Wood Boiler Control

End goal is Custom PCB, something that's easy to package.

I have a wood boiler, but it's control is a simple aquastat.

Aquastat controls an intake solenoid, and exhaust fan.

The circulation pumps run 24/7 (with no low water protection)

**Goals of the project:**

1. Display (OLED or ?) Water input and output temps (from pumps)

2. Show Outside Ambient Temp and Exhaust (flue) Temp to know if it's heating or cooling water

3. Set Temps/variables (with buttons or touch display?) or to Turn on and off relays

Example:Turn relay on at differential temp (5* below set temp of 175*)

Turn relay off at set temp (175*)

Dif temp may be set to 10+ when it's below freezing out (so automate to outside temp)

Below 150* turn relay OFF (extremely important) This is the main reason this

controller is being made. If there is no fire; it doesn't know, so it keeps fan on...

which cools the water until morning (tons of wasted stored energy!) I've lost 90*

water temp over night... that's 90* with 250gallons :O

4. Auto Stoke - To prevent no fire situation. No matter what is going on, turn the relay on for ~1min every ~60min. This will keep coals glowing hopefully! (will have to play with numbers)

5. LED Status - If it's too hot, too cold (no fire), Just right, Heating, etc (possibly OLED display to show as much info as possible, then no LEDs?)

6. Four+ Relay outputs, I'd like Fan/Intake on Relay 1, House Pump on Relay 2, Garage Pump on Relay 3. I debated separate Fan and Intake relays, but it's very important they both work together, one without the other is bad. Possibly doing auto fill using 4th relay, If it bumps low water limit switch, turn relay on for say 10 seconds to fill. If it hits limit again(has to be a leak), shut everything down and contact me via Text.

7. Limit switch on water level indicator (physical floating ball water level indicator) If water is low, it will trip the switch,(*4th relay) telling the RPi to Turn off Pumps to prevent flooding (heat exchanger in attic), loss of 1200$ in antifreeze and additive (total 250gallons) May as well turn all relays off actually. This fail safe is very important. (So I need inputs too!)

8. Email/text status updates. I would want a TEXT for emergencies (and email), and just emails for general logging (fan off, fan on, etc) so I can use the frequency of emails to tweak the differential temp logic. When it's warm outside you want low dif, cold outside you want long dif. It's a balancing act.

9. Eventually remote monitoring next to house thermostat.

*** **Wood Boiler and House Thermostat are NOT connected**, they don't know about each other. I have a separate thermostat wired from 'call for heat' to the furnace fan terminal, when it calls for heat, it just turns on the fan. The wood boiler is always doing it's own thing, keeps water between 170-175(whatever I set it to), and is always circulating water. (also give hot water in house) I will have an aquastat installed on furnace heat exchanger that will break the fan wire if temp is below say 100* to prevent blowing cold air incase of... So what has happened is boiler had no fire,ran all night cooling the water. It always kept circulating water which is fine because then the House kept temp.(I had no idea there was no fire) Then I came out in the morning and boiler was at ~80* water temp, fan running, no fire!

Habilidades: Eletrônica, Electronic Design, PCB Design and Layout, Control System Design, Microcontrolador

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( 0 comentários ) Piedmont, United States

ID do Projeto: #32284137

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