Cleaver brooks boiler troubleshooting

Breakdowns can be caused by a lot of things: from leaks to faulty mail parts. Examine your boiler every day and pay attention to any changes – unusual noises, instrument readings, cracks, changes in flame or combustion products. In the table below, there is a list of the most common causes of malfunctions.

Burner does not start1. No voltage at program relay power input terminals.
A. Main disconnect switch open.
B. Blown control circuit fuse.
C. Loose or broken electrical connection.
2. Program relay safety switch requires resetting.
3. Limit circuit not completed - no voltage at end of limit circuit program relay terminal.
A. Pressure or temperature is above setting of operation control. (Load demand light will not glow.)
B. Water below required level.
1). Low-watcr light (and alarm horn)should indicate this condition.
2). Check manual reset button, if provided, on low-water control.
C. Fuel pressure must be within settings of low pressure and high pressure switches.
D. Oil fired unit - burner gun must be in full forward position to close oil drawer switch.
E. Heavy oil fired unit - oil temperature below minimum settings.
4. Fuel valve interlock circuit not completed. A. Fuel valve auxiliary switch not enclosed.
No ignition1. Lack of spark.
A. Electrode grounded or porcelain cracked.
B. Improper electrode setting.
C. Loose terminal on ignition cable; cable shorted.
D. Inoperative ignition transformer.
E. Insufficient or no voltage at pilot ignition circuit terminal.
2. Spark but no flame.
A. Lack of fuel - no gas pressure, closed valve, empty tank, broken line, etc.
B. Inoperative pilot solenoid.
C. Insufficient or no voltage at pilot ignition circuit terminal.
D. Too much air.
3. Low fire switch open in low fire proving circuit.
A. Damper motor not elosed, slipped cam, defective switch.
B. Damper jammed or linkage binding.
4. Running interlock circuit not completed.
A. Combustion or atomizing air proving switches dcfcctivc or not properly set.
B. Motor starter interlock contact not closed.
5. Flame detector defective, sight tube obstructed, or lens dirty.
Pilot flame, but no main flame1. Insufficient pilot flame.
2. Gas Fired Unit.
A. Manual gas cock closed.
B. Main gas valve inoperative.
C. Gas pressure regulator inoperative.
3. Oil fired unit.
A. Oil supply cut off by obstruction, closed valve, or loss of suction.
B. Supply pump inoperative.
C. No fuel.
D. Main oil valve inoperative.
E. Check oil nozzle, gun and lines.
4. Flame detector defective, sight tube obstructed or lens dirty.
5. Insufficient or no voltage at main fuel valve circuit terminal.
Burner stays in low fire1. Pressure or temperature above modulating control setting.
2. Manual-automatic switch in wrong position.
3. Inoperative modulating motor.
4. Defective modulating control.
5. Binding or loose linkage, cams, setscrews, etc.
Shutdown occurs during firing1. Loss or stoppage of fuel supply.
2. Defective fuel valve; loose electrical connection.
3. Flame detector weak or defective.
4. Lens dirty or sight tube obstructed.
5. If the programmer lockout switch has not tripped, check the limit circuit for an opened safety control.
6. If the programmer lockout switch has tripped:
A. Check fuel lines and valves.
B. Check flame detector.
C. Check for open circuit in running interlock circuit.
D. The flame failure light is energized by ignition failure, main flame failure, inadequate flame signal, or open control in the running interlock circuit.
Shutdown occurs during firing7. Improper air/fuel ratio (lean fire).
A. Slipping linkage.
B. Damper stuck open.
C. Fluctuating fuel supply.
1). Temporary obstruction in fuel line.
2). Temporary drop in gas pressure.
3). Orifice gate valve accidentally opened (heavy oil).
8. Interlock device inoperative or defective.
Modulating motor does not operate1. Manual-automatic switch in wrong position.
2. Linkage loose or jammed.
3. Motor does not drive to open or close during pre-purge or close on burner shutdown.
A. Motor defective.
B. Loose electrical connection.
C. Damper motor transformer defective.
4. Motor does not operate on demand.
A. Manual/automatic switch in wrong position.
B. Modulating control improperly set or inoperative.
C. Motor defective.
D. Loose electrical connection.
E. Damper motor transformer defective.