Common Fault Handling for Steam Generators

      A steam generator primarily consists of two main parts: the heating section and the water injection section. In terms of control, the heating section can be further divided into electric contact pressure gauge-controlled heating and pressure controller-controlled heating, with such generators typically equipped with control circuit boards. The water injection section includes both manual water injection and pump-driven water injection.

I. Common faults in the water injection section:

(I) Automatic water injection generator fails to inject water:

(1) Check if the water pump motor has power or is experiencing phase loss, and restore it to normal operation.

(2) Check if the water pump relay has power, and restore it to normal operation. If the circuit board does not output power to the relay coil, replace the circuit board.

(3) Check if the high-water level electrode is properly connected to the casing and if the terminals are corroded, then restore it to normal operation.

(4) Check the water pump pressure and motor speed; repair the pump or replace the motor (the motor power should not be less than 550W).

(5) For steam generators using float level controllers for water injection, besides checking the power supply, inspect whether the low-water level contacts of the float level controller are corroded or incorrectly connected. Restore to normal after repair.

(II) Automatic water injection generator injects water continuously:

(1) Check whether the voltage controlled by the circuit board for the water level electrode is normal. If not, replace the circuit board.

(2) Repair the high-water level electrode to ensure good contact.

(3) For generators using float level controllers, first check if the high-water level contacts are making good contact, then check if the float is buoyant or if the float chamber is taking in water. Replace if necessary to resolve the issue.

II. Common faults in the heating section:

Generators controlled by pressure controllers, lacking water level displays and circuit board control, rely primarily on float level controllers for heating control. When the water level is adequate, the float’s buoyancy point activates the control voltage, engaging the AC contactor to initiate heating. This type of generator has a simple structure and is widely used in the market. Common heating failures in such generators often originate from the float level controller. First, check the external wiring of the float level controller to ensure the upper and lower control wires are correctly connected. Then, remove the float level controller and check if the float moves freely. At this point, manually test it and use a multimeter to verify whether the upper and lower control points can connect. If everything checks out, inspect whether the float chamber is taking in water. If the float chamber is flooded, replace it to resolve the fault.