9/15/2019 Boiler Troubleshooting | 2015-03-02 | ACHRNEWS

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Boiler Troubleshooting
A Summary of Boiler Tips

With the heating season in full force, it is a good time to review

March 2, 2015 best practices in heating troubleshooting. The following article
Greg Mazurkiewicz covers boilers. The following information is a summarized section
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from HVAC Troubleshooting, a guide book published by BSRIA, a test, instruments, research,
9/15/2019 Boiler Troubleshooting | 2015-03-02 | ACHRNEWS

and consultancy organization headquartered in the United Kingdom.

The full guide covers the most common building heating, cooling, and controls systems and
assumes a sound knowledge of the investigation/check procedures to be carried out. As well as
the summary below, the full boiler troubleshooting section of the guide can be downloaded from
www.bsria.co.uk/goto/boiler-trouble.

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.
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9/15/2019 Boiler Troubleshooting | 2015-03-02 | ACHRNEWS
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.

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9/15/2019 Boiler Troubleshooting | 2015-03-02 | ACHRNEWS
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 boiler’s 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

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9/15/2019 Boiler Troubleshooting | 2015-03-02 | ACHRNEWS
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.

Editor’s Note: The complete HVAC Troubleshootingguide is available for purchase from BSRIA’s
Bookshop at https://www.bsria.co.uk/information-membership/bookshop/publication/hvac-
troubleshooting-bg252014/ in electronic or hard-copy format. It is also available as part of
BSRIA Bookshop’s set of five guides that enable you to buy a suite of facility maintenance guide
books at a discounted price. Go to https://www.bsria.co.uk/information-
membership/bookshop/publication/maintaining-facilities-guide-set/.

Readers of the ACHR News can purchase the HVAC guide or the set for a 10 percent discount.
Enter BOOKACHR upon checkout.

Publication date: 3/2/2015

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