28142 Rev 15 TROUBLESHOOTING
Gentherm Global Power Technologies Page 69
Check the SI Power Supply (FPCi Board)
The SI Module (also known as the FPCi Board) starts and monitors the TEG’s burner. It also
charges the internal startup battery. The board itself is potted, so troubleshooting is not
possible in the field, but the board will not normally require service. Follow these steps to
verify that the SI Module is getting power:
1. Start the TEG after it has been allowed to cool for 30-60 minutes.
2. Upon start up, probe and measure the voltage between the Red and Black wires of
the SI Module’s connector plug, see Figure 32 and Figure 33. Voltage should be
between 13.7 V and 14.2 V.
3. Repeat the measurement after 20 minutes, voltage should again be between 13.7 V
and 14.2 V.
Follow these steps to check the power supply battery charging circuit and ignition controller
voltage Supply:
1. Start the TEG.
2. After twenty minutes of TEG operation, check the battery voltage.
3. Voltage should be 6.5 V or greater.
Check the Internal Battery Capacity
Follow these steps to check whether the internal startup battery holds a charge:
1. With the TEG allowed to cool and the manual shutoff valve turned off, remove the
two orange wires from the terminals of the pressure switch and short them together.
2. Measure the battery voltage within 60 seconds of shorting the pressure switch wires
together. If battery voltage drops below 6 V during this time, replace the battery.
Check the Solenoid Valve
The 5220 is equipped with a solenoid valve to control fuel flow to the burner and act as a
safety shutoff. A faulty solenoid valve may prevent a TEG from starting or shutting down
correctly. There are two ways to check the solenoid valve:
1. If you cannot hear the solenoid valve audibly “click” open when sparking begins,
allowing fuel to flow, then unplug the solenoid valve connector from the back of the
valve. Measure the resistance across pins 1 and 2 on the back of the solenoid valve.
A 12V solenoid valve will have a nominal resistance of 72 Ohms, and a 24V solenoid
will have a nominal resistance of 288 Ohms. Resistance values significantly above
these indicate a damaged coil. Replace the solenoid valve if coil resistance is high.
2. Unplug the connector from the back of the solenoid valve and then apply fuel pressure
to the TEG. While the SI is sparking, carefully measure the voltage across terminals
1 and 2 on the solenoid valve plug. If voltage is less than 11V, check power supply to
the SI Module (Section 10.2.5). If the SI Module is getting correct power, replace the SI
Module.
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