1	Service Technician Training TES Installation Procedures
2	TES Trailer Requirements Payload Capacity Dimensions Tongue Length Ventilation Hose Access Door
3	PAYLOAD CAPACITY The approximate combined weight of the standard TES package with three 100# propane tanks is 1600 lbs.
4	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.
5	Tongue Length A four foot tongue is require to be able to mount the AT70 Propane Tank Rack.
6	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.
7	VENTILATION
8	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.
9	There are Four Steps in the TES Installation Process Layout Anchoring Exhaust Propane
10	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.
11	LAYOUT
12	ANCHORING Trailer Use Mounting – No Wheels Portable Use Mounting – With Wheels
13	TRAILER MOUNT
14	PORTABLE MOUNT
15	PORTABLE MOUNT
16	PORTABLE MOUNT
17	EXHAUST The outdoor vent cap cannot be used in an enclosed trailer.
18	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.
19	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.
20	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.
21	EXHAUST Drill 12 holes, each 3/16” in diameter around the edge of the flange on the Exhaust cap (NM4330).
22	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
23	EXHAUST
24	EXHAUST Use a crimping tool to crimp top edge of Tapered Exhaust Adapter
25	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.
26	EXHAUST
27	EXHAUST Cut a section of 7” single wall galvanized pipe 1” longer than your earlier measurement. Place pipe onto Tapered Exhaust Adapter.
28	EXHAUST Insert crimped end of adapter and pipe assembly into bottom of Exhaust cap and set adapter over TES exhaust outlet.
29	PROPANE Propane tank rack Regulator and Bulkhead fitting Hoses Portable Use Regulator
30	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.
31	PROPANE
32	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.
33	PROPANE Drill a 1-1/2” hole through inner wall only. Drill a 7/8” hole through outer wall.
34	PROPANE Assemble regulator, fittings and bracket
35	PROPANE Assemble Bulkhead Fitting. Use different nipples for walls with different thickness.
36	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.
37	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.
38	PROPANE Secure the Regulator Bracket to the trailer wall with eight screws. Regulator Bracket can be mounted horizontally or vertically.
39	PROPANE
40	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.
41	PROPANE
42	PROPANE Remove four screws and turn small vent as needed. Do not have vent pointing toward bracket.
43	PROPANE Connect ¼” 90˚ Street Elbow to the inlet port of propane regulator. Connect Male POL fitting to ¼” Elbow.
44	PROPANE Connect 3-Tank Adapter to POL fitting and the three propane tanks.
45	PROPANE Connect ½” 90˚ Street Elbow to the Bulkhead Fitting. Connect the ½” Gas Shutoff Valve to the elbow.
46	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.
47	PROPANE
48	PROPANE
49	PROPANE
50	PROPANE Test propane lines for leaks Sound and smell Manometer Leak Test Leak Testing Solution
51	PROPANE
52	PROPANE Remove plug from inlet pressure tap on main gas valve.
53	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)
54	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.
55	PROPANE
56	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.
57	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.
58	PROPANE
59	PROPANE Disconnect the 10’ TES propane hose from the 15’ Trailer propane hose.
60	PROPANE Connect TES propane hose to Propane Regulator.
61	PROPANE 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.
62	PROPANE 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.