Posts Tagged ‘boiler controls’
Questions have been asked about the proper mounting of a Low Water Cutoff on a steam boiler.
Notice: The measurements given in this article will be close to the measurements necessary for the installation and may not be the same as the recommended measurements by the boiler manufacturer or the manufacture of the Low Water Cutoff. Care MUST be taken to follow installation measurements supplied by the manufacture of the boiler and control.
The first issue to answer is…Is this installation for a primary or secondary LWCO? The Primary LWCO is the operating LWCO and the Secondary LWCO usually incorporates a manual reset and is used for a safety backup for the primary.
Note: on a steam boiler please make sure you have a set of water gauge cocks in the installation. The “center line” of the visible glass should correspond with the boiler’s COLD WATER LINE.
The next issue for the service person to identify is the location of the COLD WATER LINE on the boiler. This is the “normal” cold water fill line as established by the boiler manufacturer. After the boiler’s cold water line is located, look at the LWCO and locate the level mark on the body of the LWCO. With these two marks established installation can now begin.
Primary LWCO Installation:
As a primary LWCO the level mark of the LWCO should be placed for mounting between 1 3/8” to 1 ½” below the boiler’s cold water line which will establish the boiler’s normal operating range.
½” to 3/8” below the LWCO’s level mark will be the burner’s “cut-off level”
Secondary Safety LWCO:
As a secondary safety LWCO the level mark of the control should be placed for mounting between the 1” to 1 ½”area below the primary LWCO’s burner cut-off level. Careful attention MUST be made not to let the float drop below the lowest visible level of the site glass.
Before commissioning the boiler for final usage PLEASE test the Primary and Seconday LWCO levels and make adjustments as needed for proper levels.
I would like to thank Peerless Boilers for their help with information and drawings supplied in this article.
Need to replace the older M series Fireye controls? Honeywell has introduced the Honeywell ECHO retrofit solution for replacing the Fireye TFM and UVM FSG controls. The ECHO (R7210M series) controls are a Smart Fit series of controls which allow the contractor to replace the older Fireye M series controls without the extensive wiring required in the past.
The Honeywell ECHO system is based on the standard Honeywell 7800 series controls and all of the standard 7800 series components will work with this control. With the Honeywell ECHO you can now expand the functions that were limited on the Fireye M Series controls to include displays that improve diagnostics and troubleshooting and including the addition of Modbus to connect the equipment to a building automation system.
How easy is the Honeywell ECHO system to install? Simply remove the old Fireye M series control, attach the Echo’s metal conversion frame, and plug in the ECHO control… Add the required purge timing card (if needed), the flame amplifier , and the Flame detector for UV systems…It’s that easy…
While your at it sign up for the Stromquist & Company Boiler Vision Program and save even more !!
So when you need to replace an older Fireye M series control give us a call here at Stromquist and Company and listen to the ECHO….
Finding the right part number to order your replacement boiler controls is not always easy. The main reason is that there are a lot of different controls and controls manufacturers that make up a boiler control system. Each manufacturer has a different part numbering system and location for the part number on the boiler control. Let’s face it the last thing you want to be doing in a hot boiler room is trying to figure out what the part number is and where it is located.
Stromquist & Company has developed a new and easy way for you to order your boiler controls and save time and money. Read More
Stromquist & Company sold the first Delphi control systems in the United States. We are pleased to report that the installation of this advanced flamesafeguard system was very easy and our customer is thrilled with how well the system is working. Check out Matt’s demo of the amazing new Honeywell Delphi System!
The ML7999 Universal Parallel Positioning Actuator allows for a direct connection to fuel valves and dampers in the boiler system, thereby eliminating mechanical linkages. The ML7999 actuator is designed to operate combustion air dampers, butterfly gas valves, oil modulation valves, and flue gas recirculation systems requiring up to 100 lb-in torque. Each ML7999 has its own ID, so when the R7999 communicates with the ML7999 it is communicating with only the ML7999 chosen for commissioning. The R7999 Controlinks Controller is a microprocessor feature driven controller. The controller must be commissioned by using the ZM7999 software on a PC or laptop using a minimum operating system of Windows 95 or the S7999B System Display.
Commissioning consists of five basic steps:
1. Connect the R7999 to the communications port of your PC and logon to the software with a password. The password prevents the changing of your modulation curve without permission.
2. Specify the base configuration: one or two fuels, with or without FGR.
3. Select system parameters such as Low Fire Hold.
4. Specify the characteristics of the actuators (ML7999) and set the valve/damper end points for each actuator.
5. Create a modulation curve (profile) for each fuel and verify it from maximum to minimum modulation. This curve can have up to 20 points on the curve to allow for smooth money saving transitions from start to stop.
ML7999 Controlinks UPPA actuator
Commissioning of the ML7999 basically consists of location of the minimum and maximum open/closed position of the valve/damper and locking down the actuator.
Working together, the ML7999 and the R7999 allow the burner fuel to air ratio to be adjusted independently to maximize burner efficiency and reduce fuel consumption, which typically pays for the Controlinks system within one year.
S7999B1000 Controlinks Touch Screen
Let Stromquist and Company help you with your Honeywell Controlinks needs by calling us at 1-800-241-9471 or contacting one of our many CGNA members.
Yes, there is an answer! The never ending questions from clients about boiler energy savings, maximizing burner efficiency, reducing emissions and reduced excess air, increased equipment life, increased system reliability, flexibility and increased safety can now be answered.
With ever increasing popularity the Honeywell “Controlinks” fuel air ratio commercial/industrial combustion controls are sweeping the market.
To look at the future we need to understand how boiler efficiency was dealt with in the past. When a boiler is first commissioned at a new site the combustion efficiency is set by the installer using a combustion analyzer and adjusting the single modulating motor with jackshafts and their linkages to the fuel valve and air damper to achieve the best combustion efficiency. This “setup” during startup fixes the air-to-fuel ratio over the firing range of the boiler. Over time environmental and physical changes will reduce this “optimum” setup. Changes in temperature, pressure, and humidity, along with physical wear on the linkages and jackshafts, will alter the fixed air-to-fuel ratio causing increased operating and maintenance costs. The weakest “link” in this system is the linkage so let’s go “LINKAGELESS.”
The basic Honeywell Controlinks system consists of an R7999 Controlinks Controller, Q7999 Universal Subbase, ZM7999 Commissioning Software, and the ML7999 Universal Parallel Positioning Actuator (UPPA).
How the Controlinks system works… Four separate UPPAs (ML7999) replace the single actuator used with mechanical cam and linkage systems, providing independent control of the combustion air damper, the primary fuel, the secondary fuel, and the Flue Gas Recirculation (FGR) damper if used. The UPPAs (ML7999) are controlled by the Controlinks Controller (R7999), which responds to the load, and firing rate demands setup by the installer using a combustion efficiency analyzer throughout the boiler run/load cycle.
R7999 Controlinks Controller
ML7999 Controlinks Actuator
My next post will be on commissioning the Controlinks system, followed by a discussion on Controlinks features.
Let Stromquist and Company help you with your Honeywell Controlinks needs by calling us at 1-800-241-9471 or contacting one of our many CGNA members.
Honeywell has added a new Delphi video presentation to its Environmental and Combustion Controls website.
Go to: http://customer.honeywell.com/Business/Cultures/en-US/Default.htm and look to the left of the page under the “What’s New” section, then click on the Delphi Combustion Efficiency Panel Video Presentation (in red) and follow instructions to the video.
Other Delphi and related Information:
http://www.controltrends.org/2010/02/on-site-training-for-honeywell-delphi-2/
http://www.controltrends.org/2009/11/first-commercial-installation-of-delphi/
http://www.controltrends.org/2009/08/honeywell-announces-delphi/
http://www.controltrends.org/2009/08/simply-amazing-product/
http://www.controltrends.org/2009/08/honeywell-abc900-advanced-burner-control/
http://www.controltrends.org/2009/08/honeywell-mf020-oxygen-sensors/
Boiler contractors see these valves all the time when working on equipment. Generally the steam relief valve is often little understood, often incorrectly installed, and usually neglected. A little refresher on these valves might be in order.
How Relief Valves Work
As the pressure of the steam within a boiler approaches the set pressure of the valve, the steam pressure on the underside of the actuating disc approaches the pressure of a spring applied to the outer side of the disc. When equilibrium is passed, the disc starts to lift off its seat. The moment this happens, steam is suddenly released all around the disc to what is called the “huddling chamber.” This chamber increases the area of the disc that sees steam pressure, thus increasing force. This increased area under steam pressure makes the pressure much more unbalanced in the direction of the valve discharge opening and therefore pops the valve into a wide open position. When the valve opens with a “pop” the valve seat is preserved from wiredraw caused by slow opening.
Closure of the valve occurs only after the boiler pressure is dropped several pounds below the set point. The reduction of the area of the disc seeing steam causes the disc to firmly close against the valve seat.
Relief Valve Installation
Proper installation of a steam relief valve seems somewhat simple and is, as long as two areas of concern are followed.
The first area of concern is valve distortion. Valve distortion occurs when the valve is improperly wrenched in, using the valve body instead of supplied wrench flats. Distortion also occurs when the discharge side of the safety relief valve is made to bear the weight of the discharge piping. To prevent this distortion use a short nipple from the valve to an independently supported bell reducer or drip pan elbow. These valves are precision devices and any distortion will affect accuracy and calibration.
The second area of concern is discharge piping. For a safety valve to do its job it must be sized properly to adequately relieve all the steam the boiler is capable of producing while operating at its maximum. All piping to or from a safety relief valve must be at least as large as the valve’s connections. Also, the restrictive effect of elbows and the friction losses in pipe must be taken into account. For this reason, piping runs should be as short as possible and pipe sizes should be generous.
If you need help in replacing or sizing a steam relief valve please contact Stromquist and Company at 1-800-241-9471. All others can order this product from one of our affiliates at CGNA.
Due to difficulties in obtaining some machined components and because of declining sales, the M&M Series 150E Low Water Cut-Off and all its variants are being discontinued as of December 31, 2009. This will impact the 150E, 1507E, and replacement heads for those products.
M&M recommends the Series 150S float style Low Water Cut-Off as a direct replacement for the 150E and the new 1575 as an alternative for clients that wish to continue using a probe-style device.
From a replacement parts perspective, the 150S replacement head will bolt directly to an existing 150E body. Some minor wiring modifications may be required, and the user should be aware that the time delays and the pump differential are not adjustable on the 150S. Keep in mind that it is also good practice to use a relay between the 1501S and the boiler feed pump.
Being an avid motorcycle rider, vintage motorcycle restorer, and photographer I am reminded, while on a long trip or during a tough restoration project, how our hobbies and our jobs are so much the same if you do them with the same vigor and dedication. (Yes that’s me in the yellow shirt next to the dark blue BMW.)
Ever notice after a good vacation you often say ” I need a vacation”? Why is it that our hobbies are so much work?
These thoughts ran through my mind when I came off a job site, which I am proud to say Stromquist and Company was associated with. The job was the first commercial installation of the new Honeywell Delphi system that was the featured product for installation. Three days of intense conversations with Honeywell, job project managers, and end users left me at the end of each day completely worn out mentally and physically. The job was hard and taxing, but when the boilers fired off without a hitch and the client was beaming with delight, I was just as satisfied as if I completed a successful motorcycle trip or finished a restoration.
As wholesalers we at times forget the long time effects of our jobs as we move on to the next project. What we do matters and it matters to a lot of people and it matters to us because it’s not just a job, it’s a continuation of our own sense of being and satisfaction.
My restored 1965 Honda 150 Dream and my 1969 Bridgestone Mach 2 RS (graciously given to me to restore by Stromquist’s own Bob Koch. Thank you so much Bob.)
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