If my gas burner is not starting, how do I troubleshoot this?

There is on each ALKAR oven a series of lights called the sequence monitor, which is usually located on the motor control pane door (usually 18 lights if the oven was manufactured before 1992, 16 if later than 1992). As the oven starts up, each light indicateds that safety has been met and it proceeds to the next step. If a particular safety is not met, the process stops at that point, so the sequence monitor will indicate where to begin troubleshooting. Now available on the new Windows version DDC control program, this sequence monitor is also on the operator's screen for added convenience.

1. Main Blower Running or Auxiliary Contact on Main Blowers Starter
   Possible problem and correction
   1. Mounting screws loose.
   2. Bad contacts - replace.
   3. Magnetic coil in starter defective.
   4. Overloads kicked out - check and reset if necessary.
   
    
2. Air Flow Switch
   To prove main blower running, senses positive pressure.

   

   Possible problem

   1. Water or moisture in diaphragm.
   2. Tubing or pipe plugged with creosote.
   3. Bad microswitch (replace air flow pressure switch).
   4. Ruptured diaphragm.
   
    
3. Combustion Air Switch
   To provide for proper combustion, fan running and pressure.

   Possible problem

   1. Bad microswitch (replace combustion air pressure switch).
   2. Ruptured diaphragm.
   
    
4. Prove Oven Door Open
   This is a insurance safety requirement. Before ignition of oven's pilot light, doors have to be open.

   Problem

   1. Bad microswitch (moisture shorting switch out is frequent problem after clean up).

   
   NOTE: Ovens built after 1992 do not have the door switches. The flame safeguard has a pre-set 4 minute purge time. Once this is set, it cannot be tampered with.

   
   

5. Prove Fresh Air Intake Damper Open 
   1. Micro switch failed.
   2. Set screw loose, cam turning on damper shaft.
   3. Micro switch loose on mounting bracket.
   
    
6. Prove Exhaust Damper Open
   This is a insurance safety requirement. Before ignition of oven's pilot light, damper has to be open.
   1. Set screw loose, cam turning on damper shaft.
   2. Micro switch loose on mounting bracket.
   3. Defective micro switch.
   
    

7. Prove Safety Valve Closed
   In most cases,the gas burner has two fluid actuator gas valves. They both must be proven in closed position before ignition is possible.

   

   1. Micro switch loose on mounting bracket inside actuator head.
   2. Micro switch defective.

   

8. Prove Low Fire Start
   Prove gas burner in minimum firing rate before ignition.  Problem
   1. Gas burner linkage broken.
   2. Set screw loose on crank arm.
   3. Set screw loose on cam.
   4. Microswitch defective.
   5. Microswitch loose on bracket.

   

9. Exhaust Fan Running
   Interlock or auxiliary contact on exhaust fan starter.
   1. Mounting screws loose.
   2. Defective contacts.
   3. Magnetic coil on exhaust fan starter defective.
   
    
10. Low Gas Press Cut-off
    To prove gas pressure is not low. 
    1. Low gas pressure switch has to be reset.
    2. Defective switch (ruptured diaphragm; replace low gas pressure switch).
    3. Vent valve coil burned out; gas pressure too low when burners in high fire.
    4. Defective microswitch. Replace pressure switch.

    

11. High Gas Press Cut-off
    To prove gas pressure is not too high.
    1. High gas pressure switch has to be reset.
    2. Defective micro switch or ruptured diaphragm (replace low gas pressure switch).
    3. Main gas regulator malfunction (possible dirt in seal).
    
     
12. High Temperature Limit Supply Air
    To prove blower air discharge not in excess of 350°F to 550°F.
    1. Loose belts on main blower.
    2. Reset high temperature limit switch.
    3. Possible bad thermal assembly; replace hi limit switch.
    
     
13. Purge Timer Terminal Number 5*
    Allows oven to purge itself for 3 minutes before attempting to light gas pilot.
    1. Defective micro switch in timer.
    2. Clutch defective in purge. Replace purge timer.
    3. Motor defective in purge timer.
    4. Low voltage caused by moisture in door micro switch.

    
    *NOTE: This timer is only on ovens manufactured in 1991 or earlier. Ovens manufactured since 1992 have the purge time pre-set and built into the Flame Safeguard.

    

14. Pilot Solenoid On
    Prove ignition transformer
    1. Defective microswitch in pilot cut-off timer.(*On ovens built prior to 1992.)
    2. Defective Flame Safeguard.
     
15. Flame Safeguard Terminal Number 5 Prove main safety gas valve open (cleared for high fire).
    1. Defective flame relay RF-1 circuit in Fireye flame safeguard (replace flame safeguard).
    2. Defective flame rod or ultra-violet eye (check voltage at flame safeguard).