Troubleshooting Spark Pilot Intermittent Control Module Flame Signal and Ground

I notice the gas boiler at times seems to spark longer than it should at times. Therefore I am testing the spark ignition control module for a flame signal. After verifying the flame signal current produces 5 microamps. I ohm out and check the continuity of the ground wire for the pilot control module. I change the ground wires' stake on connectors.

[@michtwn]

I had this happen on my Dunkirk boiler. It would spark and light the pilot , turn on the gas valve and then shut down and start the cycle over again. The problem ended up being the ignition control module. I put in a new ignition control module and it fixed the problem.

[@thehvachacker]

The cleaning was all needed to stop that backfiring. I still have that ignition module on the boiler. I should replace it, the ignition goes sitter longer than I like. I am in the middle of repiping this boiler and hooking up an indirect water heater. The one I soldered a tank leak shut in April started leaking again

[@michtwn]

@@thehvachacker I have noticed that when I first start the boiler in the fall , it sparks much longer when it first starts up. After the first run, it goes back to normal.

[@kevinshurtleff]

Thanks for making this, I was mistakenly assuming it was my flame sensor or ignition module that was bad, but it was the ground. You saved me a few hundred bucks.

[@tinman3518]

Power ventor is pulling pilot flame away from pilot burner as in your video at end. change pilot burner to bent spark rod (1149944) and spark will light every time. To test, remove MV wire (main valve solenoid terminal on gas valve. Leave PV ( pilot solenoid terminal on gas valve). Turn on boiler and only pilot will work. Now you can watch pilot flame with mirror, with door on and off.

[@tinman3518]

pilot flame when it's cold, shrinks until warms up. As it warms up gas flame will expand at pilot hood. Problem is spark rod is to far from pilot hood when it's cold. Put mirror near pilot and then blow hot air towards it and watch flame. Change out pilot burner to Honeywell pilot burner 1149944 (which has a bent spark rod built for ICP furnace). this pilot can be changed on any gas appliance with Honeywell pilot burner with spark issues

[@Ted_E_Bear]

The Great Hacker is the best in history at anything, even beats MacGyver !!

[@throttlebottle5906]

maybe your leaving open a door that's normally closed when your in there or the lid off it could be changing the air flow and having pilot suck-out. then again, I think you said gas valve was replaced, maybe the pilots adjusted too low when it has a longer off cycle and cool down, it could also be somewhat loosing ground with thermal cycling. ** those control boxes can do that when going bad also, capacitor failures inside I think I have a crystal ball in my head lol. later in video it looked exactly like flame suckout with the cover back on, turn the pilot gas up higher if you can and check the controls voltage output to the valves pilot coil, it may be under-volting and not opening fully. also make sure there isn't a rusted/corroded away flow restriction plate on the power vent blower. been quite a while since I've dealt with that style control setup, slowly recalling all the past flubbers on them.

[@MrRonluker]

Now in gonna test from here to here.

[@paulberger5003]

38 minutes? Needed content but edit down to 7 minutes and you are onto something!

[@More350Power]

It looked almost like the pilot wasnt feeding enough gas or like you said isnt getting enough air. Hope your staying safe and healthy !

[@edjovi3677]

bill had a lots of late ignitions and it was in the gas valve too and the modular most times !!! edbonjovi !!! aka leak master plumbing

[@thehvachacker]

This is snowballing. At least it's my own time not a customer paying for the labor. Module can cause interesting intermittent issues. Along with gas valves.

[@DeeJaySpy]

You did not explain how the path of the Flame sensor back to the igition device is. Maybe i missed that. I see several possibilities 1. Via the pilot gas pipe 2. Via Chassis 3. Via the Main Gas pipe... (and there is a lot of dope on the pipe which impacts grou d to the valve

[@thehvachacker]

I thought i did explain the ground was the path the flame signal travels back to the ignition module. Why i was testing the wire going from gas valve ground to controller. I will go over it again in the next video when I get time to play with my boiler again. Main gas pipe to gas valve is a scary connection. the 3/4 to 1/2" fitting was sent all the way into valve. I wouldn't think this would cause a pilot issue, yet create a pressure drop on main burner. The chassis is allowing the flame current to travel back to ignition module. The pilot orifice inside the ignition module could be partially restricted. I couldn't remove it during maintenance why I have a new one to replace. I'm leaning on an air fuel mixture of the pilot. the end of the video i show it not igniting.

[@luvdogsandhorses]

Video too long to keep my attention because picture was too far away from the control you were discussing to follow along

[@llservice3376]

Don't know if I saw you use it in one of your videos but DeoxIT electrical contact cleaner works really well with oxidized contacts

[@throttlebottle5906]

just noticed the radon mitigation setup, with the gauge clearly showing it's working, I didn't notice or pay attention in previous videos. doh!

[@TheGhettoLobster]

Very interesting video. I will remember this in the field next time I run into a problem with intermittent spark modules. Appreciate sharing your knowledge and experience. What do you think the problem is?

[@natepeterson7145]

Pilot wasn't lighting at last part of video, I'm sure you checked your footage though

[@thehvachacker]

Yes i caught that and decided to put that into the video. I found out this happens only when the door is on. Reason why when testing I couldn't replicate. I been so busy working on my house and watching my daughter the boiler hasn't been top priority since correcting the exploding ignition problem. it wa around 2 am when I stopped filming this vid. I hope today to get to play more with the boiler. Some kind of air fuel mixture of the pilot is off.

[@aifrisyad7491]

is the GND wire connect to burner and parallel to module?

[@marksiegfried]

You need to call a HVAC technician because you're lost.

[@THExBIGxBADxWOLF93]

Lol literally what I’m thinking in all these videos trying to learn from lol

[@melvinwillingham233]

You should be checking for Micro amps DC VOLTS

[@josephdanno1011]

Hey how are you I have installed an ac spilt system. I turn it on and set it to cooling it worked after switching to heating it shut off as soon as the compressor started and then the whole unit lost power and not responding. I haven’t checked the indoor unit fuse yet need some tips I would appreciate that

[@justdissin7340]

You probably figured it out by now but sounds like an issue with 220v wire. Let me know if you fixed it. Its been a yr now since ur post

[@leoaz4667]

Where are you Brother I really miss your videos

[@dougshakell8003]

Get another control some have led and will tell u a code as well it will show the flame signal during pilot or main flame. Dude this is the basics.

[@dougshakell8003]

Brother that is not how to check flame signal. U need a micro amp meter in series of flame rod. Those Honeywell controls lock out a signal less than 1.25ma a just mentioned of pilot flame will increase and decrease signal. Good grounding to pilot burner is very important. Your controller is a universal replacement. You should replace with correct one. That allows 3 trial periods or attempts it will lock out. Be save dude these are the way issues start.

[@IFIXCASTLES]

Better get Steve lavatomy on the job.

[@thehvachacker]

Not sure he would find the problem here faster. If only it wasn't 2 am when i finally caught the ignition not working. Or I would of gone further and instant ignition every time

[@IFIXCASTLES]

@@thehvachacker im joking with you!

[@thehvachacker]

It’s all good. I gave your comment a thumbs up before responding. I always joke with coworkers about getting a real tech to take care of my jobs

[@edjovi3677]

bill its edbonjovi were did you go are u ok let me know thank u leak master

[@23Skadoosh]

I got hit with 220 once. That wasn’t a fun day in the neighborhood.

[@samsungtv4u]

Up to 60 second spark

[@leoaz4667]

It sucks when you reach out to you tube people you follow and admirer and they blow you off asking if they are okay during this coronavirus academic. I'm so tired of I'm better than you people. You tube has a wealth of people who treat their followers better

[@samsungtv4u]

Bad ground..

[@realestateservicessaleshea99]

I believe you state it's has the wrong pilot pattern🤔🥃🍺 There's a reason the manufacture put a twin pilot pattern🤔🥃🍺🍺 Just say'n.🤔🍺🥃 Stay safe. Retired keyboard super tech. Wear your safety glasses.

[@edbonjovi9133]

Bad ground. Edbonjovi

[@Abhishek-C92]

3 rd view.

[@thehvachacker]

1-10 is always good place to come in out 300

[@Arieldny]

this guy is not too knowledgeable