5-84 Troubleshooting – General Troubleshooting Tips
FlexFit – Linkageless Control – Revision 1.0
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UTILITIES MFG CORPORATION
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General Troubleshooting Tips
As Murphy's Law would predict, burner control system issues usually happen at the worst possible time. Therefore, it's wise to
be prepared with a troubleshooting plan. Often, we are quick to jump directly into xing a problem when, in fact, it would benet us
to be methodical with our process.
As you begin troubleshooting, it may feel that it takes more time to go through a full process. But, in the end, it will save time
and money, when you are able to x it right the rst time, with as few trips to the job site as possible. If troubleshooting becomes too
frustrating, ask for help. Sometimes bringing in a fresh set of eyes can quickly uncover what you have been missing. Even if your
objective is to pull in an outside resource, following your own troubleshooting plan will speed the process because you will be able
to provide the detailed information to those you contract to help. You may use the tips below or follow your own troubleshooting
plan. Many of these steps can be performed at the same time or might only take a few minutes, but by methodically approaching
troubleshooting, it could save many hours and thousands of dollars.
1.
WARNING
Do not jumper any inputs connected to eld devices or attempt to bypass any
safety switches, controls, or parameters. Doing so may cause an unsafe con-
dition that could result in equipment damage, personal injury, or death.
Gather Information – The rst step of any burner control system troubleshooting exercise involves gathering as much
information about the problem as possible. Instead of immediately diving in and attempting the rst thing to come to mind
to get the equipment running, rst step back and determine how the equipment is supposed to operate, what technical
documentation is available, and if there is someone familiar with this or similar equipment who may have experienced
this same issue.
• Talk with the operator or rst person to notice a problem. Get as much information from them while it is fresh in their
mind. Take pictures!
• Gather as much information as possible about what was going on at the time of the problem. Try to be as specic
and dened as possible in stating the problem that is occurring. What was the operating state at the time of the fault?
Was maintenance being performed? Did something unusual happen for the rst time in a long time?
• If there was a lockout, you can see a list of lockout messages by going to Main Menu > Lockout Data. The current
FlexFit I/O can be viewed by going to Main Menu > Utilities > I/O Data Display.
2. Understand the malfunction and the role the malfunctioning equipment plays within the entire process. When you under-
stand how the equipment and process is supposed to work, you can understand what part of it is not functioning correctly.
Always check to ensure equipment is lined up for normal operation, i.e., On/Off switch, mode selection switch, etc.
• Analyze the performance of the equipment to make sure it truly has a failure and is not simply reacting to an external
condition. Determine if the trouble has slowly developed (i.e., drift) or if it is a sudden failure.
• Document everything. You may need to turn the information over to another technician to nish xing the problem.
You may see this problem again, and documentation will help you x it faster next time. You may forget what the
exact symptoms were; don't rely on your memory.
3. Narrow down possible faulty functions based on the information gathered above. Identify what can be measured so that
you can identify items that are outside the acceptable range. For example, are there voltage readings or temperature
readings that would help you evaluate the source of the problem?
• Review previous documentation. Have you seen this problem before? What worked last time? Is this a recurring
problem that might indicate a more serious problem?
• Look at available manuals, owcharts, diagrams, P&IDs, and schematics.
• Be sure to include functions such as detectors, switches, cables, meters, wiring, connectors, piping, lters, and
regulators. Wiring is always a probable cause!
• Do not get locked in on what a technician "knows" the trouble to be. Past troubleshooting experience and hunches
certainly play a part in guring out what is the faulty function. However, do not ignore hard evidence just because
one assumes trouble is known prior to proper troubleshooting steps.
4. Identify the source of the problem using available data and analytical tools to isolate the defective component. This could
involve isolating components and evaluating their parameters
• Do not be discouraged if several hours of troubleshooting reveal that a function is good. Proving a function is operating
properly is important to the troubleshooting effort because it narrows down the possibilities of where the problem is
located. The rst function you choose to check out often will not be the faulty one.
• Sometimes a quick x can narrow down the fault to the real problem. If something can be rapidly accomplished, they
are worth doing (i.e. replace a fuse, installing a loaner controller, etc.). If it xes the problem, much time is saved.
If it doesn't x the problem, then only a moment is lost and information about certain parts of the system is gained.
Note
Documentation is vital to
successful troubleshoot-
ing. Many troubleshooting
efforts break down due
to insufcient information
or loss of key indications
at the time of failure.
Write everything down,
take pictures, and
check everything.
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