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Thread: HLT Setting Off Internal Alarm in Boiler's Burner Control

  1. #1
    Join Date
    Apr 2018
    Location
    Long Valley, NJ, USA
    Posts
    2

    HLT Setting Off Internal Alarm in Boiler's Burner Control

    Good Afternoon,

    I came into a position at a Brewpub where I replaced the old Head Brewer who was let go. In my process of learning the system (a 7 BBL Pub Brewing System, steam jacketed, with the Combi Mash/Lauter Tun on top and Hot Liquor Tank on the bottom), my Steam Boiler started receiving an Internal Alarm last Friday Afternoon. Initially, I couldn't reset the Alarm on the Honeywell 7800 Burner Controller, but we were able to get a new one, and this Burner Control resets and starts heating the water in the boiler to steam again. But, we are still running into the problem of the Boiler shutting off every 30 minutes or so, due to what the LCD on the Burner Control only says is an "Internal Error". There is no other information coming from the Burner Controller's LCD. Upon external investigation of the equipment, the Bolier still works in heating up water and transmitting steam to my two vessels (the Brew Kettle as well as the Combi Mash/Lauter Tun - HLT), the input and output pipes on the HLT are hot, and there is excess steam being blown off by the Condensation Tank. In fact, each time I turn on my Control Panel, for power to go to my Thermal controller made by Partlow, you can hear the Solenoid Valve making clicking noises, as if it's calling for the Steam necessary to do its job and heat the HLT water. But then,after a little while, an alarm is sent to the Burner Controller, and a few times, if I let it go longer than an hour or so, an alarm light is triggered in the Partlow controller.

    I am the only brewer on staff at this brewpub, and while I can still brew for the time being by heating my brewing water in the kettle and then transferring it to the HLT, it's adding at least an hour or so to my brew days, and that is unacceptable for my time constraints on a long-term basis. Please, if anyone has any advice on how to fix this issue, and solve this problem, so the HLT doesn't have to keep setting off an alarm to the boiler, and I'm able to heat my HLT overnight to 162F (approximately), and begin brewing immediately the next morning, I'd definitely appreciate it.

    Mike

  2. #2
    Join Date
    Nov 2009
    Location
    Moab, Utah
    Posts
    469

    Boiler Limit Controls

    [QUOTE=MikeRestVillage;235762]Good Afternoon,

    " But then,after a little while, an alarm is sent to the Burner Controller, and a few times, if I let it go longer than an hour or so, an alarm light is triggered in the Partlow controller."

    This statement is not logical or in accord with how Flame safety controls operate.
    https://customer.honeywell.com/resou...0s/65-0126.pdf
    While note 5, Fig.7 describes being able to use an "external " contact set in series with the onboard operating limits, this is not standard practice and would have to be implemented carefully.
    So in other words, the flame control only responds to limits being reached and this is where you need to start. If there is an external contact set that has been wired in series with the controller limits then its likely not set up correctly. Otherwise, you have an issue with the boiler which needs sorting out by a qualified Boiler Service Tech. Its critical to know what limit is being opened and why. This is isolation of the matter.
    Warren Turner
    Industrial Engineering Technician
    HVACR-Electrical Systems Specialist
    Moab Brewery
    " No Cell Phone Zone."

  3. #3
    Join Date
    Apr 2018
    Location
    Long Valley, NJ, USA
    Posts
    2
    [QUOTE=Starcat;235783]
    Quote Originally Posted by MikeRestVillage View Post
    Good Afternoon,

    " But then,after a little while, an alarm is sent to the Burner Controller, and a few times, if I let it go longer than an hour or so, an alarm light is triggered in the Partlow controller."

    This statement is not logical or in accord with how Flame safety controls operate.
    https://customer.honeywell.com/resou...0s/65-0126.pdf
    While note 5, Fig.7 describes being able to use an "external " contact set in series with the onboard operating limits, this is not standard practice and would have to be implemented carefully.
    So in other words, the flame control only responds to limits being reached and this is where you need to start. If there is an external contact set that has been wired in series with the controller limits then its likely not set up correctly. Otherwise, you have an issue with the boiler which needs sorting out by a qualified Boiler Service Tech. Its critical to know what limit is being opened and why. This is isolation of the matter.

    Forgive me as I am not a technician on boilers, flame safety rules, or the like. I was hired as a brewer and am trying to learn the system on my own as best as possible. So that is why I’m asking for help and advice.

    I initially filled my HLT with 51 F water, and set my destination temperature to 162. However, when I came back the next morning, the water was only at 92 F. I proceeded to transfer the water to the boil kettle to heat up to the desired strike temperature. I did that and mashed in. Then I added more water to the kettle and heated it up for sparring at 172 F. Realizing that I needed to Vorlauf and would need the kettle to do so, I moved the water at 172 to the HLT. I overlooked the fact that my destination temperature was still set at 162 F, so when the water came into the HLT at 172 F, my assumption is that this is what caused the error that I’m having, because the water I added tot the HLT was already 10 degrees hotter than the desired temperature set. If that’s the case, what can I do to reset this controller so the alarm signal stops going to the Burner?

    Thank you.

  4. #4
    Join Date
    May 2012
    Location
    Livermore, CA
    Posts
    566
    Is the problem with your steam boiler electronics or the electronics controlling your brewhouse? Typically, and this was covered earlier, the boiler has its own discrete controls that manage the pressure and temperature of the steam, you have a separate device controlling when a tank gets steam via a solenoid valve. It is possible that its been wired in such a way that if no tank is calling for steam that the boiler would be switched to the off state, though I think this would be very odd.

    Its not clear by your descriptions of the functioning as to how the whole system is wired, and thus most people here could only speculate. If you are not familiar with the equipment in such a way that you know what talks to what(ie, you installed it or were there when it was), then you need to bring someone in who does, because talking someone through diagnosing an electrical issue is difficult or impossible if neither knows what they are looking at. Pictures could help as well, but I think for speeds sake, you should have a boiler tech come in and give it a look.

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