Modulating Boiler System

• US 20090001186A1
• Filed: 06/28/2007
• Published: 01/01/2009
• Est. Priority Date: 06/28/2007
• Status: Active Grant

• Current Assignee: Wescast Inc. (Mestek Incorporated)
• Original Assignee: Wescast Inc. (Mestek Incorporated)
• Inventors: Cohen, Kenneth W.
• Granted Patent: US 8,490,886 B2
• Time in Patent Office: Days
• US Class Current: 237/8.A
• CPC Class Codes: F24D 19/1009 for central heating
• CPC Class Codes: F24D 19/1048 Counting of energy consumption
• CPC Class Codes: F24H 15/144 Measuring or calculating energy consumption
• CPC Class Codes: F24H 15/156 Reducing the quantity of energy consumed; Increasing efficiency
• CPC Class Codes: F24H 15/176 Improving or maintaining comfort of users
• CPC Class Codes: F24H 15/212 Temperature of the water
• CPC Class Codes: F24H 15/355 Control of heat-generating means in heaters
• CPC Class Codes: F24H 9/2007 for water heaters
• CPC Class Codes: F24H 9/2014 using electrical energy supply
• CPC Class Codes: G05D 23/19 characterised by the use of electric means G05D23/1393 takes precedence
• CPC Class Codes: G05D 23/1917 using digital means

Abstract

A modulating boiler system for heating a structure including a controller, a boiler operatively connected to the controller, and a thermostat operatively connected to the controller and boiler. The controller assesses a level of thermostat activity over a predetermined measuring period and adjusts the boiler in response to the level of activity to increase the boiler'"'"'s efficiency.

Claims

1. A modulating boiler system for heating a structure comprising:

a controller;

a boiler in operative connection with said controller;

a thermostat in operative connection with said controller and said boiler; and

wherein said controller determines an activity level of said thermostat over a predetermined time period and adjusts said boiler in response to said activity level.

2. The modulating boiler system of claim 1 wherein said activity level is an exponential moving average of an amount of time said thermostat is on during said predetermined time period.

3. The modulating boiler system of claim 1 wherein said activity level is a second exponential moving average created from a first exponential moving average of an amount of time said thermostat is on during said predetermined time period.

4. The modulating boiler system of claim 2 wherein said exponential moving average is between 0 and 1.

5. The modulating boiler system of claim 2 wherein said controller adjusts said boiler by regulating energy input to said boiler.

6. The modulating boiler system of claim 5 wherein said controller regulates energy input to said boiler by multiplying said exponential moving average by a maximum BTU of said boiler and then adjusting said energy input as required.

7. The modulating boiler system of claim 1 wherein said predetermined time period is a 1-hour interval.

8. A system for heating a structure comprising:

a controller;

a boiler in operative connection with said controller;

at least one thermostat in operative connection with said controller and said boiler; and

wherein said controller creates an exponential moving average of an amount of time that said thermostat is on over a predetermined time period and adjusts said boiler in response to said exponential moving average.

9. The system for heating a structure of claim 8 wherein said controller adjusts said boiler by multiplying said exponential moving average by a maximum BTU of said boiler to regulate energy input to said boiler.

10. The system for heating a structure of claim 8 wherein said exponential moving average is between 0 and 1.

11. The system for heating a structure of claim 8 wherein said predetermined time period is approximately a 1-hour interval.

12. The system for heating a structure of claim 8 where said at least one thermostat is two or more thermostats.

13. The system for heating a structure of claim 12 wherein said controller creates an exponential moving average for each of said two or more thermostats and multiplies the highest of said exponential moving averages by a maximum BTU of said boiler to adjust energy input to said boiler.

14. A method of increasing boiler efficiency comprising the steps of:

assessing an activity level of at least one thermostat over a predetermined time period, said at least one thermostat being in operative connection with a boiler; and

adjusting said boiler in response to said activity level of said thermostat.

15. The method of claim 14 wherein said activity level is an exponential moving average of an amount of time said at least one thermostat is on during said predetermined time period.

16. The method of claim 15 wherein said boiler is adjusted by regulating energy input to said boiler.

17. The method of claim 16 comprising the additional step of:

determining an appropriate energy input to said boiler by multiplying said exponential moving average by a maximum BTU for said boiler.

18. The method of claim 15 wherein said at least one thermostat is two or more thermostats and an exponential moving average is created for each of said two or more thermostats.

19. The method of claim 18 comprising the additional step of:

selecting a highest exponential moving average from said exponential moving averages for said two or more thermostats.

20. The method of claim 19 wherein said boiler is adjusted in response to said highest exponential moving average.