Furnace control system and method

• US 10,094,591 B2
• Filed: 08/15/2012
• Issued: 10/09/2018
• Est. Priority Date: 08/15/2011
• Status: Active Grant

• Current Assignee: Carrier Corporation (Carrier Global Corporation)
• Original Assignee: Carrier Corporation (Carrier Global Corporation)
• Inventors: Garloch, Duane D., Thompson, Kevin D.
• Primary Examiner(s): Huson, Gregory
• Assistant Examiner(s): HEYAMOTO, AARON H
• Application Number:
  US13/586,045
• Publication Number:
  US 20130042851A1
• Time in Patent Office: 2,246 Days
• Field of Search: 126 99 R, 126120
• CPC Class Codes: F24H 15/242 Pressure
• CPC Class Codes: F24H 15/25 Temperature of the heat-generating means in the heater
• CPC Class Codes: F24H 15/31 of valves having only one inlet port and one outlet port, e.g. flow rate regulating valves
• CPC Class Codes: F24H 15/345 Control of fans, e.g. on-off control control of fans of heat pump units F24H15/375
• CPC Class Codes: F24H 15/36 of burners
• CPC Class Codes: F24H 15/421 using pre-stored data
• CPC Class Codes: F24H 15/486 using timers
• CPC Class Codes: F24H 3/065 using fluid fuel
• CPC Class Codes: F24H 9/2085 using fluid fuel

Abstract

A method for operating a furnace system includes initiating a start sequence comprising starting an inducer fan operative to induce an air flow through a burner assembly, a heat exchanger portion and a collector portion, determining whether an air pressure in the collector portion is above a first threshold value, starting a furnace ignition sequence including providing fuel to the burner assembly, igniting a fuel and air mixture and starting an ignition timer responsive to determining that the air pressure in the collector portion is above the first threshold value, determining whether the ignition timer has expired, determining whether the air pressure in the collector portion is above a second threshold value responsive to determining that the ignition timer has expired, and stopping the provision of fuel to the burner assembly responsive to determining that the air pressure in the collector portion is not above the second threshold value.

Claims

1. A method for operating a furnace system, the method comprising:

receiving a start instruction at a controller;

initiating a start sequence comprising;

starting an inducer fan operative to induce an air flow through a burner assembly, a heat exchanger portion and a collector portion;

comparing an air pressure to a first threshold value;

starting a furnace ignition sequence including providing fuel to the burner assembly, mixing the fuel with induced air, igniting the fuel and air mixture and starting an ignition timer responsive to determining that the air pressure is above the first threshold value;

determining whether the ignition timer has expired;

determining whether the air pressure is above a second threshold value responsive to determining that the ignition timer has expired; and

stopping the provision of fuel to the burner assembly responsive to determining that the air pressure is not above the second threshold value;

wherein the first threshold value is less than the second threshold value.

2. The method of claim 1, wherein the method further comprises outputting a fault indicator responsive to determining that the air pressure is not above the first threshold value.

3. The method of claim 1, wherein the method further comprises stopping the provision of fuel to the burner assembly responsive to determining that the air pressure is not above the first threshold value.

4. The method of claim 1, wherein the method further comprises sending a fault indication responsive to determining that the air pressure is not above the second threshold value.

5. The method of claim 1, wherein the method further comprises:

incrementing a fault counter responsive to determining that the air pressure is not above the second threshold value;

determining whether the fault counter has reached a fault counter threshold value; and

initiating the start sequence responsive to determining that the fault counter has not reached the fault counter threshold value.

6. The method of claim 1, wherein the air pressure comprises air pressure in the collector portion.

7. The method of claim 1, wherein determining that the air pressure is above the first threshold value is based on air pressure in the collector portion and determining whether the air pressure is above the second threshold value is based on air pressure in an inducer portion.

8. The method of claim 1, wherein the air pressure comprises air pressure in at least one of the collector portion and an inducer portion.

9. A method for operating a furnace system, the method comprising:

receiving a start instruction at a controller;

initiating a start sequence comprising;

starting an inducer fan operative to induce an air flow through a burner assembly, a heat exchanger portion and a collector portion;

comparing an air pressure to a first threshold value;

starting a furnace ignition sequence including providing fuel to the burner assembly, mixing the fuel with induced air, igniting the fuel and air mixture and starting an ignition timer responsive to determining that the air pressure is above the first threshold value;

determining whether the ignition timer has expired;

determining whether the air pressure is above a second threshold value responsive to determining that the ignition timer has expired;

stopping the provision of fuel to the burner assembly responsive to determining that the air pressure is not above the second threshold value;

incrementing a fault counter responsive to determining that the air pressure is not above the second threshold value;

determining whether the fault counter has reached a fault counter threshold value; and

initiating the start sequence responsive to determining that the fault counter has not reached the fault counter threshold value;

starting a fault timer responsive to determining that the fault counter has reached the fault counter threshold value;

determining whether the fault timer has expired; and

initiating the start sequence responsive to determining that the fault timer has expired.

10. A furnace system comprising:

an inlet duct communicatively connected to an air source and a burner assembly;

a heat exchanger portion communicatively connected to an output of the burner assembly;

a collector portion communicatively connected to an output of the heat exchanger assembly;

an inducer portion communicatively connected to an output of the collector portion and an exhaust duct;

a gas valve communicatively connected to a fuel source and the burner assembly;

a first pressure sensor operative to sense a pressure in the collector portion;

a second pressure sensor operative to sense a second pressure in the collector portion; and

a controller operative to control the gas valve, and the inducer portion, the controller operative to receive a start instruction, initiating a start sequence comprising starting the inducer portion, receive a signal from the first pressure sensor and determine whether the sensed pressure is above a first threshold value, starting a furnace ignition sequence including controlling the gas valve to provide fuel to the burner assembly and starting an ignition timer responsive to determining that an air pressure in the collector portion is above the first threshold value, determining whether the air pressure in the collector portion is above a second threshold value, and stopping the provision of fuel to the burner assembly by controlling the gas valve responsive to determining that the air pressure in the collector portion is not above the second threshold value;

wherein the first threshold value is less than the second threshold value.

11. The system of claim 10, wherein the start sequence further comprises outputting a fault indicator responsive to determining that the air pressure in the collector portion is not above the first threshold value.

12. The system of claim 10, wherein the start sequence further comprises stopping the provision of fuel to the burner assembly responsive to determining that the air pressure in the collector portion is not above the first threshold value.

13. The system of claim 10, wherein the start sequence further comprises outputting a fault indication responsive to determining that the air pressure in the collector portion is not above the second threshold value.

14. A furnace system comprising:

an inlet duct communicatively connected to an air source and a burner assembly;

a heat exchanger portion communicatively connected to an output of the burner assembly;

a collector portion communicatively connected to an output of the heat exchanger assembly;

an inducer portion communicatively connected to an output of the collector portion and an exhaust duct;

a gas valve communicatively connected to a fuel source and the burner assembly;

a first pressure sensor operative to sense a pressure in the collector portion;

a second pressure sensor operative to sense a pressure in the inducer portion; and

a controller operative to control the gas valve, and the inducer portion, the controller operative to receive a start instruction, initiating a start sequence comprising starting the inducer portion, receive a signal from the first pressure sensor and determine whether the sensed pressure is above a first threshold value, starting a furnace ignition sequence including controlling the gas valve to provide fuel to the burner assembly and starting an ignition timer responsive to determining that an air pressure in the collector portion is above the first threshold value, determining whether the air pressure in the inducer portion is above a second threshold value, and stopping the provision of fuel to the burner assembly by controlling the gas valve responsive to determining that the air pressure in the inducer portion is not above the second threshold value;

wherein the first threshold value is less than the second threshold value.

15. The system of claim 14, wherein the start sequence further comprises outputting a fault indicator responsive to determining that the air pressure in the collector portion is not above the first threshold value.

16. The system of claim 14, wherein the start sequence further comprises stopping the provision of fuel to the burner assembly responsive to determining that the air pressure in the collector portion is not above the first threshold value.

17. The system of claim 14, wherein the start sequence further comprises outputting a fault indication responsive to determining that the air pressure in the collector portion is not above the second threshold value.