User guide

© The Fulton Companies 2013
MAINTENANCE FTCS-IOM-2013-1114 SECTION 4
4-16
TABLE 10N  PILOT FLAME FAILURE TROUBLESHOOTING
Problem Potential Remedy
Pilot  ame strength is
inadequate
Cycle the unit. During the pilot trial for ignition, carefully observe the pilot  ame strength.
On Honeywell controllers, the pilot  ame strength must be between 1.25 to 5.0 VDC. On Fireye controllers, the pilot  ame strength
must be greater than 10 VDC.
Current controls are supplied with a test switch that can hold the programmer in the pilot trial for ignition stage. If a pilot signal
greater that 0.0 but less than the minimum required is detected, look through the sight hole provided on the burner plate of the
heater to visibly detect  ame. If  ame is seen, make small adjustments to increase pilot gas and air to provide larger  ame.
Pilot sensing device does not
work properly
Cycle the unit. If a pilot signal of 0.0 is detected, look through the sight hole provided on the burner plate of the heater to visibly
detect  ame.
If  ame is seen, your  ame detection device or ampli er may be faulty. If the unit has a  ame rod, lockout and tag heater’s electrical
circuit and fuel supply. Pull pilot assembly out of unit. Inspect the  ame rod. If the  ame rod is corroded, shows signs of heat
impingement, has been turned o or has cracks in the porcelain, replace with a new  ame rod.
Reinstall and cycle unit. If the unit has a U.V. scanner, lockout and tag heater’s fuel supply. Remove U.V. scanner from U.V. sight tube.
Make sure that the lens of the scanner is clean. Use a lighter or match and make a  ame in front of the scanner eye. Lens should
 icker. If unit does not  icker, change U.V. scanner. If this change does not work, change U.V. ampli er. Reinstall and cycle unit.
Room air pressure is di erent
from outside air pressure
Check room air pressure relative to outside air pressure. Heater room pressure should equal outside air pressure. Signi cant
di erences in pressure will result in an erratic  ame, which will not deliver a strong  ame signal.
TABLE 10O  MAIN FLAME FAILURE TROUBLESHOOTING
Problem Potential Remedy
Main  ame strength is
inadequate
Cycle the unit. During the main  ame proving period , carefully observe the pilot  ame strength. Current controls are supplied with a
test switch that can hold the programmer in the main  ame proving period.
If a main signal is greater than 0.0 but less than the minimum required is detected, look through the observation port to try to visibly
see  ame. A combustion change may be necessary to establish main.
If observed  ame is blue, slightly decrease the air damper setting and recycle. If  ame is red or orange, slightly increase air damper
setting and recycle. Once adequate  ame signal is established, reset input and combustion throughout range of modulation.
Flame sensing device does not
work properly
Cycle the unit. If a signal of 0.0 is detected, look through the sight hole provided on the burner plate of the heater to visibly detect
 ame. If  ame is seen, your  ame detection device or ampli er may be faulty.
If the unit has a  ame rod, lockout and tag heater’s electrical circuit and fuel supply. Pull pilot assembly out of unit. Inspect the  ame
rod. If the  ame rod is corroded, shows signs of heat impingement, has been burned o or has cracks in the porcelain, replace with a
new  ame rod. Reinstall and cycle unit.
If the unit has a U.V. scanner, lockout and tag heater’s fuel supply. Remove U.V. scanner from U.V. sight tube Make sure that the lens
of the scanner is clean. Use a lighter or match and make a  ame in front of the scanner eye. Lens should  icker. If unit does not  icker,
change U.V. scanner. If this change does not work, change U.V. ampli er. Reinstall and cycle unit.
Room air pressure is di erent
from outside air pressure
Check room air pressure relative to outside air pressure. Heater room pressure should equal outside air pressure. Signi cant
di erences in pressure will result in an erratic  ame, which will not deliver a strong  ame signal.
Unit is experiencing too great
of a restriction
At the breaching of the heater, take a draft reading. Draft should read between -.02” w.c. and -.04” w.c. with the heater o and
between -.04” w.c. and -.08” w.c. with the unit on. A restrictive draft would be a draft that was positive. A restrictive draft is usually
the result a stack that is undersized, a stack with too many elbows or a stack whose cap or piping is warped and damaged. Another
source of restriction results from broken refractory. If the unit’s refractory breaks, large enough pieces could block the  ue passes.
The burner should be pulled for refractory inspection. A broken refractory should be cleaned out and replaced.