Automation for gas heating boilers: device, principle of operation, review of manufacturers

Heating needs vary at different times of the day. In the morning and evening, when everyone is at home, not only heat is required, but also hot water. At night, it is better to lower the temperature by a few degrees. Several standard heating programs can be “hardwired” into the memory - the user just needs to select the appropriate one. A standard heating program includes one or more comfortable and reduced heating modes alternating throughout the day, sometimes with different temperatures in each period. It often happens that on weekdays during working hours there is no one at home, and on weekends a different heating program is required. To avoid the hassle of reprogramming, many systems are able to “create” one or more “weekly” heating programs.

If weather-compensated heating is used, it is also necessary to adjust the temperature curve, i.e. program the required boiler water temperature (it is determined using a sensor installed at any point in the system, usually at the inlet or outlet of the coolant to the boiler) depending on the outside air temperature. Let's say the heating should be turned on when the air temperature is below 20 °C. This is the first point of the curve.

When the outside temperature drops, more heating is required, but how strong depends on the conditions, in particular on the heat loss of the building: the higher they are, the more intense the heat needs to be. Typically, several such curves are “hardwired” into the control module controller; the required one is selected based on specific conditions. After selecting the curve, the boiler water temperature is set at the point of the lowest air temperature for the given region. This completes the setup.

The heating on/off time and the temperature curve setting can be programmed either from the user or service level. Some systems allow you to create your own heating programs in addition to the standard ones.

Heating programs are convenient because they allow the system to operate effectively in automatic mode. For greater convenience, several more modes are provided. Most of them can be easily turned on manually from the control module.

The “winter/summer” mode is adjusted either manually or automatically (with weather-dependent control). If the system includes a DHW circuit, in “summer” mode energy is spent only on heating sanitary water in the water heater tank, and the boiler can be completely turned off. If you are away from home for a long time, it is advisable to turn on the “vacation” mode, in which a predetermined low temperature will be maintained, and the circuit

The DHW will turn off. Of course, the freeze protection program has priority over all others; it will not completely turn off the boiler, but fuel consumption will be much more economical.

Various manufacturers also offer some other preset programs, for example, temporarily turning off the heating for ventilation or a “party” mode, which, when turned on, extends the period of comfortable heating for some time. Other available control functions depend on the system configuration. If it has a hot water tank, you can set up one-time heating modes (when a large amount of hot water is needed at odd times) and thermal disinfection (periodic heating of water to kill bacteria in it).

All modes are usually turned on and off from the central control module. If the system has additional room regulators, some modes can be activated from them, but this depends on the settings. In any case, there is nothing difficult in setting the desired mode at the user level.

Types of automation for heating boilers

The automation works properly, accurately and reliably, increases the efficiency of heating equipment, promotes reasonable consumption of energy resources and makes the operation of the heating system simple, comfortable and absolutely safe.

The automatic system protects heating installations from overloads and activates an emergency shutdown of the gas supply in the event of sudden force majeure circumstances. Additionally, the equipment regulates the level of combustion intensity and current fuel consumption, allowing owners to save money on heating the premises.

The automatic unit has flexible settings and allows the owner to set the most convenient operating parameters for the equipment.

Based on the basic operating principle and design features, automation for gas-powered equipment is divided into:

• energy dependent devices;
• energy-independent devices.

Systems of the first type are complex electronic units that require an uninterrupted electrical supply to operate correctly. The second types of devices are simplified mechanical structures that do not require energy supply.

Type #1 - volatile products

A volatile module is a small electronic device that responds to the supply of a fuel resource. It turns on and off when the main gas valve is activated or closed. It has a complex design and a large number of elements and microcircuits.

Allows owners to solve the following tasks:

• activation or termination of gas supply;
• starting the heating system in automatic mode;
• adjusting the power level of the base burner (due to the presence of a thermostat);
• turning off a running boiler both in emergency situations and within a user-specified mode;
• displaying current indicators on the display (the general level of air temperature in the room, the point to which the working coolant has been heated, etc.).

More sophisticated modules have additional functionality and offer users unlimited and most convenient conditions for monitoring the operation and control of the unit. Electronic panels provide full protection of heating equipment from malfunction of the three-way valve and prevent the boiler from freezing.

If the temperature in the room drops sharply, the “smart” system itself starts the heating equipment and turns it off when the home is filled with comfortable warm air.

The self-diagnosis option available for individual modules prevents operational failures and facilitates the timely identification of faulty parts and assemblies in the system. It makes it possible to notice a breakdown as early as possible and replace some small element even before it creates a real problem for the equipment.

Minor breakdowns of the heating system eventually turn into global complications and entail costs associated with the repair and dismantling (full or partial) of the equipment. Self-diagnosis helps to identify a malfunction and makes it possible to eliminate it in a timely manner.

Electronic automation, responsible for the safe operation of the equipment, ensures uninterrupted operation of the boiler, prevents the system from overheating and shuts off the gas supply in the event of a drop in draft or extinguishment of the flame in the burner.

The range of energy-dependent automation on the market today is pleasingly diverse. Useful and necessary mini-units are produced by world-famous brands and small companies that are just trying to earn their place in the sun.

Volatile automation is presented in the form of a control panel, where the user can set convenient operating parameters for the equipment. The cost of a “smart” element is high, but the costs are justified, because with the help of a control unit you can reduce resource consumption without any damage to your own comfort

Among the models offered there are both very simple products and more advanced units with a programming option.

On them, the user can select the most suitable individual settings for himself and program the system to operate in day/night mode or, based on the weather forecast, set a certain level of heating of the house or apartment for a period of 1 to 7 days.

Type #2 - non-volatile units

Non-volatile automation is simpler and more practical. Control and adjustment are carried out manually using mechanical rotary toggle switches and are not difficult even for those who are far from technology. The device operates completely autonomously and does not need to be connected to a central electrical system.

To heat a residential building and supply hot water to the taps, it is enough to turn the control knob in the direction of increase by 2-3 divisions. If you need to take a bath or shower, the toggle switch must be set to the maximum setting

The product is marked with a digital scale with a list of values ​​from minimum to maximum. To activate, the user selects the desired mark and in this way sets the appropriate operating temperature directly to the boiler.

After these manipulations, the thermostat is connected and takes control of the specified heating mode. The boiler actively works until the room warms up to the desired temperature. Then the thermostat turns off the gas supply to the system and is activated again only when the room gets colder.

The operating principle is based on the specific design of the device. The gas boiler thermocouple built into the heat exchanger is equipped with a special rod. It is made from a special iron-nickel alloy called invar.

The physical characteristics of this advanced material give it the ability to almost instantly capture minimal temperature fluctuations.

If the room becomes too hot or too cold, the size of the rod changes. The connecting valve reacts to this and promptly shuts off or activates the flow of gas to the burner.

The presence of a non-volatile automatic control system allows users to set the most suitable temperature regime in their house or apartment and use fuel economically without overpaying on utility bills

Additionally, non-volatile automation has sensitive draft and flame sensors. If the pressure in the pipe suddenly decreases or the draft level in the chimney drops for some reason, the supply of the resource is immediately stopped and gas leakage can be avoided.

Non-volatile automation costs quite reasonable money and, unlike electronic analogues, does not require the purchase and installation of a stabilizer that controls voltage and equalizes unexpected surges in the central power grid

Correct operation of the flame sensor is ensured by a special plate. During normal and correct operation of the system, it is in a slightly curved state.

In this way, the part holds the shutoff valve in the “ Open ” mode. When the flame becomes smaller, the plate is leveled and the valve closes under its pressure.

Expert advice: how to protect yourself from controller breakdowns

Repair of control units for gas boilers is not a common occurrence. However, before purchasing equipment from a certain manufacturer, ask if there are service centers in your region.

To protect yourself from troubles at the wrong time, you should, with the help of specialists, inspect the boiler before and after the heating season. A network voltage stabilizer will help protect the electrical controller from pressure surges, thereby protecting the device from damage.

You can prevent possible damage to the control unit the first time it is put into operation. The unit system is complex and fragile in its own way; settings may be lost during transportation or assembly of the equipment. Therefore, during installation, they first carefully check all the subtleties associated with the wiring, water and gas supply, and then check the operation of the CU sensors.

The latest models of controllers have been brought to almost complete independence. The gas boiler control unit reports faults using indicators, as can be seen in the diagram below.

If you notice any failure, even a minor one, it is better to immediately call a boiler service specialist, this will prevent a serious breakdown and save yourself from more serious problems.

Heating appliances are often the subject of experiments, which result in towel dryers for example. At a technology competition in 2007 in the United States, among the various designs one could see a radiator in the form of a rack of hangers, designed in the shape of a chair with a heated seat.

Modern home heating equipment is as convenient as possible for users. Having set the necessary parameters for the device, you do not need to constantly monitor its operation, relying on the automatic mode. And timely diagnostics of heating devices will allow you to avoid troubles due to incorrect operation or breakdowns.

An example of installing the controller can be found in the video:

Design and operating principle

The automation that controls the operation of a gas boiler consists of many elements, conditionally divided into two subgroups. The first includes mechanisms that ensure the full and safe functioning of the boiler itself. The second includes devices that make it possible to operate the heating system in the most convenient and user-friendly mode.

Components of a security system

Several modules are responsible for the operational safety of the unit:

1. Flame controller - consists of two main parts - a solenoid valve and a thermocouple. Shuts off gas promptly and reliably and prevents leakage.
2. Thermostat - maintains the set temperature of the coolant and protects the system from overheating. When the coolant cools down to minimum temperatures, the module starts the boiler into operation, and after recording peak-high readings, it turns it off, completely relieving the owners of the need to constantly pay attention to the system.
3. The draft control sensor is responsible for stopping the gas supply to the burner in the event of a change in the basic position of the bimetallic plate, thus preventing gas leakage.
4. Safety valve - monitors the amount of coolant in the circuit.

In addition to all the above useful qualities, the automation has a number of additional functions that increase the comfort of using the equipment.

The device performs automatic ignition of the gas burner, selects the most effective operating mode, promotes rational consumption of energy resources and conducts independent diagnostics, saving the owners from all these activities.

Operating principle of security automation

Current regulatory documentation says that the safety system for gas boilers must be equipped with a device that stops the operation of the entire system and shuts off the gas supply in the event of an unexpected breakdown or any other force majeure circumstances.

To carry out this task, automation must keep under control such parameters as:

• gas pressure in the system;
• presence of an optimal size flame in the burner;
• full, high-quality traction;
• working coolant temperature level.

When the gas pressure in a non-volatile mechanical system drops to a critical level, the resource supply immediately stops. This happens automatically due to the presence of a valve mechanism set to a certain value.

Volatile electronic devices are designed slightly differently. In them, the above function is performed by a minimum/maximum pressure switch.

As the number of atmospheres increases, the membrane with the rod bends, opening the power contacts of the boiler itself. Gas stops flowing and is not supplied until the pressure level is restored.

It is prohibited by law to independently troubleshoot problems and somehow interfere with the basic functionality of the equipment. Only a qualified specialist - an employee of the gas supply company - can correct any problems that arise.

If the flame disappears in the burner, the thermocouple cools down and stops producing current. After this, the electromagnetic damper in the valve no longer functions and gas stops flowing to the burner. When the thrust drops, the bimetallic plate heats up intensely, changes shape and acts on the valve, causing it to stop supplying fuel.

The coolant temperature is kept under control by a thermostat. It ensures that the user-selected heating mode is maintained, while preventing the system from overheating and failing.

Nuances of the system's functioning

Volatile electronic automation operates based on information received from sensors. The microprocessor and internal controller analyze this data, process it and provide the system with commands that are optimally suited for a particular situation.

In order for electronic automation to function normally for a long time, it is necessary to call a technician annually to inspect the equipment, diagnose the microprocessor and view memory module reports

Mechanics have a slightly different principle. When the boiler is turned off, the internal gas valve is completely closed. At the moment the equipment is started, the washer on the valve is squeezed out and the passage for the fuel resource to the igniter is forced to open. Ignition stimulates heating of the thermocouple and voltage is generated across it.

This resource uses an electromagnet to maintain the valve in the open position. By turning the washer manually, the user can effortlessly adjust the level and power of his heating equipment.

Cost of equipment

Review of popular models and manufacturers

The market for advanced gas equipment and related elements includes automation from both domestic and foreign manufacturers. According to the principle of operation, all devices are absolutely identical, but in terms of design there are significant differences between them.

The presence of automatic control in the gas heating system makes it possible to comfortably heat the room and rationally use energy resources. With a reasonable approach, savings can range from 30 to 43%

The cost of modules varies over a wide range. Simple mechanical products with a minimum of functions belong to the budget class and are sold at the lowest price. Advanced electronic panels are valued much higher, but provide the user with more extensive options for individual settings and control of operation.

Some devices, such as SABC automation, in addition to basic functions, are equipped with a built-in pressure stabilizer. This allows for more precise adjustment of the operation of gas equipment

Programmable electronic devices are considered luxury. They enable the owner to set an operating plan for the equipment for a long period of time, taking into account seasonal weather conditions and the current outside air temperature.

No. 1 - automatic EUROSIT 630

The automatic non-volatile unit EUROSIT 630 produced by the Italian company Sit Group (Eurosit) occupies a leading position in the market in terms of sales.

It is considered universal and works effectively with parapet and floor-standing boilers with a power from 7 to 24 kW. Switching on/off, igniting the pilot burner and setting the desired temperature are carried out using one handle with a button.

The Eurosit 630 module is a modern unit for controlling gas equipment. Fully complies with international standards and safety requirements for such devices. Has a European quality certificate and a guarantee from the manufacturer

The product is characterized by a high level of reliability, can withstand significant operating loads and has extensive functionality. The structural elements are “hidden” in the housing, to which sensor cables and other connecting tubes are routed.

The ignition time of the heating boiler using the Eurosit 630 automatic system is 10 seconds. Gas is immediately supplied to the system and very soon the room warms up to the set temperature

Inside the unit there is a cut-off valve, a spring valve and a pressure regulator. The gas supply is carried out from below or from the side according to the user’s wishes. In terms of cost, the unit is included in the budget category.

No. 2 - Honeywell 5474 module

The Honeywell 5474 device is manufactured by the German concern Honeywell , which has been specializing in the development and sale of various types of automation for more than a hundred years. Works correctly with domestic gas boilers with a power of up to 32 kW.

Honeywell 5474 is a non-volatile device for controlling the heating system. Equipped with micro-torch burners made of heat-resistant stainless steel. They ensure better gas combustion, reduce the emission of harmful substances into the atmosphere and prevent excess soot from depositing in the chimney

The Honeywell 5474 automatic system is equipped with a basic set of control functions that guarantee efficient operation of the boiler with absolute safety for users.

In automatic mode, the product maintains the specified coolant temperature (from 40 to 90 degrees), turns off the boiler in the event of a fuel supply cutoff, lack of draft at the required level in the chimney, reverse draft occurs, or burner extinguishment.

No. 3 - premium automation from Honeywell

In addition to inexpensive budget models, Honeywell also produces other types of automatic equipment, for example, luxury chronothermostats of the premium ST series or programmed thermostats Honeywell YRLV430A1005/U.

The YRLV430A1005/U device, with the widest possible functionality, has a user-friendly interface and does not cause any difficulties for customers during use. The cost of the product is quite high, but still lower than that of competitors offering models with similar characteristics

These electronic panels allow you to set the heating equipment the most detailed and precise settings, up to changing the temperature several times a day depending on the time of day, weather conditions and personal wishes.

No. 4 - Orion device

The Orion automatic device is manufactured in Russia. The device includes a piezoelectric ignition and a draft sensor.

The Orion device looks simple and has a minimal set of functions. Its capabilities are not too great, but, thanks to its reasonable price and basic control method, the unit is in demand

The device turns off the gas in case of random extinguishing of the burner or lack of the required draft. When the room temperature drops, the thermostat activates the fuel supply and the boiler resumes operation.

The transition to the flame reduction mode when a certain (user-specified) temperature is reached occurs automatically and allows you to save fuel resources.

"SMART HOMES"

The concept of a “smart home” involves centralized control and interaction of several systems simultaneously. To create comfort in a room, temperature alone is not enough; you also need to take care of the ventilation or air conditioning system and air humidity. Some elements that involve the joint operation of heating with other systems can be controlled by some standard controllers, for example, when connecting window opening sensors, you can program the heating of rooms to be turned off when ventilating.

Elements of heating systems from different manufacturers communicate with each other using different protocols and using different buses - in short, they “speak different languages.” To integrate “smart heating” into a “smart home”, most likely, you will need an interface module (gateway) for the heating installation controller, connecting it with other systems not related to heating equipment. The advantages of simultaneous control of all home systems, and not just heating, are obvious; it all depends on the complexity of the system.

Which to choose

Mechanical control units require user attention to start the boiler and during operation. The settings of such parameters as gas consumption, boiler power and coolant temperature are set with a significant error, approximately and are adjusted if necessary only manually. In contrast, they do not depend on electricity and its quality, and are more reliable and durable. The main advantage is the low cost of the automation and the boiler as a whole.

Electronic control allows you to set the optimal operating mode, even taking into account the daily and weekly schedule. The work is fully automated. Start-up, main operation mode and response to any emergency situations occur without user participation. Setting system parameters is much more accurate. The temperature of the coolant is adjusted down to a degree, and gas consumption is significantly reduced, because the boiler will only work when it is really necessary. However, you will have to pay a lot of money for comfort.

Considering that a boiler is bought only once and for a long time, if the budget allows, it is better to give preference to gas boilers with electronic filling in combination with a UPS and a stabilizer.

General conclusion

The use of a wireless thermostat for a gas boiler simplifies the operation of heating equipment. The simplest models are inexpensive. But their installation involves laying wire communications. Therefore, total costs may increase significantly compared to the preliminary plan. More complex sets use radio frequency to transmit control and control signals. Installing such products is not difficult to do yourself. Their high cost is due to their advanced functionality.

How to purchase a temperature sensor for a heating boiler: market overview