Transcript Service Technician Training

Service
Technician Training
TES Installation Procedures
TES Trailer Requirements
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.
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.
Tongue Length
A four foot tongue is require to be able 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.
VENTILATION
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.
The door should be held open during TES operation
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.
LAYOUT
ANCHORING
Trailer Use Mounting – No Wheels
Portable Use Mounting – With Wheels
TRAILER MOUNT
PORTABLE MOUNT
Turnbuckle
Turnbuckle
Floor Anchor
Support Frame
Trailer Floor
Floor Anchor
PORTABLE MOUNT
Floor Anchor
Turnbuckle
PORTABLE MOUNT
EXHAUST
The outdoor vent cap 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.
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.
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”
EXHAUST
Drill 12 holes, each 3/16” in diameter
around the edge of the flange on the
Exhaust cap (NM4330).
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
EXHAUST
EXHAUST
Use a crimping tool
to crimp top edge of
Tapered Exhaust
Adapter
Crimping Tool
Adapter 8” x 7”
NM4390
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
Ridge
EXHAUST
EXHAUST
Cut a section of 7”
single wall
galvanized pipe 1”
longer than your
earlier
measurement.
Place pipe onto
Tapered Exhaust
Adapter.
EXHAUST
Insert crimped
end of adapter
and pipe
assembly into
bottom of
Exhaust cap
and set adapter
over TES
exhaust outlet.
PROPANE
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.
PROPANE
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.
PROPANE
Drill a 1-1/2” hole through inner wall only.
Drill a 7/8” hole through outer wall.
7/8” 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
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
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.
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.
Bulkhead Plate
Screw #10 x 1” PHP
NM4372
NM4354
PROPANE
Secure the
Regulator Bracket to
the trailer wall with
eight screws.
Regulator Bracket
can be mounted
horizontally or
vertically.
Vertical Mount
PROPANE
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.
PROPANE
Large Vent
Small Vent
Horizontal Mount
PROPANE
Remove four screws and turn small vent
as needed. Do not have vent pointing
toward bracket.
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
Male POL Fitting- ¼” MPT
PMEF-181
PROPANE
Connect 3-Tank
Adapter to POL
fitting and the three
propane tanks.
PROPANE
Connect ½” 90˚ Street Elbow to the
Bulkhead Fitting.
Connect the ½” Gas Shutoff Valve to the
elbow.
Gas Shutoff Valve
NM4336
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.
PROPANE
PROPANE
PROPANE
10’ Hose From TES
Adapter ½” Male Flair x ½”
FPT
NM4215
NM4339
Adapter ½” Male Flair x
3/8” FPT
15’ Hose From Valve
NM4339
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
PROPANE
Outdoor Hood
PROPANE
Remove plug from inlet pressure tap on
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)
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.
PROPANE
2nd Stage Low
Pressure Tap
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.
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.
PROPANE
Requirements for operation outside of trailer
Propane Regulator
NM4320
Male 1/2” Male Flare x 1/2” mpt
Male POL Fitting x 1/4” mpt
NM4338
PMEF-181
PROPANE
Requirements for operation outside of trailer
Disconnect the 10’ TES propane hose
from the 15’ Trailer propane hose.
Disconnect Here
10’ TES Propane Hose
15’ Trailer Propane Hose
PROPANE
Requirements for operation outside of trailer
Connect TES propane hose to 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.
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.