Podcast
Questions and Answers
EASY What is fundamental to boiler operation?
EASY What is fundamental to boiler operation?
- Boiler manual
- Control system
- Equipment knowledge (correct)
- Troubleshooting guide
What is assumed about the operator in the troubleshooting guide?
What is assumed about the operator in the troubleshooting guide?
- Having little knowledge of the boiler
- Thoroughly familiar with the firing equipment and controls (correct)
- Having no experience with boiler operations
- Having a good understanding of the control system only
What is the main purpose of the troubleshooting guide?
What is the main purpose of the troubleshooting guide?
- To install and adjust the boiler
- To prevent downtime or delays
- To find the solution to the problem
- To identify the cause of the problem (correct)
What should be checked if the blower motor does not start?
What should be checked if the blower motor does not start?
What is the first step to resolve the issue of a blown fuse?
What is the first step to resolve the issue of a blown fuse?
What is the remedy for a main disconnect switch open?
What is the remedy for a main disconnect switch open?
What is the benefit of following a routine when troubleshooting?
What is the benefit of following a routine when troubleshooting?
What is the first step to take when the low water indication light comes on?
What is the first step to take when the low water indication light comes on?
What is the recommended approach to troubleshooting?
What is the recommended approach to troubleshooting?
What could be the cause of a lack of spark?
What could be the cause of a lack of spark?
What should be done if the programmed combustion control 'test/run' switch is in the test position?
What should be done if the programmed combustion control 'test/run' switch is in the test position?
What could be the cause of insufficient pilot or low-fire flame?
What could be the cause of insufficient pilot or low-fire flame?
What should be done if the boiler pressure is above the high-low fire control setting?
What should be done if the boiler pressure is above the high-low fire control setting?
What could be the cause of a blower starting but stopping again after 5-10 seconds?
What could be the cause of a blower starting but stopping again after 5-10 seconds?
What should be done if the lockout switch has tripped?
What should be done if the lockout switch has tripped?
What could be the cause of the programmer flame failure lockout switch being open?
What could be the cause of the programmer flame failure lockout switch being open?
What should be done if the damper positioning switch is in the wrong position?
What should be done if the damper positioning switch is in the wrong position?
What could be the cause of a loss of fuel?
What could be the cause of a loss of fuel?
Before operating a boiler, what is essential?
Before operating a boiler, what is essential?
MEDIUM What is the primary goal of the troubleshooting guide?
MEDIUM What is the primary goal of the troubleshooting guide?
What should be done if the main disconnect switch is open?
What should be done if the main disconnect switch is open?
What is a possible reason for the blower motor not starting?
What is a possible reason for the blower motor not starting?
What should be checked if the programmed combustion control flame fails?
What should be checked if the programmed combustion control flame fails?
What is essential to prevent costly downtime or delays?
What is essential to prevent costly downtime or delays?
What should be done if the limit control circuit is not completed?
What should be done if the limit control circuit is not completed?
Why is it important to have a thorough knowledge of the control system?
Why is it important to have a thorough knowledge of the control system?
What should be checked if the boiler pressure is above the high-low fire control setting?
What should be checked if the boiler pressure is above the high-low fire control setting?
What could be the cause of a lack of spark?
What could be the cause of a lack of spark?
What should be done if the lockout switch has tripped?
What should be done if the lockout switch has tripped?
What could be the cause of a lack of fuel?
What could be the cause of a lack of fuel?
What should be done if the damper positioning switch is in the wrong position?
What should be done if the damper positioning switch is in the wrong position?
What could be the cause of the programmer flame failure lockout switch being open?
What could be the cause of the programmer flame failure lockout switch being open?
What should be done if the blower starts, but stops again after 5-10 seconds?
What should be done if the blower starts, but stops again after 5-10 seconds?
What could be the cause of an inoperative damper motor?
What could be the cause of an inoperative damper motor?
What should be done if the limit switches are open, interlocks open, or draft fan motor failure?
What should be done if the limit switches are open, interlocks open, or draft fan motor failure?
What could be the cause of a low air pressure switch?
What could be the cause of a low air pressure switch?
What is the primary assumption made about the boiler before troubleshooting begins?
What is the primary assumption made about the boiler before troubleshooting begins?
HARD What is the purpose of regularly checking the actual operation against the normal sequence?
HARD What is the purpose of regularly checking the actual operation against the normal sequence?
In which situation would the remedy be to close the main disconnect switch?
In which situation would the remedy be to close the main disconnect switch?
What is the recommended approach to troubleshooting?
What is the recommended approach to troubleshooting?
What is essential to possess before operating a boiler?
What is essential to possess before operating a boiler?
What should be checked if the programmed combustion control flame fails?
What should be checked if the programmed combustion control flame fails?
What is the benefit of having a thorough knowledge of the control system?
What is the benefit of having a thorough knowledge of the control system?
What is the remedy for a blown fuse or tripped overload?
What is the remedy for a blown fuse or tripped overload?
What is the probable cause of a spark, but no flame, condition in a boiler?
What is the probable cause of a spark, but no flame, condition in a boiler?
What should be checked if the programmer flame failure lockout switch is open?
What should be checked if the programmer flame failure lockout switch is open?
What is the remedy for a low-fire switch open condition?
What is the remedy for a low-fire switch open condition?
What could be the cause of a loss of fuel in a boiler system?
What could be the cause of a loss of fuel in a boiler system?
What should be done if the boiler pressure is above the high-low fire control setting?
What should be done if the boiler pressure is above the high-low fire control setting?
What could be the cause of an inoperative damper motor?
What could be the cause of an inoperative damper motor?
What should be done if the limit switches are open, interlocks open, or draft fan motor failure?
What should be done if the limit switches are open, interlocks open, or draft fan motor failure?
What is the probable cause of a blower motor not starting?
What is the probable cause of a blower motor not starting?
What could be the cause of improper air-fuel ratio?
What could be the cause of improper air-fuel ratio?
What should be done if the damper positioning switch is in the wrong position?
What should be done if the damper positioning switch is in the wrong position?
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Study Notes
Troubleshooting Guide for Steam and Hot Water Boilers
- Fundamental equipment knowledge is essential for boiler operation and troubleshooting.
Common Problems During Boiler Operation
- Many issues can arise during routine boiler operation, including problems with startup and operation.
- Proper installation and adjustment of the boiler, as well as operator familiarity with firing equipment and controls, are assumed.
Troubleshooting Methods
- Systematic checks of the actual operation against the normal sequence can help determine the source of the trouble.
- Follow a routine to avoid overlooking obvious causes of trouble.
- A good knowledge of the control system can make troubleshooting easier.
Problem and Remedy
- Main disconnect switch open: Close switch.
- Blown fuses, tripped overloads, loose electrical connections: Refer to manufacturer manual, check for power to supply terminals on programming control.
- Programmed combustion control flame failure, safety lockout switch tripped: Reset flame failure lockout switch on programmed combustion control.
- Limit control circuit not completed: Check boiler pressure or temperature, water level, and low water indication light.
Ignition Problems
- Lack of spark: Electrodes grounded, porcelain cracked, improper electrode setting, loose terminal on ignition cable, or inoperative ignition transformer.
- Spark, but no flame: Lack of fuel, closed manual valves, clogged oil filter, empty fuel tank, incorrect pilot gas pressure, or inoperative solenoid on pilot or low-fire fuel valve.
Fuel and Air Problems
- Insufficient pilot or low-fire flame: Adjust pilot or low-fire flame.
- Supply to main nozzles restricted or cut off: Check for obstruction, closed valve, or inoperative solenoid valve.
- Inoperative programmer: Check flame relay, detector, contacts, and amplifier.
Pressure and Control Problems
- Boiler pressure above high-low fire control setting: Wait until pressure drops to where there is a load demand.
- Damper positioning switch in wrong position: Check damper linkage.
- Inoperative damper motor: Check motor for cause and replace if necessary.
- Defective high-low fire or modulating control: Replace modulating control.
Fuel and Flame Failure Problems
- Loss or stoppage of fuel: Check fuel system for reason.
- Defective fuel valve, loose electrical connections: Repair or replace fuel valve.
- Flame detector weak or defective: Change detector.
- Lens dirty or sight tube obstructed: Clean lens or sight tube.
- Lockout switch has tripped: Check fuel lines and valves, flame detector, and timer and relay contacts.
Interlock and Air-Fuel Ratio Problems
- Improper air-fuel ratio: Slipping linkage, damper stuck open, fluctuating fuel supply pressure, or temporary obstruction in fuel line.
- Interlock device inoperative or defective: Replace or repair interlock.
Damper and Motor Problems
- Damper positioning switch in wrong position: Place switch in correct position.
- Linkage loose or jammed: Repair linkage.
- Motor does not drive to “open” or close during pre-purge: Check appropriate contacts (see manual).
- Motor does not operate on demand: Check damper positioning switch, high-low fire or modulating control, and motor operation.
Troubleshooting Guide for Steam and Hot Water Boilers
- Fundamental equipment knowledge is essential for boiler operation and troubleshooting.
Common Problems During Boiler Operation
- Many issues can arise during routine boiler operation, including problems with startup and operation.
- Proper installation and adjustment of the boiler, as well as operator familiarity with firing equipment and controls, are assumed.
Troubleshooting Methods
- Systematic checks of the actual operation against the normal sequence can help determine the source of the trouble.
- Follow a routine to avoid overlooking obvious causes of trouble.
- A good knowledge of the control system can make troubleshooting easier.
Problem and Remedy
- Main disconnect switch open: Close switch.
- Blown fuses, tripped overloads, loose electrical connections: Refer to manufacturer manual, check for power to supply terminals on programming control.
- Programmed combustion control flame failure, safety lockout switch tripped: Reset flame failure lockout switch on programmed combustion control.
- Limit control circuit not completed: Check boiler pressure or temperature, water level, and low water indication light.
Ignition Problems
- Lack of spark: Electrodes grounded, porcelain cracked, improper electrode setting, loose terminal on ignition cable, or inoperative ignition transformer.
- Spark, but no flame: Lack of fuel, closed manual valves, clogged oil filter, empty fuel tank, incorrect pilot gas pressure, or inoperative solenoid on pilot or low-fire fuel valve.
Fuel and Air Problems
- Insufficient pilot or low-fire flame: Adjust pilot or low-fire flame.
- Supply to main nozzles restricted or cut off: Check for obstruction, closed valve, or inoperative solenoid valve.
- Inoperative programmer: Check flame relay, detector, contacts, and amplifier.
Pressure and Control Problems
- Boiler pressure above high-low fire control setting: Wait until pressure drops to where there is a load demand.
- Damper positioning switch in wrong position: Check damper linkage.
- Inoperative damper motor: Check motor for cause and replace if necessary.
- Defective high-low fire or modulating control: Replace modulating control.
Fuel and Flame Failure Problems
- Loss or stoppage of fuel: Check fuel system for reason.
- Defective fuel valve, loose electrical connections: Repair or replace fuel valve.
- Flame detector weak or defective: Change detector.
- Lens dirty or sight tube obstructed: Clean lens or sight tube.
- Lockout switch has tripped: Check fuel lines and valves, flame detector, and timer and relay contacts.
Interlock and Air-Fuel Ratio Problems
- Improper air-fuel ratio: Slipping linkage, damper stuck open, fluctuating fuel supply pressure, or temporary obstruction in fuel line.
- Interlock device inoperative or defective: Replace or repair interlock.
Damper and Motor Problems
- Damper positioning switch in wrong position: Place switch in correct position.
- Linkage loose or jammed: Repair linkage.
- Motor does not drive to “open” or close during pre-purge: Check appropriate contacts (see manual).
- Motor does not operate on demand: Check damper positioning switch, high-low fire or modulating control, and motor operation.
Troubleshooting Guide for Steam and Hot Water Boilers
- Fundamental equipment knowledge is essential for boiler operation and troubleshooting.
Common Problems During Boiler Operation
- Many issues can arise during routine boiler operation, including problems with startup and operation.
- Proper installation and adjustment of the boiler, as well as operator familiarity with firing equipment and controls, are assumed.
Troubleshooting Methods
- Systematic checks of the actual operation against the normal sequence can help determine the source of the trouble.
- Follow a routine to avoid overlooking obvious causes of trouble.
- A good knowledge of the control system can make troubleshooting easier.
Problem and Remedy
- Main disconnect switch open: Close switch.
- Blown fuses, tripped overloads, loose electrical connections: Refer to manufacturer manual, check for power to supply terminals on programming control.
- Programmed combustion control flame failure, safety lockout switch tripped: Reset flame failure lockout switch on programmed combustion control.
- Limit control circuit not completed: Check boiler pressure or temperature, water level, and low water indication light.
Ignition Problems
- Lack of spark: Electrodes grounded, porcelain cracked, improper electrode setting, loose terminal on ignition cable, or inoperative ignition transformer.
- Spark, but no flame: Lack of fuel, closed manual valves, clogged oil filter, empty fuel tank, incorrect pilot gas pressure, or inoperative solenoid on pilot or low-fire fuel valve.
Fuel and Air Problems
- Insufficient pilot or low-fire flame: Adjust pilot or low-fire flame.
- Supply to main nozzles restricted or cut off: Check for obstruction, closed valve, or inoperative solenoid valve.
- Inoperative programmer: Check flame relay, detector, contacts, and amplifier.
Pressure and Control Problems
- Boiler pressure above high-low fire control setting: Wait until pressure drops to where there is a load demand.
- Damper positioning switch in wrong position: Check damper linkage.
- Inoperative damper motor: Check motor for cause and replace if necessary.
- Defective high-low fire or modulating control: Replace modulating control.
Fuel and Flame Failure Problems
- Loss or stoppage of fuel: Check fuel system for reason.
- Defective fuel valve, loose electrical connections: Repair or replace fuel valve.
- Flame detector weak or defective: Change detector.
- Lens dirty or sight tube obstructed: Clean lens or sight tube.
- Lockout switch has tripped: Check fuel lines and valves, flame detector, and timer and relay contacts.
Interlock and Air-Fuel Ratio Problems
- Improper air-fuel ratio: Slipping linkage, damper stuck open, fluctuating fuel supply pressure, or temporary obstruction in fuel line.
- Interlock device inoperative or defective: Replace or repair interlock.
Damper and Motor Problems
- Damper positioning switch in wrong position: Place switch in correct position.
- Linkage loose or jammed: Repair linkage.
- Motor does not drive to “open” or close during pre-purge: Check appropriate contacts (see manual).
- Motor does not operate on demand: Check damper positioning switch, high-low fire or modulating control, and motor operation.
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