Gentherm 5220 User Manual

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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.

Table of Contents

Questions and Answers:

M
manningdanielAug 13, 2025
How to fix Gentherm 5220 Portable Generator when burner does not ignite?
- S
  Shawn CisnerosAug 13, 2025
  If your Gentherm Portable Generator's burner won't ignite, it could be due to several reasons. There might be air in the fuel line, so you should purge the fuel lines. The supply gas pressure could be too low, requiring you to increase the gas supply pressure. A dirty fuel filter can also cause this, so drain the regulator sediment. Other potential causes include incorrect fuel pressure adjustment (adjust the TEG fuel manifold pressure), a plugged or incorrect fuel orifice (replace the fuel orifice), an open TCO (check TCO continuity and replace if open), a dirty air filter (clean the air filter), incorrect air-shutter adjustment (open the Air Shutter slightly), or a faulty SI system (maintain the SI system).

Gentherm 5220 Specifications

General

Brand	Gentherm
Model	5220
Category	Portable Generator
Language	English

Summary

Safety Information

General Warnings

Covers critical warnings about fire, explosion, damage, and injury.

Gas Leak Precautions

Instructs actions to take if a gas leak is detected, including evacuation and contact.

About This Manual

Health and Safety

Details safety guidelines, warnings, cautions, and required operator qualifications.

Quick Start Procedure

Installation

Guides users through the physical setup and connection of the TEG unit.

Start Up

Outlines the procedure for initiating the TEG's operation sequence.

Tuning

Explains how to adjust the TEG for optimal performance after startup.

Process Description

Fuel System

Describes the components and function of the system that delivers fuel to the burner.

Spark Ignition System

Explains the operation of the spark ignition control system for starting the burner.

220-Watt Limiter

Current Limiter

Provides overload protection by reducing output voltage during excess current draw.

220-Watt Limiter/Converter (L/C)

Protective Voltage Limiter

Limits input voltage to ensure optimal performance and protect the TEG.

Voltage Converter

Installation

Precautions

Lists essential safety and installation guidelines to follow before setup.

Supplying Fuel

Connecting Customer Load

Installing Limiter/Converter (L/C)

Installing CP Interface System

Startup and Shutdown

TEG Start-Up

Step-by-step guide for initiating the TEG's ignition and operation sequence.

Power Output Evaluation

Ambient Temp Effects on Vset/Power

Explains how ambient temperature influences TEG voltage and power output.

Determining Vset and Power

Guides on calculating required Vset and expected power at site conditions.

Determining Vset and Power Graphically

Vset and Rated Power

Explains how to measure and set Vset for optimal power generation.

Vset Shortly after Ignition

Procedure to check Vset shortly after the TEG has started and warmed up.

Vset After TEG Stabilized

Procedure to check Vset after the TEG has reached stable operating temperature.

Adjustment

Tuning the TEG

Outlines the sequence of adjustments to optimize TEG power output.

Fuel Pressure Adjustment

Guides on adjusting fuel pressure to achieve the correct Vset and power.

Air-Shutter Adjustment

Explains how to adjust the air shutter for optimal combustion and performance.

Air Shutter Adj. Using Meter

Air Shutter Adj. Using Analyzer

Maintenance

Recommended Periodic Maintenance

Outlines the recommended service intervals and checks for the TEG.

Evaluate Vset

Routine Service

Fuel System Maintenance

Troubleshooting

Burner Troubleshooting

Guides for diagnosing and resolving issues related to the burner.

Spark Ignition System Troubleshooting

Guides for diagnosing and resolving issues with the burner ignition system.

Check Spark Electrode

Check Pressure Switch

Electronics Assembly Examination

Guides for checking and troubleshooting the L/C and Limiter electronics.

Power Unit Examination

Guides for diagnosing potential damage or faults in the power unit.

Check Internal Resistance

Procedure to measure the internal resistance of the TEG power unit.

Check for Internal Short

Steps to identify potential internal electrical shorts within the power unit.