HIGH SYSTEM PRESSURE



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TES Troubleshooting

3 – HIGH SYSTEM PRESSURE

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 Pressure Gauge

With the TES unit cool and the pump OFF, the TES system will typically hold 12 to 20 psi in fluid pressure. Before proceeding with the tests in this step, this pressure must be released.

If so equipped you can open the manual pressure relief valve to release this pressure or open the safety pressure relief valve if necessary. Place a pan under the back left side of the TES unit to catch the fluid released from the safety pressure relief valve.

Once the pressure has been released, check the pressure reading on the gauge.

▪ If it reads 0psi – Proceed to Step #2.

▪ If it reads above 0psi – Replace the pressure gauge and proceed to Step #2.

Step #2 By-Pass Valve

Open the By-Pass Valve located between the quick connect. Turn the knob counter-clockwise to open the valve. Turn the pump switch to the ON position. Can you hear the pump running?

▪ Yes – Continue with testing.

▪ No – Go to TES 2.

If there is air in the system the pressure reading may be erratic. As the air is removed from the system and fluid is re-filled the pressure should stabilize. Check the gauge reading.

▪ If the pressure does not stabilize or the pressure reads less than 20psi – Go to TES 2.

▪ If it reads between 20 to 30 psi – Proceed to Step #6.

▪ If the pressure reads above 20-30psi – Continue with testing.

Connect one end of a section of 3/4” TES hose to one outlet quick connect and the other end of the hose to one inlet quick connect. Turn the pump switch to the ON position. Check the gauge reading.

▪ If it reads between 20 to 30 psi – Replace the By-Pass valve and proceed to Step #6.

▪ If the pressure reads above 20-30psi – Proceed to Step #3.

Step #3 Pressure Reducing Valve

Before proceeding with the tests in this step, the system pressure must be released.

If so equipped you can open the manual pressure relief valve to release this pressure or open the safety pressure relief valve if necessary. Place a pan under the back left side of the TES unit to catch the fluid released from the safety pressure relief valve.

Once the pressure has been released, disconnect the wires going to the Solution Pump. Keep the System Pressure Pump wires connected. Turn the pump switch to the ON position. Is the System Pressure pump running?

▪ Yes – Continue with testing

▪ No – Go to TES 2.

After the pump runs a while it should build up the system pressure to 12-20psi and shut off.

▪ The pump does not shut off – Proceed to Step #4.

▪ Pressure is between 12-20psi when pump shuts off – Proceed to Step #5.

▪ Pressure goes over 20psi before the pump shuts off – Repair or replace the Pressure Reducing Valve. Reconnect Solution Pump wires and return to Step #1.

Step #4 System Pressure Pump

There can be four reasons why the pump is not shutting off.

1. The pump is not pumping well enough to build enough pressure to shut off the pressure switch.

2. There is a restriction in the supply line to the pump preventing it from pressurizing.

3. The pressure switch is bad and not shutting off even if there is enough pressure.

4. There is a leak in the system that is preventing the system from pressurizing.

With the system pump running check around the TES unit for any fluid leaks and repair them.

▪ If leaks were found and repaired – Return to Step #3.

▪ If no leaks were found – Continue with testing.

What is the maximum pressure reading on the TES gauge while only the system pump is running?

▪ Over 30psi – Replace the pressure switch on the Flojet System Pressure pump and return to Step #3.

▪ 30psi or less – Check the filter in the fluid reservoir and clean as needed. Remove the hose from the reservoir to the pump and check the hose for restrictions and replace the hose as needed. Disconnect the hose coming from the System Pressure pump where it connect to the Pressure Reducing Valve. Connect a tee fitting with a pressure gauge a valve and hose long enough to reach back to the fluid reservoir. Turn the pump on and check the flow of fluid from the pump back to the reservoir.

o If the flow is weak or sputters – Repair or replace the Flojet System Pressure pump and return to Step #3.

o If the flow is strong and steady – Turn the valve to the OFF position. What does the pressure gauge read?

▪ Under 30psi – Repair or replace the Flojet System Pressure pump and return to Step #3.

▪ Over 30psi – Does the pump Shutoff?

• Yes – Return to Step #3.

• No - Adjust or replace the pressure switch and return to Step #3.

Step #5 Checking for Restrictions

Remove the screen from the Spiro-vent use an extractor or wet vac to vacuum the fluid out of the boiler from the open of the Spiro-vent.

If the machine is equipped with the old style Spiro-trap filter remove the screen and clean out the Spiro-trap filter. Reassemble the filter and proceed with this step.

If the machine has the new style by-pass filter, replace the filter element and proceed with this step.

Remove the header from the right side of the boiler. Use a 3/4” boiler brush to clean out the heat exchanger tubes as needed. Use a flashlight or boroscope to look inside the tubes to check for obstructions.

After the heat exchanger tubes are cleaned, replace the header o-rings and re-install the header.

Disconnect the two hoses from the fluid inlet and outlet manifold. Check the hoses for restrictions or damage and replace the hoses as needed. Connect a 1” ID water hose to the barb on the outlet manifold (Left Side). Connect a 1” ID drain hose to the barb on the inlet manifold (Right Side). Open the By-Pass valve and turn on the water supply to flush out the inlet/outlet manifold assembly. Close and open the By-Pass to check its operation and replace as needed. Connect open quick connects to the quick connects on the manifold to flush the out. You can also connect the water supply hose to the quick connects to further clean them.

Once the boiler heat exchanger tubes, quick connects, hoses, inlet/outlet manifold and By-Pass valve are cleaned, use air to blow any remaining water out of the manifold and hoses. Make sure the reservoir is filled with TES Thermal Exchange Fluid, open the By-pass valve and turn the pump on to re-fill the system with fluid. Let the pump run until the air is removed from the system and the pressure stabilizes.

When the system is re-filled with fluid – Proceed to Step #6

Step #6 System Test

Connect all hoses and TEX boxes. With the By-Pass Valve open, turn the pump switch to the ON position. Check the gauge pressure. If there is air in the system the pressure reading may be erratic. As the air is removed from the system and fluid is re-filled the pressure should stabilize.

▪ If the pressure does not stabilize or the pressure reads less than 20psi – Go to TES 2.

▪ If it reads between 20 to 30 psi – Continue with testing.

▪ If the pressure reads above 30psi – Return to Step #1.

Close the By-Pass valve and check the pressure.

▪ If it reads between 30 to 40 psi – Continue with testing.

▪ If the pressure reads above 40psi – There is a restriction somewhere in the hoses, quick connects and/or TEX boxes. Remove the quick connect from each hose and flush each hose out with water. Clean out and replace quick connects as needed. Connect one hose to one quick connect on each TEX box and remove the other quick connect. Use water to flush out the TEX boxes. Clean out and replace quick connects as needed. Use compressed air to blow the water out of the hoses and TEX boxes after flushing. Connect all of the hoses to the TES unit and refill the hoses and TEX boxes with new fluid. Once all hoses and TEX boxes are cleaned and refilled with fluid, return to the beginning of Step #6.

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

▪ Yes – Continue with testing.

▪ No – Go to TES 1.

Place air movers in each TEX box and turn the switches to the low speed setting. Open the propane tank valves and turn the heater switch ON and OFF as needed to ignite the heater.

▪ If the heater does not light – Go to TES 5.

▪ If the heater lights – Allow the TES unit to heat up and watch the pressure gauge.

▪ If the unit does not heat up – Go to TES 8.

▪ If the pressure goes above 50psi – Turn heater switch to the OFF position and close propane tank valves. Allow pump and air movers to run until system is cool. Release pressure and recharge or replace the expansion tank and return to the beginning of Step #6 or contact your nearest service center for advice or assistance.

▪ If the pressure stays below 50psi - Turn heater switch to the OFF position and close propane tank valves. Allow pump and air movers to run until system is cool then Exit.

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