Boiler Programming Controls

Learning Outcome
When you complete this module you will be able to:
Describe the operation of programming controls and discuss the proper testing
and maintenance procedures.

Learning Objectives
Here is what you will be able to do when you complete each objective:
1. Describe the operation of equipment that is used to automatically start-up and
shut-down boilers.
2. Interpret operating sequence bar graphs and provide a typical sequence of
start-up and shut-down events.
3. Apply a boiler start-up and shut-down programmer troubleshooting guide.

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INTRODUCTION
Boiler combustion control is of two types: on-off (or multi-range) and
modulating. On-off control is common in small packaged boilers, especially those
used in building heating systems.
In on-off and multi-range control the fuel and air for combustion are either
flowing at full rate (or in multi-range at one of several set rates, such as low,
medium or high) or completely shut off. Thus, each time the boiler starts up, it has
to go through the standard checks associated with a safe start-up procedure. The
start-up programmer is the device that coordinates these checks and the ignition
sequence.
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PROGRAMMING CONTROLS
Boilers, equipped with interrupted pilots or with direct spark ignition, require
controls that will provide proper order of operation, or sequencing of combustion
controls, during start-up or shutdown. Such a control system must also insure that
proper operating conditions, such as water level, fuel pressure, etc., exist for safe
boiler operation.

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Programmed Start-Up of Boilers with Natural Draft

A common type of controller or programming relay system used on gas- and oilfired heating boilers with either natural or forced draft, is illustrated in Fig. 1.

Figure 1
Programming Control

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When used on gas-fired boilers with natural draft, the operation of this control
system is as follows:
1. The operating control initiates a start-up and closes the switch.
2. The load relay of the programming control closes its electrical contacts and
energizes the ignition transformer and pilot gas valve to light the pilot flame.
3. When the pilot flame is established, the flame detector senses the flame and
causes the programming control to close the electrical circuit to the main gas
valve.
4. The main gas valve opens and the burner is ignited by the pilot flame.
5. When the main flame is established by the pilot flame, the ignition
transformer and pilot gas valve are de-energized and closed, if an interrupted
pilot is used.
The programming control will keep the main burner in operation until the desired
preset operating steam pressure or water temperature is reached. At this time, the
operating control will open the switch causing the load and flame relay of the
programming control to also open and close the main fuel valve. The
programming control system is now ready to be started again when the boiler
steam pressure or water temperature drops to the lower desired value. The
operating control may be similar to the on-off controller with a glass tube mercury
switch described in a previous module.
Sometimes during start-up, the pilot burner may fail to ignite; or if the pilot does
go on, the gas burner may fail to ignite. In either case, a lockout switch will be
energized after a short trial period of 15 to 30 seconds from the time of start-up.
This switch will open the electrical circuit to the ignitor, pilot, and main gas valve
so the start-up sequence will be stopped until the operator resets the control by
pushing the reset button. Some control systems may permit a second attempt to
light the pilot and main burner after a false start before the control has to be reset.
The control must also be reset if the main burner should fail.

Programmed Start-Up of Oil-Fired Boiler With No Pilot

1. The operating control will close a switch when the boiler pressure or water
temperature drops to a preset desired value.
2. The load relay of the programming control will close its electrical contacts.
This energizes the ignition transformer, fuel oil shut-off valve, and motor
driving the air fan or blower and fuel pump.
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3. The spark from the ignition transformer ignites the main burner.
4. The flame detector (photocell) senses the flame and causes the flame relay to
close.
5. The ignition transformer is then de-energized.
In case of ignition failure during boiler start-up or main burner failure during
operation, the control will lock out. The operator must correct the problem and
reset the control before the ignition sequence can start again.

Programmed Control Sequence of Automatic Boilers

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A fully automatic packaged firetube heating boiler has a highly sophisticated

programming control which includes one or more timers and several relays. This
control serves two primary functions:
1. It programs the operation of the forced draft fan or blower, ignition system,
fuel valves, and control system in a proper sequence. This includes a suitable
purge period before ignition and after burner shut down.

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2. It monitors both the pilot and main flames, and does not allow the electrical
circuit to the main fuel valve to be energized unless the pilot flame has been
established and proven. It also de-energizes the electrical circuit to the fuel
valve within 1 to 4 seconds upon loss of flame.
The programming control also includes safety features related to boiler
start-up. If any part of the starting sequence is not properly completed, it
terminates the start-up sequence and purges the furnace.
Purging a furnace means forcing a flow of air through a furnace for a set period of
time when the burner is not in operation. The purpose of purging is to remove any
combustible gases that may have collected in the furnace while the burner is not
in operation, and which could cause a furnace explosion when the pilot is lit
again.
Programming controls used on packaged firetube boilers will vary in their
operation, especially in the timing of the programming sequence as different types
of burners, methods of ignition, and operating controls may be used. The principle
of operation for each of these controls, however, is very similar.

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Since it is impossible to give a detailed description of the operation of every type

of programming control used on heating boilers, only a general description of
operation of a typical programming control will be described. Any person who
requires specific information about a particular boiler should consult the
manufacturers operations manual supplied with the boiler.
A careful study of the electrical diagram of a burner circuit shown in Fig. 2 is
necessary in order to understand the general operating principles of a
programming control system.

Figure 2
Basic Packaged Boiler Control Circuit
This diagram shows how the various components of the combustion equipment
for a gas-fired boiler are controlled by the programmer. Before describing the
actual operation, the following points should be observed:
1. The operation of the timer motor is controlled by the master relay through
contacts A and B.
2. The timer motor operates the T switches by means of cams located on its
shaft.
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3. The flame failure relay in the control circuit of the main fuel valve is closed
only when the scanner sights the flame of either the pilot or the main burner.
4. All the operating and limit switches (1-6) are placed in series. Power is
supplied to the master relay and switches T2, T3, and T4 only when all the
limit switches are closed.

1.

Start-Up Conditions

Before a steam or hot water boiler can be started by a programming control, the
following conditions must be fulfilled:
(a) The water in the boiler drum must be above the cutoff point of the
low-water fuel cutoff (or two cutoffs if two are required as shown in the
diagram) so its switch is closed (5 and 6 in the diagram).
(b) The steam pressure or water temperature must be at or below the cut-in
setting of the operating control so its switch (2) is closed. The switch for the
high limit control (3) will also be closed.
(c) If the boiler is gas-fired, the fuel supply pressure to the burner valves must be
above the cutout point of the low gas pressure cutoff (4) so this switch can be
closed. All manually operated valves in the fuel lines to the pilot and main
burner must also be open.
If the boiler is oil-fired, the fuel lines and oil pump must be properly primed
to assure uninterrupted fuel supply to the burner control valve(s). Manually
operated valves in these lines must also be open.
(d) The main power switch or breaker must be closed so the electronic circuit in
the programming control panel is energized, and power is available to the
motor starting relays. Either the starting switch (1) or the operating control
(2) is open depending on whether the boiler is started manually or
automatically. Once the manual switch (1) is closed on initial boiler start up
after maintenance, inspection, etc., the operating control (2) will start the
firing sequence when the pressure drops to the minimum desired value.

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2.

Start-Up Sequence

(a) Boiler ignition sequence is initiated when the starting switch or operating
control is closed. This energizes the master relay which opens its B contacts
and, at the same time, closes the A contacts. This energizes the timer motor
through switch T5. The cam on the timer motor shaft closes switch T1
immediately to start the fan motor. When the air flow to the burner is
established, the low air pressure switch is closed.
(b) Air is now blown through the furnace to purge it of any combustible gases
which may have collected there.
(c) When the purge period is completed, the timer closes switch T2, which
energizes the ignition transformer and causes the ignitor to start sparking.
Switch T3 is also closed at this time to energize the solenoid, which will open
the pilot gas valve. The sparking of the ignitor lights the pilot flame.
(d) The flame detector will sense the pilot flame immediately and its signal is
amplified by the electronic circuit to close the flame failure relay.
(e) After allowing a short period of time for the pilot flame to be established, the
timer closes switch T4. This closes the electrical circuit to the solenoid of the
main gas valve so the main gas valve opens and the main burner is lit by the
pilot flame.
(f) After the main flame is established, the timer opens switches T2 and T3 to
open the electrical circuit to the ignitor and pilot gas valve. The flame
detector or scanner is now supervising the main burner flame only.
(g) The timer then changes switch T5 to the B circuit of the master relay. Since
the circuit that is connected to T5 is open, the power to the timing motor is
shut off, and the timer motor stops.

NOTE:

This programming sequence can also be applied to an oil-fired boiler

equipped with a pilot except that the pilot is usually kept lit during the
on period of the boiler.

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3.

Shutdown Sequence

(a) When the steam pressure or hot water temperature rises to the cutout point of
the pressure or temperature operating control such as a glass tube mercury
switch, the on-off controller opens its switch. This will open the electrical
circuit (number 2 in Fig. 3) to de-energize the solenoid of the burner fuel
valve. The burner valve will close and extinguish the flame.
(b) Since the flame scanner no longer senses the flame, the electronic circuit is
broken and the flame failure relay is opened.
(c) The opening of the pressure or temperature control switch also de-energizes
the master relay. As a result, contacts A open and contacts B are closed.
Since switch T5 is closed in the B circuit, the power supply to the timer motor
is re-established and the timer starts again. The timer opens switch T4 in the
electrical circuit to the main fuel valve.
(d) After a short period of time, known as the post purge, the timer will open
switch T1 and shut off the fan. At the same time the timer moves T5 back to
the A circuit. Since the master relay is de-energized and the A contacts are
open, the power supply to the timer motor is interrupted and it stops.
When the steam pressure or hot water temperature drops back again to the
cut-in point of the operating control, the control switch will close again. This
energizes the master relay to start the timer, and the start-up sequence will be
carried out again. Once the power supply to the boiler has been established
and the starting switch has been closed, the operation of the boiler becomes
fully automatic.

OPERATING SEQUENCE BAR GRAPHS

As mentioned earlier, there are variations in the operating sequence of
programming controllers and the timing of the various steps in each sequence.
These variations are most easily shown with the aid of bar graphs. Below follow
examples of the application of a programming control for two boilers, each with
different burners and operating controls.
It is assumed that all conditions for start-up as described above have been met.
Oil-Fired Boiler
The bar graph in Fig. 3 shows an operating sequence of a programming control
for an oil-fired boiler with on-off operating control, single nozzle burner, and
direct spark ignition. The chart following the bar graph describes the events in the
starting sequence.
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Figure 3
Bar Graph for Fire-Eye Programming Control

Time
Seconds

Dial
Indication

Starting switch or operating control switch closes; master

relay energized. Timer starts. Fan motor starts. Start of
purge period.

Low air flow cut-out switch must be closed otherwise

ignition will not take place and timer will recycle to start
position.

10

Timer stops if flame relay is not in open position. Lock-out

switch is then energized.

30

Timer stops if fuel pressure switch is not closed.

37

End of purge period. Ignition transformer energized, igniter

starts sparking. Fuel valve opens. Start of ignition trial
period.

44

End of ignition trial period. During this period the flame

sensor must have picked up sight of flame and flame relay
must have pulled in, otherwise fuel valve closes and safety
lock-out switch is energized.

47

No action with direct spark ignition.

57

Ignition off when interrupted spark is used. When

intermittent spark is used, it will stay on during entire firing
period.

Start-up

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60

DOT

End of start-up cycle. Beginning of normal firing period.

Timer stops. Burner and blower remain in operation until
heat demand is satisfied and operating control reaches its
cut-out point.

60

DOT

Operating control switch opens or starting switch on panel

is moved to off. Master relay de-energized. Fuel valve
closes. Scanner loses sight of flame, flame relay opens
switch. Timer restarts. Start of after-purge period.

75

End of after-purge period. Blower motor stops, timer stops.

The system is now ready again for a restart whenever
operating control reaches its cut-in point.

When the burner fails to ignite during the ignition trial period, the lock-out switch
is energized and actuates an alarm (light, bell or horn). The timer will return to its
starting position (0 on dial), however, it will not be able to start a new cycle until
the heater of the lock-out switch has cooled down and the switch has been
manually reset by pushing the button. The same procedure takes place when the
flame fails during normal operation.
Each time the operating control or a limit switch such as the low water fuel cutoff opens and shuts down the boiler, or when the power fails, the boiler will
automatically start up again when the switch closes or power has been restored. In
these cases the lock-out switch will not be actuated.

Gas-Fired Boiler
The bar graph in Fig. 4 shows an operating sequence of a programming control
for a gas-fired boiler with modulating control and pilot ignition. The chart that
follows describes the events in the sequence.
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Figure 4
Bar Graph for Programming Control
Time
Seconds

Timer
Indicator

Starting switch closed. Operating control in cut-in position.

Master relay energized. Timer starts. Blower (fan) starts.
Programmer takes command of damper motor, damper set in
high fire position. Start of purging period at maximum air
flow.

Low air flow switch must be closed.

20

Damper placed in low fire position for purge at reduced

flow. Low fire switch must close otherwise ignition cannot
take place.

27-40

Flame relay switch must be open otherwise timer stops and

lock-out switch is energized.

45

End of purge period. Ignition energized. Pilot gas valve

opens. Start of trial period. When scanner sights pilot flame,
flame relay closes.

55

Main gas valve energized, main burner lights. Start of main

burner ignition trial period.

Start-up

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70

Pilot valve and ignition de-energized. The programmer

releases control of damper motor. Damper and fuel valve are
now placed in high fire position by the modulating operating
control if boiler is on automatic control, or they are placed
on the demand setting of the firing rate selector switch if
boiler is on manual control.

105

DOT

End of starting cycle. Beginning of normal firing period.

Timer motor stops. Burner and blower remain in operation
until heat demand is satisfied and operating control reaches
its cutout point.

DOT

15

Shutdown
Operating control opens. Master relay and fuel valve
de-energized. Scanner loses sight of flame, flame relay
opens. Timer restarts. Programmer takes control of
modulating motor and holds it in low fire position. Start of
after-purge period at low air flow.
End of after purge period. Blower stops. Timer stops.

The system is now ready for start-up whenever the operating control closes again.

NOTE:

Should the pilot fail to ignite during its trial period, with the result that
the scanner will not detect a flame, then the pilot and ignition will be
shut off and the main fuel valve will not be energized. Should the main
burner fail to ignite during its trial period, the fuel valve will close
again.
In both cases the timer will complete its full cycle during which time a
lock-out switch will trip, actuating an alarm (light, bell or horn) and
prevent the timer from starting a new cycle. Only after the lock-out
switch has been manually reset, will the timer be able to start up again.
It should be pointed out again that the starting sequences shown in
Figs. 3 and 4 are only examples of the many control sequences
possible. The timing of many other sequences varies considerably
from those described above.
Each time the operating control or a limit switch such as the low water
cut-off switch or the fuel pressure switch opens and shuts down the
boiler, or after a power failure, the boiler starts up automatically again
when the switch closes or power has been restored. However, should
the boiler shut down due to a flame failure, it will not start again until
the lock-out relay has been manually reset.

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TROUBLE SHOOTING GUIDE (Automatically Fired Boilers)

On the following pages some general guide lines are given to find the cause of the
trouble that may occur during start-up and operation of automatically fired
heating boilers.
It is assumed that the boiler has been properly installed and adjusted and that it
has been in operation for some time prior to the trouble listed below. It is further
assumed that the operator is thoroughly familiar with the firing equipment and
controls as well as the manual for the boiler.
The points under each heading are stated as briefly as possible to simplify
locating the source of trouble. Methods of correcting the trouble can usually be
found in the boiler manual or the accompanying equipment bulletins.
A good knowledge of the control system will make trouble shooting much easier.
Costly downtime or delays can be prevented by systematic checks of the actual
operation against the normal sequence to determine at what point the operation
strays from normal. Follow a routine in order not to overlook an obvious cause of
trouble.

TROUBLESHOOTING GUIDE
(Automatically Fired Boilers)
COMPLAINT: Blower Does Not Start
POSSIBLE CAUSE

REMEDY

1.

Main disconnect switch open.

- Close switch.

2.

Blown fuses, tripped overloads,

loose electrical connections.

- Refer to manufacturers manual.

- Check for power on power supply terminals on
programming control.
- If master relay pulls in and timer starts but blower
motor does not start, check for power on solenoid
circuit of motor starter.

3.

Combustion control safety lock-out

switch tripped.

- Reset safety lock-out switch.

4.

Limit control circuit not completed.

- Boiler pressure or temperature above cut-in setting

of operating control.
- Water below required level.
- Low water indicating light, if provided,
should indicate this condition.
- Check manual reset button, if provided,
on low water fuel cut-off.

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5.

Motor defective.

- Replace motor.

6.

Blower starts but stops again after

5 to 10 seconds.

- Check the low air pressure switch.

COMPLAINT: No Ignition
POSSIBLE CAUSE

REMEDY

1.

Lack of spark.

Electrodes grounded or porcelain cracked.

Improper electrode setting.
Loose terminal on ignition cable, cable shorted.
Inoperative ignition transformer.
Check appropriate program relay contacts.

2.

Spark but no flame.

- Lack of fuel due to closed manual valves, clogged

oil filter, empty fuel tank, incorrect pilot gas
pressure.
- Inoperative solenoid on pilot or low-fire fuel valve.

3.

Low fire switch open.

- Damper motor not operative, slipped cam, defective

switch.
- Damper jammed or linkage binding.

4.

Timer switch in test position and

timer stopped in prepurge.

- Place timer switch to the run position.

COMPLAINT: Pilot or Low-Fire Flame, No Main Flame.

POSSIBLE CAUSE

REMEDY

1.

Insufficient pilot or low-fire flame.

- Adjust pilot or low-fire flame.

2.

Supply to main nozzles restricted

or cut off.

- Check for obstruction, closed valve.

- Inoperative solenoid valve.
- Check oil nozzles.

3.

Inoperative programmer.

- If flame relay does not pull in when pilot flame

lights, check flame detector, contacts, amplifier.
- Flame detector defective, sight tube obstructed or
detector lens dirty.
- If flame relay pulls in but fuel valve is not
energized, check for voltage at test jacks of
programmer. (See manual).

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COMPLAINT: Burner Stays On Low-Fire

POSSIBLE CAUSE

REMEDY

1.

Boiler pressure above high-low fire

control setting.

- Wait till pressure drops to where there is a load

demand.

2.

Damper positioning switch in

wrong position.

- Check damper linkage.

3.

Inoperative damper motor.

- Check motor for cause and replace if necessary.

4.

Defective high-low fire or

modulating control.

- Replace modulating control.

5.

Binding or loose linkage, cams,

setscrews, etc.

- Repair linkages.

COMPLAINT: Shutdown Occurs During Firing

POSSIBLE CAUSE

REMEDY

1.

Loss or stoppage of fuel.

- Check fuel system for reason.

2.

Defective fuel valve, loose

electrical connections.

- Repair or replace fuel valve.

3.

Flame detector weak or defective.

- Change detector.

4.

Lens dirty or sight tube obstructed.

- Clean lens or sensing tube.

5.

If the programmer lock-out switch

has not tripped, check the limit
circuit controls, interlock, or
blower motor.

- The flame failure light is energized by ignition

failure, inadequate flame signal, or open control in
the non-recycling interlock circuit.
- The light will not be energized by the opening of
any control in the limit circuit.

6.

If the lock-out switch has tripped.

- Check fuel lines and valves.

- Check flame detector.
- Visually check appropriate timer and relay contacts
(refer to program control manual).
- Check blower motor and all interlocks.
- Lock-out switch malfunctioning
- Stuck contacts.

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POSSIBLE CAUSE

REMEDY

7.

Improper air-fuel ratio.

- Slipping linkage.
- Damper stuck open.
- Fluctuating fuel supply.
- Temporary obstruction in fuel line.
- Pressure reducing valve in gas line defective.

8.

Interlock device inoperative or

defective.

- Replace or repair interlock.

COMPLAINT: Damper Motor Does Not Operate

POSSIBLE CAUSE

REMEDY

1.

Damper positioning switch in

wrong position.

- Place switch in correct position.

2.

Linkage loose or jammed.

- Repair linkage

3.

Motor does not drive to open or

close during prepurge or close on
burner shutdown.

- Check appropriate contacts (See manual).

4.

Motor does not operate on demand.

- Damper positioning switch in wrong position.

- High-low fire or modulating control improperly set
or inoperative.

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