrocoil Heat Exchanger
23. Hopper Barrel Puff Bung 50. Gas Line Access Port
24. Flare Stack 51. Process Control Unit (PCU) and Control Logic
25. Air Blower 52. Main Operation Panel

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III. Identifying the PowerPallet Control Panel and PCU Components

53. Hour Meter a. Power Input k. Low Range Pressure

54. Oxygen Sensor Air/Fuel b. FETs Sensors
Ratio Dial c. RS232 Communication Port l. High Range Pressure
55. LCD Display d. ATX Power Supply Sensors
56. 4 Input Buttons e. Input Buttons and Keypad Off-board m. Analog Inputs
57. System Main Power Connection n. ATmel MicroProcessor
58. Engine Key Switch f. Relay Board I/O Connectors o. CAN Bus
59. Dual Gas Blower g. Thermocouple Screw Terminal Communication Port
Adjustment Knob Connectors p. Reset Button
60. Air Blower Adjustment h. Thermocouple Standard Connectors q. Status LEDs
Knob i. LCD Display and Contrast Knob r. USB Communication Port
61. PCU USB Connection Port j. Micro SD card s. Servo Control Ports
62. Warning Alarm t. Timer

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IV. Description of the GEK Gasifier Process Flows

The GEK Process starts with the introduction of feedstock into the hopper. After the hopper, the
feedstock passes through an auger and enters the gasifier. The auger is controlled by a level switch
incorporated into the reactor lid. The feedstock fills the GEK reactor and stages needed for passes
through the stages of gasification: drying, pyrolyisis, combustion, and reduction. The hot gas exits the
reactor and passes through a cyclone to separate char particulates. The GEK Gasifier systems are
designed to utilize the heat from the gas produced to dry the incoming feedstock through the Drying
Bucket. After the Drying Bucket, the gas passes through the gas filter and gas drive system. The GEK
Gasifier systems have two main valves to switch between one of two operational modes: Flare or
Engine Mode (or other gas utilization mode). For Engine Mode, the Pyrocoil heat exchanger, included
in the TOTTI design, increases the efficiency of the reaction by supporting the heat needed for the
pyrolysis zone by utilizing the waste heat from the exhaust of an engine or other process.

The GEK Gasifier Kits and the PowerPallet have different gas drive systems as shown in the
GEK Process Flow diagram above. For the GEK Kits, the gas enters the gas filter, and passes through
the ejector venturi gas drive system. Here the air is then mixed for the flare.
For the PowerPallet, the gas by-passes the filter on start-up and the blower system provides gas and air
for the flare. After start-up, the flare is then shut off and the engine pulls gas through the gas filter.
The Basic GEK Kit does not include the Drying Bucket, Pyrocoil, or Auger shown in the diagram
above. The Basic GEK Kit has a simple lid on top of the reactor and is to be filled manually. The Basic
GEK Kits are offered as the most simple experimental development platform.
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V. Description of GEK System Components

Feedstock Hopper
The feedstock hopper comes stock with the GEK Gasifier models. The GEK Gasifier kits and
PowerPallet come with hopper volumes of 30 gallons (0.1 m^3) and 55 gallon (0.2 m^3),
respectively. The hopper for the GEK Kit and PowerPallet systems are to be sealed to maintain
the vacuum of the system. A puff lid safety release valve is included on the hopper lidMoisture
from the drying process is collected by condensation in a monorator ring incorporated in the
hopper design.
Drying Bucket
After the hopper, the feedstock then enters into the Drying Bucket which is a heat exchanger
that heats up the incoming biomass with the hot exiting gases from the gasifier. The hot gases
exit the reactor between 250-350C and enter into the cyclone then Drying Bucket across a series
of baffles to heat the incoming biomass to about 100C. The baffles to knock particulates
entrained in the gas stream. The L-shape form factor of the GEK TOTTI is intentional to
separate the drying zone from the pyrolysis zone. This is advantageous because water competes
with the heat needed to vaporize the tar from the feedstock. Water vapor will also decrease the
solubility of the vaporizing tar in the pyrolysis zone. Another consequence of having water in
the pyrolysis zone is the tenancy for tar and soot particles to agglomerate around droplets of
water. This increases the droplet/particle size of the components that will then be partially
oxidized in the combustion zone which decreases the efficiency of combustion and tar cracking.
The efficiency of combustion and tar cracking increases when the fuel or tar particle/droplet
size decreases.
Feedstock Auger and Fuel Level Switch
The feedstock auger comes stock with the GEK TOTTI and the PowerPallet and is controlled by
a level switch that is located on top of the reactor lid. The fuel level switch is wired to a 12vDC
circuit as normally closed (NC). For the PowerPallet, the PCU logic registers the current draw
of the motor, switch state, and cycle frequency. The table below presents the logic for the
possible auger states.

Biomass Auger State Table

Auger State Possible Causes Action
no current auger is off log state
low current for 1 no feedstock transport (out of Alarm sounds. If no operator
minute feedstock, bridging in hopper), intervention after 3 minutes, automatic
broken motor, or broken auger shutdown of engine.
indicator
normal current feedstock transport and normal auger none
operation
high current motor working against bound Reverse auger for 3 sec
feedstock/jammed auger (configurable)or until reversing high
current, then drive auger forward.

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10 forward/ jammed auger Alarm sounds.

reverse cycles
20 jammed auger is non-fixable Automatic engine shutdown.
forward/reverse
cycles
auger on too no feedstock transport (out of Alarm sounds. If no operator
long (low feedstock, bridging in hopper) intervention after 6 minutes, automatic
current for 4 shutdown of engine.
minute and fuel
switch state not
changing)

If the Fuel Switch changes state, this will reset the alarm and resume normal operation. Because
of the variability of characteristics in various feedstocks, the difference between the high and
low current thresholds is user configurable.

GEK Gasifier Reactor

• Air inlet
At the air inlet a check valve allows air to enter the negative pressure system during
normal operation, but does not allow expanding hot wood gas to escape through the inlet
during shut down. The Air Inlet allows the air to pass through the Air Neck in which the
air flow is divided among the 5 air lines for the 10kW and 20kW GEK reactor sizes. The
air lines pass through the hot wood gas exiting the reactor to heat up the incoming air
while cooling the wood gas.
• Air Nozzles
The air nozzles experience the hottest temperatures in the reactor as they introduce the
air into the combustion zone. The air nozzles are able to withstand these temperatures
and do not need replacement very often, however, the reactor is designed to offer the
replacement of air nozzles if needed. The air nozzles are to be oriented to point directly
to the center of the reduction bell.
• Lighting Port
This port allows the operator to light the reactor with a small propane torch at the
combustion zone during start-up. This port is then closed with the 1/2 cap during
operation. If needed, lighting fluid can be squirted into this port to help light the reactor.
• Reduction bell
The reduction bell is the heart of the downdraft gasifier. The reduction bell controls the
flow velocity and thus residence time of the gases passing through the combustion and
reduction zone. Because the combustion reactions are many more times faster than the
slower reduction reactions, the diameter of the top cone on the reduction bell is smaller
and tapers down to a restriction to keep the combustion zone stable and preventing it
from 'creeping'. The reduction reactions are slower endothermic reactions that proceed
with the available heat from combustion. Here the char that has fallen into the bottom of
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the cone from the pyrolysis zone, reduces the combustion products. The gasifier ends the
reactions in a metastable state before the reaction reaches equilibrium to maximize CO
and H2 production. While the reduction bell can withstand many hours of normal
operation, the reactor is designed to be able to replace the reduction bell if needed.
• Ash Grate and Grate Shaker
The ash grate lies below the reduction bell to support the charcoal in the reduction zone
but allow smaller char/ash to pass through toward the bottom of the gasifier. Smaller
char granules increases the bulk density which decreases the void space in the bulk.
Decrease in void space limits the gas flow through the media and creates resistance to
flow in the system. The grate shaker controls monitor the pressure ratio across the
reactor to shake the grate for a given shake time and interval. These settings can be
configured through the PCU menu screens. The pressure ratio (P_ratio) is calculated as
P_comb/P_react. The table below provides the conditions of the P_ratio value ranges.

Pressure Ratio Ranges and Conditions for Grate Shaker Control

Pressure Ratio (P_ratio); Condition
PCU LCD display [/100]
<20 bad, restricted gas flow due to packed reduction bell
~30 not good but workable, restricted gas flow due to packed
reduction bell
30-60 good operating conditions
>60 bad, reduction bell not filled. Feedstock empty, bridging in
reactor or bridging in hopper.

Increasing the amount of grate shaking can purge the bell too quickly and over fill the
char/ash reservoir at the bottom. Once this reservoir is filled, the grate is no longer able
to purge the small char particles, and the gasifier will have to be shut down and cleaned
out. APL intends to release an ash take off system so that the char/ash can be purged
without shutting the unit down which will increase the continual run time.
Cyclone
After the wood gas leaves the gasifier, it passes through a cyclone that separates the larger
particulates that may have entrained in the gas stream. Condensate and particles fall through to
the trap at the bottom of the cyclone. The cyclone jar should be emptied before operation if it
reaches capacity. during operation of the GEK system by closing off the ball valve at the bottom
and emptying the trap. This is included in all of the GEK models.
Packed Bed Gas Filter
The packed bed filter is16 gal (0.06 m^2) and is to be filled with charcoal between 1/16-1/4''
particle size. While any charcoal can be used, the char that is purged from the gasifier can be
collected and sifted to the required particle size and used in the filter. It is recommended to use
the active char left over from the gasifier because the basic high temp char adsorbs the wood
tars as most tar compounds are acidic. The 5 inch space below the filter media bottom grate is
reserved for condensing in the filter and a bung is provided for draining the condensate.
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• For the GEK Kits, on top of the filter media should be a fine filter such as fabric or fine
mesh to prevent the filter media or fine particulates into the exiting gas stream. The final
filter size will depend on what is needed for your end use gas requirements. The filter
grate lays on top of the final fine filter to hold it in place and keep it from entraining in
the gas stream.
• For the PowerPallets, two oiled fine foam filter disks are provided for use in the gas
filter. One 65dpi and the other 45dpi are layered on the top of the filter media in this
order. The filter disks can be cleaned with warm soapy water, dried and re-oiled for
reuse.
Gas Drive System
The gas drive system is used to motivate the flow through the system during start-up. As flow
increases, temperature increases. When the reactor temperatures reach the target minimum
temperature of 750C, (>800C ideally), tar content in the gas stream may be low enough for use
in engines. For full heat modes, gas drive systems that operate the system to flows that are
within the bounds of the gasifiers temperature range for the given feedstock are preferred.
• For the GEK Kits: An ejector venturi gas drive system both creates suction on the
system and mixes air in to the gas for the flare burner. The ejector venturi operates
by providing compressed air at ~100psi for 6-8 CFM to the ejector nozzle. The
ratio of motive compressed air and gas is only about 25% of the air/gas ratio
needed for the flare. A manual air pre-mix valve is provided right before the
ejector venturi that allows the air needed for the air/fuel ratio for the burner. While
the ejector venturi can operate over a wide range of flow rates with no moving
parts, this drive system has a higher power demand for a given flow and may not
be appropriate for off grid applications for the system for this version release.
• For the PowerPallets Two squirrel cage blowers in series are controlled together with a
single knob on the control panel and are used to draw a vacuum on the system. The dual
blower design allows for the maximum volumetric flow rate of gas needed for start-up
powered solely by the stand alone 12V DC system on-board. A third blower is used to
introduce air into the flare burner. For the blower system, the gas bypasses the packed
bed filter and goes straight to the flare. This prolongs the life of the packed bed filter as
it filters the gas for use in the engine. The blowers are serviceable and can be taken apart
and cleaned easily using isopropyl alcohol or the like. Complete combustion in the flare
is ensured by adjusting the gas and air blowers to the right ratio to bring the combustion
in the flare stack down to the bottom-most part of the flare stack. The blowers have a
low power demand and are appropriate for start up for the stand alone off-grid systems
but may only operate at the lower end of the gas flow capacity of the gasifier providing
less heat than the gasifier is capable of in full heat mode.
Flare Stack and Igniter
For the PowerPallet, the igniter automatically turns on when P_react>0.5 WC and the engine is
not running. When these conditions are true, the igniter relay turns on the igniter at the top of
the flare stack to ensure that the flare lights and the gas (including CO) is not escaping from the
system. The GEK Kits do not come with an igniter and it is required to light the flare manually.
Lighting the flare with a hand-held propane torch is highly recommended.
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Engine Gas Valve

The manual engine gas valve is installed with the PowerPallet that is opened for Engine Mode.
For the GEK Kits, this valve is not included, but a port is available to connect an engine or other
gas service.
Air-Mix Valve/Servo and Oxygen Sensor
For the Power Pallet, the air-mix servo acts as an automated wood gas carburetor to adjust to the
correct air/gas ratio for the engine. The PCU receives the signal from the MTX Wideband
Oxygen Sensor that is in the exhaust stream of the engine. With this signal, the PCU adjusts
from the lean or rich mixture to the proper air to fuel ratio for the PowerPallet using PID
controls. The GEK Kits come with a manual valve that can be adjusted to allow for the correct
air/fuel ratio needed down stream, though an oxygen sensor is not included in the GEK Kits.
Engine
The PowerPallet and Powertainer combine the complete GEK Gasifier system with an engine
and automated controls. The GEK Kits are provided as a stand alone gasifier for manual
operation as a platform allowing for a variety of alternative development projects and custom
controls.
• Engines offered with the PowerPallets
• 10kWPP- Kubota DG 9782: 3cyl natural gas engine.
• 20kWPP- GM Vortec 3.0L 4cyl gasoline engine.
• Alternate power options include:
• CHP applications are allowed through capturing the useful heat out of the
radiator.
• shaft power for vehicles or PTO applications.
Please see the engine manuals for more information.
Governor
The Woodward Governor controls the RPM with information from the MPU sensor on the
engine for the PowerPallet. The governor configurations can be modified using the governor L-
Series Configuration Tool program (Windows only). Within this program, the settings and
control dynamics can be changed (Target RPM, over speed threshold, PID controls, droop,
governor-to-governor networking for multiple systems, automatic shut down states, etc).
Default configurations are set during testing before the shipment of each PowerPallet.
Please see the Woodward Governor manual for further information.
Generator
A Meccalte generator comes stock with the PowerPallet and Powertainer systems. The Meccalte
generators may be configured to 120V/208/240V AC, 60/50Hz, and in single, split, or three
phase configurations.
Please see the generator manuals for more information.
Pyrocoil
For the Power Pallet, the heat from the engine exhaust is utilized by passing through the
Pyrocoil heat exchanger to provide heat to the pyrolysis zone thus increasing the efficiency of
the gasifier. The Pyrocoil comes with the TOTTI GEK Kits in conjunction with the
Auger/Drying Bucket system. For the GEK Kits, other waste heat streams may be utilized with
the Pyrocoil.
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CO Meter
CO meters are provided with all of the systems from ALL Power Labs as a safety precaution to
alert the operator in the rare case of a CO leak.
Thermocouples
Two main thermocouples are provided with all of the GEK Systems. These act as the
'tachometer' for the GEK Gasifier. For the GEK Kits, a thermocouple reader is provided that
gives the option for F or C readings. The PowerPallet temperatures are read by the PCU and are
displayed on the LCD screen in Celsius. The two thermocouples are:
• Top of Reduction Bell temperature (T_tred), measures temperature of the combustion
zone at 3/8ths inside the restriction of the Reduction Bell.
• Bottom of Reduction Bell temperature (T_bred), measures the temperature of the
reduction zone at 1'' inside the bottom opening of the Reduction Bell.
If more thermocouples are needed for your project, ALL Power Labs offers the Research
Experimenters Kit that includes gas flow monitoring and control equipment, tar testing supplies,
thermocouples (including a multi temperature probe with 6 different temperature detection
points along a single probe) and more. For more information contact [email protected].

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VI. Description of Control Panel and the PCU Components

Process Control Unit (PCU)

The PCU comes standard with the PowerPallet. ALL Power Labs also offers the PCU board separately
in full or half fill configurations for alternative development projects. This section mainly describes the
PCU as its integrated on the PowerPallet system.

• Power Input
The power requirement for the PCU is 9-12 vDC, 1A.
• Field Effect Transistors (FETs)
The 8 FETs control component relays. On/off switching for pumps, motors, solenoids,
etc. For the PowerPallet systems, the FETs are wired to the components as follows:
1. Feedstock Auger
2. Grate Shaker
3. Flare Igniter
4. Engine Ignition Coil
5. Engine Starter Motor
6. Oxygen Sensor Power
7. Warning Alarm
8. Auxiliary (not in use)
• RS232 Communication Port
This port allows communication with the PCU. The code on the PCU of the PowerPallet
outputs all sensor data to the serial port. For more information see section IV.
Datalogging with the PCU.
• Thermocouple Connectors
Standard plug connections are offered on ports T0-T6 and screw terminal connections
are available for T7-T14. For the PowerPallet, T0 is populated with T_tred thermocouple
and T1 detects the temperature of T_bred.
• MicroSD card port
Card not included. Currently no code has been written for the SD card that is on board
the PCU. However, user code may be generated for datalogging, etc by interfacing via
SPI.
• Differential Pressure Sensors
Two ranges of pressure sensors are located on the PCU board, high range (P0-P3) +/- 28
WC and low range (P4 & P5) +/- 8 WC.
On the PowerPallets, the dedicated pressure sensors are
• P0-Combustion Pressure (P_comb), measures pressure at the top of the
reactor.
• P1-Reactor Pressure (P_react), measures the pressure after the reduction
zone near the gas outlet.
• P3-Filter Pressure (P_filt), measures the pressure at the outlet of the
packed bed filter.

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• Keypad
Four buttons are available for user input.
• LCD screen and contrast knob
The LCD screen allows adjustment of the contrast for better visibility.
• Analogue Inputs (from first colum top down to second column)
1. Coolant Temperature
2. Feedstock Auger Current
3. Key Switch State
4. Oxygen Sensor Signal
5. Aux- Governor Signal (not in use)
6. Throttle Position
7. Engine Oil Pressure
8. Fuel Switch State
• Microprocessor: Atmel ATmega 1280
• CANbus communication port
Currently no code is included for the CANbus. However, user generated code could
make use of this digital bus communication port.
• Reset Button
Resets the PCU.
• Frequency Timer
This port is typically used for hertz measurement from the generator.
• Status LEDs
The power (PWR) LED comes on when power is applied to the PCU board. The
diagnostic (DIAG) LED is prompted in the code to blink for each loop in the code logic.

For more information on the PCU, refer to the GCU Technical Manual, the Gasifier-Control-Unit page
on the GEK Wiki website, and the PCU-Getting Started documentation.

Relay Board
The Relay Board manages the interface between the PCU and the wire harness of the
PowerPallet and Powertainer models. The Relay Board does not come with the GEK Kits or the
stand-alone PCU kit orders.

• PCU Power connection

Provides clean 12 vDC power to the PCU from the ATX power supply.
• FET Outputs
Interfaces the FET outputs from the PCU to the wiring harness.
• ATX Power Supply
Power input from the on-board 12v battery supply to the ATX and clean power output
from the ATX to power the PCU.
• ATX module

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A current draw from the on-board 12 vDC battery supply would otherwise drop the
instantaneous voltage available. To prevent this voltage drop from resetting the control
board, the ATX provides clean reliable power to the PCU. A 10 amp input fuse is used
for the ATX circuit.
• Governor RS232USB converter chip
The RS232 chip on the Relay Board replaces the previous RS232 dongle that is used to
communicate with the governor. The governor RS232 communication port passes
through the Relay Board and provides a USB connection on the front of the main control
panel. Connect a computer to the governor USB port on the main control panel to
configure the settings through the governor program.
• Relay Bank (from left to right):
1. Feedstock Auger Forward Relay (fuse: 15A)
2. Feedstock Auger Reverse Relay (fuse: 15A)
3. Grate Shaker Relay (fuse: 10A)
4. Flare Igniter Relay (fuse: 10A)
5. Aux Relay (not in use) (fuse: 10A)
6. Engine Ignition Coil Relay (fuse: 10A)
7. Engine Starter Relay (fuse: 10A)
8. Oxygen Sensor Power Relay (fuse: 10A)
9. Other component fuses:
1. Main Power Fuse (25A)
2. Air and Gas Blowers Fuse (10A)
• Input/Output catagories for Relay Board & # of connections (from left to right):
1. Battery (2)
2. Fuel Switch (4)
3. GEK Harness (10)
4. Governor Harness (12)
5. Blowers (12)
6. Key Switch/Panel Harness
• Analogue Inputs
• MTX Wideband Oxygen Sensor signal input/output
• Air Mixture (wood gas carburetor) Servo Control pass through
• JP1-Board Configuration Jumper
• 1&2=20kWPP configuration
• 2&3=10kWPP Configuration

For more information on the logic and controls of the PowerPallet please see "KS_PowerPallet v1.1
Controls."

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VII. Datalogging with the PCU

The code running on the PCU provided with the PowerPallets outputs all the sensor data via the
USB port at a baud rate of 115200. Use a terminal program such as PuTTy Tel (puttytel.exe) to access
the serial port. When the board is powered, connect to the board via USB connection on your computer
and datalog the values by the following:

Windows
1. Open puttytel
2. In the Datalogging tab, choose a location to save files (you can also save files with the
date and time as part of the name)
3. Enter the correct COM# that the PCU registers under.

Mac
1. Open terminal
2. Use the following command:
3. screen -L /dev/tty.usbserial.
This will also save the output to the user folder in a file named screenlog.0

ALL Power Labs, Inc

Berkeley, CA
[email protected]
[email protected]