User Guide

27
TROUBLESHOOTING
Table 8.1: Boiler Troubleshooting Guide
PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION
Burners not
functioning.
1. No power to limit control display.
2. No call for heat (no decimal after 3-digit display).
3. Water temperature above limit control economizing
setpoint (ECON TARGET).
4. Open safety control, as indicated on HydroStat display:
a) Flame rollout switch (LIMITS), or
b) Blocked vent switch (LIMITS).
c) Vent damper (V-PWR, V-SW).
d) Low water (LOW WATER).
e) No pilot (FLAME).
5. Gas off at boiler gas valve.
6. Gas off external to boiler.
7. Plugged orifice.spuds.
8. Improper wiring.
1. Check line voltage wiring and fuses. Check transformer.
2. Check thermostat. See HydroStat instructions.
3. See HydroStat instructions.
4. See also HydroStat instructions.
a) Replace switch. Locate cause and correct.
b) Reset switch. Locate cause and correct.
c) Refer to vent damper manufacturer’s instructions.
Replace if necessary.
d) Add water or clean sensor. See HydroStat instructions.
e) See HydroStat and Honeywell instructions.
5. Start boiler using Operating Instructions.
6. Check any gas valves in the line.
7. Check, clean and re-install.
8. Check and correct in accordance with wiring diagrams
in Section 6.
Burners will not
shut down.
1. Defective gas valve.
2. Short circuit.
1. See HydroStat and Honeywell instructions.
Replace if necessary.
2. Check and correct wiring.
Flashback or
burning at
orifice spuds.
1. Manifold gas pressure too low.
2. Improperly sized/drilled orifice spuds.
3. Leaking gas valve.
4. Burrs on orifice.
5. Low supply gas pressure.
6. Excessive downdraft or draft problems in boiler room.
1. Adjust to proper pressure.
2. Install correct spuds.
3. Replace valve.
4. Remove burrs.
5. Contact gas supplier if natural gas.
Adjust regulator if LP gas.
6. Check air supply, ventilation and venting system.
Delayed ignition. 1. Pilot burner/orifice clogged.
2. Overfiring.
3. Misaligned burners or pilot.
4. Draft problem in boiler room.
1. Clean pilot burner and orifice.
2. Reduce rate to input on rating label.
3. Realign burners or pilot.
4. Check air supply, ventilation and venting system.
Excessive
condensation
in vent.
1. Underfiring.
2. Limit control set to low.
3. Economizer setting too high.
4. Vent pipe too long.
5. Inadequate chimney or venting system.
1. Increase rate to input on rating label.
2. Reset limit to highest setting. See HydroStat instructions.
3. Reset Economizer setting. See HydroStat instructions.
4. Reposition boiler to reduse length.
5. Check chimney and venting recommendations.
Boiler not heating
properly.
1. Underfiring.
2. Limit control set to low.
3. Economizer setting too high.
4. Air in system.
5. Circulator malfunctioning.
6. Circulator system clogged.
7. Incorrect thermostat heat anticipator setting.
1. Increase rate to input on rating label.
2. Reset limit to highest setting. See HydroStat instructions.
3. Reset Economizer setting. See HydroStat instructions.
4. Vent air from all points in system.
5. Check circulator, replace if necessary.
6. Shut down annd cool boiler,drain and flush system.
7. Adjust heat anticipator.
Fumes or gas odors. 1. Leaks in gas piping or fittings.
2. Leaks in gas service line or meter.
3. Obstructed chimney.
4. Obstructed flueways or vent.
5. Undersized chimney or vent, high draft loss in vent.
6. Draft problem in boiler room.
7. Overfiring.
8. Vent damper malfunctioning.
1. Locate and repair or replace.
2. Shut down boiler and notify gas provider.’
3. Check, repair and/or clean chinmey.
4. Clean flueways or vent and remove obstructions.
5. Check National Fuel Gas Code and vent manufacturer’s
recommendation.
6. Check air supply, ventilation and venting system.
7. Reduce rate to input on rating label.
8. Refer to vent damper manufacturer’s instructions.
Replace if necessary.