Goodbye Will-Burt, hello LOGO. Cindy Ashley (our boiler) now has a brain!
Replaced the out fire timer with a Siemens LOGO 230RC programmable relay. This tiny relay has over 25 different types of built-in timers, counters, etc that can be used in thousands of combinations. It can do 8 inputs and 4 outputs. It also displays up to 10 screens of live data. The cost is around $200 with programming software and cable. To see how easy it is to program, go to http://www.youtube.com/watch?v=QRZU7ezUmAc
So far, the LOGO does the following, utilizing just 2 inputs and 3 outputs;
Out fire Control
Instead of running the stoker a few minutes every hour regardless of how many times it already ran during the hour, it now resets to 0 to start timing up again anytime the stoker comes on before the timer times out. It is currently set at 90 minutes from the last stoker run, it will come on for 90 seconds.
With the old out fire timer, the boiler would come on over 1,600 times in a season when it didn't need to. The new control should cut down coal and electric usage. It also reduces the chance of pushing the boiler temperature into the high limit unnecessarily in warm weather, reducing the chance of out fires.
Dump Zone Control
If the stoker has not run for 4 hours, a set of relay contacts close in parallel with one of our zone thermostats on the Honeywell zone valve for 30 minutes. This should reduce boiler temperature to the point that the stoker will come on.
If the fines lever was not pulled in the last 50 hours, it triggers the auto dialer to call my cell phone with an alert condition warning. This indicates by association that the ashes were not taken out. This will be changed to 28 hours in the colder weather.
Preventive Maintenance Alert
If the stoker hours for the season exceeds 1,500 hours, it triggers the auto dialer to call my cell phone with an alert condition warning. This will remind me to brush the burner chamber.
It currently displays;
How many hours it has been since the ashes were taken out.
How many hours it has been since the last stoker run.
How many hours total the stoker has run for the year.
How many hours the stoker ran for the prior day. This can be compared with heating degree days for boiler efficiency comparisons.
Attached are some pictures of the installation.