Tecvalco CWT Vacuum Heater Retrofit

The Profire Solution

Tecvalco worked with Profire as the burner management and combustion controls partner to add automatic re-light capability, improve operating visibility, and support the end user’s field needs while keeping Tecvalco’s CWT heater design intact.

The retrofit centered on a PF2200-SB BMS Controller installed in a metal enclosure. This gave the heater a burner management platform to support automatic re-light capability, integrate key field devices, and provide clearer application control.

Automatic re-light addressed the primary field need. With the retrofit, the heater could recover from nuisance pilot losses through a controlled burner management sequence instead of relying on manual intervention.

Profire also supplied and integrated fuel train components, thermocouples, solenoids, a temperature transmitter, and a vacuum transmitter. These components worked together as part of a controls package built to improve automation, monitoring, and serviceability.

The system monitors four key temperature points:

• Glycol before it transitions to steam
• Steam temperature
• Heater outlet temperature
• Station outlet temperature

Steam and station outlet readings support process control, while the heater outlet reading provides an added layer of equipment protection. Together, the four inputs give the system more operating context than a basic on/off retrofit.

Vacuum tracking adds visibility into heater health. CWT heater performance depends on vacuum condition, and vacuum loss can develop over time. The vacuum transmitter gives operators a clearer view of that condition to support maintenance planning.

The retrofit also preserved Tecvalco’s burner design. Profire modified the pilot system and integrated the controls, but did not replace or redesign the burner. Profire’s role was to improve, optimize, and augment the existing heater with burner management, monitoring, and control capabilities.

Profire also supported the controls-side documentation and integration details needed for the TSSA field inspection and certification path led by Tecvalco.

Key elements included:

• PF2200-SB burner management: PF2200-SB BMS Controller installed in a metal enclosure
• Automatic re-light capability: Added functionality to support controlled recovery when site conditions affect pilot operation
• Vacuum monitoring: Live vacuum tracking to support heater health visibility
• Four-point temperature monitoring: Glycol, steam, heater outlet, and station outlet readings integrated into the system
• Fuel train integration: Fuel train components, solenoids, thermocouples, and pilot modifications added to support reliable operation
• OEM-supported retrofit approach: Profire supported Tecvalco with controls documentation and system integration while Tecvalco remained the heater OEM
• Inspection support: Profire provided controls-side support for the TSSA field inspection and certification path led by Tecvalco

The Result:

The retrofit gave Tecvalco a stronger way to support an installed CWT Vacuum Heater with added burner management, automatic re-light capability, and expanded monitoring.

For OEMs, that’s the value of this project. When a customer needs more automation or visibility from an installed heater, the OEM doesn’t have to solve the full controls scope alone. Profire can support burner management, monitoring, integration, and documentation while the OEM stays connected to the appliance design and customer requirement.

For Tecvalco, the project created a practical retrofit model for installed CWT heaters. It also created a controls approach expected to support future factory-integrated options once approved and proven.

For end users with a preferred heater OEM, the project shows that Profire can work through the OEM relationship to support burner management and combustion controls upgrades while keeping the manufacturer connected to the appliance.

The result was an OEM-supported retrofit that improved heater automation and visibility, preserved Tecvalco’s appliance design, and helped build a clearer path for future Tecvalco heater packages with integrated Profire controls.