Temperature and low water monitoring for boiler systems

A system for monitoring low water cutoff and temperature in a boiler comprising:

• a temperature sensor within a housing inserted into a well within a boiler tapping;
• conductors connecting to said temperature sensor and protruding from said housing;
• a semi-rigid sheath surrounding said conductors and securing a conductive member of a low water cutoff sensor, said sheath surrounding said thermistor conductors and covering a substantial portion of the length of said thermistor conductors, providing rigidity for said thermistor conductors and allowing insertion within said well without having said thermistor conductors collapse upon insertion, while simultaneously securing said resilient, compression-fit conductor;
• said low water cutoff sensor including:
• said conductive member connecting to a low water cutoff conductive wire, and forming a compression fit against said well interior, wherein said conductive member comprises a resilient, compression-fit conductor in the form of a shaped wire clip, a peripheral or semi-peripheral resilient conductive band, or a solidly-shaped conductive material, compress fitted within said well interior to form electrical contact with said well interior without soldering or welding said conductive member to the interior of said well, such that said conductive member and said low water cutoff conductive wire are at approximately the same voltage potential as said well;
• a conductive nut threaded for connection to said well and in electrical communication with said boiler interior wall;
• and
• a controller comprising:
• a microprocessor:
• a unity buffer receiving input signals from said probe and providing a high impedance input for said microprocessor;
• and
• software for filtering said temperature sensor and said low water cutoff sensor inputs, and monitoring said low water cutoff to determine if said probe is properly inserted in said well to avoid a run-away boiler condition.

A method for replacing an existing temperature sensor in a single tapping well within a boiler with a dual functioning low water cutoff sensor and temperature sensor probe, said method comprising:

• removing said existing temperature sensor from said single tapping well;
• slidably inserting said dual functioning low water cutoff sensor and temperature sensor probe within said well, said dual functioning probe comprising:
• said temperature sensor probe having a housing and conductors protruding from said housing, peripherally protected by a semi-rigid sheath;
• said low water cutoff sensor probe including a conductive member connecting to a low water cutoff conductive wire, said conductive member secured with conductors of said temperature sensor probe and forming a compression fit against said well interior without soldering or welding said conductive member to the interior of said well, said conductive member and said low water cutoff conductive wire in electrical communication with said well, such that said conductive member and said low water cutoff conductive wire are at approximately the same voltage potential as said well;
• connecting said probe to a microcontroller circuit;
• and
• operating said probe using a microcontroller having software for filtering said temperature sensor and said low water cutoff sensor inputs.

An apparatus for measuring temperature and low water cutoff in a boiler comprising:

• a probe having a dual measurement function within a well inserted in a tapping into said boiler including:
• a temperature sensor including at least one thermistor in a housing;
• thermistor conductors connecting to said at least one thermistor and protruding from said housing;
• and
• a low water cutoff sensor including a conductive member connecting to a low water cutoff conductive wire, and forming a compression fit against said well interior without soldering or welding said conductive member to the interior of said well, said conductive member and said low water cutoff conductive wire in electrical communication with said well, such that said conductive member and said low water cutoff conductive wire are at approximately the same voltage potential as said well;
• said probe forming a rigid construction for slidably inserting within said tapping;
• and
• a controller comprising:
• a microprocessor:
• a unity buffer receiving input signals from said probe and providing a high impedance input for said microprocessor;
• and
• software for filtering said temperature sensor and said low water cutoff sensor inputs.