Car gas equipment. How a gas boiler works, how a gas reducer-evaporator for LPG equipment on a car works

The constant rise in the price of gasoline makes car owners more and more interested in gas-cylinder equipment or the so-called HBO. In this article, we will talk about what HBO is in a car, when it is expedient to use it, and also what is the economic effect of its installation.

A set of gas cylinder equipment for installation in a car (toroidal cylinder)

LPG equipment means a set of technical means and units that allow the use of a mixture of petroleum liquefied gases (propane-butane) as fuel. At the same time, it is possible to switch from traditional fuel (gasoline) to gas, which allows you to choose the most economical mode of car operation in terms of consumption.

The composition of the gas-cylinder equipment includes the following main components:

  • Cylinder for gas with a capacity of 40 liters. There are standard cylindrical modifications and toroidal ones, which can be placed in the spare wheel well, which makes it possible to save the useful volume of the trunk.
  • A ventilation box with a multi-valve, including a flow and filling valve, a control device for determining the gas level in the tank, and a suction pipe. The design of this unit allows you to prevent emergency gas leakage and ensure the removal of its vapors from the trunk.
  • A fuel type switch is mounted inside the car, allowing you to select gas or gasoline.
  • A filter valve that cleans the gas mixture from existing impurities.
  • Electromagnetic gasoline and gas valves that allow cutting off the supply of an unused type of fuel to the combustion chamber. For injection type engines, a special injector emulator is used.
  • A gas reducer that maintains the required pressure of the gas supplied to the combustion chamber. This unit has been specially designed for installation on vehicles, so its dimensions and shape guarantee easy installation under the hood.
  • Reducer-evaporator - provides the transition of liquefied gas into a gaseous state of aggregation, which is required for engine operation. It is worth noting the fact that such a unit is present only in HBO of 1-4 generations, in newer equipment (5th generation) gas is supplied to the combustion chamber in a liquid state. Instead, a pressure regulator is used to maintain optimal parameters of the gas mixture.

The gas coming from the container (cylinder) passes through the multivalve and through the high pressure line enters the filter valve. At this stage, the mixture is cleaned from resinous deposits and mechanical mixtures contained in it.

When the transition to gaseous fuel is turned on, the gasoline flows are cut off, and the gas enters the evaporator reducer or pressure regulator (for HBO 5). At this stage, the high pressure of the mixture is reduced to the standard parameters. Given the significant temperature drop caused by the transition of the fuel to a gaseous state, it is mandatory to connect this unit to the engine cooling system. This will prevent freezing of the diaphragms and the gearbox housing.

Thanks to the vacuum pressure (vacuum), the gas flows through the low pressure line directly into the carburetor or into the mixer, which is mounted between the throttle valves and the air filter.

Features of the installation of HBO

Given the increased danger that distinguishes any gas-cylinder equipment, its installation should be carried out only by an experienced contractor who has the appropriate approval. At the same time, gas cylinders must be regularly checked and calibrated.

Keep in mind that any HBO must be mandatory registered with the traffic police, otherwise the owner may be punished with a fine, the amount of which is established by the rules and legislation.

Video about HBO in a car

Generations of HBO

At the moment, 5 generations of HBO are used in practice, while the first of them are operated mainly on obsolete machines, installation on modern models is impractical due to high fuel consumption.

  • The equipment of the 1st generation uses mechanical devices that are controlled by a vacuum method. It is applied on petrol carburetor engines.
  • The 2nd generation includes the same mechanical hardware with an additional electronic control unit. Mounted on injection engines.
  • Synchronous gas injection is carried out by 3rd generation equipment. In various modifications, it is used on both carburetor and injection cars.
  • Units of the 4th generation provide sequential distributed gas injection, control is carried out using electronically controlled electromagnetic nozzles.
  • The most modern and efficient equipment of the 5th generation, which supplies gas in a liquid state to the combustion chamber.

Given the current cost of liquefied gas, the use of LPG for cars and trucks is justified, and also confirmed by the economic effect.

The practice of using gas-balloon equipment has shown the possibility of saving up to 30% of money on fuel. But when choosing a HBO kit, you need to pay attention to its features, since a certain type of HBO is installed for engines of various types.

LPG or LPG equipment - devices that are installed on the machine and allow the use of gas as fuel. The use of gas equipment in a car allows you to reduce gasoline costs and increase engine life, reduce repairs, and also reduce the amount of harmful emissions. With daily movements in the region of 100 km, the installation of HBO on a car pays off within 3-4 months.

WHAT IS HBO

Many motorists have heard of HBO, but do not know the decoding of this abbreviated name. And everything is simple: this is the name of the system of devices that supply gas from the cylinder to the engine, that is, gas equipment. This design is mounted as an auxiliary, and its presence allows you to switch from gasoline to gas. Let's consider schematically what is included in this HBO in the car. To simplify the listing as much as possible: a cylinder, gas pipelines and devices that provide the correct gas supply. The first important device on the “cylinder-motor” line is the evaporator.

It is necessary in order to turn liquefied (liquid) propane into a gaseous state using antifreeze from the engine cooling system. Due to the temperature difference, the gas evaporates and already in this form enters the gas reducer. What role does the reducer play? The most important: it helps to supply gas in the right amount and controls pressure. The last section of the pipeline leads to a mixer or a ramp with nozzles (depending on the generation of HBO). The system provides a gas filter, because the ingress of mechanical particles into the cylinders of an internal combustion engine is unacceptable.

Pressure gauges are also connected to control the pressure in the cylinder and reducer. In injection machines, gas equipment is controlled by a separate electronic unit. From it, the “gas / gasoline” button is displayed in the salon. This means that if HBO is installed, the standard power system also remains, and you can switch to gasoline at any time.

HISTORY OF GAS EQUIPMENT

Italy is a pioneer in LPG equipment. More than 50 years ago, small family-owned companies in northern Italy began to develop the production of components for converting petrol cars to natural gas. Italy to this day is the main supplier of gas equipment for cars and new gas technologies.

Recently, this baton has been actively picked up by such countries as Poland, especially in the field of electronics, Turkey, China and Lithuania. In addition to Italy, which today is the country with the largest distribution of gas equipment for cars, many cars with Euro LPG also appeared in Poland, Russia, Ukraine - Milano Ukraine, in South America, India, China and Australia. In many of these countries, automakers produce either all-gas or dual-fuel (eg petrol and gas) vehicles directly on the assembly line.

The principle of operation of HBO

Gas equipment on a car works on various forms of gas: liquefied and gaseous. Most often, liquefied gas is used for work - a propane-butane mixture. Less often - compressed natural gas (methane). There are few methane gas stations, so compressed gas cylinders are not popular. How does the HBO system work? The gas flows from the cylinder through the filter to the reducer. Since it is under pressure in the cylinder (about 16 atm), it moves by gravity through the pipe. Once in the reducer, liquefied gas is converted into steam - it evaporates. To do this, the reducer reduces its pressure and heats it up. During engine operation, heat from the engine is used to heat the liquid gas. After the reducer, gas vapors pass through another filter and enter the mixer.

In many HBO systems, the flow to the mixer occurs through nozzles. Their number corresponds to the number of cylinders - pistons. And their opening is controlled by an electronic control unit. By giving commands to the injectors, the control unit regulates the number of injections and the amount of gas that enters the combustion chamber. Starting the engine and the first 20 - 30 seconds of operation take place on gasoline. As soon as the gearbox warms up, the gas equipment control system automatically turns on the gas supply and its injection into the combustion system.

In this case, the supply of gasoline is automatically turned off. The reverse transition to gasoline occurs when the pressure in the gas pipes decreases, that is, when the gas in the cylinder runs out. In addition, the control system has the ability to manually switch between petrol and gas modes. The described principle of operation is a scheme for liquefied propane-butane fuel. For natural gas (methane), a different scheme is used. Since it is a gas, it goes directly to the gas injectors and then to the combustion chamber without a filter and a reducer.

Registration of gas equipment

Gas equipment must be documented in the relevant services. This statement is true and greatly limits the ability to install HBO with your own hands. The fact is that in order to register HBO at the Traffic Inspectorate, you need to present a special certificate and license for the right to engage in work on the installation of such gas equipment. It turns out that independent interventions in the design of the car are unacceptable.

Among motorists, the question has been raised more than once that a car with an installed but unregistered gas power system cannot pass MOT. Such cars with LPG refuse to be registered or deregistered by the traffic police. Problems will arise, but only if there are no relevant documents for the installed HBO. Documents for LPG legally may also be asked for at a gas station, although this does not occur in practice.

The difficulties are related to the fact that the installation of any systems, and especially from the 4th generation and above, will require a significant re-equipment of the car. For HBO-4, you need to drill holes in the intake manifold for gas injectors, you need to cut the wiring to the gasoline injectors, connect to the car's sensors, etc.

Generations of HBO

HBO is a technical system that is being developed and modernized. Therefore, today there are 6 generations of gas equipment. They differ in the principle of gas supply and the way to turn off the supply of gasoline. Note: by and large, all HBO systems can be divided into 3 main groups and intermediate hybrid types between them. The three main HBO systems are: for carburetor (mechanical) fuel injection; for injector distributed injection; for direct injection of fuel into the engine. Let's describe six generations of equipment - their action and differences. HBO-1 is a system with mechanical blocks that are installed exclusively on carburetor engines. Their reducer injects gas through nozzles at low pressure inside the mixer. Therefore, it was called "vacuum".

This system has many shortcomings and complaints, fires are not rare; HBO-2 - a system for carburetor and simple injection engines, but upgraded with an electromagnetic gearbox. This made it possible to organize the supply of gas, it at various pressures in the mixer, made it easier to start the engine, a “cold” start was possible. The electromagnetic gearbox also made it possible to control the choice of fuel with a button from the passenger compartment; HBO-3 is a system for injection engines in which the gearbox is equipped with controllers and operates in a fully automatic mode. It reads the readings of the oxygen sensor in the exhaust gases and regulates the composition of the gas mixture according to them. Also, the gearbox has a temperature sensor that allows it to turn on only after warming up. Another improvement of HBO-3 is injector emulators. They imitate the operation of gasoline injectors so that the electronic unit does not put the engine into emergency mode. Injector emulators removed the need to build a separate petrol valve into the system. First generation gas equipment systems are considered obsolete.

Among the other three, HBO-4 received the most popularity due to the optimal combination of price and quality of its work. It is what most drivers prefer to install. HBO-4 - system for injection engines. Improvement of HBO-4 are gas nozzles. They take on the function of injecting gas into the mixer-collector. And relieve the gearbox from the need to build up pressure to inject gas into the mixer. The number of nozzles corresponds to the number of piston-cylinders. A controller is installed on each nozzle, which controls its operation - determines the amount of injected gas and the injection frequency. There are no gasoline emulators here, their function is performed by the electronic unit itself. He, the control unit, suspends the operation of gasoline injectors and starts gas ones. At the same time, the petrol block continues to operate without petrol injections. HBO of the fourth and subsequent generations are systems of periodic (cyclic, phase) supply of fuel (gas). This supply allowed to reduce the consumption of liquefied fuel.

HBO of subsequent generations, the 5th and 6th, do not operate on gaseous methane, since they use exclusively liquefied gas. In their design, liquefied fuel enters the combustion chamber in liquid form, bypassing the vaporization phase. HBO-5 - gas is injected in the form of a liquid, which is called "liquid injection". It is fed into the chamber by fuel pumps built into the cylinder (similar to the gasoline supply system). To supply liquid fuel, the pump pumps pressure up to 5 atm. A pressure reducer works to continuously pressurize the system. A slight increase in pressure prevents the liquid gas from evaporating when heated by a running engine. This system starts easily without gasoline, without having to warm up the engine on gasoline. They also feature reduced gas consumption and increased power. There is no reducer-evaporator in HBO-5; HBO-6 put on engines with direct injection. Uses liquefied gas. The HBO-6 system consists of a tank that is connected to the gasoline fuel supply line. HBO-5 and 6 are the most expensive options for installing gas equipment on a car.

Installation Features

What to consider when installing gas equipment on a car? Reducer - a device that will take place under the hood. Therefore, it is necessary to choose the optimal location for it. It must be available for maintenance - periodic replacement of filters. It is necessary to mount the gearbox on the car frame, it cannot be mounted on the engine, due to vibrations. Hoses for supplying antifreeze should not be bent or kinked. Antifreeze hoses are connected to the system in parallel.

Then the antifreeze will be supplied to the reducer and radiator of the stove in equal quantities. There should not be a hot muffler near the gas cylinder and there should not be any vibrating body parts. The gas injectors are located as close as possible to the petrol injectors. The mixture should be as close as possible to the candle - this ensures the stability of its combustion. However, the installation of LPG requires professional knowledge, so this section is more of an aid to control the installation of LPG equipment on your car.

HBO SAFETY

The word "gas" in itself carries a certain danger, therefore, manufacturers of gas systems pay great attention to the safety of their systems.

The fittings of the gas cylinder are equipped with fire, emergency and electromagnetic valves, as well as a valve that shuts off the gas flow in case of a break in the gas line. Under the hood of the car, gas-cylinder electronics instantly cut off the gas supply, in case of using gasoline or stopping the engine of the car.

All HBO components undergo mandatory certification and numerous tests confirming their safety. The safety standards for gas-balloon equipment on cars installed in the secondary market are absolutely identical to the standards of gas cars produced by automakers. By installing HBO on a car, you can be sure that you are protected in the same way as the owner of a gas car with gas equipment installed directly on the conveyor.

There are some opinions about the dangers of using gas equipment in a car. In fact, this is nothing more than a myth.

Benefits of HBO

Gas equipment for cars is more economical than the operation of a gasoline or diesel engine. It reduces fuel consumption and extends engine life. Here is a description of the main advantages of cars "on gas": A car with LPG can run on both gas and gasoline. Fuel costs are reduced. The ride quality of the car is improved: it moves softer, without jerks, starts and accelerates faster. The amount of harmful emissions is reduced. This is due to more complete combustion of fuel. The mixture of propane and butane has a high octane number (up to 108), due to which it burns out almost completely, leaving no exhaust gases or other emissions. Note: according to studies, the percentage of reduction of harmful emissions for a carbureted engine is 2/3 or 70%. For diesel - half or 52%. Also, the advantages of HBO include: an increase in the service life of the engine, due to the careful attitude to the engine, more complete combustion of fuel, less carbon deposits on the cylinders; increase in car mileage without refueling; instead of one gas tank in the car - two tanks with two types of fuel. The advantages listed above are inherent in LPG systems installed in licensed proven workshops using high-quality certified equipment. It is also important after installing HBO to do maintenance and change filters in a timely manner. Namely - every 10 - 15 thousand km. Note: the first inspection after the installation of HBO must be completed earlier - already after 1.5 thousand km.

Disadvantages of HBO

Significant cash costs for the installation of gas equipment on a car. Its cost is several tens of thousands. In addition, it is necessary to arrange the installation of additional equipment in the traffic police, which will also require money and time. Reducing the amount of free space - relevant for cars with a small trunk. However, this drawback can be made irrelevant if you use a remote gas cylinder model, which is mounted outside the body and does not take up space inside the trunk or passenger compartment. Increasing the number of technical inspections and payment for their implementation. Increased safety requirements - gas is more dangerous than gasoline. Installing new equipment will void the manufacturer's warranty. Therefore, it is not always appropriate for a new car with a factory warranty.

MODERN TRENDS IN GAS EQUIPMENT FOR CARS

At present, in addition to traditional and injection gas-balloon equipment, new directions of development have appeared on cars. These are diesel gas systems, the so-called gas diesels. In other words, the use of gas on diesel cars.

In such HBO systems, gas is supplied to the engine simultaneously with the supply of the main fuel - diesel. The use of gas-diesel equipment can significantly reduce fuel costs, this is especially true for use on mainline tractors.

The second modern direction is the use of gas in gasoline cars with direct gasoline injection. On these modern cars, gasoline injectors are installed directly into the combustion chamber of the engine. LPG for direct injection, which can be installed on these machines, also uses the simultaneous supply of gas and gasoline.

Another modern trend is deepening the links between gas and automotive control systems. Modern LPG equipment can communicate with regular car controllers through data transmission systems using certain protocols, which allows you to inform the driver, for example, through an on-board computer, about problems or malfunctions in the operation of LPG equipment.

The newest models of gas boilers are characterized by high power and heating speed. However, their prices, to put it mildly, bite. You can try to use a more economical option and put new automation on the old boiler or fix the old one. The principle of operation and the automation of old-style gas heating boilers will be explained in this article.

Old-style boilers were produced in accordance with the gas parameters and the features of the heating system, which were in use several decades ago. These are, for example, the KChM, AOGV models. At the same time, their durability makes them possible to use for many more years. But with automation, the trouble is, quite often it fails. In such a situation, there are three options:

  • diagnose existing automation and replace the necessary parts;
  • to equip a reliable and high-quality unit with a modern automatic system;
  • buy a new boiler.

The difference, of course, is in the price of the issue, the efforts and time of the owner.

Consider the cheapest option - troubleshooting gas automation on an old boiler. However, to begin with, let's figure out why an automatic system in the coolant is generally provided for.

Gas automation allows you to regulate and maintain the required level of coolant temperature, and also serves to automatically stop the gas supply in an emergency. Installing automation on an old gas boiler will allow you to be sure that if the burner flame goes out, then after a short time the system will work to stop the gas supply without your participation.

Attention!
Automation, in addition to regulating and maintaining the temperature at a given level, ensures the safety of using the heater and allows you to save on heat consumption.

If you want to change automation, then keep in mind that domestic manufacturers produce models that fit almost any old coolant. Imported automation can not be installed on everything. In addition, when installing foreign automation on old-style gas boilers, not all of its functions may work - the design features of the boiler will not allow it.

On a note!
The choice of automation for gas boilers is diverse. The most popular is the system from Italian manufacturers, for example, SIT. The second place in popularity is held by American automation (Honeywell). The choice of Russian (SABC, Orion) and Ukrainian manufacturers (Fakel, Iskra, Flame, APOK-1) is great.

The principle of operation of automation on old-style gas boilers

Frequent problems in heating a room with gas boilers are the attenuation of the flame in the burner and the gas content of the room. This happens for several reasons:

  • insufficient draft in the chimney;
  • too high or too low pressure in the pipeline through which gas is supplied;
  • extinction of the flame on the igniter;
  • leakage of the impulse system.

In the event of these situations, the automation is triggered to stop the gas supply and does not allow the room to be gassed. Therefore, the installation of high-quality automation on an old gas boiler is the elementary safety rules when using it for space heating and water heating.

All automation of any brand and any manufacturer has one principle of operation and basic elements. Only their designs will differ. The old automatics "Flame", "Arbat", SABK, AGUK and others work according to the following principle. In the event that the coolant cools down below the temperature set by the user, the gas supply sensor is triggered. The burner starts heating water. After the sensor reaches the temperature set by the user, the gas sensor automatically turns off.

On a note!
When using modern automation, it is possible to save heat up to 30%.
 Automation of the old model is non-volatile, does not need electricity. Its adjustment, connection and disconnection are made by a person. Commands are transmitted using electromagnetic pulses.

The video tells how the automation of gas boilers AOGV, KSTG works.

Basic elements of automation

The main elements of automation for a gas boiler are:

  • thermostat;
  • shut-off valve;
  • thrust sensor;
  • flame sensor;
  • igniter tube;
  • igniter;
  • burners.

Let's try to explain in an accessible way how automation works for a gas boiler, disassembling it into its main elements and talking about their functions.

The gas passes through a gas cleaning filter. Then it enters the solenoid valve that regulates the supply of fuel to the burner. Next to the valve are temperature and draft sensors that monitor indicators and signal that they are out of acceptable limits. Also, the automation kit for gas boilers includes a thermostat with a bellows and a rod, designed to set the desired temperature. A special button is used to adjust the indicators. When the water is heated to the temperature set by the user, the thermostat is activated, the gas supply to the burner stops, while the igniter continues to work. When the water cools down by 10-15 degrees, the gas supply resumes. The burner ignites from the igniter. The automation is put into operation manually.

Flame and draft sensors

Flame and draft sensors work on this principle. The draft sensor reacts to the deterioration of the smoke draft and transmits an impulse to the control system. It is located in a smoke hood. Equipped with a plate made of an alloy of two metals: iron and nickel. When the draft deteriorates, flue gases accumulate and heat up the plate. It is deformed, the contacts open at the same time, the flow of fuel into the combustion chamber stops. When the temperature decreases, the plate returns to its normal state.

The temperature sensor works on the same principle. When the water in the boiler is heated above the set temperature, the lever mechanism is activated and the temperature regulator valve closes. The flow of gas stops, the burners go out.

When the water cools, the sensor bellows compresses, the lever mechanism is activated, the temperature regulator valve opens, the gas begins to flow, and the burners light up.

The most common malfunctions of automation and methods for their elimination

Before setting up the automation on the boiler, it is necessary to diagnose it. As a rule, serious malfunctions occur that require the intervention of a specialist. Adjustment can also be entrusted to the gas master. Or you can make it yourself by reading the instruction manual.

Attention!
Before each seasonal operation, it is necessary to check the operation of the safety sensors.

Most often, the filter becomes clogged, problems arise with valves, sensors burn out due to power surges, and a gas leak is detected. Proper cleaning of the filter must be done by the master. You can try to replace electronic elements yourself by carefully studying the operating instructions for your boiler.

In order to replace the temperature sensor, it is necessary to turn off the gas boiler and cool the water to a temperature of 40 degrees. Shut off the flow of coolant, remove the control knob by unscrewing the screw. Next, remove the RTV adjustment screw. Remove sensor bellows with support washer. Loosen the union nut of the sensor bulb. Install the bulb of a working sensor into the boiler jacket and tighten it hermetically. Install the sensor bellows in the pipe seat, install the support washer on the bellows, install the PTB adjustment screw and adjust the temperature.

If there are problems with the ignition of the igniter, then one of its possible causes is a malfunction of the draft sensor. In this case, it must be dismantled, diagnosed, checked the contacts, cleaned, and, if necessary, replaced with a new one.

Also common reasons why the igniter does not ignite may be:

  • malfunction of the gas valve;
  • clogging of the hole in the igniter nozzle (it is possible to clean it with a wire);
  • strong draft of air;
  • low gas pressure at the inlet.

When turning off the gas supply, it is necessary to check the chimney (it may be clogged), the electromagnet, the gas pressure at the inlet to the gas boiler.

Attention!
For the diagnosis and repair of gas boiler automation, it is necessary to invite a specialist. Inept actions can exacerbate the problem and lead to undesirable consequences.

For automation systems AGUK, AGU-T-M, AGU-P, the most common problem is the burnout of a bimetallic plate, which is used as a sensitive element.

In Arbat and Orion, only a thermocouple and a thrust sensor, as well as an electromagnetic valve (rarely), can be replaced. The automation unit is practically beyond repair. In Arbat, the system shutdown button often breaks.

Typical problems for automatics SABC are damage to the membranes of the main valve, drying of the gland packing of the temperature controller, resulting in gas leakage. Impulse tubes, bimetallic plates, ball valves are subject to control.

In conclusion, I would like to emphasize once again that automation is designed to maintain the operation of heating equipment in a safe mode. Therefore, it is simply necessary for owners of gas boilers.

This video shows troubleshooting the AOGV boiler automation, a step-by-step assembly process and testing the result.

Gas fuel equipment or LPG equipment can be installed on any model of cars equipped with carburetor engines or engines with a fuel injection system and electronic control. If their design allows you to place a cylindrical or toroidal gas cylinder for gas equipment.

The device of LPG equipment on a car, components and parts, installation locations, principle of operation.

The design solutions of gas-cylinder components are very diverse depending on the types of engines for which they are intended, and on the manufacturers that produce them. The gas equipment of the car is placed in three places: in the engine compartment, passenger compartment and luggage compartment. Installed in the engine compartment of the car:

– Gas reducer-evaporator.
- Mixer.
– Solenoid gas valve.
– Electromagnetic petrol valve.

Installed in the car interior on the dashboard.

– Switch of types of fuel "Gas - Petrol" with the block of indication of the modes "Gas - Petrol" and amount of fuel in a gas cylinder.
- Fuse.

Installed in the luggage compartment of the car.

– Gas cylinder with shut-off and safety fittings.
- Portable filling device.

On some models of LPG equipment, a metering device is installed that is designed to supply a certain amount of gas corresponding to the engine operating mode, except for idling, as well as a tee plug with an adjusting screw or screws.

This is a steel tank designed to store liquefied petroleum gas at a temperature of minus 40 to plus 45 degrees. On a passenger car, it is mounted in a compartment or in a niche for a spare wheel, and on light vehicles - on. The gas cylinder has a cylindrical or toroidal shape. Various volumes and geometric dimensions allow you to choose the best option for placing the cylinder in the trunk of a car.

The cylinder is equipped with a ventilation box with a hermetically sealed lid. Under the cover are filling and expendable valves, a scale with an arrow showing the level of gas in the cylinder, a filling cup.

In some designs of gas-cylinder equipment for refueling a gas cylinder, it is necessary:

– Open the cover of the ventilation box.
– Close the flow valve.
– Screw the adapter into the filling cup.
– Connect a filling nozzle to the adapter.
– Open the filling valve on the gas bottle.
– Open the valve of the filling nozzle.

After the cylinder is 80–85% filled with gas (the shut-off valve in the cylinder is activated, and a characteristic click is heard), these operations are performed in the reverse order. In the future, if the car is stored outdoors (outdoor storage), the flow valve can be left open.

Installed on a unified flange of a gas cylinder using a gasket that ensures the tightness of the connection. It is a receiving device when filling the cylinder with liquefied petroleum gas and ensures the supply of the latter to the gas pipeline. The unit includes an inlet fitting and a filling valve with a check valve, a flow fitting and flow valves for the liquid and vapor phases, and a cylinder filling level limiting mechanism (multivalve).

The unit is closed with a hermetic casing, which reliably separates its contents from the internal volume of the car. Ventilation of the inner space of the casing is carried out through a drainage tube led outside the car body. The cylinder is filled with liquefied gas through the filling valve (3). The gas enters the cylinder, overcoming the forces of the ball (2), which is under the action of the spring.

The balloon is filled with gas and the float (11) rises. The automatic valve (9) cuts off the flow of gas into the cylinder. The ball (2) blocks the return flow of gas from the cylinder. From the cylinder, gas enters the line through the gas intake pipe (10), squeezing the ball of the high-speed valve (4) through the flow valve (13).

Under normal operating conditions, the flow and fill valves are in the open position. They are closed when the car is parked for a long time, in the event of a gas leak, as well as in case of malfunctions, maintenance and repair of gas equipment. If the cylinder is heated above 45 degrees, the safety valve (1) opens to reduce the gas pressure.

The control arrow (7) on the scale (8) indicates the amount of gas in the cylinder. The fuel gauge can be displayed on the fuel type switch in the car interior. The pointer is actuated by a magnet built into the multivalve (9). It, together with the scale, is protected by a transparent cover (6). The maximum allowable amount of gas to be charged is pre-set with screws (12).

Designed for filling a gas cylinder, it is mounted on a bracket (7) with a nut (8) under the rear bumper of a car. It is connected to the filling line via a fitting (10). The filling nozzle of the gas column is attached to the body (3) with a sealing rubber gasket (2). The pressurized gas opens the valve (6) and fills the gas cylinder. After filling is complete, the valve closes hermetically.

Pass the gas pipeline under the floor of the car away from the exhaust pipes. It is protected from contact with parts by PVC or rubber tubes. Pipelines are fixed on the car body with special brackets using self-tapping screws with an interval of no more than 800 mm. The high-pressure gas pipeline throughout the entire length from the cylinder to the gas solenoid valve and from it to the evaporator reducer is made of copper or stainless steel with factory flaring.

If the gas pipeline is made of steel, then its connection to the equipment units is carried out using a stop cap nut. Such a connection allows for multiple disassembly, but when tightening, excessive force must be avoided to avoid tearing off the bottom of the union nut. Compensation rings are provided at the ends of the pipeline. The tube is bent to form a ring with a diameter of 50–80 mm, which protects the pipeline from breakage due to vibration.

The tightness of the high-pressure gas pipeline is ensured by a nipple connection of the cone coupling type. Such a connection includes a pipeline (3), a cone coupling (1), a thrust nut (2) and an attached part (nipple). Tightness is achieved by means of a conical coupling (1) made of brass. Such a connection allows multiple disassembly with the replacement of the cone coupling with a new one. The coupling should fit snugly on the tube at a distance of 2-3 mm from its end.

In low-pressure pipelines, rubber hoses made of petrol-resistant rubber are used to connect the gas reducer to the mixer. Hose connections on fittings are fastened with screw clamps.

They are set for the purpose of executing commands that control the supply of gasoline or gas in the power systems of vehicles equipped with equipment. In some cases, valves are structurally combined with filters that clean the fuel entering the system.

Solenoid gas valve.

Serves to open the gas supply channel to the reducer and shut it off when running on gasoline. It is controlled remotely from the passenger compartment by means of the "Gas" - "Petrol" switch. Filters do not require regular maintenance: washing or replacement is enough. In some designs, it should be cleaned every 30,000 kilometers of the car. When the ignition is on and the switch is set to the "Gas" position, the valve opens, and the gas enters the evaporator reducer through the high pressure pipeline. When the ignition is on, the valve is in the "Closed" position.

Electromagnetic petrol valve.

Serves for opening (closing) the channel for supplying gasoline to the carburetor, at the same time the gas supply is shut off. A screw (tap) is provided at the bottom of the valve for mechanical (manual) opening of the valve. In the event of a failure of the electronic control unit for gas equipment, this screw should be screwed into the valve (or turn the tap) so that you can continue driving.

The valves in the gas line differ from the valves installed in the gas pipeline only in the design of the inlet and outlet fittings intended for connecting metal gas supply pipes.

Solenoid valve for interrupting or resuming the supply of gas or gasoline.

The solenoid valve for interrupting or resuming gas supply or has increased reliability, consumes little current (no more than 0.7 A) and operates at low voltage, the power of the electromagnet coil is 4 watts. The valve filter does not require regular maintenance, flushing or replacement. The gas filter can be a permanent magnet installed at the inlet to the electromagnetic gas valve.

Gas solenoid valves with filter are controlled by a fuel type switch. They are designed to shut off the gas supply when the engine is running on gasoline, to shut off the gas supply when the ignition is off, and to filter the gas. The petrol solenoid valve shuts off the petrol supply when the engine is running on gas.

The solenoid petrol valve should be installed in such a place that the length of the petrol pipeline between it and the petrol pump is as short as possible. The fact is that when working on gasoline in this area, a constant level of gasoline is maintained, maintained by the gasoline pump. Gasoline can become very hot, causing an undesirable increase in pressure in the hose. And the shorter it is, the more secure it is.

For the same reason, special attention must be paid to the reliable sealing of the connections between the gasoline pump and the gasoline solenoid valve. The valve is always closed. It serves for remote control of fuel supply. The valve body has a manual actuator in the form of a handle or valve. Manual control is used during pumping gasoline with a gasoline pump in the cold season, after a long parking of the car and in the event of an electromagnet failure.

In this case, the handle or valve is transferred to the "Open" position. After pumping gasoline, the handle or valve is set to the “Closed” position - this is their permanent position, and the fuel type switch in the cabin to the “Gasoline” position. If this is not done, then the engine will simultaneously run on both gasoline and gas. In this case, even turning off the remote fuel switch will not help, and this is unacceptable.

Gas reducer-evaporator for LPG equipment on a car.

Designed to convert the liquid phase of gas into steam and supply the vapor phase to the mixer. Every 1500–2000 kilometers (on a hot engine), unscrew the plug (screw) located at the bottom of the gearbox and drain the condensate (oily sediment). Reducers-evaporators play an important role in the operation of gas equipment, so they should be given special attention.

Gas reducers installed on cars have the same purpose. They serve to automatically reduce the gas pressure in the supply system to a predetermined level with a constantly changing gas pressure, depending on its quantity and ambient temperature.

The gas reducer must provide the required characteristics of the state of the gas at the outlet in a wide temperature range, when switching from one engine operation mode to another. It should automatically shut off the gas supply when the engine is off.

Based on the book "Automotive gas fuel systems".
Vladimir Zolotnitsky.

Domestic heating boilers using natural and liquefied gas do not need constant monitoring by the user. Combustion and maintenance of the required coolant temperature are monitored by electronic and mechanical units built into any heat generator by the manufacturer. Our task is to explain how automation for a gas boiler works and what types of devices are used in modern water heating installations.

Automatic blocks of floor boilers

The vast majority of outdoor gas boilers are equipped with safety automatics that operate without an external power source (non-volatile). According to the requirements of regulatory documents, automation equipment must shut off the gas supply to the burner and igniter in three emergency cases:

  1. Extinction of the flame of the main burner due to blowing out or for other reasons.
  2. When there is no or sharply reduced natural draft in the chimney.
  3. The pressure drop of natural gas in the main line is below the critical level.

For reference. The implementation of these functions is mandatory for gas boilers of all types. Many manufacturers add a fourth level of safety - protection against overheating. When the temperature of the coolant reaches 90 °C, the valve stops supplying gas to the main burner at the signal of the sensor.

In various gas models from different manufacturers, non-volatile automation of the following types (brands) is used:

  • Italian blocks EuroSIT (Eurosit) series 630, 710 and 820 NOVA (heating units "Lemax", "Zhitomir 3", Aton and many others);
  • Polish devices "KARE" (heat generators "Danko", "Rivneterm");
  • American automatic control devices Honeywell (heaters of the Zhukovsky plant of the Comfort line);
  • domestic products of ZhMZ, SABK, Orion, Arbat firms.

Fuel supply system in the simplest AOGV devices equipped with ZhMZ valves. The burner is hidden in the lower part of the body.

We have listed the most common brands of automation, which are often installed on hot water boilers of the same company. For example, the Zhukovsky plant completes budget versions of AOGV devices with its own ZHMZ safety units, heat generators of the middle price category with EuroSIT devices, and powerful models with Honeywell automatic valves. Let's consider each group separately.

SIT Group Brand Gas Valves

Of all the types of automation found in boiler plants, EuroSIT safety blocks are the most popular and reliable in operation. They are recommended by companies - suppliers of natural fuels, including for replacing the old gas equipment of boilers KCHM, AGV, and so on. They work without problems as part of Polidoro, Iskra, Vakula, Thermo and others microtorch burners.

The exact names of the three models used are as follows:

  • 630 SITs;
  • 710 MiniSIT;
  • 820 NOVA.

Sockets for connection of thermocouple, main and pilot burner are located on the bottom panel of the valve

For reference. The SIT Group discontinued production of the 630 and 710 series, considering them obsolete. It was replaced by a new automatic safety of heating boilers - gas valves 820 NOVA, 822 NOVA, 840 SIGMA and 880 Proflame (powered by batteries). But old products are easy to find on sale.

In order not to bore you with the details of the design of automatic EuroSIT devices, we will briefly explain the principle of operation using the example of the simplest block of the 630 series:

  1. When the handle is turned to the “ignition” position and pressed from above, you forcibly open the solenoid valve that passes gas to the pilot burner (igniter). You click the button of the piezoelectric element that generates a spark that ignites the wick.
  2. By holding the main handle for 30 seconds, you allow the pilot flame to warm up. The thermal bulb generates a voltage (EMF) of 20-50 millivolts, which fixes the electromagnet in the open state. Now the handle can be released.
  3. Set the main handle to the desired position and thus supply gas to the main burner. The latter ignites and begins to heat the heat exchanger with the water of the heating system, as shown in the diagram.
  4. When the water reaches a certain temperature, a capillary sensor is triggered, gradually closing the second thermostatic valve. The fuel supply to the burner device stops until the sensor cools down and the valve plate opens the way for gas. The igniter continues to burn in standby mode.

Note. Older modifications of automation were not equipped with temperature sensors and ignition units, so matches were required to start the heat generator.

Scheme of connecting the automation unit to the gas burner

A membrane valve, which plays the role of a pressure regulator, is responsible for the normal supply of gas in the device. When it falls below a predetermined value, the fuel channel closes and an emergency shutdown of the boiler occurs. Other situations lead to refusal:

  1. The burner and the wick that heats the thermocouple go out. Voltage generation stops, the solenoid valve closes the fuel passage.
  2. If the draft in the chimney unexpectedly disappears, the sensor located in this channel overheats and breaks the power supply circuit of the electromagnet. The result is similar - the fuel supply is blocked.
  3. In heaters equipped with overheating sensors, the electrical circuit is broken after the water reaches a temperature of 90-95 °C.

When the gas automatics triggered an emergency shutdown, the restart of the boiler by the user is blocked for 1 minute, before the fuel supply is resumed. The operation of the system is clearly reflected in the training video:

Differences between the 710 MiniSIT and 820 NOVA models

According to the principle of operation, these blocks do not differ from their predecessor - the 630th series. Changes in automation 710 MiniSIT - purely constructive:

  • 2 buttons "Start" and "Stop" are taken out separately together with the solenoid valve;
  • the main handle only rotates the thermostat rod and regulates the temperature of the coolant;
  • an ignition unit with a piezo igniter button is built into the product body;
  • the basic package of the device includes a bellows-type temperature sensor with a capillary tube;
  • added gas pressure stabilizer.

In block 710 MiniSIT, the handle acts as a temperature regulator and puts the heater into standby mode with a burning igniter

For reference. In the first versions of the 710th family, a spark igniter was not provided.

The latest 820 NOVA product line has been redesigned to improve stability, reliability and throughput. We want to highlight 2 improvements that are important from a user perspective:



Non-volatile room thermostat connection scheme

In this section, it makes sense to mention Honeywell automatic gas valves, which work in a similar way. Their main difference is the increased throughput, which allows the blocks to be used in high power boilers (30-70 kW).

Polish automatic "Kare"

Few manufacturers practice the installation of Polish security systems on gas boilers. The reason is banal: in terms of reliability, the product loses to products from Italy, the USA and Germany, but at a price more expensive than domestic boiler automation.

We called the product "system" because it consists of several blocks, although the general principle of operation remains the same:

  • gas filter;
  • valve - gas pressure regulator;
  • a thermostat with an adjusting handle is separately installed;
  • membrane thermostatic valve;
  • piezoelectric igniter button.

Scheme of the Polish system "Kare"

The nodes and sensors are interconnected by capillary tubes. In fact, this is the same SIT or Honeywell device, only broken into separate parts. This is a plus: it is more convenient and cheaper to change parts.

Products of domestic firms

As you understand, the automation of the boiler, made in the post-Soviet space, does not contain any revolutionary solutions and technological breakthroughs. To implement the three safety functions, the same principles are used - the inclusion of an electromagnet by voltage (EMF) of a thermocouple, a membrane gas valve and a draft sensor that breaks the circuit.


Scheme of the ZhMZ safety valve

It makes no sense to talk in detail about the design of blocks from the brands SABK, Orion and ZhMZ (Zhukovskiy Zavod). These products are characterized by the simplest device, low cost and low reliability. Thermocouples burn out almost every year, and the thermostat turns off and starts the burner too abruptly, which causes a loud bang, sometimes looking like a microexplosion.

The devices work normally in the first years of operation, then they need to be monitored and, fortunately, spare parts are available for sale and are inexpensive. An example of eliminating a typical malfunction of ZhMZ automation, see the video:

Electronics of wall units

A feature of these heat generators is the electronic control of the processes of ignition, combustion and maintaining the temperature of the coolant. That is, wall-mounted gas boilers (and some floor-standing ones) are equipped with volatile automation powered by electricity.

An important point. Despite the many "bells and whistles" introduced into the design of mini-boiler rooms, mechanics are still in charge of safety functions. The three types of emergency situations listed above will be processed by the equipment regardless of the presence of voltage in the mains.

The automatic gas boiler was created for the maximum convenience of the owners of apartments and private houses. To start the heater, just press 1 button and set the desired temperature. Let us briefly describe the algorithm of the unit operation and the elements involved in it:

  1. After the specified start-up actions, the heat generator controller collects sensor readings: coolant and air temperature, gas and water pressure in the system, checks for draft in the chimney.
  2. If everything is in order, the electronic board supplies voltage to the electromagnetic gas valve and at the same time - a discharge to the ignition electrodes. The wick is missing.
  3. The main burner ignites and gives full power in order to heat the coolant as soon as possible. Its work is monitored by a special flame sensor. The controller includes a built-in circulation pump.
  4. When the coolant temperature approaches the set threshold, which is recorded by the overhead sensor, the combustion intensity will decrease. Step burners switch to low power mode, and modulating burners smoothly reduce the fuel supply.
  5. Having reached the heating threshold, the electronics will shut off the gas. When the sensor detects water cooling in the system, automatic ignition and heating will be repeated.

Note. In turbocharged boilers with a closed combustion chamber, the controller also starts and stops the fan.

The instructions for the wall-mounted gas boiler indicate that the unit is designed to work in a closed heating system, so the automation monitors the water pressure. If it falls below the permissible limit (0.8-1 bar), then the burner will go out and will not light up until the problem is fixed.

Many imported boilers operate according to a volatile scheme, for example, Buderus Logano, Viessmann and so on. How the installation of electronic gas equipment takes place, the master will tell in an accessible language in the video:

Conclusion

Many homeowners do their own maintenance of their heating units. Hence, interest arises in the operation of automation of gas boilers of various types. We have covered this issue, but we do not recommend repairing safety valves yourself if you do not understand the topic. The maximum that can be done is to clean the strainer, replace the unusable membrane or electromagnet. It is better to entrust the setting of the burner or igniter flame to a master gasman.

Note. The article uses materials from the manufacturer of boilers "Lemax", posted on

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