Home

Service Manual - TES - Thermal Energy Systems

1. POWER OPERATOR HI LIMIT LOW FLOW MAIN GAS When the POWER light is the only light ON it indicates that the solution temperature has exceeded both the Operator set point and the Hi Limit set point and the burner has shut OFF This could mean that the Hi Limit set point is set too low or that there 1s a flow restriction to the TEX units and the heater is getting too hot If only one TEX unit is connected and the by pass valve is opened too much or there is a flow restriction that reduces the amount of heat draw from the system the heater may overheat and exceed the Hi Limit set point even if it is adjusted properly Re set Operator and Hi Limit controls and add TEX units to improve flow as needed to correct the overheating If this light pattern occurs while the TES unit is cool and control temperatures are properly set it could indicate an electrical problem in the control panel contact your nearest service center for assistance POWER OPERATOR HI LIMIT MAIN GAS NA If the HI LIMIT and MAIN GAS lights are OFF and the POWER OPERATOR and LOW FLOW lights are ON the Hi Limit set point may be set below the operator set point temperature Reset the Hi Limit control set point to proper temperature The Hi Limit set point must be at least 20 F above the Operator set point temperature The Operator set point is preset at the factory at 200 F It could also indicate a failure of the Hi limit control Repair wiring or replace hi limit control
2. HEADER NUT 57 0492 INLET amp OUTLET A C O ad LI JLU J OL IQ sb HOL Baia gt OUTDOOR VENT CAP PRO9 0123 COVER HEADER 55 TES 2 TOP COVER SS TES 15 LOWER FRONT PANEL 03 0729 TES HEATER COVER FLUID RESERVOIR NM5004 HOOD ASSY SS TES HEATER 70 1215 HANDLE ASSEMBLY TES NM4249 TES BASE ASSEMBLY wa 66 LATCH W LOCK amp KEY NM4218 PLATE WHEEL MOUNT TES NM4277 6 PLEXIGLASS PANEL NM4265 18A PIN SNAPPER Ya X 2 NM4226 FOOT RETAINER TES DOOR ASSY SS 19 SUPPORT BACK PANEL BASE SS TES CONTROL PANEL Ia Ee a ID VINYL 57 SUPPORT SIDE PANEL BASE SS MW mere ELBOW 90 1 8 F F BRASS BR290 KNOB PANEL DOOR NM4271 BIE 14 X 1 8 MPT BRASS BRO10 SCREW 10 32 X1 2 SOCHD SS NM4061 kad ASSY SS HOSE ACCESS NS TES WHEEL PNEUMATIC RIGID NM4225 PANEL TES SIDE PANEL SS TES hull TES WHEEL PNEUMATIC SWIVEL NM4224 BACK PANEL SS TES TRIMLOCK EDGE PROTECTOR NM4273 Sold per inch 13 SUPPORT FRONT PANEL SS NS TES DECAL SET NM4284 FRONT SUPPORT BASE SS TANK FLUID RESERVOIR TES NM4275 42 10 amp 10A 10 amp 10A 1 OUTDOOR VENT CAP PRO9 0123 10 PLATE WHEEL MOUNT TES NM4277 2 TOP COVER 55 TES 10A PIN SNAPPER 4 X 2 NM4226 RETAINER TES COVER FLUID RESERVOIR FLUID RESERVOIR NM5004 Nn HANDLE ASSEMBLY TES NM4249 TES WHEEL PNEUMATIC NM4
3. Then turn the pump OFF and close the by pass valve Unit is ready to return to service 19 System Pressure Pump A Flojet 30psi pump is used to maintain system fluid pressure replace lost fluid and prime the solution pump The only required maintenance is to keep an adequate supply of TES Thermal Fluid in the reservoir and check and clean the acorn strainer in the reservoir to prevent debris from restricting the flow to the pump If pump does not pump properly the pump can be repaired or replaced as needed System Pressure Pump System Pressure Pump Removal a b 5 d c Disconnect power cord from the TES unit Dtain fluid from reservoir Save fluid for re use Remove 1 2 ID hoses from pump outlet and inlet Use towel to soak up any spilled fluid Disconnect wires from pump motor and pressure switch Remove four bolts holding pump to TES unit base and remove pump from TES unit To teplace Demand Pressure Switch Remove screw holding cover on switch and remove cover Disconnect two wires from switch Remove two screws holding switch to pump housing and remove switch Remove diaphragm between pump and switch and replace with new diaphragm Place new switch on housing and secute with two screws Reconnect two wires to switch and replace cover aa SE Pressure Switch To replace Valve Chamber 1 Remove screw holding cover on switch and remove cover 2 Disconnect two wires from switch 3 Remove
4. check burner flame and check for propane leaks Repair as needed Turn heater OFF after testing and allow system to cool before turning pump OFF Close the propane tank valve and disconnect the regulator and hose from the tank Disconnect the power cord Re install the outdoor hood assembly and front jacket panel The system is ready to return to service Flame Roll Out Shield 29 Burner Drawer 6 Replacement of main gas valve 7 8 a b c d e f g h i j k D m n o p q r 5 t Converting Gas Valve to LP a Close the propane tank valve and disconnect the regulator and hose from the tank Disconnect the electrical power to the TES unit Remove the outdoor hood assembly and front jacket panel Disconnect the propane hose from the main gas valve Disconnect all electrical wires from the main gas valve Disconnect the pilot gas tube from the main gas valve Un thread the gas valve from the burner assembly pipe Thread the outlet port of the new gas valve on to the burner assembly pipe Use thread sealant Reconnect the pilot gas tube to the main gas valve Pilot Tube Reconnect all electrical wires to the main gas valve Turn the knob on top of the main gas valve to the ON position Re connect the propane hose to the main gas valve and propane tank Open the valve on the propane tank Use thread sealant and check for propane leaks on the inlet side of the valve Repair as nee
5. 4 Female QC to 2 1 2 Male QC s AH104 Outlet Solution Tee 3 4 Male QC to 2 1 2 Female QC s AH106 TEX Thermal Exchangers MB212 TES Thermal Fluid Gallon CROIGL QD Wraps Large AH10L QD Wraps Medium AH10M Adapter for Dual Propane Tanks AT68 Adapter for Triple Propane Tanks AT69 Trailer Rack for 3 Propane Tanks AT70 TES Trailer Mount Support Frame AT78 Trailer Fan Kit AT76 Shelf for 4 Air Movers AT72 Shelf for 6 Air Movers AT74 Trailer Vent Cap J cap NM4330 Floor Anchor NM4328 High Altitude Burner Jets The efficient operation of this heater depends on the proper fuel air mixture in the combustion chamber The amount of fuel required for proper combustion will vary with changes in altitude With less oxygen available for combustion at higher altitudes less fuel can be burned and the Btu input rating of the heater is reduced by 4 for each 1000 feet above sea level The standard TES unit is designed for operation at elevations from sea level to 2000 feet Use of the TES unit at altitudes above 2000 feet will require replacing the burner jets with smaller jets to reduce the gas flow to match the lower oxygen levels If the jets are not changed the excess fuel will result in poor combustion and black soot build up that will impair the heater s performance or damage the heater Burner jet replacement should only be performed by trained technicians The following Burner Jets are available for operatio
6. Reset breakers or move cord to another outlets Heater Power Light Not Faulty power cord Replace cord Replace 2 amp fuse amp Check wiring amp test Repair as Heater Fuse Blown needed Faulty switches or internal wiring Check wiring amp test switches Repair as needed Faulty indicator light Replace light Heater Solution temperature above set point Normal Operation If needed raise set point Operator Light Loss of power see Power Light All other lights also off Not Lighted Faulty switches or internal wiring Check wiring amp test switches Repair as needed Faulty indicator light Replace light Lighted To reduce the risk of injury repairs to electrical propane or fluid pressure systems should only be performed by experienced technicians Contact your nearest service center for assistance 16 Problem Case Solution Heater Flow rate too low Check Pump Open by pass valve to increase flow Low Flow Light Solution temp over operator set point Normal Operation Operator light also off Not Lighted See Power Light All other lights also off Faulty switches or internal wiring Check wiring amp test switches Repair as needed Faulty indicator light Replace light Heater Solution temperature above set point Normal Operation If needed raise set point Hi Limit Light See Power Light All other lights also off Not Lighted Faulty switches or internal wiring Chec
7. an extractor ot wet vac to draw additional fluid out of TES unit d Remove 1 ID hose from pump outlet and remove 1 1 4 ID hose from pump inlet Use towel to soak up any spilled fluid e Disconnect wires from junction box on side of pump motor f Remove four bolts holding pump to TES unit base and remove pump from TES unit g Remove eight casing bolts from pump Remove casing from pump assembly h Remove guidevane and guidevane seal ring 1 Remove impeller locknut and remove impeller by turning counter clockwise when looking at front of pump Wear glove or use rag to protect hand when turning impeller j Insert two pry bars 180 apart between the seal housing and motor adapter The mechanical seal should come off the motor shaft with the seal housing k Remove the four bolts holding the motor adapter to the motor D Push out the mechanical seal out from the motor side of the seal housing 33 m Replace old parts with new as needed ot clean old parts before re assembly Replace old motor with new motor if n o p needed All mechanical seal components must be in good condlition or leakage may result Replacement of complete seal assembly should be considered whenever seal has been removed A light lubricant such as glycerin can be used to ease re assembly Do not contaminate mechanical seal surfaces with lubricant Replace secure motor adapter to motor with four bolts Inspect casing o ring and replace as needed Casi
8. as needed 19 OPERATOR HI LIMIT LOW FLOW MAIN GAS If all lights are OFF the heater switch may be in the OFF position Turn switch ON and check power supply to assure that power is being supplied to the TES unit If the lights are still OFF remove Hood Assembly to access wiring and check fuse Replace 2 amp fuse as needed or contact your nearest service center for assistance POWER OPERATOR HI LIMIT LOW FLOW MAIN GAS If the POWER light is OFF and the other lights are ON there is a problem with the light panel or other wiring Contact your nearest service center for assistance POWER OPERATOR HI LIMIT LOW FLOW MAIN GAS If the POWER HI LIMIT and MAIN GAS lights are ON and the OPERATOR and LOW FLOW lights are OFF there is a problem with the light panel or other wiring Contact your nearest service center for assistance If the POWER OPERATOR LOW FLOW and MAIN GAS lights are ON and the HI LIMIT light is OFF there is a problem with the light panel or other wiring Contact your nearest service center for assistance POWER OPERATOR HI LIMIT LOW FLOW MAIN GAS If the POWER LOW FLOW HI LIMIT and MAIN GAS lights are ON and the OPERATOR light 1s OFF there 1s a problem with the light panel or other wiring Contact vour nearest service center for assistance 20 Heater Flow Path FLUID RESERVOIR PRESSURE RELIEF FLOW VALVE SWITCH I nr EE ee xU b PRESSURE REDUC
9. decrease the size clockwise to make the flame larger g Replace the screw cap over the pilot adjusting screw h Turn the heater OFF and run the pump to cool of the system if needed 1 Close the valve on the propane tank and disconnect propane regulator and hose from tl Turn the pump OFF and disconnect the power cord k The system is ready to return to service 3 Pilot Assembly Removal a Close the propane tank valve and disconnect the regulator and hose from the tank b Disconnect the electrical power to the TES unit c Remove the outdoor hood assembly and front jacket panel d Disconnect the pilot gas tube from the main gas valve e Disconnect the orange igniter wire from the burner ignition control f Remove the Flame Roll Out Shield g Remove the two screws connecting the pilot assembly to the burner drawer assembly h Remove the pilot assembly from the heater i Disconnect the pilot gas tube from the pilot assembly Replace the pilot gas tube and compression fittings as needed j Remove the pilot orifice from the pilot assembly Clean or replace the pilot orifice or replace the complete pilot assembly as needed k Reconnect the pilot tube to the cleaned repaired or new pilot assembly Make sure the tube is installed in the same position or a new tube is bent correctly so the other end of the pilot gas tube will line up with the pilot gas outlet port on the main gas valve D Place the pilot assembly back int
10. four screws holding pump housing onto bearing cover and remove housing 4 Remove valve chamber from housing and replace with new valve chamber Make sure o ring is in place on top of valve chamber and properly aligned to seat inside pump housing 5 Place housing and valve chamber back on top of bearing cover and secure with four screws 6 Reconnect two wires to switch and replace cover Valve Chambet 34 Diaphragm Drive Assembly To replace Diaphragm amp Drive Assembly Diaphtagm amp Drive Assembly includes Diaphragm Lower Housing Bearing Cover Cam and Bearing 1 Remove screw holding cover on switch and remove cover 2 Disconnect two wires from switch 3 Remove four screws holding upper pump housing onto lower housing bearing cover and remove upper housing and valve chamber 4 Remove two screws holding bearing cover onto motor Rotate the lower housing bearing cover to align drain notch with set screw on cam bearing assembly 5 Use 1 8 Allen wrench to loosen set screw and slide cam bearing assembly off of motor shaft and remove the Diaphragm Drive Assembly 6 Coat the motor shaft with grease or anti seize lubricant 7 Take the new Diaphragm Drive Assembly and slide the cam bearing assembly onto the motor shaft Position shaft so set screw is aligned with indentation on shaft and tighten set screw Set screw must be set into indentation for proper alignment 8 Re install the two screws holding the bear
11. of property damage or injury repairs to electrical systems should only be performed by experienced technicians Contact your nearest service center for assistance If solution lines pump or heater are leaking unplug machine power cord from outlet before approaching or touching machine Remove Feet or carpet clamps from snout of air mover before placing air mover into TEX Thermal Exchanger to prevent damage to air seal gasket 10 This heater operates with hot solution under pressure TES Thermal fluid under pressure and at high temperature can cause burns severe personal injury ot death The TES Thermal Energy System must be operated and maintained propetly to reduce the tisk of burns or other injuries 9 Always turn Pump ON before turning Heater ON e Always turn Heater OFF and allow solution to cool before turning Pump OFF e Turn Heater OFF allow solution to cool then turn Pump OFF and disconnect power cord before disconnecting any hose from the TES unit e Turn Heater OFF allow solution to cool and turn Pump OFF before disconnecting any hose from the thermal exchangers solution tees or other hoses e Wear eye protection when connecting and disconnecting hoses e Stainless steel covers and doors have sharp edges Wear leather work gloves when connecting or disconnecting quick connects or performing maintenance or repair procedures on the TES unit 9 With pump OFF hoses and fittings will retain 12 psi system p
12. personal injury or death e If solution lines pump or heater are leaking unplug machine power cord from outlet before approaching machine 11 Heater Operation Procedure Knowledge of the proper operation of the heater and heat exchange system is required for safe operation and to keep heater and components operating properly 1 2 3 4 5 6 7 Place the TES unit in an area close to 8 convenient entry point for hoses to heat exchangers Heater must be level and in a well ventilated area Consideration must be given to the security of the selected area in regards to theft tampering and safety Place and secure TES unit to prevent movement during operation Propane tanks must be placed in proper use position on a solid level area and secured if necessary to prevent tipping Position TES unit and tanks to keep tanks away from heater Connect the hoses to the outlet and inlet quick connects and run hoses to TEX Thermal Exchangers as needed Wear leather gloves and eye protection when connecting hoses For proper heater operation two or more TEX Thermal Exchangers should be connected to the heater For extended hose runs use more 3 4 TES hoses for improved flow Place quick connect wraps on all hose connections to hold heat and prevent burning from contact with hot brass fittings Add TES Thermal Fluid to reservoir as needed to keep fluid level above half full Connect the power supply cord to the TES heater C
13. pressure or counterclockwise to decrease the pressure n Turn the heater OFF and run the pump to cool of the system o Replace the plastic cap over the HI and LOW pressure adjustment screws p Close the valve on the propane tank and remove the manometer Replace the outlet pressure tap plug Use thread sealant on the tap plug and check for propane leaks q Turn the pump OFF and disconnect the power cord t The system is ready to return to service 2 Adjusting Pilot Flame If the pilot flame is small or lazy and does not touch the ground electrode the inlet gas pressure may be too low ot the pilot orifice may be partially restricted Make sure propane tanks are full Check the inlet gas pressure and remove pilot orifice and clean as needed before attempting to adjust the pilot flame If the pilot flame is hard and noisy the inlet gas pressure may be too high Check the inlet gas pressure before adjusting the pilot flame If pilot flame adjustment is necessary proceed as flows a Connect the propane regulator and hose to the propane tank b Connect the power cord to the TES unit c Turn the pump switch ON and open the by pass valve You will not need to hook up any hoses or TEX units d Open the valve on the propane tank and turn the heater switch ON Use a Phillips screw driver to remove the screw cap covering the pilot adjusting screw f Use a flat blade screw driver to turn pilot adjusting screw clockwise to
14. turn switch OFF and back on to repeat ignition process This procedure mav need to be repeated several times to get air out of the lines and allow the burner to fire When the POWER OPERATOR and HI LIMIT lights are ON and the LOW FLOW and MAIN GAS lights are OFF it is an indication that the solution flow is too low to trigger the Flow Switch and the burner will not fire Make sure pump switch is ON pump is running and showing pressure on gauge At least two TEX Thermal Exchangers must be connected for proper flow With the TEX units connected and pump ON open the Bv Pass Valve to increase the solution flow Open the valve slowlv until the LOW FLOW light comes ON Once LOW FLOW light comes ON continue opening the bv pass valve 1 4 1 2 turn If the LOW FLOW light does not come ON recheck vour hose connections and repeat the procedure 18 MAIN GAS During normal operation there may be times when the POWER and HI LIMIT lights are ON and the other lights are OFF This indicates that the Operator set point temperature has been reached and the heater is not firing When the Operator set point is reached the burner shuts OFF and the MAIN GAS light goes OFF The power to the Flow switch and LOW FLOW light goes through the Operator control so when the OPERATOR light goes out when the Operator set point is reached the LOW FLOW light will turn OFF too When the solution temperature cools below the Operator set point the lights will all come back ON
15. 0 BARB 1 2 X 1 8 MPT BRASS BARB 1 2 X 1 2 MPT BRASS MODIFIED E NS HOSE CLAMP 9 16 1 1 4 SS PHO9 NS GROMMET Ya NS SCREW TEK 10 X 5 8 SS NM4263 Z P N ON 100 CASING 1L81 FIG LENE SOLUTION PUMP 123 DEFLECTOR 5K7 ST NM4204 304 IMPELLER 13K286 LOCKNUT 347 GUIDEVANE 5125 349 SEAL RING 5K269 Eat EE 370 SOCKET HEAD 13 65 NIE 1 371 BOLTS MOTOR 13K252 408 DRAIN amp VENT 6L3 C pros ease 4128 O RING DRAIN 51 99 ues 1 O RING CASING 4128 100 370 51 SYSTEM PRESSURE PUMP AP23 PRESSURE REDUCING VALVE NM4234 SCREW CAP z Internal cartridge assembly with integral strainer LOCKNUT check valve 52 TES THERMAL EXCHANGER MB212 1 QUICK CONNECT 12 FEMALE NM4200 11 RETAINER PLATE GASKET NM4241 BRASS 2 QUICK CONNECT 1 2 NM4201 12 SCREW 10 32 X 3 8 PH SS MALE BRASS S 1 BODY TEX THERMAL NM4250 NS ELBOW 90 1 STREET M F BRO36 EXCHANGER PLASTIC BRASS SCREW 10 32 X 7 8 BHCS SS NM4240 BARB 5 8 X MPT BRASS BR286 NUT 10 32 NYLOCK SS NM4081 HOSE 5 8 ID HI TEMP NM4237 53 fs p 54 Warrantv Your TES Thermal Energy System is designed to give you years of reliable service If a problem should arise use the troubleshooting section in the operation manual to diagnose and c
16. 225 B ms 5 OF ak SIDE PANEL SS TES NS TES WHEEL PNEUMATIC NM4224 ONE JE sm Jaw BRASS BARB 4 X 1 8 MPT BRO10 TES DECAL SET NM4284 BRASS 7 TUBING 4 ID VINYL 57 XAF1 FLUID RESERVOIR TES NM4275 HOOD ASSY SS TES HEATER 70 1215 TRIMLOCK EDGE NM4273 PROTECTOR Sold AA inch EN TES BASE ASSEMBLY ME 43 oh e l OUTLET HEADER CONNECTS TO PUMP INLET CONNECTS TO EXPANSION TANK CONNECTS TO FLUID RESERVOIR PARTS LIST ON PAGE 50 44 CONNECTS TO PRESSURE REDUCING VALVE CONNECTS TO HEATER OUTLET HEADER HOSE VENTS THROUGH MACHINE BASE PARTS LIST ON PAGE 50 45 PARTS LIST ON PAGE 50 PARTS LIST ON CONNECTS TO HEATER INLET HEADER PAGE 50 47 m CONNECTS TO SPIROVENT PARTS LIST ON PAGE 50 48 CONNECTS TO FLO JET PUMP INLET PARTS LIST ON PAGE 50 49 1 FLOW SWITCH PR1425 5 PUMP FLOJET 30PSI AP23 3 NIPPLE 1 1 2 BRASS l 4 TEE 1 1 2 X 1 FPT BRASS W 5 BUSHING 1 1 2 X 1 1 4 NM4219 6 NIPPLE 1 1 4 CLOSE NM4220 STAINLESS STEEL 7 SPIRO VENT NM4205 BARB 2 X 12 FPT BRASS BRO26 9 HOSE ID HI TEMP NM4274 10 ELBOW 90 1 1 4 MPT NM4221 W 1 1 4 BARB 11 EN HOSE 1 1 4 ID PER FOOT NM4210 12 13 End VALVE PRESSURE REDUCING NM4234 BARB 1 2 X 1 2 MPT BRASS BRO32 EXPANSION TANK 6 NM4207 ELBOW 45 34 M F BRASS
17. BR278 1 NIPPLE 3 4 X 2 BRASS 17 ELBOW 90 F F BRASS PRESSURE RELIEF VALVE BARB 1 2 X 3 4 MPT BRASS 18 PR30 0360 19 NM4214 20 BARB 1 2 X 3 8 MPT BRASS BRO30 21 HOSE 1 ID HI TEMP NM4211 22 BARB 1 X 3 MPT BRASS BRO50 23 CLAMP EXPANSION TANK SUPPORT NM4269 24 TEE Ya FPT BRASS NIPPLE 3 4 HEX BRASS VALVE GATE Ya BR248 BRO78 25 26 NM4212 27 TEE FPT BRASS MODIFIED 1 8 FPT PRESSURE GAUGE TAP ELBOW 90 3 8 STREET M F 28 BR284 3 BR288 ELBOW 90 3 4 STREET M F ELBOW 90 1 8 MPT X 1 4T HOSE 3 16 X 36 1 4FT ENDS BR259 9 30 31 32 NM4202 QUICK CONNECT FEMALE BRASS 50 kull ss SOLUTION PUMP HI TEMP NM4204 WASHER 2 X 1 SS NM4264 QUICK CONNECT MALE BRASS NM4203 34 35 36 PANEL FRONT SS 3 SOLUTION FILTER SPIRO TRAP NM4206 3 x NIPPLE 1 2 CLOSE BRASS 39 BUSHING 1 1 4 X BRASS BRO86 NM4222 41 PANEL SIDE SS TES COVER FLUID RESERVOIR NM5004 43 PANEL TOP SS TES 44 GASKET NM5059 45 a TANK SOLUTION TES PANEL BACK SS TES 47 48 NIPPLE END TAPPED 1 2 FPT 49 STRAINER ACORN 1 2 FPT PP14 806540 ELBOW 90 1 2 M F BRASS BR286 NS SCREW 1 20 X 1 BHCS SS 10 TANK COVER NUT 4 20 NYLOCK SS 10 TANK COVER HOSE CLAMP 34 1 3 4 SS PHO11 NS HOSE CLAMP 7 32 5 8 SS PHOS NM4275 BRO1
18. ES UNLESS OTHERWISE SPECIFIED t 1 4 ON FRACTIONAL DOTS L ON DECIMAL DINS HI LIMIT PLUGCOPT gt VENT DAMPER BL mani O T o l TE AN mel ee 111 ET FIL VR8304Q INTERMITTENT GAS VALVE 24V 24 PUMP SWITCH m Po To Transformer To Heater Switch Power Supply B N J g Ground from Power Er Cord amp Outlet Hour Meter Flojet System Pressure Pump BLACK ORANGE Ground Solution Pump New Style Gray motor sss 8886 _ s 25 To Heater Switch Power Supply from Power Cotd amp Outlet Ground Flojet System Pressure Pump Solution Pump Old style blue motor WHITE ka a a a aq a an 26 5 9 lo Transformer Ground Heater Maintenance amp Service Proper maintenance is required to keep the heater operating property prevent downtime and to extend the hye of your equipment Caution Servicing inspection and adjustment must be done by trained technician in accordance with all applicable local and national codes Improper servicing or adjustment can damage the heater WARNING Disconnect electrical power and shutoff propane tank valve before performing any service or maintenance Failure to do so may result in severe personal injury or death The heater should be cleaned and inspected once a year Make sure that the burn
19. ING VALVE EXPANSION TANK SPIRO VENT FILTER HOT FLUID OUTLET QUICK WARM FLUID CONNECTS INLET RETURN QUICK BY PASS VALVE CONNECTS COLD FLUID 21 1 2 MALE INLET QUICK CONNECT lt _ dm dem aba Qu I WA TEX THERMAL EXCHANGER NM4255 1 2 FEMALE OUTLET QUICK CONNECT HOT FLUID 65 95 WARM FLUID ER 22 TES Heater For extended hose runs use additional sections of TES 3 4 hose for improved flow TES Outlet Hose 3 4 x 50 Red with 3 4 QC s AH108 TES Inlet Hose 3 4 x 50 Blue with 3 4 AH110 Inlet Solution Tee AH104 Em CR Cp 555525 Outlet Solution Tee AH106 HOT FLUID L WARM FLUID TEX Inlet Hose 5 8 x 50 Red je 1 2 QC s TEX Outlet Hose H112 5 8 x 50 Blue with 1 2 QC s N AH114 f uu Qa TEX TEX Heat Exchanget NM4255 Heat Exchanget NM4255 23 TES Wiring Diagram BOILER ir w LI W 115 LINE BR 8 1 L BJ Dy Dy Dy ji dech HSV NEUTRAL __ 4 GD MA kal Lal kal Y WY LOW HIGH FIRE FIRE 115V SOURCE FOR PUMP MAX 9 AMPS MM MOB at pr PRR Lantai NO WO D i KEV BK BLACK BL BLUE BR BROWN G GREEN GY GRAY O ORANGE PK PINK PR PURPLE R RED W WHITE Y YELLOW F FUSE IGN IGNITION CABLE TOLERANC
20. Service Manual BRIDGEPOINT SYSTEMS Bridgepoint Systems 542 W Confluence Ave Salt Lake City UT 84123 Phone 801 261 1282 e Fax 801 268 3856 Revised 02 19 07 Copyright Bridgepoint Systems Inc 2006 Table of Contents Introduction 3 General Information d Installation 5 SECTION 1 Propane Safety 6 Propane Vaporization 8 Heater Operation Safety 9 SECTION 2 Heater Operation 12 Troubleshooting 16 Flow Path 21 Wiring Diagrams 24 SECTION 3 Maintenance amp Service 27 e Propane Gas Pressure Adjustment 27 e Adjusting Pilot Flame 28 e Burner Jet Replacement 29 e Main gas Valve Replacement 30 e Combustion Chamber Inspection 30 e Heat Exchanger Inspection 31 e Vent System 31 e Propane Leaks 31 e Controls 32 e Expansion Tank 33 e Solution Pump 33 e System Pressure Pump 34 e Pressure Reducing Valve 36 e Fluid Filtering 37 e Wheels 37 Parts 39 Warrantv 55 Copyright Bridgepoint Systems Inc 2006 2 Introduction This manual is a guide for proper service and maintenance procedures needed to maintain safe operation of this unit Read and understand this manual completely before performing service or maintenance on this unit This manual should be kept in your service department for future reference Any questions pertaining to the maintenance or servicing of this unit should be directed to Bridgepoint Systems Local regulations regarding the storage transportation and use of propane may re
21. a qualified propane system service technician To reduce the risk of property damage or injury repairs to propane systems should only be performed by experienced technicians Contact your nearest service center for assistance Check with your local propane supplier for local regulations regarding the use storage and transportation of propane PROPANE VAPORIZATION AND TES OPERATION The ambient air temperature and the level of propane in the tank both affect the vaporization rate of the propane e At 70 F a full 100 propane tank has a maximum draw of 300 000 BTU per hour At the same temperature a 1 2 full 100 tank has a maximum draw of 167 000 BTU per hour e At OFa full 100 tank has a maximum draw of 113 000 BTU per hour At the same temperature a 1 2 full 100 tank has a maximum draw of 64 000 BTU per hour The following chart shows the number of hours the TES boiler can run in at full burn at different temperatures This is not necessarily the maximum operation time for the TES unit The amount of time the boiler is off or in low fire operation will increase the total use time Higher ambient temperatures higher structure interior temperatures as well as a lower number of TEX Thermal exchangers used and even setting the air movers on lower settings for less air flow will all reduce the full burn time to allow much longer run times in practical applications To determine how many propane tanks to use how much continuous full burn run
22. and flow rate may change and the by pass valve may need to be re adjusted to maintain flow and keep the heater firing 13 When the TES unit is adjusted properly and operating normally close and lock control panel cover on TES unit CHANGING PROPANE TANKS 1 2 3 4 5 6 7 8 9 Unlock and open conttol panel Turn TES unit heater OFF Leave pump switch ON Close valves on propane tanks Close gas shutoff valve between tanks and TES unit if so equipped Remove regulator and hoses from propane tanks Reconnect regulator and hoses to new full propane tanks Slowly open valves on propane tanks Then slowly open gas shutoff valve if so equipped Check for propane leaks If leaks are found or suspected follow safety procedures If no leaks are detected continue with procedure Turn TES unit heater switch to the ON position Observe indicator lights When all lights are illuminated system is within operating limits and the heater is firing If all the other lights are on but the MAIN GAS light does not come on turn the heater switch off for 5 10 seconds and turn it back on again wait 5 10 seconds and retry as needed It may take a few tries to get the air out of the propane lines and allow the heater to fire Observe TES unit operation until temperature stabilizes or solution temperature returns to the operator set point Open by pass valve as needed to maintain proper flow rate to engage flow switch on heate
23. ap 36 21 TES Thermal Energy Fluid To prevent freeze damage in freezing conditions and provide corrosion protection for the heater components TES Thermal Energy Fluid is used in this heater The freezing point of TES Thermal Fluid is thirty degrees below zero Fahrenheit 30 F In locations where freezing is not a concern a 50 50 mix of TES Thermal Energy Fluid and distilled water can be used The TES unit hoses and TEX Thermal Exchangers come pre filled with TES Thermal Energy Fluid If fluid leaks out or is drained during repairs the heater pump fittings and hoses must be re filled with this solution and air must be removed from the system for proper operation See the solution pump section for instructions on how to add fluid and remove air from the system To operate the heater a continuous flow of solution at a flow rate high enough to activate the flow rd switch must be maintained qg Approximately 20 to 22 gallons of solution are reguired to completely fill the TES unit hoses and w 7 TEX Thermal Exchangers The TES Thermal Fluid should be filtered after the first 300 hours of operation and every 1000 hours thereafter Use the TES Fluid Filter kit AT80 Kit includes 6 filter cartridges 2 na CRO1GL Replacement Filter Cartridges NM4325A TES Thermal fluid under pressure and at high temperature can cause burns severe personal injury or death Do not attempt to perform filtering procedure w
24. are fitting on bottom of cap over stem on valve Hold a cup under the filter and open the valve 1 4 turn for short time to drain some fluid and remove additional debris Close valve and clean cap before replacing cap Use a towel to wipe up any spilled fluid i Spiro t 15 Spiro vent The Spiro vent removes air from the solution system No maintenance is required small amount of water coming out of the vent is normal Continuing water flow may indicate that the internal check valve is being held open by debris The Spiro vent can be disassembled cleaned or replaced as needed To clean Spiro vent a Remove the vent hose from barb on Spiro Vent b Hold Body of Spiro Vent with one pipe wrench while you use a second pipe wrench to loosen the top section and remove it from the Spiro Vent body c Remove the metal plate from the bottom of the top section d Rinse out the top section and check float operation Remove floats and clean valve seats as needed Then replace the metal plate e Pull screen out of Spiro Vent body and rinse screen before replacing f Thread the top section back onto the Spiro Vent body and tighten using the two pipe wrenches g Reconnect the vent hose to the barb and tighten the hose clamp 32 16 17 18 Expansion Tank The expansion tank absorbs pulsations and pressure spikes in the solution system Check bladder pressure and re pressurize as needed to maintain 12psi Over charging the
25. d level of protection To test the TES Thermal Energy Fluid take a small fluid sample from the bottom of the Spiro Trap or drained from a quick connect on the TES unit A sample taken from the reservoir may not accurately reflect the condition of the majority of the fluid in the system The amount of fluid needed will depend on the size and type of tester used A refractometer may only require a few drops A propylene glycol tester may require a few ounces If the fluid is dirty it should be filtered before testing Propylene glycol coolant testers are less expensive 3 00 20 00 but refractometers 100 00 200 00 are much more accurate Follow the testing directions for your specific tester Replace the TES Thermal Fluid if the protection level has dropped below the expected temperature range in your operation area Refractometer 37 Propylene Glycol Coolant Tester 22 TES Wheels Check tire pressure before each job Add air and repair tires as needed to maintain adequate air pressure Maximum tire pressure is 50psi You will find two grease zerks on each rigid wheel and three zerks on each swivel wheel Use grease gun to lubricate the axles bearings and swivel bearings in each wheel assembly as needed to maintain proper operation Frequency of lubrication and amount of grease needed will vary with amount of use and conditions of use Grease Zerks 38 Parts Replacement parts available for repair of your LES Hea
26. ded Reconnect the electrical power to the TES unit Turn the Pump ON and open the by pass valve You will not need to hook up any hoses or TEX units Turn the heater switch to the ON position and check for propane leaks on the outlet port and pilot gas tube connection Repair as needed Turn the heater OFF Let the pump run to cool the system as needed the turn the pump OFF Close the valve ON the propane tank and disconnect the regulator and hose from the tank Disconnect the power cord from the TES unit Re install the outdoor hood assembly and front jacket panel The system is ready to return to service Regulator Cover Close the propane tank valve and disconnect the regulator and hose from the tank Disconnect the electrical power to the TES unit Remove the outdoor hood assembly and front jacket panel Remove regulator cover assembly from the main gas valve Remove the white stem and spring from the main gas valve Insert the black stem and spring into the gas valve Re install the regulator cover and secure with the two screws Place the LP Conversion Label on the main gas valve Follow instructions to check and adjust inlet and outlet gas pressure to main gas valve White Stem amp Spring Black Stem amp Spring seq Regulator Cover Removed Combustion Chamber Inspection a b c d e f 9 h i Close the propane tank valve and disconnect the regulator and hose from the tank Disconnec
27. eight 450 lbs Pump All stainless steel liquid end construction Close coupled end suction single stage centrifugal pump with high temp seal 3 4HP 3450 rpm 75 psi Maximum liquid temperature 250 F 120 C TEX THERMAL EXCHANGER Height 19 7 8 Length 24 Width 20 5 8 Weight 50 lbs Standard Equipment TES Heater Assembly 1 10 Propane Hose with Regulator 4 TEX Thermal Exchangers 2 TES Hose 3 4 x 50 Red Insulated w 3 4 Quick connects 2 TES Hose 3 4 x 50 Blue Insulated w 3 4 Quick connects 4 TEX Hose 5 8 x 50 Red Insulated w 1 2 Quick connects 4 TEX Hose 5 8 x 50 Blue Insulated w 1 2 Quick connects 2 Inlet Solution Tee 3 4 Female QC to 2 1 2 Male QC s 2 Outlet Solution Tee 3 4 Male QC to 2 1 2 Female QC s 4 QD Wraps Large 8 QD Wraps Medium Copyright Bridgepoint Systems Inc 2006 4 Additional Optional Equipment Wheel Kit AT 52 50 Power Cotd AX33 Shock Buster GFCI AX126 TES Hose 3 4 x 50 Red Insulated w 3 4 Quick connects AH108 TES Hose 3 4 x 50 Blue Insulated w 3 4 Quick connects AH110 TES Hose 3 4 x 25 Red Insulated w 3 4 Quick connects AH116 TES Hose 3 4 x 25 Blue Insulated w 3 4 Quick connects AH118 TEX Hose 5 8 x 50 Red Insulated w 1 2 Quick connects AH112 TEX Hose 5 8 x 50 Blue Insulated w 1 2 Quick connects AH114 Inlet Solution Tee 3
28. er tube are on the top Repeat the procedure for the three other burner jets Reinstall the Flame Roll Out Shield and secure with two screws Re install the outdoor hood assembly and front jacket panel The system is ready to return to service Burner Drawer amp Burner Removal a b c d e f g h i r s Close the propane tank valve and disconnect the regulator and hose from the tank Disconnect the electrical power to the TES unit Remove the outdoor hood assembly and front Jacket panel Disconnect the propane hose from the main gas valve Remove the Flame Roll Out Shield Remove the two screws that attach the burner drawer to the base panel Disconnect the wires from the main eas valve Pull the burner drawer out until the burners are fully exposed Inspect each burner for damage ot signs of detertoration Use a brush or compressed atr to remove any debris from the burner ports Do not re install damaged or badly corroded burners replace them with new burners Re install the cleaned repaired or new burner drawer Reinstall the Flame Roll Out Shield and secure with two screws Re connect all electrical wires to the main gas valve and the burner ignition module Re connect the propane hose to the main gas valve Use thread sealant Reconnect the regulator and hose to the propane tank Open the valve on the propane tank Reconnect the power cord Open by pass valve and turn pump ON Turn heater ON
29. ermal Exchangers and the pump is ON and running For better flow and heater operation have at least two TEX Thermal Exchangers connected Then open the by pass valve slowly until the LOW FLOW light comes on Once the LOW FLOW light comes on continue opening the by pass valve 1 4 1 2 turn If the LOW FLOW light does not come on recheck your hose connections and repeat the procedure or contact your nearest service center for advice or assistance o 1 all the other lights are on but the MAIN GAS light does not come on turn the heater switch off and turn it back on again wait 5 10 seconds and repeat as needed It may take a few tries to get the air out of the propane lines and allow the heater to fire o When the solution temperature reaches the Operator set point the OPERATOR LOW FLOW and MAIN GAS lights will turn off and the heater will stop firing o When the Solution temperature reaches the Hi Limit set point the HI LIMIT and MAIN GAS lights will turn off and the heater will stop firing o 1 the solution flow rate is too low the LOW FLOW and MAIN GAS lights will turn off and the heater will stop firing 13 11 Turn the air movers ON for each TEX unit 12 Observe TES unit operation until the temperature stabilizes or the operator set point is reached for the first time and then heater re starts after cooling Open by pass valve as needed to maintain proper flow rate to engage flow switch on heater As the system heats up pressure
30. ers and ignition components are free from dust soot dirt corrosion or other deposits that would impair the heater s performanc Visually check the pilot and main burner flames to ensure proper operation WARNING Yellow floating flames indicate a lack of combustion air Do not operate the boiler until the problem is solved or severe personal injury EN NORMAL LIFTING 1 Propane Gas Pressure An inlet manifold pressure of 12 WC must be maintained for proper opetation of the heater Check and adjust as follows a b f 9 HARD FLAME TOO MUCH AIR YELLOW TIPPING YELLOW FLAME MARGINAL TOO LITTLE AIR HI LO Adjustment Screws Connect the propane regulator and hose to the propane tank Testing is best when performed with a full tank Remove plug and attach a manometer to the inlet pressure tap on the main gas valve Remove the regulator adjustment screw cap from the gas regulator Open the valve on the propane tank and check the pressure reading on the manometer and adjust as needed Minimum 12 WC amp Maximum 14 WC Rotate the white plastic regulator adjustment screw clockwise to increase the pressure or counterclockwise to decrease the pressure Replace the regulator adjustment screw cap Close the valve on the propane tank and remove the manometer Replace the inlet pressure tap plug Use thread sealant on the tap plug and check for propane leaks Next use the manomete
31. et temperature before the demand for heat has been met the aquastat high limit should shut the heater off The water temperature should never exceed the maximum set point of 240 F The aquastat high limit cannot be repaired If it fails to function properly it must be replaced HI LIMIT High Limit Control Mounted on Control Panel 13 Pressure Relief Valve The pressure relief valve should not weep or discharge water at normal system pressures If it does perform a try lever test Even if the valve is not leaking a try lever test should be performed once every two months Before performing test place a container under the discharge hose port on the machine base to catch fluid released during the test With the TES unit pump ON hold the test lever open for at least 5 seconds to flush the valve seat free of sediment and debris Then release the lever and allow the valve to snap shut If the lever does not activate or there is no evidence of discharge Shut off the TES unit immediately and replace the pressure relief valve If the valve continues to weep or discharge at normal system pressures replace the pressure relief valve 9 Never try to clean or repair the relief valve 14 Spiro trap Solution Filter Make sure valve on bottom of filter is closed before removing cap Remove cap on bottom of Spiro Filter to remove debris collected by filter The cap can be used as a knob to turn and open the valve Place squ
32. expansion tank may cause the pressure relief valve to open and discharge fluid If pressure continuously leaks or bladder is ruptured replace the expansion tank with new tank set at 12psi bladder pressure Expansion Tank Solution Reservoir Holds a supply of TES Thermal Fluid to be added to the closed loop solution system that may leak during the connecting and disconnecting of the hoses and heat exchangers or to replace the volume of air removed by the Spiro Vent with liquid to maintain the system level and maintain flow and pressure The System Pressure Pump draws the solution from the tank and pumps it into the system as needed Add TES Thermal Fluid as needed to maintain the fluid level above the 1 2 full point in the reservoir Keep lid on tank during storage and operation to keep debris or other contamination out of tank Check and clean filter screen and remove debris from tank as needed Remove and dispose contaminated fluid Solution Pump The solution pump provides the solution flow and pressure for the heater system The solution pump requires no periodic maintenance The closed loop system must be filled with TES Thermal Fluid and air must be removed for proper pump operation To prime pump add fluid and remove air from system a With the pump OFF open the by pass valve b Make sure fluid reservoir is filled Add TES Thermal Fluid as needed c Turn the pump ON The System Pressure Pump will pump fluid from the reservoir i
33. g Valve Located between the Expansion Tank and Spiro Vent this valve is used with the System Pressure Pump to maintain the system pressure by automatically opening when fluid is required to increase system pressure The valve is factory preset to the normal system pressure of 12psi The valve is equipped with a fast fill feature used to override the normal operation when filling and purging the system To activate the fast fill With power cord connected to the TES unit and the Pump switch ON push and hold in the green knob on the valve l Pressure Reducing Valve To adjust the svstem pressure L 2 J 4 gt 6 Use a screw driver to pop off the green cap and remove cap and spring Loosen the lock nut base of the valve Adjust the pressure by turning the screw cap Turn the screw cap clockwise to increase the pressure and counter clockwise to decrease the pressure Release fluid from the system and check the pressure Re adjust as needed Hold the screw cap while tightening the lock nut Replace spring and green cap To clean the valve 1 A Use a screw driver to pop off the green cap and remove cap and spring Unscrew the screw cap Keep the lock nut tight Remove the whole valve cartridge together with the screw cap from the valve body Clean the cartridge in clear cold water only and then re install the cartridge into the valve body This procedure will not alter the pressure setting Replace spring and green c
34. g the heater in a sloped position will change the position of the burner flame in relation to the burner tubes and heat exchanger This can result in property damage personal injury or loss of life e Secure TES unit and propane tanks as needed to prevent movement during operation e Colder temperatures will decrease the vaporization rate of Propane and may require the use of additional tanks and more frequent refilling of the tanks to supply enough propane to maximize heater output e Do not use the TES unit if outdoor temperature may drop close to or below 30 F TES Thermal Fluid has a freezing point of approximately 30 F If the heater shuts off freezing of the fluid will cause severe damage to the TES unit TEX Thermal Exchangers hoses and fittings Store your equipment indoors and protect from freezing Do not place the TES unit in a location that would subject it to runoff from adjacent buildings e The combustion of propane produces carbon dioxide carbon monoxide and oxides of nitrogen An adequate supply of combustion air and sufficient ventilation is required to prevent these compounds from accumulating in toxic concentrations Carbon monoxide is a colorless and odorless gas If you are exposed to carbon monoxide you may experience any or all of these symptoms o Headaches tightness across the forehead and temples o Weatiness weakness dizziness and vomiting o Loss of muscular control Watering and smarting
35. he vent cap and top jacket panel g Remove the back jacket panel h Remove the flue collector i Carefully lift the heat exchanger out of the unit and inspect it thoroughly The outside surfaces of the copper tubes should be free of any soot deposits A slight black smudge may be normal Black soot indicates poor combustion Green deposits indicate condensation due to low water return temperatures In either case the heat exchanger must be cleaned thoroughly with water and the problem resolved before the heater is returned to service 9 Sagging or distorted heat exchanger tubes are an indication of low water flow through the system A damaged heat exchanger must be replaced and the cause of the damage corrected before the heater is returned to service Replace the heat exchanger k Re install the flue collector back jacket panel top jacket panel and vent cap D Re install the left and right headers and mounting studs m Re connect the heater to the system plumbing n Re fill the system with TES Thermal Fluid o Re connect the electrical power turn on the pump and bleed the air from the system before returning the heater to service Heater Vent System Outdoor Vent Cap The outdoor vent cap must be in place during outdoor operation If the heater is installed in a closed trailer with a ducted vent system thoroughly inspect the vent system for any signs of blockage corrosion or leakage Immediately replace any unsound vent sy
36. ing cover to the motor 9 Replace valve chamber into the upper pump housing Make sure o ring is in place on top of valve chamber and properly aligned to seat inside the upper pump housing 10 Place the upper housing and valve chamber back on top of lower housing assembly and secure with four screws 11 Reconnect two wires to switch and replace cover To replace Pump Head Pump Head includes Upper Housing with switch Valve Chamber and Diaphragm amp Drive Assembly 1 Remove screw holding cover on switch and remove cover 2 Disconnect two wires from switch 3 Remove four screws holding upper pump housing onto lower housing bearing cover and remove upper housing and valve chamber 4 Remove two screws holding the lower housing assembly onto motor Rotate bearing cover to align drain notch with set screw on cam bearing assembly 5 Use 1 8 Allen wrench to loosen set screw and slide cam bearing assembly off of motor shaft and remove the lower housing assembly 6 Coat the motor shaft with grease or anti seize lubricant 7 On the new pump head remove four screws holding upper pump housing onto lower housing bearing cover and remove upper housing and valve chamber 8 Slide the cam bearing assembly of the new lower housing assembly onto the motor shaft Position shaft so set screw is aligned with indentation on shaft and tighten set screw Set screw must be set into indentation for proper 9 Re install the two screws hold
37. ing the lower housing assembly to the motor 10 Replace valve chamber into the upper pump housing Make sure o ring is in place on top of valve chamber and properly aligned to seat inside the upper pump housing 11 Place the upper housing and valve chamber back on top of lower housing assembly and secure with four screws 12 Remove screw holding cover on switch and remove cover 13 Connect the two wires to switch and replace cover System Pressure Pump Replacement f 9 h i k L Place new or repaired pump back into TES unit and secure to base with four bolts Reconnect wires to the junction box on the side of the Solution Pump Refer to the wiring diagram for the correct wire connections Reconnect the 1 2 ID hoses to pump outlet and inlet Tighten the hose clamps Re fill the solution reservoir with TES Thetmal Fluid With the pump OFF open the by pass valve Turn the pump ON The System Pressure Pump will pump fluid from the reservoir into the pump inlet lines Add TES Thermal Fluid as needed to keep the reservoir filled Continue to run until flow becomes steady and most of the air is removed from the flow Observe pressure gauge Pressure will stabilize as air is removed from system and system is pressurized Add TES Thermal Fluid to the fluid teservoir as needed to maintain adequate fluid level Then turn the pump OFF and close the by pass valve Unit is ready to return to service 35 20 Pressure Reducin
38. ith TES fluid temperature over 120 F To filter the TES fluid 1 Turn the TES heater off and allow the TES Thermal Fluid to cool before filtering the fluid 2 When the fluid has cooled turn pump OFF 3 Close by pass valve 4 Connect one red 3 4 TES hose to outlet quick connect on TES unit Connect splitter two red TEX hoses and two TEX thermal exchangers Connect filter outlet connector to one inlet quick connect of TES unit 6 Connect one blue 3 4 TES hose to filter inlet connector Connect splitter and two blue TEX hoses to blue TES hose Connect the two blue TEX hoses to the two TEX thermal exchangers to complete the loop 7 Turn pump on and run for 5 minutes 8 Turn pump off Disconnect the hoses and TEX thermal exchangers and connect the remaining hoses and TEX thermal exchangers the same way the others were connected and repeat the process to filter the other hoses and Tex thermal exchangers Switch filter to other inlet quick connect and red 3 4 TES hose to the other outlet quick connect Turn pump ON and run for 5 minutes 10 Turn pump off Disconnect the hoses and TEX thermal exchangers Remove and dispose filter cartridge Replace with new clean filter cartridge sn Breakdown or dilution of the propylene glycol in the solution over time may reduce the protection ability of the TES Thermal Energy Fluid The TES Thermal Energy Fluid should be tested periodically to determine the current concentration an
39. k wiring amp test switches Repair as needed Faulty indicator light Replace light Heater Solution temp over operator set point Normal Operation Main Gas Valve Solution temp over Hi limit set point Normal Operation Light Not Lighted Fr O rate too low Check Ad NEE Open by pass valve to increase flow Loss of power of power See Power Light All other lights also off l Power Light All other lights also off ng ss s Failed lgnition heater Faulty Vave Valve Replace Main Gas Valve Main Gas Valve Faultv indicator light Replace light Refill Tanks Check Hoses regulator and Out of Propane connections Svstem Faulty switches or internal wiring Check wiring amp test switches Repair as needed Overheating Flow rate too low Check Pump Open by pass valve to increase flow Not enough Heat draw from system Turn air movers switches to higher speed Increase number of TEX Thermal Exchangers System Faulty switches or internal wiring Check wiring amp test switches Repair as needed Not Heating Out of Propane Refill Tanks Check Hoses and connections Too Much Heat loss from system Turn air movers switches to lower speed Reduce number of TEX Thermal Exchangers Reduce length of hose being used Insulate fittings By pass Valve opened too much Adjust by pass valve as needed Check pump hoses and connections Adjust by Flow Rate too low pass valve Faulty Heater Check heater je
40. l stabilize as air is removed from the system Add TES Thermal Fluid to reservoir as needed Excessive cavitation air release or fluid loss may indicate a system fluid leak Check fittings hoses and TEX Thermal exchangers for leaks and repair or replace as needed 9 Close and lock hose access door on TES unit 10 Turn TES unit heater switch to the ON position Observe indicator lights When all lights are illuminated system is within operating limits and the heater is firing e POWER When lighted indicates that the heater switch is in the ON position and the heater has power e OPERATOR When lighted indicates that the solution temperature is below the preset temperature limit and the heater can fire Operator set point is 200 F preset at the factory e HI LIMIT When lighted indicates that the solution temperature is below the Hi Limit safety setting and the heater can fire The Hi Limit set point should be at least 20 F above the Operator set point And never set above 230 F e LOW FLOW When lighted indicates there is adequate solution flow and the heater can fire e MAIN GAS When lighted indicates the main gas valve is open and the heater is firing e When the lights are not all lighted look for the following See the troubleshooting section for more information on the meaning different light configurations o When the LOW FLOW light does not come on make sure you have all your hoses connected to the TEX Th
41. meter to barb 2 Open gas shut off valve and open propane tank valves to pressurize system 3 Close propane tank valves 4 Bleed pressure from line to reduce pressure reading on manometer by 1 2 WC Reading on manometer should be between 9 10 WC 5 After 10 minutes if pressure does not drop system is free of leaks i If pressure drops open propane tank valves and Check propane connections and fittings for leaks using soapy water Tighten re seal or replace fittings as needed the repeat system test until system tests OK u If pressure goes up propane tank valve was not closed properly or needs to be replaced Close or replace valve and repeat test d The outside of the propane tanks should be protected from rusting by periodic painting in a light reflective color White e Do not use damaged or rusted tanks Tanks that show excessive denting bulging gouging or corrosion must be removed from service 31 Operator Control Mounted under Outdoor Hood 12 Controls a Check the thermostat or operating controls for proper operation Use the heater operation section as a guide for checking the thermostat operation b Check flow switch for proper operation Use the heater operation section as a guide for checking the flow switch operation c The aquastat high limit controls the maximum water temperature in the heater It should be set at least 20 F above the operator control set point If the water temperature reaches the s
42. n of your TES unit at higher altitudes 2000 4000 Feet NM4294 4 required 4000 6000 Feet NM4296 4 required 6000 8000 Feet NM4298 4 required Burner jets are installed at the factory for operation at the altitude of your location at the time your unit was shipped from the factory Check the rating plate to assure jets are matched to your altitude Copyright Bridgepoint Systems Inc 2006 5 Propane Safety Propane is highly tlammable always contained under pressure and the liquid can freeze skin It is important to understand the safety rules for propane storage and use e Propane or LP gas is a true gas compressed into liquid form for easy transportation and storage While stored in a compressed liquid form most appliances such as the TES Heater use propane vapor only Propane tanks designed for vapor service must be transported stored and used in the proper position Do not transport store or use vertical cylinders in a horizontal position Never use a horizontal tank on its improper side Failure to follow these guidelines may allow liquid propane to get into the heating system create unsafe conditions and damage the heater e Do not fill propane tanks to more than 80 of capacity e Secure the tanks during transportation storage and use to prevent falling and rolling e Do not use damaged or rusted tanks Tanks that show excessive denting bulging gouging or corrosion must be removed from service Do
43. ng o ring can be lubricated with super lube to ease assembly Re install impeller turn in clockwise direction to tighten Re install and tighten impeller locknut Tighten to 10ft Ibs of torque Re install guidevane Inspect guidevane o ring and replace as needed Do not lubricate guidevane o ring Make sure o ring is not pinched by impeller during re assembly Re install pump casing and secure with the eight bolts Check assembled unit for binding and correct as needed before tightening bolts Tighten bolts in a star pattern to prevent o ring binding Place pump back onto TES unit base and secure with the four bolts Reconnect wires to junction box on side of motor Refer to wiring diagram to check wire connections Reconnect the 1 1 4 hose to the barb on the pump inlet and reconnect the 1 hose to the barb on the pump outlet Tighten the hose clamps Reconnect the power cord to the plug on the TES unit With the pump OFF open the by pass valve Re fill the fluid reservoir with TES Thermal Fluid Turn the pump ON The System Pressure Pump will pump fluid from the reservoir into the pump inlet lines Add TES Thermal Fluid as needed to keep the reservoir filled Continue to run until flow becomes steady and most of the air is removed from the flow Observe pressure gauge Pressure will stabilize as air is removed from system and system is pressurized Add TES Thermal Fluid to the fluid teservoir as needed to maintain adequate fluid level
44. not attempt to repair propane tanks valves or regulators Do not operate the TES Heater with a propane tank inside a closed trailer e Keep a dry chemical fire extinguisher with a B C rating within 50 feet of tanks during use ot storage e Laws concerning the proper storage of propane tanks may vary in different jurisdictions Consult your local fire protection authorities e Do not use a wrench to close tank valve These valves are designed to be closed leak tight by hand If a wrench is needed to stop leaking remove the tank from service immediately and have the valve replaced by a qualified professional e When connecting propane regulator and hose to the tank valve turn the fitting nut counter clockwise to tighten Draw the fitting snug with the proper wrench Do not over tighten No thread sealant is needed e Do not smoke in the area of the propane tanks or heater Do not operate the TES Heater indoors Before operating the TES Heater check around the heater for the smell of propane Propane gas is heavier than air and can collect in low areas Check around base of the heater for the smell of propane A distinctive odor is added to propane However propane leaks cannot always be detected by smell Some people do not have a good sense of smell or certain conditions may affect your sense of smell In rare cases propane gas can lose its added odor This is called odor fade It may occur when air water or rust accumula
45. nto the pump inlet lines Add TES Thermal Fluid as needed to keep the reservoir filled d Continue to run until flow becomes steady and most of the air is removed from the flow Observe pressure gauge Pressure will stabilize as air is removed from system Add TES Thermal Fluid to the fluid reservoir as needed to maintain adequate fluid level e Turn the pump OFF and close the by pass valve f Connect hoses and TEX Thermal exchangers to the TES Heater and turn pump ON The System Pressure Pump will pump fluid from the reservoir into the solution pump inlet lines and the solution pump will pump the fluid into the hoses and TEX units As the air is replaced by fluid in the hoses and released through the Spiro vent add TES Thermal Fluid as needed to keep the reservoir filled g Continue to run until flow becomes steady and the air is removed from the flow Observe pressure gauge Pressure will stabilize as air is removed and system is pressurized Add TES Thermal Fluid to the fluid reservoir as needed to maintain adequate fluid level h Turn the pump OFF and disconnect hoses and TEX Thermal Exchangers Solution Pump Repair a Disconnect power cord from the TES unit b Drain fluid from reservoir Save fluid for re use c Drain fluid from heater and fittings Connect open 3 4 male quick connect or drain hose to outlet quick connect on the TES unit Open by pass valve and allow fluid to drain into a clean bucket Save fluid for re use Use
46. o the heater and secure with the two screws 28 4 Burner Jet Replacement 5 m Re install the Flame Roll Out Shield and secure with the two screws n o p q r s t a b c d Re connect the pilot gas tube and igniter wire Reconnect the electrical power cord Open the valve on the propane tank and turn the pump ON Turn the heater switch ON and check for propane leaks Repair as needed Turn the heater OFF Let the pump run to cool the system as needed the turn the pump OFF Close the valve ON the propane tank and disconnect the power cord Re install the outdoor hood assembly and front jacket panel The system is ready to return to service Burner Tube Close the propane tank valve and disconnect the regulator and hose from the tank Disconnect the electrical power to the TES unit Remove the four sheet metal screws and remove the outdoor hood assembly Remove the one sheet metal screw and two screws with nuts and remove the front jacket panel Remove the two sheet metal screws and remove the Flame Roll Out Shield I I Burner Jet Lift the back end of the burner tube and pull burner tube away from the first burner jet Boere Unscrew the first burner jet and install the new burner jet Use thread sealant on the burner jet threads Slip the front of the burner tube back over the burner jet and place the tab of the back end back into the slot to re install the burner tube Make sure openings on the burn
47. of the eyes If any of these symptoms should develop get into fresh air immediately see your doctor for treatment and have your heater checked and repaired as needed If the TES unit is to be installed for use in a closed trailer It must have an exhaust stack installed to vent the burner exhaust through the roof of the trailer There must be sufficient ventilation to exhaust the heat and supply adequate combustion air to the burner Ambient air temperature above 130 F inside the trailer may adversely affect the operation of the pump and heater A 7 diameter exhaust stack with vent cap is required A J cap or other wind resistant vent cap should be used Never install an exhaust pipe of a diameter different than that of the heater draft hood 6 of clearance is required between the exhaust stack and any combustible materials Use the shortest straightest exhaust system possible Two roof vents must be installed to exhaust the heat from the trailer and allow proper flow of combustion air The roof vents must have a total minimum free area of 100sq in When calculating the vent area consideration must be given to the blockage effects of louvers grills and screens The installation of two roof vents should easily provide sufficient vent air space when allowing for blockage The Power vents should not be used The heater should not be subjected to negative air pressure Negative air pressure can affect the burner flame and exhaust fl
48. onnect the propane hose and regulator to the propane tank Use a tee connector to connect two or three tanks together for larger jobs Operation time per 100 Ib tank is dependant on altitude and heat draw requirements Heat draw requirements can change with the outside temperature number of TEX Thermal Exchangers length of hose used and air flow required to float the carpet The average operation time per tank using four TEX Thermal Exchangers is 12 16 hours Longer operation time can be expected using fewer heat exchangers Shorter operation time can be expected in lower temperature use when the decrease in the vaporization rate will decrease the BTU hr available from each propane tank Open the valves on the connected propane tanks Open valve slowly to allow lines to slowly pressurize Opening valve too quickly may activate flow restrictor valve in POL fitting and stop gas flow to heater Wait 5 minutes and check around heater tanks and hoses for gas leaks e If no gas leaks are detected proceed with start up procedures e Ifa gas leak is detected or suspected close tank valves and follow safety procedures 12 8 Turn pump ON to circulate solution through heater and activate flow switch Listen for air release or cavitation in pump Observe pressure gauge reading Pressure reading will vary with the number of TEX units used the length hose used and position of by pass valve Gauge should read between 30 50psi and pressure wil
49. orrect the problem if possible If you are unable to determine the cause or solution to the problem contact your distributor or Bridgepoint Systems for assistance Bridgepoint Systems warrants the heat exchanger inside the TES unit to be free from defects in material or workmanship for five years from the date of purchase Bridgepoint Systems warrants the roto molded body of the TEX Thermal Exchanger to be free from defects in material or workmanship for five years from the date of purchase All other components of the TES Thermal Energy System are warranted to be free of defects in material and workmanship for one year from the date of purchase During the warranty period Bridgepoint Systems will at its option repair or replace components which prove to be defective e This warranty does not provide for replacement of complete units due to defective components e Service Labor is only covered for the first 90 days after the date of purchase e Any costs for transportation are not covered in this warranty e Replacement parts are warranted only for the remainder of the original warranty period This warranty shall not apply to defects resulting from improper operation lack of maintenance hard water deposits condensation chemical corrosion unauthorized modification misuse abuse or exposure to freezing temperature conditions without proper propylene glycol amp water solution This warranty does not cover normal wear items such as o ring
50. ow Openings for the combustion air supply must have a total minimum free area of 100 sq in When calculating the vent area consideration must be given to the blockage effects of louvers grills and screens The openings must be within 12 but not less than 3 from the floor of the trailer A power vent fan may be used to bring in air The free air space of the hose access door can be used as part of the total vent space The blockage of the hoses must be considered when calculating the free space of the hose access door The hoses may reduce the total free area to a total less than the required 100 sq in and require the addition of a second vent This heater is an electrical appliance Care must be taken to reduce the risk of electrical shock Use a Ground Fault Interrupting GFI device to reduce the risk of electrical shock Extension cords must be rated for outdoor use grounded and able to deliver the proper current to the heater and pump 10 amps Do not use a multiple outlet power cord to connect to TES unit plug Keep cord connections off the ground Protect cord connections from rain or other water sources Never operate this heater with a damaged power cord If the power cord is damaged it must be replaced Unplug machine power cord from outlet before connecting or disconnecting quick connects on TES unit Unplug machine power cord from outlet before performing any repair on the TES heater or pump To reduce the risk
51. r As the system heats up pressure and flow rate may change and the by pass valve may need to be re adjusted to maintain flow and keep the heater firing When the TES unit is adjusted properly and operating normally close and lock control panel cover on TES unit 14 HEATER SHUTDOWN PROCEDURE 1 2 3 4 5 6 7 8 2 Unlock and open control panel on TES unit Turn TES unit heater switch OFF and leave pump switch ON Close valves on propane tanks Close gas shutoff valve between tanks and TES unit if so equipped Keep air movers running through TEX Thermal Exchangers to draw heat and cool the heating system When the solution temperature has cooled to the point where you can comfortably handle the quick connects and hoses Approximately 120 F or lower turn the pump OFF Turn the air movers OFF at each TEX unit Unlock hose access door on the TES unit Disconnect power cord from the power outlet and heater connection Roll up and store cord Disconnect hoses from TES Heater and TEX Thermal Exchangers Wear eye protection and leather gloves when disconnecting or connecting hoses With pump OFF hoses and fittings will retain 12 psi system pressure Quick connects may stick open and leak Press nipple on quick connect to release fluid and flush debris and allow the quick connect to re seal Wrap a towel around quick connects when disconnecting hoses to catch released fluid 10 Roll up and store hoses 11 Disconnec
52. r to check the outlet pressure on the main gas valve The system should be cool and solution temperature should be more than 20 degrees below the operator set point temperature h Remove the plug and attach a manometer to the outlet pressure tap on the main gas valve 27 i Turn the pump switch ON and open the by pass valve In most cases to check the pressure you will not need to hook up any hoses or TEX units If you need to adjust and recheck the pressure settings you may need to connect hoses and TEX units to cool the system down so you can re heat and check both the high and low pressure settings Open the valve on the propane tank and turn the heater switch ON k Remove the plastic cap covering the HI and LOW pressure adjustment screws When heater is firing check the pressure reading on the manometer When the heater is cool the initial firing will be the high or 2 stage mode and the pressure reading should be 10 0 WC on the manometer Adjust the HI pressure adjustment screw as needed to set the pressure at 10 WC Rotate the HI pressure adjustment screw clockwise to increase the pressure or counterclockwise to decrease the pressure m Continue running the heater as it heats up it will switch to low or 1 stage mode In the low or 1 stage setting the pressure should be 4 9 WC Adjust the LOW pressure adjustment screw as needed to set the pressure at 4 9 WC Rotate the LOW pressure adjustment screw clockwise to increase the
53. ressure Quick connects may stick open and leak Press nipple on quick connect to release fluid and flush debris and allow the quick connect to re seal e Wrap a towel around quick connects when disconnecting hoses to catch released fluid Do not operate this heater unless all panels are in place and properly secured Keep hose access door on TES unit closed and locked during operation Keep control panel door on TES unit closed and locked during operation Do not leave keys in locks e Keep cover on TES fluid reservoir during operation e Add TES Thermal Fluid to reservoir as needed to maintain an adequate fluid supply to pump and heater e Hot brass fittings can damage some carpets or cause burns Wrap and insulate quick connects and solution tees to prevent damage or burning e Hoses must be rated to handle 230 F fluid temperatures 5 8 or 3 4 ID for adequate flow and insulated to hold heat and protect from burns e Do not use water in heater hoses or heat exchangers Use only TES Thermal Fluid Failure to do so may result in damage to heater and will void warranty Do not by pass Flow Switch A continuous adequate flow of solution through heater must be maintained Failure to do so may result in damage to heater and will void warranty e Never try to repair the pressure relief valve If the valve fails to operate properly replace the valve Removal or restriction of the pressure relief valve could damage heater cause severe
54. s valve seals pump seals hoses quick connects cords tires burner jets or other items which require replacement as a result of ordinary usage To obtain warranty service for the TES Thermal Energy System contact your distributor or Bridgepoint Systems If the unit must be returned to Bridgepoint Systems or an authorized service center the purchaser shall prepay shipping charges for products returned for warranty service e No returned items will be accepted by Bridgepoint Systems without prior authorization All returns must have a return authorization number issued by Bridgepoint Systems clearly marked on the exterior of the package Bridgepoint Systems makes no other warranty either expressed or implied with respect to this product The remedies provided herein are the purchaser s sole and exclusive remedies In no event shall Bridgepoint Systems be liable for any direct indirect special incidental or consequential damages This warranty gives you specific legal rights You may also have other rights which vary from jurisdiction to jurisdiction 55
55. stem piping This applies to exhaust vents and combustion air supply vents Combustion air vents must have a minimum of 100 square inches of open space near the floor and 100 square inches of open space near the roof or in roof vents When the outside air temperature is above 60 F a power vent fan must be used to bring in cooler air to provide adequate cooling for TES operation Power exhaust fans should not be used The fan should have at least 600 cfm of air movement Locate the fan within 12 but not less than 3 TN from the floor of the trailer MEE Exhaust piping must be single wall galvanized metal vent pipe the same diameter of the draft flue collar 7 diameter The trailer vent cap placed on top of the trailer must be a wind resistant rain cap Use the shortest straightest vent system possible Trailer Vent Cap A minimum clearance of 6 must be kept between the exhaust vent pipe and any combustible materials Propane Leaks Read Safety Information Section of this manual Though only qualified professionals should service your propane system there are maintenance procedures you must perform to keep your system operating safely a Check propane hoses for wear or damage every time before using heater Replace hoses as needed b Before operating TES unit check around the heater for the smell of propane c Perform system leak test 1 Remove plug from Main Gas Valve Inlet pressure tap and install barb Connect Mano
56. strict or prohibit the operation of the TES Thermal Energy System in some areas Check with your local fire safety authorities before operating this equipment Warning Improper installation operation adjustment alteration service or maintenance can cause property damage personal injury or loss of life Installation and service must be performed by a qualified installer service agency or gas provider Bridgepoint Systems is in no way responsible and is excluded from liability in respect to any loss or damage which may arise due to improper installation operation or maintenance This manual is written specifically for the TES Thermal Energy System units manufactured by Bridgepoint Systems 542 W Confluence Ave Salt Lake City UT 84123 801 261 1282 Information in this manual is subject to change without notice and does not represent a commitment on the part of Bridgepoint Systems Copyright Bridgepoint Systems Inc 2006 3 General Information TES HEATER ASSEMBLY 200 000 Btu Propane LP Gas Boiler Outdoor Model Stainless steel covers and Stainless Steel base with powder coated steel reinforcements and mounting feet Height 36 3 8 Without wheels amp vent cap 45 7 8 With wheels amp without vent cap 47 3 8 Without wheels amp with vent cap 56 7 8 With wheels amp vent cap Length 47 1 2 Without handle 50 With handle Width 25 5 8 at base 35 1 8 at widest point Outdoor Hood W
57. t propane regulator and hose from tank Store propane hose and regulator 12 Remove and store air movers and TEX Thermal Exchangers 13 Store propane tank and heater 15 Section Heater Troubleshooting Circuit Breaker Too much current demand on circuit Move plug to another outlet amp circuit Blowing Move plug to another outlet 8 circuit Repair or replace pump as needed Replace pump motor Remove and clean or replace hoses amp fittings as needed Faultv power cord Replace cord Faulty switches or internal wiring Check wiring amp test switches Repair as needed Solution Pump Building circuit breaker tripped Reset breakers or move cord to another outlet not running Faultv power cord Replace cord Faultv switches or internal wiring Check wiring amp test switches Repair as needed Pump thermal protector tripped Allow pump motor to cool and restart Pump motor faultv Replace pump motor Pump seized trips breaker Repair or replace pump head Check motor Prime pump amp bleed air from system Add Fluid as needed Solution Check System pressure pump Pressure Reducing Valve Pump Air in System and wiring Pumping Low on Fluid Add fluid prime pump amp bleed air from system Faulty Pump Repair or replace Solution Pump Low Voltage Check wiring amp test switches Repair as needed Restriction in hoses and fittings Remove and clean or replace hoses amp fittings as needed Building circuit breaker tripped
58. t the electrical power to the TES unit Remove the outdoor hood assembly and front jacket panel Disconnect the propane hose from the main gas valve Remove the Flame Roll Out Shield Remove the two screws that attach the burner drawer to the base panel Disconnect the wires to the main gas valve and the burner ignition module Pull the burner drawer out Inspect the combustion chamber panels using a mirror and light If any of the combustion chamber panels are damaged or show signs of deterioration replace them Replacement of the combustion chamber panels requires that the heat exchanger be removed Re install the burner drawer and Flame Roll Out Shield Re connect all electrical wires to the main gas valve and the burner ignition module Re connect the propane hose to the gas valve Use thread sealant and check for propane leaks 30 9 10 11 Heat Exchanger Inspection amp Cleaning a Close the propane tank valve and disconnect regulator and hose from the tank b Disconnect the electrical power cord to the TES unit c Relieve the system solution pressure and drain fluid Connect a system drain hose to an outlet quick connect and direct flow into a bucket Use an extractor or wet vacuum to remove all fluid from the TES unit d Disconnect the heater from the system plumbing Disconnect hoses and fittings so that header can be removed from heater e Remove the left and right headers and mounting studs f Remove t
59. ter 200 000 BTU BOILER NM4227 LP PROPANE COMPLETE OUTDOOR USE Includes 6 amp 7 TES BASE ASSEMBLY TES WHEEL PNEUMATIC NM4224 gear TES WHEEL PNEUMATIC NM4225 88 eR TES SA PIN SNAPPER Va X 2 NM4226 FOOT RETAINER TES LAB kalil id 39 40 a mug COMBUSTION CHAMBER s PANEL FRONT REFRACTORY 05 0045 TOGGLE SWITCH ssl rod ch BURNER DRAWER ASSEMBLY 70 1370 RUBBER COVER TOGGLE NS160 0 2000 FT ALTITUDE SWITCH FLUE COLLECTOR 70 1258 HOURMETER NM4300 10 PANEL REAR PANEL REARJACKET 03 0721 PRESSURE GAUGE 60PSI NM4230 a LEFT mum 03 0774 NS V BAFFLES 03 0871 HEAT EXCHANGERS PANEL RIGHT JACKET 03 0775 HEADER O RING 06 0001 14 PANEL FRONT UPPER 03 0759 VENT DAMPER 7 09 0009 JACKET JACKET 47 0 1999 PT 49 2000 3999 FT 50 4000 5999 FT HEAT EXCHANGER 51 6000 7999 FT 122 INLET OUTLET 52 8000 9999 FT or Mer RETURN PROPANE COVER RETURN HEADER 03 0737 THERMOCOUPLE 10 0211 25 SHIELD FLAME ROLL OUT 03 0906 PRESSURE RELIEF VALVE PR13 0004 26 BURNER TUBE 10 0251 GAUGE SENSOR WELL 13 0102 STAINLESS STEEL MANIFOLD BURNER 10 0454 HI LIMIT SENSOR WELL 13 0104 re KNOB HI LIMIT CONTROL 14 0120 MAIN GAS VALVE LP PR71579 OPERATOR CONTROL 2 PR1417 PROPANE STAGE 2 STAGE 30 BURNER IGNITION PR16 0054 NS IGNITION CABLE PR1621 CONTROL S8610M TRANSFORMER PR15 0002 HEADER STUD 57 0223 32 GAUGE TEMPERATURE 14 0004 NS
60. tes in a propane tank The smell of escaping gas can also be absorbed by water some soils or other materials If you think your propane gas has lost its odor contact your propane dealer to check it out Electronic gas detectors are commercially available and may provide an additional means of warning about the presence of propane Use soapy water to check connection for propane leaks Never use a match or flame to check for propane leaks If you suspect a leak o 130 not attempt to start heater o Close the valves on the propane tanks o 130 not touch any electrical cords plugs or switches in the area of the suspected leak o 130 not operate any phone or electrical device in the area of the suspected leak o Leave the area until the propane smell dissipates If a large amount of propane is being released or the gas cannot be dissipated leave the area and contact the fire department o Have the propane system checked and repaired before using the heater Absolutely no alterations or modifications should be made to your propane system The slightest modification or alteration to your propane system by untrained personnel may cause a potentially dangerous or life threatening situation Do not operate this heater if any part has been under water Have a qualified propane system service technician inspect the system and replace any part of the control system that has been under water Have the propane system checked annually by
61. time can be expected from a TES unit and when tanks should be re filled or replaced to maintain the proper propane flow for the TES unit use the following chart Number of 100 Hours of TES Unit Operation at continuous full burn at various temperatures Propane Cylinders 0 1999 Ft Operation OF Number of 1007 Hours of TES Unit Operation at continuous full burn at various temperatures Propane Cylinders 2000 3999 Ft Operation OF Number of 1007 Hours of TES Unit Operation at continuous full burn at various temperatures Propane Cylinders 4000 5999 Ft Operation OF 40 F O Ng Number of 100 Hours of TES Unit Operation at continuous full burn at various temperatures Propane Cylinders 6000 7999 Ft Operation OF The heater may continue to burn longer than these times indicate but the heat input from the propane available to heat the fluid will be less than the 200 000 BTU maximum Heater Operation Safety This heater is designed for outdoor use It is not to be operated indoors e The TES unit was designed for outdoor use and is not to be used indoors The TES unit can be operated from an enclosed trailer with the proper installation and venting for combustion air and exhaust Do not place TES unit where exhaust fumes can enter buildings The TES unit must be at least 10 ft away from any door window or gravity air inlet into any building and at least 3 ft from any overhang e The TES unit must level during operation Usin
62. ts burners etc Repair as needed Heater Cycling Faulty switches or internal wiring Check wiring amp test switches Repair as needed Too Often Flow rate too low Check Pump Open by pass valve to increase flow Increase number of TEX Thermal Exchangers Check hoses Hose may be restricted Un kink repair or replace hoses Not enough Heat draw from system Turn air movers switches to higher speed Increase number of TEX Thermal Exchangers To reduce the risk of injury repairs to electrical propane or fluid pressure systems should only be performed by experienced technicians Contact your nearest service center for assistance 17 TES INDICATOR LIGHT PANEL CONFIGURATIONS SA 1 Indicates Light is ON Indicates Light is OFF TN POWER OPERATOR HI LIMIT LOW FLOW MAIN GAS When all the lights are ON as shown above the heater is operating normallv and the heater is firing POWER OPERATOR HI LIMIT LOW FLOW MAIN GAS When the POWER OPERATOR LOW FLOW and HI LIMIT lights are all ON and the MAIN GAS light is OFF it means a lack of propane or ignition failure is preventing the burner from firing This is a common occurrence at initial start up as air is bled from the propane hoses Check the propane supplv and shutoff valves to be sure propane is being supplied to the heater Turn the power switch ON wait 5 10 seconds for ignition to fire and if the burner does not fire and light does not come

Service Manual - TES - Thermal Energy Systems

Contents

Download Pdf Manuals

Related Search

Related Contents