At Bacon Engineering, we understand that boiler controls are the nerve center of any steam or hot water system. Whether in industrial facilities, commercial buildings, or institutional operations, well-maintained boiler controls ensure not only safety but also energy efficiency and system reliability. In this article, we explore what boiler controls are and how to properly maintain them to keep your systems running at peak performance.

What Are Boiler Controls?

Boiler controls are devices and systems that regulate the various functions of a boiler, including temperature, pressure, water level, and combustion. These controls are essential for:

• Safety – preventing overpressure or dry firing
• Efficiency – minimizing fuel consumption
• Reliability – maintaining consistent operation and heat delivery
• Compliance – meeting regulatory requirements for emissions and performance

Common types of boiler controls include:

• Temperature and pressure controls
• Burner management systems
• Water level controls
• Safety devices like low-water cutoffs and high-limit switches
• Programmable Logic Controllers (PLCs) for automation
• Combustion air/fuel ratio controls

How to Maintain Boiler Controls

Proper maintenance of boiler controls not only extends equipment life but also helps prevent costly downtime and hazards. At Bacon Engineering, we recommend the following best practices:

1. Visual Inspection (Daily or Weekly)

• Monitor indicators
• : Check control panels for abnormal readings or warning signals.
• Inspect connections: Ensure wiring is intact and free from corrosion or damage.
• Look for external issues: Check for water leaks, overheating, or soot accumulation.

2. Test Safety Devices (Weekly or Monthly)

• Low Water Cutoff (LWCO): Test manually or use automatic diagnostics to ensure the system will shut down safely in low-water conditions.
• High-Limit Switches: Trip these intentionally during maintenance to verify they trigger boiler shutdown properly.
• Compare instrument readings: Cross-check pressure and temperature controls against known-good gauges.

3. Calibration and Adjustment (Quarterly or Annually)

• Calibrate sensors: Use certified test equipment to verify accuracy of temperature, pressure, and level sensors.
• Adjust control parameters: Recalibrate burner controls and setpoints to optimize performance.
• Verify PLC inputs: Zero and scale analog inputs to maintain consistent system response.

4. Clean Control Components

• Flame sensors: Clean flame rods and scanners to avoid false shutdowns.
• Control panels: Remove dust and dirt buildup to protect sensitive electronics.
• Water level chambers: Blow down chambers to clear sediment and ensure proper operation.

5. Update Software and Firmware

For systems using digital or PLC-based controls, keeping firmware and software updated ensures maximum functionality and security. Always keep backup copies of your current programs and configurations before making changes.

6. Log Maintenance Activities

Document each inspection, test, calibration, or part replacement. Keeping a detailed maintenance log allows your team to spot trends and preemptively address potential failures before they become critical.

7. Replace or Upgrade Aging Components

Boiler controls degrade over time, especially in demanding industrial environments. Replace sensors and switches that show drift or sluggish response, and consider upgrading to modern digital controls for improved diagnostics and remote monitoring.

Partner With Bacon Engineering

Bacon Engineering provides expert services for boiler control systems, from design and installation to preventive maintenance and emergency repair. We help facilities across Canada maintain safe, efficient, and compliant boiler operations. Whether you're operating high-pressure steam systems or low-temperature hydronic boilers, our team is ready to support your success.

Need help maintaining your boiler controls? Contact Bacon Engineering today.