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START
BEFORE TROUBLESHOOTING,
FAMILIARIZE YOURSELF WITH
THE STARTUP AND
CHECKOUT PROCEDURES.
TURN GAS SUPPLY OFF,
TURN THERMOSTAT
(CONTROLLER) TO
"CALL FOR HEAT."
POWER TO
MODULE? (24 V
NOMINAL)
YES
SPARK
ACROSS
IGNITER/
SENSOR
GAP?
YES
TURN GAS SUPPLY
ON AND RECYCLE
"CALL FOR HEAT."
PILOT BURNER
LIGHTS?
YES
SPARK
STOPS WHEN
PILOT IS
LIT?
YES
MAIN BURNER
LIGHTS?
YES
SYSTEM
RUNS UNTIL "CALL
FOR HEAT"
ENDS?
YES
"CALL FOR HEAT" ENDS
SYSTEM
SHUTS
OFF?
YES
REPEAT PROCEDURE UNTIL
TROUBLE FREE OPERATION
IS OBTAINED.
Figure 8.1: Intermittent Ignition System Troubleshooting Sequence
INSTALLATION AND OPERATING INSTRUCTIONS
NOTE: "CALL FOR HEAT" 24 VAC SUPPLY IS CONNECTED TO THE 24 V TERMINAL ON THE CONTROL.
CHECK LINE VOLTAGE POWER, LOW VOLTAGE TRANSFORMER, LIMIT CONTROLLER, THERMOSTAT (CONTROLLER), AND WIRING ALSO.
NO
CHECK AIR PROVING SWITCH ON COMBUSTION AIR BLOWER SYSTEM (IF USED) AND THAT THE VENT DAMPER END SWITCH (IF USED)
IS MADE.
PULL IGNITION LEAD AND
NO
CHECK SPARK AT MODULE.
CHECK IGNITION CABLE, GROUND WIRING, CERAMIC INSULATOR, AND SPARK GAP ARE CORRECT.
CHECK BOOT OF THE IGNITION CABLE FOR SIGNS OF MELTING OR BUCKLING, TAKE PROTECTIVE ACTION TO SHIELD CABLE
AND BOOT FROM EXCESSIVE TEMPERATURES.
CHECK THAT ALL MANUAL GAS VALVES ARE OPEN, SUPPLY TUBING AND PRESSURES ARE GOOD, AND PILOT BURNER
ORIFICE IS NOT BLOCKED (PILOT GAS FLOWING).
CHECK ELECTRICAL CONNECTIONS BETWEEN MODULE AND PILOT OPERATOR ON GAS CONTROL.
NO
CHECK FOR 24 VAC ACROSS PV-MV/PV TERMINALS ON MODULE. IF VOLTAGE IS OKAY, REPLACE GAS CONTROL.
IF NOT, REPLACE MODULE.
NOTE: IT MAY BE NECESSARY TO RECYCLE THE 'CALL FOR HEAT" MORE THAN ONCE TO CLEAR THE PILOT SUPPLY TUBES OF AIR.
NOTE: IF CONTROL GOES INTO LOCKOUT OR RETRY DELAY, RESET THE "CALL FOR HEAT."
CHECK CONTINUITY OF IGNITION CABLE AND GROUND WIRE.
CLEAN FLAME ROD.
CHECK ELECTRICAL CONNECTIONS BETWEEN FLAME ROD AND MODULE.
NO
CHECK FOR CRACKED CERAMIC FLAME ROD INSULATOR.
CHECK THAT PILOT FLAME COVERS FLAME ROD AND IS STEADY AND BLUE.
ADJUST PILOT FLAME.
IF PROBLEM PERSISTS REPLACE MODULE.
CHECK FOR 24 VAC ACROSS PV-MV/PV TERMINALS ON MODULE. IF NO VOLTAGE, REPLACE MODULE.
NO
CHECK ELECTRICAL CONNECTIONS BETWEEN MODULE AND GAS CONTROL INCLUDING SAFETY CONTROLS WIRED IN THE CIRCUIT.
IF OKAY, REPLACE GAS CONTROL.
NOTE: IF CONTROL GOES INTO LOCKOUT OR RETRY DELAY, RESET THE "CALL FOR HEAT."
CHECK CONTINUITY OF IGNITION CABLE AND GROUND WIRE.
NOTE: IF GROUND IS POOR OR ERRATIC, SHUTDOWNS MAY OCCUR OCCASIONALLY EVEN THOUGH OPERATION IS NORMAL
AT THE TIME OF CHECKOUT.
NO
CHECK THAT PILOT FLAME COVERS FLAME ROD AND IS STEADY AND BLUE, PILOT FLAME MUST NOT BE MOVING AROUND DUE TO
OUTSIDE AIR FLOWS, ETC.
ADJUST PILOT FLAME. CHECK GAS PRESSURE MEETS APPLIANCE SPECIFICATIONS WHILE APPLIANCE MAIN BURNER ON AND ALL
OTHER GAS APPLIANCES ON THE SUPPLY ARE OPERATING AT FULL RATE.
IF CHECKS ARE OKAY, REPLACE MODULE.
CHECK FOR PROPER THERMOSTAT (CONTROLLER) OPERATION.
NO
REMOVE MV LEAD AT MODULE, IF VALVE CLOSES, RECHECK TEMPERATURE CONTROLLER AND WIRING. IF NOT, REPLACE
GAS CONTROL.
SPARK OK?
NO
REPLACE MODULE
YES
27
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