Flame sensor verification

• US 5,722,822 A
• Filed: 05/03/1995
• Issued: 03/03/1998
• Est. Priority Date: 05/03/1995
• Status: Expired due to Term

• Current Assignee: Carrier Corporation (Carrier Global Corporation)
• Original Assignee: Carrier Corporation (Carrier Global Corporation)
• Inventors: Kelly, Daniel L., Wilson, Larry E., Knotts, Craig R.
• Primary Examiner(s): Jones, Larry
• Application Number:
  US08/433,183
• Time in Patent Office: 1,035 Days
• Field of Search: 431/25, 431/24, 431/18, 431/66, 431/77, 431/13, 431/12, 431/14, 431/78, 126/116 A
• US Class Current: 431/25
• CPC Class Codes: F23Q 23/10 electrically

Abstract

Method and apparatus are disclosed for checking the responsiveness of a circuit which senses the presence of a flame produced by a burner within a furnace. A programmed processor associated with the circuit measures the time the circuit takes to indicate the presence of a flame. A warning is generated when the measured time exceeds a predetermined allowable time. The allowable time is determined by taking into account the decreased responsiveness of an electrode that indicates the presence of the burner flame.

Claims

1. A system for detecting the presence and quality of a flame being produced by an electrically grounded burner of a furnace, said system comprising:

an electrode mounted in the path of a flame produced by the burner;

an alternating current voltage source connected through a first capacitor and a first resistor to said electrode, said alternating current voltage source causing current to flow through the electrode and through a flame impinging on the electrode to the burner, the current flow through the flame producing an attenuated voltage condition at the electrode caused by the relative conductivity of the flame for positive versus negative voltage fluctuation of the alternating current voltage;

a second resistor connected at one end to a junction between said first resistor and said first capacitor;

a second capacitor connected to the opposing end of said second resistor, said second capacitor in combination with said first capacitor and said second resistor defining a second current path to ground from the alternating current voltage source, said second capacitor charging over time to a capacitance voltage level indicative of the attenuated voltage condition at the electrode; and

a processor having an input for sensing when the second capacitor has reached the capacitance voltage level indicative of the attenuated voltage condition at the electrode, said microprocessor including means for measuring the time the second capacitor takes to achieve the capacitance voltage level indicative of the attenuated voltage condition at the electrode.

2. The system of claim 1 further comprising:

a shunting transistor connected across the second capacitor, said shunting transistor being furthermore connected to an output of said processor whereby said means for measuring the time the second capacitor takes to achieve the capacitance voltage level indicative of the attenuated voltage condition at the electrode comprises a means for turning on the shunting transistor so as to discharge the second capacitor and a means for turning the shunting transistor off.

3. The system of claim 2 further comprising:

a second transistor connected to an input of said processor, said second transistor being furthermore connected to a junction between said second resistor and said second capacitor, said second transistor being operative to change voltage levels at the input to said processor when the voltage level of the second capacitor reaches the capacitance voltage level indicative of the attenuated voltage condition at the electrode and wherein said means for measuring the time the second capacitor takes to achieve the capacitance voltage level indicative of the attenuated voltage condition at the electrode comprises means for detecting when the input to said microprocessor changes voltage levels.

4. The system of claim 3 wherein said means for measuring the time the second capacitor takes to achieve the capacitance voltage level comprises:

means for measuring the elapsed time between turning off said shunting transistor and the detection of the voltage level change at the input to said microprocessor;

means for comparing the measured elapsed time with a predetermined allowable time; and

means for indicating when the measured elapsed time exceeds the predetermined allowable time.

5. The system of claim 3 wherein said means for measuring the time the second capacitor takes to achieve the capacitance voltage level comprises:

means for inquiring whether the input to the microprocessor has switched voltage levels;

means for reading the elapsed time following the mining off of said shunting transistor;

means for comparing the read elapsed time with a maximum allowable time; and

means for indicating when the read elapsed period of time exceeds the maximum allowable time.

6. A process for checking the responsiveness of a system for sensing the presence and quality of a flame generated by a burner within a furnace, the system including an electrode which experiences an attenuated A.C. voltage condition when a flame from the burner impinges on the electrode, the system furthermore including a capacitor which charges to a voltage level indicative of the attenuated voltage condition experienced by the electrode when a flame from the burner impinges on the electrode, said process comprising the steps of:

causing an alternating current to flow through the electrode and through a flame impinging on the electrode;

discharging the capacitor for a predetermined period of time;

allowing the discharged capacitor to again begin charging as a result of the flame impinging on the electrode;

initiating a clock timer following said step of allowing the discharged capacitor to again begin charging;

reading the clock timer when capacitor has changed to a voltage level indicative of the attenuated voltage condition experienced by the electrode;

comparing the read clock time to an allowable period of elapsed clock time if the capacitor has charged to the voltage level indicative of the attenuated voltage condition of the electrode; and

displaying a message indicating when the read clock time is greater than the allowable period of time.

7. The process of claim 6 further comprising the steps of:

comparing the read clock time to a maximum allowable period of clock time when the capacitor has not charged to the voltage level indicative of the attenuated voltage condition at the electrode; and

displaying a message indicating when the read clock time exceeds the maximum allowable period of clock time.

8. A system for checking the presence and quality of a flame being produced by a burner in a furnace, said system comprising:

an electrode mounted in the path of the time produced by the burner;

an alternating current voltage source, connected to said electrode, for causing current to flow through the electrode and through the flame to the burner acting as a ground for the current flow when a flame is present;

a resistance-capacitance circuit for filtering the alternating current voltage being applied to the electrode, said resistance capacitance circuit including a capacitor which normally experiences a voltage build up in response to current initially flowing through the electrode and through the flame to the burner;

a processor for measuring the time that the capacitor in the resistance-capacitance circuit takes to build up sufficient voltage to indicate the presence of a time, said processor generating a message indicating when the measured time exceeds a predetermined time during which the capacitor is to have built up sufficient voltage to indicate the presence of a flame; and

a display for displaying the message generated by said processor indicating when the measured time exceeds a predetermined period of time during which the capacitor is to have built up the sufficient voltage to indicate the presence of a flame.

9. The system of claim 8 further comprising:

a shunting transistor, connected across the capacitor experiencing the voltage build up, and furthermore connected to an output of said processor whereby said shunting transistor is operative to discharge said capacitor in response to a predefined logic level signal from said processor.

10. The system of claim 9 further comprising:

a second transistor, responsive to the build up of voltage across the capacitor in the resistance capacitance circuit, for conducting when the voltage buildup across the capacitor reaches a sufficient voltage to indicate the presence of a time; and

a voltage source, upstream of said second transistor, for defining the voltage level being applied to an input of the processor when said second transistor begins conducting in response to the build up of voltage across the capacitor in the resistance capacitance circuit to a sufficient voltage to indicate the presence of a flame.

11. A process for checking the responsiveness of a circuit which detects the presence and quality of a flame produced by a burner in a furnace, said process comprising the steps of:

generating an A.C. voltage potential between an electrode and the burner of the furnace;

filtering an A.C. voltage waveform upstream of the electrode thorough a resistor and a capacitor;

measuring the time it takes to build up a voltage in the capacitor due to the voltage condition occurring at the electrode when a flame is present;

determining when the measured time exceeds a predetermined period of time during which the build-up of voltage in the capacitor is to occur; and

displaying a warning indicating that the circuit for detecting the presence and quality of a flame is exceeding the predetermined period of time.

12. The process of claim 11 wherein said step of measuring the time it takes to build up a voltage in the capacitor comprises the steps of:

discharging the capacitor for a predetermined period of time;

initiating a timer when said step of discharging the timer is terminated;

checking whether the build up in voltage in the capacitor indicate that a flame is present; and

reading the timer when said detecting step indicates a time is present.

13. The process of claim 12 further comprising the steps of:

reading the timer when said step of checking the build up in voltage in the capacitor does not indicate a flame being present;

comparing the read time of the timer with a maximum allowable period of time; and

displaying a message indicating no flame being present when the read time of the timer exceeds the maximum allowable period of time.