A friend and excellent engineer visited over the weekend and between us we decided to improve the burner a little. The first change we decided to make was to add some insulation. I measured the temperature around the outside of the boiler with a non contact thermometer at approx. 350°F in the area of the firebox. The mounting plate that holds the burner was approaching that temperature as well. The air box was lower but still this is an excessive temperature. The Auger pipe was solid from the hopper to the burner unit and since I have both 4″ pipe and 4″ tube we decided to make a thermal break in the auger feed for additional safety. The 4″ pipe even though it is surrounded by the air box eventually gets warm and since the feed auger has a fair amount of room between the auger and the pipe there is a certain amount of fuel that remains in the pipe and at shut down this can smolder. So to remove this problem and make the unit more safe a redesign was initiated. Adding insulation between the air chamber and the burner with the addition of a thermal break prompted us to take the unit apart, check it over and see how everything was faring as well as make improvements. But of course after the burner and hopper were cut apart and on the bench more improvements were noted. Most of the improvements now fall into minor design for manufacturing type areas, maybe a little less welding and a little more tabbed nut and bolt assembly so minor changes can be made more quickly. Of course being able to pull the auger feed away from the burner assembly without unbolting anything will be a big change and improvement. I am going to make the air box bolt on as well. Should be reassembled for another test on Wednesday.
Of course it wouldn’t be a weekend if we didn’t play with the software. We added a For loop to the thermistor function to improve the accuracy. I added an array to smooth the results using a moving average. But most importantly we found the lingering problem with the LCD characters being garbled. It was a wiring issue. Now fixed it has run 24hours without a problem and I am confident it will stay fixed now. The next step will be to add a capacitor if the problem resumes. I am quite confident it will not be a problem however since it looks more solid even. There is less flickering and more solid character display. So all in all a fun and productive weekend.