Boiler control comprising analog up/down timer circuit for generating variable threshold signal

• US 10,247,426 B2
• Filed: 03/01/2017
• Issued: 04/02/2019
• Est. Priority Date: 02/04/2015
• Status: Active Grant

• Current Assignee: Martin Kanner
• Original Assignee: Martin Kanner
• Inventors: Kanner, Martin, Bauman, Arthur
• Primary Examiner(s): Wilson, Gregory A
• Application Number:
  US15/446,703
• Publication Number:
  US 20170176022A1
• Time in Patent Office: 762 Days
• CPC Class Codes: F24D 19/1009 for central heating
• CPC Class Codes: F24D 3/02 with forced circulation, e.g. by pumps pump constructions F04
• CPC Class Codes: F24H 15/104 Inspection; Diagnosis; Trial operation
• CPC Class Codes: F24H 15/20 characterised by control inputs
• CPC Class Codes: F24H 15/223 in the water storage tank
• CPC Class Codes: F24H 15/254 Room temperature
• CPC Class Codes: F24H 15/258 Outdoor temperature
• CPC Class Codes: F24H 15/335 Control of pumps, e.g. on-off control control of compressors of heat pumps F24H15/38
• CPC Class Codes: F24H 15/36 of burners
• CPC Class Codes: F24H 15/37 of electric heaters
• CPC Class Codes: F24H 15/395 Information to users, e.g. alarms
• CPC Class Codes: F24H 15/407 using electrical switching, e.g. TRIAC
• CPC Class Codes: F24H 15/486 using timers
• CPC Class Codes: F24H 9/13 for water heaters
• CPC Class Codes: F24H 9/2035 using fluid fuel
• CPC Class Codes: H02M 3/07 using capacitors charged and discharged alternately by semiconductor devices with control electrode , e.g. charge pumps
• CPC Class Codes: H03K 3/0231 Astable circuits H03K3/0315 takes precedence
• CPC Class Codes: H03K 5/086 generated by feedback

Abstract

An apparatus comprises a sensor circuit configured to detect activation of at least one circulator arranged to circulate liquid from a boiler through at least one circulation loop and back to the boiler. An analog up/down timer circuit has an input coupled to an output of the sensor circuit and generates a variable threshold signal that varies as a function of an activation time of the at least one circulator. A burner control circuit receives the variable threshold signal from the analog up/down timer circuit and generates an ignition control signal based at least in part on comparison of a temperature sensor signal of the boiler with the variable threshold signal. An ignition driver receives the ignition control signal from the burner control circuit and generates an ignition signal for a burner configured to burn fuel to heat the liquid in the boiler based at least in part on the ignition control signal.

Claims

1. An apparatus comprising:

a sensor circuit configured to detect activation of at least one circulator arranged to circulate liquid from a boiler through at least one circulation loop and back to the boiler;

an analog up/down timer circuit having an input coupled to an output of the sensor circuit and configured to generate a variable threshold signal that varies as a function of an activation time of said at least one circulator;

a burner control circuit configured to receive the variable threshold signal from the analog up/down timer circuit and to generate an ignition control signal based at least in part on comparison of a temperature sensor signal of the boiler with the variable threshold signal; and

an ignition driver configured to receive the ignition control signal from the burner control circuit and to generate an ignition signal for a burner configured to burn fuel to heat the liquid in the boiler based at least in part on the ignition control signal;

wherein a control signal generated by the sensor circuit varies as a function of an activation state of said at least one circulator; and

wherein the analog up/down timer circuit in generating the variable threshold signal is controllably switched between charge and discharge modes of operation responsive to the control signal.

2. The apparatus of claim 1 wherein said at least one circulator comprises a plurality of circulators and the sensor circuit comprises a current sense circuit arranged in series with respective alternating-current control lines of the plurality of circulators.

3. The apparatus of claim 1 wherein said at least one circulator comprises a plurality of circulators and the analog up/down timer circuit comprises:

a pulse source;

a charge storage element;

a charge pump coupled between the pulse source and the charge storage element; and

a discharge pump coupled between the pulse source and the charge storage element;

wherein a pulse signal generated by the pulse source is utilized to charge the charge storage element via the charge pump in the charge mode of operation and to discharge the charge storage element via the discharge pump in the discharge mode of operation; and

wherein the analog up/down timer circuit is controllably switched between the charge and discharge modes of operation responsive to variations in the control signal resulting from changes in activation states of respective ones of at least a subset of the plurality of circulators.

4. The apparatus of claim 3 wherein the analog up/down timer circuit is configured in a particular one of the charge and discharge modes of operation responsive to an up/down control signal generated by the sensor circuit.

5. The apparatus of claim 3 wherein the charge pump and the discharge pump are driven by respective ones of complemented and uncomplemented versions of the pulse signal generated by the pulse source.

6. The apparatus of claim 3 wherein the analog up/down timer circuit further comprises:

a charge distribution circuit coupled between the charge pump and the charge storage element;

wherein the charge distribution circuit comprises first and second circuit paths separating energy from the charge pump into respective first and second portions;

the first circuit path providing the first portion of the charge pump energy to the charge storage element; and

the second circuit path diverting the second portion of the charge pump energy away from the charge storage element.

7. The apparatus of claim 3 wherein the analog up/down timer circuit further comprises:

a discharge distribution circuit coupled between the discharge pump and the charge storage element;

wherein the discharge distribution circuit comprises first and second circuit paths separating energy from the discharge pump into respective first and second portions;

the first circuit path providing the first portion of the discharge pump energy to the charge storage element; and

the second circuit path diverting the second portion of the discharge pump energy away from the charge storage element.

8. The apparatus of claim 1 further comprising a dual boiler sense circuit, the dual boiler sense circuit comprising:

a first temperature sensor configured to generate the temperature sensor signal as a first temperature sensor voltage; and

a second temperature sensor configured to generate a second temperature sensor voltage.

9. The apparatus of claim 8 further comprising a fault detection circuit configured to monitor the first and second temperature sensor voltages and to generate a fault indication signal if the first and second temperature sensor voltages differ from one another by more than a designated amount.

10. The apparatus of claim 1 wherein the ignition driver comprises a first relay circuit configured to control a state of a first switch arranged in series with an alternating-current control line of the burner based at least in part on the ignition signal.

11. The apparatus of claim 10 further comprising a fault driver comprising a second relay circuit configured to control a state of a second switch arranged in series with the first switch and the alternating-current control line of the burner based at least in part on a fault indication signal generated by a fault detection circuit.

12. A method comprising:

detecting activation of at least one circulator arranged to circulate liquid from a boiler through at least one circulation loop and back to the boiler;

generating a variable threshold signal that varies as a function of an activation time of said at least one circulator;

generating an ignition control signal based at least in part on comparison of a temperature sensor signal of the boiler with the variable threshold signal; and

generating an ignition signal for a burner configured to burn fuel to heat the liquid in the boiler based at least in part on the ignition control signal;

wherein detecting activation of said at least one circulator comprises generating a control signal that varies as a function of an activation state of said at least one circulator; and

wherein generating the variable threshold voltage comprises controllably switching a source of the variable threshold voltage between charge and discharge modes of operation responsive to the control signal.

13. The method of claim 12 wherein said at least one circulator comprises a plurality of circulators and detecting activation of at least one circulator comprises sensing current in respective alternating-current control lines of the plurality of circulators.

14. The method of claim 12 wherein said at least one circulator comprises a plurality of circulators and generating a variable threshold signal that varies as a function of an activation time of the circulator comprises:

charging a charge storage element via a charge pump in the charge mode of operation; and

discharging the charge storage element via a discharge pump in the discharge mode of operation;

wherein the source of the variable threshold voltage is controllably switched between the charge and discharge modes of operation responsive to variations in the control signal resulting from changes in activation states of respective ones of at least a subset of the plurality of circulators.

15. The method of claim 12 further comprising:

generating the temperature sensor signal as a first temperature sensor voltage indicative of a temperature of the liquid in the boiler; and

generating a second temperature sensor voltage also indicative of a temperature of the liquid in the boiler.

16. The method of claim 15 further comprising:

monitoring the first and second temperature sensor voltages; and

generating a fault indication signal if the first and second temperature sensor voltages differ from one another by more than a designated amount.

17. The method of claim 12 further comprising controlling a state of a first switch arranged in series with an alternating-current control line of the burner based at least in part on the ignition signal.

18. The method of claim 17 further comprising controlling a state of a second switch arranged in series with the first switch and the alternating-current control line of the burner based at least in part on a fault indication signal.

19. A heating system comprising:

a boiler;

a burner configured to burn fuel to heat liquid in the boiler;

at least one circulation loop;

at least one circulator configured to circulate liquid from the boiler through said at least one circulation loop and back to the boiler;

a sensor circuit configured to detect activation of said at least one circulator;

an analog up/down timer circuit having an input coupled to an output of the sensor circuit and configured to generate a variable threshold signal that varies as a function of an activation time of said at least one circulator;

a burner control circuit configured to receive the variable threshold signal from the analog up/down timer circuit and to generate an ignition control signal based at least in part on comparison of a temperature sensor signal of the boiler with the variable threshold signal; and

an ignition driver configured to receive the ignition control signal from the burner control circuit and to generate an ignition signal for the burner based at least in part on the ignition control signal;

wherein a control signal generated by the sensor circuit varies as a function of an activation state of said at least one circulator; and

wherein the analog up/down timer circuit in generating the variable threshold signal is controllably switched between charge and discharge modes of operation responsive to the control signal.

20. The system of claim 19 wherein said at least one circulator comprises a plurality of circulators and the analog up/down timer circuit comprises:

a pulse source;

a charge storage element;

a charge pump coupled between the pulse source and the charge storage element; and

a discharge pump coupled between the pulse source and the charge storage element;

wherein a pulse signal generated by the pulse source is utilized to charge the charge storage element via the charge pump in the charge mode of operation and to discharge the charge storage element via the discharge pump in the discharge mode of operation; and

wherein the analog up/down timer circuit is controllably switched between the charge and discharge modes of operation responsive to variations in the control signal resulting from changes in activation states of respective ones of at least a subset of the plurality of circulators.