Here’s a practical, step-by-step way to search for issues, like a technician would do in the field.

1️⃣ Start with safety (always first)

Before touching anything:

• Shut off gas supply if abnormal smell or flame

• Lockout / tagout power and gas

• Ventilate the area well

• Never bypass safety interlocks

If safety devices are tripping, that’s already a big clue, not an inconvenience.

2️⃣ Observe the burner behavior

Careful observation saves time. Ask:

• ❌ No ignition?

• 🔥 Ignition but flame goes out?

• 🔁 Frequent shutdown?

• 🔥 Flame unstable, yellow, noisy, or lifting?

• 📉 Low heat output?

• ⛔ Alarm or fault code on controller?

Write down exactly what happens and when (startup, full load, shutdown).

3️⃣ Check gas supply system

Most burner problems start here.

Gas pressure

• Measure inlet pressure (before regulator)

• Measure outlet pressure (after regulator)

• Compare with burner nameplate specs

Common problems:

• Low pressure → weak flame / no ignition

• High pressure → flame instability / safety trip

• Pressure fluctuation → burner hunting

Gas components

Check:

• Gas filter → clogged?

• Solenoid valves → opening fully?

• Regulator → creeping or unstable?

• Manual valves → fully open?

👉 Dirty gas filters cause more burner problems than people expect.

4️⃣ Inspect ignition system

If burner fails to light or loses flame quickly:

Ignition parts

• Ignition electrode → cracked, dirty, wrong gap

• Ignition cable → loose or damaged

• Ignition transformer → weak spark

Flame detection

• Flame rod / UV sensor → dirty or misaligned

• Grounding → poor grounding causes false flame failure

• Controller flame signal → check μA value if available

⚠️ Many “burner failures” are actually flame detection problems, not combustion issues.

5️⃣ Examine air supply & combustion

Air problems = bad flame.

Air system

• Blower motor running correctly?

• Air damper position correct?

• Air pressure switch functioning?

• Intake blocked by dust or insects?

Flame appearance (very important)

• 🔵 Blue, stable flame → good

• 🟡 Yellow flame → insufficient air

• 🔥 Flame lifting → too much air or high gas pressure

• 💥 Pulsating / noisy → poor air-gas ratio

6️⃣ Check burner controller & interlocks

Modern burners rely heavily on controls.

Verify:

• Correct startup sequence

• No skipped steps (pre-purge, ignition time)

• Limit switches (high temp, pressure, airflow)

• Fault history in controller (if available)

Resetting without understanding = problem will return.

7️⃣ Inspect mechanical parts

• Burner head → carbon buildup?

• Nozzle → blocked or worn?

• Mixing tube → damaged?

• Seals → air leakage?

Mechanical wear slowly causes efficiency loss, not sudden failure.

8️⃣ Test under real operating load

Some problems appear only at:

• High fire

• Low fire

• Modulating transition

Check:

• Gas pressure stability

• Flame signal strength

• Temperature response

• Noise and vibration

9️⃣ Common symptoms → quick diagnosis

🔧 Pro tip

Always troubleshoot in this order:
Gas → Air → Ignition → Flame detection → Control

Random checking wastes time.

Phone: 86 185 6630 3837
WhatsApp: 86 185 66303837
Email: ekelairn@gmail.com
Web: http://www.ekgas.com