Block 2 - Maintenance of Gas-Fired Appliances - Service Fuel & Air Delivery Systems

Question 1

Why are maintenance procedures for gas-fired appliances crucial?

Answer 1

To ensure their safe and efficient operation.

Specific maintenance requirements may vary depending on the type and model of the appliance.

Question 2

What should be inspected regularly on the heat exchanger?

Answer 2

Cracks, corrosion, and other signs of damage.

Cleaning surfaces to remove soot, scale, or debris is essential for efficiency.

Question 3

What is a key task when inspecting the venting system?

Answer 3

Check for obstructions such as bird nests or debris.

Ensure vent pipes are securely connected and free from gaps or leaks.

Question 4

What indicates efficient combustion in a burner?

Answer 4

Blue flames.

Yellow or orange flames may indicate an issue.

Question 5

What maintenance is required for pumps?

Answer 5

Check operation, lubricate bearings, inspect for leaks, and verify motor performance.

Proper alignment and tension of belts are also important.

Question 6

What should be inspected on fans?

Answer 6

Signs of wear, imbalance, or damage.

Clean fan blades and check motor bearings for wear.

Question 7

What must be tested on safety valves?

Answer 7

Proper operation and ensure they are not stuck or malfunctioning.

Question 8

What is the objective of inspecting flue gas exhaust systems?

Answer 8

Check for obstructions and integrity of venting materials.

Ensure draft control devices are operating correctly.

Question 9

What should be done with combustion air fans during maintenance?

Answer 9

Inspect for proper operation and cleanliness.

Ensure motors and bearings are in good condition.

Question 10

What is a general maintenance tip related to record keeping?

Answer 10

Keep detailed records of maintenance activities, including dates and tasks performed.

Question 11

True or False: Regular inspections should only be conducted during heating seasons.

Answer 11

False.

Inspections should be conducted regularly, even during non-heating seasons.

Question 12

What is the purpose of diagnostics during maintenance?

Answer 12

To ensure proper functioning and identify potential issues.

Question 13

What should be visually inspected during diagnostics?

Answer 13

Signs of wear, damage, or irregularities in components.

Look for cracks, corrosion, or leaks.

Question 14

What electrical parameters should be measured?

Answer 14

Voltage and current levels.

Ensure they are within the manufacturer’s specified ranges.

Question 15

What is the objective of measuring temperatures during diagnostics?

Answer 15

Ensure that temperatures are within the acceptable range for components.

Question 16

Fill in the blank: Pressures must be confirmed at the required levels for _______.

Answer 16

[safe and efficient operation]

Question 17

What should flow rates be compared against?

Answer 17

The manufacturer’s recommendations.

Question 18

What is the purpose of confirming compliance with the manufacturer’s specifications?

Answer 18

To ensure the appliance is operating according to guidelines.

Question 19

What should be done if excessive vibration is detected?

Answer 19

Use vibration monitoring tools and inspect for loose components.

Question 20

What is an important aspect of documentation during diagnostics?

Answer 20

Document all measurements, observations, and adjustments made.

Question 21

What is the benefit of comparing current readings with historical data?

Answer 21

To identify trends or deviations that may indicate emerging issues.

Question 22

What is a systematic approach in diagnostics?

Answer 22

Starting with visual inspection before moving on to specific parameters.

Question 23

What is the purpose of replacing consumable OEM parts?

Answer 23

They may require replacement rather than repair because they are not serviceable.

Question 24

What does the regulator repair/maintenance in this lesson refer to?

Answer 24

The ‘Fisher LS200 Regulator Manual’

This manual provides guidelines for maintaining and repairing the Fisher LS200 regulator.

Question 25

What is the maximum recommended time interval for regulator maintenance and inspection according to Fisher?

Answer 25

Every 10 years ## Footnote This recommendation is for parts replacement and ensures the regulator functions correctly.

Question 26

What should be done before attempting any maintenance or disassembly of a regulator?

Answer 26

Isolate the regulator from system pressure and relieve all internal pressure ## Footnote This step is crucial to avoid personal injury or equipment damage.

Question 27

What should be checked and cleaned if a screen flow streamer is included?

Answer 27

Check and clean the screen flow streamer ## Footnote Operation with a dirty screen flow streamer can cause performance drop.

Question 28

What should be ensured when replacing the balance diaphragm and orifice?

Answer 28

Follow all steps and precautions carefully ## Footnote Proper alignment and care during installation are essential to avoid damage.

Question 29

True or False: Lever action regulators come with replacement kits that include lever or linkage sets.

Answer 29

False ## Footnote These kits do not include lever or linkage sets; a new regulator should be purchased if those parts need replacement.

Question 30

What is the suggested maintenance frequency for relief valve parts?

Answer 30

Depending upon service conditions ## Footnote Regular inspection is necessary to ensure proper functionality.

Question 31

What type of lubricant should be used on O-rings during reassembly of relief valves?

Answer 31

Lightly lubricated before assembly ## Footnote This helps ensure a proper seal and function.

Question 32

Fill in the blank: The sensing line should be checked for _______ and cleaned if needed.

Answer 32

debris ## Footnote Ensuring the sensing line is clear is vital for accurate regulator operation.

Question 33

What is the function of a lubricated plug valve?

Answer 33

To permit flow when rotated to align the hole with the downstream direction of the pipe ## Footnote The grease barrier prevents close contact between the plug and body.

Question 34

What are the two general procedures applicable to lubricated plug valves?

Answer 34

Stick Sealant Service Procedure and Sealant Gun Service ## Footnote These methods are used for injecting sealant into the valve.

Question 35

What should be done if the sealant is not being injected into the valve?

Answer 35

Use valve flush purge compound to break up obstructions ## Footnote This can help clear blockages preventing sealant from entering.

Question 36

What is the suggested valve leak test frequency according to the manufacturer?

Answer 36

Annually or during PM maintenance ## Footnote This ensures safe and reliable operation of the valves.

Question 37

What is the acceptable leakage limit for valves according to local codes?

Answer 37

15 bubbles per minute ## Footnote Exceeding this limit requires immediate attention and possible removal from service.

Question 38

Fill in the blank: Safety shut-off valves often have _______ that can be replaced.

Answer 38

proof of closure switches ## Footnote While many SSOVs are non-serviceable, some parts can still be replaced.

Question 39

What should be done if a control spring of a different set pressure range is installed?

Answer 39

Remove the set pressure range on the spring case and indicate the new range ## Footnote This ensures that the regulator operates correctly with the new spring.

Question 40

What is a key consideration when tightening bolts during maintenance?

Answer 40

Torque them to the correct specifications ## Footnote Proper torque is crucial for the integrity and safety of the assembly.

Question 41

What are SSOVs?

Answer 41

Non-serviceable valves that cannot be repaired if they break down, like Maxon and Eclipse valves. ## Footnote Some parts, like proof of closure switches, may still be replaceable.

Question 42

Which solenoid valves can be repaired?

Answer 42

ASCO valves can be repaired with kits that include diaphragm, spring, O-rings, etc. ## Footnote Repair kits provide a comprehensive solution for solenoid valve maintenance.

Question 43

What is a benefit of using repair kits for Honeywell V5055 valves?

Answer 43

Repair kits allow for maintenance without removing the valve body from the piping.

Question 44

What is the status of the Honeywell V4055 actuator?

Answer 44

Non-serviceable and needs to be replaced if it leaks hydraulic fluid. ## Footnote Core replacement options may provide discounts on rebuilt actuators.

Question 45

What should be done to bearings and linkage connections?

Answer 45

They should be lubricated with a light oil and inspected for cleanliness and tightness.

Question 46

What is a typical greasing schedule for motor bearings?

Answer 46

Intervals can be every month, quarter, or year depending on motor load, run time, and ambient temperature.

Question 47

What are the consequences of over-greasing motor bearings?

Answer 47

Can cause internal bearing pressure, higher friction and heat, and damage seals.

Question 48

How should you grease motor bearings?

Answer 48

Grease should be applied while the motor is running and warm, dispensing the recommended amount through grease fittings.

Question 49

What are the steps to test an electric motor?

Answer 49

Conduct electrical tests, vibration tests, thermal tests, dynamic tests, noise tests, and insulation tests.

Question 50

What is the function of a combustion air pressure switch?

Answer 50

Ensures the proper flow of combustion air before ignition begins.

Question 51

What should be checked during a visual inspection of a combustion air pressure switch?

Answer 51

Look for burnt wires, corrosion, or physical damage.

Question 52

What indicates a faulty combustion air pressure switch during continuity testing?

Answer 52

If there is no continuity after blowing into the tubing connected to the switch.

Question 53

What should the pressure switch be set to in relation to the high fire pressure reading?

Answer 53

About 80% to 90% lower than the high fire pressure reading.

Question 54

True or False: The air pressure switch is typically located downstream of the control valve.

Answer 54

False. It is located upstream of the control valve.

Question 55

Fill in the blank: The manufacturer of the motor and the manufacturer of the bearing will have a specific recommended _______.

Answer 55

greasing schedule.

Question 56

What should be done if there is play in the bearings?

Answer 56

They should be replaced.

Question 57

What can cause premature wear of motor bearings?

Answer 57

Insufficient lubrication leading to higher friction and heat.

Question 58

What is the purpose of a grease gun in greasing motor bearings?

Answer 58

To dispense the exact amount of grease needed.

Question 59

What should be done if grease comes out of the purge valve during greasing?

Answer 59

Stop adding any more grease to avoid overfilling issues.

Question 60

How can you ensure the motor shaft is clean before installing new bearings?

Answer 60

Remove corrosion, moisture, and dust particles using a Scotch-Brite pad.

Question 61

What is a safe method to heat a bearing for installation?

Answer 61

Using a proper induction heater with a demagnetization cycle.

Question 62

What are key signs of motor bearing failure?

Answer 62

Corrosion damage, presence of water, and grit particles in lubrication.