Maintenance
5-12
750-382
CBT
The alert (or lockout) list will appear, showing date and time for each item. Pressing an individual item in the list
will display additional information. Diagnostic information available for lockouts includes annunciator status,
states of system inputs, and steam pressure at time of lockout.
The Falcon display touch-screen interface is a valuable tool to help identify and resolve conditions that prevent
normal and safe operation of the boiler. The focus of this section is to help the boiler operator utilize the Falcon
display interface to evaluate and correct conditions that can cause nuisance shutdowns and contribute to unsafe
operation of the boiler.
There are 3 levels of “alarm” conditions utilized by the Falcon controller: Lockout, Hold, and Alert. Lockouts and
Holds indicate interruptions in boiler operation, whether occurring as part of the normal operating sequence or
due to an abnormal condition. Lockouts always require a manual reset to resume operation, while Holds will
automatically resume when the hold condition is removed or satisfied. Alerts indicate conditions or events
which, while not preventing normal boiler operation, may be of interest in evaluating boiler operating conditions.
Alerts require no operator acknowledgment and are for informational purposes only.
A Lockout will result in boiler shut down and always requires a manual reset of the Falcon controller. In certain
cases, a lockout may also require a manual reset of a safety control interlock device connected to the Falcon.
These include the auxiliary low water cut-off, high limit control, and gas pressure limit controls. Typically, a
safety interlock can only be reset when the condition that caused the lockout has been corrected (i.e. water level
returns to normal allowing the auxiliary low water cut-off to be reset).
Lockouts, Holds, and Alerts will often provide clues to the cause of the interruption or abnormal condition that
generated the message. However, sometimes these messages can be misleading and may not point directly to
the actual cause of the condition. A careful reading of this chapter, the rest of the manual, and the boiler specific
wiring diagram will help in resolving boiler interruptions and abnormal conditions.
The key to diagnosing recurring nuisance interruptions is to identify the underlying cause of the condition that led
to the interruption. Once the underlying cause is identified a permanent solution can implemented. Too often,
safety controls are reset without proper analysis of the operating condition that caused the boiler operation inter-
ruption. If not adequately addressed, the interruptions tend to be repeated with increasing frequency resulting in
down time and increased maintenance. Merely resetting a safety control device does not resolve the cause of the
condition that led to the lockout!
The following chart takes a methodical approach to diagnosing abnormal boiler operating conditions. This
approach begins with the “Problem” as identified by the operator. The 2nd column indicates displayed messages
(“Display Message”) by the Falcon display interface that will generally provide clues to the cause of the problem.
The 3rd column lists “Possible Causes” and/or related “Symptoms” associated with the “Problem” and “Dis-
played Message”. The 4th column recommends a “Diagnostic Check” that should be investigated for a potential
cause or system. The last column provides recommendation for “Corrective Measures” to resolve the problem
and return to normal operation.
This chart includes the most common conditions and resolutions for successful ClearFire boiler operation. It does
not include all possible lockouts and alerts. The Falcon controller appendix has a comprehensive list of lockouts,
holds, and alerts. The boiler operator can use this format and method to diagnose other conditions that may not
be included here.
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