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Pilot LPG Monitoring System

Pilot Gas Monitor
Pilot Gas Monitor

In my mind, the most dangerous thing onboard any boat is the LPG system, as the gas is heavier than air, any leaks tend to collect in the bilges, just waiting for an ignition source. To mitigate this possibility, we’re fitting a gas monitoring system that will sound an alarm & cut off the supply in case of a leak.

Monitor Unit
Monitor Unit

Here’s the monitor itself, the two sensor model. It’s nice & compact, and the alarm is loud enough to wake the dead.

Control Board
Control Board

Not much inside in the way of circuitry, the brains of the operation is a Microchip PIC16F716 8-bit microcontroller with an onboard A/D converter (needed to interface with the sensors), running at 4MHz. The solenoid valve is driven with a ULN2803 Darlington transistor array.
The alarm Piezo sounder can be seen to the right of the ICs, above that is a simple LM7805 linear regulator providing power to the electronics.

Remote Sensor
Remote Sensor

The pair of remote sensors come with 3.5m of cable, a good thing since the mounting points for these are going to be rather far from the main unit in our installation.

Sensor Element
Sensor Element

The sensor itself is a SP-15A Tin Oxide semiconductor type, most sensitive to butane & propane. Unlike the Chinese El-Cheapo versions on eBay, these are high quality sensors. After whiffing some gas from a lighter at one of the sensors, the alarm triggered instantly & tripped the solenoid off.

Solenoid Valve
Solenoid Valve

The solenoid valve goes into the gas supply line after the bottle regulator, in this case I’ve already fitted the adaptors to take the 10mm gas line to the 1/2″ BSP threads on the valve itself. This brass lump is a bit heavy, so support will be needed to prevent vibration compromising the gas line.

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Audi TT Roof Hydraulics

Pump
Pump

This is the hydraulic system from an Audi TT that would power the soft top. Here is the hydraulic pump unit. Oil Tank is on the left. Power is 12v DC at ~20A

Cylinders
Cylinders

The pair of hydraulic cylinders that attached to the roof mechanism.

Limit Switch
Limit Switch

One of the cylinders has a limit switch built in. The brass bolt coming out of the side of the head is one contact. The other contact is the cylinder body.

Hose
Hose

Marking on the hoses. This is Parker Polyflex hydraulic hose. 1/8″ ID.

Motor
Motor

Drive motor for the hydraulic pump. Standard DC permanent magnet motor.

Motor Suppression
Motor Suppression

Motor power terminals & suppression capacitors. As the reversing relays actually short the motor out when de-energized, there is a lot of arcing at the brushes without some suppression.

Reversing Relays
Reversing Relays

Reversing relay stack. Each relay is a SPDT configuration. The pair are arranged as a DPDT bank to reverse the motor, depending on which relay is energized.

Tank
Tank

Detail of the oil tank showing the level markings.

Power Valve
Power Valve

Solenoid valve on top of the unit. This valve provides full pump pressure to the cylinders when energized.