Series 16 H Troubleshooting
Contents
1. IX Service WARNING Service on this boiler should be undertaken only by trained and skilled personnel from a qualified service agency Inspections should be performed at intervals specified in this manual Maintain manual in a legible condition Keep boiler area clear and free of combustible materials gasoline and other flammable vapors and liquids Do not place any obstructions in boiler room that will hinder flow of combustion and ventilation air The service instructions contained in this manual are in addition to the instructions provided by the manufacturer of the boiler components Follow component manufacturer s instructions Component manufacturer s instructions were provided with the boiler Contact component manufacturer for replace ment if instructions are missing Do not install start up operate maintain or service this boiler without reading and understanding all of the component instructions Do not allow the boiler to operate with altered disconnected or jumpered components Only use replacement components identical to those originally supplied by Crown Boiler Company A General Inspection and service must be conducted 4 Remove burner access panel s annually Turn off electrical power and gas supply while 5 Mark location of Main Burner with Pilot Bracket on conducting service or maintenance Follow instructions manifold TO TURN OFF GAS TO APPLIANCE See Lighting a Operating Instructions on insid2. NOTE IT MAY BE NECESSARY TO RECYCLE THE CALL FOR HEAT TO CLEAR THE PILOT SUPPLY TUBING OF AIR NOTE IF MODULE GOES INTO RETRY DELAY RESET THE CALL FOR HEAT CHECK CONTINUITY OF IGNITION CABLE AND GROUND WIRE CLEAN FLAME ROD CHECK ELECTRICAL CONNECTIONS BETWEEN FLAME ROD AND MODULE CHECK FOR CRACKED CERAMIC FLAME ROD INSULATOR CHECK THAT PILOT FLAME COVERS FLAME ROD AND IS STEADY AND BLUE ADJUST PILOT FLAME IF NECESSARY IF PROBLEM PERSISTS REPLACE MODULE STOPS WHEN S NO PILOT IS LIT YES MAIN BURNER LIGHTS CHECK FOR 24 VAC ACROSS PV MVIPV TERMINALS ON MODULE IF NO VOLTAGE REPLACE MODULE NO CHECK ELECTRICAL CONNECTIONS BETWEEN MODULE AND GAS CONTROL IF OKAY REPLACE GAS CONTROL YES NOTE IF MODULE GOES INTO RETRY DELAY RESET THE CALL FOR HEAT CHECK CONTINUITY OF IGNITION CABLE AND GROUND WIRE NOTE IF GROUND IS POOR OR ERRATIC SHUTDOWNS MAY OCCUR OCCASIONALLY EVEN THOUGH OPERATION IS NORMAL AT THE TIME OF CHECKOUT CHECK THAT PILOT FLAME COVERS FLAME ROD AND IS STEADY AND BLUE ADJUST PILOT FLAME IF CHECKS ARE OKAY REPLACE MODULE SYSTEM RUNS UNTIL CALL FOR HEAT ENDS YES CALL FOR HEAT ENDS CHECK FOR PROPER THERMOSTAT CONTROLLER OPERATION REMOVE MV LEAD AT MODULE IF VALVE CLOSES RECHECK TEMPERATURE CONTROLLER AND WIRING IF NOT REPLACE GAS CONTROL YES Y REPEAT PROCEDURE
3. RCF parts or attempt any service or repair work involving RCF without wearing the following protective gear 1 A National Institute for Occupational Safety and Health NIOSH approved respirator Long sleeved loose fitting clothing Gloves Eye Protection Take steps to assure adequate ventilation Wash all exposed body areas gently with soap and water after contact Wash work clothes separately from other laundry and rinse washing machine after use to avoid contaminating other clothes Discard used RCF components by sealing in an airtight plastic bag RCF and crystalline silica are not classified as hazardous wastes in the United States and Canada First Aid Procedures If contact with eyes Flush with water for at least 15 minutes Seek immediate medical attention if irritation persists If contact with skin Wash affected area gently with soap and water Seek immediate medical attention if irritation persists If breathing difficulty develops Leave the area and move to a location with clean fresh air Seek immediate medical attention if breathing difficulties persist Ingestion Do not induce vomiting Drink plenty of water Seek immediate medical attention 43 FLUE BRUSH Se a FLUE BAFFLE REMOVAL VENT DAMPER DRAFT HOOD BLOCKED VENT SWITCH 1 PULL UP FROM REAR CORNER OF BAFFLE JACKET TOP PANEL 2 ROTATE BAFFLE INSIDE FLUEWAY WHILE CONTINUING TO RAISE REAR CORNER I
4. and vacuum removing all scale and soot See Figure 48 Remove all obstructions Replace all deteriorated parts 7 Clean boiler heating surface accessible from and support properly Seal all joints combustion chamber with straight handle wire D Remove Main Burners for cleaning changing orifice plugs or repairs 8 Reinsert baffles into flueways by reversing steps iven in Figure 48 Tabs at t f each baffle should 1 Shut down gas boiler in accordance with Lighting rest on top of flue pins Operating Instructions on inside of Front Removable Door Close Manual Shut off Valve 9 Install Canopy See Section II Boiler Assembly Paragraph 2 Remove Front Removable Door Raise Lower Front Tie Bar 10 Install Jacket Top Panel Draft Hood Vent Damper 3 Disconnect ignition system 42 if used and Vent System Important Product Safety Information Refractory Ceramic Fiber Product Warning The Repair Parts list designates parts that contain refractory ceramic fibers RCF RCF has been classified as a possible human carcinogen When exposed to temperatures above 1805 F such as during direct flame contact RCF changes into crystalline silica a known carcinogen When disturbed as a result of servicing or repair these substances become airborne if inhaled may be hazardous to your health AVOID Breathing Fiber Particulates and Dust Precautionary Measures Do not remove or replace
5. ER TO CALL FOR HEAT CHECK LINE VOLTAGE POWER LOW VOLTAGE TRANSFORMER LIMIT CONTROLLER THERMOSTAT CONTROLLER AND WIRING NO ALSO CHECK AIR PROVING SWITCH ON COMBUSTION AIR BLOWER SYSTEM IF USED AND THAT THE END SWITCH IF USED IS MADE POWER TO MODULE 24 V NOMINAL DAMPER SWITCH CHECK YES IF DAMPER IS OPEN CONTROL WAITS 60 SECONDS FOR DAMPER TO CLOSE ONCE CLOSED CONTROL WAITS 60 SECONDS FOR DAMPER TO REOPEN IF CONFIGURED _ DAMPER IS CLOSED CONTROL WAITS 60 SECONDS FOR DAMPER TO OPEN DAMPER SWITCH CHECK NO CHECK DAMPER CONNECTION DAMPER WIRING AND 24 V CONNECTION ON CONTROL REPLACE DAMPER AND DAMPER HARNESS IF NECESSARY YES IF CONFIGURED BEGIN PREPURGE FOR 30 SECONDS SPARK OK PULL IGNITION LEAD AND CHECK SPARK AT MODULE CHECK IGNITION CABLE GROUND WIRING CERAMIC INSULATOR AND GAP AND CORRECT NO REPLACE MODUL SENSOR BS GAP CHECK BOOT OF THE IGNITION CABLE FOR SIGNS OF MELTING OR BUCKLING TAKE PROTECTIVE ACTION TO SHIELD CABLE AND BOOT FROM EXCESSIVE TEMPERATURES CHECK THAT ALL MANUAL GAS VALVES ARE OPEN SUPPLY TUBING AND GAS PRESSURES ARE TO SPECIFICATION AND PILOT BURNER ORIFICE IS NOT BLOCKED CHECK ELECTRICAL CONNECTIONS BETWEEN MODULE AND PILOT OPERATOR ON GAS CONTROL CHECK FOR 24 VAC ACROSS PV MV PV TERMINALS ON MODULE IF VOLTAGE IS OKAY REPLACE GAS CONTROL IF NOT REPLACE MODULE
6. Flash Fast rapid blinking Next System Action Initiate new trial for ignition after retry delay completed Initiate new trial for ignition Flash code will remain through the ignition trial until flame is proved If situation self corrects within 10 seconds control returns to normal sequence If flame out of sequence remains longer than 10 seconds control goes to Flash code 6 4 see below Control remains in wait mode When the fault corrects control resumes normal operation after a one minute delay Control remains in wait mode When the fault corrects control resumes normal operation after one minute delay Initiate new trial for ignition after retry delay completed 5 minute retry delay then initiate new trial for ignition Control waits until flame is no longer sensed and then goes to soft lockout Flash code continues Control auto resets from soft lockout after one hour Control auto resets from soft lockout after one hour Recommended Service Action If system fails to light on next trial for ignition check gas supply pilot burner spark and flame sense wiring flame rod contamination or out of position burner ground connection If system fails to light on next trial for ignition check gas supply pilot burner flame sense wiring flame rod contamination burner ground connection Check for pilot flame Replace gas valve if pilot flame present If no pilot flame cycle Call for Heat
7. If error repeats replace control Check flame sense lead wire for damage or shorting Check that flame rod is in proper position Check flame rod ceramic for cracks damage or tracking Check transformer and AC line for proper input voltage to the control Check with full system load on the transformer Check gas supply pilot burner spark and flame sense wiring flame rod contamination or out of position burner ground connection Check gas supply pilot burner flame sense wiring contamination of flame rod burner ground connection Check for pilot flame Replace gas valve if pilot flame present If no pilot flame cycle Call for Heat If error repeats replace control Reset by cycling Call for Heat If error repeats replace the control Heartbeat Constant second bright second dim cycles Asingle flash code number signifies that the LED flashes X times at 2Hz remains off for two seconds and then repeats the sequence X Y flash codes signify that the LED flashes X times at 2Hz remains off for two seconds flashes Y times at 2 Hz remains off for three seconds and then repeats the sequence 46 Honeywell El Trouble Shooting Guide START BEFORE TROUBLESHOOTING FAMILIARIZE YOURSELF WITH THE STARTUP AND CHECKOUT PROCEDURES NOTE 24 VAC CALL FOR HEAT IS ALWAYS CONNECTED TO THE TH W TERMINAL ON THE MODULE TURN GAS SUPPLY OFF TURN THERMOSTAT CONTROLL
8. T MAY BE NECESSARY TO PUSH FRONT OF BAFFLE DEEPER INTO THE FLUEWAY TO COMPLETE THE ROTATION FLUE BRUSH JACKET FRONT REMOVABLE DOOR FLAME_ROLL OUT SWITCH SOFT BRISTLE BRUSH THE BAFFLE CLEAR THE EDGES 7 N MAIN BURNER 4 i Q OF THE FLUEWAY BURNER AIR SHUTTER 3 LIFT BAFFLE OUT OF FLUEWAY ONCE EDGES OF TZ77Z7ZZ7 ZZZZZZZZZ777Z7Z7777Z77ZZ7ZZZA Figure 48 Boiler Flueway Cleaning F Clean Combustion Chamber by vacuuming Exercise care to avoid damaging Base Insulation G Install Burners by reversing procedures used to remove bumers Verify Main Burners are properly located on support bracket in Base Rear Panel seated on Main Burner Orifices and secured with hitch pin Table 13 Pilot Burner Location clips Verify Main Burner with Pilot Bracket is in proper location See Table 13 H Lubrication Manufacturers Instruction should be followed on all parts installed on boiler requiring lubrication This includes type of lubricant to be used frequency of lubrication and points to lubricate Burners numbered left to right as viewed from front of boiler L Check operation Refer to Section System Start up 44 Honeywell El Ignition Module Yellow LED Flame Codes Yellow LED Flash Code Indicates Recommended Service Action Weak Flame Signal System will operate reliably but flame signal is less than desired Note This indication may flash tem
9. UNTIL TROUBLE FREE OPERATION IS OBTAINED
10. e of Front Removable 6 Remove hitch pin clips from Main Burner Orifices Door 7 Hold Main Burner on throat Lift slightly to raise rear of burner Push to rear of boiler until burner WARNING clears Main Burner Orifice Lift burners out 8 Check burners to be sure they do not contain foreign Label all wires prior to disconnection when Wiring errors can cause servicing controls improper and dangerous operation Verify proper operation after servicing B Maintenance of Low Water Cut off if used Follow matter or restrictions Clean burners with a soft bristle brush blow any dirt out with compressed air or use a vacuum cleaner See Figure 48 Clean Boiler Flueways See Figure 48 instruction manual provided with low water cut off a Operating Instructions on inside of Front Removable C Vent System Check for Door Close Manual Shut off Valve 1 obstructions 2 Disconnect vent system Remove Draft Hood 2 accumulations of soot 3 Remove Jacket Top Panel 3 deterioration of vent pipe or vent accessories due to 4 Remove Canopy from top of boiler condensation or other reasons 5 Remove flue baffles Refer to Figure 48 for 4 proper support no sags particularly in horizontal instructions on how to remove baffles from runs flueways Remove any accumulated scale or soot 5 tightness of joints Remove all accumulations of 6 Thoroughly clean flueways with flue brush soot with wire brush
11. porarily during or Perform routine maintenance to assure optimum flame signal shortly after lightoff on some applications Marginal Flame Signal less than 1 1 YA System may not operate reliably over time Service call Check gas supply pilot burner flame recommended sense wiring contamination of flame rod Note This indication may flash temporarily during or burner ground connection shortly after lightoff on some applications No Flame or Flame Signal Flash Code Descriptions Heartbeat Constant second bright second dim cycles The flash code number signifies that the LED flashes X times at 2Hz remains off for two seconds and then repeats sequence 45 Honeywell El Ignition Module Green LED Status Codes Green LED Flash Code Indicates X Y OFF No Call for Heat Flash Fast Startup Flame sense calibration Heartbeat Normal operation 5 minute Retry Delay Pilot flame not detected during trial for ignition Recycle Flame failed during run Flame sensed out of sequence Flame sense leakage to ground Low secondary voltage supply below 15 5 Vac 5 minute Retry Delay On every third retry on same Call for Heat On every 6th flame failure during run on the same Call for Heat Flame sensed out of sequence longer than 10 seconds Soft lockout due to error detected during self check sequences 6 2 6 3 6 4 Flash Code Descriptions
Download Pdf Manuals
Related Search