Pump Not Working

TES Master Page TES Resources

TES Troubleshooting

2 – PUMP IS NOT RUNNING

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.

Step #1 Check 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.

o Voltage found – Replace the extension cord as needed to restore power to the TES unit and continue with testing.

o 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.

o Circuit breaker continues to blow – Proceed to Step #5.

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.

Make sure that the fluid reservoir is full of TES Thermal Exchange Fluid. For this test, the propane tanks do not need to be connected or the tank valves can remain closed. Open the By-pass valve located between the TES quick connects. Connect a power cord to the TES unit and turn the pump switch to the ON position.

Does the building circuit breaker blow?

· Yes – Proceed to Step #5

· No - Can you hear the large solution pressure pump running?

· Yes – Proceed to Step #3.

· No – Proceed to Step #2.

Step #2 Solution Pump

With the pump switch in the ON position, use an AC Voltmeter to test for power between terminal #4 where the white wires are connected & terminal #5 where the black wires are connected on the 115V terminal block.

· Voltage found – Continue with testing.

· No voltage found – Check the white jumper wire connecting terminal #2 and terminal #4 and repair or replace the jumper wire to assure that there is a good connection between the two terminals. Check the continuity of the black wire from terminal #1 to the pump switch and the black wire from the pump switch to terminal #5. Repair or replace the wires as needed to restore continuity. With the pump switch in the ON position retest for power between terminal #4 and terminal #5 of the 115V terminal block.

o Voltage found – Continue with testing.

o No voltage found – Replace the pump switch and retest.

§ Voltage found – Continue with testing.

§ No voltage found – Return to Step #1.

The black and white wires from terminal #5 and terminal #4 run to the wiring box on the solution pump. These wires connect to the solution pump and the white and black wires going to the system pressure pump. The color of the solution pump wires which connect to the white and black wires will vary with different models of pump motors used. The white wire from the terminal block connects to the white wire to the system pressure pump and the yellow wire to the solution pump motor on all models. The black wire from the terminal block connects to the black wire to the system pressure pump and three different wire combinations on the different solution pump motors.

The blue 3/4HP motor the black wires connect to the blue wire.

The gray 3/4HP motor the black wires connect to the blue and orange wires.

The blue 1.5HP motor the black wires connect to the blue, red and orange wires.

With the pump switch in the ON position, test for power at the black and white wires from the terminal block where they connect to the motor.

· Voltage found – Continue with testing.

· No voltage found – Repair or replace the white and black wires as needed to restore the power to the pump motor and continue with testing.

Reconnect the white and black wires from the terminal block to the solution pump motor and the system pressure pump wires. Turn the pump switch to the ON position.

· If the pump runs – Proceed to Step #3

· If the pump does not run – Repair or replace the pump as needed and proceed to Step #3.

Step #3 System Pressure Pump

· Yes – Proceed to Step #4.

· No – Push in the green knob on the pressure reducing valve. When you press the knob, does the system pressure pump start running?

o Yes – Proceed to Step #4.

o No – Continue with testing.

Disconnect the black and white power wires coming from the solution pump wiring box from the system pressure pump wires. With the pump switch in the ON position, test the wires coming from the solution pump for power.

· Voltage found - Repair or replace the system pressure pump and continue with testing.

· No voltage found – Repair or replace the white and black wires from the solution pump as needed to restore power to the system pressure pump. Reconnect the wires to the system pressure pump. Turn the pump switch to the ON position.

o Yes – Proceed to Step #4.

o No – Push in the green knob on the pressure reducing valve. When you press the knob, does the system pressure pump start running?

· Yes – Proceed to Step #4.

· No – Repair or replace the system pressure pump.

Step #4 Pump Test

Can you hear the large solution pressure pump running?

· Yes – Continue with testing.

· No – Return to Step #1 and check everything again or contact your nearest service center for advice or assistance.

Can you feel or hear the small system pressure pump running?

· Yes – Continue with testing

· No – Push in the green knob on the pressure reducing valve. When you press the knob, does the system pressure pump start running?

o Yes – Continue with testing.

o No – Return to Step #3 and check everything again or contact your nearest service center for advice or assistance.

With the pumps running check the pressure on the gauge. The pressure may be erratic as the system starts up. As the air is removed from the fluid and the system pressure pump fills the system the pressure should stabilize. With no TEX boxes connected and the by-pass valve open the pressure should read between 20-30psi.

· If the pressure reads normally – Continue with testing.

· If the pressure is low, high or stays erratic – Go to TES 1.

Turn the heater switch to the ON position. Does the LOW FLOW light turn ON?

· Yes – Continue with testing.

· No – Go to TES 1.

Let the system run for a while to be sure the pumps keep operating properly.

· If the pumps run without problem – Exit.

· If the pressure is low, high or stays erratic – Go to TES 1.

· If the building circuit breaker blows – Proceed to Step #7

Step #5 Building Circuit Breaker Blowing

· If the building circuit breaker blows as soon as the TES unit is plugged in – Continue with this step.

· If the building circuit breaker blows when the pump switch is turned ON – Proceed to Step #6

· If the building circuit breaker blows when the heater switch is turned ON – Go to TES 4.

· If the building circuit breaker blows after the machine is running a while – Proceed to Step #7.

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 - 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 – Proceed to Step #6.

· 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.

o 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 proceed to Step #6.

o 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 Proceed to Step #6.

§ If the circuit breaker does not blow – Proceed to Step #6.

Step #6

Disconnect the black wire coming from the pump switch where it connects to terminal # 5 of the 115V terminal block. Connect the cord to the TES plug and turn the pump switch to the ON position.

· 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

Reconnect the black wire from the pump switch to terminal #5 of the 115V terminal block. Disconnect the black and white wires going to the pumps from terminal # 4 and terminal #5. Connect the cord to the TES plug and turn the pump switch to the ON position.

· If the circuit breaker blows – Repair or replace the wires to the hour meter or replace the hour meter as needed to remove the short and continue with testing.

· If the circuit breaker does not blow – Continue with testing

Reconnect the pump wires to terminal #4 and terminal #5 of the 115V terminal block.

The blue 3/4HP motor the black wires connect to the blue wire.

The gray 3/4HP motor the black wires connect to the blue and orange wires.

The blue 1.5HP motor the black wires connect to the blue, red and orange wires.

· Disconnect the white and black wires from all other wires in the wiring box of the solution pump.

Reconnect the black and white wires to the system pressure pump to the wires from the terminal block. Disconnect the other ends of these wires from the system pressure pump. Do not connect the solution pump wires. Connect the cord to the TES plug and turn the pump switch to the ON position.

· If the circuit breaker blows – Repair or replace the wires to the system pressure pump 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 system pressure pump. Connect the cord to the TES plug and turn the pump switch to the ON position.

· If the circuit breaker blows – Repair or replace the system pressure pump as needed to remove the short and continue with testing.

· If the circuit breaker does not blow – Continue with testing.

Reconnect the solution pump wires to the black and white wires from the terminal block. Connect the cord to the TES plug and turn the pump switch to the ON position.

· If the circuit breaker blows – Repair or replace solution pump as needed to remove the short and proceed to Step #7.

· If the circuit breaker does not blow – Proceed to Step #7.

Step #7 Shorts Which Occur During Operation or Intermittent Problems

Even if the pumps have tested OK in the previous sections they can overheat as they run and start to draw excessive current. This can cause the circuit breaker to blow.