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Solve Common Trouble for Boiler Combustion

1. The ignition rod does not discharge spark, how to remedy?


Cause of Fault:

(1)    Carbon slag is held in the gap of ignition rod.
(2)    Ignition rod is cracked and damaged or is wetted or has leakage of electricity.
(3)    Ignition rod has wide gap or no gap.
(4)    Ignition rod is fixed forward and it contacts with cyclone pan
(5)    Ignition rod transformer has fault.


Debugging Method:

(1)    Clearing carbon deposit
(2)    Replacing new ignition rod
(3)    Adjusting gap in 4~5mm
(4)    Adjusting distance from cyclone pan in 0~10mm.
(5)    Replacing new one.


2. Although the ignition rod has the spark, it does not ignites, how to remedy?


Cause of Fault:

(1)    The gap of cyclone pan is blocked by carbon deposit with bad ventilation.
(2)    Oil nozzle is not clean, blocked or worn out.
(3)    The angle of throttle is too large, thus dying out with air blowing.
(4)    The distance between the end of ignition rod and the front of oil nozzle is improper (standing out or retracting)
(5)    First solenoid valve is blocked
(6)
   Oil is too thick, does not easily flow or filtering system is
blocked or oil valve is not opened, the oil pump has not pressure
because of inadequate oil-absorption.

(7)    The filtering mesh of oil pump is blocked.
(8)    Oil pump is worn without pressure.
(9)    Oil quality is not correct or oil contents moisture


Debugging Method:

(1)    Cleaning cyclone pan
(2)    Cleaning oil nozzle or replacing
(3)    Gradually reducing the throttle angle;
(4)    Adjusting the distance from the front of oil nozzle in 3~4mm
(5)    Dismounting and cleaning solenoid valve
(6)    Check filtering mesh and heat-preservation of oil pipe and oil quality
(7)    Dismounting oil pump and carefully removing filtering mesh and cleaning
(8)    Replacing oil pump
(9)    Replacing oil.


3. Fire dies out for ten seconds after igniting (no fire in second channel), how to remedy?


Cause of Fault:

(1)    Phototransistor is dirty or damaged, monitoring is abnormal.
(2)    Oil nozzle is dirty or seriously worn out.
(3)    Throttle is too small or the regulating valve in stack is closed.


Debugging Method:

(1)    Cleaning or replacing new one.
(2)    Cleaning or replacing
(3)    Adjusting throttle.


4. The fire is getting normally in the first channel but the fire dies
out in the second channel or the flame flashes unstably and dies out in
backfiring, how to remedy?


Cause of Fault:

(1)    The throttle in second channel is large.
(2)
   The micro-switch (the group outward in outside of throttle) of oil
valve in the second channel is improperly set (larger than the air
volume of throttle in second channel)

(3)    The oil nozzle in the first channel is dirty.
(4)    The viscosity of oil is too higher so that it is not easy to be atomized.
(5)    The distance from cyclone pan to oil nozzle is improper.
(6)    The oil nozzle in the second channel is dirty.
(7)    The heating temperature of fuel is too high so that oil contents steam. Oil pump does not pump oil well.
(8)    The oil contents moisture.


Debugging Method:

(1)    Gradually decreases the air volume of throttle and trying again.
(2)
   The set value should be larger 5 – 10o than that of throttle in the
first channel (the second group from outward to inward in cam switch),
(It is not permitted for same angles of    two groups or for the value
in the first group to be smaller than the value in the second group).

(3)    Cleaning or replacing new one.
(4)    Replacing the type of oil.
(5)    Adjusting to 0 ~ 10mm.
(6)    Cleaning or replacing.
(7)    Decreasing heating temperature of fuel to 50℃ less or more.
(8)    Replacing oil.


5. When oil pump operates, there is abnormal sound, how to remedy?


Cause of Fault:

(1)    Oil volume is inadequate or filtering mesh is blocked.
(2)    Oil temperature is too high.
(3)    Oil temperature is too low and viscosity is too high.


Debugging Method:

(1)    Checking the valve and filtering mesh in oil pipe, cleaning filtering mesh of oil pump.
(2)    Decreasing heating temperature.
(3)    Heating temperature or thinning.


6. The burner shut down automatically when it operates in normal
pressure and temperature and meanwhile, the warning lamp for is lit, how
to remedy?

      

Cause of
Fault:
It means that the refractory in boiler is burned or other
materials in hearth are burned so that the infrared sensor
(light-sensitive resistor) is induced abnormally.

 
    

Debugging Method: Checking the failure in boiler and debugging
(specially paying attention to whether the leaked heat-transferred oil
is burned in hearth).


7. The motor can not be started up when PLC operates normally, how to remedy?


Cause of Fault:

(1)    The motor is not connected to three-phase power supply.
(2)    The thermal relay of motor activates


Debugging Method: Checking and repairing to restore normal operation.


8. PLC does not operate, how to remedy?


Cause of Fault:

(1)    Fuse is broken.
(2)    Control power supply is not switched on.
(3)    The continuous circuit is broken.


Debugging Method: Checking and repairing to restore normal operation.


9. Although the motor operates, throttle and PLC don’t work and stay in 0o position, how to remedy?


Cause of Fault:The micro switch  of fourth group in printing
circuit board of throttle (The fourth switch arranged inward) is set
improperly (lower than 0o) or the contact point of switch is not well.

       

Debugging Method: The cam of switch is set on 5o or 10o or new circuit is replaced.


10. The burner does not start up under the normal conditions, how to remedy?


Cause of Fault: except that the above-said power supply and interlock circuit are normal,

(1)    If the heater is not hot, the element of temperature limit switch (red) is skipped.
(2)    If the heater is hot, the temperature switch is out of order.


Debugging Method:

(1)    Press the red element to restore.
(2)    Dismounting for measuring and replacing new one.


11. Large black smoke gives out only when there is fire in the first channel, how to remedy?


Cause of Fault:

(1)    The throttle in the first channel is not small.
(2)    Oil nozzle is worn out and badly atomizes
(3)
   The set angle of first group micro switch of throttle is smaller
than the set angle of second group; micro switch so that the oil nozzles
in two channels spray oil at same time two    hours later.


Debugging Method:

(1)    Gradually increasing throttle and trying again.
(2)    Replacing oil nozzle
(3)    The angle of micro switch in the first group should be 5 ~10o larger than that of micro switch in the second group.


12. Large black smoke gives out still after adjusting throttle, how to remedy?


Cause of Fault: Oil nozzle is worn out and can not atomize.

Debugging Method: Replacing oil nozzle


13. White smoke gives out, how to remedy?


Cause of Fault:

(1)    Throttle is too larger.
(2)    Moisture is mixed in.   

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