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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.
Revised: 06-13-08
© Copyright Bridgepoint Systems, Inc. 2008
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 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.
Revised: 06-13-08
© Copyright Bridgepoint Systems, Inc. 2008
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Step #3 System Pressure Pump
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. Can you feel or hear the small
system pressure pump running?
 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
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.
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.
Revised: 06-13-08
© Copyright Bridgepoint Systems, Inc. 2008
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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 bypass 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
Revised: 06-13-08
© Copyright Bridgepoint Systems, Inc. 2008
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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 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.
Revised: 06-13-08
© Copyright Bridgepoint Systems, Inc. 2008
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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.
The pumps can be run with the heater off to determine if they are the cause of the circuit
overload.
The solution pump can be run with the system pressure pump disconnected and the
system pressure pump can be run with the solution pump disconnected.
If the solution pump is run separately and the circuit breaker blows after it runs for a
while, the solution pump can be repaired or replaced.
When the system pressure pump is run by itself, it should only run until the system
pressure reaches 12 – 15psi then should turn itself off. If the circuit breaker blows or if it
fails to turn itself off it should be repaired or replaced.
Revised: 06-13-08
© Copyright Bridgepoint Systems, Inc. 2008
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Wires can have loose connections or bare spots that only short out when the machine is
running and vibrations cause them to move just right to short out. There is no easy way to
test these kinds of problems.
The previous steps can be used with your wiring diagrams as guides to check components
and narrow down the areas to be checked for operational or intermittent shorts. Contact
your nearest service center for advice or assistance.
Revised: 06-13-08
© Copyright Bridgepoint Systems, Inc. 2008
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