Issued April 2010 TW 5-137.

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Printed in U.S.A. Page 1 of 4

TROUBLESHOOTING
VAPOR POWER CIRCULATIC III STEAM GENERATOR
DELTA P DRUM LEVEL CONTROLS
1. GENERAL

1.1 Your unit is equipped with a microprocessor based, linkageless burner control (flame
safeguard) that provides for the functions of burner sequencing, flame supervision, system
status indication, system or self-diagnostics and troubleshooting. This burner control uses a
remote display mounted beside the touch panel on the enclosure door, and is referred to as
the AZL display. This burner control is coupled to a PLC / touch screen combination that
controls all of the non-safety related functions of the steam generator. All safety related code
devices are hard wired to the flame safeguard so that the PLC cannot impede a safety
shutdown even if the PLC were to completely malfunction. An Annunciation & Alarm Screen
further details causes of alarms, and indicators are provided on most screens of the Touch
Panel that detail critical steam generator functions.

1.2 Should you encounter problems in the operation of your steam generator, consult the message
displayed on the AZL display. This message details which component of the system caused
the steam generator to cease operating. If the AZL display says “safety loop open” the alarm
can be silenced, and the Annunciation & Alarm Screen can be viewed to see exactly which
piece of the safety loop opened to cause the Alarm.

Note: When the RESET ALL button is pressed, the annunciation screen will also
be cleared, deleting any information that may have been provided about the safety
loop. If an alarm occurs involving the safety loop, it is recommended that the
alarm be silenced and the annunciation & alarm screen be viewed before the
RESET ALL button is pressed.

After the condition that caused the alarm has been diagnosed and corrected, The RESET ALL
button can be pressed and the steam generator will again go though its light off sequence if a
call for heat is present.

1.3 When troubleshooting, refer to the wiring schematic diagram and piping schematic diagram
located in another section of the instruction manual. Other informational bulletins are also
included for the further troubleshooting of components in question.

1.4 Malfunctions could occur that are beyond the diagnostic ability of the burner control system and
the annunciation & alarm screen. This procedure lists these malfunctions as well and their
effect on the operation of the steam generator. In case of a malfunction refer to the portion of
this guide that fits your operational problem. Here you will find probable causes and
suggestions to remedy the trouble. If the suggested remedies do not work, look for a loose or
broken connection in the control system.

1.5 A well-planned and followed preventive maintenance schedule will prevent many malfunctions
from occurring. See the preventive maintenance section of your instruction manual.

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2. UNIT WILL NOT START

Problem Probable Cause Remedy

Touch Panel and Blown control transformer fuses Replace
AZL Display do Main (drive) power not turned on to steam generator Turn on main power
not power up
Defective control transformer Replace
when circuit
breaker is in on Defective circuit breaker Replace
position. Loose wires Trace down & tighten

Touch Panel and Customer supplied Emergency Stop not jumpered Install, or jumper correct
AZL Display or installed. terminals in the panel
power up, but
drive motors will Motor starter protectors tripped Reset MSP in lower panel
not start.
PLC hard switched into STOP mode. Switch PLC to RUN mode
make sure steam generator
The burner Water is not in contact with the low water probe. drum is filled appropriately
switch is set to Defective low water probe or control. Replace probe or control
FIRE, but Steam Steam generator in remote mode (if so equipped) Place in local mode
generator will not
Make sure all Air and Oil
start the firing
Insufficient Oil or Atomizing Air pressure (if firing oil) supply valves are open
sequence.
Raise setpoint or lower
Steam pressure above setpoint pressure in drum

3. UNIT WILL NOT LIGHT

Problem Probable Cause Remedy

Spark exists, but pilot
flame will not ignite.
Pilot flame ignites and
main fuel valves open but
main flame will not ignite
Pilot shutoff cock closed Open shutoff cock
Pilot gas pressure regulator set Increase or decrease
incorrectly pressure regulator setting
Insure proper gas supply to
Insufficient gas supply to pilot regulator pilot regulator
Pilot solenoid valve defective Replace
Air damper open too far Adjust using AZL display
Air in gas line supplying pilot regulator Purge line of air
Main fuel cock shut. Open
Gas throttling valve not open far enough Adjust using AZL display
Oil metering valve not open far enough Adjust using AZL display
Air in gas / oil line Purge gas or oil line of air.

4. WATER SUPPLY PROBLEMS

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 Problem Probable Cause Remedy
Verify that delta P transmitter reference
leg is full of water Remove plug and fill
The electric feedwater Correct wiring, flip + and –
control valve will not close, Valve actuator motor wired incorrectly (4-20mA)
even when the steam Power disrupted to electric feedwater Restore power to the valve
generator drum is entirely valve actuator.
full of water.
Disassemble valve from
Valve / actuator jammed actuator, verify free rotation
Valve actuator motor defective Replace
Correct wiring, flip + and –
Valve actuator motor wired incorrectly (4-20mA)
Power disrupted to electric feedwater Restore power to the valve
The steam generator will valve actuator.
not fill with feedwater. Disassemble valve from
Valve / actuator jammed actuator, verify free rotation
Valve actuator motor defective Replace
Valves to sightglass closed Open Valves
Increase size of feedwater
The steam generator Inadequate feedwater pressure or flow pumps
consistently shuts off on
low water level, especially Disassemble valve from
when at high fire. Feedwater valve not opening entirely actuator, verify free rotation
Valve actuator motor defective Replace

5. OTHER COMMON PROBLEMS

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 Problem Probable Cause Remedy
Equalizing valve on the transmitter has Close the valve and re-
Drum Level Controller does
been opened. calibrate the transmitter
not accurately read the
water level. Transmitter reference leg is not full of
water Remove plug, fill tubing leg
An indicated temperature
(coil or stack) is very high
even when the steam Inspect TC wiring and TC
generator is not firing. Red Thermocouple wire is off terminal, or connections. Replace or
light blinking on PLC thermocouple is damaged or shorted reattach

Coils consistently overheat

at minimum fire or slightly
above minimum fire. V-belts on Circulation pump broken or
slipping (if so equipped) Tighten or replace V-belts
Steam generator
circulation pump and
blower run for more than
two hours after the burner Increase cool down
has been shut off. Cool down temperature set too low temperature (in PLC logic)

6. ANNUNCIATION

6.1 The AZL display has the ability to display hundreds of different messages as well as hundreds
of different error codes. The messages will tell the operator directly what has malfunctioned,
and the error codes can be found in a table back in the control equipment tab of this manual.

6.2 The Touch Panel’s Annunciation & Alarm Screen details the elements of the Safety loop, so that
the operator may get a direct diagnosis of what specific piece of the Safety loop caused the
alarm.

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