7.4.3 Student Book © 2005 Propane Education & Research Council Page 1

7.4.3

Identifying Systematic Troubleshooting Techniques

and Guidelines for Gas Operated Equipment

Throughout this training course the importance of applying systematic gas appliance troubleshooting techniques and principles has been stated in a number of ways. This final module in the course summarizes how those techniques are utilized. In this module, you will learn to:

1. Identify fundamental troubleshooting techniques

2. Identify system and sub-system troubleshooting flowcharts

3. Set and apply quality control measures

7.4.3 Student Book © 2005 Propane Education & Research Council Page 1

Identifying Fundamental troubleshooting techniques

Figure 1. System Logic Flowchart

The operating sequence illustrated in Figure 1, created to describe the operation of a hydronic heating system, could be used to describe the operation of a number of gas appliances that use intermittent spark ignition.

7.4.3 Student Book © 2005 Propane Education & Research Council Page 2

Logic flow charts are helpful tools for technicians, because they are reminders of how the equipment is designed to operate, and the steps in the operation that must be individually examined for proper operation.

As you work on equipment you will probably find yourself constructing your own visions of system logic flowcharts either consciously or not.

If your vision closely corresponds to the way the manufacturer designed the equipment, your troubleshooting will be simple, accurate and efficient.

7.4.3 Student Book © 2005 Propane Education & Research Council Pages 2 & 3

Identifying system and sub-system troubleshooting flowcharts

Figure 2. Ignition SystemTroubleshooting Flowchart

Using the flowchart is really easy.

If you determine that the there is no spark when the call for heat is given by the thermostat, the chart helps you follow a logical series of tests or observations that yield a “yes” or “no” answer to a troubleshooting question.

7.4.3 Student Book © 2005 Propane Education & Research Council Page 4

Setting and applying quality control measures

Technical excellence calls for application of consistently high standards and techniques. There are a number of checks that a good technician will make while servicing any gas appliance. Items to check will include:

• Are the burner (and pilot, if so equipped) orifices the proper drill size for the fuel and altitude?

• Is the gas valve listed on manufacturers’ recall lists? • Is the gas control valve the proper valve for the fuel? If it is a valve

that can be converted, is it properly converted to the fuel? • Is the gas supply pressure as specified for all operating conditions?

(At system lockup and at full flow with all gas appliances operating?) • Is the venting correct for the appliance and in good condition? • Are burners operating properly and producing a proper blue flame? • Are safety controls operating properly? • Is appliance piping, including sediment traps and manual shutoffs,

installed according to codes and your company’s basic safety procedures?

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Providing quality gas appliance service to your customers is challenging and important work.

Give it your best.

Always keeping the health, safety and comfort of customers in mind and applying constantly improving technical skills will result in personal and customer satisfaction.

7.4.3 Student Book © 2005 Propane Education & Research Council Pages 5 & 6

Time to See If You Got the Key Points of This Module…

• Complete the Review on page 5.

• See if you are ready for the Certification Exam by checking off the performance criteria on page 6.