Boiler Troubleshooting

Boiler Fails to Meet System Load

One possible cause is that the boiler thermostat is set incorrectly. Corrective action is to check
the thermostat setting. Another possible cause is poor combustion. Recommended action is to
check flue, flame, and assess combustion quality.

Boiler and System Overheat

Possible cause is that system controls are faulty. Corrective action is to check voltage,
temperature settings, and safety switches.
This problem may also be caused because the control thermostat failed and high-limit thermostat
activated, or both controls may have failed. Action to be taken is to check temperatures if they
are higher than the high-limit setpoint, replace the high-limit thermostat.

Fumes in Boiler Room

Check for incorrect combustion. Perform a combustion analysis and correct.
Another possible cause is inadequate airflow for combustion. In this case, inspect the boiler,
chimney, and boiler room fresh air intake for the source of the blockage.
One more possibility is test holes in the flue that are unsealed or flue leakage. To correct, cover
the holes and check for leakage.
Finally, the boiler room fans may have stopped. In this instance, check the boiler room fans.

Boiler Does Not Ignite

There are six possible causes to look for here.
Check for a boiler internal controls failure. Investigate this possibility and reset or replace.

The boiler may have previously overheated and the overheat cut-out has not reset. Determine the
cause of the overheat condition. Once it has been corrected, reset.
The supply fuse may have blown or the supply isolated. Establish the cause of the blown fuse
and replace.
There may no pilot flame. Possibilities for this condition are: (1) a dirty or incorrectly installed
pilot nozzle check the size of the pilot nozzle and check for blockage; (2) insufficient gas
supply to pilot check the gas supply to gas safety valve; (3) pilot flame ignites but becomes
faulty immediately check the position of the flame detector probe and check the voltage of the
flame detector; and (4) thermocouple voltage is too low replace the thermocouple.
If the main burner does not light, investigate the loss of fuel to the burner, repair, and light.
There may be no ignition spark. Possibilities in this case are: (1) high tension leads not
connected at the ignition transformer or electrodes check connections; (2) short circuit or
ground fault on high tension leads check leads; (3) carbon deposit on the electrode insulation
or between the electrodes check and clean the electrodes; (4) cracked electrode insulators
check insulators; (5) excessive electrode gap measure electrode gap; (6) no supply to the
ignition transformer check ignition relay operation: (7) secondary winding of transformer
open circuited or short circuited test and inspect transformer, fix any defects found or replace;
(8) primary winding of transformer grounded, open circuited, or short circuited check
continuity and insulation resistance of primary winding.

Boiler Will Not Purge or Ignite

This problem has 12 possible causes.
First, there could be a control problem. Check the building management system control signal.
The circuit breaker could be tripped or there could be a blown fuse. Look for a possible ground
fault and reset the breaker or replace the fuse.
There may no pilot flame. Possibilities for this condition: (1) a dirty or incorrectly installed pilot
nozzle check the size of the pilot nozzle and check for blockage; (2) insufficient gas supply to

pilot check the gas supply to gas safety valve; (3) pilot flame ignites but becomes faulty
immediately check the position of the flame detector probe and check the voltage of the flame
detector; and (4) thermocouple voltage is too low replace the thermocouple.
The gas and/or electricity supplies may be off. Check the voltage and gas supply.
The thermostats could be set incorrectly. Check the thermostats and reset, repair, or replace as
necessary.
The flue gas fan may not be functioning. Check the electrical power to the fan as well as the
control signal.
There may be no ignition spark. Check the ignition coil, the electrical supply to the ignition coil,
and the electrode gap.
There could be no main flame. Check the voltage to the safety valves, and check the ionization
current, the setting of the ionization probe, and the wiring of the ionization probe.
The automatic control box may have gone to lockout because of a fault. Press the button on the
control box. If normal start-up does not occur, check whether the boilers manual gas valves are
fully open, and whether the boiler control thermostat is set at the correct value.
The flue air pressure switch may not be switching to the safe position. Replace the switch.
The boiler room emergency stop could be activated. Check the cause of this condition and reset.
Finally, the thermal links may have melted or broken. Check the cause and replace the thermal
links.

Boiler Fires Continuously

A potential cause is a thermostat fault. Investigate and either repair or replace the thermostat.
There could be a wiring fault. Check the wiring and make the required repair.
One more possibility is a control valve that is faulty or sticking. Replace the valve.

Boiler Overheats and Is Noisy

There could be poor circulation in the primary circuit. Vent the system.
Another possibility is low shunt-pump discharge pressure. There could be an obstruction in the
piping; open a piping joint and check for foreign materials. There may be an air pocket in the
line; purge the system.

Boiler Starts but Flame Goes Out Soon After

A possible cause is flue blockage. Check the flue for blockage. Check dilution fan operation.
Another potential cause is primary low-pressure hot water (LPHW) circuit failure. Check
operation of the high-temperature cut-out.

Fault in Flue Gas System

In this case, a cause may be that the flue gas fan does not run during the start sequence. Check
the control circuit.
It is also possible that the fan has stopped during operation. Check the fan, make any necessary
fixes, and restart.

High Water Temperature

A possible cause is that the system control thermostat is set too high. Check the calibration and
reset.
Another likely cause is that the circulation system pump is not working. There could be an
obstruction in the piping; open a piping joint and check for foreign materials. There may be an
air pocket in the line; purge the system.

Low Water Temperature

In this instance, one possible cause is the system control thermostat is set too low. Recommended
action is to check the calibration and reset.

Another cause is air in the system. Corrective action is to vent the system.

Generator troubleshooting

Problem
Cause
Correction
Engine is running, but no AC output is available
1. One of the circuit breakers is open.
1. Reset circuit breaker.
2. Fault in generator.
2. Contact Authorized Service Dealer.
3. Poor connection or defective cord set.
3. Check and repair.
4. Connected device is bad.
4. Connect another device that is in good condition.
Engine runs good at no-load but "bogs down" when loads are connected.
1. Short circuit in a connected load.
1. Disconnect shorted electrical load.
2. Engine speed is too slow.
2. Contact Authorized Service Dealer.
3. Generator is overloaded.

3. See Don't Overload Generator in Owner's Manual.

4. Shorted generator circuit.
4. Contact Authorized Service Dealer.
5. Clogged or dirty fuel filter.
5. Clean or replace fuel filter.
Engine will not start; or starts and runs rough.
1. Start switch in off (O) position.
1. Turn key in start switch to run ( | )
2. Fuel valve is in "Off" position.
2. Turn fuel valve to "On" position.
3. Failed battery.
3. Replace battery.
4. Low oil level.
4. Fill crankcase to proper level or place generator on level surface.
5. Dirty air cleaner.
5. Clean or replace air cleaner.
6. Clogged or dirty fuel filter.
6. Clean or replace fuel filter.
7. Out of fuel.
7. Fill fuel tank.
8. Stale fuel.
8. Drain fuel tank and carburetor; fill with fresh fuel.
9. Spark plug wire not connected to spark plug.

9. Connect wire to spark plug.

10. Bad spark plug.
10. Replace spark plug.
11. Water in fuel.
11. Drain fuel tank and carburetor; fill with fresh fuel.
12. Flooded.
12. Wait 5 minutes and re-crank engine.
13. Excessively rich fuel mixture.
13. ContactAuthorized Service Dealer.
14. Intake valve stuck open or closed.
14. ContactAuthorized Service Dealer.
15. Engine has lost compression.
15. ContactAuthorized Service Dealer.
Engine shuts down when running.
1. Load is too high.
1. See Don't Overload Generator in Owner's Manual.
2. Dirty air filter.
2. Replace air filter.
3. Clogged or dirty fuel filter.
3. Clean or replace fuel filter.
Engine "hunts" or falters.
1. Carburetor is running too rich or too lean.
1. Contact Authorized Service Dealer.

2. Clogged or dirty fuel filter.

2. Clean or replace fuel filter.

TROUBLESHOOTING OF CONDENSER
Observe
d
problem
1.

Proble
m
source
High
1a.
pressure
drop across
process
side of
condenser

Corrective measure

Shellside or
tubeside fouling

1a.

Clean inside or
outside surface of
tubes

1b.

Cooling water
1b.
temperature higher
than design

Reduce cooling
water temperature
or increase flow
rate

1c.

Low cooling water

flow rate

Increase cooling
water flow rate

1d.

Higher than design 1d.

condensible
organics/hydrocarbo
n loading

1c.

Reduce
organic/hydrocarbo
n loading or install
larger condenser

2.

3.

High
cooling
water
pressure
drop

2a.

Waterside fouling or 2a.

blockage

Clean tubing

2b.

Higher than design

cooling water flow
rate

2b.

Not a problem

Low cooling water

flow rate

3a.

Increase cooling
water flow rate

Higher than design

condensible vapor
loading

3b.

Increase cooling
water flow rate or
install larger
condenser

Higher than 3a.

design
cooling
water
temperatur
e rise
3b.

4.

High vapor 4.
outlet
temperatur
e

Poor vacuum
4a.
system performance

Clean tubing
because it is fouled

4b.

Cooling water flow

is increased or inlet
temperature is
reduced
Condenser
internals have a
mechanical
problem that
requires repair

4d.

There is a problem
with a downstream
ejector and it is
backstreaming

TROUBLESHOOTING OF STEAM TURBINES