How to choose boiler automation. Malfunctions and DIY repairs

Types of boiler automation systems

Boiler automation is available in 2 types:

1. Volatile, which operates only from the mains.
2. Non-volatile, capable of operating in autonomous mode without supplying voltage to its actuators.

Advanced energy-dependent systems have the widest range of functions, from the boiler safety system to weather-dependent control, using the latest technological solutions and integration into the Smart Home system.

Non-volatile automation is more simplified and does not have a developed control system; it is used in places with an unstable power supply, as well as on coal-fired units. The main parameters that such a system controls are: water overheating, vacuum level in the firebox and the presence of a torch in the firebox.

Automated block-modular gas boiler house

Project Options

The thermal power of the designed boiler house is 5.7 MW. The heating system is single-circuit, closed. The main fuel is natural gas, the backup fuel is diesel fuel. Established volume of natural gas consumption: 2.955 million m3/year, 0.759 thousand m3/hour.

Project Description

Feasibility study: Block-modular gas boiler house, taking into account the change of liquid fuel (fuel oil) to cheaper gaseous fuel (natural gas) with the lowest cost of maintaining a new boiler house. Project composition: 1. Water heating boilers with a total thermal power of 5 MW. The use of 3 imported automated fire-tube hot water boilers with a water heating temperature not higher than 338 K (1150 C) and an efficiency of more than 90%, with the ability to operate in autonomous mode.

2. Gas burner devices. The use of 3 imported automated combined (gas-diesel) burners that ensure safe operation, excluding human intervention, with minimal permissible emissions of pollutants into the environment.

3. Automation system for the safety of the boiler unit in accordance with the requirements of the “Rules for the design and safe operation of steam boilers with a steam pressure of not more than 0.07 MPa (0.7 kgf/cm2) of hot water boilers and water heaters with a water heating temperature not higher than 338 K (1150 C )

4. Pumping equipment of the boiler room with an automatic backup system. The use of imported pumping units with reduced energy consumption and automatic protection of basic operating parameters.

5. Automatic system for regulating boiler room power. The use of weather-dependent automatic control of boiler house power, which has the ability to operate the boiler house according to one of four standard temperature schedules for heat supply.

6. System of make-up and pre-boiler water treatment. The use of imported automated chemical water purification systems operating on the principle of Na-cationization. The use of imported automated systems for chemical purification of water from iron compounds is determined based on the results of the source water. The use of imported automated systems for complex reagent dosing to adjust the quality of the coolant.

7. Coolant flow metering system - the use of commercial gas metering units with telemetry of cold water, thermal energy and hot water flow.

8. Boiler house gas supply system - the use of block gas control points in accordance with the “Safety Rules for Gas Distribution and Gas Consumption Systems” is determined on the basis of the boiler house reconstruction project.

9. Boiler room power supply system - the use of cabinet input distribution devices for power equipment is determined on the basis of the boiler room reconstruction project.

Automation system elements

Boiler automation elements are related to the power of the unit and the requirements imposed on them by state regulations. For municipal steam boilers DKVR (E), which are most widely represented in the central heating system with steam output from 2.5 to 20 t/h and saturated steam pressure of 13 and 23 amt.

Automation consists of two parts: safety and regulation. The first switches off the boiler when the set gas parameters, vacuum in the furnace, water level in the drum, steam pressure and T of feed water are exceeded, and the second maintains the specified operating parameters of the unit using actuators.

The boiler unit automation system operates on the basis of the AGAVA 6432 microprocessor device. The boiler unit control system includes:

1. Controller AGAVA.
2. Sensors for gas/steam/air/vacuum pressure, T of feed and network water, water level in the torch drum in the furnace.
3. Cabinet KIRiA.
4. Touch screen for operating personnel with indication and archiving of all measured parameters and operation of actuators.
5. Power supply with emergency protection in the absence of stationary voltage at the control panel.
6. Flow meters of fuel, steam, feed and network water.
7. Actuators for gas, air, feed water and vacuum in the boiler, which must ensure the supply of the medium.
8. Frequency converters for controlling fan and smoke exhaust motors.

By material and type of heat exchanger

Heat exchangers can be:

• cast iron;
• copper;
• aluminum-silicon;
• made of carbon or stainless steel.

The design of the heat exchanger may also vary.

The most popular are separate heat exchangers. Heating water flows separately, and water for residents’ household needs passes separately. They are a little more expensive, but more reliable.

A bithermic heat exchanger looks like a pipe within a pipe. In the inner pipe there is DHW water, which needs to be heated, and in the outer pipe the heating coolant circulates.

The third type is a heat exchanger in which a coil is built in. The container with water is heated by the coolant flowing in the coil. An indirect heating system is good for everyone, but in the summer you will either have to heat the boiler or live without hot water.

The bithermic option is not recommended for use where there is hard water. And be prepared that every time scalding water will flow out of the tap first, and only then at the temperature you need.

Principle of operation

The operation of energy-dependent thermal process automation systems is based on the analysis of data from the microprocessor unit from primary sensors. All service mode settings that determine the normal operation of the boiler unit are displayed on the main panel, which is installed either on the boiler itself for household units or AOGV, or on a remote control panel for industrial and municipal devices.

Modern boilers are equipped with special programmers that configure multi-day operating modes of the equipment, taking into account the weather forecast; the average outside air temperature is used to test operating modes.

In addition to sensors, the automatic system can be equipped with a controller integrated with the boiler bus for transmitting encoded signals and communication modules that guarantee communication with the consumer of thermal energy via the Internet network remotely using phones. Therefore, with such a high level of service, it is very important that the gas boiler is in good working order, and the automation repairs are carried out by a service center.

Operating principle and types of volatile systems

How does a gas boiler automation work? Volatile systems require electricity and are complex electronic devices that independently regulate fuel supply and flame power, which means they help save money on home heating.

Room thermostat

The thermostat is located in the room where the temperature needs to be controlled. Sensors make measurements.

If the temperature drops below the set value, the thermostat sends a signal to the boiler and it automatically starts working.

When t reaches values ​​that are comfortable for residents, the valve closes and the boiler stops working.

Connects to the boiler with a cable.

Daily programmer

The device performs the same role as a thermostat, but with the ability to set a program for 24 hours. Programs the temperature for heating and hot water supply by time. A day later the cycle repeats.

It is connected to the boiler by cable and via radio.

Weekly programmer

It has greater capabilities for programming the climate in the house. There are ready-made modes and customizable ones. Range of action – from 30 m and more. The data is displayed on a backlit display. Devices can be selected according to color for a specific interior.

Weekly programmer Auraton 2025

Modern devices not only regulate the temperature, but also carry out self-diagnosis of the equipment, control the operation of the pump and protect the boiler from freezing.

Electronics or mechanics

Modern boiler units, especially Western ones, are equipped with electronic boiler control systems, the cost of which reaches up to 30% of the total installation cost. The advantages of such a system are obvious; there is one drawback: it is afraid of unstable operation of Russian electrical networks. Therefore, it must be operated with reliable stabilizers and autonomous power supplies.

The range of regulation and control of the electronic system is practically unlimited: from pressure and temperature of the coolant to weather-dependent control of the heating unit.

In the safety system, the boiler will be turned off from the fuel supply at high/low gas pressure, torch separation, lack of vacuum in the furnace, low/high pressure and coolant temperature.

Mechanical actuators are also installed - a gas shut-off valve that is triggered by unacceptable gas pressure and a safety relief valve that protects the internal circuit of the boiler from high environmental pressure.

Mechanical systems operate only using mechanical valves and sensors that send a signal to the actuator or BURS ignition unit.

For example, the Buderus boiler unit is started by squeezing the gas valve washer, at the same time it opens and gas is supplied to the igniter. It heats up a thermocouple, which produces a current with enough voltage to drive an electromagnet to hold the valve open.

Next, the power of the boiler unit is set by the regulator, which allows gas to flow in the required volume with the operating pressure, and the heating process is controlled by a thermostat.

Brief overview of products from popular manufacturers

The second place in popularity among foreign gas valves after the “Italians” is confidently occupied by American-made Honeywell automatics. The simplest budget model of a combined device works on the same principle as EUROSIT and has the same set of functions.

Under this brand, there are other types of automation on the market for gas boilers and other gas installations with advanced capabilities. For example, the Honeywell VR 400 model is equipped with two valves with a servo drive for working with electronic control units of gas boilers or remote controllers. The device has the following additional functions:

• smooth ignition system;
• modulation operating mode;
• built-in mesh filter;
• maintaining the burner mode “low flame”;
• additional outputs for connecting minimum and intermediate pressure switches.

Considering the operating conditions in the post-Soviet countries, the installation of automation on a gas boiler, which is adapted to these conditions, does not lose its relevance. Such devices are offered by many Russian manufacturers, among them Orion combined gas valves and SABC automation deserve attention. The latter is manufactured (Ulyanovsk), and the range of products for gas installations is very wide.

It includes both the simplest safety devices with a minimum set of functions, and equipment sets that include several units: control, power and gas burner. SABC brand products are well known to consumers for their affordable cost and maintainability.

Installing SABC

Orion automation is also widely popular, namely the Orion - 16 and Orion - 20 models for household boilers. These 2 products use the same principle in their work with a thermocouple, solenoid valve and piezo ignition, only in addition to the main functions, these devices can support low flame mode burners when the set coolant temperature is reached. The range of their application is gas boiler installations with a power of up to 32 kW.

https://youtube.com/watch?v=6jTJyCcGkSo

Which automation is better?

Today, the boiler equipment market is oversaturated with proposals for boiler automation coming from both imported and domestic manufacturers.

The first ones are very expensive and capricious, they do not tolerate the operating conditions of Russian engineering networks, the second ones are less functional. The best automation for a boiler is always its own, that is, produced in a single configuration by the manufacturer.

It is there at the stands that it receives the correct settings with the operating modes of the unit. An equally important factor in boiler room automation is the manufacturer’s warranty, which must guarantee its operation free of charge for at least a year and replace the unit if it fails.

German

German automation for boilers Vaillant, Honeywell, AEG, Bosch is quite popular on the Russian market, which is explained by its excellent consumer quality, durability and reliability. High level of automation and protection. Recently, German manufacturers have established automation of condensing boilers, ensuring efficiency. almost 100%.

Italian automatics

EuroSIT 630 is considered the best Italian automatic system for gas boilers in the world. It is produced in full compliance with EU standards, but at the same time has a lower price than German systems.

The EuroSIT 630 boiler automation covers all parameters of the boiler operation, but is very sensitive to the operating parameters of the gas line and electrical network. For this system, it is mandatory to install input voltage stabilizers.

Russian

Recently, more and more boilers are being purchased with Russian automation systems, since they provide a good protection system and reliable boiler control at the lowest prices.

The experience gained with automation of processes in industrial boiler houses has been successfully integrated into the operation of household boilers using the latest technologies and developments from European manufacturers. Among the large number of Russian companies, especially the most popular are Neva-Transit and Lemax.

Commissioning of a wall-mounted boiler

For installation and initial start-up of a wall-mounted gas boiler, it is better to contact the organization of the specifics in question. The presence of all approvals and appropriate qualifications for the installation of water heating equipment on the part of the service center will allow you to purchase a warranty, as well as extend it with proper operation in subsequent years. All this must be accompanied by documentation in the form of an act or card with a stamp and signature.

In addition to the provided warranty, when contacting specialists, another advantage is the safe installation and adjustment for economical operation of the gas boiler. Safety means the absence of gas leakage and the risk of unwanted ignition.

Installation features

According to SNiP requirements, the heating boiler must be connected to the gas main using a copper pipe or a stainless steel bellows hose. The presence of a gas shut-off valve is mandatory. It is also possible to use various types of adapters and fittings for connection. We must not forget about the presence of gaskets and sealing materials at the joints.

Gas boilers can only be mounted on fireproof walls at a distance of at least 2 centimeters. Otherwise, a fireproof material (plaster, metal or ceramics) must be placed between the boiler and the wall. The distance to the wall should be more than 3 centimeters, and the sheet area should exceed the dimensions of the heating installation in width and height.

Another important condition for placing a gas boiler is the presence of a hood and a window with elements of free air access. After installing the heating boiler, it is necessary to check for gas leaks using an electronic device or a soap solution.

Commissioning

The sequence of actions when starting a wall-mounted gas boiler may differ slightly and be as follows:

The best manufacturers of boiler automation and safety systems

The best manufacturers of automation systems for household boilers on the Russian market are considered to be the following companies: Aries, Orion, Eurosit, Nech st24 wpa 120, Honeywell and Atos wpa 120.

Aries

Automation for OWEN boilers operates using OWEN PLC controllers with TRM, which constitute a complex of protection and control of shut-off and control valves and valves, which ensures economical management of the fuel combustion process and energy efficiency of units, both single-circuit and double-circuit.

The devices are equipped with RS485/RS232 communication interfaces, allowing integration into a common automated system of several control and protection objects when operating on several heating boilers.

Orion

Automation "Orion" of mechanical type for gas fuel boilers. Equipped with an electric traction sensor and a piezoelectric ignition system. The boiler is protected in case of flame separation and low draft pressure. Automatic regulation occurs based on the low return coolant temperature parameter. In this case, based on a signal from the temperature sensor, the regulator valve increases the gas flow to the burner and, conversely, at a high water temperature in the heating circuit, the gas flow decreases.

Eurosit

Eurosit 630 is an Italian gas automatic for a boiler unit with a non-volatile valve, a modulation thermostat and a function for starting the burner device. It is put into operation manually by pressing the washer-regulator of the solenoid valve, after which the gas flows to the igniter.

After igniting the igniter, the temperature sensor creates a voltage sufficient to keep the valve open and reach operating power. The safety of the unit is ensured by cutting off the gas when the temperature of the coolant is exceeded, shutting off the gas to the torch, stopping the blower fan and the circulation pump.

Nech st24 wpa 120

Polish automation for a group of solid fuel and gas boilers, complete with control of the operation of a blower fan and an electric circulation pump for an in-house heating system.

The control unit is installed on the boiler body. The controller sets the temperature of the internal air in the room, then the boiler of a private house operates in automatic mode, the actuators are a gas valve-regulator, a blower fan and a centrifugal pump.

The control panel has an LCD display with visualization of coolant heating processes and boiler operating parameters.

Honeywell

Automation made in Germany by Honeywell is considered the most reliable and efficient, capable of adjusting the coolant in the temperature range from 40 to 90 C. The boiler is protected according to the following parameters: low gas pressure, flame separation and low coolant temperature.

The price of the kit is very high, which reduces its attractiveness. Therefore, the manufacturer recently began to produce economy class equipment.

Atos wpa 120

Another Polish automation system, mainly included with the Tech ST-24 solid fuel boiler with WPA 120 fan.

The microprocessor controller monitors and controls the heating temperature of the supply coolant, the operation of the blower fan and circulation pump and signals an emergency situation during boiler operation.

The ATOS command controller for gas boilers has a built-in ANTI-STOP system, which supplies gas to the boiler in the summer and automatically turns it on every two weeks for 30-50 seconds to prevent corrosion processes and jamming of the centrifugal circulation pump.

Tasks and goals

Modern boiler room automation systems are able to guarantee trouble-free and efficient operation of equipment without direct operator intervention. Human functions are reduced to online monitoring of the performance and parameters of the entire complex of devices. Boiler room automation solves the following problems:

• Automatic start and stop of boiler units.
• Regulation of boiler power (cascade control) according to the specified initial settings.
• Control of feed pumps, monitoring of coolant levels in the working and consumer circuits.
• Emergency stop and activation of signaling devices if the system operating values ​​exceed the established limits.

Gas boiler automation repair

If the boiler automation was purchased together with the boiler, it is configured at the manufacturer, then its operation is very reliable throughout the entire period stated by the equipment manufacturer.

Problems occur more often on European equipment, which are caused by the instability of Russian engineering systems. The most common breakdowns occur in the igniter, shut-off valve, electronic board and temperature sensors.

What you can do yourself

If the safety automation along with the boiler is under warranty, then it is better to contact a service center in case of any breakdown.

Many manufacturers in EU countries require equipment to be submitted for service only through branded centers and even after the end of warranty service. In these situations, it is not recommended to perform independent repairs. It is also unacceptable to change electronic control boards yourself.

The only thing that the user can repair on his own is to carry out testing and minor repairs to the mechanical part of the actuators and sensors.

Basic malfunctions and their repairs

Malfunctions of automatic gas boilers, which are most often encountered in practice, compiled from reviews of users and specialists in the field of maintenance and repair of household boilers.

Causes of the malfunction:

1. The torch on the igniter does not light, the nozzle or gas filter is clogged, clean it from dirt and blow it out.
2. A gas valve is defective, if it is under warranty, it is preferable to replace it with a new one at a service center.
3. There is no contact between the cable and the traction sensor, the cable is disconnected and the contacts are cleaned.
4. The draft sensor does not work; if the contacts are short-circuited and the cable is disconnected, the torch does not go out; it needs to be replaced with a new one.
5. The thermocouple gives -EMF less than 0.3 mV; the thermocouple needs to be replaced.

Automation of boilers today is not a whim of the owner, but a requirement of standards for the safe operation of such units. It is achieved by using a variety of control and protection means: mechanical, hydraulic, pneumatic, electronic and computer, which are often combined depending on the level of automation and its cost.

The use of automatic systems in boiler operation increases their safety and ensures the most energy-efficient operating modes.

Automation of boiler equipment

The modern market is widely represented by both individual instruments and devices, and automation kits of domestic and foreign production for steam and hot water boilers. Automation tools include:

• ignition control and flame presence equipment, which starts and controls the fuel combustion process in the combustion chamber of the boiler unit;
• specialized sensors (thrust pressure meters, temperature, pressure sensors, gas analyzers, etc.);
• actuators (solenoid valves, relays, servos, frequency converters);
• control panels for boilers and general boiler equipment (remotes, touch screens);
• switching cabinets, communication lines and power supply.

When choosing technical means of management and control, the closest attention should be paid to safety automation, which eliminates the occurrence of abnormal and emergency situations