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Section IV: Troubleshooting

WARNING:

All troubleshooting procedures must be followed completely by competent personnel familiar with

boilers and accessories.

CAUTION:

Read and follow all instructions before troubleshooting any boiler equipment.

A. Normal

Operation

All Lattner forced draft gas-fired boilers follow the same
operating sequence:

Turn the pump switch ON.

McDonnell Miller pump control turns on the pump or
solenoid water valve.

Pump or solenoid valve fills boiler.

McDonnell Miller shuts off the pump or solenoid
water valve when water is at normal operating level.

Turn boiler switch to the ON position.

Gas valve opens and main burners light.

Boiler pressure will rise to the pressure controller’s
set point. The then controller will shut off the gas
valve.

When the boiler calls for water, the McDonnell Miller
level control will turn on the pump or solenoid water
valve.

If the pump cannot fill the boiler, the McDonnell
Miller low water cut-off will shut down the boiler. If
the McDonnell Miller does not shut down the boiler,
the auxiliary low water cut-off will shut down the
boiler.

10.

If the boiler has optional controls, refer to the wiring
diagram.

B. Basic Service Tools

The following basic equipment will aid in troubleshooting
Lattner boilers. Not all equipment is needed for every repair:

Schematic diagram of the boiler

Volt/ohm meter

Ammeter

Gas pressure gauge

Flame simulator

Continuity tester

Flue gas analyzer

Carbon monoxide sampler

C. Before You Begin

Before you begin any troubleshooting procedures, check the
following:

Make sure the pilot is lit.

Be certain boiler switch is on and that there are 115
volts supplied to the boiler control circuit.

Be certain pump switch is ON and check for proper
pump voltage and phase if different from boiler
circuit.

Check if breaker is tripped or if fuse is blown.

Make sure there is water in the boiler.

Be certain manual gas cock is open and that gas is
supplied to the boiler.

Be certain that all manual resets have been
pushed.

Note: All Lattner boiler controls are wired in series.

The boiler operating controls and limits form a series
circuit. When all switches close, the boiler should fire.

Содержание Lattner

Страница 1: ...Instruction Manual WLF Steam Boilers 2006 to 2007 ...

Страница 2: ...Firing The Boiler N Pressuretrols Controller Limit O Start Up of Standard Burners Section II Boiler Care A General B New Boiler Clean Out C Water Conditions D Water Treatments Chemicals E Water Softener F Foaming Bouncing Chemicals G Water Treatment Summary H Blowdown I Feedwater System J Burner Adjustment K Sight Glass L External Inspections M Internal Inspections Section III Maintenance A Daily ...

Страница 3: ...ng Pipe I Warrick Relay Replacement J Auxiliary Low Water Cut Off Probe Cleaning Section IV Troubleshooting A Normal Operation B Basic Service Tools C Before You Begin Lattner Boiler Limited Warranty Standard Terms Conditions Product Support Literature 22 23 23 24 24 Page 25 25 25 25 Page 28 Page 29 Page 30 ...

Страница 4: ...vessel with ASME Code required stay bolts It is symmetrical in layout and completely water backed assuring a balanced flow circulating pattern under all load conditions 5 Inner Casing A non metallic gas barrier encases the heat transfer fins to ensure proper gas travel from the combustion chamber into each heat transfer zone This barrier is covered with a steel wrapper that is in turn covered with...

Страница 5: ...s a float actuated device a snap acting single pole single throw switch activates a pump contactor for ON OFF pump or solenoid valve operation 5 Auxiliary Low Water Cut Off An additional control separate from the primary low water control is provided to prevent burner operation if a low low water condition exists This device is an internal probe control located on the top of the pressure vessel an...

Страница 6: ... mounted on the boiler This panel contains as a minimum the following components 1 Boiler ON OFF Switch Provided to interrupt control power to the 120 volt control circuit Does not disconnect the main power source 2 Pump ON OFF Switch Provided to isolate the pump control circuit 3 Terminals Provided for the connection of the 120 1 60 volt supply and for external connections for field wiring 4 Rela...

Страница 7: ...l hydrostatic pressure test This test includes the integral steam and water trim piping and the trim valves An ASME P 6 piping hydro certificate can be provided for an additional cost 3 Burner Controls To ensure proper operation of the combustion safeguard control ignition and main fuel light off the burner manufacturer subjects the packaged burner to a preliminary factory fire test All burner and...

Страница 8: ...t etc place the boiler on rollers or on 2 pipes and roll the boiler into place If the unit is dragged attach chains to the base frame only CAUTION DO NOT lay the boiler on its side as the panels will not support the weight of the boiler without sustaining damage If the entry is too narrow for the boiler and controls to pass through removal of the trim and controls can be executed One should proper...

Страница 9: ... 7 Walls Ceilings When passing through combustible walls or ceilings a stack thimble is required The thimble must be double wall stack 6 larger in diameter than the vent stack The material used to close the opening between the stack and the stack thimble must be non combustible F Boiler Shipped with Controls Removed 1 Reassemble See assembly print in this section p 15 2 Wiring Re wiring the contro...

Страница 10: ...gh the drain should be piped to the sewer Some codes require the water to pass through an air gap before entering the sewer 9 Aftercooler If the water must be cooled before entering the sewer required by some codes then an aftercooler must be used The aftercooler attaches to the separator drain connection and mixes cold water with the hot drain water Units may be either manual or automatic Select ...

Страница 11: ...part of the gas train piping This will void any warranty on the gas train assembly 7 Codes Standards All gas piping must be done in accordance with all applicable codes National Fuel Gas Code utility company requirements local building codes etc K Boiler Feed Systems 1 Condensate Return Systems a Make Up Water Supply Connect city water line to the float valve provided with the boiler feed system L...

Страница 12: ...lve If a solenoid water valve is used make sure the water supply is connected N Pressuretrols Controller Limit 1 Standard All Lattner steam boilers will have at least two pressure switches a controller and a limit 2 Controller Before the boiler is started the steam pressure is 0 psi At this point the controller is in the ON condition and is calling for heat When the boiler switch is turned on the ...

Страница 13: ...he manual reset on the limit switch must then be reset before the boiler will operate again 10 More Information For any additional information on the Honeywell Pressuretrols refer to the Honeywell product sheet in the back of this manual O Start Up of Standard Burners CAUTION All work performed on gas fired equipment or gas train components must be done by qualified personnel 1 Turn boiler switch ...

Страница 14: ...y Data may vary by location environment fuel gas pressure BTU content and more REFER TO BURNER NAMPLATE AND BURNER MANUAL FOR MORE SPECIFIC INSTRUCTIONS including low NOx burner instructions for California and Texas Constituent Value Required Gas Pressure Maximum 14 w c Required Gas Pressure Minimum varies by burner Manifold Pressure See burner nameplate O2 4 5 to 7 5 CO2 8 to 10 CO Less than 100 ...

Страница 15: ...going back through the pump and into the boiler If this is not possible then the new boiler clean out procedure becomes imperative NOTE Never fill a hot empty boiler with cold water C Water Conditions 1 Oxygen Scavenging The oxygen will then attack exposed metal surfaces This leads to corrosion and localized pitting of the metal 3 Scale Deposits As the water boils the dissolved minerals will separ...

Страница 16: ...H 8 5 to 10 Total Dissolved Solids 2 000 ppm or 116 8 grains maximum Oxygen 0 ppm Alkalinity Less than 300 ppm Chloride Less than 500 ppm Sodium Phosphate Less than 100 ppm H Blowdown 1 Purpose of Blowdown The water treatment chemicals keep these substances suspended in the water Eventually the concentration of these substances increases and must be removed This is done by blowdown Blowdown remove...

Страница 17: ...shers are not in place the gasket will twist causing the glass to break 4 Proper Installation L External Inspections 1 Maintenance External inspections are routine observations of the visible portions of the boiler By noticing the normal boiler operation many problems can be detected before they become serious 2 Piping Check the piping for leaks This includes steam pipes condensate pipes feedwater...

Страница 18: ... boiler is being used If the boiler uses large quantities of untreated hard water the boiler may need to be inspected every 60 days If the boiler uses minimal quantities of make up water i e closed loop systems and the water is treated the boiler may need to be inspected only once a year Many state and or city codes require annual internal boiler inspections 4 Gaskets The hand hole gaskets and the...

Страница 19: ...ve wear or leaks 2 Test the McDonnell Miller and auxiliary low water cut off for proper operation By opening the blowdown valves with the boiler firing the burners must shut off during this test If the burners do not shut off the control may require immediate servicing 3 Drain the sight glass 4 Visually inspect the boiler and water feed system for any water or steam leaks in the piping 5 Check the...

Страница 20: ...pilot flame Notify service organization if readings are high low or fluctuating Hand Hole Plates Monthly Operator Visually check for leakage and replace gaskets as necessary Firing Rate Control Annually Service Technician Verify BTU input and gas pressure and check with combustion test analyzer Igniter or Pilot Annually Operator Make visual inspection and check flame strength with appropriate equi...

Страница 21: ...ate rocks back and forth remove the high spots on the hand hole plate with a file Note Do not leave the hand hole plate installed without the gasket 11 Install the gasket on the hand hole plate Make sure the gasket is pressed firmly down on to the hand hole plate Do not use any grease lubricants or adhesives when installing handhold gaskets 12 Reinstall the hand hole plate into the boiler 13 Repla...

Страница 22: ...ower fixture Be careful not to break the sight glass when removing 7 Assemble the new sight glass as shown ALWAYS replace the gaskets and brass washers when installing a new sight glass 8 Slide the new glass into the upper fixture Glass should clear the lower fixture and tilt into position 9 Slide the sight glass down into the lower fixture Equalize the gap between the upper and lower fixtures 10 ...

Страница 23: ... or float arm 10 Check the float for any holes Hold the float submerged in a bucket of water and look for any air bubbles coming from the float 11 Always reassemble the McDonnell Miller operating mechanism to the body with a new gasket 12 Reinstall the eight bolts to the operating mechanism Draw up the bolts evenly to prevent damage to the gasket body or operating mechanism Do not over tighten the...

Страница 24: ...screws on top of the probe enclosure with a Phillips screwdriver 3 Remove the wire from the probe using a 5 16 wrench or a crescent wrench Only the wire on the probe is to be removed 4 Use a 13 16 spark plug socket and remove the probe 5 Clean the stainless steel probe and probe fitting 6 Reinsert the probe using a 13 16 spark plug socket Only tighten the probe enough to stop any steam leaks Over ...

Страница 25: ... If the McDonnell Miller does not shut down the boiler the auxiliary low water cut off will shut down the boiler 10 If the boiler has optional controls refer to the wiring diagram B Basic Service Tools The following basic equipment will aid in troubleshooting Lattner boilers Not all equipment is needed for every repair 1 Schematic diagram of the boiler 2 Volt ohm meter 3 Ammeter 4 Gas pressure gau...

Страница 26: ...up inside of boiler 3 Operating pressure switch Honeywell Controller is not operating correctly Boiler shuts down on auxiliary low water cut off 1 Pump switch is turned OFF 2 Probe wired incorrectly 3 Probe has scale dirt or debris on it 4 Probe not seated in probe socket properly 5 Auxiliary level control relay wired incorrectly 6 Foaming problem in boiler possible chemical over treatment 7 Water...

Страница 27: ...ge readings If sufficient check gas pressure an air damper setting Check electrodes setting If flame rod pilot flame rod may have to be re positioned 2 Check ignition cable and electrode porcelain for damage or breaks which could cause short 3 Check for loose or broken wires Burner will not start even though burner has never failed before or has been running on normal cycle without failure 1 Opera...

Страница 28: ...for which the Purchaser may be liable to other persons or damages to property The remedies set forth in this Warranty are exclusive and the liability of Lattner with respect to any contract or sale shall not exceed the cost of repair or replacement of the boiler or other equipment manufactured by Lattner The above Warranty shall not apply to any boiler or other equipment manufactured by Lattner wh...

Страница 29: ...ges in transit and a minimum 15 restocking charge and only if the authorized material is in new and unused condition and returned within one year from original date of shipment The credit will be based on the original invoice price or the current price whichever is lower less the applicable restocking charge SECURITY INTEREST For the purposes of securing payment the Company may issue a lien on the...

Страница 30: ...gasket is in place make one last cleaning swipe of the mating surface in the boiler Use a rag wrapped around your finger 4 Set crab then center plate in opening and tighten nut enough to give a snug fit Then snug up with 1 4 turn of wrench SPECIAL NOTES If gasket leaks while pressure is being built up tighten only enough to stop leakage Never over compress a gasket Gaskets on the bottom of a boile...

Страница 31: ...ase vacuum pressure in the boiler would suck the cover plate in and allow the water to leak out of the boiler Re using gaskets after they have been in service is not recommended Topog E Bolt Gaskets when required should be used with Topog E Handhole Gaskets Topog E Gaskets are sold for use in steam water air and other selected applications only Recommendations for use of Topog E Gaskets are based ...

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Страница 46: ...ternal threads To do so may cause the sealing compound to enter the valve and cause seat leakage Do not use the valve body or bonnet for installing the valve in threaded connections Use the wrench flats provided to tighten the valve to the connecting pipe and do not overtighten To do so may cause valve leakage 4 For flanged valves use new gaskets and tighten the mounting studs evenly Operation 1 M...

Страница 47: ...ressure is more than 10 times desired outlet pressure EMERGENCY EXPOSURE LIMITS Maxitrol Tested RV52 RV53 3 psi 210 mbar RV61 RV81 RV91 RV111 5 psi 350 mbar RV131 15 psi 1050 mbar GAS CONTAINMENT EXPOSURE LIMITS RV 52 RV53 15 psi 1050 mbar RV61 RV81 RV91 RV111 RV131 25 psi 1750 mbar Please note that internal damage may occur when exposed to these pressures AMBIENT TEMPERATURE LIMITS RV52 RV53 RV61...

Страница 48: ...agm material is cut from the finest synthetic coated fabrics available All other parts are carefully specified corrosion resistant or plated material Pipe sizes of 1 2 3 4 1 1 1 4 1 1 2 2 2 1 2 3 and 4 are available Models through the 3 size are threaded the 4 RV131 is flanged At the emergency exposure limits there may be no regulation but all models will contain gas They will suffer no internal d...

Страница 49: ...w rate of 21 172 CFH the pressure drop is 2 w c 3 Multiply this by two to obtain recommended differential pressure 4 w c 4 Subtract 4 differential pressure from 10 w c inlet pressure to obtain maximum recommended outlet pressure setting of 6 w c Pressure Drop Chart Model Number and Pipe Size A G A MAX Pressure DropÑinches w c mbar 0 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 1 2 3 4 RV52 1 2 x 1 2 3 4 x 3 ...

Страница 50: ... 4 8 122 6 4 164 4 4 111 5 4 138 1 6 41 RV81 3 8 NPT 6 4 162 8 4 213 6 153 7 178 2 51 RV91 2 pipe 1 2 NPT 8 5 216 10 8 275 6 5 165 9 1 232 2 3 60 RV91 2 5 pipe 1 4 NPT 8 3 212 10 5 267 7 1 181 9 1 232 2 4 62 RV111 3 4 NPT 11 5 284 15 1 373 9 229 13 4 324 3 5 89 RV131 3 4 NPT 18 2 462 23 25 590 13 9 353 18 458 5 1 129 Model Number A G A Certified Springs Other Springs Available RV52 3 to 6 7 5 15 4...

Страница 51: ...ar fugas o afectar el funcionamiento del regulador Si usted sospecha que un regulador Maxitrol ha sido expuesto a más del doble de la presión máxima de entrada como se muestra en la tabla siguiente cierre el paso del gas y haga que el sistema sea verificado por un experto SAFETY WARNING INSTRUCTIONS FOR MAXITROL GAS PRESSURE REGULATORS NOTE GAS PRESSURE REGULATORS WILL NOT TURN OFF THE FLOW OF GAS...

Страница 52: ...sed within the temperature range and not in excess of the maximum inlet pressure shown in the following table and should be in the mounting position indicated Maxitrol regulators can be used with all fuel gases 10 In case of any doubt please contact the Service Manager Maxitrol Company Southfield MI USA Phone 248 356 1400 Mounting Position Posición de Montaje D C A B B Vertical Flow Flujo Vertical...

Страница 53: ...operating controls installed on the boiler After installation check for proper operation of all of the limit and operating controls before leaving the site We recommend that secondary redundant Low Water Cut Off controls be installed on all steam boilers with heat input greater than 400 000 BTU hour or operating above 15 psi of steam pressure At least two controls should be connected in series wit...

Страница 54: ...OFF PUMP ON 3 4 DIFFERENTIAL 19mm PUMP OFF BURNER OFF NORMAL BOILER WATER LINE 113 16 DIFFERENTIAL 46mm BURNER CUT OFF LEVEL 3 8 9 5mm BELOW CAST LINE OPERATION Maximum Pressure 150 psi 10 5 kg cm2 Electrical Ratings Settings and Differential Pressures Values are 8 3 2mm Series 150 150S 157 and 157S 150 psi 10 5 kg cm2 Levels 150 psi 10 5 kg cm2 Levels 0 psi 0 kg cm2 150 psi 10 5 kg cm2 Approximat...

Страница 55: ...g will occur at slightly different levels than indicated above Model 158 158S 150 psi 10 5 kg cm2 Levels 0 psi 0 kg cm2 150 psi 10 5 kg cm2 Pressure Settings and Differential Pressures continued 150 psi 10 5 kg cm2 MOTORIZED VALVE OPEN CLOSED 3 4 DIFFERENTIAL 19mm MOTORIZED VALVE CLOSED BURNER OFF NORMAL BOILER WATER LINE 113 16 DIFFERENTIAL 46mm BURNER CUT OFF LEVEL 3 8 9 5mm BELOW CAST LINE Appr...

Страница 56: ...FFERENTIAL 35mm Values are 8 3 2mm 150 psi 10 5 kg cm2 Levels Approximate Distance Above Cast Line Differential Setting In mm In mm Pump 1 Off 15 16 24 5 16 8 Pump 1 On 5 8 16 Pump 2 Off 5 8 16 3 8 16 Pump 2 On 1 4 6 4 Pump 1 Off 13 8 41 3 4 19 Pump 1 On 5 8 16 Pump 2 Off 7 8 22 7 8 22 Pump 2 On 0 0 Model 159 159S 0 psi 0 kg cm2 150 psi 10 5 kg cm2 Pressure Settings and Differential Pressures cont...

Страница 57: ...f STEP 1 Determine the Elevation at Which the Low Water Cut Off Pump Controller Must be Installed INSTALLATION TOOLS NEEDED Two 2 pipe wrenches one 1 flathead screw driver and pipe sealing compound IMPORTANT Follow the boiler manufacturer s instructions along with all applicable codes and ordinances for piping blow down valve and water gauge glass requirements 13 8 STEAM EQUALIZING PIPE VERTICAL E...

Страница 58: ...ve G directly below the lower cross of the water equalizing pipe F Note 1 NPT tappings are provided with the exception of some 157 and 157S mod els which are 14 NPT b For Models 150 B and 150S B and Series 157 and 157S For all other models proceed to Step 3 Screw the w NPT steel plug C provided in tapping A Series 157 and 157S Models 150 B and 150S B STEP 3 Installing a Water Gauge Glass Required ...

Страница 59: ...uld cause damage to the boiler and or boiler system Failure to follow this warning could cause electrical shock an explosion and or a fire which could result in property damage personal injury or death WARNING Switch Operation For all Models except 158 158S and 159 159S For Models 158 and 158S Boiler feed pump off burner on alarm off Boiler feed pump on burner on alarm off Boiler feed pump on burn...

Страница 60: ...T OFF AND ALARM SWITCH ALARM CIRCUIT TERMINALS LOW WATER CUT OFF TERMINALS L PUMP SWITCH PUMP CIRCUIT TERMINALS LOW WATER CUT OFF AND ALARM SWITCH ALARM CIRCUIT TERMINALS LOW WATER CUT OFF TERMINALS L IMPORTANT There must be a minimum space of 1 2 13mm between connector fittings and electrical live metal parts Automatic Reset All models except 158S and 159S Automatic Reset Model 158S Manual Reset ...

Страница 61: ...he burner circuit exceeds the switch s electrical rating 2 Pilot Switch To holding coil of a starter when the pump circuit exceeds the switch s electrical rating LINE LOAD 1 2 4 5 6 LINE LOAD 1 2 4 5 6 1 2 4 5 6 ALARM NEUTRAL HOT ALARM NEUTRAL HOT 1 2 4 5 6 1 2 4 5 6 SEE PUMP CONTROL CIRCUIT TO NEUTRAL TO BURNER CONTROL CIRCUIT HOT ALARM 1 2 4 5 6 LOAD LINE 3 PHASE SEE PUMP CONTROL CIRCUIT ALARM 1...

Страница 62: ...a boiler not being fired and or not at pressure Actual operating ranges are shown on page 2 in the Operation section If the burner comes on immediately turn the boiler off and make the necessary corrections Failure to follow this warning could cause an explosion or fire and result in property damage personal injury or death WARNING 7 8 M J 22mm b The boiler should begin to fill with water Watch th...

Страница 63: ...he water level reaches approximately d 22mm above the horizontal cast line press the reset button N The burner should then come on d Continue watching the gauge glass J to see that the water continues to rise to approximately 1a 35mm 17 16 37mm for MD models above the horizontal cast line M The pump should shut off the motorized valve should close with Models 158 and 158S or with Models 159 and 15...

Страница 64: ...epair Procedure provided Snap switches must be replaced as an assembly CAUTION Replacement Switch Assembly Replacement Mercury Tubes 2 Wire Pump 3 Wire Burner NOTE More frequent blow down may be necessary due to dirty boiler water and or local codes BLOW DOWN PROCEDURE Blow down the control when the water in the boiler is at its normal level and the burner is on Slowly open the upper then the lowe...

Страница 65: ...g level Listings U L limit control recognition 353 240 and 208 volt units are not U L limit control recognized Installation 1 Install octal socket in appropriate enclosure using two 6 or 8 metal screws 1A Install rail mount socket on appropriate rail DIN mount in appropriate enclosure if applicable 2 Wire control per wiring diagram following N E C and local codes 3 Install control module in socket...

Страница 66: ...power However loss of liquid will cause control to de ener gize and remain so until liquid again rises to electrode and pushbutton is depressed Dirty Electrode Detection The LED will flash every half second once the probe resistance reaches a value greater than the nominal control sensitivity rating The relay state will not change until it exceeds the nominal sensitivity by more than 25 typically ...

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