Hello all; I have a Crane Sunnyday boiler #15-5 190,000 btu/hr burner capacity that is equiped with a Liberty model LBP200 power gas burner serial #5497 natural gas rated at 200,000 btu/hr max input. This power gas burner has a Franklin electric cage fan motor at 115 volts. Two line voltage thermostats, one for each of the two floors. Newly installed components include: Gas valve is a Honeywell VR8345M4302 24 volts outlet setting is factory set at 3.5 in. wc. The transformer is a Honeywell Tradeline AT72D rated at 40 VA @ 24 VAC. Electronic ignition controller is Honeywell S8610U3009 intermitent pilot, continuous retry. Igniter is Honeywell 392431. Also a solid core plug wire with ceramic protection over ignition wire.
This setup worked great (except for the spark wire needing to be replaced every 6 months due to the end getting burned at the ignitor) for three years but had three year old components that the parts change monkey (me) replaced with the new components in an attempt to fix the " no pilot ignition with the fan running" that arose about a month ago. After the new components were installed, it is still acting exactly the same. The older components were obviously still good.
During my testing, I removed the power burner unit and found a broken wire inside that for a short time caused no 110 volt power leaving the unit to fire up the ignition transformer. I attached it to the only terminal on the terminal strip that did not have a wire and the ignitor started working again, but still no pilot flame and I didn't find the broken wire tip under any of the screws. I pulled the burner out and flipped it upside down to watch the pilot in action and as I cupped the area aroung the pilot, it lit up so I adjusted the ignitor so that it would ignite and reinstalled the burner into the boiler. Still no flame action for the pilot, so I separated the burner unit/fan, and the ignition system with separate 110v cords. I plugged the ignition cord into the power coming from the hi, lo temp cutout switches on the boiler and the pilot lit right up and then the main burner light right after that so I immediately plugged in the burner fan and the boiler heated just like it is supposed to, until the boiler reaches high temp and shuts down, but after the boiler temp cools down and the system calls for heat The pilot won't light on it's own. So for the boiler to heat I need to follow that routine each time.
I think ether the wiring is wrong (sabotage), or a component is bad within the power burner unit, or air turbulence at the pilot. The only things in the burner are the fan, terminal strip, transformer, a small contact, and some wiring. Would you all have a wiring schematic and component function description for the inside of the Liberty Combustion corp. model LBP200 so I can understand the burner wiring better. Does the transformer run the fan at two different speeds, or what is it even there for? Why does the pilot ignite only when the fan is not running when it used to light fine while the fan was feeding combustion air? Money is in short supply, but I would appreciate upgrade recommendations to this system.
Thank you very much Masters of the appliance world for any assistance you can offer!