4BE3.5 U4 C3 Obj 4 EMH
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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?

  • 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?

  • 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?

    <p>Power to supply terminals on programming control</p> Signup and view all the answers

    What is the first step to resolve the issue of a blown fuse?

    <p>Refer to the manufacturer manual</p> Signup and view all the answers

    What is the remedy for a main disconnect switch open?

    <p>Close the switch</p> Signup and view all the answers

    What is the benefit of following a routine when troubleshooting?

    <p>To prevent overlooking obvious causes of trouble</p> Signup and view all the answers

    What is the first step to take when the low water indication light comes on?

    <p>Check the manual reset button</p> Signup and view all the answers

    What is the recommended approach to troubleshooting?

    <p>Systematic checks of the actual operation against the normal sequence</p> Signup and view all the answers

    What could be the cause of a lack of spark?

    <p>Electrodes grounded or porcelain cracked</p> Signup and view all the answers

    What should be done if the programmed combustion control 'test/run' switch is in the test position?

    <p>Place the test/run switch in the run position</p> Signup and view all the answers

    What could be the cause of insufficient pilot or low-fire flame?

    <p>All of the above</p> Signup and view all the answers

    What should be done if the boiler pressure is above the high-low fire control setting?

    <p>Wait until the pressure drops to where there is a load demand</p> Signup and view all the answers

    What could be the cause of a blower starting but stopping again after 5-10 seconds?

    <p>Low air pressure switch</p> Signup and view all the answers

    What should be done if the lockout switch has tripped?

    <p>Check the fuel lines and valves</p> Signup and view all the answers

    What could be the cause of the programmer flame failure lockout switch being open?

    <p>All of the above</p> Signup and view all the answers

    What should be done if the damper positioning switch is in the wrong position?

    <p>Place the switch in the correct position</p> Signup and view all the answers

    What could be the cause of a loss of fuel?

    <p>All of the above</p> Signup and view all the answers

    Before operating a boiler, what is essential?

    <p>Familiarity with the control system and boiler operations manual</p> Signup and view all the answers

    MEDIUM What is the primary goal of the troubleshooting guide?

    <p>To help find the cause of trouble during boiler operation</p> Signup and view all the answers

    What should be done if the main disconnect switch is open?

    <p>Close the switch</p> Signup and view all the answers

    What is a possible reason for the blower motor not starting?

    <p>Lack of power on the motor starter circuit</p> Signup and view all the answers

    What should be checked if the programmed combustion control flame fails?

    <p>The flame failure lockout switch</p> Signup and view all the answers

    What is essential to prevent costly downtime or delays?

    <p>Systematic checks of the actual operation against the normal sequence</p> Signup and view all the answers

    What should be done if the limit control circuit is not completed?

    <p>Check the boiler pressure or temperature</p> Signup and view all the answers

    Why is it important to have a thorough knowledge of the control system?

    <p>To troubleshoot issues more efficiently</p> Signup and view all the answers

    What should be checked if the boiler pressure is above the high-low fire control setting?

    <p>Wait until pressure drops to where there is a load demand</p> Signup and view all the answers

    What could be the cause of a lack of spark?

    <p>Electrodes grounded, or porcelain cracked</p> Signup and view all the answers

    What should be done if the lockout switch has tripped?

    <p>Check all of the above</p> Signup and view all the answers

    What could be the cause of a lack of fuel?

    <p>Defective fuel valve, loose electrical connections</p> Signup and view all the answers

    What should be done if the damper positioning switch is in the wrong position?

    <p>Place switch in correct position</p> Signup and view all the answers

    What could be the cause of the programmer flame failure lockout switch being open?

    <p>Ignition failure, inadequate flame signal, or an open control in the non-recycling interlock circuit</p> Signup and view all the answers

    What should be done if the blower starts, but stops again after 5-10 seconds?

    <p>Check the low air pressure switch</p> Signup and view all the answers

    What could be the cause of an inoperative damper motor?

    <p>Motor defective</p> Signup and view all the answers

    What should be done if the limit switches are open, interlocks open, or draft fan motor failure?

    <p>Check the limit circuit controls, interlock, or blower motor</p> Signup and view all the answers

    What could be the cause of a low air pressure switch?

    <p>Manual reset button, if provided, on low water fuel cut-off</p> Signup and view all the answers

    What is the primary assumption made about the boiler before troubleshooting begins?

    <p>The boiler has been properly installed and adjusted.</p> Signup and view all the answers

    HARD What is the purpose of regularly checking the actual operation against the normal sequence?

    <p>To prevent costly downtime or delays.</p> Signup and view all the answers

    In which situation would the remedy be to close the main disconnect switch?

    <p>When the main disconnect switch is open.</p> Signup and view all the answers

    What is the recommended approach to troubleshooting?

    <p>Following a routine to ensure obvious causes are not overlooked.</p> Signup and view all the answers

    What is essential to possess before operating a boiler?

    <p>Fundamental equipment knowledge.</p> Signup and view all the answers

    What should be checked if the programmed combustion control flame fails?

    <p>The power to the supply terminals on the programming control.</p> Signup and view all the answers

    What is the benefit of having a thorough knowledge of the control system?

    <p>It makes troubleshooting easier.</p> Signup and view all the answers

    What is the remedy for a blown fuse or tripped overload?

    <p>Refer to the manufacturer's manual for guidance.</p> Signup and view all the answers

    What is the probable cause of a spark, but no flame, condition in a boiler?

    <p>Lack of fuel, due to closed manual valves, clogged oil filter, or empty fuel tank</p> Signup and view all the answers

    What should be checked if the programmer flame failure lockout switch is open?

    <p>All of the above</p> Signup and view all the answers

    What is the remedy for a low-fire switch open condition?

    <p>Check damper motor and linkage</p> Signup and view all the answers

    What could be the cause of a loss of fuel in a boiler system?

    <p>All of the above</p> Signup and view all the answers

    What should be done if the boiler pressure is above the high-low fire control setting?

    <p>Wait until the pressure drops to meet the load demand</p> Signup and view all the answers

    What could be the cause of an inoperative damper motor?

    <p>All of the above</p> Signup and view all the answers

    What should be done if the limit switches are open, interlocks open, or draft fan motor failure?

    <p>Check the blower motor and interlocks, and repair or replace as necessary</p> Signup and view all the answers

    What is the probable cause of a blower motor not starting?

    <p>Low air pressure switch</p> Signup and view all the answers

    What could be the cause of improper air-fuel ratio?

    <p>Damper stuck open or fluctuating fuel supply pressure</p> Signup and view all the answers

    What should be done if the damper positioning switch is in the wrong position?

    <p>Place the switch in the correct position</p> Signup and view all the answers

    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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    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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