Service Technician Training

Service Technician Training
TES Installation Procedures This portion of the technician training will focus on the requirements and procedures for the proper installation of the TES Thermal Energy System in a trailer.

TES Trailer Requirements
Payload Capacity Dimensions Tongue Length Ventilation Hose Access Door The first step in the installation process is to assure that the trailer is properly sized and equipped for transporting and operating the TES unit and accessories. The following factors must be considered: Payload Capacity Dimensions Tongue Length Ventilation Hose Access Door

PAYLOAD CAPACITY The approximate combined weight of the standard TES package with three 100# propane tanks is 1600 lbs. The approximate weight of the standard TES Thermal Energy System package with three 100# propane tanks is 1600 lbs. The payload capacity of the trailer must be able to carry this weight plus the weight of any additional supplies or equipment which may be needed.

Inside Dimensions To maintain proper clearances around the TES unit and to carry accessories and other equipment a minimum 6’ x 12’ area with a 6’ ceiling is required. A 6-1/2’ ceiling is required to stack TEX boxes four high. If the TES unit is to be operated inside the trailer there must be 6” of clearance between the TES unit and any combustible materials. You will also need to maintain clearance for access to connect the power cord and hoses as well as access to the control panel for start up and operation monitoring. To maintain the proper clearances around the TES unit and to carry accessories and other equipment a minimum 6’ x 12’ area with a 6’ ceiling is required. A 6-1/2’ ceiling is required to stack the TEX boxes four high.

Tongue Length A four foot tongue is require to be able to mount the AT70 Propane Tank Rack. A four foot tongue is required to mount the AT70 Propane Tank Rack.

VENTILATION A 200,000 btu propane fired boiler requires 200 square inches of incoming air vent space to provide combustion air flow. This will consist of one lower vent within 12 inches of the floor and a roof vent. Each vent of 100 square inches. When calculating the vent area, consideration must be given to the blockage effects of louvers, grills and screens. The standard TES unit has a 200,000 btu propane fire heater that requires 200 square inches of incoming air vent space to provide combustion air flow. (The 250,000 btu TES unit will require 250 square inches.) This will consist of lower vent within 12 inches of the floor and a roof vent. Each vent must be at least square inches. When calculating the vent area consideration must be given to the blockage effects of louvers, grilles and screens.

VENTILATION Inlet Air Fan Roof Vent
In most applications two roof vents are used to assure that the minimum requirement for air space is exceeded. An inlet air fan can be used to assure adequate air flow from a inlet air opening that is actually less than the required square inches and must be used to provide adequate cooling during operation when the outside temperature is over 60˚F. Inlet Air Fan Roof Vent

HOSE ACCESS DOOR A hose access door is required to allow the hoses to be run out of the trailer while allowing the doors to be locked for security during operation. The open space of the hose door can be included in the calculation of the total available vent space. A hose access door is required to allow the hoses to be run out of the trailer while allowing the doors to be locked for security during operation. The open space of the hose door can be included in the calculation of the total available air inlet vent space. A latch or hook should be used to hold the door open during TES operation. The door should be held open during TES operation

There are Four Steps in the TES Installation Process
Layout Anchoring Exhaust Propane Once you have the proper trailer, the installation process can begin. There are four steps in the TES installation process: Layout Anchoring Exhaust Propane

LAYOUT Determine the positioning of the TES unit and accessories.
Balance load to reduce tongue weight Minimum of 6” between the TES unit and wall of trailer and any combustible materials. TES exhaust outlet centered between roof beams. Use wall e-channel to secure hoses and TEX boxes. Floor anchors can be installed as needed without interference from beams or other obstructions. The Layout Step is determining the positioning and placement of the TES unit and accessories. Balance the load to keep the tongue weight within the proper range for the towing vehicle. Maintain the minimum 6” clearance between the TES unit and the walls of the trailer and any combustible materials. Center the TES exhaust outlet between roof beams. Use the wall E-channel to secure hoses and TEX boxes Assure that the Floor anchors can be installed as needed without interference from floor beams or other obstructions.

LAYOUT Here is a drawing of a typical TES layout.

ANCHORING Trailer Use Mounting – No Wheels
Portable Use Mounting – With Wheels The next step is anchoring the TES unit. There are two ways to mount the TES unit. Trailer Use Mounting – No Wheels Portable Use Mounting – With Wheels.

TRAILER MOUNT When the TES will be used only in the trailer and the wheels are not required, the mounting feet of the TES unit can be bolted directly to the floor of the trailer. Each foot has four bolt holes. Two bolts should be placed through each foot to secure the unit properly.

PORTABLE MOUNT When the TES unit will be used outside of the trailer and the wheels have been installed on the TES unit, floor anchors and turnbuckles are used to secure the TES unit and a support frame is used to take the weight off of the wheels during transportation. Turnbuckle Turnbuckle Floor Anchor Support Frame Trailer Floor Floor Anchor

PORTABLE MOUNT Turnbuckle Floor Anchor
The floor anchors are installed into the trailer floor. A 3” hole saw is used to allow the d-ring of the floor anchor to be recessed in the floor. A back up plate and bolts are used to secure the anchor to the floor. Turn buckles and S-hooks are used to connect the TES unit to the floor anchors. Turnbuckle Floor Anchor

PORTABLE MOUNT Before the turnbuckles are connected the support frame is slid under the TES base. As the turnbuckles are tightened and the tires are compressed the TES frame comes in contact with the support frame. This greatly increases the stability of the unit during transportation. Low air pressure in the wheels may make it difficult to slide the frame under the Tes base. Add air to tires as needed or lift the Tes to slide the frame underneath.

EXHAUST The outdoor vent cap cannot be used in an enclosed trailer.
Next the exhaust system must be installed. The outdoor exhaust vent cap, which comes with the TES unit, is for outdoor use only and cannot be used in an enclosed trailer. Outdoor Vent Cap

EXHAUST Always use single wall galvanized metal vent pipe the same diameter as the draft flue collar. 200,000 BTU units: 7” Exhaust Pipe 250,000 BTU units: 8” Exhaust Pipe The exhaust pipe must be installed straight up through the roof with an Exhaust Cap. Always use single wall galvanized metal vent pipe the same diameter as the flue draft collar on top of the TES unit. The exhaust vent pipe must be installed straight up through the roof and topped with an approved vent cap.

EXHAUST Make sure the section of roof directly above the TES unit exhaust outlet is relatively flat and TES is positioned so exhaust outlet will be centered between the roof cross beams. Make sure the section of roof directly above the TES unit exhaust outlet is relatively flat and TES is positioned so the exhaust outlet will be centered between the roof beams.

EXHAUST Use plumb bob or level to locate and mark center spot on trailer roof directly above the exhaust outlet. Draw an 8” diameter circle & cut out circle. 8” Use a plumb bob or level to locate and mark the center spot on the trailer roof directly above the exhaust outlet. Draw an eight inch diameter circle and cut out the circle. Cover the top of the TES unit while cutting out the circle. (A nine inch circle is required for the 250,000 btu TES unit.)

EXHAUST Drill 12 holes, each 3/16” in diameter around the edge of the flange on the Exhaust cap (NM4330). Drill 12 holes, each 3/16” in diameter around the edge of the flange on the exhaust vent cap. Part number NM4330. (Part number NM4331 for the 250,000 btu TES unit.)

EXHAUST Apply a silicone, urethane or neoprene sealant to the bottom of the exhaust cap flange. Place exhaust cap on roof centered over the opening. Drill 3/16” holes through roof aligning with each hole on the flange and secure flange to roof with pop rivets. Seal edge of flange and rivets with silicone, urethane or neoprene sealant. Seal around inside edge of roof opening and exhaust cap Apply a silicone, urethane or neoprene sealant to the bottom of the exhaust vent cap flange. Place the exhaust vent cap on the roof of the trailer, centered over the opening. Drill 3/16” holes through the roof, aligning each with the hole on the flange and secure the flange to the roof with pop rivets. Seal the edge of the flange and cover the rivets with sealant. Seal around the inside edge of the roof opening and exhaust vent cap.

EXHAUST These pictures show the vent cap installed and sealed.

EXHAUST Use a crimping tool to crimp top edge of Tapered Exhaust Adapter Use a crimping tool to crimp the top edge of the tapered exhaust adapter. Part number NM (Part number NM4391 for the 250,000 btu TES unit.) Adapter 8” x 7” NM4390 Crimping Tool

EXHAUST Place the Tapered Exhaust Adapter on top of the TES Exhaust outlet and measure the distance from the bottom of the Exhaust cap to the ridge just below the crimped section of the adapter. Crimped Section Place the tapered exhaust adapter on top of the TES exhaust outlet and measure the distance from the bottom of the exhaust vent cap to the ridge just below the crimped section. Ridge

EXHAUST These pictures show the adapter in place and where the measurement is taken.

EXHAUST Cut a section of 7” single wall galvanized pipe 1” longer than your earlier measurement. Place pipe onto Tapered Exhaust Adapter. Cut a section of 7” single wall exhaust pipe 1” longer than your measurement between the exhaust vent cap and adapter. (8” pipe is require for the 250,000 btu TES unit.) Insert the crimped end of the tapered adapter into the bottom of the pipe.

EXHAUST Insert crimped end of adapter and pipe assembly into bottom of Exhaust cap and set adapter over TES exhaust outlet. Insert the crimped end of the pipe into the exhaust vent cap and place the tapered adapter over the TES exhaust outlet as shown here.

PROPANE Propane tank rack Regulator and Bulkhead fitting Hoses
Portable Use Regulator The next step is the Propane System installation. There are for areas to be addressed in this step. Propane Tank Rack Regulator and Bulkhead Fitting Hoses Portable use regulator.

PROPANE Place Propane Tank Rack (AT70) on the trailer tongue. Center rack on tongue and leave ½” to 1” space between rack and trailer wall. Move Battery box if needed. Secure rack to tongue by welding or bolting. Place the Propane Tank Rack, part number AT70, on the trailer tongue. Center the rack on the tongue and leave 1/2” to 1” space between the rack and the trailer wall. The battery box may need to be moved forward to make room for the rack. Secure the rack to the tongue by welding or bolting.

PROPANE This picture shows the proper positioning of the propane tank rack. The rack is designed to hold # propane tanks.

PROPANE Propane regulator must be mounted outside of trailer during TES operation. Select a location to mount the propane regulator and bulkhead fitting. Next to wall stud. Protected from contact. Close to propane tanks. Next install the Propane regulator. The Propane regulator must be mounted outside of the trailer during TES operation. Select a location to mount the propane regulator and bulkhead fitting. Next to a wall stud Protected from contact Close to the propane tanks

PROPANE Drill a 1-1/2” hole through inner wall only.
Drill a 7/8” hole through outer wall. 7/8” Hole Drill a 1-1/2” hole through the inside wall only. Drill a 7/8” hole through the outside wall, centered in the 1-1/2” inside wall hole. 1-1/2” Hole Wall Stud

PROPANE Assemble regulator, fittings and bracket Regulator NM4320
Nipple ½” x 1-1/2” NM4346 Elbow 90˚ ½” F-F BR296 Regulator Bracket NM4352 Screws #8 x ½” PHP NM4370 Assemble the propane regulator, fitting and bracket as shown here. Use thread sealant on all fittings. Make sure the opening on the elbow aligns with the hole in the bracket when the regulator is secured to the bracket.

PROPANE Assemble Bulkhead Fitting. Use different nipples for walls with different thickness. Bulkhead Fitting NM4334 Nipple ½” x 1-1/2” NM4346 Nipple ½” x 2” NM4348 Nipple ½” x 2-1/2” NM4350 Assemble the bulkhead fitting. Different nipples can be used for different wall thicknesses. Use thread sealant on all fittings. When assembled and connected to the regulator assembly elbow, the hex on the bulkhead fitting must be flush with the inside wall.

PROPANE Insert Bulkhead Fitting through wall and screw nipple into Regulator nipple. Hex on Bulkhead Fitting must be flush with or slightly inside the inner wall. Insert the bulkhead fitting assembly through the wall and screw the nipple into the regulator elbow. Use thread sealant on the nipple threads. Tighten to prevent leaking and assure that the Hex on the bulkhead fitting must be flush with the inside wall.

PROPANE Place Bulkhead Plate over Bulkhead Fitting and secure plate to fitting with lock washer and nut included with bulkhead fitting. Secure Bulkhead plate to wall with four screws. Place the bulkhead plate over the bulkhead fitting and secure the plate to the fitting with lock washer and nut. Then secure the bulkhead plate to the trailer wall with four screws. Two of the screws should screw into the wall stud. Bulkhead Plate NM4354 Screw #10 x 1” PHP NM4372

PROPANE Secure the Regulator Bracket to the trailer wall with eight screws. Regulator Bracket can be mounted horizontally or vertically. Secure the regulator bracket to the trailer wall with eight screws. The regulator bracket can be installed horizontally or vertically. Four of the screws should screw into wall studs. Here the bracket is installed vertically. Vertical Mount

PROPANE Here the bracket is installed horizontally. Horizontal Mount

PROPANE Check position of vents on the propane regulator. Large vent must be pointing down, or plumbed with opening pointing down. Small vent should be pointing down. The small vent can be turned. In vertical mount the small vent can’t be turned down. Turn so vent points to the left. There are two vents on the propane regulator. The small vent is the first stage vent and the larger vent is the second stage vent. Check the position of the vents. The larger vent must be pointed down or plumbed with the opening pointing down. The small vent should be pointing down. In the horizontal position the vent can be turned to point down. In the vertical position the vent cannot be pointed down, so it should be turned to point to the left.

PROPANE Large Vent Small Vent Horizontal Mount
This picture shows the large vent plumbed with an elbow to point down and the small vent turned to point down. Horizontal Mount

PROPANE Remove four screws and turn small vent as needed. Do not have vent pointing toward bracket. To turn the small vent, remove the four screws and turn the vent as needed. Do not have the vent pointing toward the bracket. Replace the four screws and tighten.

Male POL Fitting- ¼” MPT
PROPANE Connect ¼” 90˚ Street Elbow to the inlet port of propane regulator. Connect Male POL fitting to ¼” Elbow. Elbow 90˚ - ¼” Street BR282 Next, connect the 1/4” - 90˚ street elbow to the inlet port of the propane regulator. A 45˚ elbow can be substituted if desired. Then connect the male POL fitting to the elbow. Male POL Fitting- ¼” MPT PMEF-181

PROPANE Connect 3-Tank Adapter to POL fitting and the three propane tanks. Connect the 3-tank adapter to the POL fitting on the regulator and to the three 100# propane tanks in the rack.

PROPANE Connect ½” 90˚ Street Elbow to the Bulkhead Fitting.
Connect the ½” Gas Shutoff Valve to the elbow. Gas Shutoff Valve NM4336 Inside the trailer connect a 1/2” - 90˚ street elbow to the bulkhead fitting and connect the 1/2” gas shutoff valve to the elbow. Elbow 90˚ - ½” Street BR286

PROPANE Connect 15’ Propane hose to gas shutoff valve and route hose along top of wall to the side of the TES unit. Remove regulator from TES 10’ Propane hose and connect to 15’ hose from gas shutoff valve. Connect the 15’ propane hose to the gas shutoff valve and route the hose along the top of the wall to the side of the TES unit. Remove the propane regulator from the 10’ TES propane hose and connect the 10’ hose to the 15’ hose.

PROPANE This picture shows the hose from the shutoff valve along the top of the wall.

PROPANE This picture shows the connection of the two hoses. Notice the connection point is away from the heater side of the TES unit.

PROPANE 10’ Hose From TES NM4215 Adapter ½” Male Flair x ½” FPT NM4339
Here is a close up of the hose connection. 45˚ flare fittings are used on each hose with a double female swivel union to connect the two hoses. 15’ Hose From Valve NM4332 Connector ½” Female Flair x ½” Female Flair NM4342

PROPANE Test propane lines for leaks Sound and smell
Manometer Leak Test Leak Testing Solution Once the hoses are connected, we must check the propane system for leaks. Tanks must be filled with propane, adapters connected and valves closed before proceeding. There are three ways to check for leaks. Perform test outdoors with trailer doors and vents open, away from sources of ignition. Sound & smell Manometer Leak Test or pressure test. Leak Testing Solution

PROPANE Outdoor Hood Under the Outdoor Hood on the front of the heater is the main gas valve. Remove the four screws and remove the hood.

PROPANE Remove plug from inlet pressure tap on main gas valve.
Remove the plug from the inlet pressure tap on the main gas valve.

PROPANE Connect manometer to inlet pressure tap on Main Gas Valve.
Open propane tank valves to pressurize lines. Manometer should read 12” wc. (wc = Water Column) Connect a manometer to the inlet pressure tap on the main gas valve. Open the open the tank valves and gas shutoff valve to pressurize lines. The manometer should read 12” of water column.

PROPANE Close tank valves.
Release some gas from line to drop pressure 1-2” wc. If pressure remains unchanged for at least 10 minutes, the lines are leak free. If a pressure drop occurs, use leak testing solution to test all fittings to locate and repair leaks. Retest system until it tests leak free. If pressure increases tank valve is not closed tightly. Close valve and repeat test. Close the tank valves. Release some gas to drop the pressure 1-2” of water column so the gauge now reads 10”. If the pressure remains unchanged for at least 10 minutes the lines are leak free. If a pressure drop occurs, use a leak testing solution to test all fittings to locate and repair leaks. Retest system until it tests leak free. If the pressure increases the tank valve is not closed tightly. Close valve and retest. You can try closing the shutoff valve first and then the tank valves to check to see if the leak is on the machine side of the shutoff valve. Then open the shutoff valve to see if the leak is on the tank side of the shutoff valve. There is also are two pressure taps on the propane to test the regulator pressure on the high pressure side between the tanks and the regulator or the 2nd stage or low pressure side to test the pressure between the regulator and the shutoff valve.

PROPANE 2nd Stage Low Pressure Tap 1st Stage High Pressure Tap
This picture shows the pressure taps on the propane regulator. 1st Stage High Pressure Tap

PROPANE Open propane tank valve to pressurize lines.
Liberally swab all propane line fittings and connections with Leak Detecting solution and look closely for bubbles. Bubbles forming – Leak detected No bubbles forming – No leak Repair leaks and retest as needed. To use the leak testing solution, open the tank valves to pressurize the lines. Liberally swab all propane line fittings and connections with the leak testing solution and look closely for bubbles. Bubbles forming – indicates leaking No bubbles – No leaking Close the tank valves, repair leaks and retest. Repeat until no leaking is indicated on all tests.

Requirements for operation outside of trailer
PROPANE Requirements for operation outside of trailer When removing the TES unit from the trailer for portable operation, a second Propane Regulator will be required. Install 1/2” Male Flare Adapter in Inlet port of Propane Regulator If regulator was removed from TES propane hose it should already have the POL fitting. If not install POL fitting in Outlet port of Propane Regulator. When removing the TES unit from the trailer for portable operation, a second propane regulator will be required. Install a 1/2” - 45˚ Male flare fitting with 1/2” male pipe thread into the outlet port of the propane regulator. If the regulator was removed from the TES hose it should already have a male POL fitting on the inlet port. If not, one will need to be installed.

PROPANE Requirements for operation outside of trailer Propane Regulator NM4320 This picture shows the propane regulator with the fittings installed for portable TES operation. Male 1/2” Male Flare x 1/2” mpt NM4338 Male POL Fitting x 1/4” mpt PMEF-181

PROPANE Requirements for operation outside of trailer Disconnect the 10’ TES propane hose from the 15’ Trailer propane hose. Disconnect Here Disconnect the double female swivel union from the 15’ hose in the trailer. 10’ TES Propane Hose 15’ Trailer Propane Hose

PROPANE Requirements for operation outside of trailer Connect TES propane hose to Propane Regulator. Connect the 10’ hose and double female union to the propane regulator.

PROPANE Requirements for operation outside of trailer Remove 3-Tank adapter from Trailer regulator and tanks. Remove Propane tanks from rack and move to operation location and secure as needed. Connect 3-Tank adapter to tanks and TES regulator. Make sure tank valves are closed and remove the 3-tank adapter from the regulator on the trailer and remove the three tanks from the rack. Move the tanks to the operation location and secure tanks to be sure they will not tip or move during operation. Connect the three tank adapter to the three tanks and to the propane regulator and you are ready for portable operation of your TES unit. Test the Propane Hoses and fittings for leaks before operating the TES.

PROPANE Requirements for operation outside of trailer After job is completed and the TES unit and propane tanks are returned to the trailer – Reconnect TES propane hoses in trailer, check connection for leaks. After the job is completed and the TES unit and propane tanks have been returned to the trailer, reconnect the propane hoses and check connections for leaks before returning the machine to service.

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