I'm following-up on this thread Sensor for pellet burner.
On my side, I have started to monitor my pellet burner about 1-year ago.
I'm measuring global power consumption of the boiler as well as departure and return temperature of the heating circuit.
Even though, I do that since one year only, I've been thinking about how to monitor pellet consumption for at least 5 years (yeah, failure is an option ).
What I have tested:
- IR sensor on the fan of the pellet convoying motor: it failed because it was too far
- Magnetic sensor on this same fan: same failure for the same reason
- Vibration sensor: the heater vibrates ...all the time
Now, I'm about to test something quite simple: mains presence at the convoying motor. This one is quite easy (I will show you how) to design and relates quite easily to the pellet consumption: 1 second equals x grams of pellet.
How do I know the time mains are activating the motor ? Well, a zero-crossing detector.
Beware, main resistance values are key: they depend on mains value, optocoupler characteristics and ..their power. Using the displayed value (56k) will keep the power under 1/4W. The optocoupler is a LTV-814 (cheap and efficient !).
Here is a quick schema of such a detector. I will keep you posted with the results.
Hope my experience will help others.