54 Questions
EASY What is fundamental to boiler operation?
Equipment knowledge
What is assumed about the operator in the troubleshooting guide?
Thoroughly familiar with the firing equipment and controls
What is the main purpose of the troubleshooting guide?
To identify the cause of the problem
What should be checked if the blower motor does not start?
Power to supply terminals on programming control
What is the first step to resolve the issue of a blown fuse?
Refer to the manufacturer manual
What is the remedy for a main disconnect switch open?
Close the switch
What is the benefit of following a routine when troubleshooting?
To prevent overlooking obvious causes of trouble
What is the first step to take when the low water indication light comes on?
Check the manual reset button
What is the recommended approach to troubleshooting?
Systematic checks of the actual operation against the normal sequence
What could be the cause of a lack of spark?
Electrodes grounded or porcelain cracked
What should be done if the programmed combustion control 'test/run' switch is in the test position?
Place the test/run switch in the run position
What could be the cause of insufficient pilot or low-fire flame?
All of the above
What should be done if the boiler pressure is above the high-low fire control setting?
Wait until the pressure drops to where there is a load demand
What could be the cause of a blower starting but stopping again after 5-10 seconds?
Low air pressure switch
What should be done if the lockout switch has tripped?
Check the fuel lines and valves
What could be the cause of the programmer flame failure lockout switch being open?
All of the above
What should be done if the damper positioning switch is in the wrong position?
Place the switch in the correct position
What could be the cause of a loss of fuel?
All of the above
Before operating a boiler, what is essential?
Familiarity with the control system and boiler operations manual
MEDIUM What is the primary goal of the troubleshooting guide?
To help find the cause of trouble during boiler operation
What should be done if the main disconnect switch is open?
Close the switch
What is a possible reason for the blower motor not starting?
Lack of power on the motor starter circuit
What should be checked if the programmed combustion control flame fails?
The flame failure lockout switch
What is essential to prevent costly downtime or delays?
Systematic checks of the actual operation against the normal sequence
What should be done if the limit control circuit is not completed?
Check the boiler pressure or temperature
Why is it important to have a thorough knowledge of the control system?
To troubleshoot issues more efficiently
What should be checked if the boiler pressure is above the high-low fire control setting?
Wait until pressure drops to where there is a load demand
What could be the cause of a lack of spark?
Electrodes grounded, or porcelain cracked
What should be done if the lockout switch has tripped?
Check all of the above
What could be the cause of a lack of fuel?
Defective fuel valve, loose electrical connections
What should be done if the damper positioning switch is in the wrong position?
Place switch in correct position
What could be the cause of the programmer flame failure lockout switch being open?
Ignition failure, inadequate flame signal, or an open control in the non-recycling interlock circuit
What should be done if the blower starts, but stops again after 5-10 seconds?
Check the low air pressure switch
What could be the cause of an inoperative damper motor?
Motor defective
What should be done if the limit switches are open, interlocks open, or draft fan motor failure?
Check the limit circuit controls, interlock, or blower motor
What could be the cause of a low air pressure switch?
Manual reset button, if provided, on low water fuel cut-off
What is the primary assumption made about the boiler before troubleshooting begins?
The boiler has been properly installed and adjusted.
HARD What is the purpose of regularly checking the actual operation against the normal sequence?
To prevent costly downtime or delays.
In which situation would the remedy be to close the main disconnect switch?
When the main disconnect switch is open.
What is the recommended approach to troubleshooting?
Following a routine to ensure obvious causes are not overlooked.
What is essential to possess before operating a boiler?
Fundamental equipment knowledge.
What should be checked if the programmed combustion control flame fails?
The power to the supply terminals on the programming control.
What is the benefit of having a thorough knowledge of the control system?
It makes troubleshooting easier.
What is the remedy for a blown fuse or tripped overload?
Refer to the manufacturer's manual for guidance.
What is the probable cause of a spark, but no flame, condition in a boiler?
Lack of fuel, due to closed manual valves, clogged oil filter, or empty fuel tank
What should be checked if the programmer flame failure lockout switch is open?
All of the above
What is the remedy for a low-fire switch open condition?
Check damper motor and linkage
What could be the cause of a loss of fuel in a boiler system?
All of the above
What should be done if the boiler pressure is above the high-low fire control setting?
Wait until the pressure drops to meet the load demand
What could be the cause of an inoperative damper motor?
All of the above
What should be done if the limit switches are open, interlocks open, or draft fan motor failure?
Check the blower motor and interlocks, and repair or replace as necessary
What is the probable cause of a blower motor not starting?
Low air pressure switch
What could be the cause of improper air-fuel ratio?
Damper stuck open or fluctuating fuel supply pressure
What should be done if the damper positioning switch is in the wrong position?
Place the switch in the correct position
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.
Identify and solve common problems that arise during steam or hot water boiler operation. Test your knowledge of boiler troubleshooting techniques and equipment fundamentals.
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