In order to prevent emergency situations that could lead to the destruction of boiler room equipment, as well as injury and death of personnel, there is an automatic safety system. By using various sensors the pressure of water and steam is monitored, the presence of a torch on the burners, the outlet water temperature, and the water level in the steam boiler. If dangerous limits are exceeded, the sensors transmit a signal to the warning device, which signals with sound and light alarms, followed by turning off the voltage on the solenoid valve. Cutting off the voltage to the solenoid valve causes the valve to close and cut off the gas supply to the burners.

The operation of the security automation is carried out according to the following scheme:

Primary sensor - intermediate time relay - light and sound alarm - safety shut-off valve

• Ionization sensor - monitors the presence of flame in the burner.

• ECM - electric contact pressure gauge - steam pressure sensor on a steam boiler

• EKT - electric contact thermometer - water temperature sensor. Installed at the water outlet of the hot water boiler and at the economizer outlet.

• DN - pressure sensor - pressure sensor (air, gas)

• DNT - pressure and draft sensor - a sensor that controls air pressure and vacuum in the firebox.

• SPD - pressure drop alarm - vacuum sensor in the furnace.

• SPU - limit level switch - monitors the water level in the steam boiler. The SPU has two sensors that control the upper and lower water levels in the drum.

Each sensor has an electrically conductive contact that closes the electrical circuit and transmits a signal to the control relay. In one case, the closure occurs with water, in the other, through a membrane under excess pressure. The burners also use photo sensors to monitor the presence of a flame.

Automatic safety controls the necessary parameters and, if they are violated, stops the gas supply to the boiler furnace.

Control is carried out according to the following parameters:

• The torch goes out on the burners.

• Increasing steam pressure on a steam boiler.

• Increasing the water temperature at the outlet of the hot water boiler.

• Increase or decrease in gas pressure in front of the burners.

• Reduced air pressure in front of the burners.

• Reducing the vacuum in the furnace.

• An increase or decrease in the water level in the steam boiler beyond the permissible level.

• Disabling everyone circulation pumps hot water boiler.

• Power outage.

Gas industry

Gas industry In order to prevent emergency situations that could lead to the destruction of boiler room equipment, as well as injury and death of personnel, there is automation

Safety automation for boilers

820 NOVA SIT This multifunctional gas supply regulator with thermoelectric flame protection system; with gas supply blocked after the electromagnet is reset; with a three-position control knob: “off”, “pilot”, “on”; pressure regulator with servo control; electromagnetic relay on / off 820 NOVA is suitable for use in boilers, gas stoves, convectors, fireplaces and infrared heaters.

• Thermoelectric flame protection system by blocking the gas supply to the main burner.
• Locking mechanism to prevent erroneous actions.
• Modulation thermostat.
• Setting the gas supply to the pilot burner. -
• Setting device maximum flow gas or pressure stabilizer. -
• Connections for measuring gas pressure during setup. -
• Piezo igniter

Automation "ARBAT" is used for installation as part of gas burner devices in household heating boilers and devices with a power of up to 50 kW, operating on natural and liquefied gas, serves for automatic regulation gas consumption, thermal process in a heated room and turning off the gas burner device if there is no draft in the chimney or the pilot burner flame goes out.

Automatic regulation and safety "ARBAT" provides 5 degrees of protection:
— stopping the gas supply when the pilot burner flame goes out;
— turning off the burner when the gas supply is temporarily interrupted;
- stopping the gas supply in the absence of vacuum in the chimney;
— automatic blocking of gas supply to the main burner when the igniter is ignited;
— automatic maintenance of the set coolant temperature.

Automation is distinguished by its versatility, rational layout, relatively simple design with a large number of operations performed. The operation of the block does not depend on its orientation in space.

Safety automation for hot water boilers

Used for different types of boilers different kinds safety and regulation automation. This is due different conditions combustion, properties of fuels, boiler volumes and their purpose. In addition, automation for one type of boiler may differ significantly.

Types of hot water boilers and their automation

To ensure normal operating conditions, water heating boilers require automatic regulation and safety of the RBIP type, which stands for proportional integral non-contact regulator. Safety automation for gas boilers is safety valve with low pressure, which is additionally equipped with an electromagnet. If the operation of the boiler is based on the use of fuel oil as fuel, then an automatic valve is used, which is installed at the point where the fuel is supplied to the furnace. Thus, for boilers with a certain type of fuel it is necessary different types safety equipment, so when purchasing units you should pay attention to this Special attention. (See also: What you need to know about outdoor boilers?)

Valves in boilers can be controlled from a control panel remotely. Moreover, it has all the necessary locks. Thus, it is not possible to close the valve on the water pipeline until the valve on the gas pipeline is closed. Other actions that could disrupt the correct functioning of the system are also blocked, that is, the automation is fully responsible for the safe operation of the units, which reduces the risk of an accident to a minimum.

Functionality of automatic water heating boilers

In most cases, automation for boilers involves the following functions:

• Automatic ignition;
• Control of the hot water boiler during operation, for example, temperature control and maintenance;
• Keeping records of fuel consumption, which allows you to track fuel costs;
• Automatic shutdown of the hot water boiler in case of an emergency;
• Activation of sound and light alarms;
• Stop the operation of the hot water boiler if necessary.

The range of listed capabilities may vary with respect to the functionality of hot water boilers, each of which must be matched with a specific type of automation. (See also: Manufacturers of gas boilers)

For ease of use of the device, you can purchase a device with a graphic, text, or color display, on which a mnemonic diagram of objects can be displayed. Today, there are many automation modifications on the market regarding these parameters, so buyers have the opportunity to choose the most suitable option for them.

As a rule, boiler automation allows you to regulate the fuel supply according to feedback or according to temporary settings. In addition, the system is equipped with a device that is responsible for interrupting the fuel supply in the event of an emergency, which reduces the risk of an emergency situation and also significantly increases the level of safety of the equipment used.

Automatic control of hot water boilers

Safety automation for hot water boilers provides the ability to manually stop the boiler by pressing a certain button. Changes in parameters during system operation are carried out by the following sensors: (See also: Hot water boilers on gas)

• An electric pressure gauge changes the fuel pressure in the pipeline;
• Resistance thermometer (RTM) – increase in water temperature;
• Differential pressure gauge – reducing water consumption;
• With a control electrode or photoresistance FSK – flame extinguishing in the burners;
• DT draft sensor - drop in vacuum in the furnace.

Advantages of automatic boilers

This type of boiler is the most in demand today, and this is explained by a number of reasons. Firstly, automatic boilers do not require constant human presence. Secondly, if it is necessary to adjust the work process, there is no need to approach the unit; the entire process is regulated using automation. Thirdly, automation makes it possible to bring the safety of boilers during their operation to the safest level possible.

Thus, the use of automation makes it possible to make the use of this kind of units not only very convenient, but also as safe as possible. They can prevent incorrect actions (block any command and report it), prevent emergency situations by turning off the system.

Types of automatic water heating boilers

Today there are enough a large number of varieties of automation for water heating boilers and this is explained, of course, by the fact that a huge number of modifications of the boilers themselves are made. They can be divided according to the fuel used, power, size, etc. (See also: Which boiler to choose?)

This difference in units is explained by the fact that some can be used for domestic needs, others - for small industries, and others - for huge production workshops. Whatever the water heating boiler, you can choose the appropriate automation for it, and boiler automation can vary not only appearance, but also certain functionality (the presence of special control buttons, display, etc.), which completely depends on the modification of the unit itself.

It should be noted that the latest models of water heating equipment immediately imply the presence of automation, which greatly simplifies the purchase process. There is no need to additionally look for this or that model. If automation is not included in the boiler package, it is often offered to be purchased together with the unit, which is also convenient for the buyer.

Safety automation for hot water boilers

To ensure normal operation, water heating boilers require control and safety automatics of the RBIP type. The safety automatic for gas boilers is a low-pressure safety valve supplied with an electromagnet.

Automatic boiler safety and regulation

Automation kit ABU-1 for training fire-tube boiler of the “Turboterm” type

Pump control cabinet

Touch panel for indicating the operating parameters of a fire-tube boiler of the “Turboterm” type

Frequency control cabinet network pumps boiler room

Control panel and emergency interlocks of a fire-tube boiler of the “Turboterm” type

“Frivolous people don’t even stay in the toilets for long.” Gennady Malkin

By subscribing to the Set of Training and Methodological Materials for the Boiler House Operator, You will receive the book “Definition of Knowledge” for free. Test for boiler room operator.” And in the future you will receive both free and paid information materials from me.

TOR ON THE TOPIC "AUTOMATIC BOILER SAFETY AND REGULATION"

Test “Automation of boiler safety and regulation” to test the knowledge of gas boiler room operators. The main element of the boiler safety automation circuit is the gas shut-off valve. Check yours urgently professional competence and demand in the labor market!

KNOWLEDGE TEST QUESTIONS

1. Select correct option answer from those proposed. The gas shut-off valve in the automatic safety circuit of a hot water boiler is used for:

a) regulating the gas pressure entering the boiler;

b) regulating the gas flow to the boiler;

c) automatic shutdown of gas supply to the boiler if any parameter involved in the boiler safety automatic circuit is exceeded.

2. Choose the correct answer from the options provided. Delay in response of the gas shut-off valve in the automatic safety circuit for reducing the air pressure in front of the burner:

3. Choose the correct answer from the options provided. Common sensors in safety and control automation circuits are as follows:

a) only a sensor for water temperature after the boiler; b) sensor for water temperature after the boiler and sensors for gas and air pressure in front of the burner; V) common sensors There are no automatic safety and automatic boiler control circuits.

4. Choose the correct answer from the options provided. A technical pressure gauge measures pressure:

a) atmospheric; b) excessive; c) absolute; d) vacuum gauge.

5. Choose the correct answer from the options provided. Checking the serviceability of the pressure gauge is carried out:

a) every shift, by setting the pressure gauge to zero, by the boiler room operator; b) once every six months by the instrumentation and automation service; c) once a year by the State Trustee.

Liquid pressure gauges

6. Choose the correct answer from the options provided. Pressure measurement accuracy liquid pressure gauge higher y: (P - measured pressure; h - difference in liquid levels; h 1 - change in liquid level in the tube; h 2 - change in liquid level in the vessel).

a) U-shaped pressure gauge; b) cup; c) micromanometer.

7. Choose the correct answer from the options provided. Delay in response of the gas shut-off valve in the automatic safety circuit for extinguishing the burner torch:

a) is allowed and this must be reflected in Manufacturing instructions; b) is not allowed.

8. Choose the correct answer from the options provided. Work of hot water gas boiler with a faulty automatic control system:

a) not allowed; b) allowed.

9. Choose the correct answer from those given. With this position of the three-way tap of the pressure gauge:

Boiler pressure gauge with three-way valve

a) purging the siphon tube; b) checking the working pressure gauge against the control pressure gauge; c) measurement of working pressure; d) checking the pressure gauge by setting it to zero; e) accumulation of condensate in the siphon tube (if steam parameters are measured).

TEST QUESTIONS TO ASSESS ABILITIES AND SKILLS

10. Add. Automatic control of hot water boilers includes:

Dear friend! You will find the answers to this test in the Test Set for Boiler House Operators or in Study guide"Boiler room operator" These information materials are paid. It is advisable to have them in your personal library. Questions and recommendations can be left on the Contacts page of the website. See you in touch!

Best regards, Grigory Volodin

Automatic boiler safety and regulation

Test "Automation of boiler safety and regulation" to test the knowledge of gas boiler room operators. Gas shut-off valve in an automation circuit

To automate DKVR, DE boilers that run on gas/fuel oil and TVG, KV-G boilers that run on natural gas, they use automatic control kits based on the Kontur system, automatic safety and control systems in a switchboard type Shch-K2 (Shch-K2U ).

The Kontur system was mastered by the Moscow Thermal Automation Plant (MZTA) in 1978. Until that time, MZTA had produced the Kristall electronic-hydraulic system.

Rice. 28. Front panel of instruments of the “Kontur” system.

Automatic control "Contour" (see Fig. 29) designed to regulate parameters technological process boiler units.

Every automatic regulator It has:

1. Sensor (primary device).

2. Regulating device (amplifier).

Z. Actuator mechanism.

4. Regulatory authority.

D is a sensor that reacts to a change in the measured parameter and converts the change in the parameter into an electrical signal. The sensor consists of a measuring and electrical transducer.

The measuring transducer can be an elastic membrane, a manometric tube, etc.

The electrical converter consists of a differential transformer coil and a steel core.

I - primary winding of the differential transformer coil;

II - secondary winding of the differential transformer coil;

III - steel core;

IV - elastic membrane of the measuring transducer.

Rice. 29. Diagram of the automatic control system "Kontur" on steam boilers type DVKR.

The sensor receives power »Uin = 12 (24) V from its control device P.25. U out changes its value depending on the position of the steel core III.

R.25 - a regulating device with a setpoint. It supplies power to its sensor, from which an electrical signal U out is received, which is compared with a given one, and if these signals are unequal, an amplified electrical signal appears at the output of P.25, which turns on the actuator.

IM - actuator - can be hydraulic type GIM and electric type MEO (electric unirotational mechanism).

It moves the regulator.

RO is the regulatory body. Depending on the parameters that are regulated, it can be: a control damper (RZ), a blower fan guide vane (ADV), a smoke exhauster guide vane (ADV), a control valve (RK).

Regulators are installed on steam boilers:

1 - Steam pressure regulator in the boiler drum.

2 - Gas-air ratio regulator.

3 - Vacuum regulator in the furnace.

4 - Water level regulator in the boiler drum.

Automatic boiler protection is designed to shut off the fuel supply to the boiler burners if the safety parameters deviate beyond acceptable limits.

According to the parameters of the vacuum in the furnace and the water level in the drum, the fuel supply is turned off with a time delay of 15-20 sec. This eliminates the influence of short-term changes in vacuum and level, which cannot cause a boiler failure.

When the protection system is in the on state, the sensor contacts that monitor the parameters included in the circuit are closed. The corresponding intermediate relays and the electromagnet that controls the shut-off valve are energized. The fuel shut-off valve is open. The protection system remains in this state as long as the parameters included in it are within normal limits.

If one of the parameters deviates beyond the permissible limits, the contact of the corresponding sensor opens, the current disappears on the intermediate relay and the electromagnet that controls the fuel shut-off valve. Shutting off the fuel supply is accompanied by the lighting of the shutdown reason and “Boiler off” display, then the sound alarm turns on.

The protection control elements include six light displays of the TSV type (two-lamp), installed in the upper part of the front panel of the Shch-K2 (Shch-K2U) automation panel. When switched on, the display does not light up, and when the protection is triggered, the lamps of only one display light up, which indicates the reason for the operation, as well as the lamps of the “Boiler off” display.

The shut-off valve is opened using the valve levers installed on the gas pipeline in front of the boiler.

The protection controls on the Shch-K2 (Shch-K2U) panel include a boiler switch, a fuel switch, and a photosensor switch.

The boiler switch handle has four fixed positions:

1) vertical - protection is turned off;

2) 90° from the vertical clockwise - preliminary switching on (ignition of igniters);

3) 135° clockwise - the protection is fully turned on (set to standby);

4) 45° from vertical counterclockwise - protection is previously disabled.

The fuel switch handle has two fixed positions:

a) vertical - the boiler runs on fuel oil;

b) horizontal (90° counterclockwise) - the boiler runs on gas.

The photo sensor switch handle has two fixed positions:

a) vertical - the torch of the left burner is controlled;

b) 45° from the vertical counterclockwise - the torch of the right burner is controlled.

Technological protection includes:

Boiler safety automation;

Process alarm;

Automatic flame control automatic transmission.

Automatic safety sensors:

1. Gas pressure - sensor type DN or DD.

2. Air pressure - DN type sensor.

3. Vacuum in the furnace - DNT type sensor.

4. Presence of flame - electronic flame control unit with a photocell or control electrode.

5. Steam pressure - ECM (electric pressure gauge).

6. The water level in the drum can be controlled:

a) using electrodes placed in a uniform column, which is connected to the boiler drum;

b) using a level column and a differential pressure gauge-level gauge with setpoints.

The operation of the automatic safety system should lead to shutting off the fuel supply to the burners when the controlled parameters are turned off beyond the permissible values.

Considering that emergency modes most often arise due to incorrect actions of maintenance personnel when starting the boiler, the automatic safety circuit includes remote and automatic ignition as a component, during which the following must be ensured:

1. Control over correct execution pre-launch operations.

3. Filling the boiler with water.

4. Monitoring the normal state of parameters during startup.

5. Remote ignition of the igniter from the control panel.

For steam boilers Regardless of steam pressure and performance, devices must be installed that will automatically turn off the fuel supply to the heaters when:

1 - increase or decrease in fuel pressure in front of the burners;

2 - decreasing air pressure in front of burners with forced air supply;

3 - lowering the vacuum in the furnace;

4 - extinguishing the burner torch;

5 - increasing steam pressure above the working one;

6 - increase or decrease in the water level in the boiler drum beyond acceptable limits;

7 - malfunction of protection units, including loss of voltage.

The “Contour” automation system is turned on in the following sequence:

1. Prepare the boiler for ignition in accordance with the production instructions.

2. Make sure that the supply voltage is supplied to the Shch-K2 (Shch-K2U) shield.

3. The instrumentation and automation mechanic should check the installation of the necessary protection inserts:

a) the required water level in the drum;

b) the required vacuum in the press;

c) normal air pressure in front of the burners. After this, the corresponding signal board on the front panel of the shield goes out. When only the “Boiler off”, “No torch” and “Low gas pressure” displays remain lit, you must:

4. Return the boiler switch knob on the Shch-K2 (Shch-K2U) panel to the “Preliminarily switched on” position. When the handle is in this position, the igniter turns on and the “No torch” signal board goes out.

5. After the pilot light appears, cock the shut-off valve levers (open the gas passage).

6. Light each burner by manually opening the taps (valves) in front of the burners. Set the gas pressure to the burners according to the regime map (30% - no load).

7. Adjust the air supply and vacuum in the furnace.

8. After ignition of the burners with a time delay, it is turned off using the pilot light.

9. Set the boiler switch knob to the “On” position. We set the boiler protection to standby condition.

10. When the pressure in the boiler reaches operating pressure, connect the boiler to the general boiler steam manifold.

11. Make an entry in the shift log about ignition of the boiler, indicating the time.

The planned shutdown of the boiler is carried out by smoothly changing one of the parameters included in the protection system. When this parameter goes beyond the permissible limits, the protection is triggered and the boiler stops. At the same time, the operation of the protection is checked.

After turning off the boiler using the shut-off valve, close the “control” and “working” valves (valves) in front of the burners and open the purge “candles” between them. Close the valve on the gas pipeline in front of the boiler, opening the “candle” on the gas manifold of the boiler.

Close the main steam valve on the boiler and disconnect it from the main steam manifold. When the pressure in the boiler rises, release it through the safety valve. Maintain the water level in the drum within the highest operating level in the boiler.

Make an entry in the shift log indicating the time the boiler stopped.

SABK-T

Automatic safety system for gas-fired installations

Manual

M-00.00.000 PS

Maximum gas pressure in the network, kPa

Nominal gas pressure in the network, kPa

Minimum gas pressure in the network, kPa

Stabilized gas pressure at the outlet of the automation unit at a network pressure of 1.3 to 3 kPa, kPa

Maximum throughput for gas at pressure

1300 Pa, m3/h

Weight of the set, kg, no more

Ambient temperature of the boiler room, 0C

Setting range for water temperature control limits

Vacuum in the boiler furnace, Pa

Gas supply hole dimensions, inches;

nominal diameter, DN, mm

Inertia period for automatic gas supply shutdown:

In the absence of traction, sec., within

When the pilot burner goes out, sec., within

When a leak appears in the pulse system, sec., no more

Inertial period of automatic operation when igniting the pilot burner, sec, no more

Table 2.

Name parameter	Standard for automation
				SABK-8-100M	SABK-8-110M
Thermal power of the GGU, kW

4. Contents of delivery.

4.1. The completeness of the automation must correspond to table. 3.

Table 3.

Pos. in Fig.1	Node name	Quantity
	Control block
	Ignition block
	Traction sensor
	Collector
	Burner pipe
	Impulse tube
	Ignition tube
	Pulse tube laying
	Temperature sensor gasket
	Paronite gasket for traction sensor
	Square 1-Ts-25x15 GOST 8947-75
	Lock nut G1/2-B
	Locknut G1-B
	Screw M4x12
	Package

* The GGU is part of the boiler (apparatus).

5. Design and operation of the product.

5.1. The automation is a device consisting of a control unit, an igniter unit, a draft sensor, impulse tubes, an igniter tube and a gas burner device (Fig. 1).

5.2. The control unit (Fig. 2) performs the functions of igniting the igniter and the main burner pipes of the gas burner device (GGU), automatically regulating the set water temperature at the boiler outlet, maintaining set pressure gas for the burner pipes of the GGU when the gas pressure at the inlet changes from 1300 Pa to 3000 Pa (short-term up to 5000 Pa), automatic blocking of the main burner when the igniter is ignited, stopping the gas supply to the main burners and the igniter in emergency situations: when the igniter goes out, in the absence drafts in the chimney.

5.4. Schematic diagram The operation of the control unit is shown in Fig. 3.

When gas is supplied to the input of the control unit, the gas pressure “P” in the cavities of the unit before igniting the igniter (in the “OFF” position) is distributed as follows:

In cavities “2” there is inlet pressure P, valve K-1 is closed, in the remaining cavities there is no gas pressure.

When igniting the igniter, you must turn the knob from the “OFF” position. to the “IGNITION” position. In this case, gas from cavity “2” enters cavity “3” and to the igniter. At the same time, through the throttle "Dr1" the gas enters the cavity "1" and into the nozzle of the flame sensor, where it is discharged into the boiler furnace. The flame sensor is normally open, the draft sensor is normally closed. After the igniter is ignited, the bimetallic plate begins to heat up, which closes the flame sensor valve and the discharge of gas through the nozzle stops. Gas begins to flow into cavity “1” and with an increase in pressure in it, the membrane “M1” overcomes the force of the spring and the pressure on the membrane M2 lifts the valve “K-1” with a rod. After this, when the handle is returned to the “OFF” position, gas begins to flow to the igniter from cavity “2” through the open valve “K-1” (the normal operating mode of the igniter).

When the igniter is ignited, valve “K-4” of the temperature control unit closes the “Supply” nozzle and opens the “Reset” nozzle. There is no gas pressure in cavities “4”, “5”, “6”. This way the gas supply to the main burners is blocked when the igniter is ignited.

When the PTV control knob is moved to a position on the scale of 50 ¸ 90 °C, the “K-4” valve clicks to close the “Reset” nozzle and opens the “Feed” nozzle in the temperature control unit. Gas from cavity “3” enters cavity “4”. The gas pressure in the cavity “4” of the working valve, the membrane “M3”, lowers, opens the valve “K-2”. Gas from cavity “3” enters cavity “5” and then into the burner pipes of the GGU boiler, where it is ignited by the igniter flame.

When the water in the boiler is heated to a set temperature, the temperature sensor is triggered to close the “Supply” nozzle and open the “Reset” nozzle in the temperature control unit (RTB). Gas from cavities “4”, “6” is discharged into cavity “5”. The “M3” membrane rises, the “K-2” valve completely shuts off the gas supply to the gas turbine unit. The pilot light continues to burn.

When the water temperature in the boiler decreases, the temperature sensor is triggered and the “K-4” valve opens the “Supply” nozzle and closes the “Reset” nozzle. Gas from cavity 3, according to the previously described scheme, opens the working valve, thereby ensuring gas supply to the main burners of the GGU boiler. Heating of water in the boiler is resumed.

The described process is repeated periodically, thus maintaining the heating of the water in the boiler to the set temperature (50 ¸ 90 ° C).

The control unit provides stabilization of the gas pressure supplied to the main burners of the gas turbine unit when the gas pressure at the inlet to the block increases to 3000 Pa,

(short-term up to 5000 Pa).

The operating principle of the gas pressure control unit for the gas turbine unit is as follows:

When the nominal value of the gas pressure at the inlet to the control unit is exceeded (Over 1300 Pa to 5000 Pa), the pressure in cavities “2”, “3”, “4”, “5” begins to increase. High blood pressure from cavity “5”, enters under the membrane “M-4” of the gas pressure control unit. Overcoming the force of the spring, the “M-4” membrane slightly opens the “K-3” valve and the gas from the “4” cavity begins to be discharged into the “5” cavity and then through the manifold into the burner pipes. The pressure in cavity “4” decreases, and the gas pressure under the membrane “M-3” of the working valve decreases accordingly. Valve “K-2” rises higher to the seat and covers the passage of gas into cavity “5”. The gas pressure in cavity “5”, and therefore at the inlet to the GGU, decreases. Thus, in the constant operating mode of the control unit, the gas pressure in the gas turbine unit is stabilized.

In emergency situations (lack of draft, failure of the igniter flame) or when the “STOP” button is pressed (for emergency shutdown of the automation), the nozzles of the corresponding sensors open: the draft sensor, the flame sensor (or the “STOP” button valve), and from cavity “1” pneumatic control unit, gas begins to be discharged through the impulse tubes. The gas pressure in cavity “1” drops. The “M-1” membrane goes down, and the “M-2” membrane raised by it, under the gas pressure in the “3” cavity, also goes down and closes the “K-1” valve. The gas supply to the igniter and main burners is cut off. Automation is disabled.

To start the automation (after eliminating the cause of the malfunction), re-ignition of the igniter and burner pipes is required (see above).

6. Installation procedure

6.1 The layout of the automation and the location of the control unit and sensors on a boiler of a particular brand is determined by a joint decision of the manufacturers of the automation and the boiler.

6.2. Before installation of the automation, it is necessary to check gas distribution, boiler, chimney, heating system and room, which must comply with the current Safety Rules for gas distribution and consumption systems.

The gas supply pipelines to the automation must be purged. Dirt, scale, etc., if they get into the automation control unit, can disrupt its performance.

6.3. Installation of automation should be carried out in the following sequence (see Fig. 1):

Install the igniter panel onto the GGU panel with two M4x8 screws. When installing the igniter, ensure reliable fire connection with the burner pipes of the gas turbine unit. When equipping the automation with a gas burner device, install the burner pipes with the fire holes facing up and secure them.

Install the control unit on the supply gas pipeline and the GGU manifold. The length of screwing pipes into the inlet and outlet holes of the control unit is no more than 10 mm. Installation is carried out by winding the threads with FUM tape, grade 1, 0.1x10, TU 6 (GOST tow impregnated with lead white MA-011 GOST is allowed), secure with lock nuts. Before installing the control unit, calibrate the threads of the G1-B pipes (inlet and outlet). When conducting welding work plug the holes in the control unit.

Install the collector on the GGU panel.

Install the thermal cylinder with the gasket into the boiler body and secure with a union nut.

Install the draft sensor.

Install the igniter tube, pulse draft sensor and flame sensor tubes. Tubes are bent locally with a radius of at least 50 mm. During installation, ensure the tightness of the connection by installing gaskets and tightening with nuts.

7. Safety requirements.

7.1. Consumers operating automation must be familiarized with the device and the principle of its operation by gas service workers in the prescribed manner.

7.2. Installation of automation must prevent water leakage and gas leakage.

7.3. During pressure testing of the gas pipeline, preventive inspections and stops, the automation must be disconnected from the gas pipeline.

7.4. If the smell of gas is detected, it is prohibited to start ignition.

7.5. Operating a boiler with faulty automation is not allowed. To install, configure, identify and eliminate faults, the consumer must call an adjuster from a specialized gas utility company.

7.6. The consumer is prohibited from:

Produce self-installation, adjustment and repair of automation units;

Disassemble components, replace parts, block the operation of components and sensors;

Allow unauthorized persons and children to service the automation;

Ignite the gas turbine unit without checking the draft in the boiler furnace.

7.7. Installation and dismantling of automation, elimination of defects, replacement of components and parts must be carried out with the valve on the gas supply pipeline closed.

7.9. When the boiler is not working, all gas valves must be closed.

7.10. Water contact with automation units and components is not allowed.

8. Preparing for work

8.1. Installation of automation at the site and its initial inclusion as part of the boiler is carried out by a gas service specialist.

8.2. Ventilate the room in which the heating boiler is installed for 10-15 minutes. Check work supply and exhaust ventilation room by placing a strip of paper near the air ducts.

8.3. Check whether the taps on the gas pipeline descent to the boiler and on the GGU manifold (if any) are closed.

8.4. Check the presence of draft in the boiler by placing a strip of paper near the inspection hole of the gas burner device.

8.5. Ventilate the firebox and boiler flues for 10 minutes by fully opening the air supply damper located on the GGU panel. After ventilation, close the damper in accordance with the operating position.

8.6. Boiler preparation and heating system for start-up is carried out in accordance with the instructions for the heating boiler.

9. Operating procedure

Ignition of the boiler.

9.1. Set the PTV control knob of the automation unit to the “OFF” position.

9.2. Open the gas valve on the gas pipe leading down to the boiler.

9.3. Open the inspection window on the front sheet of the gas turbine unit and introduce a burning paper bundle, turn the PTV control knob to the “IGNITION” position and hold it pressed for 30 seconds. After the igniter has ignited, remove the paper string and extinguish it. Release the PTV handle after the flame sensor is triggered to close (the bimetallic plate should press the ball tightly into the flame sensor body). The presence of a flame at the end of the flame sensor is not a rejection sign when igniting the igniter.

9.4. Check whether the igniter flame is well washed around the end of the bimetallic plate, check and make sure that the gas is burning steadily on the igniter treadmill, and then close the inspection window with the damper.

9.5. Turn the PTV control knob to the scale position at 50-90°C and check the gas ignition on the burner pipes visually through the inspection window.

Keep your face away from the viewing window!

9.6. Set the PTV control knob to any desired temperature heating water in the boiler.

9.7. Check the tightness of all threaded connections using the saponification method. If leaks are detected (gas etching), tighten the connections until gas etching is eliminated.

9.8. Having verified the stable operation of the automation on the boiler with a gas turbine unit, the gas service specialist adjusts the automation according to Table 1, the control thermostat (if available) for a water temperature above 93°C.

9.9. When the set boiler water temperature is reached, the automation turns off the gas supply to the gas turbine unit and turns it on again when the temperature drops to a value determined taking into account the hysteresis zone built into the automation (the hysteresis zone should not exceed 10°C).

9.10. The gas supply to the main gas turbine unit of the boiler is automatically stopped during its operation in the following cases:

Reducing the gas pressure in the main line below 600 Pa,

Insufficient draft in the boiler furnace,

The pilot flame goes out,

Heating water in the boiler above 93°C (with a control thermostat)

The boiler can only be re-ignited after the faults have been eliminated.

Stopping the boiler.

9.11.Close the tap on the descent to the boiler.

9.12. For a short-term shutdown of the boiler (cutting off the gas supply to the burner pipes of the gas turbine unit), it is recommended, without closing the valve on the descent to the boiler, to turn the PTV control knob to the “OFF” position, while only the igniter is lit.

Setting up the temperature control unit

9.13. This adjustment is made after replacing the temperature sensor with bellows and thermal cylinder or if a discrepancy is detected between the temperature set using the control knob and the actual temperature of the boiler coolant.

9.14. Turn on automation. Set the control knob to 90°C. Unscrew the fastening screw (see Fig.2, pos. 8) and remove the handle (pos. 6). Using the thermometer built into the boiler, set the moment of heating the water to a temperature of 90°C. Tighten the adjustment screw (pos. 7) until a characteristic click is heard; the GGU burners should turn off (go out). Without changing the position of the adjustment screw, put the control knob on it, setting it to the 90°C position, and secure the control knob in this position with the screw (pos. 8). This completes the setup operation. By rotating the control knob you can set any water heating temperature (50-90°C) and check the actual water temperature in the boiler using a thermometer.

Replacing the temperature sensor

9.15. Close the tap on the descent to the boiler. Remove the control knob and unscrew the adjustment screw and remove the bellows. Remove the thermal cylinder following the operating instructions for this boiler.

9.16. Install the thermal bulb of the new temperature sensor into the boiler axle box, install the bellows and tighten the adjustment screw. Screw in the adjustment screw until it clicks, and then another 1/4 turn. Set the control knob to the “OFF” position and secure with the screw (pos. 8). Configure the temperature sensor and temperature control unit according to clause 9.14

10. Possible faults and methods for eliminating them.

10.1. The automation design is reliable and correct operation ensures long-term operation of the product. However, during the operation of the automation, malfunctions may occur, the probable causes and methods of elimination of which are indicated in the table.

Table 4.

Nature of the malfunction	Possible reason	Elimination method
Pilot burner fails to ignite	Insufficient gas pressure in the network There is a leak: Union nuts for impulse tubes. Traction Sensor Ball Seals and flame sensor The flame sensor bimetallic plate is loose The bimetallic plate of the flame sensor does not warm up well Large gap between the bimetallic strip and the flame sensor ball	Measure the pressure and, if possible, increase it Fix leaks Tighten the fastening screws Move the flame sensor closer to the bimetallic strip
When gas is supplied to the main burner, the pilot light goes out.	Reduced gas pressure in the network The chimney is clogged	Check gas pressure and draft
When the main burner is ignited, a popping sound occurs from the igniter	Poor fire connection between pilot burner and main burner	Clean the pilot tube nozzle and pilot burner holes.
Dynamic shocks in the heating system (after long-term operation), the main burner does not turn off	The temperature sensor has failed	Turn off the automation and replace the temperature sensor

11.Maintenance.

11.1. Monitoring the automation is the responsibility of the consumer. Automation maintenance is not included in the warranty obligations of the automation manufacturer.

11.2. Maintenance must be carried out at least once a year by qualified specialists from the gas industry or other service centers who have a license to carry out these works.

11.3. The procedure for concluding an agreement rests with the user of the automation. results Maintenance are entered into the automation passport in the maintenance and repair table (Appendix B).

11.4. To ensure normal operation of the automation, it is recommended to perform the following measures:

11.4.1. Weekly:

Remove dust from external surfaces;

Carry out an external inspection of the automation in order to identify mechanical damage to the devices;

Check the reliability of fastening and installation of sensors;

Visually, based on the presence of drips, check the tightness of the connections between the temperature sensors and the boiler heat exchanger;

If there is a smell of gas, check the tightness of the connections on the gas pipeline and automation by washing.

11.4.2. Annually during a planned shutdown of the boiler (after repairs, long-term shutdown or upon expiration of the warranty period):

Check the response time of the flame sensor for the igniter to go out. The time interval should be within 30-60 seconds;

Check the automatic response time to stop traction. To do this, close the boiler damper and use a stopwatch to measure the extinguishing time of the boiler burners. The time should be within 10-60 seconds;

Remove and blow out the impulse and ignition tubes. Attention. Be careful when tightening the M10 nuts on the tubes to avoid breaking them. Don't forget to install gaskets.

12. Transportation and storage.

12.1. Automation can be transported by any type of transport (for aviation, the cargo compartment is heated).

12.2. The placement of the automation and its fastening during transportation should ensure its safety.

12.3. The automation should be stored in packaged form at a temperature from + 5°C to + 35°C and relative humidity within %.

12.4. After transportation in packaging containers with sub-zero temperature Before installing the automation on the boiler, it must be kept at room temperature during the day.

13. Warranty obligations.

13.1. This automation has been tested, meets the requirements of the technical specifications and is certified equipment. No changes should be made to the design of the automation. Otherwise, the manufacturer is not responsible for the performance and safety of the automation and may require the consumer to stop using such automation.

The manufacturer guarantees the functionality of the automation only if the operating, storage, transportation and installation conditions are met.

13.2. The warranty period for the operation of the automation is 30 months from the date of sale through the market commodity network, and for supplies for non-market consumption - from the date of receipt by the consumer, but not more than 36 months from the date of manufacture.

13.3. Guaranteed shelf life - 12 months.

13.4. Average service life before decommissioning, years - 7.

13.5. If the automation fails during the warranty period, you must notify the organization that installed the automation. Together with a representative of this organization or the operating organization of the gas industry, it is necessary to draw up a defect report in the form of Appendix D, fill out a warranty card (Appendix B) and send it along with the defective unit to the address of the automation manufacturer.

13.6. Warranty repairs are subject to the following conditions:

Correct and clear filling out of the warranty card;

Presentation of the faulty device with the execution of an act and detailed description malfunctions;

Availability of a mark and stamp in the commissioning control card.

13.7. The warranty does not cover product malfunctions caused by the following reasons:

Use in violation of the requirements of the Operation Manual or careless handling;

Mechanical damage to the product as a result of impact or falling, or the use of excessive force;

Disassembly or any other outside interference in the design of the product not provided for in the Operation Manual;

Penetration of liquid, dust, insects and other foreign objects into the product;

Natural disasters (accident, fire, flood, lightning, etc.);

Careless storage and transportation of automation;

When installing automation by unauthorized persons;

Self-repair or modification of internal structure;

Incorrect connection;

Artificially blocking the operation of automation devices and sensors.

13.8. If repairs are necessary after the end of the warranty period, you must contact the manufacturer.

14. Rights and obligations of the consumer.

You have purchased a SABK-M security automatic system.

Your actions.

When purchasing, please fill out the warranty card (Appendix B to the passport) and check that the SABK-M product is complete.

After purchase, your claims for incompleteness of the product by the trading organization will not be accepted.

After the purchase Attentively study the passport and the requirements set out in it for the installation, operation and maintenance of safety automation in gas-using installations. SABC-M products have passed certification tests, meet the requirements of technical specifications and meet all safety requirements during operation in accordance with GOST 16569.

Remember!

The warranty period for SABC products is 30 months from the date of sale or receipt from the manufacturer.

To install the SABC product, you must invite specialists from the gas service (raygaz, gorgaz), who have a license to carry out this work. Check that the control coupon (Appendix A to the passport) is filled out by these specialists after completing the installation and commissioning of the SABC product.

In the event of failure of parts and automation components during installation for reasons related to manufacturing, the manufacturer will repair or replace the defective component or part sent with a certificate (Appendix D to the passport). The act is drawn up by specialists, gas services, who carry out this installation of the product with mandatory registration and approval by the head of the gas service, and a certified seal.

Repair or replacement of automation (or individual components) can only be carried out during the warranty period.

Remember!

The manufacturer or seller (trading organization) does not accept claims in the following cases:

Expiration of the warranty period;

Mechanical damage to the automation during transportation after its sale;

During installation by persons or organizations that do not have the appropriate license for this from the State Technical Supervision Authority (OGTI);

Damage or failure of automation associated with violation of storage, installation, maintenance and operation requirements;

If there is no sales mark in the warranty card (Appendix B);

If there is no mark on the installation and assembly control coupon (Appendix A);

In the absence of a malfunction certificate certified by a seal and executed in the prescribed manner (Appendix D);

Violations of safety rules in the gas industry.

The consumer is prohibited!

Operate and service SABC products by persons who have not undergone special training (instruction) and for children;

enjoy hot water from the heating system for domestic purposes;

Use fire to detect gas leaks (use soap emulsion for these purposes);

Turn on the SABC product when there is no draft in the chimney and the heating system is pre-filled with water;

Disassemble SABC products, components, replace parts, block the operation of draft and flame sensors, water temperature regulator.

A mandatory component of the boiler room is safety and regulation automation. Our company provides professional installation and maintenance of automatic systems. If the burner goes out due to any deviations in the system, there is a danger of gas leakage and explosion. To avoid this, it is necessary automatic system ignition, which will start the burner or shut off the gas supply. Installing reliable automation is a task for professionals. Order this responsible work from experienced employees by contacting us.

Installation of automatic boiler room equipment

Automation of safety and regulation is necessary in a boiler room where gas equipment is installed. It prevents dangerous situations arising from the following reasons:

• Reduced gas pressure in the network and interruption of supply. The burner goes out, and when the supply is resumed, the gas enters the boiler room atmosphere, followed by fire. The automatic safety system will turn off the supply and prevent a fire from occurring.
• Lack of traction. In case of boiler malfunctions automatic device will shut off the fuel supply and display an error message for personnel.
• Burner failure due to other reasons. Thanks to automatic control accidents will not lead to a dangerous situation.
• Overheating of the coolant in the boiler to high temperatures. When the temperature rises to 95 degrees, a regulation process starts, which levels it to acceptable values.

The basis of the security system is sensors that detect deviations of parameters beyond acceptable limits. Sensors monitor gas, air, steam pressure, presence of flame, vacuum in the furnace and other parameters. The control unit includes a thermostat and a membrane valve, with the help of which the operating parameters are equalized. The thermostat guarantees maintaining the operating temperature of the coolant with an accuracy of 2 degrees.
Control system ensures stable operation gas equipment and prevents any emergency situations. Its installation - required condition safe operation gas equipment. Design and installation may be carried out by certified employees who have undergone specialized training. We offer professional services: our employees will select everything necessary to create effective system regulation heating equipment.

Why is it beneficial to contact us?

The company's personnel have experience in equipping boiler rooms in residential buildings and industrial enterprises. We will select the appropriate solution for any task. High-quality equipment with proven equipment guarantees timely response of tracking devices to a dangerous signal and prevention of an emergency situation.
We offer a range of services: selection of equipment, professional installation, commissioning, subsequent maintenance with performance monitoring. Automatic equipment is individually selected for each object. We guarantee that we will take into account maximum wishes.
A range of services is offered according to attractive prices. Experience allows us to find profitable solutions for each client. To view the proposed prices and discuss the terms of the contract, call us. Be sure that after concluding the contract, employees will soon cope with the task. Take advantage of the offer today to get the desired result at reasonable costs!

All modern heating installations using natural gas, have high level security, which is achieved through the introduction of automation tools. They monitor and manage the operation of heating units. In this material we will consider automation for gas boilers from the most famous manufacturers, which is most often installed on domestic and imported boilers.

Functions and principle of operation of security automation

In accordance with regulatory documents automation equipment for boiler installations must stop their operation by cutting off the fuel supply during the following situations:

• the draft in the chimney is insufficient and there is a danger of burning;
• the gas pressure in the supply pipeline is too low or, conversely, too high;
• The flame on the igniter went out.

The listed situations can lead to the main burner going out and the room becoming gassed, which is unacceptable. For this reason, safety automatics for gas boilers must be installed on all old-style boilers where it was not provided by the manufacturer. Although it is often cheaper to replace a heater than to purchase and install automation on an old one. In addition to preventing gas contamination of the room or fumes, its functions also include maintaining the temperature of the coolant at a certain level specified by the user.

To understand how the automation of a gas boiler works, let’s briefly analyze its structure. It should be noted that both foreign and Russian manufacturers They use the same operating principle in their products, although the design of the devices may differ significantly. Automatic gas valves from Italian manufacturers are traditionally considered the simplest and most reliable, which is why they are most common.

A prominent representative of such gas appliances is the Italian automatic SIT, or rather, its most popular modification 630 EUROSIT, whose device is shown below.

All structural elements are placed in one housing, to which gas pipelines are connected. In addition, a capillary tube from draft and temperature sensors (thermocouples), a gas supply line for the igniter and a cable from the piezoelectric element are connected to the device. Inside there is a shut-off solenoid valve, whose normal state is “closed,” as well as a gas pressure regulator and a spring valve.

Any automatic gas boiler equipped with a EUROSIT or other combined gas valve is put into operation manually. Initially, the fuel path is blocked by an electromagnetic valve, which opens by pressing the adjusting washer, after which the fuel fills the chambers of the device and goes through a small gas pipeline to the igniter. While holding the washer, press the button of the piezoelectric device and ignite the igniter, heating the temperature-sensitive element for 10-30 seconds. This, in turn, generates a voltage that keeps the solenoid valve open, after which the adjusting washer can be released.

Then everything is simple, we turn the washer to the required division and thereby open access of fuel to the burner, which is independently ignited by the igniter. Since the automation of gas boilers is designed to support set temperature coolant, human intervention is no longer required. The principle here is this: when heated, the medium in the capillary system expands and acts on the spring valve, closing it when it reaches high temperature. The burner goes out until the thermocouple cools down and the gas supply resumes. You can study the operation of Italian SIT automation in detail by watching the video.

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 others. gas installations with advanced features. 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 by the ServiceGaz company (Ulyanovsk), and the range of products for gas installations is very wide.

It includes both the simplest safety devices with minimum set functions, as well as equipment sets, which 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.

Conclusion

Modern automation for a gas boiler plays a significant role in the safe operation of heating equipment; now it is impossible to do without it. Another thing is that more expensive Italian and American devices differ high reliability and durability, this has been tested over years of operation on various water heating installations.