Maintenance Flow Chart
SECTION 6 TROUBLE SHOOTING
Problem Cause Remedy
Power supply Check air flow switch in control panel Check fuses in control panel
Scale or sludge build up on low water probe
Check low water probe for scale Reset low water controller
Loose wire connection Check connections to all components
Gas supply Check gas pressure
Ch k i k i
Gas pressure switch Check gas pressure
R t it h
Steam pressure switch Check steam pressure switch
Ch k bl d th l l d it h
Boiler water not at normal Check boiler water indication Gas burner will not start
Main fuel valve not full closed(for FBC 400)
Check main fuel valve and position switch
Power supply Check air flow switch in control panel
Scale or sludge build up on low water probe
Check low water probe for scale Reset low water controller
Loose wire connection Check connection s to all components
Gas supply Check gas pressure
Ch k i k i
Gas pressure switch Check gas pressure
R t it h
Steam pressure switch Check steam pressure switch
Ch k bl d th l l d it h
Temperature control switch (for hot water boiler and
heavy oil boiler)
Reset temperature protection button Oil burner will not start
Boiler water not at normal Check boiler water indication
Problem Cause Remedy Main fuel valve not fully
closed(for FBC 400)
Check main fuel valve and position switch
Air pressure protection switch not act
Check air pressure protection switch (In normal condition, the switch contact should close while blower pre purge.)
Gas pressure switch not close
Check gas pressure switch
Reset gas high/low pressure protection Temperature control switch
action(for heavy oil heater)
Check temperature switch
Reset temperature protection switch Oil pressure switch not
close
Check oil pressure switch
Reset oil pressure protection button (in normal condition, the oil pressure switch contact close.)
Blower auto stop after gas burner start 5 seconds
Not enough air pressure from compressor
Check compressor and air protection switch (In normal condition, the pressure protection contact should be closed)
The blower purge at big damper but not do the next
The big damper feedback contact does not act
Adjust damper feedback block( the block is at the center rod of damper)
The blower purge at little damper but not do the next
The little damper feedback contact does not act
Adjust damper feedback block and related cam(the cam is in serve motor)
Ignition electrode dirt or crack
Clean ignition electrode and check crack
Dirty or damaged scanner Use clean cotton and check signal voltage (in normal condition, it is 5v)
Incorrect distance of ignition electrode
Adjust distance( in normal condition, the distance between electrode and steel rod is 3-5mm)
Boiler will not ignite
Manual valve in ignition line is not open or the fuel exhausted
Open manual, replace gas bottle.
Problem Cause Remedy Ignition transformer burn out Meter transformer resistance ( in normal
condition, the primary resistance is about 20 and the second is about 1000.
Ignition damper too big Consult professional personnel for adjustment
Normal The set steam pressure is reached, boiler will auto start while pressure is less than setting.
Scanner trouble Clean with cotton cloth and check signal voltage(in normal condition, signal voltage is 5V)
Fuel shut during operation Check fuel supply No reason shut down
during operation
Not enough gas pressure (gas boiler)
Check gas pressure, notify Gas company
Gas supply See above
Oil supply See above
Steam pressure switch Check steam pressure switch, readjust or replace
Scale build up in boiler Check water treatment advisor
Steam traps Check steam traps and replace as necessary
Dirty flue Clean flue side of boiler Boiler will not maintain
pressure
Steam overload Reduce
Too much treatment chemical
Dump return tank, flush system or stop treatment for a week.
Wet stream
Too high water level Drop boiler water(in normal condition, boiler water should be in middle of the glass sight.
Pump will not cut off Earth connection Check for tightness and clean
Problem Cause Remedy Probe connection Check for tightness and clean
Dirty probes Clean or replace
Water level relay damaged Replace
Air/steam lock in pump Check For Bad Steam Traps
Ch k f h k l i t f d li
Blocked water feed line Check and clean if necessary Feed pump runs but does
not put water into boiler
Impellers damaged Replace pump
Probe connections Check for tightness and clean
Dirty probes Clean or replace
Water level relay damaged Replace Feed pump will not start
in time
Earth connection Check for tightness and clean
Probe connections Check for tightness and clean
Dirty probes Clean or replace
Water level relay damaged Replace Low water alarm /burner
shut off will not act in time
Earth connection Check for tightness and clean
Other troubles: The boiler program control is Honeywell 7800 with automatic self check. If user chose the display, it will bring about convenience and provide information for the service personnel, the following table is the program trouble information:
Honeywell 7800 trouble information Fault
Number
Annunciation Message
Description
Fault 1 *No Purge Card* Purge card problem.
Fault 2 *AC
Frequency/Noise*
Lockout due to inability to take minimum number of samples.
Fault Number
Annunciation Message
Description
Fault 3 *AC Line Dropout* Lockout due to AC line dropout detected Fault 4 *AC Frequency* Lockout due to AC line frequency too fast.
Fault 5 *Low Line Voltage* Lockout due to insufficient AC line voltage.
Fault 6 *Purge Card Error* Purge card parity is bad.
Fault 7 *Flame Amplifier* Flame sensed when checked for ampli-check system.
Fault 8 *Flame Amp/shutr* Flame sensed when checked for shutter-check system.
Fault 9 *Flame Detected* Flame detected during Standby and time limit has expired.)
Fault 10 *Preignition ILK* Preignition interlock open during Standby and time limit has expired.
Fault 13 *Airflow Sw. On* Airflow switch shorted and limit has expired in Standby(demand was present)
Fault 14 *High Fire Sw* High Fire switch open and time limit has expired during prepurge.
Fault 15 *Flame Detected* Flame sensed when shutter open and no flame is expected during Standby.
Fault 17 *Main Flame Fail* Main flame failure during Run after flame has been on for a while.
Fault 18 *Flame Detected* Flame detected during Purge or Waiting, when no flame should exist.
Fault 19 *Main Flame Ign.* Flame loss detected, main flame did not ignite or failed during first 10s of Run
Fault 20 *Low Fire Sw. Off* Low Fire switch open time limit has expired during Waiting.
Fault 23 *Airflow Switch* Combustion airflow interlock fault during Waiting.
Fault 24 *Internal Fault* Flame interlock is enabling fuel valves and no flame is present.
Fault 25 *Internal Fault* Flame interlock feedback indicates it is not enabling main valve.
Fault 28 *Pilot Flame Fail* Pilot flame failure.
Fault 31 *Low Fire Sw. Off* Low fire interlock switch failed to close during Run.
Fault 32 *Airflow Switch* Airflow switch failed to make or opened.
Fault 33 *Preignition ILK* Preignition interlock opened
Fault 35 *Internal Fault* Safety relay feedback showed off when it should be on.
Fault Number
Annunciation Message
Description
Fault 36 *Internal Fault* Main valve relay feedback showed off when it should be on.
Fault 37 *Internal Fault* Pilot valve relay feedback showed off when it should be on.
Fault 38 *Internal Fault* Ignition relay feedback showed off when it should be on.
Fault 39 *Internal Fault* Pilot valve 2 relay showed off when it should be on.
Fault 40 *Internal Fault* Safety relay feedback on when it should be off.
Fault 41 *Main Valve On* Main valve relay feedback showed on when it should be off.
Fault 42 *Pilot Valve 1 On* Pilot valve relay feedback showed on when it should be off.
Fault 43 *Ignition On* Ignition relay feedback showed on when it should be off.
Fault 44 *Pilot Valve 2 On* Pilot valve 2 relay feedback showed on when it should be off.
Fault 45 *Low Fire Sw. Off* Low fire switch opened.
Fault 46 *Flame Amp Type* Type and/or FFRT changed since initial read.
Fault 47 *Jumpers Changed* Field jumpers have changed since initial read.
Fault 50 *Jumpers Wrong* Illegal jumper combination selected (as defined by the burner sequence).
Fault 51 *Flame Too Strong* Measured flame signal is to strong.
Fault 52 *Internal Fault* Pilot valve 2 relay feedback showed off when it should be on.