Thermal Solutions Pilot Flame Failure

Ross_7

Check your gas pressure on high & low firing, and check it while there are any other gas appliances in the building running simultaneously. Make it sure the gas pressure remains within the manufacturer's recommendations. I had some Raypak ADB-750's a few years ago, that had intermittent flame lockouts like yours. What is your flame signal? Just a few suggestions. Good luck!

Mijola

Thermal Solutions Pilot Flame Failure

I have a Thermal Solutions 500K modulating boiler that locks out on flame failure (code 28) daily. The boiler will run fine during the day, then needs to be manually reset in the morning, after locking out sometime during the night. After the factory technician was on site for 2 days, the boiler ran fine for 12 days, but then the problem started again. Has anybody out there experienced this same problem, and what was done to fix this?

c.t.kay

thermal solutions "upgraded" the pilot assembly. they are presently looking into this type of problem,i have two 1.5m units,low pressure gas trains nyc con ed,4"-5" gas pressure,full modulation etc.we have had pilot & main flame issues. but first check in coming gas pressures

Unknown

Is the pilot using

a solenoid valve? If so we have been having some problems with solenoids not opening fully or chattering when opening causing flame shut down.

Canadasteam

Thermal Solutions pilot problems

Greetings, the pilot of the thermal solutions size 500 did have a tendency to make carbon from too rich a gas mixture right on the tip of the spark rod. The spark would fail due to this condition. The recommended gas input pressure should not be lowered but the mix air orifice hole located within the last elbow must be inspected for burrs or obstructions etc. This orifice hole is drilled into a 1/4"-20 grub type steel screw and can be removed for maintenance. Also, the spark rod will produce a string of carbon if it is located any less than 1/8" away from the pilot tube wall. You must now inspect the burner air filter on the fan. A dirty filter will decrease the amount of air available for the pilot mix. Annual cleaning of the pilot assembly is described in the OEM booklet supplied with the boiler. The on/off firing boilers` UV scanner has a tendency to over heat at times. The scanner should be protected by an insulating fibre block mounted below the scanner attaching nut, if its not there you can get one from your local thermal solutions agent the component is called a "heat block" and the part number is 8026217, or contact Thermal Solutions in Lancaster PA.
Good luck

Canadasteam

Thermal solutions

Hi CT look carefully at the possibility of heat getting to the scanner of the burner, they do have a tendency to over heat.

Good luck

Joyce Vino, Tech for Thermal Solutions

pilot failure #28

Check your air tubing connections coming off the blower motor. There is a 3 way split in the tubing. Take off the connections and check for pipe dope. Clean it out.
Check flame signal during 1st 5 seconds of pilot ignition, if 0vdc, no spark is present. Check ignition transformer and ignition cable, check ignition electrode for cracks in ceramic, remove pilot assembly and check for carbon build up. if present, clean carbon. check & tighten pilot assembly ground wire.
If 5 vdc for 5 seconds then drops to 0 vdc for 6 thru 10 seconds, spark is present but not gas.check sol valve and adjust gas pressure to match fire test. Remove and clean gas orifice (set screw with hole drilled in it) if needed, then replace orifice.

I did have one job that the exhaust piping was too close to the makeup air piping and the gas was blowing back down the inlet piping and making the unit run too rich. The inlet should have a gooseneck as to avoid that and be at least 18" from each other.

Thermal solutions offers free tech support. Anyone can call in for help Mon-friday 8:00 am to 5:00 pm. We are happy to help you with any problems you may be experiencing. 717-239-7642.