PAGE 1 This document outlines questions to ask and components to check during TES troubleshooting. More detailed troubleshooting procedures are available in the TES Troubleshooting Guide. 1. Flow Light OFF: Go to Page 2 2. Pump not running: Go to Page 2 3. Burner will not light: Go to Page 2 4. Hi Limit Light OFF: Go to Page 3 5. Operator Light OFF: Go to Page 3 6. Main Gas Light OFF: Go to Page 3 7. Fluid Leaking: Go to Page 5 8. Low Heat Output: Go to Page 6 9. Overheating: Go to Page 8 10. Flame Roll-Out / Burned Wires & Melted Gauge: Go to Page 9 11. Troubleshooting Guide Outline: Go to Page 10 TES Operation & Testing Guidelines: 1. Before Running TES unit be sure you have an adequate supply of combustion air & a properly installed exhaust duct. During operation inside a trailer, the air intake fan must be on, the roof vents must be open & the trailer doors must be closed. 2. Before trying to light the heater the pump must be ON. 3. Before turning the pump ON: a. Hook up hoses & TEX boxes. At least two boxes must be connected to operate TES. It is best to have four or five boxes connected. b. Make sure the TES Fluid reservoir is full of TES Thermal Energy Fluid. You must be able to see fluid in sight tube. c. Open the By-pass valve all the way. (Turn handle Counter-clockwise to open valve) 4. Before turning the heater switch ON: a. Make sure propane tanks are full or have enough propane left to provide adequate vaporization at the operating temperature range. b. Make sure propane tanks & hoses are connected and all valves are open. 1
When you turn the pump switch ON, do you hear the main solution pump running? PAGE 2 Check the Power from source into unit & wiring from terminal block to pump switch to then pump. Repair wiring or replace pump (Troubleshooting Guide Section 2) By-pass Valve could be bad. Pressure reducing valve could be bad Check valve operation. Filter fluid, clean filters & heat exchangers. (Troubleshooting Guide Section 3) Is approx. 30PSI of pressure showing on the gauge? Higher Push the fast fill button do you hear the FloJet system pressure pump running? Lower - Check the Power to Flojet pump. Power Found? Is the pressure gauge showing a steady pressure or is it jumping around? Steady Turn Heater Switch ON See page 3 Jumping Hold the fast fill button & watch the fluid level in the Reservoir. Does the level go down? Disconnect Outlet hose & test Flojet pump flow. Good Flow Repair Wiring No Flow Is this the first time you have reached this point in the testing process? Repair or replace Pressure reducing Valve Repair or replace the Flojet System Pressure pump Failure to maintain 30psi and hold steady pressure even with the system pressure pump supplying fluid could indicate that the pressure gauge is bad or that the Main Solution Pump is not working properly. The gauge should show 12-30psi just from the fluid supplied by the Flojet System Pressure pump. If there is no pressure showing on the gauge or the fluid has drained from the gauge, replace the gauge. If the pressure is still low or jumping around repair or replace the Main Solution pump as needed. 2
PAGE 3 When you turn the Heater switch ON, look at the indicator light panel what lights are ON POWER - ON HI LIMIT - ON Check 2amp Fuse & Replace the 2amp fuse as needed. Check for causes of fuse blowing. Check 24V power at terminal #1 & #2 of 24V terminal block. Replace transformer, heater switch & wires as needed to restore power to terminals #2 & ground to #1 and the POWER light. If needed replace the light panel. (Troubleshooting Guide Section 4) If the solution temperature is over 230 F or the Hi-Limit control is set too low the light will stay off. It may turn off & on during normal operation. Let the boiler cool down, check the setting & reset control as needed. The power must first go through the hi-limit control to power the other lights. Check wires & control function Repair wires or replace control as needed to restore power to the light. If needed replace the light panel. (Troubleshooting Guide Section 6) OPERATOR - ON If the solution temperature is over 200 F or the operator control is set too low the light will stay off. It may turn off & on during normal operation. Let the boiler cool down, check the setting & reset control as needed. Check wires & control function. Repair wires or replace control as needed to restore power to the light. If needed replace the light panel. (Troubleshooting Guide Section 7) LOW FLOW - ON Make sure by-pass valve is open all the way & pump is running. Check pressure reading on gauge. If the pressure is low or jumping around, return to Page 2. Slowly turn by-pass valve clockwise to close valve. Do not close valve all the way. After completing test open valve all the way. Does the pressure go up as you close the valve? Return to Page 2 & repeat pump tests or Replace or repair pump Test the continuity through the yellow & red wires going to the flow switch & repair wires & flow switch as needed to restore continuity when the fluid flow rate is adequate and break continuity when the flow rate is low. Repair wires, replace flow switch or roll out switch as needed. (Troubleshooting Guide Section 1) MAIN GAS - ON Go to Page 4 If burner turns off, Main Gas Light turns OFF & all other lights stay ON Go to Page 4 If burner stays on, unit is OK. If burner turns off, Main Gas light turns off & any other lights turn off. 3
PAGE 4 Does the Main Gas Light come on but then turn off or does it not come on at all? Does Not Come ON at All Comes ON & turns OFF Comes ON & Blows Fuse Check power to terminal #6 of Burner Ignition control where blue wire is connected. Power found? Are any other indicator lights OFF? Return to Page 3. Most common cause would be a restriction in the propane supply. Check tank levels & make sure valves are open. Check pressure at gas valve with manometer. Replace regulator & POL fitting as needed to restore flow. Other cause could be Pilot Assy, Burner ignition control or gas valve. Replace components as needed If all other indicator lights are ON there has to be a broken wire from the terminal block to the Burner Ignition control or on some machines the roll-out switch may be bad. Check wires & replace roll out switch to restore power to terminal #6 Fuse Blows Most Common cause would be a bad Main Gas Valve. Disconnect all wires from gas valve. Turn pump & heater switches ON. Examine wires & look for other possible causes. Replace Burner Ignition control & any burnt wires. Fuse Blows Fuse Does Not Blow Reconnect the brown & gray wires to the gas valve & retest. Fuse Does Not Blow Check for spark & check power at PV & C terminals on Gas Valve Replace Burner ignition control or gas valve. (Troubleshooting Guide Section 5) Replace the gas valve Fuse Blows Reconnect the orange & red wires to the gas valve & retest. Replace the gas valve Fuse Does Not Blow 4
Where is the fluid leaking? PAGE 5 The fluid can come from Spiro-Vent or Safety Pressure Relief Valve. Clean-out Float Valve on Spiro-Vent. Replace Safety Pressure Relief Valve. Leaking from barbs under the left side of the machine base. Leaking from above burner in combustion chamber HP Solution Pump The fluid can is probably coming from a ruptured heat exchanger. Replace Tube Bundle assembly. Most likely the mechanical seal is bad. Repair or replace the HP Solution Pump. Side of combustion chamber Pump Compartment above pump Control Panel Outside of combustion chamber Flojet System Pressure Pump Repair or replace Flojet System Pressure Pump or outlet hose as needed The fluid can be coming from a ruptured heat exchanger or a leaking seal between the header & the heat exchanger. Remove Headers & replace o-rings & pressure test the Tube Bundle assembly. Replace the Tube Bundle assembly as needed. Examine hoses & fittings for leaks. Tighten hose clamps, replace hoses & fittings as needed. Also check reservoir & heat exchanger header for leaking. Examine hoses & fittings for leaks. Tighten hose clamps; replace hoses & fittings as needed. Also pressure gauge & pressure relief valve may need to be replaced. 5
PAGE 6 Does burner light and the Main Gas Light come on? Go to Page 2 Does the Main Gas light turn off or does the burner continue to burn without reaching the usual temperature? Continues to Burn Turns Off Do any other indicator lights turn OFF? Operator & Flow or Hi-Limit, Operator & Flow Flow Only Go to Page 2 Is the Hi-Limit Control set at 230 F and Operator Control set at 200 F? Reset Controls to proper temperature & test heat output Are gauges measuring temperature accurately? Test heat output Low Heat Replace gauges Does the Main Gas light turn off or does the burner continue to burn without reaching the usual temperature? Low Heat If Heat Output is now good, the machine is OK. If Heat Output is now good, the machine is OK. Continues to Burn Turns OFF Do any other indicator lights turn OFF before usual temperature is reached? Go to Page 7 Hi-Limit, Operator & Flow Operator & Flow Replace roll-out switch Replace Hi-Limit Control Replace Operator Control 6
PAGE 7 Most common cause of low heat output would be low vaporization or a restriction in the propane supply. Make sure you have the correct number of propane tanks to supply the propane necessary for heater operation at the current outdoor temperature. The vaporization rate drops with temperature & tank level. Check tank levels & fill as needed. Make sure all valves are open. Check pressure at gas valve inlet with manometer. Correct propane pressure measured at gas valve inlet. Low propane pressure measured at gas valve inlet. Check pressure at gas valve outlet with manometer. Adjust regulator or replace regulator & POL fitting, valves & hoses as needed to restore flow. Correct propane pressure measured at gas valve outlet. Low propane pressure measured at gas valve inlet. Test heat output Adjust Gas Valve or replace regulator & POL fitting, valves & hoses as needed to restore flow. Low Heat If Heat Output is now good, the machine is OK. Clean or replace burner tubes. Clean heat exchanger exterior fins. Remove right side header & clean inside of heat exchanger tubes (Troubleshooting Guide Section 8) 7
PAGE 8 If the incoming propane pressure is too high the gas valve may not be able to shut off the flow of gas, allowing the burner to run too long and overheat. Check the incoming propane pressure at the gas valve inlet. Correct propane pressure measured at gas valve inlet. Propane pressure too high, when measured at gas valve inlet. When you turn the pump OFF does the Low Flow light turn off? Replace the propane regulator. Adjust inlet pressure to proper range. Replace the Flow Switch With no TEX boxes connected, Open By-Pass Valve & turn pump ON. With heater switch ON, does the Low Flow light go OFF as you start to close the By-Pass Valve? Replace the By-Pass Valve Is the Hi-Limit Control set at 230 F and Operator Control set at 200 F? Reset Controls are set at correct temperature settings. Reset Controls are set at wrong temperature settings. Are gauges measuring temperature accurately? Reset Controls to proper temperature settings. Replace Gauges Does Operator light turn OFF when reaching the 200 F Inlet temperature? Replace Operator Control Does Hi-Limit light turn OFF when reaching the 230 F Outlet temperature? Replace Hi-Limit Control When the Hi-Limit or Operator lights turn OFF does the burner turn off? Replace Gas Valve Filter Fluid, Clean Filters, Remove right side header & clean out heat exchanger tubes. (Troubleshooting Guide Section 9) 8
PAGE 9 The most common cause of Flame Roll-Out is improper trailer ventilation (Troubleshooting Guide Section 10) An adequate supply of clean combustion air & the removal of hot exhaust gases are required for safe efficient operation of the TES unit. 1. TES Exhaust pipe must be installed as outlined in TES Installation instructions in the TES Operator s Manual & TES Install Manual. 2. Roof Vents must be installed as outlined in TES Installation instructions in the TES Operator s Manual & TES Install Manual. 3. Air Intake Fan must be installed as outlined in TES Installation instructions in the TES Operator s Manual & TES Install Manual. (Air flow must be directed into trailer.) 4. Air Intake Fan must be on and running at all times during TES operation 5. Hose access door must be installed as outlined in TES Installation instructions in the TES Operator s Manual & TES Install Manual. 6. All trailer doors must be closed during TES operation. Improper trailer ventilation may not always lead directly to Flame Roll-Out, but poor ventilation will prevent complete combustion of the propane causing soot build-up which can cause exhaust restriction allowing the heat to build-up and roll-out to damage wiring and gauges. Other Causes of soot buildup: Propane Supply Overfilled tanks can blow liquid propane through system causing soot build-up. Propane Regulator If the propane pressure & flow is too high the excess propane will not burn completely causing soot build-up. Jets The wrong size burner jets for the altitude at which the unit is operating can allow excess propane flow, which will not burn completely causing soot build-up. Gas Valve Failure Can allow excess propane flow which will not burn completely causing soot build-up. If soot build-up is found, the Heat Exchanger Tube Bundle will need to be removed & cleaned to allow the hot exhaust gasses to flow up & out the exhaust pipe. 9
1. FLOW LIGHT OFF: Possible Causes: 2. PUMP T RUNNING: Possible Causes: PAGE 10 LOW FLOW: Pump not running Power Motor Failure Pump running but not pumping Not Primed System Pressure Pump Failure Restricted Flow Pump Failure FLOW LIGHT POWER: Flow Switch High Limit Control Operator Control Wiring Light Failure POWER SUPPLY WIRING PUMP MOTOR FAILURE 3. HIGH SYSTEM PRESSURE: Possible Causes: GAUGE FAILURE PRESSURE REDUCING VALVE RESTRICTED FLOW 4. POWER TO HEATER: Possible Causes: POWER SUPPLY FUSE BLOWN WIRING TRANSFORMER FAILURE 5. BURNER WILL T LIGHT: Possible Causes: POWER TO HEATER LOW FLOW OPERATOR CONTROL HI-LIMIT CONTROL PROPANE SUPPLY Tank Level Regulator Hose Restriction PILOT LIGHT FAILURE Orifice Plugged Flame Adjustment Flame Sensor Failure Ignition Cable Failure BURNER IGNITION CONTROL Wiring Failure GAS VALVE Valve Closed Valve needs adjustment / Valve Failure 10
PAGE 11 Tes Trouble shooting 6. HI-LIMIT LIGHT OFF: Possible Causes: POWER TO HEATER FUSE BLOWN WIRING TRANSFORMER FAILURE OVERHEATED HI-LIMIT CONTROL FAILURE 7. OPERATOR LIGHT OFF: Possible Causes: POWER TO HEATER FUSE BLOWN WIRING TRANSFORMER FAILURE OVERHEATED HI-LIMIT CONTROL FAILURE OPERATOR CONTROL FAILURE 8. HEAT LOW OR HEAT: Possible Causes: PROPANE SUPPLY GAUGE FAILURE FUSE BLOWN WIRING TRANSFORMER FAILURE OVERHEATED LOW FLOW LOW FLOW SWITCH FAILURE HI-LIMIT CONTROL FAILURE OPERATOR CONTROL FAILURE 9. OVERHEATING: Possible Causes: GAUGE FAILURE WIRING BY-PASS VALVE OPEN TOO MUCH FLOW RESTRICTION LOW FLOW SWITCH FAILURE HI-LIMIT CONTROL FAILURE OPERATOR CONTROL FAILURE GAS VALVE FAILURE REGULATOR FAILURE 11
PAGE 12 Tes Trouble shooting 10. FLAME ROLL-OUT: Possible Causes: EXHAUST RESTRICTION LACK OF COMBUSTION AIR PILOT LIGHT FAILURE Orifice Plugged Flame Adjustment Flame Sensor Failure Ignition Cable Failure PROPANE SUPPLY Tank Level Regulator Hose Restriction GAS VALVE FAILURE PROPANE LEAK TEMPORARY WEATHER CONDITIONS 12
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