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TES Troubleshooting

4 – NO POWER TO HEATER

Do not turn the pump switch ON unless the By-pass valve is open or you have two or more TEX boxes and hoses connected to the TES unit.

There are only a couple of gallons of fluid in the TES boiler and during testing this fluid will heat up quickly and has no way to cool down. This can cause damage to the boiler and can create a dangerous condition.

For safety reasons we recommend that you should always have at least two TEX boxes with air movers connected to the TES unit when attempting to ignite the TES burner.

Test #1

When you turn the heater switch to the ON position, does the green power light on the control panel turn ON?

  • Yes – Proceed to Step #3A.
  • No – Proceed to Test #2.

Test#2

Test for power at the input AC terminals of the Transformer. These are the terminals on the left side where the black and white wires are connected. It should be 115VAC.

  • 115 Volts found – Proceed to Test #3
  • No voltage found – Proceed to Step #1.

Test#3

Test for power at the output AC terminals of the Transformer. These are the terminals on the left side where the red wire is on one terminal and the gray and green wires are on the other terminal. It should be 24VAC.

  • 24 Volts found – Proceed to Step #3
  • No voltage found – Proceed to Step #2.

Step #1 Check 115V Power Supply

Use an AC Voltmeter to test the power supply at the end of the extension cord where it connects to the TES unit.

  • Voltage found – Continue with testing.
  • No voltage found – Check for power at the outlet into which the extension cord is plugged.
  • Voltage found – Replace the extension cord as needed to restore power to the TES unit and continue with testing.
  • No voltage found – Reset building circuit breaker or move cord to another outlet as needed to restore power to the extension cord and return to the beginning of Step #1.
  • Circuit breaker continues to blow – Proceed to Step #4.

Connect the extension cord to the short TES electrical plug. Use an AC Voltmeter to test the power supply at terminal #1 and #2 of the 115V terminal block.

  • Voltage found – Continue with testing.
  • No voltage found – Repair or replace the short TES power cord as needed to restore power to the terminal block and continue with testing.

Connect the extension cord to the short TES electrical plug. Use an AC Voltmeter to test for power at the black wire from terminal #1 where it connects to the heater switch. Use terminal #2 for the neutral contact.

  • Voltage found – Continue with testing.
  • No voltage found – Repair or replace the black wire as needed to restore power to the heater switch and continue with testing.

Turn the heater switch to the ON position. Test for power on the outlet terminal of the heater switch.Use terminal #2 for the neutral contact.

  • Voltage found – Continue with testing.
  • No voltage found – Replace the heater switch and continue with testing.

Turn the heater switch to the ON position. Test for power on the terminal of the transformer where the black wire is connected. Use terminal #2 for the neutral contact.

  • Voltage found – Continue with testing.
  • No voltage found – Repair or replace the black wire from the heater switch to the transformer as needed to restore power to the transformer and continue with testing.

Turn the heater switch to the ON position. Test for power on the terminal of the transformer where the black wire is connected. Use the white wire on the transformer for the neutral contact.

  • Voltage found – Proceed to Step #2.
  • No voltage found – Repair or replace the white wire from the terminal block to the transformer as needed to restore power to the transformer and proceed to Step #2.

Step #2 Transformer

With the heater switch in the ON position, test for power at the output AC terminals of the Transformer. These are the terminals on the left side where the red wire is on one terminal and the gray and green wires are on the other terminal. It should be 24VAC.

  • 24 Volts found – Proceed to Step #3
  • No voltage found – Replace the transformer and proceed to Step #3.

Step #3 Check 24V Power Supply

Check the 2amp fuse in the fuse holder in the red wire connected to the outlet terminal of the transformer. Replace the fuse as needed.

With the heater switch in the ON position, test for power at terminal #1 and terminal #2 of the 24V terminal block. These are the terminals on the left side where the gray wire is on terminal #1 and the red wire is on terminal #2. It should be 24VAC.

  • 24 Volts found – Continue with testing.
  • No voltage found – Replace the fuse, fuse holder and red wire as needed to restore power to terminal #1 & #2 and continue with testing.
  • If the fuse keeps blowing – Proceed to Step #5.

Test for power at the brown wire where it connects to the power light on the control panel. Use terminal #1 as the neutral connection.

  • 24 Volts found – Continue with testing.
  • No voltage found – Repair or replace the brown wire from terminal #2 to the power light as needed to restore power to the power light and continue with testing.

Test for power at the brown wire where it connects to the power light on the control panel. Use the gray wire on the light panel COMMON terminal as the neutral connection.

  • 24 Volts found – Continue with testing.
  • No voltage found – Repair or replace the gray wire from terminal #1 to the COMMON terminal as needed to restore power to the light panel continue with testing.

When you turn on the heater switch, does the green power light turn on?

  • Yes – Proceed to Step #3A.
  • No – Replace the light panel and proceed to Step #3A.

Step #3AHeater Operating Power

With the heater switch in the ON position, test for power at the brown wire connected to the COM terminal of the Hi-Limit Control. Use terminal #1 as the neutral connection.

  • 24 Volts found – Continue with testing.
  • No voltage found –Repair or replace the brown wire from terminal #2 of the 24V terminal block to the Hi-Limit switch as needed to restore power to the COM terminal and continue with testing.

Make sure the Hi-Limit Control is turned up to the 230˚F setting. Turn the heater switch to the ON position. Does the HI-LIMITlight turn on?

  • No – Go to TES 6.
  • Yes – Make sure the operator control is turned up to the 200˚F setting. Turn the heater switch to the ON position. Does the OPERATOR light switch turn on?
  • No – Go to TES 7.
  • Yes - Open the by-pass valve and turn the pump switch to the ON position. Does the LOW FLOW light turn on?
  • No – Go to TES 1.
  • Yes – For this test you will need to connect the propane tanks, open the tank valves and connect at least two TEX boxes and hoses. Turn the heater switch on to try to light the burner. You may have to turn the heater switch ON and OFF several times to try to light the burner several times before the air is bled out of the system and propane gets to the pilot and burners.
  • If the burner lights – Exit.
  • If the burner does not light – Go to TES 5.

Step #4 Building Circuit Breaker Blowing

Plug the extension cord into the building outlet.

  • If the circuit breaker does not blow when the extension cord is plugged in – Continue with testing.
  • If the circuit breaker blows as soon as the extension cord is plugged in – Repair or replace the extension cord as needed to remove the short and continue with testing.

Disconnect the incoming power wires from terminal # 1 & terminal #2 of the 115V terminal block. Connect the power cord to the TES plug.

  • If the circuit breaker blows – Repair or replace the short cord and plug on the TES unit as needed to remove the short and continue with testing.
  • If the circuit breaker does not blow – Continue with testing.

Reconnect the wires to the 115V terminal block. Make sure the heater switch and pump switch are in the OFF position. Examine the white jumper wire connecting terminals #2 and #4 and repair or replace the wire as needed to assure it is not shorted. Examine the other white wire from terminal #2 to the transformer and repair or replace the wire as needed to assure it is not shorted. Connect the power cord to the TES plug.

  • If the circuit breaker does not blow – Continue with testing.
  • If the circuit breaker blows – Disconnect the black wire to the pump switch from terminal #1 and connect the power cord to the TES plug.
  • If the circuit breaker does not blow – Repair or replace the black wire to the pump switch or replace the pump switch as needed to remove the short and continue with testing.
  • If the circuit breaker blows – Repair or replace the black wire to the heater switch or replace the heater switch as needed to remove the short. Reconnect the black wire from the pump switch to the terminal block and connect the cord to the TES plug.
  • If the circuit breaker blows – Repair or replace the black wire to the pump switch or replace the pump switch as needed to remove the short and continue with testing.
  • If the circuit breaker does not blow – Continue with testing.

Disconnect the black wire from the 115V input side of the transformer. Connect the power cord to the TES plug and turn the heater switch to the ON position.

  • If the circuit breaker blows – Repair or replace the black wire from the heater switch to the transformer as needed to remove the short and continue with testing.
  • If the circuit breaker does not blow – Continue with testing.

Reconnect the black wire to the transformer. Connect the power cord to the TES plug and turn the heater switch to the ON position.

  • If the circuit breaker blows – Replace the transformer and continue with testing.
  • If the circuit breaker does not blow – Continue with testing.

Remove the fuse from the fuse holder between the 24V outlet side of the transformer and terminal #2 of the 24V terminal block. Connect the power cord to the TES plug and turn the heater switch to the ON position.

  • If the circuit breaker blows – Repair or replace the fuse holder and red wire as needed to remove the short. Replace the fuse and return to Test #1.
  • If the circuit breaker does not blow – Replace the fuse and return to Test #1.

Step #5 Heater Fuse Blowing

Disconnect the two brown wires from terminal #2 of the 24V terminal block. Turn the heater switch to the ON position.

  • If the fuse does not blow – Continue with testing.
  • If the fuse blows – Check the red wire from the transformer to the fuse holder and from the fuse holder to terminal #2 of the 24V terminal block. Repair or replace the fuse holder and wire as needed to assure that there is no short. With the red wire and fuse holder connected to the transformer and terminal block, turn the heater switch to the ON position.
  • If the fuse blows – Replace the transformer and continue with testing.
  • If the fuse does not blow – Continue with testing.

Of the two brown wires normally connected to terminal #2 of the 24V terminal block, one goes to the high limit control and the other goes to the light panel. Reconnect to terminal #2 the brown wire that goes to the light panel. Disconnect the other end of the wire from the light panel and turn the heater switch to the ON position.

  • If the fuse does not blow – Continue with testing.
  • If the fuse blows – Repair or replace the brown wire as needed to remove the short and continue with testing.

Reconnect the brown wire to the light panel and turn the heater switch to the ON position.

  • If the fuse does not blow – Continue with testing.
  • If the fuse blows – Replace the light panel and continue with testing.

Reconnect the other brown wire to terminal #2 of the 24V terminal block. Disconnect the other end from the Hi-Limit Control. Turn the heater switch to the ON position.

  • If the fuse does not blow – Continue with testing.
  • If the fuse blows – Repair or replace the brown wire as needed to remove the short and continue with testing.

Reconnect the brown wire to the “C” terminal of the Hi-Limit Control. Disconnect the brown wire and purple wire from the “NC” terminal of the Hi-Limit Control. Turn the heater switch to the ON position.

  • If the fuse does not blow – Continue with testing.
  • If the fuse blows – Replace the Hi-Limit Control and continue with testing.

The short purple wire connects the Hi-Limit Control to the light panel. Examine the short purple wire and replace the wire as needed to assure that there is no short in the wire. Reconnect the purple wire to the light panel and the “NC” terminal of the Hi-Limit Control. Turn the high limit control up to its set point of 230˚F and turn the heater switch to the ON position.

  • If the fuse does not blow – Continue with testing.
  • If the fuse blows – Replace the light panel and continue with testing.

Reconnect the brown wire to the “NC” terminal of the Hi-Limit Control. Disconnect the other end of the brown wire from the Operator Control. Turn the heater switch to the ON position.

  • If the fuse does not blow – Continue with testing.
  • If the fuse blows – Repair or replace the brown wire as needed to remove the short and continue with testing.

Reconnect the brown wire to the Operator Control. Disconnect the blue wire from the Operator Control. Turn the heater switch to the ON position.

  • If the fuse does not blow – Continue with testing.
  • If the fuse blows – Replace the Operator Control and continue with testing.

Reconnect the blue wire to the Operator Control. Disconnect the other end of the blue wire from 24V terminal block. (Terminal #6 on the 8 terminal block or #8 on the 10 terminal block.) Turn the heater switch to the ON position.

  • If the fuse does not blow – Continue with testing.
  • If the fuse blows – Repair or replace the blue wire as needed to remove the short and continue with testing.

Reconnect the blue wire to the 24V terminal block. Examine the jumper connection which connects the terminal where the blue wire is connected to the terminal to the left. (Terminal #5 & #6 on the 8 terminal block and #7 & #8 on the 10 terminal block.) Re-installold jumper or a new one as needed to assure there is no short. Disconnect the next jumper connecting the terminal where the orange wire is connected to the terminal on the left. (Terminal #4 & #5 on the 8 terminal block and #6 & #7 on the 10 terminal block.) Keep the orange wire connected to the terminal block. Disconnect the other end of the orange wire from the light panel. Turn the heater switch to the ON position.

  • If the fuse does not blow – Continue with testing.
  • If the fuse blows – Repair or replace the orange wire as needed to remove the short and continue with testing.

Reconnect the orange wire to the light panel. Turn the heater switch to the ON position.

  • If the fuse does not blow – Continue with testing.
  • If the fuse blows – Replace the light panel and continue with testing.

Examine the jumper connecting the terminal where the orange wire is connected to the terminal on the left. (Terminal #4 & #5 on the 8 terminal block and #6 & #7 on the 10 terminal block.) Re-install old jumper or a new one as needed to assure there is no short.

Keep the yellow wire connected to the 24V terminal block. Disconnect the other end of the yellow wire from the Flow Switch. Turn the heater switch to the ON position.

  • If the fuse does not blow – Continue with testing.
  • If the fuse blows – Repair or replace the yellow wire as needed to remove the short and continue with testing.

Reconnect the yellow wire to the “COM” terminal of the Flow Switch. Disconnect the red wire from the Flow Switch. Turn the heater switch to the ON position.

  • If the fuse does not blow – Continue with testing.
  • If the fuse blows – Replace the Flow Switch and continue with testing.

Open the By-pass Valve and turn the pump switch to the ON position.

Does pressure of approximately 30psi show on the gauge?

  • No – If the pressure is low or no pressure on gauge there may not be enough flow to trigger the Flow Switch and perform the following tests. Go to TES 2 to check pump operation or contact your nearest service center for advice or assistance.
  • Yes – Turn the heater switch to the ON position.
  • If the fuse does not blow – Continue with testing.
  • If the fuse blows – Replace the Flow Switch and continue with testing.

Reconnect the red wire to the “NO” terminal of the Flow Switch. Disconnect the other end of the red wire from the 24V terminal block. (Terminal #3 on the 8 terminal block and terminal #5 of the 10 terminal block. Turn the pump switch and heater switch to the ON position.