Benchmark 5000-6000 Operation & Maintenance Manual
SECTION 5
– TROUBLESHOOTING GUIDE
OMM-0118_B
•
GF-203
•
5/9/2019
Technical Support
•
(800) 526-0288
•
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TABLE 5-1: Boiler Troubleshooting Procedures
FAULT
INDICATION
PROBABLE CAUSES
CORRECTIVE ACTION
FLAME LOSS
DURING IGN
(continued)
7.
Pilot View Port is blocked.
8.
Carbon or other debris on Burner.
9.
Pilot gas valve is closed.
10.
Pilot ignition solenoid valve does not open.
11.
Clogged Pilot ignition piece
7.
Remove ad clean Pilot View Port. Also, ensure that the hole in the
refractory is clear.
8.
Remove View-Port and inspect Burner with Boroscope. If it is fouled
or black with soot, remove the Burner and inspect for any carbon
build-up or debris. Clean and reinstall.
9.
Open the Pilot gas valve on the upstream side of the SSOV (see
Figure 5-1).
10.
When unit goes to ignition, listen for a clicking sound at the Pilot
ignition solenoid valve to ensure it is opening.
11.
Remove and inspect the ignition piece for blockage.
FLAME LOSS
DURING RUN
1.
Worn Flame Detector or cracked ceramic.
2.
Defective Regulator.
3.
Poor combustion calibration.
4.
Debris on burner.
5.
Blocked condensate drain.
6.
Main Flame Detector is touching burner mesh.
1.
Remove and inspect the Flame Detector for signs of wear or
cracked ceramic. Replace if necessary.
2.
Check gas pressure readings using a gauge or manometer into
and out of the Air/Fuel Valve to ensure that the gas pressure into
and out of the valve is correct.
3.
Check combustion calibration using procedures in Section 4.5 of
the
Benchmark 5000
– 6000 Installation and Startup Guide,
OMM-
0117 (GF-202).
4.
Remove the burner and inspect for any carbon build-up or debris.
Clean and reinstall.
5.
Remove blockage in condensate drain.
6.
Straighten or replace Main Flame Detector
HEAT DEMAND
FAILURE
1.
The Heat Demand Relays on the
Ignition/Stepper (IGST) board failed to activate
when commanded.
2.
Relay is activated when not in Demand.
1.
Press
CLEAR
button and restart the unit. If the fault persists,
replace Ignition/Stepper (IGST) Board.
2.
Defective relay. Replace IGST Board.
HIGH EXHAUST
TEMPERATURE
1.
Poor combustion calibration.
2.
Carboned heat exchanger due to incorrect
combustion calibration.
1.
Check combustion calibration using procedures in Section 4.5 of
the
Benchmark 5000
– 6000 Installation and Startup Guide,
OMM-
0117 (GF-202).
2.
If exhaust temperature is greater than 200
o
F (93.3
o
C), check
combustion calibration. Calibrate or repair as necessary.
