Burner Will Not Light

TES Master PageTES Resources

TES Troubleshooting

5 – BURNER WILL NOT LIGHT

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.

There are only a couple of gallons of fluid in the TES boiler and during testing this fluid will heat up quickly and has no way to cool down. This can cause damage to the boiler and can create a dangerous condition.

For safety reasons we recommend that you should always have at least two TEX boxes with air movers connected to the TES unit when attempting to ignite the TES burner.

Step #1

Open the by-pass valve, make sure the Hi-Limit Control is set at 230˚F and the Operator Control is set at 200˚F. With the power cord connected to the TES plug turn the pump switch ON and turn the heater switch ON. (For the first part of this Step you do not need the propane tanks connected and the propane tank valves can remain closed.)

At this point the first four lights on the control panel should be ON.

If all four lights are ON - Continue with testing.
If the POWER light is OFF – Go to TES 4.
If the HI-LIMIT light is OFF – Go to TES 6.
If the OPERATOR light is OFF – Go to TES 7.
If the LOW FLOW light is OFF – Go to TES 1.

For this part of the Step you will need to connect the propane tanks, open the tank valves and connect at least two TEX boxes and hoses. Make sure the black control knob on top of the Gas Valve is turned to the ON position.

With the pump switch ON, turn the heater switch ON to try to light the burner. You may have to turn the heater switch ON and OFF several times to try to light the burner several times before the air is bled out of the system and propane gets to the pilot and burners. When the burner lights the MAIN GAS light will turn ON.

If the burner does not light – Continue with testing.
If the burner lights – Is the MAIN GAS light ON?
Yes – Proceed to Step #4.
No – Proceed to Step #3.

Turn off the propane tank valves. With the pump switch ON, turn the heater switch ON and test for power at the blue wire connected to terminal #6 of the burner ignition control. This is the 24V input terminal. Use terminal #1 of the 24V terminal block as the neutral connection.

No voltage found – Proceed to Step #2.
24 volts found – Retest using the gray wire connected to terminal #5 of the burner ignition control as the neutral connection.
24 volts found – Continue with testing.
No voltage found – Repair or replace the gray wire as needed to restore the connection between terminal #1 of the 24V terminal block and terminal #5 of the burner ignition control and continue with testing.

Examine the green wire ground connection between the burner drawer assembly and terminal #4 ground terminal of the burner ignition control. Repair or replace the wire as needed to assure a good connection between the burner ignition control and the burner ignition control.

Turn off the propane tank valves. With the pump switch ON, turn the heater switch ON

Observe the pilot assembly. Can you see a strong ignition spark?

Yes – Continue with testing.
No – Go to Step #1A.

Open the propane tank valves. Disconnect the brown wire from MV terminal of the Main Gas Valve. (This will prevent the burner from lighting while the pilot light is tested.)

With the pump switch ON, turn the heater switch ON

Observe the pilot assembly during the ignition sequence. Does the pilot light?

No – Proceed to Step #1B.
Yes – Does the spark stop when the pilot lights?
Yes – Proceed to Step #1C.
No – Remove the pilot assembly. Replace the pilot assembly and retest.
If the spark stops when the pilot lights – Proceed to Step #1C.
If the spark does not stop when the pilot lights - Examine the pilot flame. It should be blue, steady and envelopes 3/8” to 1/2” of the flame rod.
Flame looks blue & steady as described – Replace the burner ignition control. Reconnect the brown wire to the MV terminal on the Main Gas Valve and return to the beginning of Step #1.
Flame does not look as described – Refer to the pilot flame chart to correct pilot flame or contact your nearest service center for advice or assistance. Once pilot flame is blue & steady as described – Reconnect the brown wire to the MV terminal on the Main Gas Valve and return to the beginning of Step #1.

Step #1A Spark Ignition Circuit

Examine the orange ignition wire from the spark terminal of the burner ignition control down to the pilot assembly. Make sure there are no cuts or splices in the wire. The connections to the igniter and the burner ignition control must be clean and tight. Replace the pilot assembly if the wire is worn or damaged.

If you have not yet performed this test – Continue with this Step.
If you have previously completed this step and had spark, but the spark is not visible at the pilot assembly - The problem has to be a bad ground connection between terminal #4 and the burner drawer or a bad ignition wire on the pilot assembly. Replace the pilot assembly and ground wire or contact your nearest service center for advice or assistance.

To test the Spark Ignition Circuit you will need a short jumper wire made from spark plug wire or other heavily insulated wire.

WARNING!

The ignition circuit generates over 10,000 volts and electrical shock can result. Do not touch the stripped ends of the jumper wire and wear rubber gloves when performing this test.

Connect one end of the jumper wire to terminal # 4 ground terminal of the burner ignition control. Turn off the propane tank valves. With the pump switch ON, turn the heater switch ON and move the other end of the jumper wire towards the Spark terminal of the burner ignition control until a spark is created. Pull the jumper slowly away from the Spark terminal and note the length of the gap when the sparking stops.

No spark or spark less than 1/8” – Replace the burner ignition control, reconnect the green wire to terminal #4 the ground terminal of the burner ignition control and return to Step #1
Spark 1/8” or longer - reconnect the green wire to terminal #4 the ground terminal of the burner ignition control and return to Step #1

Step #1B Pilot Gas

An incoming manifold pressure of 12-14” of water column must be maintained for proper operation of the burners and pilot. Before beginning to test the pressure, make sure the propane tank valves are closed. Connect a manometer to the inlet pressure tap port. Open the propane tank valves and check the pressure.

If the pressure is in the range of 12-14” WC – Continue with testing.
If the pressure is less than 12” WC or more than 14” WC – Adjust the regulator to set the pressure in the correct range.
If the pressure can be adjusted and set in the range of 12-14” WC – Continue with testing.
If the pressure cannot be adjusted to the correct range – Replace the regulator and return to the beginning of Step #1B. If you have already replaced the regulator check the POL fitting, valves and hoses for restrictions or contact your nearest distributor for advice or assistance.

Once the incoming pressure is set. Disconnect the brown wire from MV terminal of the Main Gas Valve. (This will prevent the burner from lighting while the pilot light is tested.) With the pump switch ON, turn the heater switch ON

Observe the pilot assembly during the ignition sequence. Does the pilot light?

Yes – Continue with testing.

No – Replace the pilot assembly and retest.
The pilot lights – Continue with testing.
The pilot does not light – Replace the main gas valve and return to Step #1.

The pilot flame should envelope 3/8-1/2” of the flame rod. Keep the brown wire disconnected from the MV terminal of the main gas valve to prevent the burner from lighting during the pilot adjustment.

To adjust the pilot, remove the pilot gas screw cover located on the main gas valve. Turn the adjustment screw clockwise to decrease the flame size and counterclockwise to increase the flame size. When the flame adjustment is completed replace the screw cover and reconnect the brown wire to the MV terminal of the main gas valve.

If the flame is adjusted to the proper size – Return to Step #1
If the flame cannot be adjusted to the proper size – Clean or replace the pilot orifice and retest.
If the flame is adjusted to the proper size – Return to Step #1.
If the flame cannot be adjusted to the proper size – You may need to replace the main gas valve and/or the pilot assembly. Contact your nearest service center for advice or assistance.

Step #1C Burner Ignition

Check the continuity of the brown wire from terminal #1 to the MV terminal of the Main gas valve and repair as needed. Reconnect the brown wire toBurner Ignition Control and the MV terminal of the Main Gas Valve.With the pump switch ON, turn the heater switch ON to try to light the burner.

If the main burner lights –Is the MAIN GAS light ON?
Yes – Proceed to Step #4.
No – Proceed to Step #3.
If the main burner does not light –Then Check for power across the MV-MV/PV terminals on the burner ignition control.
Voltage found – Replace the main gas valve and return to Step #1
No voltage found – Replace the Pilot Assembly & retest.
Voltage found – Return to the beginning of Step #1C.
No voltage found - Replace the Burner ignition control and return to Step #1.

Step #2

There is a wiring change that will affect how you trace the power in this step.

If your TES unit has a Flame Roll-out Switch and 10 terminals on the 24V terminal Block – Proceed with this step.
If your TES unit has a Flame Roll-out Switch and 8 terminals on the 24V terminal Block – Proceed to Step #2A.
If your TES unit does not have a Flame Roll-out Switch and 8 terminals on the 24V terminal Block – Proceed to Step #2B.

Make sure the TES unit is cool, the Hi-Limit Control is set at 230˚F and the Operator Control is set at 200˚F. Close the propane tank valves. Open the by-pass valve, turn the pump switch ON and turn the heater switch ON. All of the tests in this step will be performed with these settings. First, test for Power at Terminal #3 of the 24V terminal block. Use terminal #1 as the neutral connection.

Voltage found – Repair or replace the Blue wire from terminal #3 of the 24V terminal block to the Burner Ignition Control as needed to restore power to terminal #6 the 24V connection of the Burner Ignition Control and return to Step #1.
No voltage found – Continue with testing.

Test for power at the blue wire where it connects to the Flame Roll-out Switch.

Voltage found – Repair or replace the Blue wire from terminal #3 of the 24V terminal block to the Flame Roll-out Switch as needed to restore power to terminal #3 and return to Step #1.
No voltage found – Continue with testing.

Test for power at the red wire connecting to the other terminal of the Flame Roll-out Switch.

Voltage found – Replace the Flame Roll-out switch and return to Step #1.
No voltage found – Continue with testing.

Test for power at terminal # 4 of the 24V terminal block where the red wire is connected.

Voltage found – Repair or replace the red wire from terminal #4 of the 24V terminal block to the Flame Roll-out Switch as needed to restore power to the Flame Roll-out Switch and return to Step #1.
No voltage found – Continue with testing.

Examine the jumper connecting terminal #4 with terminal #5 where the blue wire to the LOW FLOW light and the red wire to the Flow Switch are connected. Replace jumper as needed to assure continuity between terminal #4 and terminal #5. Test for power at the NO terminal of the Flow Switch where the red wire is connected.

Voltage found – Repair or replace the red wire from terminal #4 of the 24V terminal block to the Flow Switch as needed to restore power to terminal #4 and return to Step #1.
No voltage found – Continue with testing.

Test for power at the COM terminal of the flow switch where the Yellow wire is connected.

No voltage found – Continue with testing.
Voltage found – Failure of the power from the COM terminal to get to the NO terminal can only be caused by a lack of flow or a defective flow switch.
If you are not sure if you have enough flow – Go to TES 1.
If you are sure the flow is adequate - Replace the Flow Switch and return to Step #1.

Test for power at terminal #6 of the 24V terminal block where the yellow wire is connected.

Voltage found – Repair or replace the yellow wire from terminal #6 of the 24V terminal block to the Flow Switch as needed to restore power to the Flow Switch and return to Step #1.
No voltage found – Continue with testing.

Examine the jumper connecting terminal #6 with terminal #7 where the orange wire to the OPERATOR light is connected. Replace jumper as needed to assure continuity between terminal #6 and terminal #7. Examine the jumper connecting terminal #7 with terminal #8 where the blue wire to the Operator Control is connected. Replace jumper as needed to assure continuity between terminal #7 and terminal #8. Test for power at the Low Fire switch #1 “R” terminal of the Operator Control where the blue wire is connected.

Voltage found – Repair or replace the blue wire from Operator Control to terminal #8 of the 24V terminal block as needed to restore power to terminal #8 and return to Step #1.
No voltage found – Continue with testing.

Test for power at the Low Fire switch #1 “B” terminal of the Operator Control where the brown wire is connected.

Voltage found – Replace the Operator Control and return to Step #1.
No voltage found – Continue with testing.

Test for power at the NC terminal of the Hi-Limit Control where the brown wire and purple wire are connected.

Voltage found – Repair or replace the brown wire from Operator Control to Hi-Limit Control as needed to restore power to the Low Fire switch #1 “B” terminal and return to Step #1.
No voltage found – Continue with testing.

Test for power at the “C” terminal of the Hi-Limit Control where the brown wire is connected.

Voltage found – Replace the Hi-Limit Control and return to Step #1.
No voltage found – Continue with testing.

Test for power at terminal #2 of the 24V terminal block where the brown wire is connected with another brown wire and the red wire from the fuse holder.

Voltage found – Repair or replace the brown wire from terminal #2 to Hi-Limit Control as needed to restore power to the “C” terminal of the Hi-Limit Control and return to Step #1.
No voltage found – Go to TES 4.

Step #2A

First, test for Power at the blue wire where it connects to the Flame Roll-out Switch.

Voltage found – Repair or replace the Blue wire from the Flame Roll-out Switch to terminal #6 of the Burner Ignition Control to as needed to restore power to terminal #6 of the Burner Ignition Control and return to Step #1.
No voltage found – Continue with testing.

Test for power at the red wire connecting to the other terminal of the Flame Roll-out Switch.

Voltage found – Replace the Flame Roll-out switch and return to Step #1.
No voltage found – Continue with testing.

Test for power at terminal # 3 of the 24V terminal block where the red wire is connected with another red wire and a blue wire.

Voltage found – Repair or replace the red wire from terminal #3 of the 24V terminal block to the Flame Roll-out Switch as needed to restore power to the Flame Roll-out Switch and return to Step #1.
No voltage found – Continue with testing.

Test for power at the NO terminal of the Flow Switch where the red wire is connected.

Voltage found – Repair or replace the red wire from terminal #4 of the 24V terminal block to the Flow Switch as needed to restore power to terminal #4 and return to Step #1.
No voltage found – Continue with testing.

Test for power at the COM terminal of the flow switch where the Yellow wire is connected.