Furnace diagnostic system

• US 6,535,838 B2
• Filed: 01/26/2001
• Issued: 03/18/2003
• Est. Priority Date: 01/28/2000
• Status: Expired due to Fees

• Current Assignee: Robertshaw Controls Company (Schneider Electric SE)
• Original Assignee: Robertshaw Controls Company (Schneider Electric SE)
• Inventors: Cuomo, Robert W., Lewis, Robert Wayne, Johnson, Derek Daniel, Raffaelli, Joseph G., Vaughn, Eldon, Abraham, Anthony W.
• Primary Examiner(s): Hilten, John S.
• Assistant Examiner(s): PRETLOW, DEMETRIUS R
• Application Number:
  US09/772,252
• Publication Number:
  US 20020052713A1
• Time in Patent Office: 781 Days
• Field of Search: 702/130, 702/183, 702/185, 340/539, 340/555, 340/825.69, 431/13, 431/24, 431/16, 236/46.R, 236/1.A, 236/1.EA, 236/15.R
• US Class Current: 702/183
• CPC Class Codes: F23N 1/002 using electronic means F23N1/04 - F23N1/10 take precedence
• CPC Class Codes: F23N 2223/04 Memory
• CPC Class Codes: F23N 2223/08 Microprocessor; Microcomputer
• CPC Class Codes: F23N 2223/38 Remote control
• CPC Class Codes: F23N 2223/54 Recording
• CPC Class Codes: F23N 2225/04 pressure
• CPC Class Codes: F23N 2225/08 temperature
• CPC Class Codes: F23N 2227/02 Starting or ignition cycles
• CPC Class Codes: F23N 2227/04 Prepurge
• CPC Class Codes: F23N 2227/16 Checking components, e.g. electronic
• CPC Class Codes: F23N 2231/10 for component failures
• CPC Class Codes: F23N 2231/20 Warning devices
• CPC Class Codes: F23N 2231/26 for clogging air inlet
• CPC Class Codes: F23N 2233/08 with variable speed
• CPC Class Codes: F23N 5/242 using electronic means
• CPC Class Codes: F23N 5/265 using electronic means

Abstract

A furnace diagnostic system includes sensors that monitor various functions of the furnace. Data generated by such sensors may be stored for subsequent transfer or may be transferred in real time via an infra red link to a remote handheld device with which an analysis thereof is performed. The handheld device additionally allows the technician to control various furnace functions to facilitate the generation of relevant real time data. In order to further enhance the system'"'"'s diagnostics capabilities, the communication may be established with a centralized computing facility which includes a data base containing data relating to an entire population of similar furnaces.

Claims

1. A furnace diagnostic system for facilitating the troubleshooting of malfunctions in the operation of a furnace, comprising:

sensors disposed within said furnace for monitoring various parameters associated with the operation of said furnace;

electronic circuitry for transmitting by wireless means data generated by said sensors, for storing data generated by said sensors and for controlling the operation of said furnace pursuant to commands received by wireless means;

a handheld device for receiving by wireless means data from said electronic circuitry, for transmitting commands to said electronic circuitry by wireless means to control the operation of said furnace and for analyzing data received from said circuitry so as to provide guidance for identifying faulty components that may underlie a particular malfunction of said furnace; and

a centralized computing facility capable of storing historical data relating to a population of furnaces wherein said hand held device is capable of communicating with such facility to enhance its ability to diagnose malfunctions of said furnace.

2. The diagnostic system of claim 1, wherein said centralized computing facility is further capable of providing diagnostic assistance to said handheld device.

3. The diagnostic system of claim 1, wherein said parameters monitored by said sensors include ignitor operation and burner operation.

4. The diagnostic system of claim 1, wherein said handheld device is capable of performing diagnostics by controlling operations of said furnace.

5. The diagnostic system of claim 1, wherein said handheld device is capable of performing diagnostics based on historical data stored by said electronic circuitry.

6. The diagnostic system of claim 1, wherein said handheld device is capable of performing diagnostics based on real time data generated by said electronic circuitry.

8. The diagnostic system of claim 4, wherein said handheld device is further capable of performing diagnostics based on historical data stored by said electronic circuitry.

9. The diagnostic system of claim 8, wherein said handheld device is further capable of performing diagnostics based on real time data generated by said electronic circuitry.

11. The diagnostic system of claim 5, wherein said handheld is device is further capable of performing diagnostics based on real time data generated by said electronic circuitry.

14. The diagnostic system of claim 4, wherein said handheld device is further capable of performing diagnostics based on real time data generated by said electronic circuitry.

7. A furnace diagnostic system for facilitating the troubleshooting of malfunctions in the operation of a furnace, comprising:

sensors disposed within said furnance for monitoring various parameters associated with the operation of said furnace;

electronic circuitry for transmitting by wireless means data generated by said sensors, for storing data generated by said sensors and for controlling the operation of said furnace pursuant to commands received by wireless means; and

a handheld device for receiving by wireless means data from said electronic circuitry, for transmitting commands to said electronic circuitry by wireless means to control the operation of said furnace and for analyzing data received from said circuitry so as to provide guidance for identifying faulty components that may underlie a particular malfunction of said furnace, wherein said handheld device is capable of performing diagnostics based on data stored in a centralized computing facility with which said handheld device is able to communicate.

10. A furnace diagnostic system for facilitating the troubleshooting of malfunctions in the operation of a furnace, comprising:

sensors disposed within said furnace for monitoring various parameters associated with the operation of said furnace;

electronic circuitry for transmitting by wireless means data generated by said sensors, for storing data generated by said sensors and for controlling the operation of said furnace pursuant to commands received by wireless means; and

a handheld device for receiving by wireless means data from said electronic circuitry, for transmitting commands to said electronic circuitry by wireless means to control the operation of said furnace and for analyzing data received from said circuitry so as to provide guidance for identifying faulty components that may underlie a particular malfunction of said furnace, wherein said handheld device is capable of performing diagnostics by controlling operations of said furnace and wherein said handheld device is further capable of performing diagnostics based on historical data stored by said electronic circuitry, real time data generated by said electronic circuitry and on data stored in a centralized computing facility with which said handheld device is able to communicate.

12. A furnace diagnostic system for facilitating the troubleshooting of malfunctions in the operation of a furnace, comprising:

sensors disposed within said furnace for monitoring various parameters associated with the operation of said furnace;

electronic circuitry for transmitting by wireless means data generated by said sensors, for storing data generated by said sensors and for controlling the operation of said furnace pursuant to commands received by wireless means; and

a handheld device for receiving by wireless means data from said electronic circuitry, for transmitting commands to said electronic circuitry by wireless means to control the operation of said furnace and for analyzing data received from said circuitry so as to provide guidance for identifying faulty components that may underlie a particular malfunction of said furnace, wherein said handheld device is capable of performing diagnostics based on historical data stored by said electronic circuitry, real time data generated by said electronic circuitry and data stored in a centralized computing facility with which said handheld device is able to communicate.

13. A furnace diagnostic system for facilitating the troubleshooting of malfunctions in the operation of a furnace, comprising:

sensors disposed within said furnace for monitoring various parameters associated with the operation of said furnace;

electronic circuitry for transmitting by wireless means data generated by said sensors, for storing data generated by said sensors and for controlling the operation of said furnace pursuant to commands received by wireless means; and

a handheld device for receiving by wireless means data from said electronic circuitry, for transmitting commands to said electronic circuitry by wireless means to control the operation of said furnace and for analyzing data received from said circuitry so as to provide guidance for identifying faulty components that may underlie a particular malfunction of said furnace wherein said handheld device is capable of performing diagnostics based on real time data generated by said electronic circuitry and on data stored in a centralized computing facility with which said handheld device is able to communicate.

15. A furnace diagnostic system for facilitating the troubleshooting of malfunctions in the operation of a furnace, comprising:

sensors disposed within said furnace for monitoring various parameters associated with the operation of said furnace;

electronic circuitry for transmitting by wireless means data generated by said sensors, for storing data generated by said sensors and for controlling the operation of said furnace pursuant to commands received by wireless means; and

a handheld device for receiving by wireless means data from said electronic circuitry, for transmitting commands to said electronic circuitry by wireless means to control the operation of said furnace and for analyzing data received from said circuitry so as to privde guidance for identifying faulty components that may underlie a particular malfunction of said furnace wherein said handheld device is capable of performing diagnostics based on real time historical data stored by said electronic circuitry and on data stored in a centralized computing facility with which said handheld device is able to communicate.

16. A method to assist a service technician in diagnosing faults in a furnace while it is operating, said method comprising the steps of:

providing a furnace mounted controller containing a microcontroller and electronic circuitry for monitoring furnace control commands, controlling furnace operations in response to these commands, monitoring and conditioning a plurality of furnace sensor signals, converting furnace data to IRDA format, transmitting such information through an infrared communication port for external use, and receiving external commands in IRDA format through said infrared port and converting to electrical signals;

providing software resident on said microcontroller, said software designed as a state machine controlling all stages of furnace operations and performing diagnostics on furnace data;

using said microcontroller for acquiring furnace data from said electronic circuitry, storing said data, performing diagnostics on said data, providing furnace system control instructions to said electronic circuitry, and providing real time and historical data to said electronic circuitry for conversion to IRDA format and transmittal through an infrared communication port for external use;

receiving said information on a wireless hand held device containing a knowledge base and performing multiple levels of diagnostics, including controlling the said furnace controller from the hand held device, gathering historical data from the said furnace controller, gathering real time data from the said furnace controller, and analyzing data gathered from said furnace controller to determine which component or components are the cause of the malfunction and displaying this information to the service technician; and

guiding the service technician through repair steps determined by the knowledge base resident in the hand held device and the data received from the furnace controller.

17. A method to assist a service technician in diagnosing faults in an ignition system of a residential furnace while it is operating, said furnace having an inducer fan with pressure switch, an ignition device, manifold gas pressure sensor, filter differential pressure sensor, circulation blower, gas valve, and thermostat, said method comprising the steps of:

providing a furnace mounted controller containing a microcontroller and electronic circuitry for monitoring furnace control commands, controlling furnace operations in response to these commands, monitoring and conditioning a plurality of furnace sensor signals, converting furnace data to IRDA format, transmitting such information through an infrared communication port for external use, and receiving external commands in IRDA format through said infrared communication port and converting to electrical signals;

providing software resident on said microcontroller, said software designed as a state machine controlling all stages of furnace ignition and performing diagnostics on furnace data;

using said microcontroller for acquiring furnace data from said electronic circuitry, storing said data, performing diagnostics on said data, providing furnace system control instructions to said electronic circuitry, and providing real time and historical data to said electronic circuitry for conversion to IRDA format and transmittal through an infrared communication port for external use;

receiving said information on a wireless hand held device containing a knowledge base capable of performing multiple levels of diagnostics, including controlling said furnace controller from the hand held device, gathering historical data from the said furnace controller, gathering real time data from the said furnace controller, and analyzing the data gathered from the said furnace controller and determining which component or components are the cause of the malfunction and displaying this information to the service technician;

guiding the service technician through repair steps determined by the knowledge base resident in the hand held device and the data received from the furnace controller.

18. A method to assist a service technician in diagnosing faults in an ignition system of a residential furnace while it is operating, said furnace having an inducer fan with pressure switch, an ignition device, manifold gas pressure sensor, filter differential pressure sensor, circulation blower, gas valve, and thermostat, said method comprising the steps of:

providing a furnace mounted controller containing a microcontroller and electronic circuitry for monitoring furnace control commands, controlling furnace operations in response to these commands, monitoring and conditioning a plurality of furnace operations in response to these commands, monitoring and conditioning a plurality of furnace sensor signals, converting furnace data to IRDA format, transmitting such information through an infrared communication port for external use, and receiving external commands in IRDA format through said infrared communication port and converting electrical signals, wherein said electronic circuitry contains a flame current measuring circuit which, in conjunction with logic contained in the microcontroller, determines flame current by applying an AC signal and a microcontroller controlled pulse to a circuit which also receives a negative current from a flame sensor, and pulse providing positive current proportional to duty cycle to the flame present indicator circuit tending to turn off a flame present indicator, such flame sensor providing negative current to the flame present indicator circuit tending to turn on the flame present indicator, such pulse duty cycle starting at a nominal value and, if flame is not detected, being halved repeatedly until flame is detected, then being increased gradually until flame presence is no longer detected, the pulse width just before the flame is no longer detected being directly proportional to the flame current;

providing software resident on said microcontroller, said software designed as a state machine controlling all states of furnace ignition and performing diagnostics on furnace data;

using said microcontroller for acquiring furnace data from said electronic circuitry, storing said data, performing diagnostics on said data, providing furnace system control instructions to said electronic circuitry and providing real time and historical data to said electronic circuitry for conversion to IRDA format and transmittal through an infrared communication port for external use;

receiving said information on a wireless hand held device containing a knowledge base capable of performing multiple levels of diagnostics, including controlling said furnace controller from the hand held device, gathering historical data from the said furnace controller, gathering real time data from the said furnace controller, and analyzing the data gathered from the said furnace controller and determining which component or components are the cause of the malfunction and displaying this information to the service technician; and

guiding the service technician through repair steps determined by the knowledge base resident in the hand held device and the data received from the furnace controller.